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WL12000HE-03/A WL12000HE-03/B WL12000HE-03/C WL12000HE-03/D INSTALLATION & OPERATORS MANUAL 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 # ________________________________________ www.wincogen.com 16200-005 TABLE OF CONTENTS SAVE THESE INSTRUCTIONS SAVE THESE INSTRUCTIONS 2 SAFETY3 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. SAFETY DEFINITIONS SPECIFICATIONS4 GENERATOR GENERATOR ENGINE 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. INTRODUCTION5 TESTING POLICY INTENDED USES RESTRICTED USES UNIT CAPABILITIES 6 To get the best performance from your new generator, it is important that you carefully read and follow the operating instructions in this manual. GENERATOR CONNECTIONS STARTING ELECTRIC MOTORS PREPARING THE UNIT 7 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. UNPACKING LUBRICATION OIL RECOMMENDATIONS OIL ALERT SYSTEM GASOLINE BATTERY INSTALLATION BATTERY CHARGING OPTIONAL DOLLY KIT INITIAL START UP 9 BASIC OPERATION STARTING HINTS CONNECTING THE LOADS 11 APPLYING THE LOADS GROUNDING WIRING YOURGEN ENGINE CARE 13 15 MAINTENANCE SCHEDULE CHECKING THE OIL LEVEL CHANGING THE OIL DUAL ELEMENT AIR FILTER SPARK PLUG CARBON CANISTER GENERATOR CARE 17 EXERCISING THE GENERATOR GENERATOR MAINTENANCE CLEANING TROUBLESHOOTING TABLE WIRING DIAGRAM WIRING DIAGRAM CA EVAP EMISSION CONTROL LIMITED WARRANTY OPM-139/E 17 18 19 20 20 2 SAFETY IMPORTANT SAFETY INSTRUCTIONS A. Operate only in well ventilated areas. B. Never operate indoors including attached garages 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, floors). 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, 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. 4. 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 using this equipment. SAFETY DEFINITIONS DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. 5. CLEANLINESS Keep the generator and surrounding area clean. WARNING 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. 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 also be used to alert against unsafe practices. 6. SERVICING EQUIPMENT All service, including the installation or replacement of service parts, should be performed only by a qualified technician. 1. ELECTRICAL SHOCK The output voltage present in this equipment can cause fatal electric shock. This equipment must be operated by a responsible person. A. Use only factory approved repair parts. B. Do not work on this equipment when fatigued. C. Never remove the protective guards, covers, or receptacle panels while the engine is running. D. Use extreme caution when working on electrical components. High output voltage from this equipment can cause serious injury or death. E. Always avoid hot mufflers, exhaust manifolds, and engine parts. They can cause severe burns instantly. F. The use of the engine-generator set must comply with all national, state, and local codes. 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-pronged grounded receptacles and extension cords. F. Be sure the unit is properly grounded or your application. 2. FIRE HAZARD Gasoline and other fuels present a hazard of possible explosion and/or fire. A. Do not refuel when the engine is running or hot. 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. F. Follow local codes for closeness to combustible material. 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. 3 OPM-139/E SPECIFICATIONS GENERATOR ModelsWL12000HE-03/A WL12000HE-03/B WL12000HE-03/C WL12000HE-03/D Surge Watts12,000 Continuous Watts10,800 Volts120/240 Amps90/45 GENERATOR Generator Manufacturer Mecc Alte Spa Generator Model Number S20FS-160/A Part Number351836-1 Rotor Resistance6.57 Ohms Stator Resistance 0.124 Ohms Cap Winding Resistance 0.60 Ohms Capacitors31.5 mF Capacitor Part Number 300323-112 ENGINE Engine Manufacturer Honda Engine Model Number GX630RH TypeVXE1 NH1 CodeGCAMH Spark Plug Gap 0.030 in Intake Valve Clearance 0.006 - 0.010 in Exhaust Valve Clearance 0.010 - 0.012 in Oil Capacity 57 - 58 oz (1.78 - 1.81 qts) OPM-139/E 4 INTRODUCTION TESTING POLICY Before any generator is shipped from the factory, it is fully checked for performance. The generator is loaded to its full capacity, 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. INTENDED USES This engine generator set has been designed primarily for portable heavy duty commercial use. Both 120 volt and 240 volt 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. This portable unit requires large quantities of fresh air for cooling the engine and generator. 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 operate and/or store the unit outside during inclement weather without adequate protection from the elements. Failure to do so will damage the unit. DO NOT install and operate this generator in a small compartment., i.e. generator compartments of vehicles, motor homes or travel trailers. These compartments will not allow enough free flow of fresh air to reach the engine generator set for cooling and will cause the unit to overheat, damaging both the engine and generator. Small compartments will also develop hot spots where there is very little air flow and may cause a fire. PLEASE NOTE There are 3rd party companies making enclosures for generators that have been properly engineered. The use of these 3rd party enclosures is acceptable as long as they have been certified and meet current code. DO NOT attempt to operate at 50 cycles. These units are designed and governed to operate at 60 cycles only. 5 OPM-139/E UNIT CAPABILITIES 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. GENERATOR CONNECTIONS WL12000HE: 120 Volt and 240 Volt receptacles are provided for connection to various loads. The diagram below represents this 10,800 watt (rated output) generator. A & B represent the 120 volt output legs of this generator. Up to 5400 watts at 120 volts (45 Amps) can be drawn from the receptacles attached to either A or B output legs. This generator is capable of producing 45 Amps of 240 volt current at C. Check the appliance or tool nameplates for the current and voltage to insure compatibility. Remember that power taken from C reduces the power available at equally both A and B and vice versa. 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 starting current as running current. Capacitor motors are easier to start and usually require 2 to 4 times as much starting current as running current. Repulsion Induction motors are the easiest to start and require only 1 1/2 to 2 1/2 times as much starting as running current. Most fractional horsepower motors take about the same amount of current to run them whether they are Repulsion Induction (RI), Capacitor (Cap), or Split-Phase (SP) type. 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-exciting generators respond to severe overloading differently than utility power. 