Winco Emergency Rescue EC6010DR/S power generator OWNERS MANUAL
Below you will find brief information for power generator Emergency Rescue EC6010DR/S. The Emergency Rescue EC6010DR/S is a 6kw portable power generator designed for mobile use, such as vehicle mounting. It features a Yanmar diesel engine with electric key start and low oil pressure shutdown system. The generator provides 120/240 volt AC output and can be wired for both 120 volt only or dual voltage operations.
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INSTALLATION, OPERATION, and
MAINTENANCE INSTRUCTIONS
EMERGENCY
RESCUE SERIES
EC6010DR/S
60706-214
OWNERS MANUAL
Read and understand all instructions in the manual before starting and operating the generator set.
USING THIS MANUAL
Congratulations on your choice of a Winco generator set.
You have selected a high-quality, precision-engineered generator set designed and tested to give you years of satisfactory portable service.
.
To get the best performance from your new engine generator set, it is important that you carefully read and follow the operating instructions in this manual.
Should you experience a problem please follow the
“Things To Check” near the end of this manual. The warranty listed in this manual describes what you can expect from WINCO should you need service assistance in the future.
TABLE OF CONTENTS
INTRODUCTION
GUIDE TO PRODUCT SAFETY
Specification Table
Intended Uses
Restricted Uses
Unit Capabilities
Unpacking the unit
Unit Preparation
Operation/Installation
Starting
Starting Hints
Operating Speed
Connecting The Remote Start Switch
Wiring
Engine Care
Low Oil Level Shutdown System
Generator Care
Cleaning
Things To Check BEFORE
You Call For Service
Exhaust & Controls Part List
Engine Generator Set
Key Switch Parts List
Generator Assembly Parts List
Outline Drawing
DC Wiring Diagram
AC Wiring Diagram
12 MONTH WARRANTY
8
8
9
10
10
11
12
13
14
5
5
5
6
7
7
7
7
2
3
3
2
2
1 i
2
4
5
PROPER USE AND INSTALLATION
You must be sure your new engine generator set is:
* Properly serviced before starting
* Operated in a well ventilated area
* Exhaust gases are dispersed safely
* Wired by a qualified electrician
* Operated only for its designed purposes
* Used only by operators who understand its operation
* Properly maintained
COPY YOUR MODEL AND SERIAL
NUMBER HERE
No other WINCO generator has the same serial number as yours. It is important that you record the number and other vital information here, if you should ever need to contact us on this unit it will help us to respond to your needs faster.
MODEL____________________________________
SERIAL NUMBER____________________________
PURCHASE DATE____________________________
DEALER___________________________________
IMPORTANT SAFETY
INSTRUCTIONS
SAVE THESE INSTRUCTION
This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.
Read and understand all instructions in the manual before starting and operating the generator set.
This engine generator set has been designed and manufactured to allow safe, reliable performance. Poor maintenance, improper or careless use can result in potential deadly hazards; from electrical shock, exhaust gas asphyxiation, or fire. Please read all safety instructions carefully before installation or use.
Keep these instructions handy for future reference. Take special note and follow all warnings on the unit labels and in the manuals.
ANSI SAFETY DEFINITIONS
************************************************************
DANGER:
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.
***********************************************************
************************************************************
WARNING:
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
***********************************************************
***********************************************************
CAUTION:
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
************************************************************
NOTE:
CAUTION is also used on the unit labels and in this manual to indicate a situation that could result in serious damage or destruction of the equipment and possible personal injury.
1.
ELECTRIC SHOCK - The output voltage present in this equipment can cause a fatal electric shock. This equipment must be operated by a responsible person.
a.
Do not allow anyone to operate the generator without proper instruction.
b.
Guard against electric shock.
c.
Avoid contact with live terminals or receptacles.
d.
Use extreme care if operating this unit in rain or snow.
e.
Use only three-prong grounded receptacles and extension cords.
f.
Be sure the unit is properly grounded to an external ground rod driven into the earth.
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Page 1
2.
FIRE HAZARD - Deisel fuel presents a hazard of possible explosion and/or fire.
a.
Do not smoke or use open flame near the generator set.
b.
Keep a fire extinguisher nearby and know its proper use. Fire extinguishers rated ABC by NFPA are appropriate.
3.
DEADLY EXHAUST GAS - Exhaust fumes from any diesel
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.
c.
Never operate the unit in such a way as to allow exhaust gases to seep back into closed rooms (i.e.
through windows, walls or floors).
