Winco MD25KC User Manual
Mobile Diesel
Systems
OWNERS MANUAL MD25K/C
INSTALLATION AND OPERATION INSTRUCTIONS
60706-101
Read and understand all instructions in the
manual before starting and operating the generator set.
TABLE OF CONTENT
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.
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 BELOW FOR FUTURE REFERENCE.
PRODUCT SAFETY 1
SPECIFICATIONS 2
PREPARATION
UNPACKING 2
OIL REQUIREMENTS 2
FUEL REQUIREMENTS 2
COOLANT REQUIREMENTS 3
BATTERY CONNECTIONS 3
OPERATIONS
FRONT PANEL DESCRIPTION 3
FULL POWER CONNECTIONS 5
ENGINE CONTROL MODULE 5
VOLTAGE REGULATOR 6
SELECTING THE CORRECT
VOLTAGE 6
START-UP CHECKLIST 7
ELECTRIC STARTING 7
CONNECTING THE LOADS 7
UNIT STORAGE 9
50 CYCLE OPERATION 9
MAINTENANCE 9
PREVENTIVE MAINTENANCE 9
WIRING DIAGRAMS
CONTROL PANEL 99275-000
AC WIRING 99248-000
DC SCHEMATIC 99247-000
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___________________________________
GUIDE TO PRODUCT SAFETY
This engine generator set has been designed and manufactured to insure your personal safety. Improper 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 and in the manuals.
************************************************************
CAUTION:Possible Damage to Equipment.
CAUTION notes indicate any condition or practice,
which if not strictly observed or remedied, could result
in damage or destruction of the equipment.
************************************************************
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. Always operate with the housing doors closed to
reduce the operational noise level.
5. CLEANLINESS - Keep the generator and surround-
ing 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.
************************************************************
WARNING: Personal Danger.
WARNING notes indicate any condition or practice,
which if not strictly observed, could result in personal
injury or possible loss of life.
***********************************************************
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.
2. FIRE HAZARD - Diesel fuel 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.
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 internal combustion engine contain carbon monoxide, an 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).
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. Never wear neckties or other loose clothing that can
be caught in moving parts while you are servicing or
operating this equipment.
E. Use extreme caution when working on electrical
components. High output voltages from this equipment
can cause serious injury or death.
F. When servicing this unit always avoid hot mufflers,
exhaust manifolds, and engine parts. They all can cause
severe burns instantly.
G. Installing and wiring a standby generator 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.
7. LIFTING THE EQUIPMENT - When lifting always
make sure that the area under the equipment is kept
clear.
A. Be certain rigging is designed to lift unit safely.
B. Never attempt to lift the equipment unless you are
certain the lifting device has sufficient capacity.
C. Never allow the equipment to swing while suspended.
D. Be certain the supporting structure is adequate to
handle the load.
8. TOWING THE EQUIPMENT - When towing this
equipment always use a vehicle large enough for safe
operation.
A. Never tow without the safety chains secured.
B. Always use the proper size hitch ball on the vehicle.
C. Never attempt to tow with a vehicle that does not
have side mirrors installed.
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SPECIFICATIONS
UNPACKING
GENERATOR SPECIFICATIONS
MD25
KILOWATT 20 KW
KILOVOLT-AMPS (.8 PF)25 KVA
AMPERAGE 277/480 VOLT 3 PHASE 30 AMPS*
120/240 VOLT 3 PHASE 60 AMPS*
120/208 VOLT 3 PHASE 69 AMPS*
120/240 VOLT 1 PHASE 80 AMPS
*Based on .8 power factor at 130 degrees C.
Derate 3% per 1000 feet (305 meters) between 300 feet
(90 meters) and 7,500 feet (2,286 meters) above sea level.
Contact the factory for rating data for operation in
altitudes above 7,500 feet (2,286 meters).
GENERATOR RESISTANCES
MD25
Main Stator .20 ohms
Main Rotor 3.5 ohms
Excitor Stator 25 ohms
Excitor Rotor .350 ohms
Excitor Voltage (F1-F2)
No Load 15 VDC
Full Load 34 VDC
Excitor Amperage (F1-F2)
No Load .58 Amps
Full Load 1.3 Amps
ENGINE SPECIFICATIONS
When unpacking the unit, be sure to inspect it carefully
for freight loss or damage. