Winco 25PTOS-3 Setup guide

WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057 507-357-6821
SERVICE DEPT. 507-357-6831
www.wincogen.com
INSTALLATION AND
OPERATORS
25PTOS-3
GENERATOR
MANUAL

2REV B
60706-199
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS 2
INTRODUCTION 2
SPECIFICATIONS 3
25PTOS
SAFETY 3
IMPORTANT SAFETY INSTRUCTIONS
ANSI SAFETY DEFINITIONS
TESTING POLICY 4
PREPARING THE UNIT 4
UNPACKING
INSTALLATION 4
FOUNDATION MOUNTING
TRAILER MOUNTING
THREE-POINT HITCH KIT
ELECTRICAL CONNECTIONS 5
OPERATION 7
PRE-START CHECKS 7
GENERATOR PROCEDURES 8
START-UP
SHUTDOWN
MAINTENANCE 8
GENERAL INFORMATION
PERIODICAL MAINTENANCE
LUBRICATION
CLEANING & INSPECTION
GENERATOR STORAGE
GENERATOR TESTING
ELECTRICAL TESTING
TESTING ARMATURE FOR OPENS AND GROUNDS
TESTING RECTIFIERS
CONDENSER TESTING
TROUBLE SHOOTING TABLE 11
36 MONTH LIMITED WARRANTY 12
COPY YOUR MODEL AND SERIAL NUMBER HERE
No other WINCO generator has the same serial number as yours.
If you should ever need to contact us on this unit, it will help us to
respond to your needs faster.
MODEL __________________________________________________
SERIAL NUMBER _________________________________________
PURCHASE DATE _________________________________________
DEALER NAME ___________________________________________
DEALER PHONE # ________________________________________
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed
during installation and maintenance of the generator. Read and
understand all instructions in the manual before starting and operating
the generator.
USING THIS MANUAL
Congratulations on your choice of a WINCO generator. You have
selected a high-quality, precision-engineered generator designed and
tested to give you years of satisfactory service.
To get the best performance from your new generator, it is important
that you carefully read and follow the operating instructions in this
manual.
Should you experience a problem please follow the “Troubleshooting
Tables” near the end of this manual. The warranty listed in the manual
describes what you can expect from WINCO should you need service
assistance in the future.
INTRODUCTION
The WINCO rotating armature power take-off generators are designed
primarily for farm use as a standby electrical power supply, utilizing the
power take-off of a tractor or truck as the prime mover. This PTO drive
generator will provide, 120/240V single phase, 60Hz electrical service
when properly driven.
NOTE:
The prime mover which drives the generator must be capable
of delivering approximately 2 HP per 1000 watts output from the
generator. Observe input RPM specications.
The generator may be foundation mounted for use as standby power
source, or trailer mounted, and used as portable electrical power
sources for areas where commercial power is not readily available,
such as out buildings.
This generator includes a color coded voltmeter to warn against high
or low voltage, three output power receptacles, an overload protection
circuit, and an electronic excitation circuit. To reduce maintenance
problems, the coupling between the generator input shaft and rotor
consists of precision helical gearing rather than a chain link drive. The
input shaft is a 1 1/8 in. diameter smooth shaft with a keyway and
center drilled for a roll pin. Both must be used at all times.
The factory thoroughly tests each generator before shipment.
All are continuous duty rated.
IMPORTANT: THE MANUFACTURER STRONGLY RECOMMENDS
RUNNING THE GENERATOR UNDER LOAD AT
LEAST ONCE A MONTH IN ORDER TO EVAPORATE ANY
ACCUMULATED MOISTURE CONDENSATION.

3REV B 60706-199
SPECIFICATIONS
25PTOS
Watts 25,000
Amps 104
Input Speed 540 RPM
Generator Speed 3600 RPM
Input Shaft 1 1/8” - keyed
Required Tractor PTO HP 50
Gear Lube
Volume 2 Pints
Type 85/90W-140
SAFETY
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important information that should be understood
and followed before the installation, operation and maintenance of the
generator. Failure to follow the safety instructions in this manual could
result in serious injury or death. Keep this manual available for future
reference.
ANSI SAFETY DEFINITIONS
DANGER:
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations.
WARNING:
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION:
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may be used to alert
against unsafe practices.
NOTE: CAUTION is also used on the unit labels and in this manual to
indicate a situation that could result in serious damage or destruction of
the equipment and possible personal injury.
1. ELECTRIC SHOCK -
The output voltage present in this equipment can cause a fatal electric
shock. This equipment must be operated by a responsible person.
A. Do not allow anyone to operate the generator without proper
instruction.
B. Guard against electric shock.
C. Avoid contact with live terminals or receptacles.
D. Use extreme care if operating this unit in rain or snow.
E. Use only three-prong grounded plugs and extension cords.
F. Be sure the unit is properly grounded to an external ground rod
driven into the earth.
2. FIRE HAZARD -
 A.Keepareextinguishernearbyandknowitsproperuse.Fire
extinguishers rated ABC by NFPA are appropriate.
3. NOISE HAZARD -
Excessive noise is not only tiring, but continual exposure can lead to
loss of hearing.
A. Use hearing protection when working around this
equipment for long periods of time.
B. Keep your neighbors in mind when permanently installing this
equipment.
4. CLEANLINESS -
Keep the generator and surrounding area clean.
A. Remove all grease, ice, snow or materials that create slippery
conditions around the unit.
B. Remove any rags or other materials that could create a
  potentialrehazard.
C. Carefully clean up any gas or oil spills before starting the unit.
5. SERVICING EQUIPMENT -
All service, including the installation or replacement of service parts,
should be performed only by a qualied technician.
A. Use only factory approved repair parts.
B. Do not work on this equipment fatigued.
C. Use extreme caution when working on electrical components.
High output voltages from this equipment can cause serious
injury or death.
D. Installing a generator is not a “do-it-yourself” project. Consult
  aqualied,licensedelectricianorcontractor.Theinstallation
must comply with all national, state, and local codes.
6. INSTALLATION -
Installing a PTO generator is not a “do-it-yourself” project. Consult
aqualied,licensedelectricianorcontractor.Theinstallationmust
comply with all national, state, and local codes.
A. Never operate the PTO drive generator without having it
properly mounted to a concrete base or approved trailer.
b. Never connect the PTO generator to an existing electrical
system without installing an isolation transfer switch.
C. Always insure the drive shaft is straight and level before
operating the generator.
8. OPERATION - PTO drive shafts (tumbling bars) have many inherent
dangers, extreme caution must be exercised when using them.

4REV B
60706-199
PREPARING THE UNIT
UNPACKING
CAUTION: EQUIPMENT DAMAGE
When you unpack your new generator, be sure to remove all of the
information sheets and manual from the carton.
1. As you receive your unit, it is critical to check it for any damage. If
any damage is noted, it is always easiest to refuse the shipment and
let WINCO take care of the freight claim. If you sign for the unit, the
transferoftheownershiprequiresthatyoulethefreightclaim
2. Before proceeding with the preparations of your new generator
for operation, take a couple of minutes to ensure the unit you have
receivedisthecorrectmodelandreviewthespecicationpagesinthis
manual to ensure that this unit meets your job requirements.
5 degrees during generator operation, even though the mechanical
design of the tumbling bar would allow greater misalignment.
B. The foundation must be solid enough to absorb generator starting
andreectedloadtorqueduringoperation.
C.Thefoundationsurfaceshouldbeat.
D. Space is required around the generator for mounting switching
devices, making connections, and for servicing.
E.Fordimensionsneededforinstallforyourspecicgenerator,please
refer to it’s outline drawing. The hardware needed is dependent on your
distinct application.
F.Thegeneratormountingbracketmustrestevenlyandrmlyonthe
foundation. Install shims if necessary to even out the foundation under
themountingpadsthenboltthegeneratorrmlyinplace.
TRAILER MOUNTING
Optional Trailer Part Number TDM76
Mount the generator on a trailer if you plan to use it as a portable
power source. When selecting or building a trailer to mount the
generator, consider the following points:
A. The trailer construction must be strong enough to support the
generator.
B. The design of the trailer must enable the trailer to remain stable
during operation, and to resist tipping caused by generator starting and
reectedloadtorque.
C. The trailer height and mounting position of the generator on the
trailer should enable aligning the drive shaft (tumbling bar) in a straight
or nearly straight line between the power take-off and generator input
shafts. Misalignment must be less than 5 degrees during generator
operation, even though the mechanical design of the tumbling bar
would allow greater misalignment.
D.Thegeneratormountingareaofthetrailerbedshouldbeat.
Allfourgeneratormountingpadsmustrestrmlyonthetrailerbed.
Install shims if necessary to even out the bed under the mounting pads,
thenboltthegeneratorrmlyinplace.
Page 3 60706-180
0310-00
B. The foundation must be solid enough to absorb generator
starting and reflected load torque during operation.
C. The foundation surface should be flat.
D. Space is required around the generator for mounting
switching devices, making connections, and for servicing.
E. The generator mounting bracket must rest evenly and
firmly on the foundation. Install shims if necessary to even
out the foundation under the mounting pads then bolt the
generator firmly in place.
TRAILER MOUNTING
Mount the generator on a trailer if you plan to use it as a
portable power source. When selecting or building a trailer to
mount the generator, consider the following points:
A. The trailer construction must be strong enough to support
the generator.
B. The design of the trailer must enable the trailer to remain
stable during operation, and to resist tipping caused by
generator starting and reflected load torque.
WARNING: Personal Injury & Equipment Damage
TRAILER MAY TIP OVER AND CAUSE INJURIES IF
WHEELS ARE NOT SPACED FAR ENOUGH APART.
Optional Trailer Part Number TDM75
C. The trailer height and mounting position of the generator on
the trailer should enable aligning the drive shaft (tumbling bar)
in a straight or nearly straight line between the power take-off
and generator input shafts. Misalignment must be less than 10
degrees during generator operation, even though the mechani-
cal design of the tumbling bar would allow greater misalign-
ment.
D. The generator mounting area of the trailer bed should be
flat.
All four generator mounting pads must rest firmly on the trailer
bed. Install shims if necessary to even out the bed under the
mounting pads, then bolt the generator firmly in place.
WINCO THREE POINT HITCH
Optional 3-Point Hitch Part Number TPH240
WARNING: Personal Injury & Equipment Damage
WHEN USING THE 3-POINT HITCH ASSEMBLY ALL THREE
POINTS MUST BE ATTACHED TO THE TRACTOR. FAIL-
URE TO DO SO WILL CAUSE THE GENERATOR TO TIP
WHEN LIFTING IT DAMAGING BOTH THE T-BAR AND THE
GENERATOR.
A. The three point hitch must be attached to the tractor at all
times during operation.
B. When operating the generator the three point hitch and
generator must be sitting on flat level ground. All four deck
pads must be in constant contact with the ground at all
times. This will reduce the vibration in both the generator
and the tumbling bar.
C. For safety the generator must be bolted to the three point
hitch deck using all four mounting bolts
INSTALLATION
FOUNDATION MOUNTING
Mount the generator on a foundation if it is to be used as a permanent
or standby power source. When planning a foundation consider the
following points:
A. The foundation location should enable aligning the drive shaft
(tumbling bar) in a straight or nearly straight line between the power
take-off and the generator input shaft. Misalignment must be less than
TESTING POLICY
Before any generator is shipped from the factory, it is fully checked
for performance. The generator is loaded to its full capacity, and the
voltage, current, and frequency are carefully checked.
Rated output of generator is based on engineering tests of typical units,
and is subject to, and limited by, the temperature, altitude, fuel, and
otherconditionsspeciedbythemanufacturerofapplicableengines.
A. NEVER allow children around the drive shaft when it is in
operation.
B. Keep all safety guards and shields in place and securely
tightened.
C. Never operate a drive shaft that has been damaged or had the
safety shield removed.
D. Never step over a drive shaft while it is running.
E. Never wear a necktie, loose articles of clothing, or anything else
that can be caught in moving parts.
F. Never try to stop drive shaft with your hand or your foot.

5REV B 60706-199
WARNING: PERSONAL INJURY & EQUIPMENT DAMAGE
Trailer may tip over and cause injuries if wheels are not spaced far
enough apart.
THREE-POINT HITCH KIT
Optional 3-Point Hitch Part Number TPH241
WARNING: PERSONAL INJURY & EQUIPMENT DAMAGE
When using the 3-point hitch assembly all three points must be
attached to the tractor. Failure to do so will cause the generator to tip
when lifting it damaging both the t-bar and the generator.
A. The three point hitch must be attached to the tractor at all times
during operation.
B. When operating the generator the three point hitch and generator
mustbesittingonatlevelground.Allfourdeckpadsmustbein
constant contact with the ground at all times. This will reduce the
vibration in both the generator and the tumbling bar.
C. For safety the generator must be bolted to the three point hitch deck
using all four mounting bolts.
Page 3 60706-180
0310-00
B. The foundation must be solid enough to absorb generator
starting and reflected load torque during operation.
C. The foundation surface should be flat.
D. Space is required around the generator for mounting
switching devices, making connections, and for servicing.
E. The generator mounting bracket must rest evenly and
firmly on the foundation. Install shims if necessary to even
out the foundation under the mounting pads then bolt the
generator firmly in place.
TRAILER MOUNTING
Mount the generator on a trailer if you plan to use it as a
portable power source. When selecting or building a trailer to
mount the generator, consider the following points:
A. The trailer construction must be strong enough to support
the generator.
B. The design of the trailer must enable the trailer to remain
stable during operation, and to resist tipping caused by
generator starting and reflected load torque.
WARNING: Personal Injury & Equipment Damage
TRAILER MAY TIP OVER AND CAUSE INJURIES IF
WHEELS ARE NOT SPACED FAR ENOUGH APART.
Optional Trailer Part Number TDM75
C. The trailer height and mounting position of the generator on
the trailer should enable aligning the drive shaft (tumbling bar)
in a straight or nearly straight line between the power take-off
and generator input shafts. Misalignment must be less than 10
degrees during generator operation, even though the mechani-
cal design of the tumbling bar would allow greater misalign-
ment.
D. The generator mounting area of the trailer bed should be
flat.
All four generator mounting pads must rest firmly on the trailer
bed. Install shims if necessary to even out the bed under the
mounting pads, then bolt the generator firmly in place.
WINCO THREE POINT HITCH
Optional 3-Point Hitch Part Number TPH240
WARNING: Personal Injury & Equipment Damage
WHEN USING THE 3-POINT HITCH ASSEMBLY ALL THREE
POINTS MUST BE ATTACHED TO THE TRACTOR. FAIL-
URE TO DO SO WILL CAUSE THE GENERATOR TO TIP
WHEN LIFTING IT DAMAGING BOTH THE T-BAR AND THE
GENERATOR.
A. The three point hitch must be attached to the tractor at all
times during operation.
B. When operating the generator the three point hitch and
generator must be sitting on flat level ground. All four deck
pads must be in constant contact with the ground at all
times. This will reduce the vibration in both the generator
and the tumbling bar.
C. For safety the generator must be bolted to the three point
hitch deck using all four mounting bolts
ELECTRICAL CONNECTIONS
CAUTION:
Only qualied electricians should install electrical wiring. Wiring must
conform to all applicable national, state, and local codes. (Reference:
National Fire Protection Association Manual No. 70, National Electrical
Code.)
DANGER: PERSONAL INJURY:
If the generator is to be used as a standby power source,, a manual
transfer switch must be installed to separate the generator and the
commercial power lines. The switch must isolate the generator from the
commercial power lines and the load when the generator is on standby,
and must isolate the commercial power lines from the load and the
generator when the generator is supplying power. See the following
diagrams.
A properly rated and installed double throw manual power isolation
transfer switch must be used with a standby generator. The transfer
switch isolates the load from the power line and allows you to safely
operate your loads without endangering the power line repair crew. See
previous diagrams
The load, connected to the normal terminals of the transfer switch, is
energized by the normal power line when the switch is in the normal
position. The generator, connected to the emergency terminals of the
switch, furnishes power when the switch is in the emergency mode
position.
Therearetwowaystoinstallamanualtransferswitch.Therstshown
on the left side of page 6 is to install the switch between the watt-hour
meter and the normal distribution panel. As with any system you must
install an entrance rated breaker before the manual transfer switch. The
manual transfer switch must in all cases be equal to or greater than the
rating of the entrance rated breaker.
The second way to install the system is to purchase and install an
emergency distribution panel and move the circuits you wish to back
up to the new distribution panel. In this case the manual transfer switch
only has to be sized to the amperage of the circuit breaker in the main
distribution panel that is feeding it. See the right hand drawing of the
previous diagrams
Beforedecidingwhichsystemtoinstall,rstdeterminewhichloadsyou
can safely run on your PTO generator and the cost of buying a large
manual transfer switch versus the cost of a smaller switch and the
additional distribution panel.
The only assembly work required after unpacking the generator is to
assemble the load disconnect plug, which is contained in a bag in the
subpack carton packed in the generator crate.
The bag contains an instruction sheet, 2 plug bodies, four contacts,
two handle and the hardware to assembly the disconnect plug. You will
needtopurchasetheappropriatelengthofnestrandedcopperwire
for your application in order to complete the assembly of the disconnect
plug. DO NOT USE SO CABLE - USE SINGLE LEAD WELDING
CABLE
A #4 Neoprene/THHN wire size is recommended.
If you require different inserts or contacts for local code,
WINCO has a variety of different inserts and contacts available.
Contact the factory at 507-357-6831 for pricing.
Page 2 60706-199 1005-00
Description
The WINCO rotating armature power take-off generators are
designed primarily for farm use as a standby electrical power
supply, utilizing the power take-off of a tractor or truck as the
prime mover. This PTO drive generator will provide, 120/240V
single phase, 60Hz electrical service when properly driven.
NOTE: The prime mover which drives the generator must be
capable of delivering approximately 2 HP per 1000 watts
output from the generator. Observe input RPM specifications.
The generator may be foundation mounted for use as standby
power source, or trailer mounted, and used as portable
electrical power sources for areas where commercial power
is not readily available, such as out buildings.
This generator includes a color coded voltmeter to warn
against high or low voltage, three output power receptacles,
an overload protection circuit, and an electronic excitation
circuit. To reduce maintenance problems, the coupling
between the generator input shaft and rotor consists of
precision helical gearing rather than a chain link drive. The
input shaft is a 1 1/8 in. diameter smooth shaft with a keyway
and center drilled for a roll pin. Both must be used at all
times.
The factory thoroughly tests each generator before shipment.
All are continuous duty rated.
IMPORTANT: THE MANUFACTURER STRONGLY RECOM-
MENDS RUNNING THE GENERATOR UNDER LOAD AT
LEAST ONCE A MONTH IN ORDER TO EVAPORATE ANY
ACCUMULATED MOISTURE CONDENSATION.
UNPACKING
CAUTION: Equipment Damage
DO NOT invert generator during unpacking. The Gearcase
contains oil which will leak out if inverted during unpacking.
Unpack the generator as follows:
1. Remove the carton.
2. Examine the unit for damage.
3. Find the small subpack carton packed in the large carton.
Be careful not to throw away the subpack carton with the
large carton.
4. Open the subpack carton and make sure it contains:
a. Generator instruction manual
b. Load disconnect plug (disassembled, in bag)
5. Remove the four bolts which hold down the generator feet
to the pallet.
6. Lift the generator from the pallet by means of the lifting eye
on the top of the generator.
7. Inspect the generator carefully for freight loss or damage.
If loss or damage is noted at time of delivery, require that
the person making the delivery make note of the loss or
damage on the freight bill, or sign the consigner’s memo
of the loss or damage. Contact the carrier for claim
procedures.
When loss or damage is noted after delivery, segregate the
damaged material, and contact the carrier for claim proce-
dures.
“Concealed damage” means damage to the contents of a
package which is not evident when the package is delivered
by the carrier, but which is discovered later. The carrier or
carriers are responsible for merchandise lost or damaged in
transit. The title to the goods rests with the consignee when
the goods are shipped FOB factory, and only the consignee
can legally file claims. Two years are allowed in which to file
suit after a claim is disallowed in writing by the carrier.
Assembly
The only assembly work required after unpacking the genera-
tor is to assemble the load disconnect plug, which is con-
tained in a bag in the subpack carton packed in the generator
crate.
The bag contains an instruction sheet, 2 plug bodies, four
contacts, two handle and the hardware to assembly the
disconnect plug. You will need to purchase the appropriate
length of fine stranded copper wire for your application in order
to complete the assembly of the disconnect plug. DO NOT
USE SO CABLE - USE SINGLE LEAD WELDING CABLE
The following wire sizes are recommended for each unit.
Generator Size
Model AWG Insulation
25PTOC #4 Neoprene/THHN
If you require different inserts or contacts for local code,
WINCO has a variety of different inserts and contacts avail-
able. Contact the factory at 507-357-6831 for pricing.
Figure 1
SINGLE PHASE
4 WIRE CONNECTION
CONTACTS
All 4 contacts
must be used.

6REV B
60706-199
Page 4 60706-199 1005-00
ELECTRICAL CONNECTIONS
CAUTION:
Only qualified electricians should install electrical wiring.
Wiring must conform to all applicable national, state, and local
codes. (Reference: National Fire Protection Association
Manual No. 70, National Electrical Code.)
DANGER: PERSONAL INJURY
IF THE GENERATOR IS TO BE USED AS A STANDBY
POWER SOURCE, A SPECIAL DISCONNECT SWITCH
MUST BE INSTALLED TO SEPARATE THE GENERATOR
AND THE COMMERCIAL POWER LINES. THE
DISCONNECT MUST ISOLATE THE GENERATOR FROM
THE COMMERCIAL POWER LINES AND THE LOAD WHEN
THE GENERATOR IS ON STANDBY, AND MUST ISOLATE
THE COMMERCIAL POWER LINES FROM THE LOAD AND
THE GENERATOR WHEN THE GENERATOR IS SUPPLYING
POWER. SEE FIGURE 5.
Typical Connection Methods for Generator Power Service
Figure 5
Typical Connection Methods for Generator Power Service
WARNING: EQUIPMENT DAMAGE
Never use acid core solder. When soldering insure no excess solder
runs down on the contact surface - Solder on the contact surface will
not allow the contacts to mate properly causing them to burn up.
Each wire should be stripped back 7/8 of an inch and inserted into
one of the contacts in the plug kit. You will then either need to solder
them together using a good grade of resin core solder or they can be
crimped with an appropriate compression crimper or both.
Approved Crimping tools are:
1. Anderson Power Products
2. ETC Model HHS hydraulic crimper
3. ITT Blackburn NO. 1640
4. T&B (Thomas & Betts) #TBM5
To complete the assembly of the disconnect plug refer to the instruction
sheet in the plug kit.
WARNING: ELECTRICAL SHOCK
DURING THE NEXT STEP, THE LOAD DISCONNECT PLUG
SHOULD NOT BE PLUGGED INTO ITS RECEPTACLE. ALSO, MAKE
SURE THAT THE EQUIPMENT TO WHICH THE PLUG LEADS
(CABLES) ARE BEING CONNECTED IS NOT ENERGIZED (LIVE).
Strip the insulation off the free end of each of the plug leads (cables),
and connect them to the load transfer switch (or directly to the load).

7REV B 60706-199
OPERATION
Output power available and load determination
Before using the generator, read and understand the following
information.
Generator output current (amperage) is internally limited by three circuit
breakers. If too much demand is placed on a generator output (if you
try to drive too many motors with it, for example), one of the circuit
breakers will trip, cutting off the output in order to protect the generator.
A 20 Amp push-to-reset circuit breaker protects the 120V duplex
receptacle output circuit. 20 Amps is the total limit for both outputs of
the duplex receptacle.
A 50 Amp push-to-reset circuit breaker protects the 240V receptacle
output circuit.
A large two pole (three pole for three phase) switch type main circuit
breaker protects the generator windings and output circuits, including
the load disconnect receptacle outputs. The load disconnect receptacle
on the 25PTOC is the largest gray receptacle on the generator output
panel.
To aid in determining how much load can be applied to the generator,
and how it should be distributed among the generator output
receptacles, the following formulas may be useful. Get load voltages,
current, and wattage from the nameplates on the equipment in the
load.
Load current (in Amps) x Load voltage = Load wattage
Amps x Volts = Watts
Watt/1000 = kW
Load wattage / Load wattage = Load current (in Amps)
Example:250W,120Voodlightload:250W/120V=2Amps(parrots.)
NOTE:
Electric motors require more current to start than to run. Commonly,
the current rating given on a motor nameplate is the full load (running)
current required by the motor, not its starting current, which is a lot
higher. Motor starting current requirements vary greatly, by motor size
and type. Repulsion-induction type motors are the easiest to start,
typically using 1 1/2 to 2 1/2 times as much current to start as to run;
capacitor type motors usually require 2 to 4 times as much current
to start as to run; split-phase type motors are the hardest to start,
normally using 5 to 7 times as much current to start as to run.
PRE-START CHECKS
WARNING: PERSONAL INJURY
When working on or around these generators, do not wear loose tting
clothing or any articles that may get caught in moving parts.
1. Visually inspect the generator. Check for:
A. Correct mounting
B. Physical damage
C. Debris in cooling vents and screens (could cause generator to
overheat)
IMPORTANT: The manufacturer recommends that, if the generator
has been stored for any length of time, before using it, the operator
removes the control box cover and cooling fan screen. Then inspect
the generator for rodent nests or other objects that could cause the
generator binding and/or overheating. See “cleaning portion of the
Maintenance section.
2.Checkgearcaseoillevel.Caseshouldbelledwithoiltoplug
marked “OIL LEVEL”. Fill or remove oil as required.
NOTE: Either too little or too much oil can harm the equipment.
See“lubrication”portionofMaintenanceforoilspecications.
3. Make sure the drive shaft (tumbling bar) is assembled with its
universal joint knuckles “synchronized”. If the knuckles are not
synchronized, the bar will chatter when rotating, which will cause the
generatoroutputvoltagetoicker.
DANGER: PERSONAL INJURY
Power take-off must be DISENGAGED at this time.
Page 6 60706-199 1005-00
7. Check all electrical connections in the system to be ener-
gized by the generator. Make sure the connections are cor-
rect and are tight.
8. Make sure all loads are turned off. Do not start the genera-
tor under load.
GENERATOR STARTING PROCEDURE
1. With the power take-off drive disengaged, start the engine
which will drive the generator. Run the engine long enough
to warm it up before proceeding, so that it will run smoothly
and achieve full power under generator load.
2. With engine idling, engage the power take-off drive.
3. Watch the voltmeter on the generator and slowly increase
engine speed until the output reaches approximately 260
volts, in green portion of voltmeter scale.
4. With engine and generator running smoothly, switch on
the electrical load while watching the voltmeter.
NOTE: Equipment Damage
If the load includes motors turn them on one at a time, highest
starting current motor first, next highest second, etc.
Readjust engine throttle to keep generator output under load
at 240V (in green portion of voltmeter scale). If engine is
equipped with speed governor, it may automatically readjust
the throttle as the load changes and keep the generator output
at the proper level. However, some governors are not sensitive
enough to maintain proper output under changing load, and in
such cases the throttle will have to be manually readjusted .
GENERATOR SHUTDOWN PROCEDURE
1. Switch off electrical load.
2. Reduce speed of engine driving generator to idle.
3. Disengage power take-off drive, and allow generator to
coast to a stop.
WARNING: Personal Injury
Never try to manually stop the generator. Always let it coast
until it stops.
5. Shut off the engine.
4. Disconnect drive shaft (tumbling bar)
power take-off end first, then generator end.
Figure 6
Figure 7
3. Make sure the drive shaft (tumbling bar) is assembled with
its universal joint knuckles “synchronized,” as illustrated in
Figure 7. If knuckles are not synchronized, the bar will chat-
ter when rotating, which will cause the generator output
voltage to flicker.
DANGER: Personal Injury
POWER TAKE-OFF MUST BE DISENGAGED AT THIS TIME.
4. Couple the tractor to the generator with the drive shaft (tum-
bling bar). Couple the tumbling bar to the generator input
shaft first, then to the power take-off shaft. Check align-
ment, tractor, power take-off shaft (tumbling bar), and gen-
erator input shaft should form a straight (or nearly straight)
line, with less than 15° misalignment between the shafts.
Misalignment will cause generator output voltage to flicker.
CAUTION:
Make sure that all tumbling bar lock pins are engaged and
that all safety shields are in place before operating the PTO
generator.
5. Make sure no binding exists in generator or gear box. If
binding is found, locate the cause and correct it before pro-
ceeding.
6. Make sure that the electrical loads to be driven by the gen-
erator will not draw more current than the ratings of the
generator receptacle or cord set which will supply the cur-
rent.
Page 6 60706-199 1005-00
7. Check all electrical connections in the system to be ener-
gized by the generator. Make sure the connections are cor-
rect and are tight.
8. Make sure all loads are turned off. Do not start the genera-
tor under load.
GENERATOR STARTING PROCEDURE
1. With the power take-off drive disengaged, start the engine
which will drive the generator. Run the engine long enough
to warm it up before proceeding, so that it will run smoothly
and achieve full power under generator load.
2. With engine idling, engage the power take-off drive.
3. Watch the voltmeter on the generator and slowly increase
engine speed until the output reaches approximately 260
volts, in green portion of voltmeter scale.
4. With engine and generator running smoothly, switch on
the electrical load while watching the voltmeter.
NOTE: Equipment Damage
If the load includes motors turn them on one at a time, highest
starting current motor first, next highest second, etc.
Readjust engine throttle to keep generator output under load
at 240V (in green portion of voltmeter scale). If engine is
equipped with speed governor, it may automatically readjust
the throttle as the load changes and keep the generator output
at the proper level. However, some governors are not sensitive
enough to maintain proper output under changing load, and in
such cases the throttle will have to be manually readjusted .
GENERATOR SHUTDOWN PROCEDURE
1. Switch off electrical load.
2. Reduce speed of engine driving generator to idle.
3. Disengage power take-off drive, and allow generator to
coast to a stop.
WARNING: Personal Injury
Never try to manually stop the generator. Always let it coast
until it stops.
5. Shut off the engine.
4. Disconnect drive shaft (tumbling bar)
power take-off end first, then generator end.
Figure 6
Figure 7
3. Make sure the drive shaft (tumbling bar) is assembled with
its universal joint knuckles “synchronized,” as illustrated in
Figure 7. If knuckles are not synchronized, the bar will chat-
ter when rotating, which will cause the generator output
voltage to flicker.
DANGER: Personal Injury
POWER TAKE-OFF MUST BE DISENGAGED AT THIS TIME.
4. Couple the tractor to the generator with the drive shaft (tum-
bling bar). Couple the tumbling bar to the generator input
shaft first, then to the power take-off shaft. Check align-
ment, tractor, power take-off shaft (tumbling bar), and gen-
erator input shaft should form a straight (or nearly straight)
line, with less than 15° misalignment between the shafts.
Misalignment will cause generator output voltage to flicker.
CAUTION:
Make sure that all tumbling bar lock pins are engaged and
that all safety shields are in place before operating the PTO
generator.
5. Make sure no binding exists in generator or gear box. If
binding is found, locate the cause and correct it before pro-
ceeding.
6. Make sure that the electrical loads to be driven by the gen-
erator will not draw more current than the ratings of the
generator receptacle or cord set which will supply the cur-
rent.

8REV B
60706-199
4. Couple the tractor to the generator with the drive shaft (tumbling
bar).Couplethetumblingbartothegeneratorinputshaftrst,thento
the power take-off shaft. Check alignment, tractor, power take-off shaft
(tumbling bar), and the generator input shaft should form a straight (or
nearly straight) line, with less than 15 degrees misalignment between
theshaftsMisalignmentwillcausegeneratoroutputvoltagetoicker.
CAUTION:
Make sure that all tumbling bar lock pins are engaged and that all
safety shields are in place before operating the PTO generator.
5. Make sure no binding exists in generator or gearbox. If binding is
found, locate the cause and correct it before proceeding.
6. Make sure that the electrical loads to be driven by the generator will
not draw more current than the ratings of the generator receptacle or
cord set which will supply the current.
7. Check all electrical connections in the system to be energized by the
generator. Make sure the conenctions are correct and are tight.
8. Make sure all loads are turned off. Do not start generator under load.
GENERATOR PROCEDURES
START-UP
1. With the power take-off drive disengaged, start the engine which will
drive the generator. Run the engine long enough to warm it up before
proceeding, so that it will run smoothly and achieve full power under
generator load.
