60707-121 Operators Manual & Parts List CSA DL6000I/C & CSA DL6000IE/C

60707-121 Operators Manual & Parts List CSA DL6000I/C & CSA DL6000IE/C
CSADL6000I/C
CSADL6000IE/C
INSTALLATION, OPERATION,
and MAINTENANCE INSTRUCTIONS
Read and understand all instructions in the manual before starting and
operating the generator set.
USING THIS MANUAL
COPY YOUR MODEL AND SERIAL
NUMBER HERE
Congratulations on your choice of a DYNA generator
set. You have selected a high-quality, precisionengineered generator set designed and tested to give
you years of satisfactory portable service.
To get the best performance from your new engine
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 DYNA should you need service assistance
in the future.
No other DYNA 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_____________________________________
PROPER USE AND INSTALLATION
You must be sure your new engine generator set is:
* Properly serviced before starting
* Operated in a well ventilated area
* Operated so that 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
UNIT SPECIFICATIONS
GENERATOR
Surge Watts
Continuous Watts
Volts
Amps
Receptacles
Nema 5-20R (120V)
Nema L14-30R (120/240V)
ENGINE
Model Number
Type & Code
Fuel Capacity
Run Time - Full Load
Run Time - Half Load
Starting System
Stop System
COMPLETE UNIT
Weight
Dimensions LxWxH
6000
5500
120/240
22.9
2 (20A Duplex)
1 (30A Twistlock)
Briggs & Stratton Intek
Electric Start
Recoil Start
210417
210412
0134-E1
0070-E1
4.5 Gallons
6.5 Hours
10.2 Hours
Electric/Recoil Recoil
Key Switch
Panel Switch
153 lbs.
150 lbs.
26.25" X 17.5" X 21.4"
TABLE OF CONTENTS
INTRODUCTION
UNIT SPECIFICATIONS
GUIDE TO PRODUCT SAFETY
BASIC INFORMATION
Intended Uses
Restricted Uses
Unit Capabilities
PREPARING THE UNIT
Unpacking the unit
Unit Preparation
Low Oil Level Shutdown System
STARTING INSTRUCTIONS
Initial Starting
Starting
Starting Hints
Stopping And Storage
Operating Speed
Connecting The Loads
OPERATOR CARE AND MAINTENANCE
Engine Care
Generator Care
Cleaning
Troubleshooting - Things To Check BEFORE
You Call For Service
Generator Parts List
Complete Unit Parts List
Receptacle Panel Parts List
Wiring Diagram
WARRANTY
i
i
1
2
2
2
3
3
3
4
4
4
4
5
5
6
6
6
7
7
8
9
10
10
GUIDE TO PRODUCT SAFETY
3. DEADLY EXHAUST GAS - Exhaust fumes from any
gasoline engine contain carbon monoxide, an invisible,
odorless and deadly gas that must be mixed with fresh air.
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, 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.
a. Operate only in well ventilated areas.
b. Never operate indoors.
c. Never operate the unit in such a way as to allow
exhaust gases to seep back into closed rooms (i.e.
through windows, walls or floors).
4. NOISE HAZARD - Excessive noise is not only tiring, but
continual exposure can lead to loss of hearing.
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.
______________________________________________________
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.
c. Carefully wipe up any gas or oil spills before starting
the unit.
d. Never allow leaves or other flammable material to
build up around the engine exhaust area.
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. Never remove the protective guards, cover, or
receptacle panels while the engine is running.
d. Use extreme caution when working on electrical
components. High output voltages from this
equipment can cause serious injury or death.
e. Always avoid hot mufflers, exhaust manifolds, and
engine parts. They all can cause severe burns
instantly.
f. Installing a home-standby 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.
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.
2. FIRE HAZARD- Gasoline and other fuels always present a
hazard of possible explosion and/or fire.
a. Do not refuel when the engine is running or hot. Allow
the engine to cool at least two minutes before refueling.
b. Keep fuel containers out of reach of children.
c. Do not smoke or use open flame near the generator set
or fuel tank.
d. Keep a fire 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.