4.
NOISE HAZARD - Excessive noise is not only tiring, but continual exposure can lead to loss of hearing.
a.
Use hearing protection equipment when working around this equipment for long periods of time.
b.
Keep your neighbors in mind when permanently installing this equipment.
5. CLEANLINESS - Keep the generator and surrounding area clean.
a.
Remove all grease, ice, snow or materials that create slippery conditions around the unit.
b.
Remove any rags or other material that could create potential fire hazards.
c.
Carefully wipe up any fuel or oil spills before starting the unit.
d.
Never allow leaves or other flammable material to build up around the engine exhaust area.
6.
SERVICING EQUIPMENT - All service, including the installation or replacement of service parts, should be
performed only by a qualified technician.
a.
Use only factory approved repair parts.
b.
Do not work on this equipment when fatigued.
c.
Never remove the protective guards, cover, or receptacle panels while the engine is running.
d.
Use extreme caution when working on electrical components. High output voltages from this equipment can cause serious injury or death.
e.
Always avoid hot mufflers, exhaust manifolds, and engine parts. They all can cause severe burns instantly.
f.
Installing a generator set is not a “do-it-yourself” project. Consult a qualified, licensed electrician or contracor. The installation must comply with all national, state, and local codes.
g.
Always make sure unit is disabled before placing your hands anywhere near the fan, belts, alternator or water hoses.
1335-00
SPECIFICATIONS
MODEL EC6010DR/R
Generator
Surge Watts
Continuous Watts
Volts
AMPs @ 240 Volts
6000
5500
120/240
22.9
Engine
Size
Model
9.9 HP
Yanmar WL100V
Type See Engine Shroud For Type
Fuel Capacity- N/A - External, Customer Supplied Tank
Fuel Consumption
Starting System
.7 gal/hr
12 Volt Electric
Key - Local/Remote
Muffler
Stop System
Low Tone
Key - Local/Remote
Complete Unit
Weight (dry)
Dimensions LxWxH
290 LBS
26.3 X 18.125 X 21.7
Owner Must Provide
Fuel
Oil Type
#2 Diesel
10W-30 CD or higher for -4 o
F to 86 o
F
See engine manual for additional oil information.
Oil Capacity 1.7 Quarts (1.6 L.)
1. DO NOT remove from the base assembly. Removal of the generator from the base assembly or operating without the shock mounts installed may cause excessive vibration and damage to the engine generator set.
2. DO NOT operate this generator without the compartment door open., i.e. generator compartment of rescue vehicles, motor homes or travel trailers. Closed compartments will not allow enough free flow fresh air to reach the engine generator set for cooling. Overheating will cause damage to both the engine and the generator. Small compartments may also develop hot spots where there is very little air flow and could cause fire.
3. DO NOT attempt to operate this unit at 50 cycles. These units are designed and governed to operate at 60 Cycles only.
UNIT CAPABILITIES
Generator Connections - The diagram below represents a typical 5500 watt generator. Receptacles A and B are the two
120 Volt duplex receptacles. Up to 2750 watts at 120 volts (22.9
Amps) can be taken from the generator at each of the receptacles. This generator produces 120 and 240 volt, 60 Hz
(Hertz), AC (Alternating Current).
CAUTION: EQUIPMENT DAMAGE
CAUTION MUST BE EXERCISED TO PREVENT
OVERLOADING EITHER OF THE GENERATORS
120 VOLT OUTPUT CIRCUITS (A OR B).
INTENDED USES
1. These engine generator sets have been designed specifically for vehicle mounting and mobile use. The generator output is available in the junction box on the top of the generator shell.
Receptacles are not provided in the “control box” since the unit is intended to be wired into the vehicles electrical distribution system. The vehicle electrical distribution system must include a main line circuit breaker (MLCB) to protect the generator and your wiring. The vehicle distribution wiring and receptacles carry the generator output power to the loads (portable lights appliances and tools). These units are dual wound generators, with two separate 120 Volt windings. These windings can be connected for full power 120 volt OR 120/240 volt output. When connected for 120/240 dual voltage, the 120 volt loads must be split and balanced to avoid overloading one of the generator 120 volt windings. See unit capabilities for further explanation.
2. These units require large quantities of fresh air for cooling of both the engine and the generator. Fresh air is drawn from both the engine end and the generator end and is exhausted at the center of the unit. For safety, long life and adequate performance, these units should not be run in small compartments without the access door open to allow positive fresh air flow.
RESTRICTED USES
Check the appliance or tool nameplates for the current and voltage to insure compatibility. Remember that power taken from receptacle C reduces the power available at both A and B.
Any remaining 120 volt loads should be equally divided between
A and B. Failure to split the load will cause permanent damage to the stator. Although circuit breakers are provided, damage due to overloading constitutes abuse and will not be warranted.
Starting Electric Motors - Electric motors require much more current (amps) to start them than to run them. Some motors, particularly low cost split-phase motors, are very hard to start and require 5 to 7 times as much current to start them as to run them. Capacitor motors are easier to start and usually require 2 to 4 times as much current to start them as to run them.
Repulsion Induction motors are the easiest to start and usually require 1 1/2 to 2 1/2 times as much to start them as to run them.
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Most fractional horsepower motors take about the same amount of current to run them whether they are of Repulsion-Induction
(RI), Capacitor (Cap), or Split-Phase (SP) type. The chart below shows the approximate current required to start and run various types and sizes of 120 volt 60 cycle electric motors under average load conditions.
RUNNING STARTING AMPS
HP AMPS SP CAP RI
1/6
1/4
1/3
1/2
1
3.2
4.5
16 TO 22
22 TO 32
6 TO 13
9 TO 18
5 TO 8
7 TO 12
5.2
26 TO 35 10 TO 21 8 TO 17
7.2
NOT MADE 14 TO 29 11 TO 18
13.0
NOT MADE 26 TO 52 20 TO 33
The figures given above are for an average load such as a blower or fan. If the electric motor is connected to a hard starting load such as an air compressor, it will require more starting current. If it is connected to a light load, or no load such as a power saw, it will require less starting current. The exact requirement will also vary with the brand or design of the motor.
Self-excited generators respond to severe overloading differently than the utility. 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.
UNPACKING
When you unpack your new ENGINE GENERATOR, be sure to remove all the information sheets and manuals from the carton.
1. This power plant was in good order when shipped. Inspect the power plant promptly after receiving it. If damage is noted, notify the transportation company immediately; request proper procedures for filing a “concealed damage” claim. Title to the equipment and responsibility for filing claim rests with you when a generator is sent F.O.B. shipping point. Only you can legally file a claim.
2. Before proceeding with the preparation of your new engine generator set for operation, take a couple of minutes to insure that the unit you have received is the correct model and review the specification pages in this manual to insure that this unit fits your job requirements.
UNIT PREPARATION
Before your engine generator was shipped from our factory it was fully checked for performance. The generator was load tested to its full capacity, and the voltage and frequency were carefully checked and adjusted.
CAUTION: EQUIPMENT DAMAGE
RUNNING THE GENERATOR SET UNDER THESE
CONDITIONS MAY RESULT IN DAMAGING THE
GENERATOR STATOR AS WELL AS THE MOTOR
WINDING.
Because the heavy surge of current required for starting motors is required for only an instant, the generator will not be damaged if it can bring the motor up to speed in a few seconds of time. If difficulty is experienced in starting motors, turn all other electrical loads off and if possible reduce the load on the electric motor.
1. Lubrication - Before starting the engine, fill the crankcase to the proper level with a good quality oil. The recommended grade of oil and quantity of oil required is listed in the engine operators manual. 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 are not covered by the generator or the engine manufacturers warranty.
Motor Starting Capacity - listed below you will find the motor starting capability of your engine generator set.
Generator
Model
EC6010DR
Motor Size
(code “G” capacitor start)
3.0 HP
Trying to start a larger motor or higher code (ie. J or K) motor may result in damage to both the generator and the electric motor especially 120 volt motors.
CAUTION: EQUIPMENT DAMAGE
THIS UNIT HAS BEEN SHIPPED WITHOUT OIL. Failure to maintain the engine oil at the proper level will result in serious engine damage.
a. Make sure the engine is level b. Remove the oilcap/dipstick (ref 1) from either side of the engine and wipe off with a clean cloth.
c. Fully re-insert oil cap/deipstick, but do not screw in. d. Remove oil cap/dipstick. The oil level should be between the upper mark (ref 2) and the lower mark (ref 3) on the oil cap/dipstick.
e. Fill engine with proper grade and weight of oil.
f.
Fully reinsert oil cap/dipstick and hand tighten. Ovetightening the oil cap/dipstick will damage it.