2. With the engine idling, engage the power take-off drive.
3. Watch the voltmeter on the generator and slowly increase engine
speed until the output reaches approximately 260 Volts, in green
portion of voltmeter scale.
4. With engine and generator running smoothly, switch on the electrical
load while watching the voltmeter.
NOTE: EQUIPMENT DAMAGE
If the load includes motors, turn them on one at a time, highest starting
current motor rst, next highest second, etc.
Readjust engine throttle to keep generator output under load at 240V
(in green portion of voltmeter scale). If engine is equipped with speed
governor, it may automatically readjust the throttle as the load changes
and keep the generator output at the proper level.
SHUTDOWN
1. Switch off electrical load.
2. Reduce Speed of engine driving generator to idle.
3. Disengage power take-off drive and allow generator to coast to a
stop.
WARNING: PERSONAL INJURY
Never try to manually stop the generator. Always let it coast until it
stops.
4. Shut off the engine.
5.Disconnectdriveshaft.Powertake-offendrst,thenthegenerator
end.
MAINTENANCE
GENERAL INFORMATION
Themaincomponentsofthegeneratorare:armature,eldcoils,
cooling fan, brushes, brush holder assembly, end brackets, and
rectier.Beforeperforminganymaintenanceonthegenerator,isolate
and/or disable the drive system so the unit can not be accidentally
started while being repaired.
The trouble shooting chart lists various symptoms of poor generator
operation with possible causes and the appropriate corrective action.
You will need a volt-ohm meter or test light to check some of the
causes. For some of the other causes you will need to check generator
speed. To check generator speed, you can use a frequency meter, a
tachometer, or a 120V-60Hz electric clock and a correctly operating
wrist watch (run the electric clock and a correctly power and compare
the clock’s second hand movement with that of the wrist watch. They
should run at the same speed. If the clock runs faster, generator speed
is too high, and vice versa).
CAUTION: EQUIPMENT DAMAGE
Most electrical equipment in North America operates satisfactory at
frequencies between 58.5 and 62 Hz (cycles per second). Operating
the generator at frequencies outside that range may cause damage to
the generator and/or to electrical equipment driven by the generator.
PERIODICAL MAINTENANCE
Service/maintenance items include periodic external physical
inspection for missing hardware or damage to mounting or drive
system and checking the oil level in the gearcase. It is recommended
that the generator be operated at least monthly under normal loads to
familiarize operators with the procedures and controls as well as to dry
out any accumulated condensation or other moisture in the generator
electrical windings. The maintenance and service attention invested will
ensure getting the peak performance that was designed to the unit.
Routine preventative maintenance minimizes costly repairs and
generator down-time. Before each use, inspect the generator: gearcase
oil level should be correct, cooling vents and screens should be
clear, and generator mounting hardware should be tight. Clean and
inspect the generator after storing it for long periods, and after using
it in extremely dusty conditions or in severe weather, such as rain or
blowing snow.

9REV B 60706-199
LUBRICATION
The generator bearings are factory lubricated and sealed, and require
no further lubrication.
The generator input shaft should be cleaned and lubricated with a
thinlmofgreasebeforeinstallingthedriveshaftandeachtimeitis
removed.
The drive shaft (tumbling bar) requires greasing. Keep the universal
joints in the coupling shaft free from grease and dirt build-up.
NOTE:
Do not over lubricate the universal joints.
Check the generator gearcase oil level before each use of the
generator. Maintain the oil level at the oil level plug height. The
generatorisshippedwithlubricantinthegearcase.Specicationsfor
the gearcase lubricant are:
API Serice: GL-5
Grade: SAE 85W-90-140
Amount: 2 Pints
The following kind of oil are recommended for use in the generator
gearcase: Mobile SAE 85W-90-140 API Service GL-5, Sunonco/
DX XL80W90-140, Kendal Three Star 85W-140, Amoco 85W140 or
equivalent.
CAUTION: EQUIPMENT DAMAGE
Donotoverllgeneratorgearcase.Overllingcausesoverheatingand
oil seal failure.
Change oil at least once every six months. Change it more often if
you use the generator in bad weather. Use the following procedure to
change generator gearcase oil:
1. Remove gearcase breather. Soak breather in cleaning solvent, then
allow to dry.
2. Remove oil level, check plug.
3. Remove the oil drain plug, drain the oil into a clean oil resistant
container, 1 quart or larger. Check the oil for metal. Fine metal dust
in the oil does not indicate trouble, but metal chips do. Dismantle the
gearcaseandlookfordamagedgearsifyoundmetalchipsintheoil.
4.Replacetheoildrainplug.Rellthegearcasethroughthebreather
port with new oil of the recommended type. Fill the case up to oil level
check plug height (it will take about 2 pint).
Page 760706-199 1005-00
MAINTENANCE
General Information
The main components of the generator are: armature, field
coils, cooling fan, brushes, brush holder assembly, end
brackets, and rectifier. Before performing any maintenance
on the generator, isolate and/or disable the drive system so
the unit can not be accidentally started while being repaired.
The troubleshooting chart lists various symptoms of poor
generator operation with possible causes and the appro-
priate corrective action. You will need a volt-ohm meter or
test light to check some of the causes. For some of the
other causes you will need to check generator speed. To
check generator speed you can use a frequency meter, a
tachometer, or a 120V-60Hz electric clock and a correctly
operating wrist watch. (Run the electric clock on generator
power and compare the clock’s second hand movement
with that of the wrist watch. They should run at the same
speed. If clock runs faster, generator speed is too high,
and vice versa.)
CAUTION: Equipment Damage
Most electrical equipment in North America operates
satisfactorily at frequencies between 58.5 and 62 Hz
(cycles per second.) Operating the generator at frequen-
cies outside that range may cause damage to the genera-
tor and/or to electrical equipment driven by the generator.
Periodical Maintenance
Service/maintenance items include periodic external physi-
cal inspection for missing hardware or damage to mounting
or drive system and checking the oil level in the gear case.
It is recommended that the generator be operated at least
monthly under normal loads to familiarize operators with the
procedures and controls as well as to dry out any accumu-
lated condensation or other moisture in the generator elec-
trical windings. The maintenance and service attention
invested will insure getting the peak performance that was
designed into the unit.
Routine preventive maintenance minimizes costly repairs
and generator down-time. Before each use, inspect the
generator: gear case oil level should be correct, cooling
vents and screens should be clear, and generator mount-
ing hardware should be tight. Clean and inspect the
generator after storing it for long periods, and after using
it in extremely dusty conditions or in severe weather, such
as rain or blowing snow.