60707-121
Page 1
6009-00
INTENDED USES
These engine generator sets have been designed primarily
for portable use. Both 120 and 240 volt AC receptacles are
provided in the 'control panel' to plug in your loads (lights,
portable tools, and small appliances). These units are dual
wound generators, therefore the 120 Volt loads must be
equally split with 1/2 of the rated capacity available on
each of the two 120 Volt circuits. See unit capabilities for
further explanation.
These portable units require large quantities of fresh air for
cooling of both the engine and the generator. Fresh air is
drawn from both the engine end and the generator end and
is exhausted at the center of the unit. For safety, long life
and adequate performance, these units should never be
run in small compartments without positive fresh air flow.
RESTRICTED USES
DO NOT remove from the cradle assembly. Removal of
the generator from the cradle assembly may cause
excessive vibration and damage to the engine generator
set.
DO NOT install and operate these portable generators in a
small compartment., i.e. generator compartment of
vehicles, motor homes or travel trailers. These
compartments will not allow enough free flow fresh air to
reach the engine generator set for cooling and will cause
the unit to overheat damaging both the engine and the
generator. Small compartments will also develop hot spots
where there is very little air flow and may cause a fire.
DO NOT attempt to operate at 50 cycles. These units are
designed and governed to operate at 60 cycles only.
UNIT CAPABILITIES
Generator Connections - The diagram below represents a
typical 5500 watt generator. Receptacles A and B are the
two 120 Volt duplex receptacles. Up to 2750 watts at 120
volts (22.9 Amps) can be taken from the generator at each
of the receptacles. This generator produces 120 and 240
volt, 60 Hz (Hertz), AC (Alternating Current).
CAUTION: EQUIPMENT DAMAGE
CAUTION MUST BE EXERCISED TO PREVENT
OVERLOADING EITHER OF THE GENERATORS
120 VOLT OUTPUT CIRCUITS (A OR B).
Check the appliance or tool nameplates for the current and
voltage to insure compatibility. Remember that power taken
from receptacle C reduces the power available at both A and
B. Any remaining 120 volt loads should be equally divided
between A and B. Failure to split the load will cause
permanent damage to the stator. Although circuit breakers
are provided, damage due to overloading constitutes abuse
and will not be warranted.
Starting Electric Motors - Electric motors require much
more current (amps) to start them than to run them. Some
motors, particularly 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. Repulsion Induction motors are the easiest to
start and usually 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 of RepulsionInduction (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
RUNNING
AMPS
1/6
1/4
1/3
1/2
1
3.2
4.5
5.2
7.2
13.0
SP
STARTING AMPS
CAP
RI
16 TO 22
6 TO 13
22 TO 32
9 TO 18
26 TO 35 10 TO 21
NOT MADE 14 TO 29
NOT MADE 26 TO 52
5 TO 8
7 TO 12
8 TO 17
11 TO 18
20 TO 33
The figures given above are for 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-excited generators respond to severe overloading
differently than the power line. 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 MOTOR
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 difficulty is experienced in starting motors,
turn all other electrical loads off and if possible reduce the
load on the electric motor.
6009-00
Page 2
60707-121
UNPACKING
BATTERY INSTALLATION
CAUTION: EQUIPMENT DAMAGE
If you intend to use the power plant’s electric start system,
you will need to purchase a battery to operate it. Units
equipped with a recoil or rope start will operate satisfactorily
without a battery. A twelve volt battery, group U1 rated at
235 CCA or larger is recommended for this electric start
engine generator set. Follow the battery manufacturer's
recommendations for servicing and charging prior to use.
THIS UNIT HAS BEEN SHIPPED WITHOUT OIL. Failure
to maintain the engine oil at the proper level will result in
serious engine damage.
When you unpack your new ENGINE GENERATOR be sure
to remove all the information sheets and manuals from the
carton.
CAUTION: EQUIPMENT DAMAGE
1. This power plant was in good order when shipped.
Inspect the power plant promptly after receiving it. If
damage is noted, notify the transportation company
immediately; request proper procedures for filing a
“concealed damage” claim. Title to the equipment and
responsibility for filing a claim rests with you when a
generator is sent F.O.B. shipping point. Only you can
legally file a claim.
