Dyna LC4500, LC4500I, LC5000H, LLC4500, LLC4500E Installation, Operation And Maintenance Instructions

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INSTALLATION, OPERATION, and MAINTENANCE INSTRUCTIONS

PORTABLE GENERATORS

LC SERIES

DLC SERIES

LLC SERIES

TFLC SERIES

Read and understand all instructions in the manual before starting and

operating the generator set.

USING THIS MANUAL

Congratulations on your choice of a DYNA generator set. You have selected a high-quality, precisionengineered generator set designed and tested to give you years of satisfactory portable service. To get the best performance from your new engine generator set, it is important that you carefully read and follow the operating instructions in this manual. Should you experience a problem please follow the “Things To Check” near the end of this manual. The warranty listed in this manual describes what you can expect from DYNA should you need service assistance in the future.

PROPER USE AND INSTALLATION

You must be sure your new engine generator set is: * Properly serviced before starting * Operated in a well ventilated area * Operated so that exhaust gases are dispersed safely * Wired by a qualified electrician * Operated only for its designed purposes * Used only by operators who understand its operation * Properly maintained

COPY YOUR MODEL AND SERIAL

NUMBER HERE

No other DYNA generator has the same serial number as

yours. It is important that you record the number and other vital information here. If you should ever need to contact us on this unit it will help us to respond to your needs faster.

TABLE OF CONTENTS

INTRODUCTION i FEATURES BY MODEL 1 GUIDE TO PRODUCT SAFETY 2 BASIC INFORMATION 3 Intended Uses 3 Restricted Uses 3 Unit Capabilities 3 PREPARING THE UNIT 4 Unpacking the unit 4 Unit Preparation 4 BASIC OPERATION 5 Battery Charging 5 Low Oil Level Shutdown System 5 Initial Starting 6 Starting 6 Starting Hints 6 Stopping And Storage 6 Operating Speed 6 Connecting The Loads 7 OPERATOR CARE AND MAINTENANCE 8 Engine Care 8 Generator Care 8 Cleaning 8 Troubleshooting - Things To Check BEFORE You Call For Service 9 Schematic Wiring Diagram 10 24 MONTH WARRANTY 1 0

MODEL______________________________________ SERIAL NUMBER _____________________________ PURCHASE DATE_____________________________ DEALER_____________________________________

