Winco 2FS Series Setup guide

1
12095-10 60706-230
INSTALLATION AND
OPERATORS MANUAL
2FS Generators
2000 Watt Belt Drive
225 S. CORDOVA AVE
LE CENTER MN 56057
507-357-6821
SERVICE DEPARTMENT
507-357-6831
www.wincogen.com

SAVE THESE INSTRUCTIONS
This manual contains important instructions that
should be followed during installation and main-
tenance of the generator. Read and understand
all instructions in the manual before starting and
operating the generator set.
USING THE MANUAL
Congratulations on your choice of a Winco genera-
tor set. You have selected a high-quality, precision
engineered generator set designed and tested to
give you years of satisfactory service.
To get the best performance from your new genera-
tor set, 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.
TABLE OF CONTENTS
BASIC INFORMATION
 Specications    2
GUIDE TO PRODUCT SAFETY 3
UNIT CAPABILITIES 4
PREPARING THE UNIT 5
Unit Installation 5
MAINTENANCE 6
ELECTRICAL TESTING 7
TROUBLESHOOTING 8
ILLUSTRATED PARTS LIST 9
WIRING DIAGRAM 10
MAINTENANCE LOG 11
WARRANTY INFORMATION 12
PROPER USE AND
INSTALLATION
You must be sure your new generator set is:
* Properly serviced before starting.
* Operated in a well ventilated area.
* Properly exhausted and gases safely
dispersed.
* Operated only for its designed purposes.
* Used only by operators who understand
its operation.
* Properly maintained.
COPY YOUR MODEL AND
SERIAL NUMBER HERE
No other WINCO generator has the same serial
number as yours. It is important that you record
the number and other vital information here. 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_________________________________
DEALER PHONE # ________________________
UNIT SPECIFICATIONS
2FS FAMILY
Surge Watts 2040
Continuous Watts 2040
Volts 120
Amps 17.0
Receptacles OPTIONAL
UL Listed UL STD 1004-1
UL STD 1004-4
CSA 22.2 NO 100-004

SAFETY INFORMATION
This engine generator set has been designed and
manufactured to allow safe, reliable performance.
Poor maintenance, improper or careless use can
result in potential deadly hazards; from electrical
shock,orre.Pleasereadallsafetyinstructions
carefully before installation or use. Keep these
instructions handy for future reference. Take special
note and follow all warnings on the unit labels and in
the manuals.
ANSI SAFETY DEFINITIONS
***********************************************************
DANGER:
DANGER indicates an imminently hazardous situ-
ation 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 situ-
ation which, if not avoided, could result in death or
serious injury.
***********************************************************
***********************************************************
CAUTION:
CAUTION indicates a potentially hazardous situ-
ation which, if not avoided, may result in minor or
moderate injury. It may also 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. ELECTRICAL SHOCK The output voltage pres-
ent in this equipment can cause 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 only three-pronged grounded receptacles
and extension cords.
e. Be sure the unit is properly grounded.
2. FIRE HAZARD Gasoline and other fuels pres-
entahazardofpossibleexplosionand/orre.
a. Do not refuel when the engine is running or
hot.
b. Keep fuel containers out of reach of children.
c.Donotsmokeoruseopenamenearthegen-
erator set or fuel tank.
d.Keepareextinguishernearbyandknowits
proper use. Fire extinguishers rated ABC by
NFPA are appropriate.
e. Store fuel only in an approved container, and
only in a well ventilated area.
f. Follow local codes for closeness to combust-
ible material.
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.
4. CLEANLINESS Keep the generator and sur-
rounding 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, includ-
ing the installation or replacement of service parts,
shouldbepreformedonlybyaqualiedtechnician.
a. Use only factory approved repair parts.
b. Do not work on this equipment when fatigued.
c. Never remove the protective guards, covers, or
receptacle panels while the generator is
running.
d. Use extreme caution when working on electri-
cal components. High output voltage from this
equipment can cause serious injury or death.
e. The use of the generator set must comply with
all national, state, and local codes.

