Winco W165PTOT User Manual

Tractor Drive
PTO Generators

OWNERS MANUAL

INSTALLATION AND OPERATION INSTRUCTIONS

W85PTOS
W100PTO
W105PTOT
W135PTOS
W145PTOT
W150PTOS
W165PTOT

SAFETY FIRST

READ THIS MANUAL BEFORE OPERATING YOUR GENERATOR.

60706-160 REV 3

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 set.
You have selected a high-quality, precision-engineered
generator set designed and tested to give you years of
satisfactory standby service.

To get the best performance from your new generator
set, 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.

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____________________________________

TABLE OF CONTENTS

INTRODUCTION i
GUIDE TO PRODUCT SAFETY 1
DESCRIPTION 2
PREPARING THE UNIT 2

Unpacking the unit 2

Specifications 2

Assembly 2

INSTALLATION

Foundation Mounting 3

Trailer Mounting 3

ELECTRICAL CONNECTIONS 4
OPERATION 5

Pre-Start Checks 5

Starting Procedure 6

Stopping 6
MAINTENANCE 7

Lubrication 7

Cleaning 8

Storage 8

Trouble Shooting Table 8
GENERATOR CONNECTIONS

120/240 Volt Single Phase 10

120/240 Volt Three Phase 10

120/208 Volt Three Phase 11

277/480 Volt Three Phase 11
GENERATOR RECEPTACLE PANELS 12

Convenience Receptacle Wiring 13

36 MONTH WARRANTY 14

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 repair 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 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, 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 when
operating the PTO.
f. Never try to stop a turning drive shaft with your hand or
your foot.

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DESCRIPTION

The WINCO PTO drive generator will provide, depending on
the unit purchased, 120/240V single phase, 120/240V three
phase, 120/208 three phase or 277/480 three phase 60Hz
electrical service when direct-driven. Tractor or vehicle power
take-off shafts, can be used for driving these generators.

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 an Automatic Voltage Regulator (AVR)
which maintains a constant voltage output and a Frequency
meter to insure the unit is producing 60 Hz power. All the
models (except the 480 volt units) have a control panel with
two output power receptacles, and overload protection circuit
breakers, and most models are equipped with a full load
disconnect plug (not applicable on the 135, 145 and 150 kW
models) To reduce maintenance problems, the coupling
between the generator input shaft and rotor consists of
precision helical gearing. The input shaft is 1-3/4 in diameter
20 spline .

The factory thoroughly tests each of these generators before
shipment. All are continuous duty rated.

person making the delivery make note of the loss or damage
on the freight bill, or sign the consignee’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 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.

Specifications

MODEL VOLTAGE PHASE P/F AMPERAGE

W85PTOS 120/240 Single 1.0 354
W100PTOS 120/240 Single 1.0 416
W105PTOT-4 120/208 Three 0.8 365
W105PTOT-17 120/240 Three 0.8 316

W105PTOT-18 277/480 Three 0.8 158
W135PTOS 120/240 Single 1.0 560
W145PTOT-4 120/208 Three 0.8 504

W145PTOT-17 120/240 Three 0.8 436
W165PTOT-18 277/480 Three 0.8 198
W150PTOS 120/240 Single 1.0 625

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 crate.

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.

Assembly

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. NOTE - The 135kW, 145kW and 150kW units do not

ship with disconnect plugs and must be hard wired to the
main line circuit breaker.

The bag contains an instruction sheet, 2 plug bodies, four
contacts, a 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.

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

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Figure 1

60706-160 REV 3

The following wire sizes are recommended for each unit.

Generator Size
Model AWG Insulation
W85PTOS 4/0 Neoprene/THHN
W100PTOS 4/0 Neoprene/THHN
W105PTOT 4/0 Neoprene/THHN
W135PTOS 350MCM THHN NO Plug Provided
W145PTOT 4/0 THHN NO Plug Provided
W150PTOS 500MCM THHN NO Plug Provided
W165PTOT 1/0 THHN NO Plug Provided

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

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. 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. See Figure 3. When selecting or
building a trailer to mount the generator, consider the
following points:

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).

8. 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).

Installation

FOUNDATION MOUNTING

Mount the generator on a foundation if it is to be used as a
permanent or standby power source (see Figure 2). See
“TRAILER MOUNTING” if generator will be used as a portable
power source (see Figure 3). When planning a foundation
consider the following points:

Figure 3

Trailer, for Portable Operation

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.

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.

Figure 2

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