Winco ECV2512-3 User Manual

Chassis Mount
PTO Generators

OWNERS MANUAL

INSTALLATION AND OPERATION INSTRUCTIONS

ECV2510-3
ECV2512-3

SIDE VIEW

TOP VIEW

Note: Unit shown is the ECV2512 the only
dimension that changes on the ECV2510 is
the location of the input shaft

DRIVE END VIEW

SAFETY FIRST

READ THIS MANUAL BEFORE OPERATING YOUR GENERATOR.

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Read and understand all instructions in this
manual before starting and operating the
generator set.

USING THIS MANUAL

Congratulations on your choice of a Winco generator.
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 generator, it
is important that you carefully read and follow the operating
instructions in this manual.

Should you experience a problem please follow the
“Things To Check” near the end of this manual. The warranty
listed in this manual describes what you can expect from
WINCO should you need service assistance in the future.

TABLE OF CONTENTS

INTRODUCTION i
GUIDE TO PRODUCT SAFETY 1
BASIC INFORMATION

Description 2

PREPARING THE UNIT

Unpacking the unit 2

Assembly 2

INSTALLATION

Plan the Installation 2

Mounting 3

Ventilation 3

Drive Line & Lubrication 3

Pre-Wire Checklist 4

Initial Start 4

ELECTRICAL CONNECTIONS 4
FINAL SYSTEM CHECK 5
MAINTENANCE

General Information 5

Periodical Maintenance 5

Generator Maintenance 5

Lubrication 7

TROUBLE SHOOTING TABLE 8
PART LIST

Automatic Voltage Regulator 9

Generator Parts List 10

Gear Box Part List 12

WIRING DIAGRAM 13
12 MONTH WARRANTY 14

PROPER USE AND INSTALLATION

You must be sure your new generator set is:
* Properly serviced before operating
* Operated in a well ventilated area
* Exhaust gases are dispersed safely
* Wired by a qualified electrician
* 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___________________________________

SAFETY INFORMATION

This 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, exhaust gas asphyxiation, 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.

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 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. 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.
g. Do not make or break electrical connection under

load.

2. FIRE HAZARD- Gasoline, diesel and other fuels always
present a hazard of possible explosion and/or fire.

a. Keep a fire extinguisher nearby and know its

proper use. Fire extinguishers rated ABC by
NFPA are appropriate.

3. DEADLY EXHAUST GAS - Exhaust fumes from any engine
contain carbon monoxide, an invisible, odorless and
deadly gas that must be mixed with fresh air.

a. Operate only in well ventilated areas.
b. Never operate indoors.

4. NOISE HAZARD - Excessive noise is not only tiring, but
continual exposure can lead to loss of hearing.

a. Use hearing protection equipment when

working around this equipment for long periods of
time.

b. Keep your neighbors in mind when permanently

installing this equipment.

5. 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 material that could

create potential fire hazards.

6. SERVICING EQUIPMENT- All service, including the
installation or replacement of service parts, should be
performed only by a qualified technician.

a. Use only factory approved replacement parts.
b. Do not work on this equipment when fatigued.
c. Use extreme caution when working on electrical

components. High output voltages from this
equipment can cause serious injury or death.

d. Always avoid hot mufflers, exhaust manifolds, and

engine parts. They all can cause severe burns
instantly.

7. INSTALLATION- Installing a PTO generator is not a “do-it­yourself” 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.

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, extereme caution must be
exercised when using them.

a. NEVER allow children around a 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 a turning drive shaft with your hand

or your foot.

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DESCRIPTION

The WINCO ECV2510/2512 PTO drive generator will
provide 120/240V single phase, 60Hz electrical service
when direct-driven. The ECV2510 requires a 1000 RPM
input shaft speed and the ECV2512 requires a 1182 RPM
input shaft speed.

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 under chassis mounted and driven
from a truck transmission with a PTO drive installed in it.

When loss or damage is noted after delivery, segregate
the damaged material, and contact the carrier for claim
procedures.

“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.