12095-10 460706-230
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 condi-
tionsspeciedbythemanufactureroftheapplicable
engines.
UNIT CAPABILITIES
GENERATOR CONNECTIONS
These generators are designed for 120 volt alternat-
ing current (AC) use only. They utilize two different
means of connecting to you loads. Some models
come with two 120 Volt outlets mounted in them and
other models come with three wire. Actual connec-
tions will be discussed later in the manual.
Check the appliance or tool nameplate for the cur-
rent and voltage to insure compatibility.
STARTING ELECTRIC MOTORS
Electric motors require much more current (amps) to
start them than to run them. Some motors, par-
ticularly low cost split-phase motors, are very hard
to start and require 5 to 7 times as much current
to start them as to run them. Capacitor motors are
easier to start and usually require 2 to 4 times as
much current to start them as to run them. Repul-
sion Induction motors are the easiest to start and
require 1 1/2 to 2 1/2 times as much to start them as
to run them.
Most fractional horsepower motors take about the
same amount of current to run them whether they
are Repulsion Induction (RI), Capacitor (Cap), or
Split-Phase (SP) type. The chart below shows the
approximate current required to start and run various
types and sizes of 120 volt 60 cycle electric motors
under average load conditions.
HP AMPS
RUNNING
STARTING AMPS
SP CAP RI
1/6 3.2 16 to 22 6 to 13 5 to 8
1/4 4.5 22 to 32 9 to 18 7 to 12
1/3 5.2 26 to 35 10 to 21 8 to 17
1/2 7.2 not made 14 to 29 11 to 18
1 13.0 not made 26 to 52 20 to 33
Theguresgivenaboveareanaverageloadsuch
as a blower or fan. If the electric motor is connected
to a hard starting load such as an air compressor, it
will require more starting current. If it is connected
to a light load, or no load such as a power saw, it will
require less starting current. The exact requirement
will also vary with the brand or design of the motor.
Self-exiting generators respond to severe overload-
ing differently than utility power. When overloaded,
the engine is not able to supply enough power to
bring the electric motor up to operating speed. the
generator responds with high initial starting current,
but the engine speed drops sharply. The overload
may stall the engine. If allowed to operate at very
low speeds, the electric motor starting winding will
burn out in a short time. The generator winding
might also be damaged.
CAUTION: EQUIPMENT DAMAGE
RUNNING THE GENERATOR SET UNDER
THESE CONDITIONS MAY RESULT IN DAMAGING
THE GENERATOR STATOR AS WELL AS THE MO-
TOR WINDING.
Because the heavy surge of current required for
starting motors is required for only an instant, the
generator will not be damaged if it can bring the
motor up to speed in a few seconds of time. If dif-
cultyisexperiencedinstartingmotors,turnallother
electrical loads off and if possible reduce the load on
the electric motor.

5
12095-10 60706-230
PREPARING THE UNIT
UNPACKING
CAUTION: EQUIPMENT DAMAGE
When you unpack your new generator be sure to
remove all the information sheets and manuals from
the carton.
1. This generator was in good order when shipped.
Inspect the generator-set promptly after receiving
it. If any damage is noted, notify the transportation
company immediately; request proper procedures
forlinga“concealeddamage”claim.Titletothe
equipmentandresponsibilityforlingaclaimrests
with you when a generator-set is sent F.O.B. ship-
pingpoint.Onlyyoucanlegallyleaclaim.
2. Before proceeding with the preparations of
your new generator for operation, take a couple of
minutes to insure the unit you have received is the
correctmodelandreviewthespecicationpagesin
this manual to insure that this unit meets your job
requirements.
UNIT INSTALLATION
CAUTION: EQUIPMENT DAMAGE
Before proceeding with the installation, be sure
that you have completely read and understood the
assembly and installation instructions.
An engine with adequate horsepower and a close
regulated(xedspeed)governorisrequiredforsat-
isfactory operation of this generator.
About 1.4 horsepower is required to produce each
1,000 watts of generator output power assuming
100%efciencyofboththeengineandthegenera-
tor.However,duetoengineandgeneratorefcien-
cies of 80 to 90%, the loss of power due to engine
driving accessories such as cooling fans, battery
charging alternators, etc., friction losses and slip-
page in the drive pulleys and belts, the general
conservative rule of thumb allowing approximately
two (2) horsepower for every 1,000 watts of genera-
tor output is much more realistic. For example, this
2,000 watt generator output will require a 4 or 5 H.P.
engine for full output, good speed/voltage regulation,
and satisfactory load performance. When determin-
ing the prime mover/generator pulley ratio to drive
the generator at the correct operating speed, bear
in mind that the power rating of most prime mov-
ers (usually an engine) varies with the speed. It
produces more power at higher speeds, less when
slowed. The prime mover must be run fast enough
to reach the desired horsepower for good generator
operation.
The drive belt system must be of adequate size and
must be tight enough to power the generator without
slippage. Be careful not to overtighten to the extent
that it puts excessive strain on the bearings. Do-
ing so can cause bearing failure and other possible
damage to the generator.
Alignment of the generator to the prime mover is
important. Misalignment of the pulleys will cause ex-
cessive belt and pulley wear and unnecessary stress
on the prime mover.
The following table shows the effect of various op-
erating speeds and electrical loads on a typical gen-
erator when matched and mounted to an adequate
prime mover.
Although individual units and models may vary
slightly, the normal voltage and frequency of typical
60 cycle engine-driven generators described in this
manual are approximately as follows when powered
byatypicalprimemover(engine)runrstwithno
load applied, then at half the generator capacity and
nallywhenloadedtoitsfullcapacityasratedonthe
nameplate.
LOAD VS. OUTPUT
Generator
Load Applied*
Speed
(RPM)
Fre-
quency
(Hz)
Voltage
(Cold)
None 3690 61.5 129V
Half 3600 60.0 120V
Full 3510 58.5 115V
* NOTE: Required generator speed must be main-
tained at 3600 +/- 90 RPM under all load conditions.
All engines have a tendency to slow down when
a load is applied. The governor on the engine is
designed to hold the engine speed nearly constant.
When the electrical load connected to the genera-
tor is increased, the engine is more heavily loaded
and as a result the speed drops slightly. This slight
decrease in speed together with the natural “voltage
drop” within the generator itself due to load current
and heating of the windings, results in a slightly
lower voltage than when the generator is running
idle.