Page i

SIZE ONLY CONTROL OPERATION AVAILABLE

FEATURES BY MODEL

ENGINE LOW OIL BATTERY FUEL 120 120/240 ELECTRIC AUTOMATIC LP/NG

TYPE SHUTDOWN CHARGER TANK VOLT VOLT START IDLE FUEL CSA

MODEL PAGE 5 PAGE 5 PAGE 4 PAGE 5 NOTE 1 NOTE 2

LC1500 B&S STD NO YES 2 QT Y E S NO NO NO NO NO

LC3000 B&S STD NO NO 3 QT YE S NO NO NO NO YES

LC3000I B&S I/C Y ES NO 3 QT YES NO NO NO NO YES

LC3000H HONDA YES NO 4 QT YES NO NO NO NO YES

LC4500 B&S STD NO NO 4 QT NO Y E S NO NO NO YES

LC4500I B&S I/C Y ES NO 6 QT NO YES NO NO NO YES

LC5000H HONDA YES NO 6 QT NO YES NO NO NO YES

LLC4500 B&S STD YES NO 4.5 GAL NO YE S NO NO NO YES

LLC4500E B&S STD YES YE S 4.5 GAL NO YES YE S NO NO YES

LLC5000H HONDA YES NO 4.5 GAL NO YE S NO NO NO YES

LLC6000 B&S STD YES NO 4.5 GAL NO YE S NO NO NO YES

LLC6000H HONDA YES NO 4.5 GAL NO YE S NO NO NO NO

LLC6000HE HONDA YE S NO 4.5 GAL NO YE S YES NO NO NO

LLC9000E B&S VGD YE S YES 4.5 GAL NO YES YES NO NO NO

LLC9500HE HONDA YE S YES 4.5 GAL NO YES YE S NO NO NO

LLC15000KE KOHLER YES YES 4.5 GAL NO YES YES NO NO NO

DLC4500 B&S I/C Y ES NO 4.5 GAL NO YES NO YES NO YES

DLC6000E B&S I/C YES YES 4.5 GAL NO YE S YE S YES NO YES

TFLC6000E B&S I/C YES YES 4.5 GAL NO YES YES NO YES NO

TFLC9000E B&S VGD YE S YES 4.5 GAL NO YES YES NO YES NO

NOTE 1: SUPPLEMENTAL INSTRUCTION SHEET 60707-201 DETAILS INSTALLATION AND OPERATION OF UNITS WITH LP/NG FUEL.

NOTE 2: SUPPLEMENTAL INSTRUCTION SHEET 60710-096 DETAILS ADDITIONAL INFORMATION FOR CSA UNITS.

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60707-101

Page 1

DYNA SERIES

GUIDE TO PRODUCT SAFETY

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 plugs and extension

cords.

f. Be sure the unit is properly grounded to an external

ground rod driven into the earth.

2.FIRE HAZARD- Gasoline and other fuels always present a

hazard of possible explosion and/or fire.

a. Do not refuel when the engine is running or hot. Allow

the engine to cool at least two minutes before refueling.

b. Keep fuel containers out of reach of children.

c. Do not smoke or use open flame near the generator set

or fuel tank.

d. Keep a fire extinguisher nearby and know its proper

use. Fire extinguishers rated ABC by NFPA are appropriate.

e. Store fuel only in an approved container, and only in a

well-ventilated area.

3.DEADLY EXHAUST GAS - Exhaust fumes from any gasoline engine contain carbon monoxide, an invisible, odorless and deadly gas that must be mixed with fresh air.

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 gas or oil spills before starting the unit. d. Never allow leaves or other flammable material to build up around the engine exhaust area.

6.SERVICING EQUIPMENT- All service, including the installation or replacement of service parts, should be performed only by a qualified technician.

a. Use only factory approved repair parts. b. Do not work on this equipment when fatigued. c. Never remove the protective guards, cover, or receptacle panels while the engine is running. d. Use extreme caution when working on electrical components. High output voltages from this equipment can cause serious injury or death. e. Always avoid hot mufflers, exhaust manifolds, and engine parts. They all can cause severe burns instantly. f. Installing a home-standby generator is not a “do-ityourself” project. Consult a qualified, licensed electrician or contractor. The installation must comply with all national, state, and local codes.

INTENDED USES

These engine generator sets have been designed primarily

for portable use. Both 120 and 240 volt AC receptacles are provided in the 'control panel' to plug in your loads (lights, portable tools, and small appliances). These units are dual wound generators, therefore the 120 Volt loads must be equally split with 1/2 of the rated capacity available on each of the two 120 Volt circuits. See unit capabilities for further explanation.

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Page 2 60707-101

BASIC INFORMATION

These portable units require large quantities of fresh air for

cooling of both the engine and the generator. Fresh air is drawn from both the engine end and the generator end and is exhausted at the center of the unit. For safety, long life and adequate performance, these units should never be run in small compartments without positive fresh air flow.

RESTRICTED USES

DO NOT remove from the cradle assembly. Removal of the

generator from the cradle assembly may cause excessive vibration and damage to the engine generator set.

DO NOT install and operate these portable generators in a

small compartment., i.e. generator compartment of vehicles, motor homes or travel trailers. These compartments will not allow enough free flow fresh air to reach the engine generator set for cooling and will cause the unit to overheat damaging both the engine and the generator. Small compartments will also develop hot spots where there is very little air flow and may cause a fire.

DO NOT attempt to operate at 50 cycles. These units are

designed and governed to operate at 60 Cycles only.

UNIT CAPABILITIES

Generator Connections - The diagram below represents a

typical 4000 watt generator. Receptacles A and B are the two 120 Volt duplex receptacles. Up to 2000 watts at 120 volts (16.6 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 GENERATOR 120 VOLT OUTPUT CIRCUITS (A OR B).