Lubrication
The generator bearings are factory lubricated and sealed,
and require no further lubrication.
The generator input shaft should be cleaned and lubricated
with a thin film of grease before installing the drive shaft and
each time it is removed.
The drive shaft (tumbling bar) requires greasing. Keep the
universal joints in the coupling shaft free from grease and
dirt buildup.
NOTE:
Do not over lubricate the universal joints.
Check the generator gear case oil level before each use of
the generator. Maintain the oil level at oil level plug height.
(See page 6 for oil level plug location.) The generator is
shipped with lubricant in the gear case. Specifications for
gear case lubricant are:
API Service: GL-5
Grade: SAE 85W-9O-140
Amount: 2 pints
The following kinds of oil are recommended for use in the
generator gear case: Mobil SAE 85W90-140 API Service GL-
5, Sunoco/DX XL80W90-140 Kendal Three Star 85W-140,
Amoco 85W140 or equivalent.
CAUTION: Equipment Damage
Do not overfill generator gear case. Overfilling causes
overheating and oil seal failure.
Change the oil at least once every six months. Change it
more often if you use the generator in bad weather. Use the
following procedure to change generator gear case oil:
1. Remove gear case breather. Soak breather in cleaning
solvent, then allow it to dry.
2. Remove oil level check plug.
3. Remove the oil drain plug, drain the oil into a clean oil
resistant container, 1 quart or larger. Check the oil for
metal. Fine metal dust in the oil does not indicate
trouble, but metal chips do. Dismantle the gear case and
look for damaged gears if you find metal chips in the oil.
4. Replace the oil drain plug. Refill the gear case through
the breather port with new oil of the recommended type.
Fill the case up to oil level check plug height. (It will take
about 2 pint.)
5. Replace the oil level check plug.
6. Replace the breather.
Cleaning and Inspection
Use a vacuum cleaner or dry low pressure compressed air
(regulated at 25-35 PSI) to clean the generator periodically.
WARNING
DO NOT CLEAN THE GENERATOR WHILE IT IS RUNNING.
Proceed as follows:
5. Replace the oil level check plug.
6. Replace the breather.
CLEANING & INSPECTION
Use a vacuum cleaner or dry low pressure compressed air (regulated
at 25-35 PSI) to clean the generator periodically.
WARNING:
Do NOT clean the generator while it is running.
Proceed as follows:
1. Remove control box cover. Vacuum or blow dust or debris from the
control box. Inspect all wiring for correct routing, fraying insulation, and
secure connections.
2. Remove end cover. Vacuum or blow dust and debris from the inside
of the generator. Inspect wiring for loose connections, fraying insulation
and correct wire routing.
3. Replace end cover and control box cover.
GENERATOR STORAGE
Before storing the generator, apply a heavy coat of grease to the
splined input shaft. Store the generator in a sheltered area, where it is
protected against snow, rain, and excessive dust.
GENERATOR TESTING
BRUSHES
Under ordinary circumstances, brushes will operate for extremely llong
periods without requiring replacement. They should be inspected after
therst500hoursofoperation,andafterevery200hoursofoperation
thereafter. Remove brushes one at a time and check for length; be sure
that each moves freely in the brush holder. Brushes should be replaced
when worn down to 3/8”. Replace brushes in complete sets, never
singly. When replacing brushes, be careful to reconnect the lead wires
properly.
Poor contact (or “skipping”) between brush and slip ring is caused by
oilandgrit,int,orotherhardsubstanceonthebrush,orbythebrush
notbeingproperlyshapedtotthesliprings.Remedythesedefects
byttingthebrushestotheslipringcurvature.Place#00sandpaper
under the brushes with the abrasive side to the brushes, and work it
back and forth until the brushes are the same shape as the slip rings.
SLIP RINGS
THe four continouous copper rings located on the end of the armature
are the generator output slip rings. For proper generator output, the
surface of the slip rings must have a smooth, shiny, highly polished
nish.Normalbrushseatingwilltransferashinyblacknishthatwill
seatthecoppersurface.Thisnishshouldnotberemovedunlessit
becomes dull or begins to build up. Under sustained use, it is advisible

10 REV B
60706-199
3. Open test. Set meter to read low resistance ( R x ohms). Holding
one meter lead on the surface of slip ring No. 1, touch other meter to
lead to the surface of slip ring No. 2, while observing the meter. The
meter should indicate continuity (low resistance - less than one ohm
istypical).Ifthemeterindicatesopencircuit(inniteresistance),part
of the armature winding is open. This may be caused by a repairable
defect in the connection at the slip ring, however, generally an open
armature will have to be replaced. Continue reading the continuity
between slip rings No. 2 to No. 3 and No. 2 to No. 4. All the slip rings
should have continuity to slip ring No. 2, the neutral ring.
TESTING RECTIFIERS
Testingeldexcitationissuppliedthroughafullwavebridgerectier.
Thistypeofrectierhasfourterminals,twoAC,aDCpositive,anda
DCnegative.Arectiermaybetestedinthefollowingmanner:
1.Taganddisconnectallleadsfromrectier.
2. Connect the red ohmmeter lead to the positive DC (+) terminal.
3. Connect the black lead to each of the AC terminals in turn. Either a
high or low resistance reading will be obtained.
4. Reserve the meter leads, black lead to the DC positive (+) and the
red lead to the AC terminals, each in turn. An opposite reading should
be observed.
5. Connect the red ohmmeter lead to the negative DC (-) terminal.
6. Connect the black lead to each of the terminals in turn. Either a high
or low resistance reading will be obtained.
7. Reverse the meter leads, black lead to the DC negative (-) and
red to the AC terminals, each in turn. An opposite reading should be
observed.
8. Check each terminal to the case. An open circuit (very high
resistance) reading should be observed. A battery powered test light
may be used. Follow the same procedures described above. A good
diode element will allow current to pass to the light in the test lamp in
only one direction.
9.Iftherectierfailsanyoftheabovetests,itshouldbeconsidered
defective and be replaced.
to check and if necessary, polish the ring surfaces with a crocus cloth
tomaintainthesmoothnish.
ELECTRICAL TESTING
Testinggeneratoreldsforopensandgrounds.
1.Disconnecteldleadsfromrectier.
2. Set multimeter to read resistance, and connect the meter leads to
theeldleads.Iftheeldisopen,meterwillreadinniteresistance
(veryhighohms).Repairorreplaceeldifitisopen.Typically
resistancefortheseeldsvaryfrom20.2to22.4ohms.
3.Leavingonemeterleadconnectedtotheeld,connecttheother
meterleadtotheeldshell.Ifthemeterindicatescontinuity,any
readingotherthaninniteresistance,theeldisgroundedandshould
berepairedorreplaced.Todeterminewhichoftheeldisgrounded,
cut the connector between the two coils and retest to determine which
coil has the low resistance path.
TESTING ARMATURE FOR OPENS AND GROUNDS
1. Remove all brushes
2. Ground faults test - set multimeter to read high resistance (meg-
ohms). Holding one meter lead against a clean spot on the armature
shaft, touch the other lead to each of the slip rings (one at a time) while
obsrving the meter. If meter indicates continuity (any reading lower than
one meg-ohm), the armature is grounded. Dirt between the slip rings
and no the insulator surface can cause grounding. If grounding was
indicated, carefully clean all dirt off the slip rings and their insulators
and recheck it. Replace the armature if it is grounded and unrepairable.

11REV B 60706-199
CONDENSER TESTING
Condensers are built into the generator circuit to minimize radio
interference during operation. If a condenser shorts out, it will also
short out the generator output. To determine whether a condenser is
shorted, stop the generator and disconnect the condenser lead wire
from the brush holder. Using a multimeter on the R x 100 scale, check
the resistance of the condenser. Normal response is a sharp swing of
the meter towards low resistance and then a steady rise towards high
resistance (open circuit). If the capacitor is shorted, it will show as a
constant low resistance.
Other wise, restart the generator without the capacitor connected to
recheck the generator output. If the generator then provides power, the
condenser was at fault and should be replaced. If the generator does
not provide power, the problem was not caused by that condenser,
reconnect the lead wire.
If these tests have not located the trouble, remove the armature and
have it tested for opens, shorts, and grounds on a growler.
SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
Low Output Voltage 1. Engine speed too slow.
2. Generator overloaded.
3. Inadequate engine horse power..
4.Incorrecteldexcitation.(noload/outputlow)
1. Check engine speed. Increase RPM if necessary.
2. Reduce load if it is higher than the rated capacity of the
generator. See generator nameplate.
3. Generator requires 2.0 HP/1000 Watt output. Obtain
larger engine if necessary.
4. Check for worn brushes and weak or broken brush
springs; replace as required. Check input AC voltage to
 rectier.CheckrectieroutputDCvoltagetopositiveDC
brush. If no DC voltage is present at the brush, replace the
 rectier.Checkfordirtysliprings.Cleanthemiftheyaredirty.
High Output Voltage Engine speed too fast. Check engine speed for correct input RPM.
Excessive Vibration 1. Power take-off misalignment excessive.
2. Loose mounting nuts and bolts or hold-down studs.
3. Universal joints in coupling shaft worn or dry.
4. Defective bearings
1. Correct misalignment. It should be less than 15°.
2.Tighten mounting nuts and bolts; repair hold-down stud
mountings.
3. Repair or replace defective parts.
4. Check for possible causes. Replace defective bearings.
No Output Voltage 1. Circuit breaker open.
2. Defective voltmeter.
3. Short circuit in the load..
4. Defective receptacles.
5. Loose (or broken) wires or connections in control
box.
6.Defectiverectier.
7. Dirty slip rings.
8. Brushes binding in holders.
9. Shorted or open armature.
10.Shortedoropeneldcoils.
1. Reset circuit breakers, replace if defective.
2. Check output with another meter, replace meter if defective.
3. Disconnect the load. Check voltage at receptacle cord set.
Check motors, appliances, and load leads for short circuit,
repair short..
4. Remove panel cover and check for voltage to the
receptacles. Replace defective receptacles..
5. Remove panel cover and check all wiring and connections.
Tighten and/or replace where necessary.
6.Testrectier.Replaceifdefective.
7. Clean and polish. Use 00 sandpaper or crocus cloth, never
use emery paper.
8. Check brushes for swelling; replace armature if open or
shorted.
9. Measure armature resistance. Replace armature if open or
shorted.
10.Measurebetweenleadsforopenorshort.Replaceeld
coils if defective.
Generator Overheating 1. Poor ventilation.
2. Generator overloaded.
3.Shortedturnsineldorarmaturewindings.
1. Clean ventilation and cooling fan screens.
2. Reduce load, then check voltage and current.
3. Replace defective components.
Oil Leak 1. Loose plug in gearcase.
2. Defective seal, gasket, or plug in gearcase.
1. Tighten plug.
2. Replaces seal(s), gasket or plugs. Maintain correct oil level.
TROUBLE SHOOTING TABLE

12 REV B
60706-199
WINCO INC. • 225 S. CORDOVA AVE. • LE CENTER, MN 56057 • 507-357-6821
36 MONTH LIMITED WARRANTY
WINCO, Inc., warrants for thirty-six months from date of shipment, that it will repair or replace at its option, for the original
user, the whole or any part of the product found upon examination, by WINCO at its factory at 225 South Cordova
Avenue, Le Center, Minnesota, or by any factory-authorized service station, to be defective in material or workmanship
under normal standby use (average less than 50 hours per month) and service.
For warranty service, return the product within 36 months from the date of purchase, transportation charges prepaid, to
your nearest factory-authorized service station or the WINCO factory. THERE IS NO OTHER EXPRESS WARRANTY.
There is no other express warranty. To the extent permitted by law, any and all warranties, including those of
merchantabilityandtnessforaparticularpurpose,arelimitedto36monthsfromdateofshipment,andliabilityfor
incidental or consequential damages or expenses is excluded. Some states do not allow limitations on the duration of an
implied warranty, and some states do not allow the exclusion or limitation of incidental or consequential damages, so that
abovelimitationorexclusionmaynotapplytoyou.Thiswarrantygivesyouspeciclegalrights;youmayhaveother
rights which vary from state to state. Note: Some states do not allow limitation on the duration of implied warranty and
some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may
notapplyineveryinstance.Thiswarrantygivesyouspeciclegalrightswhichmayvaryfromstatetostate.
EXCLUSIONS:
WINCO does not warrant drive lines, trailer tires, receptacles, or certain other component parts of the product installed by
others, since such items are warranted by their manufacturers.
WINCOdoesnotwarrantmodicationsoralterationswhichwerenotmadeorauthorizedbytheWINCOfactoryand
which affect the stability or reliability of the product.
WINCO does not warrant products which have been exposed to misuse and/or negligence or have been involved in an
accident.
WINCO does not warrant products which have been installed in such a manner as not to protect them from the adverse
environmental conditions (water, mud, insects, etc.) or have not been kept clean.
WINCO reserves the right to change or improve its products without incurring any obligations to
make such changes or improvements on products purchased previously.
This warranty is limited to bench labor and parts only, no allowance will be made for travel time, or removal and
reinstallation of the PTO unit.