INST ALLATION, OPERA TION, and
MAINTENANCE INSTRUCTIONS
EMERGENCY
RESCUE SERIES
EC6010DR/R
60706-176
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 i
GUIDE TO PRODUCT SAFETY 1
Specification Table 2
Intended Uses 2
Restricted Uses 2
Unit Capabilities 2
Unpacking the unit 3
Unit Preparation 3
Operation/Installation 4
Starting 5
Starting Hints 5
Operating Speed 5
Connecting The Load 6
Wiring 6
Engine Care 7
Low Oil Level Shutdown System 7
Generator Care 7
Cleaning 8
Things To Check BEFORE
You Call For Service 8
Outline Drawing 9
Engine/Generator Set Parts List 10
Fuel System Parts List 11
Generator Assembly Parts List 11
DC Wiring Diagram 1 2
AC Wiring Diagram 13
12 MONTH WARRANTY 14
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___________________________________
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
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.
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 use 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 exten-
sion 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.
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 install-
ing 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 compo-
nents. High output voltages from this equipment can
cause serious injury or death.
e.Always avoid hot mufflers, exhaust manifolds, and en-
gine parts. They all can cause severe burns instantly.
f. This generator set is not intended for permanent instal-
lation. Consult dealer for units intended for stand-by
service. Installing a generator set is not a “do-it-yourself”
project. Consult a qualified, licensed electrician or contractor. The installation must comply with all national,
state, and local codes.
60706-176
Page 1
SPECIFICATIONS
RESTRICTED USES
MODEL EC6010DR/R
Generator
Surge Watts 6000
Continuous Watts 5500
Volts 120/240
AMPs @ 240 Volts 22.9
Output 4 Wire Re-connectable - 120 or 120/240V
Engine
Size 9.9 HP
Model Hatz U-4 Var XI
Type - See Engine Shroud For Type
Fuel Capacity- N/A - External, Customer Supplied Tank
Fuel Consumption .7 gal/hr
Starting System 12 Volt Electric
Key - Local/Remote
Muffler Low Tone
Type - 1B40
Stop System Key - Local/Remote
Complete Unit
Weight (dry) 245 LBS
Dimensions LxWxH 26.3 X 18.125 X 21.7
Owner Must Provide
Fuel #2 Diesel
Oil Type 5W-40 CD, CE, CF, CG
See engine manual for additional oil information.
Oil Capacity 1.64 Quarts
INTENDED USES
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).
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.
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.
Page 2
60706--176
Starting Electric Motors - Electric motors require much
more current (amps) to start them than to run them.
Some motors, particularly low cost
are very hard to start and require 5 to 7 times as much
current to start them as to run them.
are easier to start and usually require 2 to 4 times as
much current to start them as to run them.
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.
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
GENERATOR STA 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,
Capacitor motors
Repulsion
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.
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.
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.
Motor Starting Capacity - listed below you will find the
motor starting capability of your engine generator set.
Generator Motor Size
Model (code “G” capacitor start)
EC6010DR 3.0 HP
60706-176
Proper Oil Level
Page 3
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.
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 for
recommendations. Never use gasoline or gasohol.
Always insure that the fuel is clean and free of all
impurities.
The unit is supplied with a fuel line installation kit. This kit
includes the 37 degree flare fittings and a short section of
fuel hose for the fuel connections. The hose is used to
connect to the vehicle fuel supply and return lines. The fuel
pump on the unit is designed to provide a 4 foot lift. If the
fuel tank requires a greater lift, the fuel pump may be
relocated to the fuel tank level to ‘push’ the fuel up to 12
feet above the pump outlet. 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.
CAUTION: EQUIPMENT DAMAGE
These electric start engines are NEGATIVE GROUND.
Use extreme caution when connecting the battery.
Connect the NEGATIVE battery terminal to GROUND.
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 Hatz 9.9 hp diesel
engine and a 6 kw generator end. The Hatz engine is a
electric key start engine with internal diagnostics. The
engine is equipped with both low oil pressure protection
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.
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
235 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.
(3) and high cylinder head temperature protection (4). If
either should occur the engine will shut it self off and
display a shutdown light.
Two additional lights will tell you the unit is running (1) and
battery charging system is working (2). The battery
charging system on these units has been disabled so as
not to infer with the charging system on your vehicle. For
that reason this lamp may stay lit. Lamp #5 is a preheat
which is not used ( See the engine operators manual for
addition information).
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.
Page 4
60706--176
INITIAL START UP
STARTING HINTS
Use the following checklist to verify the correct preparation
of the engine generator before starting.
On All Units Check:
1. Engine oil, fill as required with correct grade and
quantity.
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.
3. Visually check unit for loose parts.
STARTING and STOPPING
The throttle control on these generators 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. See
“Operating Speed” section for additional information.
1. Cold weather
.
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
Never use ether or any other starting
aides. Serious engine damage or
personal injury may result from
ignoring this simple warning.
2. Hot weather
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 Manufacturers instructions.
OPERATING SPEED
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. Position #I will turn on the
fuel solenoid and position #II will engage the starter.
The switch is spring loaded to the #I position, so when
you release the key the switch returns to this position.