2. Before proceeding with the preparation of your new
engine generator set for operation, take a couple of
minutes to insure that the unit you have received is the
correct model and review the specification pages in
this manual to insure that this unit fits your job
requirements.
These electric start engines are NEGATIVE GROUND.
Use extreme caution when connecting the battery.
Connect the NEGATIVE battery terminal to GROUND.
For your safety always connect the positive battery cable to
the “bat+” terminal first. Then connect the negative battery
cable to the “bat-” terminal. Make sure all connections are
clean and tight. Reverse the sequence when disconnecting,
disconnect the negative cable first. These engines produce
enough direct current to keep a battery charged under
normal operating conditions, but were not intended to be
used as a battery charger.
WARNING: PERSONAL INJURY
Lead acid batteries produce explosive hydrogen gas
when charging. Keep sparks, flames, and burning
cigarettes away from the battery. Ventilate the area
when charging or using the battery in an enclosed
space. Lead acid batteries contain sulfuric acid, which
causes severe burns. If acid contacts eyes, skin or
clothing, flush well with water. For contact with eyes,
get immediate medical attention.
UNIT PREPARATION
Before your engine generator was shipped from our factory it
was fully checked for performance. The generator was load
tested to its full capacity, and the voltage and frequency were
carefully checked and adjusted.
Lubrication
Before starting the engine, fill the crankcase to the proper
level with a good quality oil. The recommended grade of oil
and quantity of oil required is listed in the engine operator's
manual. The necessity of using the correct oil, and keeping
the crankcase full cannot be over emphasized. Engine
failures resulting from inadequate or improper lubricant are
considered abuse and are not covered by the generator or
the engine manufacturer's warranty.
Battery Charging
Units equipped with electric start have a small flywheel
charger built into the engine flywheel assembly for
recharging the starting battery. This flywheel charger
generates a small AC current that passes through a diode at
the end of the charging lead to produce a DC charging
current of about 1 AMP. This circuit is not designed to be
used as a battery charging circuit to recharge dead
batteries.
Gasoline Fuel
When using gasoline always use a good grade of unleaded
fuel. Leaded gasoline may be used if unleaded is not
available. Gasoline containing alcohol, such as gasohol is
not recommended. However, if gasoline with alcohol is used,
it must not contain more than 10 percent Ethanol and must be
removed from the engine during storage. DO NOT use
gasoline containing methanol. Always insure that the fuel is
clean and free of all impurities.
WARNING: FIRE DANGER
Gasoline and its fumes are VERY explosive when proper
precautions are not taken.
Never use gasoline that has been stored for an extended
period of time as the fuel will lose its volatile properties and
you will be left with only the varnish residue. This varnish like
substance will clog the carburetor and will not burn properly.
The use of a fuel additive, such as STA-BIL, or an equivalent
will minimize the formation of fuel gum deposits. If a unit has
been out of operation for an extended period of time it is best
to drain old fuel from the engine and replace with fresh fuel
before attempting to start.
60707-121
LOW OIL LEVEL WARNING SYSTEM
This engine generator sets come equipped standard with
the Briggs & Stratton OILGARD warning system.
This low oil warning system will automatically stop the
engine when the oil level is low. This feature is designed to
reduce costly repairs and downtime.
The OILGARD system uses a sensor in the engine
crankcase to sense the oil level. If a low oil level condition
should occur during operation, the low oil module will
ground out the magneto impulse, “killing” the engine. To
get the engine restarted, you must add the required amount
of oil to the engine crankcase.
Use of the OILGARD system on applications that are
subject to shock, bumping or severe angles of operation (in
excess of 15 degrees) should be avoided. This is
especially true if an unexpected shutdown would cause a
safety hazard or serious inconvenience for the operator.
Page 3
6009-00
Optional Dolly Kit
STARTING HINTS
1. Cold weather
a. Use the proper oil for the temperature expected.
b. Use fresh winter grade fuel. Winter grade
gasoline is blended to improve starting. Do not
use summer gasoline.
