Winco DP7500/A Installation And Operator's Manual

DP7500/A

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 INFORMATION 3

ANSI SAFETY DEFINITIONS

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.

INTRODUCTION 4

INTENDED USES
RESTRICTED USES

UNIT CAPABILITIES 4

GENERATOR CONNECTIONS
STARTING ELECTRIC MOTORS

PREPARING THE UNIT 5

UNPACKING
LUBRICATION
OIL RECOMMENDATIONS
OIL ALERT SYSTEM
GASOLINE
LIFTING EYE INSTALLATION

INITIAL START UP 6

BASIC OPERATION
OPTIONAL DOLLY KIT
STARTING HINTS
STOPPING AND STORING

CONNECTING THE LOADS 8

APPLYING THE LOADS
GROUNDING
WIRING

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.

MODEL __________________________________________________

SERIAL NUMBER _________________________________________

PURCHASE DATE _________________________________________

DEALER NAME ___________________________________________

DEALER PHONE # ________________________________________

ENGINE CARE 9

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

GENERATOR CARE 10

EXERCISING THE GENERATOR
GENERATOR MAINTENANCE
CLEANING

TROUBLESHOOTING 11
CONTROL PANEL WIRING DIAGRAM 11
24 MONTH LIMITED WARRANTY 12

OPM-119

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.

2

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SPECIFICATIONS

GENERATOR

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.

Model DP7500/A
Starting Watts 7,500
Running Watts 6,720
Volts 120/240
Amps 56/28

Generator Manufacturer Mecc Alte
Generator Model Number S20W-95/A
Part Number 16346-005
Rotor Resistance 4.8 Ohms
Stator Resistance 0.28 Ohms
Excitation Resistance 0.76 Ohms
Capacitor 40 µF
Capacitor Part Number 16346-312

ENGINE

Engine Manufacturer Honda
Engine Model Number GX390
Type RT2VCT2
Code GCBCT
Spark Plugs BPR6ES (NGK)
Air Filter 17211-899-000
Spark Plug Gap 0.030 in
Intake Valve Clearance 0.006 ± 0.0008 in
Exhaust Valve Clearance 0.008 ± 0.0008 in
Oil Capacity 38.4 oz (1.2 qts)

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 re.

A. Do not refuel when the engine is running or hot.
B. Keep fuel containers out of reach of children.

C. Do not smoke or use open ame near the generator set or fuel

tank.

D. Keep a 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.

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 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

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.

3. DEADLY EXHAUST GAS -

Exhaust fumes from any internal combustion 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,

oors).

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.

3REV A

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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 re hazard.

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

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.

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

6. 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 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 muf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.

INTRODUCTION

INTENDED USES

This engine generator set has been designed primarily for portable
heavy duty commercial use. Both 120 volt and 240 volt receptacles
are provided in the control panel to plug in your loads (lights, portable
tools, and small appliances). These units are dual wound generators,
therefore the 120 volt loads must be equally split with 1/2 of the rated
capacity available on each of the two 120 volt circuits.

This portable unit requires large quantities of fresh air for cooling the
engine and generator. For safety, long life and adequate performance,
these units should never be run in small compartments without positive

fresh air ow.

UNIT CAPABILITIES

GENERATOR CONNECTIONS

120 Volt and 240 Volt receptacles are provided for connection to
various loads. The diagram below represents this 7,500 watt (starting
output) generator. A & B represent the 120 volt output legs of this
generator. Up to 3,360 watts at 120 volts (56 Amps) can be drawn from
the receptacles attached to either A or B output legs. This generator
is capable of producing 28 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 equally both A and B and vice versa.

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.

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.

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.

OPM-119

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.

4

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