12095-10 660706-230
The normal slight variations in speed also directly
affect the frequency of the output current. This
frequency variation has no appreciable effect in the
operation of most loads (such as motors, lights and
most small appliances). However, timing devices and
clocks will not keep perfect time unless the engine
can keep the generator running at exactly 3600 RPM
at all times. Since this is not usually possible, minor
time errors in clocks occur.
The speed of the engine is usually adjusted so that
the generator produces proper voltage. If the adjust-
ment is made “cold,” set the voltage a little higher
than normal since it will drop a few volts as the gen-
erator warms up.
NOTE: When operating continuously at full load the
generator shell becomes very warm. It will be un-
comfortable to the touch. This is normal for any high
performance inherently regulated generator. Output
voltage should be checked periodically to ensure
proper operation of the generator and appliances.
CAUTION: EQUIPMENT DAMAGE
Low voltage may damage any motors or appliances
connected to it. Running the generator at exces-
sively high speeds results in too high voltage which
will also damage electrical devices connected to it.
Excessively high speed may also cause damage to
the generator armature windings.
Plans for installation should be prepared with proper
attention to mechanical and electrical engineering
detail to assure a satisfactory system installation.
The information in this manual is offered as a guide
tonalizingyourinstallationplans.Theinstallation
sequence is summarized below.
PLAN THE INSTALLATION
Generally these two-bearing generators are used on
portable equipment. For best service consider the
following:
1. All electrical equipment should be protected from
excessive moisture. Failure to do so will result in
deterioration of the insulation and short circuits and
grounds.
2. The generator should be installed in a sheltered
area. If the unit must be left in the open it should
always be protected with a weather cover such as a
tarp or large piece of canvas after each use to keep
out water and dust.
CAUTION: EQUIPMENT DAMAGE
Always allow the generator and prime mover to cool
before covering with a ammable weather covering.
3. Circuit Breaker protection must be installed
between the generator and the loads. This protec-
tion should be accessible to the customer with out
removing panels. Circuit breaker should be 20 Amp.
MOUNTING
CAUTION: EQUIPMENT DAMAGE
The generator must be mounted with the engine to a
common rigid base to prevent stress on the engine
and generator shafts and bearings due to vibra-
tion displacement. For permanent installations, the
engine-generator is usually mounted on a sub-frame
which can be shock mounted with special neoprene
pads on the main frame.
CONNECTING TO THE LOADS
All wiring must be completed in accordance
with NFPA 70, The National Electric Code.
The 2FS family of generators come in two different
congurations.Onemodelcomeswithtwo120Volt
receptacles mount in the end cover, connecting to
this model is only a matter of plugging in a standard
NEMA 5-15 3-wire plug into the receptacle.
Thesecondcongurationofthe2FSfamilyisa
cover plate installed in the end bracket with the
three generator output leads routed through it for
your connection The hot lead is black labeled “G1”,
the neutral lead is black, labeled “N” and the ground
lead is green.

