Winco W70PTOS Administrator Guide

www.wincogen.com
INSTALLATION & OPERATORS
MANUAL
W70PTO &
W70PTOS
GENERATORS
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 concerning this unit, it will
help us to respond to your needs faster.
MODEL __________________________________________________
SERIAL NUMBER _________________________________________
PURCHASE DATE _________________________________________
DEALER NAME ___________________________________________
DEALER PHONE # ________________________________________

2
OPM-142/D
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS 2
SAFETY 3
IMPORTANT SAFETY INSTRUCTIONS
SPECIFICATIONS 4
INTRODUCTION 5
TESTING POLICY
INSTALLATION 6
FOUNDATION MOUNTING
TRAILER MOUNTING
ELECTRICAL CONNECTIONS 7
Typical Connection Methods for Generator Power Service
OPERATION 9
PRE-START CHECKS 10
GENERATOR PROCEDURES 11
START UP
SHUTDOWN
MAINTENANCE 12
GENERAL
PERIODICAL MAINTENANCE
LUBRICATION
CLEANING & INSPECTION
GENERATOR STORAGE
TROUBLE SHOOTING TABLES 14
WIRING DIAGRAM 15
LIMITED WARRANTY 16
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. Keep
this manual available for future reference.
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.

3OPM-142/D
CAUTION
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 fire hazard.
C. Carefully clean up any gas or oil spills before starting
the unit.
CAUTION
All service, including the installation or replacement of
service parts, should be performed only by a qualified
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 qualified, licensed electrician or contractor.
The installation must comply with all national, state,
and local codes.
WARNING
Installing a PTO generator is not a “do-it-yourself” project.
Consult a qualified, 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.
WARNING
PTO drive shafts (tumbling bars) have many inherent
dangers, extreme caution must be exercised when using
them.
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.
SAFETY
IMPORTANT SAFETY INSTRUCTIONS
This engine generator set has been designed and
manufactured to allow safe, reliable performance. Poor
maintenance, improper or careless use can result in
potentially deadly hazards; from electrical shock, or fire.
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.
SAFETY DEFINITIONS
DANGER
Indicates an imminently hazardous
situation which, if not avoided, will result
in death or serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in
death or serious injury.
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.
CALIFORNIA PROPOSITION 65
WARNING: This product contains crude oil,
gasoline, diesel fuel and other petroleum
products, Antifreeze to which can expose you
to chemicals including toluene and benzene,
Ethylene glycol (ingested) which are known to the
State of California to cause cancer, birth defects or other
reproductive harm and developmental issues.
For more information go to www.P65Warning.ca.gov.
DANGER: 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.
WARNING: FIRE HAZARD
Keep a fire extinguisher nearby and know its proper use.
Fire extinguishers rated ABC by NFPA are appropriate.
CAUTION: 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
OPM-142/D
SPECIFICATIONS
GEAR LUBE
Volume 0.875 Pint
Type SAE 80-90W-140
W70PTO
Continuous Watts 69,000
Volts 120/240
Phase Single
Amps 287
Power Factor 1.0
Input Speed 540 RPM
Generator Speed 1800 RPM
Input Shaft 1 3/4” - 20 Spline
Required Tractor PTO HP 138
W70PTOS
Continuous Watts 69,000
Volts 120/240
Phase Single
Amps 287
Power Factor 1.0
Input Speed 1000 RPM
Generator Speed 1800 RPM
Input Shaft 1 3/4” - 20 Spline
Required Tractor PTO HP 138

5OPM-142/D
INTRODUCTION
TESTING POLICY
Before any generator is shipped from the factory, it is fully
checked for performance. The generator is loaded, 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 specified
by the manufacturer of applicable engines.
The WINCO 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
1-PH, 120/208V 3-PH, 120/240V 3-PH, or 277/480V 3-PH
(depending on model), 60Hz electrical service when
properly driven.
DO NOT operate and/or store the unit outside during
inclement weather without adequate protection from the
elements. Failure to do so will damage the unit.
It is acceptable to use this generator with a tractor with
less HP output than required for full power operation. The
generator will work but produce only as much kW output
as the tractor can supply HP for. For example, a 20 HP
output tractor will deliver a maximum of approximately 10
kw.
If you are using a tractor with more HP than required to
run the generator care should be taken to ensure that you
do not overload the generator causing overheating and
equipment damage. 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 frequency meter to warn against
high or low frequency, 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 3/8in. 6-spline.
IMPORTANT: THE MANUFACTURER STRONGLY
RECOMMENDS RUNNING THE GENERATOR UNDER
LOAD AT LEAST ONCE A MONTH IN ORDER TO
EVAPORATE ANY ACCUMULATED MOISTURE
CONDENSATION.
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 file 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 specification pages in this manual to
ensure that this unit meets your job requirements.

