Page 1
INSTALLATION, OPERATION, and
MAINTENANCE INSTRUCTIONS
EMERGENCY
RESCUE SERIES
EC6010DR/S
60706-214
OWNERS MANUAL
Page 2
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
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.
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 Remote Start Switch 5
Wiring 6
Engine Care 7
Low Oil Level Shutdown System 7
Generator Care 7
Cleaning 7
Things To Check BEFORE
You Call For Service 8
Exhaust & Controls Part List 8
Engine Generator Set 9
Key Switch Parts List 10
Generator Assembly Parts List 10
Outline Drawing 11
DC Wiring Diagram 12
AC Wiring Diagram 13
12 MONTH WARRANTY 14
MODEL____________________________________
SERIAL NUMBER____________________________
PURCHASE DATE____________________________
DEALER___________________________________
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IMPORTANT SAFETY
2. FIRE HAZARD - Deisel fuel presents a hazard of possible
explosion and/or fire.
INSTRUCTIONS
SAVE THESE INSTRUCTION
This manual contains important instructions that
should be followed during installation and maintenance
of the generator and batteries.
Read and understand all instructions in the manual
before starting and operating the generator set.
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
************************************************************
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.
***********************************************************
a. Do not smoke or use open flame near the generator
set.
b. Keep a fire extinguisher nearby and know its proper
use. Fire extinguishers rated ABC by NFPA are
appropriate.
3. DEADLY EXHAUST GAS - Exhaust fumes from any diesel
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.
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 fuel or oil spills before starting
the unit.
d. Never allow leaves or other flammable material to build
up around the engine exhaust area.
***********************************************************
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.
************************************************************
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
extension cords.
f. Be sure the unit is properly grounded to an external
ground rod driven into the earth.
60706-214
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 recep-
tacle panels while the engine is running.
d. Use extreme caution when working on electrical
components. High output voltages from this equipment
can cause serious injury or death.
e. Always avoid hot mufflers, exhaust manifolds, and
engine parts. They all can cause severe burns
instantly.
f. Installing a generator set is not a “do-it-yourself”
project. Consult a qualified, licensed electrician or
contracor. The installation must comply with all
national, state, and local codes.
g. Always make sure unit is disabled before placing your
hands anywhere near the fan, belts, alternator or water
hoses.
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SPECIFICATIONS
MODEL EC6010DR/R
Generator
Surge Watts 6000
Continuous Watts 5500
Volts 120/240
AMPs @ 240 Volts 22.9
Engine
Size 9.9 HP
Model Yanmar WL100V
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
Stop System Key - Local/Remote
Complete Unit
Weight (dry) 290 LBS
Dimensions LxWxH 26.3 X 18.125 X 21.7
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).
Owner Must Provide
Fuel #2 Diesel
Oil Type 10W-30 CD or higher
See engine manual for additional oil information.
Oil Capacity 1.7 Quarts (1.6 L.)
for -4
o
F to 86oF
INTENDED USES
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.
RESTRICTED USES
CAUTION: EQUIPMENT DAMAGE
CAUTION MUST BE EXERCISED TO PREVENT
OVERLOADING EITHER OF THE GENERATORS
120 VOLT OUTPUT CIRCUITS (A OR B).
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.
Starting Electric Motors - Electric motors require much more
current (amps) to start them than to run them. Some motors,
particularly low cost
and require 5 to 7 times as much current to start them as to run
Capacitor motors are easier to start and usually require 2
them.
to 4 times as much current to start them as to run them.
Repulsion 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.
split-phase motors, are very hard to start
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Page 5
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 MADE14 TO 29 11 TO 18
1 13.0 NOT MADE26 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 utility. 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 STATOR 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.
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.
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.
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.
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
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.
60706-214
a. Make sure the engine is level
b. Remove the oilcap/dipstick (ref 1) from either side of the
engine and wipe off with a clean cloth.
c. Fully re-insert oil cap/deipstick, but do not screw in.
d. Remove oil cap/dipstick. The oil level should be between
the upper mark (ref 2) and the lower mark (ref 3) on the oil
cap/dipstick.
e. Fill engine with proper grade and weight of oil.
f. Fully reinsert oil cap/dipstick and hand tighten. Ovetightening the oil cap/dipstick will damage it.
Oil should be change after the first 50 hours of operation and
every 100 hours there after. It should be checked daily.
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Page 6
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 fo recommendations. Never use gasoline or gasohol. Always insure that
the fuel is clean and free of all impurities.
The fuel pump on the unit is designed to provide a 2 foot lift. If
you requires a greater lift, a second fuel pump may be required.
Be sure to use fuel line clamps on all hose connections to prevent
them from leaking. 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.
A fuel return line must be run from the fuel return line fitting on the
top of the engine back to the supply tank. This line cannot be
routed to the fuel supply line but must be routed back to the
supply tank.
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 300 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.
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 Yanmar diesel engine and
a 6 kw WINCO generator end. The Yanmar engine is a electric
key start engine with a 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.
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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. See
page 11 for unit layout and mounting.
INITIAL START UP
CAUTION: ENGINE DAMAGE
Never operator this engine generator set for an extend period of
time under a noload or very light load condition. Doing so may
cause excessive oil usage and damage the engine.