An optional dolly kit is available for this engine generator
set. The dolly kit comes with instructions and parts list. After
installing the dolly kit, file the instructions and parts list in the
back of this manual for future reference.
INITIAL START UP
2. Hot weather
a. Use the proper oil for the temperature expected.
b. Use only summer blended gasoline. Using
gasoline left over from winter may cause the unit
to vapor lock.
c. DO NOT over-choke the unit.
Use the following checklist to verify the correct preparation
of the engine generator before starting.
Before Starting always Check:
1. Engine oil, fill as required with correct grade and
quantity.
2. Fuel level, fill as required with clean fresh fuel.
3. Visually for loose parts.
STOPPING AND STORAGE
1. Depress the stop switch mounted on the front of the
engine housing to stop the engine.
2. Turn off the fuel shut-off valve.
3. Before extended storage (over 30 days) certain
precautions must be taken to ensure the fuel doesn’t
deteriorate and clog the fuel system. Note: The use
of a fuel additive, such as STA-BIL, or an equivalent,
will minimize the formation of gum deposits during
storage. Such an additive may be added to gasoline
in the engine’s fuel tank or to gasoline in a storage
container.
STARTING
The throttle control on these generators is preset and locked
to operate at 3600 RPM (nominal) with no load speed set at
3720 RPM. Only a trained service technician should be
allowed to adjust this speed setting. See “Operating Speed”
section for additional information.
NOTICE: ENGINE START LOCKOUT
This unit will not start if it is low on oil. The lubricating
oil level must be at the full mark before the engine will
start and run.
a. Remove the remaining fuel from the fuel tank.
b. Start the engine and allow it to run until all
the fuel in the carburetor and the fuel lines has
been used up and the engine stops.
c. While the engine is warm, drain the oil and
refill with fresh oil.
d. Remove the spark plug, pour approximately
1/2 ounce (15 cc) of engine oil into the cylinder
and crank slowly to distribute oil. Replace spark
plug.
e. Clean dirt and chaff from cylinder, cylinder
head fins, blower housing, rotating screen and
muffler areas.
f. Store in a clean and dry area.
Electric Starting - If the engine is cold and stiff or if the
battery is not fully charged, starting can be made easier by
slowly hand cranking the engine through the compression
stroke before pushing the starter switch. This permits the
starter to gain momentum before the heavy load of the
compression stroke occurs. This minimizes the drain on the
battery and improves the possibility of starting under such
adverse conditions. Always keep the battery charged, but
especially during cold weather operation.
1. Turn on the fuel supply (multi-turn valve).
2. Move the choke to the full "on" position. A warm
engine will require less choking than a cold engine.
3. Turn the key to the run position.
4. Push start switch to engage the starter. The starter life
is improved by using shorter starting cycles with time
to cool off between cranking cycles. Do not operate
the starter more than 15 seconds during each minute.
Repeat if necessary.
5. When the engine starts, open the choke gradually.
OPERATING SPEED
The engine-generator must be run at the correct speed in
order to produce the proper electrical voltage and frequency.
CAUTION:
The output voltage should be checked to insure the
generator is working properly prior to connecting a load
to the generator. Failure to do so could result in damage
to equipment plugged into the unit and possible injury to
the individual.
Manual Starting - Refer to the engine manual for additional
starting, operating, and stopping instructions.
1. Turn on the fuel supply (multi-turn valve).
2. Move the choke to the full "on" position. A warm
engine will require less choking than a cold engine.
3. Move the stop switch to the run position.
4. Grasp the starter rope and pull slowly until resistance
is felt. Then pull the cord rapidly to overcome
compression, prevent kickback and start the engine.
Repeat if necessary with the choke in run position.
5. When the engine starts move the choke to the run
position.
CAUTION: EQUIPMENT DAMAGE
Never permit the choke to remain on after the engine has
run for a short time. It is not necessary to choke the
engine when it is warm. Avoid over-choking.
6009-00
EQUIPMENT DAMAGE
All engines have a tendency to slow down when a load is
applied. When the electrical load is connected to the
generator, the engine is more heavily loaded, and as a
result the speed drops slightly. This slight decrease in
speed, together with the voltage drop within the generator
itself, results in a slightly lower voltage when the generator
is loaded to its full capacity than when running no load. The
slight variation in speed also affects the frequency of the
output current. This frequency variation has no appreciable
effect in the operation of motors, lights and most appliances.
However, electronic equipment and clocks will be affected if
correct RPM is not maintained. See Load vs. Output chart.
Page 4
60707-121
Although individual units and models may vary slightly, the
normal voltage and frequency of the engine-generators
described in this book are approximately as follows, under
varying loads:
LOAD vs. OUTPUT
__________________________________________________________________________________________________________________
Generator
Frequency
Load
Speed
Applied* (RPM)
(Hz)
Voltage
120V
Recpt.
Proper utilization of the receptacles located on the control
panel is necessary to prevent damage to either the
receptacles or the generator. The generator is a limited
source of electrical power, therefore pay special attention
to the receptacle and generator ratings. The nameplate
rating can be obtained through a single receptacle as long
as the receptacle amperage rating is not exceeded.
HARD WIRING YOUR GENERATOR
__________________________________________________________________________________________________________________
None
Half
Full
3750
3600
3540
62.5
60.0
59.0
126V
122V
119V
Temporary Power
__________________________________________________________________________________________________________________
*Portion of plant’s rated output current.
The speed of the engine was carefully adjusted at the factory
so that the generator produces the proper voltage and
frequency. For normal usage, the speed setting should not
be changed. If the generator is being run continuously on a
very light load, it is often advisable to lower the operating
speed slightly. Whenever making any speed adjustments
check the unit with a voltmeter or tachometer and be sure the
speed is correct.
Lower voltage may damage both the generator and any load
connected to it. Running the engine at excessively high
speeds results in high voltage, which may significantly
shorten the life of appliances being used.
Output voltage should be checked periodically to ensure
continued proper operation of the generating plant and
appliances. If the generator is not equipped with a voltmeter,
it can be checked with a portable meter. Frequency can be
checked by using an electric clock with a sweep second
hand. Timed against a wrist watch or a stop watch the clock
should be correct within +/- 2 seconds per minute.
OPERATING YOUR GENERATOR
The engine-generators covered in this manual were designed
for portable use. DO NOT INSTALL OR OPERATE THIS
GENERATOR INDOORS. The unit should be stored in a
warm dry location. During a power outage, move the unit
outdoors to a flat dry location such as a driveway or sidewalk.
Allow the engine to warm up for two or three minutes before
applying any load. This will allow the engine to reach normal
operating temperature and oil to circulate throughout the
engine. A short warm-up time will permit the engine to work
more efficiently when the load is applied and will reduce the
wear in the engine, extending its life.
Receptacles have been provided to allow loads to be
connected to the generator. The loads should be added one
at a time. If a large motor is being started or multiple motors
are being started, they should be started individually and the
largest should be started first
Most electric tools and appliances will have the voltage and
amperage requirements on their individual nameplates.
When in doubt consult the manufacturer or a local electrician.
The nameplate amperage rating for electric motors can be
misleading. See “Starting Electric Motors” in Unit Capabilities
(page 2).
‘Hard Wiring’ this unit directly into a temporary construction
site electrical system is NOT A SIMPLE DO-IT-YOURSELF
JOB. For your safety all wiring must be done by a qualified
electrician and conform to the National Electric Code and
comply with all state and local codes and regulations.
Check with local authorities before proceeding.
WARNING: PERSONAL DANGER
A fully isolated, double pole double throw manual
transfer switch must be installed any time a generator is
being connected to an existing distribution system.
To connect these units directly to an un-powered, isolated
construction site TemPower panel, have your electrician
connect to the control panel using a 120/240 volt, four wire
twistlock plug (L14-30P). The use of locking receptacles
and locking plugs provides the convenience of quick
disconnect, for moving, while allowing non electrical workers
to safely reconnect the power. In addition they prevent the
plug from being accidentally removed by bumping or
vibration.