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 damage to the generator stator as well as the motor winding. The heavy surge of current required for starting motors is required for only an instant. The generator will not be OPM-139/E 6 09/07/07 20:34:57 32Z6L600_008 PREPARING THE UNIT 09/07/07 20:34:57 32Z6L600_008 ENGINE OIL Oil Change Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. Drain the use quickly and c OIL RECOMMENDATIONS UNPACKING ENGINE OIL Oil Change CAUTION: EQUIPMENT DAMAGE Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. 1. Place a suit Recommended Oil Outdoor temperatures determine the proper oil viscosity for then remov Drainthe the engines. used oil when the engine is warm. Warmour oil drains Winco recommends 5W-30 fully synthetic andmotor completely. Use quickly 4-stroke oil that meets or exceeds the requirements for THIS UNIT HAS BEEN SHIPPED WITH OIL. Failure to oil to give you excellent protection in cold temperatures API service category SJ or later (or equivalent). Always check the 2. Allow the u while maintaining excellent performance in oil, warmer maintain the engine a suitable container below the engine to catch the used Recommended Oiloil at the proper level will result in 1. Place bolt and ne API service label on the oil container to be sure it includes the then remove the oil filler cap, drain bolt and sealing washer. weather. serious engine damage. letters SJ or later (or equivalent). Use 4-stroke motor oil that meets or exceeds the requirements for API service category SJ or later (or equivalent). Always check the 2. Allow the used oil to drain completely, then reinstall the drain bolt and new sealing washer, and tighten the drain bolt securely. API unpack service label on the oil container to be sureset it includes theto When you your engine-generator be sure letters SJ or later (or equivalent). remove all the information sheets and manuals from the Please dispose of used motor oil in a manner that is compatible carton. with the environment. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash, pour it on the ground, Synthetic 5W-30 1. As you receive your unit, it is critical to check it for any or pour it down a drain. damage. If any damage is noted, it is always easiest to Synthetic 5W-30 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 OIL FILLER CAP AMBIENT TEMPERATURE Please disp with the en container t reclamatio or pour it d OIL FILLER CAP OIL LEVEL DIPSTICK AMBIENT TEMPERATURE UPPER LIMIT Use a full SAE 10W-30 5W-30 is recommended OILorALERT SYSTEMfor general use. 2. BeforeSAE proceeding withis the preparations of your new 10W-30 or 5W-30 recommended for general use. Use a full LOWER synthetic 5W-30 for starting/operating temperatures between 5°F synthetic for starting/operating temperatures between generator for5W-30 operation, take a couple of minutes to 5°F LIMIT 15°C) and you (－25°C). Other viscosities shown in model the chart －13°Fhave (－15°C)This and generator Other viscosities shown in the chart －13°F (－25°C). is equipped with a low oil shutdown system. ensure(－the unit received is the correct may be used when the average temperature in your area is within may be This usedHonda when the average temperature in yourmounted area is within engine uses an float switch inside and review the specification pages in this manual to the indicated range. range. If the oil level drops below a certain point the the engine. ensure that this unit meets your job requirements. the indicated SEALING WASHER low oil module on the engine will shut it down. This low oil Oil Level Check Oil Levelwarning Check system will automatically stop the engine before SEALING W DRAIN BOLT LUBRICATION Check the engine oil level with the engine stopped and in a level the oil level reaches critical danger point. This feature is position. DRAIN BOLT Check the engine oil withcostly the engine stopped and in a level designed tolevel prevent repairs and downtime. Before starting the engine, fill the crankcase to the proper position. 1. Start the engine and let it idle for 1 or 2 minutes. Stop the engine level with and a good quality oil. The recommended grade oil wait for 2 or 3 minutes. CAUTION: EQUIPMENT DAMAGE and quantity of oil required is listed in the engine operator’s 1. Start the engine and let it idle for 1 or 2 minutes. Stop the engine the engine in a level position, with the recommended oil on low oil the the oil level dipsticktab andin wipe it clean. 2. Remove 3. With manual and under service this manual. This unitand Allowing engine to fill shutdown repeatedly wait for 2 limit or 3the minutes. to the upper mark on the oil level dipstick. was shipped with most of the oil. The engine normally level may cause excessive wear which can be cumulative. 3. Fully insert the oil level dipstick, then remove it to check the oil holds 57 to 58 ounces (1.78 to 1.81 quarts) of oil. Since 2. Remove the oil level dipstick and wipe it clean. level. 3. With the en there is some trapped in the engine, when filling the Running the engine with a low oil level can cause engine to the uppe the oil level is low, remove oil fillerto cap, and fill with damage. This type of damage is not covered by the Distributor’s 4. Ifthe crankcase first time, use the the dipstick ensure thattheyou GASOLINE Fully insert the oil level dipstick, then remove it to check the oil 3. recommended oil to the upper limit mark on the oil level dipstick. Limited Warranty. do not over fill the crankcase. The full oil level mark on thelevel. dipstick is5. Reinstall depicted in the following image. When using fresh, clean, The Oil Alert systemgasoline, (applicable always types) willuse automatically stop unleaded the oil level dipstick and oil filler cap. Running th the engine before theremove oil is level falls the safe fuel. The certified operate onfill unleaded oil level isengine low, thebelow oilto filler cap,limit. and with the gasoline damage. Th 4. If the OIL FILLER However, to avoid the inconvenience of an unexpected CAP with a minimum rating of on 87level or regularly. higher. recommended toupper the octane upper limit mark the oil level Gasoline dipstick. Limited Wa shutdown, fill oil to the limit, and check the oil containing no more the 10% ethanol is acceptable. OIL LEVEL DIPSTICK the oillevel filler cap and oiland leveloil dipstick 4. Reinstall the oil dipstick fillersecurely. cap. 5. Reinstall CAUTION: EQUIPMENT DAMAGE OIL FILLER UPPER LIMIT LOWER LIMIT The Oil Ale the engine However, t shutdown, CAP Do not use unapproved gasolines, such as E15 or E85. Do not mix oil in the gasoline. Use of unapproved fuels OIL LEVELwill DIPSTICK damage the engine components and void the engine 4. Reinstall th warranty. Use of fuels with content of ethanol greater than shown above may cause starting and/or performance problems. Running