6
OPM-142/D
WARNING: PERSONAL INJURY & EQUIPMENT
DAMAGE
Trailer may tip over and cause injuries if wheels are not
spaced far enough apart.
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 15 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 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.
INSTALLATION
Note: PTO mounting holes are .75”.
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 15 degrees
during generator operation, even though the
mechanical design of the tumbling bar may allow
greater misalignment.
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. For dimensions needed for your specific generator,
please refer to it’s outline drawing. The hardware
needed is dependent on your distinct application.
F. All four generator mounting pads must rest 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.

7OPM-142/D
ELECTRICAL CONNECTIONS
CAUTION:
Only qualified electricians should install electric 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
generator when the generator is supplying power.
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.
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
first 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.
Before deciding which system to install, first 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 sub-pack carton packed in the
generator crate.
The bag contains an instruction sheet, 2 plug bodies, four
contacts, a handle and the hardware to assemble 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.
VOLTAGE
RECOMMENDED
WIRE
CONTACTS
INCLUDED
120/240 1-PH 2/0 1/0 & 1/0 to #1
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. 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 of the free end of each of the plug
leads (cables) and connect them to the load transfer switch
or directly to the load.
CONTACTS
HANDLE
HOUSING

8
OPM-142/D
Emergency
Power
System
Emergency
Power
System
Standby
Generator
Standby
Generator
Transfer
Switch
Transfer
Switch
G3
G3
L1
L1
L3
L3
G1
G1
T1
T1
T3
T3
TYPICAL HOOK UP FOR
SUPPLYING ALL CIRCUITS
WITH EMERGENCY POWER
TYPICAL HOOK UP FOR
SUPPLYING ONLY ESSENTIAL CIRCUITS
WITH EMERGENCY POWER
IMPORTANT: When making standby service hook up, make sure load to be
transferred to standby generator will not exceed generator rating.
Watthour
Meter
Watthour
Meter
To Power Line Master Switch To Power Line Master Switch
Distribution
Panel
To Refrig.
To
Refrig.
To Appliances
To
Appliances
To Air
Conditioner
To Air
Conditioner
Main
Distribution
Panel
Emergency
Distribution
Panel
To Furnace
To
Furnace
To
Range
To
Range
To
Water
Heater
To
Water
Heater
To Lights
To
Lights
To
Lights
To
Lights
To Lights
To Lights
TYPICAL CONNECTION METHODS FOR GENERATOR POWER SERVICE

9OPM-142/D
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 large two pole switch type main circuit breaker protects
the generator windings and output circuits, including the
load disconnect receptacle outputs. The load disconnect
receptacle 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 voltage = Load current (in Amps)
Example: 250W, 120V floodlight load: 250W / 120V = 2
Amps
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.

10
OPM-142/D
PRE-START CHECKS
WARNING: PERSONAL INJURY:
When working on or around these generators, do NOT
wear loose fitting 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 remove the control box cover and cooling fan
screen, then inspect the generator for rodent nests or
other objects that could cause generator binding and/or
overheating. See ‘Cleaning’ portion of the Maintenance
section.
2. Check Gearcase oil level. (See drawing) Case should be
filled 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 specifications.
3. Make sure the drive shaft (tumbling bar) is assembled
with its universal joint knuckles “synchronized,” as
illustrated below. If knuckles are not synchronized,
the bar will chatter when rotating, which will cause the
generator output voltage to flicker. Drive shafts shipped
new from WINCO are always synchronized and tethered
so they can not be taken apart.
OIL LEVEL PLUG
Page 6
60706-180 0310-00
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 volt-
age to flicker. Drive shafts shipped new from Winco are al-
ways synchronized and tethered so they can not be taken
apart.
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 10° 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 gen-
erator receptacle or cord set which will supply the current.
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. Set the manual transfer to mid or normal (up)
position.
2. 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.
3. With engine idling, engage the power take-off drive.
4. Watch the voltmeter on the generator and slowly increase
engine speed until the output reaches approximately 240 to
245 volts, in green portion of voltmeter scale.
5. Plug 4 wire load cord set into receptacle. Place transfer
switch in the emergency position.
6. Place the load circuit breaker in the “on” position. If the
breaker trips, move manual transfer switch to “off” or
normal position. Check for short circuit or grounded
connection in the load cable to the double throw switch and
repair. A breaker that trips from overload or short circuit
must be reset by moving to “off” before reclosing.
7. With engine and generator running smoothly, switch on the
electrical load while watching the voltmeter. Readjust en-
gine 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 sen-
sitive enough to maintain proper output under changing
load, and in such cases the throttle will have to be manually
readjusted .
NOTE: Equipment Damage
If the load includes motors turn them on one at a time,
highest starting current motor first, next highest second,
etc.
8. The return of normal power will be indicated by the
lamp on the front of transfer switch; (applicable only when
the transfer switch is equipped with indicating lamps or
your electrician has installed them). After sufficient time to
assure that power restoration isn’t temporary, return the
transfer switch to normal power (10 - 20 minutes).
9. Place the alternator circuit breaker in “off” position. Do not
remove plug before opening the breaker.
10. Slowly reduce power take-off speed to a minimum and
disengage the power take-off. Some tractors have a brake
on the power take-off that stops the shaft instantly. Stop-
ping the alternator rotor instantly from rated speed may
result in a broken shaft or other drive line failures.
WARNING: Personal Injury
Never try to manually stop the generator. Always let it
coast until it stops.
11. Shut off the engine.
12. Disconnect drive shaft (tumbling bar)
power take-off end first, then generator end.
13. Exercise PTO alternator for one hour under load at least
twice a year.
DANGER: PERSONAL INJURY:
Power take-off must be disengaged at this time.
4. Couple the tractor to the generator with the drive shaft
(tumbling bar). Couple the tumbling bar to the generator
input shaft first, then to the power take-off shaft. Check
alignment, tractor, power take-off shaft (tumbling bar),
and generator input shaft should form a straight (or
nearly straight) line, with less than 5° misalignment
between the tractor and generator input shafts.
Misalignment will cause generator output voltage to
flicker.
WARNING: PERSONAL INJURY:
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
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 connections
are correct and are tight.
8. Make sure all loads are turned off. Do not start the
generator under load.

11 OPM-142/D
GENERATOR PROCEDURES
START UP
1. Set the manual transfer to mid or normal (up) position.
2. 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.
3. With the engine idling, engage the power take-off drive.
4. Watch the frequency meter on the generator and
slowly increase engine speed until the output reaches
approximately 62 Hz for full loads.
5. Plug load cord set into receptacle. Place transfer switch in
the emergency position.
6. Place the load circuit breaker in the “on” position. If
the breaker trips, move manual transfer switch to “off”
or normal position. Check for short circuit or grounded
connection in the load cable to the double throw switch
and repair. A breaker that trips from overload or short
circuit must be reset by moving to “off” before re-closing.
7. With engine and generator running smoothly, switch
on the electrical load while watching the frequency meter.
Adjust engine throttle to keep generator output under load
at 60 Hz. 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.
NOTE: EQUIPMENT DAMAGE
If the load includes motors, turn them on one at a time,
highest starting current motor first, next highest second,
etc.
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 stop the generator. Always let it coast until it
stops.
4. Shut off the engine.
5. Disconnect the drive shaft (tumbling bar) power take-off
end first, then the generator end.

12
OPM-142/D
MAINTENANCE
GENERAL
The main components of the generator are: rotor and stator
assembly, cooling fan, brushes, brush holder assembly,
end brackets. 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.
LUBRICATION
The generator bearings are factory lubricated and sealed,
and require no further lubrication.
The splined generator input shaft should be cleaned and
lubricated with a thin film of grease before and after each
use of the generator.
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.
See following illustration for recommended lubrication
schedule for the coupling shaft.
Check the generator gear case oil level before each use of
the generator. Maintain the oil level at oil level plug height.
The generator is shipped with lubricant in the gearcase.
Specifications for the gearcase lubricant are:
API Service: GL-5
Grade: SAE 85W-140
Amount: 1 Pint
CAUTION: EQUIPMENT DAMAGE
Do not overfill generator gearcase. 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 the generator gearcase
oil.
1. Remove gearcase breather. Soak breather in cleaning
solvent, then allow to dry.
2. Remove oil level plug. See illustration.
OIL LEVEL 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 find metal chips in the oil.
4. Replace the oil drain plug. Refill the gearcase through the
breather port with new oil of the recommended type. Fill
the case up to the oil level check plug height. About 1
pint.
5. Replace the oil level check plug.
6. Replace the breather.
Page 7
60706-160 REV 3 3117-30
5. Shut off the engine.
4. Disconnect drive shaft (tumbling bar) power take-off end
first, then generator end.
MAINTENANCE
The following chart lists various symptoms of poor generator
operation with possible causes for them 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 the generator
speed you can use the frequency meter on the generator
control panel.
CAUTION: Equipment Damage
Most electrical equipment in North America operates satisfac-
torily at frequencies between 59 and 61 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.
GENERAL
Routine preventive maintenance minimizes costly repairs and
generator downtime. Before each use, inspect the generator:
gear case 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 condi-
tions 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 splined generator input shaft should be cleaned and
lubricated with a thin film of grease before and after each use
of the generator.
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.
See Figure 8 for recommended lubrication schedule for the
coupling shaft.
Check the generator gear case oil level before each use of the
generator. Maintain the oil level at oil level plug height. (Figure
6 illustrates 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: 1 pint
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 over-
heating 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 follow-
ing procedure to change generator gear case oil (see Figure
6):
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 1 pint.)
Figure 8

13 OPM-142/D
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.

14
OPM-142/D
SYMPTOM CAUSE(S) CORRECTIVE ACTION
No output voltage 1. Circuit breaker open
2. Defective frequency meter
3. Short circuit in the load
4. Defective receptacles
5. Loose (or broken) wires or
connections in control box
6. Defective rotating rectifier
7. Defective AVR
8. Shorted or open rotor
9. Shorted or open stator
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 repair where necessary.
6. Test rectifier. Replace if defective.
7. Repair or replace as required.
8. Measure rotor resistance. Replace rotor if open or
shorted.
9. Measure between leads for open or short. Replaces
stator if defective.
High voltage 1. Engine speed too fast.
2. Defective or misadjusted AVR
1. Check engine speed for correct input RPM
2. Adjust, repair, or replace as required
Low voltage 1. Engine speed too slow
2. Generator overloaded
3. Inadequate engine horsepower.
4. Defective or misadjusted AVR
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 HP/1000 watt output. Obtain
larger engine if necessary.
4. Repair, adjust, or replace as required.
Output voltage
flickering or
fluctuation
1. Tumbling bar (shaft) misalignment
2. Engine governor may be worn or
improperly adjusted. Set or repair
defective governor.
3. Loose connection in field circuit
4. Tumbling bar U-Joints not
synchronized
1. Reduce tumbling bar misalignment to less than 15
degrees
2. Engine governor may be worn or improperly
adjusted. Set or repair defective governor.
3. Check and tighten connections.
4. Reassemble tumbling bar.
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
degrees.
2. Tighten mounting buts and bolts; repair hold down
stud mountings.
3. Repair or replace defective parts.
4. Check for possible causes. Replace defective bearings.
Generator
overheating
1. Poor ventilation
2. Generator overloaded
3. Shorted turns in field or stator
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
geargase
1. Tighten plug.
2. Replace seal(s), gaskets or plugs. Maintain correct oil
level.
TROUBLE SHOOTING TABLES

15 OPM-142/D
WIRING DIAGRAM BACK VIEW
01203563786 9ÿ 6
9ÿ9
ÿ!ÿ#$%ÿ&'()

16
OPM-142/D
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 fitness 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 specific 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 specific 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 modifications 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.
ENGINE GENERATOR SET
LIMITED WARRANTY
WINCO INC. • 225 S. CORDOVA AVE • LE CENTER, MN 56057 • 507-357-6821