Check the appliance or tool nameplates for the current and

voltage to insure compatibility. Remember that power taken from receptacle C reduces the power available at both A and B. Any remaining 120 volt loads should be equally divided between A and B. Failure to split the load will cause permanent damage to the stator. Although circuit breakers are provided, damage due to overloading constitutes abuse and will not be warranted. Refer to the generator nameplate for your unit's capabilities.

Starting Electric Motors - Electric motors require much more

current (amps) to start them than to run them. Some motors, particularly low cost hard to start and require 5 to 7 times as much current to start them as to run them. start and usually require 2 to 4 times as much current to start them as to run them. the easiest to start and usually require 1 1/2 to 2 1/2 times as much to start them as to run them.

Most fractional horsepower motors take about the same

amount of current to run them whether they are of 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 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 13.0 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 power line. When overloaded, the engine is not able to supply enough power to bring the electric motor up to operating speed. The generator responds with high initial starting current, but the engine speed drops sharply. The overload may stall the engine. If allowed to operate at very low speeds, the electric motor starting winding will burn out in a short time. The generator winding might also be damaged.

CAUTION: EQUIPMENT DAMAGE

RUNNING THE GENERATOR SET UNDER THESE CONDITIONS MAY RESULT IN DAMAGING THE GENERAT OR ST A TOR 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.

split-phase motors, are very

Capacitor motors are easier to

Repulsion Induction motors are

UNPACKING

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.

Page 360707-101

DYNA SERIES

PREPARING THE UNIT

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 a claim rests with you when a generator is sent F.O.B. shipping point. Only you can legally file a claim.

2. Before proceeding with the preparation of your new engine generator set for operation, take a couple of minutes to insure that the unit you have received is the correct model and review the specification pages in this manual to insure that this unit fits your job requirements.

3. After removing the engine generator from the carton locate and remove the shipping strap attached to the generator shock mount. See attached tag for removal instructions.

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.

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 both the engine operator's manual and in the specifications section (pg 2) of this 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 manufacturer's warranty.

2. Gasoline Fuel - When using gasoline always use a good grade of unleaded fuel. Leaded gasoline may be used if unleaded is not available. Gasoline containing alcohol, such as gasohol is not recommended. However, if gasoline with alcohol is used, it must not contain more than 10 percent Ethanol and must be removed from the engine during storage. DO NOT use gasoline containing methanol. Always insure that the fuel is clean and free of all impurities.

WARNING: FIRE DANGER

Gasoline and its fumes are VERY explosive when proper precautions are not taken.

Never use gasoline that has been stored for an extended period of time as the fuel will lose it's volatile properties and you will be left with only the varnish residue. This varnish like substance will clog the carburetor and will not burn properly. The use of a fuel additive, such as STA-BIL, or an equivalent will minimize the formation of fuel gum deposits. If a unit has been out of operation for an extended period of time it is best to drain old fuel from the engine and replace with fresh fuel before attempting to start.

3. ELECTRIC START - If you intend to use the power plant’s electric start system, you will need to purchase a battery to operate it. Units equipped with a recoil or rope start will operate satisfactorily without a battery. A twelve volt battery, group U1 rated at 190 CCA or larger is recommended for this electric start engine generator set. Follow the battery manufacturer's recommendations for servicing and charging prior to use. Connect the battery to the electric start system using jumper cables.

CAUTION: EQUIPMENT DAMAGE

These electric start engines are NEGATIVE GROUND. Use extreme caution when connecting the battery. Connect the NEGATIVE battery terminal to GROUND.

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.

4. Optional Dolly Kit - An optional dolly kit is available for this engine generator set. The dolly kit comes with instructions and parts list. After installing the dolly kit, file the instructions and parts list in the back of this manual for future reference.

BATTERY CHARGING

Units equipped with electric start have a small flywheel

charger built into the engine flywheel assembly for recharging the starting battery. This flywheel charger generates a small AC current that passes through a diode at the end of the charging lead to produce a DC charging current of about 1 AMP. This circuit is not designed to be used as a battery charging circuit to recharge dead batteries.