the engine withby a low oil level canthe cause damage. Oil is added to the engine removing oilengine cap and Always ensure that the fuel is clean and free of all This type of damage is not covered by the Distributor’s Limited adding oil at this point. After filling the crankcase to the Warranty. impurities. proper level, be sure you properly tighten the oil fill cap.UPPER LIMIT LOWER LIMIT The Oil Alert system (applicable types) will automatically stop the WARNING: FIRE DANGER engine before the oil level falls below theon safealimit. NOTE: This engine generator must be levelHowever, surfaceto avoid the inconvenience anthe unexpected shutdown, always before you check or add oilofto system. The necessity Gasoline and its fumes are VERY explosive when proper the engine oil level before startup. of using check the correct oil and keeping the crankcase full ENGLISH 8 precautions are not taken. cannot be overemphasized. Engine failures resulting from Running the engine with a low oil level can cause engine damage. inadequate or improper lubricant are considered abuse This and type of damage is not covered by the Distributor’s Limited not covered by the generator or engine manufacturer’s Warranty. Never use gasoline that has been stored for an extended warranty. period of time as the fuel will lose its volatile properties and you will be left with varnish residue. The varnish The Oil Alert system (applicable types) will automatically stop the like substance will clog the carburetor and will not burn engine before the oil level falls below the safe limit. However, to properly. avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup. 7 8 OPM-139/E ENGLISH The use of fuel additives, 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. 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 the eyes, get immediate medical attention. See the engine manual for special instruction for operating this unit at over 5000 feet. BATTERY INSTALLATION This engine generator set is shipped with a battery tie down kit for customer installation. This kit consists of a battery tie down and hardware for installation of the customer supplied battery on the unit. BATTERY CHARGING Units 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 assembly to produce DC charging current of about 1 to 3 Amps. This circuit is not designed to be used as a battery charging circuit to recharge dead batteries. OPTIONAL DOLLY KIT An optional 4-wheel dolly kit is available for this generator. The dolly kit comes with instructions and parts list. CAUTION: EQUIPMENT DAMAGE Be sure to check the wheels properly before operating the generator. Ensure the brake has been applied. Allowing the unit to move will cause damage to the unit, drop cords or loads. If you intend to use the power plant’s electric start system, you will need to purchase and install a battery to operate it. WARNING: EQUIPMENT DAMAGE The battery positive (+) cable is shipped with a plastic protective cap. When starting manually, this protective cap must remain in place to avoid possible damage to the engine electrical system and/or generator end. A 12 Volt battery, BCI group U1 rated at 275 CCA or larger is recommended for this electric start engine-generator set. Follow the battery manufacturers recommendations for servicing and charging prior to use. Connect the battery to the electric start system using the cables provided. CAUTION: EQUIPMENT DAMAGE 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 an tight. Reverse the sequence when disconnecting, disconnect the negative cable first. These engines produce enough direct current to keep the battery charged under normal operating conditions, but were not intended to be used as a battery charger. OPM-139/E 8 INITIAL START UP not operate the starter more than 5 seconds and wait at least 10 seconds before operating the starter again. Repeat cycle if necessary. 6. When the engine starts, release the key switch, allowing it to return to the “on” position. 7. Gradually push the choke as the engine warms up. 8. The engine should promptly come up to operating speed. The throttle control on these generators is preset and INITIAL START UP ect the positive battery locked first. Then connect the to operate at 3600 RPM (nominal) with no load e “bat-” terminal.speed Make set at 3690 RPM. Only a trained service technician The throttle control on these generators is preset an and tight. Reverse should be allowed to adjust this speed setting. and locked to operate at 3600 RPM (nominal) with ecting, disconnect the no load speed set at 3690 RPM. Only a trained engines produce enough service technician should be allowed to adjust this ery charged under norNOTICE: ENGINE START LOCKOUT speed setting. ut were not intended to r. This unitNOTICE: will not start if it is low on oil. The lubricating oil ENGINE START LOCKOUT JURY level must be at the full mark before the engine will start This unit will not start if it is low on oil. The luce explosive hydrogen and run.bricating oil level must be at the full mark before the parks, flames, and engine will start and run. m the battery. Ventilate sing the battery in an batteries contain sulfuric BASIC OPERATION burns. If acid contacts well with water. For con- ELECTRIC STARTING If the engine is cold and stiff or if the battery is not fully e medical attention. charged,Ifstarting byisslowly hand the engine can is coldbe andmade stiff or ifeasier the battery not crankingfully thecharged, engine through the compression starting can be made easier by slowly stroke before cranking the engine through the comprespushing hand the starter switch. This permits the starter to gain start have a small flysion stroke before pushing the starter switch. This momentum before the heavy load of the compression engine flywheel assempermits the starter to gain momentum before the This minimizes the drain on the battery and g battery. This stroke flywheel occurs. heavy load of the compression stroke occurs. This C current that passes improvesminimizes the possibility ofthestarting under such the drain on battery and improves the adverse o produce a DC chargpossibility of starting adverse conditions. especially conditions. Always keepunder thesuch battery charged, MPS. This circuit is not Always keep the battery charged, especially during during weather operation. attery charging circuit to cold cold weather operation. 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. BASIC OPERATION 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 grade gasoline. 2. HOT WEATHER 1. Check oil level,refill refill as 1. Check oil level, asneeded needed. 2. Turn on thefuel fuel supply. RefRef “A” Lever 2. Turn on the supply. “A”. pointing Lever pointing up or up is on, lever pointing down is off. down is on, lever sideways is off. able for this generator. KIT 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. ructions and parts list. file the instructions and manual for future refer- STOPPING AND STORING 09/07/07 20:33:44 32Z6L600_005 M 3. Move the throttle lever away from the MIN. position, about 1/3 of the way toward the MAX. position. 1. Move the key to the “OFF” position. 2. Turn off the fuel supply valve. 3. Before extended storage (over 30 days) certain 6. Warm up the engine for 2 or 3 minutes. precautions must be taken to ensure the fuel doesn’t 7. If the choke knob was pulled to the CLOSED position to start the deteriorate and engine, gradually push it to the OPEN position as the engine warms up. clog the fuel system. rator is equipped with a his Honda engine uses de the engine. If the oil 6. Warm up the engine for 2 or 3 minutes. m the MIN. position, about 1/3 09/07/07 20:33:44 32Z6L600_005 point the low oil module sition. wn. This low oil warning 7. If the choke knob was pulled to the CLOSED position to start the NOTE: The use of a fuel additive, such as Sta-Bil or 3. Engage the choke it out. Aengine warm6. Warm engine engine, gradually pushby it to pulling the OPEN position as the op the engine before the 3. Move the throttle lever away from the MIN. position, about 1/3 up the engine for 2 or 3 minutes. OPEN warms of theup. wayless toward the MAX. position. equivalent choking than a cold engine. CLOwill SED minimize the formation of gum deposits anger point. This feature will require MIN. 7. If the choke knob was pulled to the CLOSED position to start the y repairs and downtime. during storage. M I N . engine, gradually push it to the OPEN position as the The engine additive may be added to gasoline in A the engines fuel tank or to gasoline in a storage container. warms up. AMAGE CLOSED OPEN THROTTLE LEVER CHOKE KNOB A. Add the fuel stabilizer to the fuel in the tank and run for 2 minutes to circulate the stabilizer throughout the STOPPING THE ENGINE fuel system. OTTLE LEVER CHOKE KNOB 4. Turn the engine switch to B. If you choose remove theswitch remaining fuel from the To stop the engine in an emergency,to simply turn the engine the ON position. THROTTLE LEVER CHOKE KNOB emote-mounted throttle control to the OFF position. Under normal conditions, use the following fuel tank, it must be drained into an approved hrottle lever shown here. Refer to procedure. Refer to the instructions provided by the equipment Some engine applications use a remote-mounted throttle controlON quipment manufacturer. manufacturer. container. rather than the engine-mounted throttle lever shown here. Refer to 60706-233 7 STOPPING THE ENGINE the instructions provided by the equipment thetoengine and allow it to run until all the fuel in 4. Turn the engine switch to themanufacturer. “on” position.STOPPING THE ENGINE1. MoveC. theStart throttle lever the MIN. position. To stop the engine an emergency, simply turn the engine switch 4. Turn the enginein switch to the carburetor and the throttle fuel lines has been used up and Some engine applications use a remote-mounted to thethe OFF simply turn the engine switch ONposition. position. Under normal conditions, use the following To stop the engine in an emergency, the engine stops. control rather than the throttle lever shown position. Under normal conditions, useengine-mounted the following procedure. Refer to the instructions provided by the equipment to the OFFENGINE SWITCH utdown repeatedly on MIN. essive wear which can TART he 5 tch, ore re than at the t. ON Some engine applications use a remote-mounted throttle control OPEN rather than the engine-mounted throttle lever shown here. Refer toCLOSED MINthe . instructions provided by the equipment manufacturer. MIN. ON manufacturer. here. procedure. Refer to the instructions provided by the equipment manufacturer. ON 1. Move the throttle lever to the MIN. position. ENGINE SWITCH position, and hold it there until the engine starts. START If the engine fails to start within 5 seconds, release the engine switch, and wait least 10 seconds before Turn the engine switch to theatSTART the position, and hold operating it there until thestarter again. 5. Operating the starter. Rotate the key switch briefly to the START engine starts. position. NOTE: Running the engine to use up the fuel in the lines and carburetor will still leave a small amount of fuel in Some engine applications use a remote-mounted throttle carburetor. It lever is best control rather than the engine-mounted throttle shown extended storage to treat the fuel here. before draining. 1. Move the throttle lever to the MIN. position. Some engine applications use a remote-mounted throttle 5. Operate the starter. control rather than the engine-mounted throttle leverENGINE shown SWITCH here. ONTurn the engine switch to the START 5. Operate the starter. START START ON MIN. START MIN. the electric starter for more than If the engine fails toUsing start within 5 MIN. 5 seconds at a time will overheat the seconds, release the engine switch, starter motor and and wait at least 10 seconds before can damage it. THROTTLE LEVER operating the starter again. ENGINE ON LEVER switch to the OFF position. 2. Turn the engine When theTHROTTLE engine starts, release the SWITCH The starter life is improved by using shorter starting cycles with time to cool2. off betweenengine cranking cycles. Do START switch, allowing it to return O N Turn the engine switch to the OFF position. START ENGINE MIN. IN. D. While the engine is warm, Mdrain the oil and refill with fresh oil. THROTTLE LEVER E. Clean dirt and chaff from cylinder, cylinder head fins, 2. Turn the engine switch to the OFF position. blower housing, screen, and muffler areas. MIN. F. Store in a clean and dry area. Using the electric starter than to the for ONmore position. 5 seconds at a time will overheat the starter motor and can damage it. When the engine starts, release the engine switch, allowing it to return OFF to the ON position. ENGINE SWITCH OFF OFF 9 OFF OPM-139/E OFF ENGINE SWITCH OPERATING SPEED CAUTION: EQUIPMENT DAMAGE SPEED ADJUSTMENTS SHOULD ONLY BE MADE BY A QUALIFIED SERVICE TECH. Whenever making any speed adjustments, check the unit with a voltmeter and a frequency meter or a tachometer and be sure the voltage and speed are correct. The engine-generator must be run at the correct speed in order to produce the proper electrical voltage and frequency. CAUTION: EQUIPMENT DAMAGE The output voltage should be checked to ensure 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. 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. 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. Although individual units and models vary slightly, the normal voltage and frequency of the engine-generator described in this manual are approximately as follows, under varying loads: LOAD vs. OUTPUT Generator Load Speed (RPM) Frequency (Hz) Voltage None 3690 61.5 125V Half 3600 60.0 120V Full 3510 58.5 115V 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 charged. If the generator is being run continuously on a very light load, it is often advisable to lower the operating speed slightly. Reference “D” in the following image is the speed adjustment for this engine. D OPM-139/E 10 CONNECTING THE LOADS The engine-generator covered in this manual was designed for portable use. Do NOT operate indoors. The unit should be stored in a warm, dry location. Move the unit outdoors to a flat, dry location for use. WARNING: PERSONAL DANGER: Operating any engine driven generator without proper air flow can result in personal injury or death. DO NOT operate this unit inside a home or garage, near vents or windows, or anywhere carbon monoxide gas could accumulate. APPLYING THE LOADS 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. CAUTION: EQUIPMENT OVERLOAD Keep the generator load within in the generator and receptacle nameplate rating. Overloading may cause damage to the generator and/or the loads. 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 the Unit Capabilities. 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. 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 receptacles amperage rating is not exceeded. GROUNDING Proper grounding of your generator is application dependent. Carefully evaluate your planned use of your generator to understand which grounding you require. If you are not sure what to do, contact a competent professional to assist you. The NFPA 70 250:34-35 are good technical references. STANDARD PORTABLE GENERATOR Your WINCO portable generator ships with a bonded neutral. You can safely use this generator without external grounding as long as all loads are powered through the receptacle panel. VEHICLE-MOUNTED GENERATOR Your WINCO portable generator ships with a bonded neutral. When mounted to a vehicle to safely distribute power it is necessary that the generator frame is bonded to the vehicle frame. The generator should only supply equipment that is cord and plug connected through receptacles mounted on the generator or the vehicle. PERMANENTLY INSTALLED GENERATORS This WINCO portable generator ships with a bonded neutral and overcurrent protection. NFPA 70 refers to this as a “separately derived system.” When connecting it to a building a transfer switch specifically designed for GFCI and bonded neutral generators is required. WIRING Plug your tools such as drills, saws, blowers, sump pump, and other items to be powered directly into the generator receptacles. Before plugging in all the tools and cord sets, recheck the rating of the generator set. Be sure it can handle the intended load and is compatible with the voltage, phase, and current ratings. ‘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/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. 1. These engine-generator sets are designed for portable heavy duty commercial use. Receptacles are provided on the control panel to permit 120 and 240 Volt portable appliances and tools to be plugged directly into them. Please note that the 3-wire 240 Volt receptacle(s) on these units are designed to power only 240 Volt tools. There are two hot leads and a ground wire, but no neutral connection, in the 3-wire 240Volt receptacle. A 4-wire receptacle (two hot, one ground, and one neutral) has been provided on the control panel for use in temporary power applications requiring 120/240 Volt power. Consult a licensed electrician for wiring the TemPower plug and connecting it as temporary service. 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, 4-wire twist-lock plug (14-60P). 11 OPM-139/E 2. If the generator set is connected to an existing distribution system, a fully isolated manual transfer switch must be installed. The transfer switch prevents damage to the generator and the 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. 3.Many homes and construction sites are wired for at least 60 to 100 Amp entrance service, much greater than the capacity of this portable generator. When installing the generator at these sites, a secondary emergency distribution panel may have to be installed. 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 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. OPM-139/E 12 YOURGEN The WINCO YourGen meter allows you to see useful information about your generator from the front panel by displaying RPMs, Voltage, frequency, load, hours, and maintenance reminders. It also has the ability to display warnings if any parameter gets outside of normal operation range. Cycle Button ( ) During normal operation, the display will toggle through on fixed delay. If you want to see any specific item, you can press the cycle button to move it to that setting. Once the display is selected, the delay before it starts toggling is approximately 5 seconds. This button is also used to reset maintenance reminders. RPM The meter will display the RPMs of the engine. This number is calculated based upon frequency and is not directly measured from the engine. The engine-generator must be run at the correct speed in order to produce the proper electrical voltage and frequency. CAUTION: EQUIPMENT DAMAGE The output voltage should be checked to ensure 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. Operating Speed: 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. Although individual units and models vary slightly, the normal voltage and frequency of the engine-generator described in this manual are approximately as follows, under varying loads: LOAD vs. OUTPUT Generator Load Speed (RPM) Frequency (Hz) None 3690 Half Full 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. The engine will govern itself at full speed. Intentionally overriding the governor and operating the generator at low 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 light bulbs and appliances being used, as well as possibly damaging the engine. CAUTION: EQUIPMENT DAMAGE SPEED ADJUSTMENTS SHOULD ONLY BE MADE BY A QUALIFIED SERVICE TECH. Whenever making any speed adjustments, check the YourGen meter and be sure the voltage and speed are correct. Output voltage should be checked periodically to ensure continued proper operation of the generating plant and appliances. Hz This is the measured frequency of the generator set. See the table in the RPM section above for an explanation of voltage and frequency ranges under load. V1 Output voltage of Line 1 (L1 on panel) to neutral. See the Load vs. Output table for an explanation of voltage and frequency ranges under load. V2 Output voltage of Line 2 (L2 on panel) to neutral. See the Load vs. Output table for an explanation of voltage and frequency ranges under load. V1-V2 Output voltage of Line 1 (L1) and Line 2 (L2). See the Load vs. Output table for an explanation of voltage and frequency ranges under load. Hours This displays the total running hours of the generator set. When the generator is turned off, the hours will remain displayed. The display is run on a CR2032, ten-year battery. Once the unit is running, the battery connected to the unit will then supply the power to the YourGen meter. Load Bars These bars indicate how much load is being used on Line 1 (L1) and Line 2 (L2). Voltage 120V Recpt 240V Recpt 61.5 120V 240V 3600 60.0 120V 240V 3510 58.5 120V 240V = 1-25% 13 = 25-50% = 50-75% = 75-100% OPM-139/E It is good practice to monitor the YourGen Meter when applying load. This will ensure the generator is balanced. Voltage 3.0V DC Battery Type CR2032 Lifetime10 Years The battery has a 10 year lifetime, in the event you need to change the battery, follow these instructions: Balanced Unbalanced 120 Volt and 120/240 Volt receptacles are provided for connection to various loads. The diagram below represents this 10,800 watt (rated output) generator. A & B represent the 120 volt output legs of this generator. Up to 5400 watts at 120 volts (45 Amps) can be drawn from the receptacles attached to either A or B output legs. This generator is capable of producing 45 Amps of 240 volt current at C. Check the appliance or tool nameplates for the current and voltage to insure compatibility. Remember that power taken from C reduces the power available at equally both A and B and vice versa. The battery is located in the control box near potentially live AC terminals. To prevent electrocution while changing the battery disable the unit by disconnecting the main battery, spark plug wire and then open the receptacle panel. Locate the backside of the YourGen meter. Gently pry the back plate off using the slot located on top. Once open, the battery will be located at the top. Using a needle nose plier, carefully pull out the battery. Battery Change Oil Warning After the first 50 hours, the engine oil should be changed. The YourGen meter will light up the oil icon ( ) and the word ‘change’ will flash. Once the oil has been changed, press and hold the cycle button for approximately 5 seconds until the warning has been removed from the display to reset the warning. The meter will then remind you of oil changes on the appropriate schedule for your generator. It is important to remember that the engine manufacturer recommends changing the oil on a calendar schedule even if the total number of operational hours have not been reached. Certain operating environments may also require more frequent oil changes. Replace the battery having the POSITIVE (+) side down. Ensure the battery is secured between the battery connections. Install Battery Between These Two Points Replace the back plate of the meter and close the receptacle panel using the screws to secure it. Reconnect the unit’s main battery. Alarms The display will start blinking and toggle to the first parameter that is out of specification. The panel will remain flashing until the fault condition returns to within the acceptable range, see following table. Frequency Voltage VAC1-VAC2 Acceptable Range 57-63 Hz 110VAC-130VAC 220VAC-260VAC Battery When the unit is off, the YourGen meter will display the hours continuously using a coin cell back-up battery inside the meter. Once the unit is running, the meter will get power from the main unit battery. OPM-139/E 14 Let the engine and exhaust system cool before touching. －Injury from moving parts. Do not run the engine unless instructed to do so. Read the instructions before you begin, and make sure you have the tools and skills required. ENGINE CARE To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a non-flammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and flames away from all fuel related parts. MAINTENANCE SCHEDULE This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher (a research octane rating of 91 or higher). Refuel in a well ventilated area with the engine stopped. If the engine has been running, allow it to cool first. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks. You may use unleaded gasoline containing no more than 10% ethanol (E10) or 5% methanol by volume. In addition, methanol A.cosolvents Start theand engine and warm it of up, stop the engine and must contain corrosion inhibitors. Use fuels ofremove spark plugthan wire to prevent it from with content ethanol orthe methanol greater shown above may cause and/or performance problems. It may also starting accidentally being started. damage metal, rubber, and plastic parts of the fuel system. Engine B. This engine has an oil drain valve for your convenience. damage or performance problems that result from using a fuel Attach a neoprene drain the oil into an with percentages of ethanol or methanol hose greaterand than shown above are not covered undercontainer. the Warranty. approved If majorRemember engine service or repair is required, contact an that an authorized Honda servicing dealer knows your authorized engine center. The manufacturer of engine best andservice is fully equipped to maintain and repair it. these engines has established an excellent world-wide ensure the best quality and reliability, use only new Honda engine To service organization. Engine service is very likely Genuine parts or their equivalents for repair and replacement. C. Remove the20:35:22 oil filter and dispose of it properly. 32Z6L600_009 available from a nearby authorized dealer or distributor. See If your equipment will09/07/07 be used on an infrequent or intermittent D. Before you install the new oil filter, clean the filter basis, please refer to the fuel section of the STORING YOUR MAINTENANCE SCHEDULE following table. mounting and coat the seal of the new oil filter ENGINE chapter (see page 11base ) for additional information OIL FILTER AIR CLEANER Each First Every 6 Every Every 2 Refer regarding deterioration. REGULAR SERVICE PERIOD (3) fuelwill clean engine oil. Use Month Months Year Years to Perform at every E. Install theChange oil filter by hand until the gasket contacts theA dirty air clea or or or Page or indicated month or perform oil filter adapter, then tighten the oil filter 1/2 to 3/4 engine 20 Hrs 100 Hrs 300 Hrs 500 Hrs operating hour interval, 1. Drain the engine oil, and retighten the drain bolt securely. clean the air fi turns. whichever comes first. SCHEDULE (se ITEM Gasoline is highly flammable explosive, you the oil filter, and and drain the oil into sealing a suitable container. 2. Remove F. Replace oil drainand bolt making sure the washer is Dispose the used oil and filter in a manner compatible with the 8 Check level Engine oil can be burned or seriously injured when refueling. in place. environment. Operating the 8 Change G.the Remove the oilheat, filter plugand and refill with new oil. Make filter, will allow Every 200 Hrs. 9 Replace Engine oil filter Stop engine and keep sparks, flame This type of da 9 Check Air cleaner away.sure to use the proper grade oil based on your Warranty. Use an oil filter socket, rather than a strap wrench, to avoid (1) 9 Clean Refuel only outdoors. operating temperature. striking and damaging the oil pressure switch. Replace Spark plug Wipe up spills immediately. ＊ Inspection 10 Check-adjust Replace Spark arrester Remove the ai Clean or repla filter elements 11 Clean (applicable types) Idle speed Check-adjust (2) ＊＊ Valve clearance Check-adjust (2) ＊＊ Combustion Clean After every 1000 Hrs. (2) ＊＊ Fuel can damage paint and some types of plastic. Be careful not to spill fuel when filling yourSEAL fuel tank. Damage caused by spilled fuel is not covered under the Distributor’s Limited Warranty. Cleaning 1. Pull the air c remove the chamber Fuel filter Replace Fuel tube Check (2) ＊＊ Every 2 years (Replace if necessary) (2) * ＊＊ Replace the paper filter only papermanual filter element only. ＊** Replace Refer the to shop ＊＊Refer to the Shop Manual. (1) Service more frequently when used in dusty areas. 09/07/07 20:35:22 32Z6L600_009 (2) These items should be serviced by your Honda servicing (1) Service more frequently when used in dusty areas. dealer, unless you have the proper tools and are mechanically proficient. be serviced by your Honda servicing (2) These items should OIL FILTER (3)dealer, For commercial operation to determine unless youuse, havelog the hours properof tools and are mechanically proper maintenance intervals. proficient. Refer to the Honda shop manual for service Change Never use stale or contaminated gasoline or an oil/gasoline OIL FILTER mixture. Avoid getting dirt or water in the fuel tank. 2. Remove the With the engine stopped and on a level surface, remove the fuel filler cap and check the fuel level.MOUNTING Refill the BASE tank if the fuelOIL level is SOCKET FILTER FILTER low. Refer to the instructions provided with themounting equipment powered bythe seal of the new oil 3. Clean the filter base, and coat NOTE: This engine requires 57oil. to 58 ounces (1.78 to 1.81 this engine for refuelling. filter with clean engine 3. Remove the the air clean 4. Remove the quarts) of oil it is completely drained. Use caution when AIRifCLEANER Refuel in a well-ventilated area before starting the engine. If the refilling the engine asa some residual oilavoid remained Use only Honda Genuine filter ormay acarburetor, filterhave of equivalent engine has been running, allow to cool. Refuel carefully to the A dirty airit cleaner will restrict air oil flow to reducing quality your model. the filter, or a the engine. Always usethe the dipstick when filling the spilling in fuel. It may be necessary tospecified lower fuel level depending procedures. engine performance. Iffor you operate theUsing engine in wrong very dusty areas, which is not oftank equivalent may cause 1. Drain the engine oil, and retighten the drain securely. the air filterfilter more often than in thequality, MAINTENANCE on bolt operating conditions. After refueling, tighten the fuelspecified cap engine withclean oilnon-Honda to prevent overfilling. engine(see damage. SCHEDULE page 7 ). securely. (3) For commercial use, log hours of operation to determine FOAM FILTER ELEMENT 2. Remove the oil filter, and drain the oil into a suitable container. proper maintenance intervals. 4. Screwplug. on the new oil filter by hand until the seal contacts the H. Replace filter Dispose the used oil and filter in a mannerKeep compatible with the gasoline away from appliance pilot lights, barbecues, filter mounting base, then an oil or filter socket tool to air tighten environment. the enginewarm without an air filter, with a damaged The oil level always be checked before the engine is electric appliances, I. Start power theOperating engine ituse up. tools,filter etc.and Failuremust to follow this maintenance schedule could result in nonandirt additional filter,the will allow to enter 3/4 the turn. engine, causing rapid engine wear. failures.6 of this manual for instructions on started.warrantable Refer to page J . After warming up the engine, recheck the oil level andAIR CHAMBER This type of damage is not covered by the Distributor’s Limited is not only aWarranty. fire Oil hazard, it causes environmental 12 the N·m (1.2 kgf·m , 9level. lbf·ft) filter tightening torque: Use oil filter socket, strapSpilled wrench,fuel to avoid checking the oil level. Take care toanremove anyrather dirtthan or adebris refill as necessary to bring it to proper damage. Wipe up spills immediately. striking and damaging the oil pressure switch. CHECKING THE OIL LEVEL from around the oil plug before removing. Be sure the oil level is maintained. ENGLISH CHANGING THE OIL SEAL Refer to the Maintenance Schedule Chart for required oil change intervals. 5. Refill the crankcase with the specified amount of the Inspection recommended oil (see page 8 ). Reinstall 7the oil filler cap and oil level dipstick. Remove the air cleaner cover and inspect the filter elements. Clean or replace dirty filter elements. Always replace damaged 6. elements. Start the engine, and check for leaks. filter DUAL ELEMENT AIR FILTER PACKING Clean and/or replace the foam pre-cleaner and the air filter 5. Inspect both 7. Stop100 the engine, and check the oilmore level asoften described on page 8 . damaged. A annually orCleaning every hours. Service under If necessary, add oil to bring the oil level to the upper limit mark scheduled in dusty conditions. the level dipstick. 1. Pullon the airoil cleaner cover latch to the unlocked position, and remove the cover. WARNING: EQUIPMENT DAMAGE 2. Remove the wing nut from the paper filter element. OIL FILTER Outdoor temperatures determine the proper oil viscosity for Never start3.or runthe the engine withandthe air filter removed. the engines. Winco recommends our 5W-30 fully synthetic Remove paper filter element foam filter element from FILTER MOUNTING BASE OIL FILTER SOCKET the air cleaner case. oil to give you excellent protection in cold temperatures while maintaining excellent performance in warmer 3. Clean the filter mounting 4. Remove thecleaner foam filter cover element from the paper filter element. the base, and coat the seal of the oil A.new Unsnap the air latches and remove filter with clean engine oil. weather. cover. AIR CLEANER COVER LATCH Use only a Honda Genuine oil filter or a filter of equivalent quality specified for your model. Using the wrong filter, or a non-Honda filter which is not of equivalent quality, may cause engine damage. 