Oil should be change after the first 50 hours of operation and every 100 hours there after. It should be checked daily.
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2. Diesel Fuel and Fuel Line Connections - Always use a good grade of # 2 diesel fuel. For cold weather, blended # 1 fuel may be used - See engine operators manual fo recommendations. Never use gasoline or gasohol. Always insure that the fuel is clean and free of all impurities.
3. Battery connection - These remote start engine generator sets require customer supplied battery cables. Connections are made directly to the engine starter solenoid post positive (+) and the engine frame negative (-). The battery cable size is determined by the length of the cable run. The engine starter requires a minimum of 300 Cold Cranking Amps (CCA) for proper starting performance.
These generator sets must be started and operated with a twelve
(12) volt battery. The 12 volt battery must be rated at 300 CCA or larger. For units mounted in vehicles, it is recommended that you use the vehicle battery. Follow the battery manufacturers recommendations for servicing and charging prior to use.
Connect the battery to the electric start system using cables that are sized for the length of run and voltage drop allowable.
CAUTION: EQUIPMENT DAMAGE
These electric start engines are NEGATIVE GROUND. Use extreme caution when connecting the battery. Connect the
NEGATIVE battery terminal to GROUND.
The fuel pump on the unit is designed to provide a 2 foot lift. If you requires a greater lift, a second fuel pump may be required.
Be sure to use fuel line clamps on all hose connections to prevent them from leaking. Consult the factory for other special applications.
WARNING: FIRE
Diesel fuel is flammable and can be ignited to cause or enlarge fires when proper precautions are not taken.
A fuel return line must be run from the fuel return line fitting on the top of the engine back to the supply tank. This line cannot be routed to the fuel supply line but must be routed back to the supply tank.
For your safety always connect the positive battery cable to the
“bat+” terminal first. Then connect the negative battery cable to the “bat-” terminal. Make sure all connections are clean and tight.
Reverse the sequence when disconnecting, disconnect the negative cable first. To prevent interference with the vehicle charging circuit, the battery charging circuit on the generator set is removed.
WARNING: PERSONAL INJURY
Lead acid batteries produce explosive hydrogen gas when charging. Keep sparks, flames, and burning cigarettes away from the battery. Ventilate the area when charging or using the battery in an enclosed space. Lead acid batteries contain sulfuric acid, which causes severe burns. If acid contacts eyes, skin or clothing, flush well with water. For contact with eyes, get immediate medical attention.
OPERATION/INSTALLATION
This engine generator set consists of a Yanmar diesel engine and a 6 kw WINCO generator end. The Yanmar engine is a electric key start engine with a low oil pressure protection.
This generator set has been pre-wired to allow the use of a second key switch at a remote location to start the engine generator set. See diagram on page 12.
This unit can be mounted inside of a compartment as long as attention is paid to proper cooling air flow. The exhaust which is turned down may be routed to any location of your choosing. See page 11 for unit layout and mounting.
INITIAL START UP
CAUTION: ENGINE DAMAGE
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’ / 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.
1335-00 Page 4
Never operator this engine generator set for an extend period of time under a noload or very light load condition. Doing so may cause excessive oil usage and damage the engine.
Use the following checklist to verify the correct preparation of the engine generator before starting.
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1. Engine oil, fill as required with correct grade and quantity.
2. Hot weather
2. Connect and prime the fuel line. The electric fuel pump can be used to fill the line and prime the injector pump. DO NOT RUN
THE ENGINE UNTIL THE NEW FUEL LINE HAS BEEN FULLY
PRIMED. Air in the fuel line can be difficult to remove. Avoid the problem by checking the fuel prime before initial start or after fuel system service (replacing fuel filter, fuel lines etc.) The engine requires clean, fresh fuel.
a. Be sure to use the proper oil for the temperature expected.
b. Use only summer blended fuel. Using old fuel left over from winter may cause damage to the engine or clogging of the fuel filters and injection pump. See Engine Manufactur ers instructions.
3. Visually check unit for loose parts.
OPERATING SPEED
STARTING and STOPPING
The engine-generator must be run at the correct speed in order to produce the proper electrical voltage and frequency.
The throttle control on this generator 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.
CAUTION: EQUIPMENT DAMAGE
The output voltage should be checked to insure the generator is working properly prior to connecting a load to the generator.
Failure to do so could result in damage to equipment plugged into the unit and possible injury to the individual.
1. Manual starting - Provision for manual starting is not provided -
If the battery is dead or defective, recharge or replace it. Refer to the engine manual for additional starting, operating, and stopping instructions.
2. Electric Starting - Always keep the battery charged, but especially during cold weather operation.
a. Turn on the fuel supply and prime the fuel line up to the injector pump.
b. Operate the key switch. In the run position the switch will turn on the fuel solenoid and the fuel pump and in the start position the starter engage. The switch is spring loaded to the run position, so when you release the key the switch returns to this position
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 may vary slightly, the normal voltage and frequency of the engine-generators described in this manual are approximately as follows, under varying loads:
CAUTION: EQUIPMENT DAMAGE
DO NOT ENGAGE THE STARTER FOR LONGER THAN 15
SECONDS. DO SO MAY DAMAGE THE STARTER.
c. The engine will start and come up to operating speed.
d. To shut the unit off rotate the key switch to the OFF position.
The unit is stopped by shutting off the fuel solenoid
STARTING HINTS
1. Cold weather.
LOAD vs. OUTPUT
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Generator Frequency Generator voltage
Load Speed (Hz) 120V 240V
Applied* (RPM) Recpt.
Recpt.
————————————————————————
None 3690 61.5
Half 3600 60.0
129V 258V
120V 240V
Full 3510 58.5
115V 230V
**************************************************************
*Portion of plant’s rated output current.
a. Use the proper oil for the temperature expected.
b. Use fresh winter grade fuel. Winter grade fuel is blended to improve starting. Do not use old or straight summer blend fuel.
CAUTION: EQUIPMENT DAMAGE
The speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency.
For normal usage, the speed setting should not be changed. If the generator is being run continuously on a very light load, it is often advisable to lower the operating speed slightly. Whenever making any speed adjustments check the unit with a voltmeter or tachometer and be sure the speed is correct.
Never use ether or any other starting aides. Serious engine damage or personal injury may result from ignoring this simple warning.
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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.
Output voltage should be checked periodically to ensure continued proper operation of the generating plant and appliances. If the generator is not equipped with a voltmeter, it can be checked with a portable meter. Frequency can be checked by using an electric clock with a sweep second hand.
Timed against a wrist watch or a stop watch the clock should be correct within +/- 2 seconds.
CONNECTING THE LOADS
WIRING
These engine generator sets are designed for mobile vehicular use. The generator output consists of two independent 120 volt windings. These windings may be connected in series to permit
120 and 240 dual voltage availability, or in parallel to provide 120 volt only power at higher amperage.
Please note that any standard 3 wire 240 volt receptacle provided by the vehicle manufacturer is designed to power only 240 volt tools. There are two hot and one ground wire.... but no neutral connection in the 3 wire 240 volt receptacle. Split 120/240 volt
TemPower service on an extension cord requires the installation of a 4 wire receptacle (2 hot, 1 ground, and 1 neutral). Consult a licensed electrician for wiring a TemPower plug and splitting the cord output into 120 and 240 volt power service.
Applying The Load - 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.
1. The generator output is provided at the junction box on top of the generator shell. Receptacles may have been provided by the vehicle manufacturer for convenient load connection. The loads should be applied gradually. When starting large electric motor(s), they should be started individually when possible. The largest motor should always be started first.
To connect this unit directly to an un-powered, isolated mobile vehicle distribution panel, have your electrician wire the generator to the load(s) using one of the following methods:
1.
Connect the generator output to a distribution panel using a fine strand (flexible) motor lead wire. Install a mainline circuit breaker at the panel to protect the generator output winding and distribution wiring. The required breaker rating will depend upon the voltage desired. Use a single pole 20 or 25 Amp breaker for the 120/240 volt (series) connection. Use a 40 or 45 Amp single pole breaker for the 120 volt only (parallel) connection.
CAUTION: EQUIPMENT OVERLOAD
Keep the generator load within the generator and receptacle nameplate rating. Overloading may cause damage to the generator and/or the loads
2.
Wire the generator output to a 120/240 volt, four wire twistlock receptacle. (NEMA L14-30 {30 Amp} or Hubbell Spec.
#CS 6365 {50 Amp}) The use of locking receptacles and locking plugs provides the convenience of quickly disconnecting the wiring for applications requiring the unit to be moved or for and security. The plug also allows non electrical workers to safely reconnect the power after moving the unit and prevents the plug from being accidentally removed by bumping or vibration.
a.
Most electric tools and devices 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 Specification
Section.
b.
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.
CAUTION: EQUIPMENT DAMAGE
Failure to properly protect and limit the load applied to the generator will cause the generator to produce low voltage and may damage the engine generator set. With the 120/240 volt connection, the 120 volt loads must be balanced to prevent overloading either of the two generator windings. It may also cause severe damage to the loads connected to the generator at that time due to low voltage. Improper loading of the generator set constitutes abuse and will not be covered by warranty.
c.
Proper utilization of the generator output power is necessary to prevent damage to either the tools or the generator. The generator is a limited source of electrical power, therefore pay special attention to the generator ratings. The nameplate rating can be obtained through a combination of all four generator leads or a single lead pair as long as the current capacity of the generator windings are not exceeded. Both the 120 and 240 volt capabilities can be utilized at the same time if so wired. See Specification
Section for proper load separation.
INSTALLING A REMOTE KEY SWITCH
This engine generator set comes equipped with a terminal block wire for the installation of a remote key switch. Any universal key switch may be used as long as it is a three position switch
(STOP, ACC and START). Below is a diagram of the terminal block that is provided on the unit on the bottom of the existing key switch.
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LOW OIL PRESSURE SHUTDOWN SYSTEM
This low oil warning system will automatically stop the engine before the oil pressure reaches an operational danger point. This feature is designed to prevent costly repairs and downtime.
Use of the oil safety shutdown system on applications that are subject to shock, bumping or severe angles of operation (in excess of 15 degrees) should be avoided. This is especially true if an unexpected shutdown would cause a safety hazard or serious inconvenience for the operator.
GENERATOR CARE
The back of you new key switch should have three connection points, battery positive, ignition (or ACC) and start. Wire are run from the terminal block to the new ignition switch. This switch may be located any where on the truck that is convenient to the operator. All these wires are control leads so 16 AWG. copper wire should be sufficient for most applications.
ENGINE CARE
Proper care and maintenance of the generator is necessary to insure a long trouble free life.
1. Exercising The Generator - The generator should be operated every three to four weeks. It should be operated for a period of time sufficient to warm the unit up and to dry out any moisture that has accumulated in the windings. If left this moisture can cause corrosion in the winding. Frequent operation of the engine generator set will also insure that the set is operating properly should it be needed in an emergency.
If major engine service or repair is required contact an authorized engine service center. The manufacturer of these engines has established an excellent worldwide engine service organization.
Engine service is very likely available from a nearby authorized dealer or distributor. Check the yellow pages of your local telephone directory under “Engines-Diesel” for the closest engine repair center or ask the dealer from whom you purchased the power plant.
2. Generator Maintenance - Any major generator service including the installation or replacement of parts should be performed only by a qualified electrical service technician. USE ONLY FACTORY
APPROVED REPAIR PARTS.
a. Bearing - The bearing used in these generators is a heavy duty double sealed ball bearing. They require no maintenance or lubrication.
1. Change the oil as recommended in the engine operators manual. It is usually required to change oil after the first 50 hours of operation and every 100 hours thereafter under normal operating conditions. If the engine is not used frequently, change the oil every 12 months, regardless of the actual number of hours of operation.
a. Remove oil drain plug at base of the engine and drain the oil with the engine warm.
b. Replace oil drain plug.
c. Remove oil filler plug and refill with new oil. Refer to the table in the engine manual for the proper grade of oil based on your operating temperature.
d. Replace filler plug.
2. Checking the Oil Level: The oil level must always be checked before the engine is started. Take care to remove any dirt or debris from around the oil fill plug before removing. Be sure the oil level is maintained.
3. Servicing Air Cleaners: Consult engine operators manual for recommendations, procedures and intervals. Service more often if necessary if very dirty. Replace the cartridge using only original equipment parts available at any engine service center.
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 dangerous both to the operator and 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. This high pressure spray could contaminate the fuel system and the generator components.
1. Keep the air inlet screen on both the engine and generator free of any dirt or debris to insure proper cooling. At least yearly remove the blower housing on the engine and clean the chaff and dirt out of the engine cooling fins and flywheel. Clean more often if necessary. Failure to keep these areas clean may cause overheating and permanent damage to the unit.
2. Periodically clean muffler area to remove all grass, dirt and combustible debris to prevent a fire.
3. On engine mufflers equipped with spark arresters, the spark arrester must be removed every 50 hours for cleaning and inspection. Replace if damaged.
