Winco EC6010DRR User Manual
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.
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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
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