The LC1500B is equipped a 10 AMP 12VDC charging

circuit which is designed to recharge dead batteries. A set of battery charging leads has been provided with the unit. These battery charging leads consist of a 12V DC connector lead wire and battery clip assemblies. There is a mating connector mounted in the receptacle panel on the unit. If the positive and negative battery leads are accidentally shorted, or are incorrectly connected to the battery, the automatic resetting DC circuit breaker in the control panel will trip to protect the generator and the battery. This breaker will reset automatically, restoring the voltage.

The open circuit charging voltage as measured with DC

meter or a volt-ohm meter will read approximately seven volts. The peak voltage will be over 16 volts in order to charge the battery . When the charger is connected to a 12 volt battery the battery voltage will immediately increase about 0.5 volts, showing that the battery is being

DYNA SERIES

Page 4 60707-101

BASIC OPERATION

charged. A DC ammeter in series with the charger output will indicate a current reading approximately equal to the DC nameplate rating if the battery is discharged.

LOW OIL LEVEL SHUTDOWN SYSTEM

Briggs & Stratton powered generators - Some engine

generator sets come equipped standard with the Briggs & Stratton OILGARD warning system.

This low oil warning system will automatically stop the engine before the oil level reaches an operational danger point. This feature is designed to prevent costly repairs and downtime.

The OILGARD system uses a float in the engine crankcase

to sense the oil level. If a low oil level condition should occur during operation, the float will ground out the magneto impulse, “killing” the engine. In addition, there is an indicator light mounted on the engine shroud near the recoil starter. This light will blink on and off to indicate a low oil level condition when you are attempting to start the unit. To get the engine started, you must add the required amount of oil to the engine crankcase.

Use of the OILGARD system on applications that are subject

to shock, bumping or severe angles of operation (in excess of 15 degrees) should be avoided. This is especially true if an unexpected shutdown would cause a safety hazard or serious inconvenience for the operator. To disable the OILGARD, remove the wire attached to the sensor unit mounted on the engine crankcase. The wire should be insulated with a connector or tape.

Honda powered generators - These engine generator sets

come equipped standard with the Honda Oil Alert System.

The Oil Alert system is designed to prevent damage caused

by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert system will automatically shut down the engine (the engine switch will remain in the ON position).

If the Oil Alert system shuts down the engine, the Oil Alert

lamp will flash when you attempt to start the engine and it will not run. If this occurs, check the engine oil level.

AUTOMATIC IDLE CONTROL

(DLC Series Only)

The automatic idle control is a gas saving, solid state

system, designed to reduce engine speed whenever the electrical load is removed from the generator. Without a slow down control, the engine would run at full speed at all times, regardless of the electrical load. With the automatic idle control switch in the 'Auto' position, the throttle control lever is electrically released when the load is turned on so it in no way interferes with the normal governor operation. When the load is turned off, the idle magnet energizes and reduces the engine speed. It does not cause incorrect operation of the carburetor or governor, but neither does it correct them.

The automatic idle control consists of a solid state module,

switch, resistor and a transformer located in the generator control box, and an electromagnet mounted on the engine near the throttle lever. The automatic idle control is only offered as a factory installed feature. It is not available for field installation.

With the automatic idle switch in the “automatic” position,the

system operates as follows:

1. After the engine has been started, and no electrical load is applied, the transformer senses and signals the solid state module to turn ON the electromagnet. This will pull and hold the throttle lever, closing the throttle on the carburetor and slowing the engine to an idle.

2. When a load is applied to the generator, the transformer senses it and sends a signal to the solid state module to turn off the electromagnet. This allows the throttle to release and allows the governor spring to open the throttle. The engine will respond and come up to the governed speed (3600 rpm).

3. When the electrical load is turned off, no power will flow through the transformer, and as a result, the automatic idle control will once again energize the magnet, pulling and holding the throttle at an idle.

When the automatic idle switch is in the “manual” position,

the engine will run at full governed speed regardless of the generator load.

INITIAL START UP

Use the following checklist to verify the correct preparation of

the engine generator before starting.