This generator is a rotating armature design with com­pound field coil windings. Normal excitation is accom­plished via the "Q" winding in the armature and a full wave
bridge rectifier. An automatic voltage regulator is installed
on the generator to maintain the correct voltage when the
unit is under load.

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 1-1/8 in diameter smooth shaft with a key way and
center drilled for a roll pin. Both must be used at all times.

WINCO thoroughly tests each of these generators 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

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. 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.

3. Remove the four bolts which hold down the generator
feet to the pallet.

4. Lift the generator from the pallet by means of the lifting
eye on the top of the generator.

INSTALLATION

********************
********WARNING**********
*********************

Before proceeding with the installation, be sure the drive
line and engine are disabled and cannot accidentally
operate while the generator is being installed.

Before beginning the installation process recheck the voltage
power rating and physical size and drive line rating and
speed, horsepower etc. Be certain they can handle the
intended load and are compatible with the required vehicle
equipment voltage, phase and current ratings. 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 finalizing your installation plans. The
installation sequence is summarized below:

A. Plan the installation :

1. Space required for installation and service
access.

2. Protected location, close to electrical connections.

3. Mounting frame.

4. Clear of moisture and dirt.

5. Shielded from excess heat and cold.

B. Mounting the generator system.
C. Clear, protected source of ventilation of generator.
D. Drive line aligned within 5 degrees (10 degrees max).
E. Pre-wire system check.
F. Initial system start-up.
G. Generator electrical power connections.
H. Final system check

A. PLAN THE INSTALLATION

1. Space Required. The space required should allow for

ample working room around and in back of generator.
A general rule to follow is 12 inches minimum clear­ance all around the unit. This allows a service person
to repair and remove generator parts in the event
service is needed. In general, all service can be
performed from the rear generator cover or the front
gear case.

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2. L ocation. Locate as close to electrical service as pos­sible. This will reduce the cost of electrical and minimize
the losses in the power conductors. Position the unit to
keep clear of the drive line and exhaust runs.

3. Mounting Support. Frame loading, frame type and
strength should be taken into consideration when
installing an emergency rescue generator under a
truck.

4. Moisture and Dirt. Protection from adverse weather
conditions and road spray must be provided without
restricting adequate ventilation for cooling. All
electrical equipment should be protected from
excessive moisture. Failure to do so will result in
deterioration of the insulation and will result in short
circuits and grounds. Foreign materials such as
dust, sand, tint and abrasive materials have a
tendency to cause excessive wear, particularly the
brushes. It is important that the unit be installed in a
reasonably clean location for best service life. Careful
planning will eliminate costly rework.

5. Heat and Cold. All generators radiate considerable heat
when they are running. In addition, these units are
generally mounted in a somewhat restricted location
which precludes natural cooling. Allow space for cool­ing air to sweep across the generator shell. It is impor­tant that the temperature of the ambient air around the
unit not exceed 105 degrees Fahrenheit while operat­ing. Additional cooling louvers or fans may be neces­sary if adequate cooling flow is not naturally provided.

B. MOUNTING THE GENERATOR SYSTEM

The generator should be bolted solid to a heavy steel
cross channel or plate. It is recommended that the
generator be mounted on a steel sub-frame which
facilitates easy removal of the generator for better service
access to the chassis or for generator repair.

Shock mounting the generator or mounting frame is
generally not recommended do to possible harmonic
vibration, drive misalignment and mounting stress.

C. VENTILATION OF GENERATOR

This is an air cooled generator. This unit is equipped
with a suction fan to cool the armature and field coils.
Therefore it will be necessary to insure that the hot air
discharge plume gets out of the mounting area.

D. DRIVE LINE AND LUBRICATION

Check gear case oil level. 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.

Make sure the drive shaft (tumbling bar) is assembled with
its universal joint knuckles “synchronized,” as illustrated in. If
knuckles are not synchronized, the bar will chatter when
rotating, which will cause the generator output voltage to
flicker.

See “Lubrication” portion of Maintenance for oil specifica­tions.

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