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TROUBLE SHOOTING
—————————————————————————--
PROBLEM (SYMPTOMS) POSSIBLE CAUSES
——————————————————————————
Won’t Start (electric) *Fouled fuel injector.
*Out of fuel.
*Dead battery.
*Defective start switch.
*Defective start solenoid.
——————————————————————————
Voltage too low *Engine speed is too low.
*Generator overloaded.
*Defective stator.
*Defective rotor (field).
——————————————————————————
Circuit Breaker Trips *Defective load.
*Defective receptacle.
——————————————————————————
Voltage too high *Engine speed is too high.
——————————————————————————
Generator overheating *Overloaded.
*Insufficient ventilation.
——————————————————————————
No output voltage *Short in load (disconnect).
*Broken or loose wire.
*Defective receptacle.
*No residual magnetism in generator.
*Defective stator.
*Defective rotor (field).
*Shorted capacitor.
*Defective diode.
———————————————————————————
EXHAUST & CONTROLS
1335-00
9
10
11
12
NI
NI
7
8
5
6
REF
3
4
1
2
PART NBR.
93849-015
16337-001
97274-000
93849-015
16086-002
15799-005
81332-003
62496-006
58166-001
15615-004
15620-000
15906-022
55505-000
81018-009
DESCRIPTION
1.5” Exhaust Clamp
Exhaust Pipe
Heat Tape
1.5” Exhaust Clamp
Exhaust Support Bracket
Fuel System Bracket
Fuel Pump
Fuel Filter
Running Time Meter
Power Outlet Box
Power Outlet Box Cover
Key Switch Assembly
3/8” Fuel Line
3/8” Hose Clamps
Page 8
QTY
8’
1
1
1
2.5’
4
1
1
1
1
1
1
1
1
60706--214
60706-214
Page 9 1335-00
KEY SWITCH ASSEMBLY
REF PART NBR.
DESCRIPTION
3
4
1
2
5
6
15773-001
15773-002
59944-016
15806-020
80623-008
99958-003
Key Switch Cover
Key Switch Bracket
12 VDC Relay
Key Switch
Terminal Block
Decal Terminal Strip
QTY
1
1
1
1
1
1
GENERATOR ASSEMBLY
7
8
9
4
5
6
REF PART NBR.
QTY DESCRIPTION
1
2
3
15013-000
21975-000
15192-000
4
4
4
#10-32 X 3.5” Screw
#10 Lockwasher
¼ -20 Hex Nut
479-000 4 ¼ Lockwasher
15857-000 1 Stator, Complete
15051-000
15068-008
15008-000
96002-040
10 97436-008
11 15106-000
12 15156-003
2 Capacitor
4
1
4
4
1
1
¼ - 20 Stator Bolts
Engine Mounting Bracket
M8-1.25 X40MM Bolt
M8 Lockwasher
End Cover Bare
Bearing Bracket
1335-00 Page 10
REF PART NBR.
QTY DESCRIPTION
13 15193-000 1 5/16” Hex Nut
14 480-001 1 5/16” Lockwasher
15 23558-000 4 5/16” X 1” DIA. X .125
THK Flat Washer
16 23197-009 1 Generator Thru Bolt
17 50215-000 1 Bearing
18 15047-001 1 Diode, STD
19 15047-002 1 Diode, REV
20 15045-007 1 Rotor, Complete
21 15088-000 1 Capacitor Strap
22 NOT USED
60706--214
60706-214
Page 11 1335-00
1335-00 Page 12
60706--214
60706-214
Page 13 1335-00
WINCO, Incorporated warrants to the original purchaser for 12 months 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, return the product within 12 months from the date of purchase, transportation charges prepaid, to your nearest WINCO
Authorized Service Center or to WINCO, Inc. at Le Center Minnesota.
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 12 months 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 reserves the right to change or improve its products without incurring any obligations to make such changes or improvement on products purchased previously.
EXCLUSIONS:
WINCO does not warrant Engines. Engines are covered exclusively by the warranties of their
respective manufacturers, see enclosed warranties.
WINCO does not warrant Batteries, or Other Component Parts that are warranted by their respec-
tive 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.
225 SOUTH CORDOVA
LE CENTER, MN 56057
507-357-6831
60706-214 1335-00

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Key features
- Vehicle mounting
- Mobile use
- Dual voltage
- Preset throttle control
- Low oil pressure shutdown system
- Remote key switch
- 12 month warranty