Before Starting always Check:

1. Engine oil, fill as required with correct grade and quantity.

2. Fuel level, fill as required with clean fresh fuel.

3. Automatic Idle is in the 'Off' position

4. Visually for loose parts.

STARTING

The throttle control on these generators is preset and locked

to operate at 3600 RPM (nominal) with no load speed set at 3750 RPM. Only a trained service technician should be allowed to adjust this speed setting. See “Operating Speed” section for additional information.

NOTICE: ENGINE START LOCKOUT

This unit will not start if it is low on oil. The lubricating oil level must be at the full mark before the engine will start.

MANUAL STARTING - Refer to the engine manual for additional starting, operating, and stopping instructions.

1. Turn on the fuel supply.

2. Move the choke to the full "on" position. A warm engine will require less choking than a cold engine.

3. Grasp starter grip and pull slowly until starter engages, then pull cord rapidly to overcome compression, prevent kickback and start the engine. Repeat if necessary.

4. When the engine starts, open the choke gradually.

5. The engine should promptly come up to operating speed.

Electric Starting - If the engine is cold and stiff or if the battery is not fully charged, starting can be made easier by slowly hand cranking the engine through the compression stroke before pushing the starter switch. This permits the starter to gain momentum before the heavy load of the

Page 560707-101

DYNA SERIES

BASIC OPERATION

compression stroke occurs. This minimizes the drain on the battery and improves the possibility of starting under such adverse conditions. Always keep the battery charged, but especially during cold weather operation.

1. Turn on the fuel supply.

2. Move the choke to the full "on" position. A warm engine will require less choking than a cold engine.

3. Engage the engine start switch briefly to the START position. The starter life is improved by using shorter starting cycles with time to cool off between cranking cycles. Do not operate the starter more than 15 seconds during each minute. Repeat if necessary.

4. When the engine starts, open the choke gradually.

5. The engine should promptly come up to operating speed.

CAUTION: EQUIPMENT DAMAGE

Never permit the choke to remain on after the engine has run for a short time. It is not necessary to choke the engine when it is warm. Avoid over-choking.

STARTING HINTS

1. Cold weather a. Use the proper oil for the temperature expected. b. Use fresh winter grade fuel. Winter grade

gasoline is blended to improve starting. Do not use summer gasoline.

c. A slightly richer fuel mixture will usually

improve cold starting.

2. Hot weather a. Use the proper oil for the temperature expected. b. Use only summer blended gasoline. Using

gasoline left over from winter may cause the unit to vapor lock.

c. DO NOT over-choke the unit.

STOPPING AND STORAGE

1. Depress the metal stop strip on top of the engine to

‘ground out’ the spark.

2. Before extended storage (over 30 days) certain

precautions must be taken to ensure the fuel doesn’t deteriorate and clog the fuel system. Note: The use of a fuel additive, such as STA-BIL, or an equivalent, will minimize the formation of gum deposits during storage. Such an additive may be added to gasoline in the engine’s fuel tank or to gasoline in a storage container.

a. Remove the remaining fuel from the fuel tank. b. Start the engine and allow it to run until all

the fuel in the carburetor and the fuel lines has been used up and the engine stops.

c. While the engine is warm, drain the oil and

refill with fresh oil.

d. Remove the spark plug, pour approximately

1/2 ounce (15 cc) of engine oil into the cylinder and crank slowly to distribute oil. Replace spark plug.

e. Clean dirt and chaff from cylinder, cylinder

head fins, blower housing, rotating screen and muffler areas.

f. Store in a clean and dry area.

OPERATING SPEED

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 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.

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 book are approximately as follows, under varying loads:

__________________________________________________________________________________________________________________

Generator Frequency Generator voltage Load Speed (Hz) 120V Applied* (RPM) Recpt.

__________________________________________________________________________________________________________________

None 3750 62.5 129V Half 3600 60.0 120V Full 3540 59.0 115V

__________________________________________________________________________________________________________________

*Portion of plant’s rated output current.

The speed of the engine was carefully adjusted at the

factory so that the generator produces the proper voltage and frequency. For normal usage, the speed setting should not be changed. If the generator is being run continuously on a very light load, it is often advisable to lower the operating speed slightly. Whenever making any speed adjustments check the unit with a voltmeter or tachometer and be sure the speed is correct.