Home Standby
If the generator set is connected to existing (electrical)
wiring circuits it is permitted only through a fully isolated
manual transfer switch. The transfer switch prevents
damage to the generator and other circuit components if
main line power is restored while the generator is
connected. Installing a transfer switch also permits the use
of normal fusing.
Many homes and construction sites are wired for at least 60
to 100 Amp entrance service, much greater than the
capacity of these portable generators. When installing the
generator at these sites, a secondary emergency distribution
panel may have to be installed, such as the Emergency
Transfer/Service (ET/S) system available through your
Winco dealer. The emergency distribution panel must be
installed by a licensed electrician according to all applicable
codes. The electrician will move the critical circuits to be
powered during the outage to the emergency panel. Keep
in mind only a limited amount of amperage is available from
the generator set. Some circuit breakers may still have to
be turned off to prevent an overload on the generator during
the initial start up. See the nameplate on your generator for
the amperage capabilities of your unit.
CAUTION: EQUIPMENT DAMAGE
These engine generator sets are inherently self regulating
based on engine speed. The engine governor will
automatically adjust itself to the load. No harm to the
generator will result if it is operated with no load connected.
60707-121
Page 5
Failure to properly limit and balance the load applied to
the generator will cause the generator to produce low
voltage and may damage the engine generator set. It
may also cause severe damage to the loads connected
to the generator at that time. Improper loading of the
generator set constitutes abuse and will not be covered
by warranty.
6009-00
CAUTION: EQUIPMENT OVERLOAD
c. Wash foam pre-cleaner in liquid detergent and
water
d. Wrap foam pre-cleaner in cloth and squeeze dry.
e. Saturate foam pre-cleaner in engine oil. Squeeze
to remove excess oil.
f. Install foam pre-cleaner over paper cartridge.
Reassemble cover and screw down tight.
Keep the generator load within the generator and
receptacle nameplate rating. Overloading may cause
damage to the generator and/or the loads .
Grounding
All units must be grounded. Drive a 3/4 or 1" copper pipe or
rod into the ground close to the engine-generator set. The
pipe must penetrate moist earth. Connect an approved
ground clamp, to the pipe. Run a no. 10 Awg wire from
clamp to the generator ground lug on the generator. Do not
connect to a water pipe or to a ground used by a radio
system.
ENGINE CARE
If major engine service or repair is required contact an
authorized engine service center. The manufacturer of
these engines has established an excellent worldwide
engine service organization. Engine service is very likely
available from a nearby authorized dealer or distributor.
Check the yellow pages of your local telephone directory
under “Engines-Gasoline” for the closest engine repair
center or ask the dealer from whom you purchased the
power plant.
Replace the cartridge included with Dual Element Air
Cleaner yearly or every 100 hours. Service more often if
necessary.
5. Spark Plug - Clean and reset gap at .030" every 100
hours of operation. Do not blast clean spark plug. Clean by
scraping or wire brushing and washing with a commercial
solvent. Poor spark will occur if terminal does not fit firmly
on spark plug. If this happens reform the terminal to fit
firmly on spark plug tip.
GENERATOR CARE
Proper care and maintenance of the generator is necessary
to insure a long trouble free life.
1. Exercising The Generator - The generator should be
operated every three to four weeks. It should be
operated for a period of time sufficient to warm the
unit up and to dry out any moisture that has
accumulated in the windings. If left, this moisture can
cause corrosion in the winding. Frequent operation of
the engine generator set will also insure that the set
is operating properly should it be needed in an
emergency.
1. Change the oil after the first five hours of operation
and every 50 hours thereafter under normal
operating conditions. Change engine oil every 25
hours of operation if the engine is operated under
heavy load, or in high ambient temperatures.
a. Remove oil drain plug at base of the engine
and drain the oil with the engine warm.
b. Replace oil drain plug.
c. Remove oil filler plug and refill with new oil.
Refer to the table in the engine manual for the
proper grade of oil based on your operating
temperature.
d. Replace filler plug.
