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Generators & Electric Motors General Discussion Antique Generators and Old Electric Motors: Questions and answers about restoring and showing old power generation systems.

Generators & Electric Motors General Discussion

WINCO 3500 Portable Generator


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  #11  
Old 09-14-2018, 11:22:44 PM
Mark Schneider Mark Schneider is online now
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Default Re: WINCO 3500 Portable Generator

Well Steve it was almost exactly as you said it would be. The "socket" was actually the remains of a light duty push switch that activated a relay for the high amp starter connection. Also found the grounding lug but am unsure at this time how it was utilized.

It's a good thing you had me pop the lid on the wiring cover. I saw some things in there that I didn't want to see....
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  #12  
Old 09-14-2018, 11:40:05 PM
Mark Schneider Mark Schneider is online now
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Default Re: WINCO 3500 Portable Generator

It appears that there was some "magic smoke" in the wiring compartment at one time. The resistor(?) that's fried is connected to the + battery lug on one end with the other lead going into the generator. The wire that is laying on the top of it with the insulation burned off looks like it got cooked when the resistor turned red. I checked the resistor with an ohmmeter and it is open...no surprise!

Any ideas what happened here and is the generator still salvageable?
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  #13  
Old 09-15-2018, 08:39:32 AM
David C David C is offline
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Default Re: WINCO 3500 Portable Generator

Mainly play with Onans, but it looks like someone did not think about the resistor getting hot and melting the insulation off of the red wire. Not a good idea to let any wiring touch any kind of a resistor in the control box. I would pull the cover off of the generator end and see if it looks like anything got hot in there and if not, I would find a replacement resistor, repair the wire and give it a shot.

David C.
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  #14  
Old 09-15-2018, 12:22:39 PM
Vanman Vanman is offline
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Default Re: WINCO 3500 Portable Generator

With one side of the resistor going to the battery, I would guess that it is for battery charging. The other end needs to connect to a diode or reverse current relay. The former could short and the latter could get stuck closed, resulting in the cooking of that resistor when the set is shut down. Likely did not harm the generator, and it would work fine without it, just wouldn't charge the battery. Look under the brush cover (you'll want to do that anyway) and see what you can find.
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Old 09-16-2018, 01:29:06 PM
Steve Dawkins Steve Dawkins is offline
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Default Re: WINCO 3500 Portable Generator

Part of your ground lug is missing. Those copper mechanical lugs have a base (which is still mounted to your genset) and a square-ish shaped barrel with a set screw (that is missing). I have seen these style lugs in Home Depot. Remove your base and take it with you, to match up the lug. Yours is probably a #2 or #1/0 lug.

That ground lug can be used to connect the B- cable, or to attach a wire to a ground rod or other known ground.
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Old 09-17-2018, 11:36:24 PM
Mark Schneider Mark Schneider is online now
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Default Re: WINCO 3500 Portable Generator

It's a good thing that you guys suggested taking the cover off the generator head. Had to clean a mouse nest out of the bottom. Here are some pictures:

1. The red wire you see is the one that is hooked to the burnt out resistor on the other end.

2. Slip rings...AC side. Can't visually see the brush length.

3. Commutator bars...DC side. Some discoloration on several bars...could be the mice.

4. General view of the armature and field coil. Armature does have some rust on it in spots...probably from the rodents.
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  #17  
Old 09-17-2018, 11:45:59 PM
Railroads Railroads is offline
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Default Re: WINCO 3500 Portable Generator

It's a nice generator and should clean up fairly well. I wish I could find a screamer that well made.

Robert
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  #18  
Old 09-18-2018, 12:05:11 AM
Mark Schneider Mark Schneider is online now
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Default Re: WINCO 3500 Portable Generator

I did find what I think may be the cause for the battery charging resistor toasting.

1. It appears that when the starting switch was damaged the side panel was removed and the two wires that were on the switch were then hooked to the same terminal. This would seem to be a mistake. The blue wire is ground and the orange one is the signal wire to the start relay.

2. The previous owner had a lot to say about this genset but he never mentioned utilizing the battery start. So if it was manually started with the two wires joined the relay would engage as soon as the battery charging current started. The current would then flow to the starter lead which would be a ground (?). If so the resistor would be the weak link in the chain and would overheat until failure.

3. Found this wiring diagram online in the Winco archives. This should help take some of the head scratching out of the diagnostics after viewing pictures of questionable worth!
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  #19  
Old 10-05-2018, 10:36:37 PM
Mark Schneider Mark Schneider is online now
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Default Re: WINCO 3500 Portable Generator

Along with the wiring diagram I was also able to print off the parts breakdown w/ part numbers off the WINCO archive site. I located a dealer in Bismarck ND and called in the 2 part numbers I wanted. The parts man said he would see what was available. The old numbers superseded into new numbers and here is what they sent.

The starting switch turned out to be a simple on-off toggle switch. I think a normally open push button switch would be a better choice for this application so I'll be looking for something different.

The battery charging resistor# ended up to be a diode. I really don't see this being useful as well. Would there be another source for the resistor??? Unfortunately any useful writing is cooked off this one. Maybe a potentiometer ??
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  #20  
Old 10-06-2018, 01:15:52 AM
AlanR AlanR is offline
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Default Re: WINCO 3500 Portable Generator

The diode is probably the 'rectifier' part of the 'rectifier and heatsink assembly' shown in the gen end on your ipl schematic - maybe in cross-referencing, the parts man got one line off? As far as the battery charge resistor, a common potentiometer isn't rated for NEARLY enough current - the gen end is probably putting out 30-40 volts dc once the gen is running, which the resistor is dropping to 13-14 volts at 1 or 2 amps to charge the battery. So if we're dropping 25 volts at 2 amps in the resistor, that's 50 watts, which is a substantial resistor. While adjustable power resistors are available, it would be best if you get the gen running and measure the voltage on the gen side of the resistor, then someone can suggest an appropriate size and value for the resistor.
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