Lower voltage may damage both the generator and any

load connected to it. Running the engine at excessively high speeds results in high voltage, which may significantly shorten the life of appliances being used.

Output voltage should be checked periodically to ensure

continued proper operation of the generating plant and appliances. If the generator is not equipped with a voltmeter, it can be checked with a portable meter. Frequency can be checked by using an electric clock with a sweep second hand. Timed against a wrist watch or a stop watch the clock should be correct within +/- 2 seconds per minute.

LOAD vs. OUTPUT

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Page 6 60707-101

BASIC OPERATION

CONNECTING THE LOADS

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.

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 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 Unit Capabilities (page 3).

These engine generator sets are inherently self regulating

based on engine speed. The engine governor will automatically adjust itself to the load. No harm to the generator will result if it is operated with no load connected.

Proper utilization of the receptacles located on the control

panel is necessary to prevent damage to either the receptacles or the generator. The generator is a limited source of electrical power, therefore pay special attention to the receptacle and generator ratings. The nameplate rating can be obtained through a single receptacle as long as the receptacle amperage rating is not exceeded.

Grounding - All units must be grounded. Drive a 3/4 or 1"

copper pipe or rod into the ground close to the enginegenerator set. The pipe must penetrate moist earth. Connect an approved ground clamp, to the pipe. Run a no. 10 Awg wire from clamp to the generator ground lug on the “end cover”. Do not connect to a water pipe or to a ground used by a radio system.

The engine-generators covered in this manual were

designed for portable use. Do NOT install or operate this generator indoors. The unit should be stored in a warm dry location. During a power outage, move the unit outdoors to a flat dry location such as a driveway or sidewalk.

Many homes today are wired for at least 60 to 100 Amp

entrance service, much greater than the capacity of these portable generators. Do not attempt to power a home with this portable generator. This generator set is suitable for powering individual appliances or emergency lighting.

available from a nearby authorized dealer or distributor. Check the yellow pages of your local telephone directory under “Engines-Gasoline” for the closest engine repair center or ask the dealer from whom you purchased the power plant.

1. Change the oil after the first five hours of operation and every 50 hours thereafter under normal operating conditions. Change engine oil every 25 hours of operation if the engine is operated under heavy load, or in high ambient temperatures.

a. Remove oil drain plug at base of the engine

and drain the oil with the engine warm.

b. Replace oil drain plug.

c. Remove oil filler plug and refill with new oil. Refer to the table in the engine manual for the proper grade of oil based on your operating

temperature.

d. Replace filler plug.

2. Checking the Oil Level: The oil level must always be checked before the engine is started. Take care to remove any dirt or debris from around the oil fill plug before removing. Be sure the oil level is maintained. FILL TO POINT OF OVERFLOWING or on units with the extended oil fill to the “FULL” mark on the dipstick.

3. Cartridge Air Cleaner - Remove and clean cartridge yearly or after every 25 hours, whichever occurs first. Service more often if necessary. Clean by tapping gently on flat surface. If very dirty, replace the cartridge using only original equipment parts available at any engine service center.

Do not use petroleum solvents, such as kerosene, to attempt to clean the cartridge. They may cause deterioration of the cartridge. DO NOT OIL CARTRIDGE, DO NOT USE PRESSURIZED AIR TO CLEAN OR DRY CARTRIDGE.

4. Dual Element Air Cleaner - Clean and re-oil foam pre- cleaner at three month intervals or every 25 hours, whichever occurs first. Service more often under dusty conditions.

a. Remove knob and cover.

b. Remove foam pre-cleaner by sliding it off the paper cartridge.

c. Wash foam pre-cleaner in kerosene or

liquid detergent and water

d. Wrap foam pre-cleaner in cloth and

squeeze dry.

e. Saturate foam pre-cleaner in engine oil.

Squeeze to remove excess oil.

f. Install foam pre-cleaner over paper

ENGINE CARE

If major engine service or repair is required contact an

authorized engine service center. The manufacturer of these engines has established an excellent world-wide engine service organization. Engine service is very likely

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DYNA SERIES

OPERATOR CARE AND MAINTENANCE

cartridge. Reassemble cover and screw down tight.

Replace the cartridge included with Dual Element Air Cleaner yearly or every 100 hours. Service more often if necessary.

5. Spark Plug - Clean and reset gap at .030" every 100 hours of operation. Do not blast clean spark plug. Clean by scraping or wire brushing and washing with a commercial solvent. Poor spark will occur if terminal does not fit firmly on spark plug. If this happens reform the terminal to fit firmly on spark plug tip.

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.

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.

LOW OIL LEVEL SHUTDOWN SYSTEM

Briggs & Stratton powered generators - These engine

generator sets come equipped standard with the Briggs & Stratton OILGARD warning system.

This low oil warning system will automatically stop the engine before the oil level reaches an operational danger point. This feature is designed to prevent costly repairs and downtime.

The OILGARD system uses a float in the engine crankcase to

sense the oil level. If a low oil level condition should occur during operation, the float will ground out the magneto impulse, “killing” the engine. In addition, there is an indicator light mounted on the engine shroud near the recoil starter. This light will blink on and off to indicate a low oil level condition when you are attempting to start the unit. To get the engine started, you must add the required amount of oil to the engine crankcase.

Use of the OILGARD system on applications that are subject

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

crack ed or otherwise damaged, replace it.

Using damaged or cracked receptacles can be

both dangerous to the operator and

destructive to th e

Honda powered generators - These engine generator sets

come equipped standard with the Honda Oil Alert System.

The Oil Alert system is designed to prevent damage caused

If the Oil Alert system shuts down the engine, the Oil Alert

lamp will flash when you operated the starter, and the engine will not run. If this occurs, check the engine oil level.

GENERATOR CARE

Proper care and maintenance of the generator is necessary to insure a long trouble free life.

1. Exercising The Generator - The generator should be operated every three to four weeks. It should be operated

DYNA SERIES

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OPERATOR CARE AND MAINTENANCE

Page 960707-101

DYNA SERIES

24 MONTH

Limited Warranty

WINCO warrants to the original purchaser that the alternator is free from defects in workmanship and material for a period of

two years*, provided it is installed, operated and maintained in accordance with WINCO written instructions.

*NOTE: Units used for rental, demonstrations, commercial or prime power applications such as construction or utility,

are warranted for 90 days. Units that are resold are not covered under this warranty. Any further warranty, whether expressed or implied, rests solely with the reseller.

WINCO’s sole liability, and Purchaser’s sole remedy for a failure under this warranty, shall be limited to the repair of the

product. At WINCO’s option, material found to be defective in material or workmanship under normal use and service will be repaired or replaced. This warranty does not include circuit breakers, receptacles or ENGINES. Engines are covered exclusively by the warranties of their respective manufacturers.

THERE IS NO OTHER EXPRESS WARRANTY.

To the extent permitted by law, any and all warranties are limited to 24 months from date of purchase. The user shall

determine the suitability of the product for its intended use prior to placing the unit in service. The user shall assume all risks and liability in connection with determining the suitability of the unit for its particular use. Neither the manufacturer nor the seller shall be liable for any injury, loss or damage arising out of improper use or operation of this unit. In no event is WINCO liable for incidental or consequential damages.

Some states do not allow limitation on the duration of implied warranty and some states do not allow the exclusion or

limitation of incidental or consequential damages, so the above limitations may not apply in every instance. This warranty gives you specific legal rights which may vary state to state.

WINCO reserves the right to change or improve its products without incurring any obligations to make such changes or

improvements on products previously purchased.

WINCO does not warrant products which have been subjected to misuse, negligence, modified or altered in any way or have

been involved in an accident.

For warranty service, return the product, transportation charges prepaid, to your nearest WINCO Authorized Service Center or

to WINCO at Le Center Minnesota. When requesting warranty service, evidence of original purchase date must be presented.

Phone - (612) 357-6831 FAX - (612) 357-4857

DYNA SERIES P/N 60707-101

225 S. Cordova Ave. LeCenter, Mn

Dyna LC4500, LC4500I, LC5000H, LLC4500, LLC4500E Installation, Operation And Maintenance Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual