Winco EC6010DRS User Manual
INSTALLATION, OPERATION, and
MAINTENANCE INSTRUCTIONS
EMERGENCY
RESCUE SERIES
EC6010DR/S
60706-214
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
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___________________________________
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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60706--214
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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