Use the following checklist to verify the correct preparation of the
engine generator before starting.
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Page 7
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.
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 Manufactur
ers instructions.
3.Visually check unit for loose parts.
STARTING and STOPPING
The throttle control on this generator 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.
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. In the run position the switch will
turn on the fuel solenoid and the fuel pump and in the start
position the starter engage. The switch is spring loaded to the
run position, so when you release the key the switch returns to
this position
CAUTION: EQUIPMENT DAMAGE
DO NOT ENGAGE THE STARTER FOR LONGER THAN 15
SECONDS. DO SO MAY DAMAGE THE STARTER.
c. The engine will start and come up to operating speed.
d. To shut the unit off rotate the key switch to the OFF position.
The unit is stopped by shutting off the fuel solenoid
STARTING HINTS
1. Cold weather.
OPERATING SPEED
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 engine-generators described
in this manual are approximately as follows, under varying loads:
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.
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.
60706-214
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.
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Page 8
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.
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
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.
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.
1. 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.
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
a. 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.
b. 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.
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:
1. 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 25 Amp breaker for
the 120/240 volt (series) connection. Use a 40 or 45 Amp single
pole breaker for the 120 volt only (parallel) connection.
2. 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 120/240 volt
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.
c. 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.
1335-00
INSTALLING A REMOTE KEY SWITCH
This engine generator set comes equipped with a terminal block
wire for the installation of a remote key switch. Any universal key
switch may be used as long as it is a three position switch
(STOP, ACC and START). Below is a diagram of the terminal
block that is provided on the unit on the bottom of the existing key
switch.
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Page 9
LOW OIL PRESSURE 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
The back of you new key switch should have three connection
points, battery positive, ignition (or ACC) and start. Wire are run
from the terminal block to the new ignition switch. This switch
may be located any where on the truck that is convenient to the
operator. All these wires are control leads so 16 AWG. copper
wire should be sufficient for most applications.
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.
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 50 hours
of operation and every 100 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.
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.
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.
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 technician. 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.
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.
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. 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.
60706-214
3. On engine mufflers equipped with spark arresters, the spark
arrester must be removed every 50 hours for cleaning and
inspection. Replace if damaged.
Page 7
1335-00
Page 10
TROUBLE SHOOTING
—————————————————————————--
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.
——————————————————————————
EXHAUST & CONTROLS
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.
———————————————————————————
1335-00
REF PART NBR. DESCRIPTION QTY
1 93849-015 1.5” Exhaust Clamp 1
2 16337-001 Exhaust Pipe 1
3 97274-000 Heat Tape 8’
4 93849-015 1.5” Exhaust Clamp 1
5 16086-002 Exhaust Support Bracket 1
6 15799-005 Fuel System Bracket 1
7 81332-003 Fuel Pump 1
8 62496-006 Fuel Filter 1
9 58166-001 Running Time Meter 1
10 15615-004 Power Outlet Box 1
11 15620-000 Power Outlet Box Cover 1
12 15906-022 Key Switch Assembly 1
NI 55505-000 3/8” Fuel Line 2.5’
NI 81018-009 3/8” Hose Clamps 4
Page 8
60706--214
Page 11
8 1116-000 Bolt 5/16-18 X 1” 2
9 16249-000 Flange Nut 5/16-18 10
REF PART NBR. DESCRIPTION QTY
10 98806-000 Flat Washer 3/8 X 2” 4
ENGINE GENERATOR SET
11 16250-000 Flange Nut 3/8-16 4
12 91658-006 Bolt 3/8-16 X 2.25” 2
13 477-000 Bolt 5/16-18 X 3/4” 8
14 91658-014 Bolt 3/8-16 X 3.5” 2
60706-214
Page 9
REF PART NBR. DESCRIPTION QTY
1 15806-002 Yanmar Engine L100V 1
2 15041-024 Complete Generator REF
3 15084-003 Adapter 1
4 99036-000 Oil Pressure Switch 1
5 15797-003 Base 1
6 98906-003 Oil Drain Valve 1
7 98807-000 Shockmount 4
1335-00
Page 12
KEY SWITCH ASSEMBLY
REF PART NBR. DESCRIPTION QTY
1 15773-001 Key Switch Cover 1
2 15773-002 Key Switch Bracket 1
3 59944-016 12 VDC Relay 1
4 15806-020 Key Switch 1
5 80623-008 Terminal Block 1
6 99958-003 Decal Terminal Strip 1
GENERATOR ASSEMBLY
REF PART NBR. QTY 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 15008-000 1 Engine Mounting Bracket
9 96002-040 4 M8-1.25 X40MM Bolt
10 97436-008 4 M8 Lockwasher
11 15106-000 1 End Cover Bare
12 15156-003 1 Bearing Bracket
1335-00
REF PART NBR. QTY DESCRIPTION
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 10
60706--214
Page 13
60706-214
Page 11
1335-00
Page 14
DC WIRING CONNECTIONS
1335-00
Page 12
60706--214
Page 15
AC WIRING CONNECTIONS
60706-214
Page 13
1335-00
Page 16
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
60706-214 1335-00
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