Winco DL6000HEE User Manual

PORTABLE GENERATORS

DL5000H/C DL6000H/D DL6000HE/E

INSTALLATION AND OPERATORS MANUAL

WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057 507-357-6821 SERVICE DEPT. 507-357-6831 wincogen.com

SAVE THESE INSTRUCTIONS

PROPER USE AND INSTALLATION

This manual contains important instructions that should be followed during installation and maintenance of the generator and battery. Read and understand all instructions in the manual before starting and operating the generator set.

USING THE 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 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 “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.

You must be sure your new engine generator set is: * Properly serviced before starting. * Operated in a well ventilated area. * Properly exhausted and gases safely dispersed. * 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_________________________

TABLE OF CONTENTS

INTRODUCTION 2 BASIC INFORMATION Speciﬁ cations 2 SAFETY INFORMATION 3 UNIT CAPABILITIES 4 PREPARING THE UNIT Unpacking the Unit 5 Unit Preparation 5 Battery Installation 6 INITIAL START UP 8 Basic Operation 8 Manual Starting 8 Electric Starting 8 Stopping & Storage 9 Operating Speed 9 CONNECTING THE LOADS 10 Wiring 10 ENGINE CARE 11 GENERATOR CARE 12 TROUBLESHOOTING 13 CONTROL PANEL WIRING DIAGRAM 14 WARRANTY INFORMATION 15

PURCHASE DATE_________________________

DEALER_________________________________

DEALER PHONE # ________________________

UNIT SPECIFICATIONS

GENERATOR MODEL DL5000H

Surge Watts 5,000 Continuous Watts 4,500 Volts 120/240 Amps 37.5/18.75 Engine Honda GX270RT2VNT2 Generator WINCO 15359-039

GENERATOR MODEL DL6000H/DL60000HE

Surge Watts 6,000 Continuous Watts 5,500 Volts 120/240 Amps 45.8/22.9 Engine Honda Recoil start GX340RT1VDE2 Electric start GX340RT2VWE2 Generator WINCO 15041-006

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SAFETY INFORMATION

This engine generator set has been designed and manufactured to allow safe, reliable performance. Poor maintenance, improper or careless use can result in potentially deadly hazards; from electrical shock, exhaust gas asphyxiation, or ﬁ re. 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

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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. ***********************************************************

b. Keep fuel containers out of reach of children. c. Do not smoke or use open ﬂ ame near the generator set or fuel tank. d. Keep a ﬁ re extinguisher nearby and know its proper use. Fire extinguishers rated ABC by NFPA are appropriate. e. Store fuel only in an approved container, and only in a well ventilated area. f. Follow local codes for closeness to combustible material.

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

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WARNING:

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. ***********************************************************

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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. ***********************************************************

1. ELECTRICAL SHOCK The output voltage present in this equipment can cause fatal electric shock. This equipment must be operated by a responsible person. a. 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.

2. FIRE HAZARD Gasoline and other fuels present a hazard of possible explosion and/or ﬁ re. a. Do not refuel when the engine is running or hot.

4. NOISE HAZARD Excessive noise is not only tiring, but continual exposure can lead to loss of hearing. a. Use hearing protection when working around this equipment for long periods of time. b. Keep your neighbors in mind when using this equipment.

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 materials that could create a potential ﬁ re hazard. c. Carefully clean up any gas or oil spills before starting the unit.

6. SERVICING EQUIPMENT All service, including the installation or replacement of service parts, should be performed only by a qualiﬁ ed technician. 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 mufﬂ ers, 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.

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TESTING POLICY

UNIT CAPABILITIES

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 speciﬁ ed by the manufacturer of the 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).

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 ﬂ ow.

GENERATOR CONNECTIONS

DL6000H/DL6000HE - 120 volt and 240 volt receptacles are provided for connection to various loads. The diagram below represents this 5500 watt (rated output) generator. A & B represent the 120 volt output legs of this generator. Up to 2250 watts at 120 volts (22.9 Amps) can be drawn from each of the receptacles attached to either of the A or B output legs. This generator is capable of producing

22.9 Amps of 240 volt current at C. Check the appliance or tool nameplates for the current and voltage to insure compatibility. Remember that power taken from C reduces the power available at both A and B and vice versa.

RESTRICTED USES

DO NOT remove from the cradle assembly. Re-

moval 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 ﬂ ow 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 ﬂ ow and may cause a ﬁ re.

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 certiﬁ ed and meet current code.

DO NOT attempt to operate at 50 cycles. These units are designed and governed to operate at 60 cycles only.

Reference A & B = 120 Volt Receptacle NEMA 5-20 (120V-20A) Reference C = 120/240 Volt Twistlock Receptacle NEMA L14-30 (120/240V-30A)

DL5000H - the same principles apply to this unit as the one described above, only you are limited to 4500 watts or 18.75 amps at each 120 volt receptacle and 18.75 amps at 240 volt.

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.

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Most fractional horsepower motors take about the same amount of current to run them whether they are Repulsion Induction (RI), Capacitor (Cap), or Split-Phase (SP) type.

If the electric motor is connected to a hard starting load, such as an air compressor, it will require more starting current. If it is connected to a light load, or no load such as a power saw, it will require less starting current. The exact requirement will also vary with the brand or design of the motor.

Self-exciting generators respond to severe overloading differently than utility power. When overloaded, the engine is not able to supply enough power to bring the electric motor up to operating speed. The generator responds with high initial starting current, but the engine speed drops sharply. The overload may stall the engine. If allowed to operate at very low speeds, the electric motor starting winding will burn out in a short time. The generator winding might also be damaged.

CAUTION: EQUIPMENT DAMAGE

RUNNING THE GENERATOR SET UNDER THESE CONDITIONS MAY RESULT IN DAMAGE TO THE GENERATOR STATOR AS WELL AS THE MOTOR WINDING.

1. This generator-set was in good order when shipped. Inspect the generator-set promptly after receiving it. If any damage is noted, notify the transportation company immediately; request proper procedures for ﬁ ling a “concealed damage” claim. Title to the equipment and responsibility for ﬁ ling a claim rests with you when a generator set is sent F.O.B. shipping point. Only you can legally ﬁ le a claim.

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

LUBRICATION

Before starting the engine, ﬁ ll the crankcase to the proper level with a good quality oil. The recommended grade of oil and quantity of oil required is listed in the engine operator’s manual and below in this manual. This unit was shipped with most of the oil removed. The engine normally holds 19 to 20 ounces of oil. Since there is some trapped oil in the engine, when ﬁ lling the crankcase the ﬁ rst time use the dipstick to ensure that you do not over ﬁ ll the crankcase. The blow-up shows the full oil level mark on the dipstick.

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 difﬁ culty is experienced in starting motors, turn all other electrical loads off and if possible reduce the load on the electric motor.

PREPARING THE UNIT

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.

When you unpack your new engine-generator set be sure to remove all the information sheets and manuals from the carton.

Oil is added to the engine by removing the oil ﬁ ll cap and adding oil at this point. After ﬁ lling the crank- case to the proper level, be sure you properly tighten the oil ﬁ ll cap. NOTE: This engine generator must be on a level surface before you check or add oil to the system.

OIL FILLER CAP/DIPSTICK

OIL FILL HOLE (bottom edge)

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.

UPPER LIMIT

LOWER LIMIT

Oil Recommendations

Outdoor temperatures determine the proper oil viscosity for the engines. Use the chart to select the best viscosity for the outdoor temperature range expected.

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