2. Generator Maintenance - Any major generator service
including the installation or replacement of parts should be
performed only by a qualified electrical service technician.
USE ONLY FACTORY APPROVED REPAIR PARTS.
a. Bearing - The bearing used in these
generators is a heavy duty double sealed ball
bearing. They require no maintenance or
lubrication.
b. Receptacles - Quality receptacles have been
utilized. If a receptacle should become cracked or
otherwise damaged, replace it. Using damaged or
cracked receptacles can be both dangerous to the
operator and destructive to the equipment.
2. Checking the Oil Level: The oil level must always be
checked before the engine is started. Take care to remove
any dirt or debris from around the oil fill plug before
removing. Be sure the oil level is maintained. Fill to the
“FULL” mark on the dipstick.
3. Cartridge Air Cleaner - Remove and clean cartridge
yearly or after every 25 hours, whichever occurs first. Service
more often if necessary. Clean by tapping gently on flat
surface. If very dirty, replace the cartridge using only original
equipment parts available at any engine service center.
Do not use petroleum solvents, such as kerosene, to
attempt to clean the cartridge. They may cause
deterioration of the cartridge. DO NOT OIL CARTRIDGE,
DO NOT USE PRESSURIZED AIR TO CLEAN OR DRY
CARTRIDGE.
4. Dual Element Air Cleaner - Clean and re-oil foam
pre-cleaner at three month intervals or every 25 hours,
whichever occurs first. Service more often under dusty
conditions.
a. Loosen screws and remove cover and air cleaner
assembly from base.
b. Remove foam pre-cleaner by sliding it off the
paper cartridge.
6009-00
CLEANING
Remove dirt and debris with a cloth or brush. DO NOT use
high pressure spray to clean either the engine or the
generator. This high pressure spray could contaminate the
fuel system and the generator components.
1. Keep the air inlet screen on both the engine and
generator free of any dirt or debris to insure proper cooling.
At least yearly remove the blower housing on the engine
and clean the chaff and dirt out of the engine cooling fins
and flywheel. Clean more often if necessary. Failure to
keep these areas clean may cause overheating and
permanent damage to the unit.
2. Periodically clean muffler area to remove all grass,
dirt and combustible debris to prevent a fire.
3. On engine mufflers equipped with spark arresters, the
spark arrester must be removed every 50 hours for cleaning
and inspection. Replace if damaged.
Page 6
60707-121
TROUBLESHOOTING HINTS
PROBLEM (SYMPTOMS) POSSIBLE CAUSES
——————————————————————————
Won’t Start
*Low oil level.
*Fouled spark plug.
*Out of fuel.
*Stop switch in stop position.
*Gummed up fuel system.
*Fuel turned off.
——————————————————————————
Voltage too low
*Engine speed is too low.
*Generator overloaded.
*Defective capacitor.
*Defective stator.
*Defective rotor (field).
——————————————————————————
Circuit Breaker
*Over Loaded.
Trips
*Defective receptacle.
*Defective circuit breaker
*Too small/long of drop cord.
——————————————————————————
Voltage too high
*Engine speed is too high.
——————————————————————————
Generator
*Overloaded.
overheating
*Insufficient ventilation.
——————————————————————————
No output voltage
*Short in load (disconnect).
*Broken or loose wire.
*Defective receptacle.
*No residual magnetism
(in generator).
*Defective stator.
*Defective rotor (field).
*Defective capacitor.
*Defective diode.
*Circuit breaker off or defective.
——————————————————————————
GENERATOR ASSEMBLEY
REF #
7
9
14
15
19
26
27
28
29
67
68
72
60707-121
Part Number
16346-101
16346-102
16346-103
16346-104
54665-000
16346-105
16346-106
16346-107
16346-108
16346-109
16346-110
16346-111
QTY
1
1
1
1
1
2
2
4
1
1
1
1
Description
Bearing End Bracket
Drive End Bracket
Rotor Assembly
Fan
Bearing
Diode
Varistor
Stator Bolts
Rotor Bolt
Stator Cover Band
Engine Mounting Bracket
Stator Assembly
Page 7
6009-00
COMPLETE UNIT ASSEMBLY
REF#
6009-00
Part Number
QTY
Description
1
2
3
4
5
467-000
480-000
64062-000
16249-000
16250-000
2
2
4
4
1
Cap Screw 5/16-18 X .75
Lockwasher 5/16
Shock Mounts
Locknut 5/16-18
Flange Nut 3/8-16
6
7
8
NI
NI
464-000
16335-001
15676-005
15767-005
15767-016
1
1
1
1
1
Cap Screw 3/8-16 X.75
Generator Support
Battery Tray (1)
Negative Battery Cable (1)
Positive Battery Cable (1)
9
10
11
15617-002
63073-025
58684-011
1
1
1
End Cover Assembly
Cradle Assembly
Edge Trim
Page 8
60707-121
REF#
Part Number
QTY
Description
12
13
14
15482-000
16346-001
15632-005
1
REF
1
14
15632-006
1
Gas Cap
Complete Generator Assembly
Engine B/S Intek (1)
210417-0134-E1
Engine B/S Intek (2)
210412-0070-E1
15
16
17
18
19
468-000
480-000
466-000
512-000
16133-000
2
2
2
2
2
20
21
22
23
81018-008
98771-000
62999-001
40078-000
1
1
2
28"
24
64024-000
25
15462-029
(1) Model DL6000IE only
(2) Model DL6000I only
1
1
Cap Screw 5/16-18 X 1.5
Lockwarsher 5/16
Cap Screw 1/4-20 X .75
1/4 Flat Washer
Leather Washer
Clamp
Fuel Valve
Fuel Line Clamp
1/4" Fuel Line
Fuel Tank 4.5 Gal.
Fuel Tank Tray
RECEPTACLE PANEL
REF#
1
2
3
4
5
60707-121
Part Number
57030-009
97360-000
50766-000
91286-001
16346-013
QTY
1
1
2
2
1
Description
Circuit Breaker 25A/240V
Receptacle Nema L14-30P
Duplex Receptacle Nema 5-20P
Circuit Breaker 20A/120V
End Cover
Page 9
6009-00
WIRING DIAGRAMS
24 MONTH
Limited Warranty
WINCO warrants to the original purchaser that the alternator is free from defects in workmanship and material for a period of
two years*, provided it is installed, operated and maintained in accordance with WINCO written instructions.
*NOTE: Units used for rental, demonstrations, commercial or prime power (off grid) applications such as construction
or utility, are warranted for 90 days. Units that are resold are not covered under this warranty. Any further warranty,
whether expressed or implied, rests solely with the reseller.
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. This warranty does not include circuit breakers, receptacles or ENGINES. Engines are covered
exclusively by the warranties of their respective manufacturers.
THERE IS NO OTHER EXPRESS WARRANTY.
To the extent permitted by law, any and all warranties are limited to 24 months from date of purchase. The user shall
determine the suitability of the product for its intended use prior to placing the unit in service. The user shall assume all risks
and liability in connection with determining the suitability of the unit for its particular use. Neither the manufacturer nor the
seller shall be liable for any injury, loss or damage arising out of improper use or operation of this unit. In no event is WINCO
liable for incidental or consequential damages.
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 state to state.
EXCLUSIONS
WINCO does not warrant Engines. Engines are covered exclusively by the warranties of their respective manufacturers, see
enclosed warranties.
WINCO does not warrant Batteries, Receptacles or Other Component Parts that are warranted by their respective
manufacturers.
WINCO reserves the right to change or improve its products without incurring any obligations to make such changes or
improvements on products previously purchased.
WINCO does not warrant products which have been subjected to misuse, negligence, modified or altered in any way or have
been involved in an accident.
For warranty service, return the product, transportation charges prepaid, to your nearest WINCO Authorized Service Center or
to WINCO at Le Center Minnesota. When requesting warranty service, evidence of original purchase date must be presented.
Phone - (507) 357-6831
FAX (507) 357-4857
www.wincogen.com
6009-00
225 S. Cordova Ave.
LeCenter, Mn 56057-1805
P/N 60707-121
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising