Winco W6010DE/I, W6010KE-03/A Installation And Operator's Manual

W6010DE/I
W6010DE/J
W6010KE-03/A
W6010KE-03/B
GENERATOR
INSTALLATION AND
OPERATORS MANUAL
16200-014
www.wincogen.com
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS
3
SAFETY INFORMATION
4
SPECIFICATIONS5
GENERATOR
GENERATOR
ENGINE
INTRODUCTION6
TESTING POLICY
INTENDED USES
RESTRICTED USES
UNIT CAPABILITIES
7
PREPARING THE UNIT 8
BATTERY INSTALLATION
INITIAL START UP
10
11
CONNECTING THE LOADS
12
YOURGEN ENGINE CARE
14
16
GENERATOR CARE
18
GENERATOR CONNECTIONS
STARTING ELECTRIC MOTORS
Load Types
UNPACKING
LUBRICATION
OIL RECOMMENDATIONS
DIESEL FUEL
LIFTING EYE INSTALLATION
OPTIONAL DOLLY KIT
BASIC OPERATION
STARTING HINTS
STOPPING
APPLYING THE LOADS
GROUNDING
WIRING
MAINTENANCE SCHEDULE
CHANGING THE OIL
CHECKING THE OIL LEVEL
AIR FILTER
EXERCISING THE GENERATOR
GENERATOR MAINTENANCE
CLEANING
TROUBLESHOOTING19
WIRING DIAGRAM
20
CA EVAP EMISSION CONTROL
21
LIMITED WARRANTY
22
OPM-133/F
2
SAVE THESE INSTRUCTIONS
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.
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.
To get the best performance from your new generator, it is
important that you carefully read and follow the operating
instructions in this manual.
Should you experience a problem please follow the
“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.
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 # ___________________________________
3
OPM-133/F
SAFETY INFORMATION
This manual contains important information that should be
understood and followed before the installation, operation
and maintenance of the generator. Failure to follow the
safety instructions in this manual could result in serious
injury or death. Keep this manual available for future
reference.
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.
SAFETY DEFINITIONS
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation
WARNING which, if not avoided, could result in death
or serious injury.
Indicates a potentially hazardous situation
which, if not avoided, may result in minor or
CAUTION
moderate injury. It may also be used to alert
against unsafe practices.
DANGER
NOISE HAZARD
Excessive noise is not only tiring, but continual exposure
can lead to loss of hearing.
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 when working around this
equipment for long periods of time.
B. Keep your neighbors in mind when using this
equipment.
CALIFORNIA PROPOSITION 65
WARNING: This product contains crude oil,
gasoline, diesel fuel and other petroleum
products, Antifreeze to which can expose you
to chemicals including toluene and benzene,
Ethylene glycol (ingested) which are known to the
State of California to cause cancer, birth defects or other
reproductive harm and developmental issues.
For more information go to www.P65Warning.ca.gov.
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 materials that could create
a potential fire hazard.
C. Carefully clean up any gas or oil spills before starting
the unit.
ELECTRICAL SHOCK
The output voltage present in this equipment can cause
fatal electric shock. This equipment must be operated by a
responsible person.
SERVICING EQUIPMENT
All service, including the installation or replacement of
service parts, should be performed only by a qualified
technician.
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 to an external
ground rod driven into the earth.
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.
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.
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).
OPM-133/F
4
SPECIFICATIONS
GENERATOR
ModelsW6010DE/I & /J
W6010KE-03/A
W6010KE-03/B
Starting Watts6,010
Running Watts
W6010DE/I & /J
5,160
W6010KE-03/A5,000
W6010KE-03/B5,000
Volts120/240
Starting Amps 50/25
Running Amps
W6010DE/I & /J
43/21.5
W6010KE-03/A40/20
W6010KE-03/B40/20
GENERATOR
Generator Manufacturer
Mecc Alte Spa
Generator Model Number S16W-130/A
Part Number16346-006
Rotor Resistance3.95 Ohms
Stator Resistance
0.360 Ohms
Cap Winding Resistance
0.60 Ohms
Capacitors25 mF
Capacitor Part Number
16346-612
ENGINE
Engine Manufacturer
Kohler
Engine Model Number
KD440
Fuel TypeDiesel
Oil Capacity
41.6 oz. (1.3 qts)
5
OPM-133/F
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 operate generator where it could get wet or have
pooling water near it. This generator is NOT weatherproof.
Failing to keep generator in a dry area may cause an
electrical shock, resulting in injury or death.
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 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 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 engineered and meet
applicable code.
DO NOT attempt to operate at 50 cycles. These units are
designed and governed to operate at 60 cycles only.
OPM-133/F
6
UNIT CAPABILITIES
GENERATOR CONNECTIONS
The figures given in the previous chart 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-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 may also be damaged.
W6010DE: 120 Volt and 240 Volt receptacles are provided
for connection to various loads. The following diagram
represents this 5,160 watt (rated output) generator. A &
B represent the 120 volt output legs of this generator. Up
to 2,580 watts at 120 volts (43 Amps) can be drawn from
the receptacles attached to either A or B output legs. This
generator is capable of producing 21.5 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 equally at
both A and B and vice versa.
CAUTION: EQUIPMENT DAMAGE
Running the generator set under these conditions may
result in damage to the generator stator as well as the
motor winding.
W6010KE: 120 Volt and 240 Volt receptacles are provided
for connection to various loads. The following diagram
represents this 5,000 watt (rated output) generator. A &
B represent the 120 volt output legs of this generator. Up
to 2,500 watts at 120 volts (40 Amps) can be drawn from
the receptacles attached to either A or B output legs. This
generator is capable of producing 20 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 equally at
both A and B and vice versa.
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.
Motor starting capacity - 2HP code ‘G’ capacitor start
engine.
Trying to start a larger motor or higher code motor, i.e. ‘J’
or ‘K’, may result in damage to both the generator and the
electric motor, especially 120 Volt motors.
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.
LOAD TYPES
This generator is designed and rated for general
commercial use. The running watts rating assumes a
variable load. If your application has a fixed load that does
not vary, an additional derate of 20% from the running
watts is recommended to ensure the longest useful life of
the engine and generator end.
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. The
following chart shows the approximate current required to
start and run various types and sizes of 120 Volt 60 cycle
electric motors under average load conditions.
STARTING AMPS
HP
Running
Amps
Split Phase
Motor
Capacitor
Motor
Repulsion
Induction Motor
1/6
3.2
16 to 22
6 to 13
5 to 8
1/4
4.5
22 to 32
9 to 18
7 to 12
1/3
5.2
26 to 35
10 to 21
8 to 17
1/2
7.2
Not Made
14 to 29
11 to 18
1
13
Not Made
26 to 52
20 to 33
7
OPM-133/F
PREPARING THE UNIT
UNPACKING
OIL RECOMMENDATIONS
CAUTION: EQUIPMENT DAMAGE
Always check oil level prior to use. Failure to maintain the
engine oil at the proper level will result in serious engine
damage.
Outdoor temperatures determine the proper oil viscosity for
the engines. Winco recommends our 5W-30 fully synthetic
oil to give you excellent protection in cold temperatures
while maintaining excellent performance in warmer
weather.
When you unpack your engine-generator set be sure to
remove all the information sheets and manuals from the
carton.
1. As you receive your unit, it is critical to check it for any
damage. If any damage is noted, it is always easiest to
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
2. Before proceeding with the preparations of your new
generator for operation, take a couple of minutes to ensure
the unit you have received is the correct model and review
the specification pages in this manual to ensure that this
unit meets your job requirements.
LUBRICATION
DIESEL FUEL
CAUTION: EQUIPMENT DAMAGE
Failure to maintain the engine oil at the proper level will
result in serious engine damage.
Always use a good grade of # 2 diesel fuel. For cold
weather, blended #1 fuel may be used. Fuel cetane number
should be 45 or higher and the fuel MUST be low sulfur
or ultra low sulfur fuel. See engine operators manual for
additional fuel recommendations including Bio-Diesel fuel.
Never use gasoline or gasohol. Always ensure that the fuel
is clean and free of all impurities. Always be sure to keep the
strainer in place when filling the fuel tank.
Before starting the engine, verify the crankcase is filled to
the proper level with a good quality oil. The recommended
grade oil and quantity of oil required is listed in the engine
operator’s manual and under the service tab in this manual.
This unit was shipped with oil in it. The engine normally
holds 1.3 quarts (41.6 oz.) of oil. Use the dipstick to ensure
that you have the proper oil level in the crankcase. The full
oil level mark on the dipstick is depicted in the following
image.
WARNING: FIRE DANGER
Diesel fuel is flammable and can be ignited, causing or
enlarging fires when proper precautions are not taken.
Never use fuel that has been stored for an extended period
of time. Fuel will lose its volatile properties and you will
be left with a ‘gum’ or varnish residue. This varnish-like
substance will clog the filters, fuel lines, and injectors. Old,
contaminated, stale fuel 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.
Oil is added to the engine by removing the oil cap and
adding oil at this point. After filling the crankcase to the
proper level, be sure you properly tighten the oil fill cap.
NOTE: This engine generator must be on a level surface
before you check or add oil to the system.
The necessity of using the correct oil and keeping the
crankcase full cannot be overemphasized. Engine failures
resulting from inadequate or improper lubricant are
considered abuse and not covered by the generator or
engine manufacturer’s warranty.
OPM-133/F
8
LIFTING EYE INSTALLATION
5
In the bag of parts for the lifting eye, ensure all of the
required materials are included: 2 qty - 5/16-18 x 2.25
button head socket screws (#1); 2 qty - washers (#2); 2 qty .3125-18 flange (#3); 1 qty - lifting eye (#4).
1. Place the bottom of the lifting eye (#4) under the cross
bar (#5).
CAUTION: EQUIPMENT DAMAGE
Ensure the lifting eye is NOT installed on top of the cross
bar.
2. In each hole, place 1 washer (#2) between the top of the
cross bar and the button head screw (#1). Secure the screw
and flange, ensuring it is torqued.
OPTIONAL DOLLY KIT
An optional 2-wheel dolly kit is available for this generator.
The dolly kit comes with its own instructions and parts list.
CAUTION: EQUIPMENT DAMAGE
Be sure to check the wheels properly before operating the
generator.
9
OPM-133/F
BATTERY INSTALLATION
This engine generator set is shipped with a battery tie down
for customer installation.
DANGER: EXPLOSIVE FIRE RISK
Never smoke when near batteries. Do not cause a flame or
spark in the battery area. Always discharge static electricity
from your body before touching batteries by first touching
a ground metal surface.
A customer supplied 12 Volt battery, BCI group U1 rated
at 300 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.
WARNING
The electrolyte is diluted sulfuric acid that is harmful to the
skin and eyes. It is electrically conductive and corrosive.
The following precautions must be always be taken.
Installation and servicing of batteries must be performed or
supervised only by personnel knowledgeable of batteries
and the required precautions. Keep unauthorized personnel
away from batteries.
1. Always wear full eye protection and protective
clothing.
2. Where electrolyte contacts skin, wash off immediately
with water.
3. If electrolyte contacts the eyes, flush thoroughly and
immediately with water and seek immediate medical
attention.
4. Spilled electrolyte is to be washed down with an acid
neutralizing agent. A common practice is to use a
solution of one pound of bicarbonate of soda (baking
soda) to one gallon of water. The bicarbonate of soda
solution is to be added until the evidence of reaction,
foaming, has ceased. The resulting liquid is to be
flushed water and the area dried.
When installing or replacing batteries, use proper group/
size starting battery. The battery should be a maintenance
free lead acidic design. Deep cycle batteries will NOT work
for this application.
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.
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.
CAUTION
Do NOT open or mutilate the battery. Released electrolyte
is known to be harmful to the skin and eyes and to be very
toxic. A battery presents a risk of electrical shock and high
short circuit current. The following precautions must be
observed when working with batteries:
1. Remove watches, rings and other metal objects.
2. Use tools with insulated handles.
3. Check both the battery cable ends and the battery
posts to be sure they are free of corrosion.
4. Always connect the battery positive first and then
connect the battery negative cable. When removing
the battery cables from the battery reverse the
procedure, disconnect the negative cable first and
then the positive cable.
5. Be sure all connections are tight and coat the
terminals and cable end with dialectic grease.
OPM-133/F
SERVICING BATTERIES
Batteries used on these units may over time lose water.
This is especially true if you are using a trickle charger to
maintain your battery. When refilling the battery with water
use only distilled water. Tap water will shorten the service
life of the battery.
Never fill the battery above the fill line. Overfilling above
the upper level line may cause the electrolyte to overflow,
resulting in corrosion to the engine or nearby parts.
Immediately wash off any spilled electrolyte following the
procedure above.
Note: always make sure that a new battery is fully charged
before installing it on a generator set.
All connections must be clean and tight. Check the
electrolyte (fluid) in the battery periodically to be sure it is
above the plates. Never allow the battery to remain in a
discharged condition.
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.
10
INITIAL START UP
The throttle control on these generators is preset and
locked to operate at 3600 RPM (nominal) with no load
speed set at 3690 RPM. Only a trained service technician
should be allowed to adjust this speed setting.
5. Return key to 1st position when engine is running (Ref A).
A
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. This engine will not start without a battery. The
fuel shut-off solenoid requires 12V DC to operate.
NOTE: While the engine is running, all warning lights
should be off except the OK light.
BASIC OPERATION
STARTING HINTS
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, especially
during cold weather operation.
1. COLD WEATHER
Use the proper oil for the temperature expected.
CAUTION: EQUIPMENT DAMAGE
Never use ether or any other starting aides. Serious engine
damage or personal injury may result from ignoring this
simple warning.
1. Check oil level, refill as needed.
2. Make sure the fuel solenoid valve lever is in the down
position. This lever should never be put in the up position.
The lever is located under the key switch as pictured.
2. HOT WEATHER
Use the proper oil for the temperature expected.
STOPPING
1. Move the key to the “OFF” position.
0
2. Make sure the fuel solenoid valve lever is in the down
position. The lever is located under the key switch as
pictured. The generator will not shutdown if this lever is
in the up position.
3. Turn key to 1st position (Ref A).
A
4. Turn key to the 2nd position - starting (Ref B).
B
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: Running the engine to use up the fuel in the lines
and carburetor will still leave a small amount of fuel in
carburetor. It is best extended storage to treat the fuel
before draining.
A. While the engine is warm, drain the oil and refill with
fresh oil.
B. Clean dirt and chaff from cylinder, cylinder head fins,
blower housing, screen, and muffler areas.
C. Store in a clean and dry area.
11
OPM-133/F
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.
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.
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.
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.
CAUTION: EQUIPMENT DAMAGE
Diesel engines should never be run for an extended period
of time with a very light load or no load on them, it may
do permanent damage to the engine if run under these
conditions.
OPM-133/F
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.
12
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 (L14-30P).
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. This
generator is GFCI protected, so the transfer switch needs
to be GFCI compatible. If the transfer switch is not GFCI
compatible, the breaker on the generator will always trip.
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 a[[lied 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.
13
OPM-133/F
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:
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).
= 1-25%
LOAD vs. OUTPUT
Generator
Load
Speed
(RPM)
Frequency
(Hz)
None
3690
Half
3600
Full
3510
OPM-133/F
Voltage
120V
Recpt
240V
Recpt
61.5
125V
258V
60.0
120V
240V
58.5
115V
230V
= 25-50%
= 50-75%
= 75-100%
It is good practice to monitor the YourGen Meter when
applying load.
This will ensure the generator is balanced.
14
Balanced
Unbalanced
120 Volt and 240 Volt receptacles are provided for
connection to various loads.
the YourGen meter. Gently pry the back plate off using the
slot located on top.
The following diagram represents this 5,160 watt (rated
output) generator. A & B represent the 120 volt output legs
of this generator. Up to 2,580 watts at 120 volts (43 Amps)
can be drawn from the receptacles attached to either A
or B output legs. This generator is capable of producing
21.5 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 equally at both A and B and vice versa.
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.
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:
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
and then open the receptacle panel. Locate the backside of
15
OPM-133/F
ENGINE CARE
MAINTENANCE SCHEDULE
Daily or
Every 10
hrs
Check Oil
ü
Check oil filter
ü
Check dry air cleaner
ü
Every
250* hrs
Fuel tank cleaning
ü
Clean cooling fins
ü
Replace engine oil
ü
Replace oil filter
ü
C. Replace oil drain plug.
D. Remove oil fill cap.
Every
500** hrs
E. Fill to correct level with oil. Reinstall cap.
F. Remove the oil filter and dispose of it properly.
Replace fuel filter
ü
Set and clean
injectors
ü
Rocker arm
adjustment
ü
* If engine use is infrequent; every year
** If engine use is infrequent; every 2 years
If you are using oil of a quality lower than the
recommended one then you will have to replace it every
150 hours
If major engine service or repair is required, contact an
authorized engine service center. The manufacturer of
these engines has established an excellent world-wide
engine service organization. Engine service is very likely
available from a nearby authorized dealer or distributor.
CHANGING THE OIL
Change the oil after the first 50 hours of operation and
yearly or 250 hours thereafter under normal operating
conditions.
Outdoor temperatures determine the proper oil viscosity for
the engines. Winco recommends our 5W-30 fully synthetic
oil to give you excellent protection in cold temperatures
while maintaining excellent performance in warmer
weather.
A. Change oil while the engine is still warm, the oil will
flow more freely.
B. Remove the oil drain bolt at base of the engine and
drain the oil into an approved container.
NOTE: This engine requires 41.6 oz. (1.3 qts) of oil if it is
completely drained. Use caution when refilling the engine
as some residual oil may have remained in the engine.
Always use the dipstick when filling the engine with oil to
prevent overfilling.
H. Replace oil filter and filter plug.
I. Start the engine and warm it up.
J . After warming up the engine, recheck the oil level and
refill as necessary to bring it to the proper level.
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 plug before removing. Be sure the oil level is
maintained. Fill to the “FULL” mark on the dipstick.
AIR FILTER
Clean the filtering element with air blast. Air must be blown
from inside to outside the cartridge at a distance of at least
6 inches from the paper. Lightly and repeatedly tap the
element on a hard surface to eliminate all excess dirt.
WARNING: EQUIPMENT DAMAGE
Never start or run the engine with the air filter removed.
A. Remove the cover.
Drain Bolt
OPM-133/F
16
B. Remove the wing nut.
C. Remove the filter element.
D. Check the rubber seal is undamaged.
E. 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.
F. Clean the dirt from the inside of the air cleaner body
and cover. Reinstall the filter in housing. Tighten the
wing nut securely.
G. Install and secure the cover.
H. Remove and clean the pre-filter if clogged.
17
OPM-133/F
GENERATOR CARE
Proper care and maintenance of the generator is necessary
to ensure a long trouble free life.
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.
OPM-133/F
18
TROUBLESHOOTING
Problem
Possible Causes
Won’t start
Low oil level
Out of fuel
Start switch in OFF position
Fuel Valve turned off
Plugged fuel filter
Blown fuse in key switch
Battery required to open solenoid
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
GFCI type of load i.e. a building with
bonded neutral
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
Will not shutdown
Fuel solenoid valve lever is in up
position
19
OPM-133/F
OPM-133/F
G1
N
G1
G2
20
G2
GND
GND
N
G1
GND
N
GND
G2
G1
G1
G2
G1
GND
G1
G2
N
N
N
WIRING DIAGRAM
CALIFORNIA EVAPORATIVE EMISSION CONTROL
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board is pleased to explain the evaporative emission control system’s warranty on your model
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.
21
OPM-133/F
LIMITED WARRANTY
WINCO Incorporated warrants to the original purchaser for the warranty period 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.
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, contact a Winco Authorized Service Center within the warranty period from date of purchase.
*NOTE: Units that are resold by original owner are not covered under this warranty. Any further warranty, whether expressed or
implied, rests solely with the reseller.
THERE IS NO OTHER EXPRESS WARRANTY.
To the extent permitted by law, any and all warranties, including those of merchantability and fitness for a particular purpose, are limited
to the warranty period from date of purchase. In no event is WINCO liable for incidental or consequential damages.
Note: 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 from state to state.
WINCO, INC. WARRANTY EFFECTIVE DATE
Air cooled units purchased for stock have 1 year to be sold. The warranty to the original retail customer commences on the date of
sale of the product to them. All liquid cooled units have 180 days from the Winco invoice to submit a start up date. If no startup form is
submitted, then warranty period starts on the Winco invoice date unit was sold.
Date of sale is defined as the day the customer takes delivery of the product. This warranty shall remain in effect to the original purchaser
for the period stated on the sales literature. The warranty is not transferable and the retail customer must retain his original bill of sale as
proof of purchase date.
WINCO, Inc. agrees to the following obligations during the warranty period:
1. To warrant any defect in material or workmanship of products sold under the WINCO and DYNA brand
names in accordance with the warranty statements in the operator’s manuals.
2. To reimburse authorized WINCO, Inc. Service Centers/Dealers for the cost of parts plus standard ground
UPS shipping charges for all valid warranty repairs and to reimburse same said service centers/dealers for
reasonable labor charges based on WINCO’s current warranty labor reimbursement rate.
3. To furnish its authorized service centers/dealers with the necessary parts to make the repairs. WINCO
Generator Warranty Periods & Restrictions
WINCO GENERATOR WARRANTY PERIODS & RESTRICTIONS
Industrial Portables
WL Models - 3 Years, See Notes 1 & 2
W Models - 3 Years, See Notes 1, 2, & 5
DP Models - 3 Years, See Notes 1 & 2
HPS Models - 2 Years, Home Use ONLY; Commercial use* is 90 Day Warranty, See Note 1
EMERGEN-C (EC) Series
2 Years, See Note 1
DE Series
1 Year/2000 hours, No Travel Time
Mobile Diesel Series
1 Year/2000 hours, No Travel Time
PTO Series
15kW & 10kW - 1 Year, Limited Farm Standby Only
25kW thru 165kW - 3 Years, Limited Farm Standby Only/Commercial use* 1 Year
Two Bearing Series
1 Year, Bench Labor and Parts only
Gaseous/Packaged Standby Series (PSS)
Air-Cooled Models (PSS8, PSS12, & PSS20) – 2 Years/2000 Hours Standby Only See Notes 3 & 4 Prime Power use 1 Year/2000 Hours See
Notes 3 & 4
Liquid-Cooled Models (PSS21 - PSS150) - 2 Years/2000 Hours Standby Only See Notes 3 & 4 Prime Power use 1 Year/2000 Hours See
Notes 3 & 4
Diesel Standby Series (DR)
Liquid-Cooled Models (DR12 - DR600) - 2 Years/2000 Hours Standby Only See Notes 3 & 4
Prime Power use 1 Year/2000 Hours See Notes 3 & 4
Accessories (Installed on Generator or shipped loose)
1 Year from factory invoice or 2000 Hours (whichever occurs first)
OPM-133/F
22
Automatic Transfer Switches (ATS)
See ATS Manufacturer’s Warranty
NOTES
Note 1: First 2 years of warranty coverage includes Parts and Bench Labor Only, no travel time or labor allowance for removal or
reinstallation of the product from its application.
Note 2: 3rd Year warranty coverage is parts only/no labor.
Note 3: Round trip mileage is limited to 200 miles per trip and a total of 2 trips per repair unless authorized in writing by the WINCO
Service Dept.
Note 4: Mileage allow on permanently installed units only. Trailer mount units is bench labor only.
Note 5: W3000 is a 1 Year Warranty.
*Commercial use is defined as Construction, Rental, Prime Power, or use in a business of any type including agricultural and hobby. Prime
Power use is defined as any application where the generator set is being used ‘off-grid’ where there is no utility power present. Standby
use is defined as an application where utility power is present -and- the generator set is used as emergency backup during utility power
outages.
WINCO reserves the right to change or improve it’s products without incurring any obligations to make such changes or improvements
on products purchased previously.
EXCLUSIONS:
WINCO does not warrant Engines. Engines are covered exclusively by the warranties of their respective manufacturers.
WINCO does not warrant Batteries, or Other Component Parts that are warranted by their respective manufacturers.
WINCO does not warrant modifications or alterations which were not made by WINCO, Inc.
WINCO does not warrant products which have been subjected to misuse and/or negligence or have been involved in an accident.
This warranty does not include travel time, mileage, or labor for removal or reinstallation of WINCO product from its application, unless
specifically authorized.
WHAT IS COVERED BY WARRANTY
1. Generator end including rotor, stator, end brackets, and bearing.
2. Control box including transformers, circuit breakers, wiring, resistors, and switches.
3. LP/NG fuel system including fuel solenoid, demand regulator, carburetor, and hoses.
4. Cradle assembly including cradle, cross member, and shock mounts that fail. Shock mounts damaged from rough
handling are not covered.
5. Reasonable travel time for the PSS & DR series generators only, that are permanently installed.
6. Ground shipping charges for warranty parts, no premium service, domestic US shipments only.
WHAT IS NOT COVERED BY WARRANTY
1. Products which have been subjected to alteration, modification, neglect or unauthorized repairs not approved in
writing by Winco, Inc.
2. Products no longer owned by the original purchaser.
3. Products with shipping or freight damage. File a freight claim with the delivery carrier.
4. Products suffering normal wear, accidents, improper maintenance or improper protection in storage. Products
damaged by rough handling, such as shock mounts on cradle assemblies.
5. Pressure or steam cleaning of products, cleaning of fuel system, or flushing of cooling system.
6. Replacement of filter, belts, antifreeze, or lubricants.
7. Electrical items, such as light bulbs, receptacles, spark plugs, or any items damaged by welding or jump starting.
8. Any repeat or shop come-back repairs resulting from poor service work or improper diagnosis and testing.
Replacement of parts as a trial-and-error method of diagnosis will not be considered for warranty.
9. Replacement parts other than those sold by Winco, Inc.
10. Damage caused by fire, flood, lightning or any other natural disaster.
11. Damage caused by improper protection during installation, (i.e. not protecting contactor in the ATS panel and
getting wire trimming or debris from drilling the box in the contactor coil or contacts.)
12. Damage caused by over loading of the generator and failure to adequately provide overload protection.
13. LP/NG fuel adjustments or conversion from one fuel to another.
14. Adjustment of any kind, all units are 100% load tested before shipping.
15. Any damage caused by the use of the equipment for purposes other than for which it was designed.
16. Engines - All engines used by Winco, Inc. are warranted by their respective manufacturer’s.
17. Batteries - Must be returned to original battery manufacturer.
18. Damage caused by improper installation or failure to provide adequate ventilation.
19. Cosmetic repairs, such as repainting.
20. Freight charges for transportation to and from a Warranty Service Center.
21. Rental costs of renting replacement generators.
22. Travel time or service calls unless specifically authorized by Winco, Inc. in writing.
GENERAL INFORMATION
The WINCO, Inc. Service Department is open from 7:30 AM to 4:30 PM Central Standard time.
It is located at 225 South Cordova Ave., Le Center, MN, 56057-1805.
Phone Numbers: Service Department - 507-357-6831 FAX Line - 507-357-4857. Email address is [email protected]
The phone number to for the General Switchboard/Sales Department is 507-357-6821.
23
OPM-133/F
225 S. CORDOVA AVE • LE CENTER, MN 56057
Sales: 507-357-6821• [email protected]
Service: 507-357-6831 • [email protected]
www.wincogen.com
OPM-133/F
24