4. Screw on the new oil filter by hand until the seal contacts the filter mounting base, then use an oil filter socket tool to tighten the filter an additional 3/4 turn. Oil filter tightening torque: 12 N·m (1.2 kgf·m , 9 lbf·ft) FOAM FILTER ELEMENT AIR CHAMBER AIR CLEANER COVER WING NUT ENGLISH PAPER FILTER ELEMENT AIR CLEANER CASE 5. RefillNeoprene the crankcase hose, 1/2”with I.D. the specified amount of the recommended Cut to length oil (see page 8 ). Reinstall the oil filler cap and oil level dipstick. PACKING 6. Start the engine, and check for leaks. 15 7. Stop the engine, and check the oil level as described on page 8 . If necessary, add oil to bring the oil level to the upper limit mark on the oil level dipstick. OPM-139/E 5. Inspect both filter elements, and replace them if they are damaged. Always replace the paper filter element at the scheduled interval (see page 7 ). B. Remove the wing nut. C. Remove the paper filter element and foam element from the air cleaner case. D. Remove the foam filter elements from the paper filter element. E. Inspect both filter elements and replace them if damaged. Always replace the paper filter element at the scheduled interval. F. To loosen debris, gently tap the air filter on a hard surface. If the air filter is excessively dirty replace with a new filter. You can use pressurized air (not to exceed 30 psi) to clean the filter. Always blow the compressed air from inside to the outside. G. Wash the foam filter element in liquid detergent and water. Then allow it to thoroughly air dry. Dip the foam filter element in clean engine oil and squeeze out all the excess before reinstalling it. The engine will smoke when started if too much oil is left in the foam. H. Clean the dirt from the inside of the air cleaner body and cover. Reinstall the air filter in housing making sure the packing is in place beneath the filter element. Tighten the wing nut securely. I. Install and secure the cover. SPARK PLUG Replace annually or every 300 hours of operation. Always replace with the same spark plug that came in the engine and check gap before installing. Spark plug gap is 0.030”. Poor spark will also occur if spark plug wire does not fit firmly on spark plug. If this happens, reform the terminal to fit firmly on spark plug tip. CARBON CANISTER Designed to collect, store, and dispose of fuel vapors created in the fuel tank/fuel system. The canister should last the life of the unit as long as it stays dry. OPM-139/E 16 GENERATOR CARE TROUBLESHOOTING TABLE Proper care and maintenance of the generator is necessary to ensure a long trouble free life. Problem Possible Causes Won’t start Low oil level Fouled spark plug Out of fuel Start switch in OFF position Fuel Valve turned off Plugged fuel filter Blown fuse in key switch Voltage too low Engine speed is too low Generator overloaded Defective stator Defective rotor (field) Defective capacitor Circuit breaker trips Defective load Defective receptacle Excessive load Voltage too high Engine speed is too high Generator overheating Overloaded Insufficient ventilation No output voltage Short in load (disconnect) Tripped or defective circuit breaker Broken or loose wire Defective receptacle No residual magnetism (in generator) Defective stator Defective rotor (field) Shorted capacitor Shorted diodes on rotor GFCI receptacle tripped 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 enginegenerator set will also ensure that the set is operating properly should it be needed in an emergency. 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. CLEANING Remove dirt and debris with a cloth or brush. DO NOT use high pressure spray to clean either the engine or the generator. The 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 ensure 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 fly wheel. 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. 17 OPM-139/E WIRING DIAGRAM WL12000HE-03/A WL12000HE-03/C OPM-139/E 18 WIRING DIAGRAM GND G1 G1 G3 G3 N N N G1 GND G1 G3 G3 GND G1 N G3 GND G1 G3 G1 GND N N G1 G3 G1 WL12000HE-03/B WL12000HE-03/D 19 OPM-139/E ENGINE GENERATOR SET 36 MONTH LIMITED WARRANTY WINCO warrants to the original purchaser for 36 months or 1000 hours, whichever occurs first, that goods manufactured or supplied by it will be free from defects in workmanship and material, provided such goods are installed, operated and maintained in accordance with WINCO written instructions and applicable codes. 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. For warranty service, return the product within the warranty period, to your nearest WINCO Authorized Service Center or to WINCO in Le Center Minnesota. Duration Consumer, Commercial and Rental Parts & Labor: 24 Months Parts Only: 24-36 Months EXCLUSIONS: • • • • • • • • Normal maintenance consumables or labor. This warranty does not cover travel time, mileage or labor for removal or re-installation of WINCO product from its application. Normal wear and tear. Costs of rental equipment. WINCO does not warrant engines. Engines are covered exclusively by the warranties of their respective manufacturers. WINCO does not warrant component parts that are warranted by their respective manufacturers. WINCO does not warrant modifications or alterations which were not made by WINCO. WINCO does not warrant products which have been subjected to misuse and/or negligence or have been involved in an accident. Proof of proper maintenance must be furnished upon request. THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE DESCRIBED HEREIN. THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, OR OTHERWISE CREATED, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY, OR WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE. WINCO is liable for the repair or replacement of the product only and is not liable for incidental or consequential damages as permitted by your state. This warranty gives you specific legal rights which may vary from state to state. CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board is pleased to explain the evaporative emission control system’s warranty on your model 2020 generator. In California, new equipment that uses small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards. WINCO must warrant the evaporative emission control system on your generator for the period listed below provided there has been no abuse, neglect or improper maintenance of your equipment leading to the failure of the evaporative emission control system. Your evaporative emission control system may include parts such as: carburetor, fuel tank, fuel cap, fuel lines (for liquid fuel and fuel vapors), fuel line fittings, fuel line clamps, carbon canisters, and carbon canister mounting brackets. MANUFACTURER’S WARRANTY COVERAGE The evaporative emission control system is warranted for two years. If any evaporative emission related parts on your equipment are defective, the parts will be repaired or replaced by WINCO. OPM-139/E 20LE CENTER, MN 56057 • 507-357-6821 WINCO INC. • 225 S. CORDOVA AVE • ">
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