Winco DP3000/T Installation And Operator's Manual

DP3000/T

GENERATOR

INSTALLATION AND

OPERATORS

WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057 507-357-6821

MANUAL

SERVICE DEPT. 507-357-6831

www.wincogen.com

TABLE OF CONTENTS

SAVE THESE INSTRUCTIONS 2
TESTING POLICY 2
SPECIFICATIONS 3

GENERATOR
ENGINE

SAFETY 3

IMPORTANT SAFETY INSTRUCTIONS
ANSI SAFETY DEFINITIONS

INTRODUCTION 4

INTENDED USES
RESTRICTED USES

UNIT CAPABILITIES 4

GENERATOR CONNECTIONS
STARTING ELECTRIC MOTORS

PREPARING THE UNIT 4

UNPACKING
LUBRICATION
OIL RECOMMENDATIONS
OIL ALERT SYSTEM
GASOLINE

SAVE THESE INSTRUCTIONS

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

USING THIS MANUAL
Congratulations on your choice of a WINCO generator. You have
selected a high-quality, precision-engineered generator designed and
tested to give you years of satisfactory service.

To get the best performance from your new generator, it is important
that you carefully read and follow the operating instructions in this
manual.

Should you experience a problem please follow the “Troubleshooting
Tables” near the end of this manual. The warranty listed in the manual
describes what you can expect from WINCO should you need service
assistance in the future.

COPY YOUR MODEL AND SERIAL NUMBER HERE
No other WINCO generator has the same serial number as yours.
If you should ever need to contact us on this unit, it will help us to
respond to your needs faster.

INITIAL START UP 5

BASIC OPERATION
STARTING HINTS
STOPPING AND STORING

CONNECTING THE LOADS 7

APPLYING THE LOADS
GROUNDING

ENGINE CARE 8

MAINTENANCE SCHEDULE
CHECKING THE OIL LEVEL
CHANGING THE OIL
WIRING
AIR FILTER
SEDIMENT CUP
SPARK PLUG
CARBON CANISTER

GENERATOR CARE 10

EXERCISING THE GENERATOR
GENERATOR MAINTENANCE
CLEANING

TROUBLESHOOTING 10
OUTLINE DRAWING 11

MODEL __________________________________________________

SERIAL NUMBER _________________________________________

PURCHASE DATE _________________________________________

DEALER NAME ___________________________________________

DEALER PHONE # ________________________________________

TESTING POLICY

Before any generator is shipped from the factory, it is fully checked
for performance. The generator is loaded to its full capacity, and the
voltage, current, and frequency are carefully checked.

Rated output of generator is based on engineering tests of typical units,
and is subject to, and limited by, the temperature, altitude, fuel, and

other conditions specied by the manufacturer of applicable engines.

RECEPTACLE WIRING DIAGRAM 11
36 MONTH LIMITED WARRANTY 12

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SPECIFICATIONS

GENERATOR

Model DP3000/T
Surge Watts 3,000
Continuous Watts 2,500
Volts 120/240
Amps 25/12.5

Generator Manufacturer Mecc Alte
Generator Model Number S16W-75C
Part Number 16346-017
Rotor Resistance 2.62 Ohms
Stator Resistance 0.97 Ohms
Excitation 5.46 Ohms
Capacitor 40 mF
Capacitor Part Number 15051-000

ENGINE

Engine Manufacturer Honda
Engine Model Number GX160
Type UT2VA2
Code GCBPT
Spark Plugs BPR6ES (NGK)
Air Filter 17210-ZE1-822
Spark Plug Gap 0.030 in
Intake Valve Clearance 0.003 ± 0.0008 in
Exhaust Valve Clearance 0.004 ± 0.0008 in
Oil Capacity 19.5 oz (.61 qts)

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 -

A. Keep a re extinguisher nearby and know its proper use. Fire

extinguishers rated ABC by NFPA are appropriate.

3. 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 permanently installing this
equipment.

SAFETY

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important information that should be understood
and followed before the installation, operation and maintenance of the
generator. Failure to follow the safety instructions in this manual could
result in serious injury or death. Keep this manual available for future
reference.

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 be used to alert
against unsafe practices.

4. 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 re hazard.

C. Carefully clean up any gas or oil spills before starting the unit.

5.SERVICING EQUIPMENT -

All service, including the installation or replacement of service parts,

should be performed only by a qualied technician.

A. Use only factory approved repair parts.
B. Do not work on this equipment fatigued.
C. Use extreme caution when working on electrical components.
High output voltages from this equipment can cause serious
injury or death.
D. Installing a generator is not a “do-it-yourself” project. Consult

a qualied, licensed electrician or contractor. The installation

must comply with all national, state, and local codes.

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INTRODUCTION

INTENDED USES

This engine generator set has been designed primarily for portable
heavy duty commercial use. Both 120 volt, NEMA 5-20R has been
provided in the control panel to plug in your loads (lights, portable tools,
and small appliances).

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.

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 ow.

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 this generator in a small compartment.,
i.e. generator compartments of vehicles, motor homes or travel

trailers. These compartments will not allow enough free 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

ow and may cause a 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 certied and

meet current code.

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

CAUTION: EQUIPMENT DAMAGE

Running the generator set under these conditions may result in
damage to the generator stator as well as the motor winding.

The heavy surge of current required for starting motors is required for
only an instant. The generator will not be damaged if it can bring the

motor up to speed in a few seconds of time. If dif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

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

UNIT CAPABILITIES

GENERATOR CONNECTIONS

DP3000/T: Rated at 3,000 starting Watts and 2,500 continuous Watts.
Generator full output can be drawn from the 120 Volt GFCI NEMA 5-20
receptacles, mounted on the end of the generator.

STARTING ELECTRIC MOTORS

Electric motors require much more current (amps) to start than to run.
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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CAUTION: EQUIPMENT DAMAGE

THIS UNIT HAS BEEN SHIPPED WITH OIL. Failure to maintain the
engine oil at the proper level will result in serious engine damage.

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

1. As you receive your unit, it is critical to check it for any damage. If
any damage is noted, it is always easiest to refuse the shipment and
let WINCO take care of the freight claim. If you sign for the unit, the

transfer of the ownership requires that you le the freight claim

2. Before proceeding with the preparations of your new generator
for operation, take a couple of minutes to ensure the unit you have

received is the correct model and review the specication pages in this

manual to ensure that this unit meets your job requirements.

LUBRICATION

Before starting the engine, check that the crankcase has the proper
level of a good quality oil. The recommended grade oil and quantity
of oil required is listed in the engine operator’s manual and in the Oil
Recommendations section of this manual. The engine normally holds

19.5 ounces (0.61 quarts) of oil. Use the dipstick to ensure that you

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