Once the engine is started the only way to reengage the
starter if the engine should stop is to rotate it to the O
position and then back to the #I and #II position. The
engine has a built in lockout that prevents the starter
from being engaged once the unit has started.
c. The engine will start and come up to operating
speed. Light number 1 should light up at this point to
indicate the unit is operating properly.
d. To shut the unit off rotate the key switch to the O
position and the unit is stopped by shutting off the fuel
solenoid
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 enginegenerators described in this book are approximately as
follows, under varying loads:
60706-176
Page 5
LOAD vs. OUTPUT
**************************************************************
Generator Frequency Generator voltage
Load Speed (Hz) 120V 240V
Applied* (RPM) Recpt. Recpt.
————————————————————————
None 3690 61.5 129V 258V
Half 3600 60.0 120V 240V
Full 3510 58.5 115V 230V
**************************************************************
*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.
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.
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
b.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.
c. 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.
d.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.
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
1. 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.
a. 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.
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.
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:
a.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 23 Amp breaker for
Page 6
60706--176
the 120/240 volt (series) connection. Use a 40 or 45
Amp single pole breaker for the 120 volt only (parallel)
connection.
b.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.
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/
240v 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.
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 worldwide
engine service organization. A listing of service centers is
included with the engine operators literature package.
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.
1. Change the oil as recommended in the engine
operators manual. It is usually required to change oil after
the first 25 hours of operation and every 250 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.
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.
LOW OIL LEVEL 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
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.
2.Generator Maintenance - Any major generator service
including the installation or replacement of parts should
be performed only by a qualified electrical service man.
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.
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.
60706-176
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.
Page 7
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.
—————————————————————————--
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.
——————————————————————————
——————— ———————————————————
——————————————-
Page 8
60706--176
UNIT LAYOUT
60706-176
Page 9
12 16249-000 4 5/16-18 Flangenut
13 98807-000 4 Shockmount
14 91658-007 4 3/8-16 X 2.5 HHCS
15 16250-000 4 3/8-16 Flangenut
16 98806-000 4 Safety Washer
10 15797-001 1 Base Assembly
11 580-000 4 5/16-18 X 1.25 HHCS
7 16086-001 1 Tail Pipe Support
8 477-000 8 5/16-18 X 5/8 HHCS
9 16249-000 8 5/16-18 Flangenut
5 93489-015 1 Muffler Clamp
6 16086-000 1 Exhaust Pipe
RE F PART NBR. QTY DESCRIPTION
1 99068-000 1 Engine Hatz U-4 V ar X1
2 15041-024 REF Generator Assembly
3 15615-004 1 Connection Box
4 15620-000 1 Connection Box Cover
ENGINE GENERATOR SET
Winding Spec. SS1560
AC Connections AC381
X1 - X2 .22 Ohms
X3 - X4 .22 Ohms
Q1 - Q2 .55 Ohms
Rotor 1.05 Ohms
Resistances
NI 97382-000 1 Warning Decal
NI 97381-000 1 Diesel Fuel Decal
NI 53113-001 1 Winco Decal
17 15084-003 1 Generator Adapter Bracket
18 15869-001 REF Fuel System Assembly
19 58166-001 1 Running Time Meter
20 97274-000 96" High T emp Tape
NI 15209-000 1 Safety Decals
NI 15859-000 1 Connection Decal
RE F PART NBR. QTY DESCRIPTION
Page 10
60706--176
RE F PART NBR. QT Y DESCRIPTION
FUEL SYSTEM
RE F PART NBR. QT Y DESCRIPTION
5 72300-003 1 Hose Fitting
6 72303-001 1 Bulkhead Fitting
7 95145-001 1 Plug
8 40078-000 8" Fuel Hose
9 81018-009 1 Hose Clamp
10 56879-000 1 Elbow Fitting
1 1 63644-000 1 #10-24 X 1/2 Screw
12 99671-000 1 #10 Flangenut
1 81332-001 1 Fuel Pump
2 15799-001 1 Mounting Bracket
3 81018-009 1 Hose Clamp
4 40078-000 25" Fuel Hose
13 59944-016 1 Relay (12V)
14 99407-001 1 Engine Wiring Harness
15 463-000 2 1/4-20 X 1/2 Capscrew
16 16248-000 2 1/4-20 Flangenut
GENERA TOR ASSEMBLY
RE F PART NBR. QT Y DESCRIPTION
RE F PART NBR. QT Y DESCRIPTION
1 15013-000 4 #10-32 X 3.5” Screw
2 21975-000 4 #10 Lockwasher
3 15192-000 4 ¼ -20 Hex Nut
4 479-000 4 ¼ Lockwasher
5 15857-000 1 Stator , Complete
6 15051-000 2 Capacitor
7 15068-008 4 ¼ - 20 Stator Bolts
8 15008-001 1 Engine Mounting Bracket
9 96002-040 4 M8-1.25 X40MM Bolt
10 97436-008 4 M8 Lockwasher
1 1 15106-000 1 End Cover Bare
12 15156-003 1 Bearing Bracket
60706-176
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
Page 11
DC WIRING CONNECTIONS
Page 12
60706--176
AC WIRING CONNECTIONS
60706-176
Page 13
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 respective 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
60706-176 5300-00
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