7
12095-10 60706-230
MAINTENANCE
GENERAL
Themaincomponentsofthegeneratorare:eld
frame,eldcoils,armature,brushes.brushholder
assembly, brackets, armature, and generator cooling
fan.
BRUSHES
Under ordinary circumstances brushes will operate
for thousands of hours without requiring replace-
ment.Theyshouldbeinspectedaftertherst
1000 hours of operation, and after every 500 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”. Always replace
brushes in complete sets, never singularly. When
replacing brushes be careful to reconnect the lead
wire properly. Poor contact or “skipping” between
brush and slip ring can be caused by oil and grit,
int,orotherhardcontaminantsubstancesonthe
brushes, or by the brush not being properly shaped
totthesliprings.
Remedy these defects by cleaning the rings and
brushesandthen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 continuous copper rings located at the end of
armature are the power collector rings or ‘slip rings’.
For proper generator output, the surface of these slip
ringsmusthaveahighlypolishednish.Undersus-
tained use, it is advisable to check and occasionally
polish ring surfaces with a crocus cloth to maintain
thenishundernormalconditions.Thisshouldnot
be required more than once each thousand hours of
operation.
ELECTRICAL TESTING
TESTING COILS FOR OPENS AND GROUNDS
1.Disconnecteldleadsfromrectier.
2. Set multi-meter to read resistance, and connect
themeterleadstotheeldleads.Ifeldisopen,
meterwillreadinniteresistance(veryhighohms),
repairorreplaceeldifitisopen.Typicalresistance
fortheseeldsvariesfrom12.8to14.1ohms.
3.Leavingonemeterleadconnectedtotheeld,
connecttheothermeterleadtotheeldshell.If
meter indicates continuity (any reading - should be
inniteresistance),theeldisgroundedandshould
be repaired or replaced. To determine which of the
eldsisgrounded,cuttheconnectorbetweenthe
two coils and retest to determine which coil has the
low resistance path.

12095-10 860706-230
TESTING ARMATURE FOR OPENS AND
GROUNDS
1. Remove all brushes.
2. Ground fault test. Set milti-meter to read high
resistance (mega-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 observing the meter. If meter indicates
continuity (any reading lower than one mega-
ohm), the armature is grounded. Dirt between the
slip rings and on the insulator surface can cause
grounding. If grounding was indicated, carefully
clean all dirt off the slip rings and their insulators
and then recheck it. Replace the armature if it is
grounded and unrepairable.
3. Testing for opens. Set meter to read low resis-
tance (R x 1 ohms). Holding one meter lead on
the surface of slip ring # 1, touch the other lead to
surface of slip ring # 2 while observing the meter.
Meter should indicate continuity (low resistance
- less than one ohm is typical). If the meter indi-
cates an open
circuit(inniteresistance)partofthearmature
winding is open. This may be caused by a re-
pairable defect in the connection at the slip ring,
however generally an open armature will have to
be replaced.
TESTING RECTIFIERS
Theeldexcitationissuppliedthroughfullwave
bridgerectier.Thistypeofrectierhasfourtermi-
nals: two AC and a DC positive (+) and DC negative
(-). Nothing is connected to the DC negative (-) in
this generator.
Arectiermaybetestedinthefollowingmanner:
1.Disconnectallleasfromrectier.
2. Connect the red ohmmeter lead to the positive
DC (+) terminal.
3. Connect the black lead to each of the AC termi-
nals in turn. Either a high or low resistance reading
will be obtained.
4. Reverse the meter lead, (black lead to the DC
positive (+) and red to the AC terminals, each in
turn. An opposite reading should be observed.
5. Check each terminal to the case. An open circuit
(very high resistance) reading should be observed.
If a battery powered test light is used follow the
same procedures described above. A good diode
element will allow current to pass to the light in the
test lamp when the lead are connected in the for-
ward direction.
6.Iftherectierfailsanyoftheabovetests,it
should be considered defective and replaced.

9
12095-10 60706-230
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
No output or low voltage. 1. Open or shorted armature.
2.Openorgroundedeldcoil(s).
3. Generator operating below
correct RPM speed.
4. Generator overloaded.
5. Short circuit in the load.
6. Loose (or broken) wires or
connections in the control box.
7.Defectiverectier.
8. Dirty slip rings.
9. Brushes binding in holders.
10. Loss of residual magnetism.
1. Replace armature.
2.Replaceeldcoil(s).
3. Generator must be operated at
3600 RPM +/- 90 RPM for proper
output voltage.
4. Reduce load to generator
nameplate.
5. Disconnect the load. Check
motors, appliances and load leads
for short circuits. Repair short.
6. Remove panel cover and
check all wiring and connections.
Tighten and/or repair where nec-
essary.
7.Testrectier.Replaceifdefec-
tive.
8. Clean and polish. Use 00
sandpaper and crocus cloth,
never emery paper.
9. Check brushes for swelling.
Replace defective brushes. Clean
brush holders.
10. Check output voltage with
sensitive meter. If very low (i.e.
1/2volt)asheldswitha12VDC
battery.
Output voltage too high. Engine speed too high. See engine manual.
Generator overheating. 1. Generator overloaded.
2. Armature rubbing pole shoes.
3. Poor ventilation.
4.Shortcircuitinelds.
5. Short turns in armature.
1. Reduce load.
2. Check bearing condition.
Checkeldshellbearingbracket
alignment.
3. Clear inlet and outlet air vents
of debris. If unit is housed, ensure
at least 2 ft. clearance on all sides
and that inlet and outlet vents are
of adequate size.
4. Repair or replace - open or
shortedeldsshouldbereplaced.
Groundedeldsmayberepaired
by insulating at the point where
the ground occurs.
5. Replace armature.
Sparking at the brushes. 1. Generator overloaded.
2. Brushes not seated properly.
3. Slip rings rough or eccentric.
4. Brushes sticking in brush
holder.
5. Brushes worn down shorter
than 3/8 inch.
1. Reduce load.
2. Contour brushes (see maint.).
3. Redress slip rings (see maint.).
4. Remove brushes and inspect
and correct problem.
5. Replace brush. NOTE: Al-
ways replace brushes a full set at
a time.
TROUBLESHOOTING CHART

12095-10 10 60706-230
ILLUSTRATED PARTS LIST
REF # PART NUMBER QTY DESCRIPTION
1 20556-002 4 # 10-32 Thru Bolt
2 8929-000 1 End Bracket
 3 7924-000 1 Bafe
4 61689-000 1 Field Shell & Base Assy.
5 63941-008 1 Hot Surface Decal
6 53644-000 4 Screw
7 61427-000 1 Output Shaft End Bracket
8 6372-000 4 Hex Nut
9 23607-000 3 AC Brush
10 59690-000 3 AC Brush Holder
11 60928-000 1 Cover Plate
12 61687-000 1 Field Shell & Coil Assy.
13 60925-000 1 Upper Field Coil
14 60925-001 1 Lower Field Coil
15 60931-000 1 Receptacle Cover Plate
60931-001 1* Recpt. Cove Plate UL Model
62170-000 1** Cover Plate
16 60960-000 2 Receptacle
17 91286-015 1* 15 Amp Circuit Breaker
 18 53976-000 1 Rectier
19 59688-000 3 Barrier Spacer
NI 23532-000 1 Spacer
NI 41384-017 1 Copper Strap
NI 40746-000 6 # 8-32 X 5/16 Screw
NI 21361-000 1 Key
NI 61426-000 1 Armature & Bearing Assy.
NI 64917-002 1 UL Decal
NI Not Illustrated
* UL Model only
** 2FSM2P-1/A3 only

11
12095-10 60706-230
WIRING DIAGRAM
2FS WITH “Q” WINDING
WIRING DIAGRAM
2FS WITHOUT “Q” WINDING

12095-10 12 60706-230
12 MONTH LIMITED WARRANTY
WINCO, Incorporated warrants to the original purchaser for 12 months that goods
manufactured or supplied by it will be free from defects in workmanship and material,
provided such goods are installed, operated and maintained in accordance with WINCO
written instructions.
WINCO’s sole liability, and Purchaser’s sole remedy for a failure under this warranty,
shall be limited to the repair of the product. At WINCO’s option, material found to be
defective in material or workmanship under normal use and service will be repaired or
replaced. For warranty service, return the product within 12 months from the date of
purchase, transportation charges prepaid, to your nearest WINCO Authorized Service
Center or to WINCO, Inc. at LeCenter Minnesota.
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12monthsfromdateofpurchase.In
no event is WINCO liable for incidental or consequential damages.
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.
WINCO reserves the right to change or improve it products without incurring any obliga-
tions to make such changes or improvements on products purchased previously.
EXCLUSIONS:
WINCO does not warrant Engines. Engines are covered exclusively by the warranties
of their respective manufacturers, see enclosed warranties.
WINCO does not warrant Component Parts that are warranted by their respective manu-
facturers.
WINCOdoesnotwarrantmodicationsoralterationswhichwerenotmadebyWINCO
Inc.
WINCO does not warrant products which have been subjected to misuse and/or negli-
gence or have been involved in an accident.
This warranty does not include travel time, mileage, or labor for removal or reinstallation
of WINCO product from its application.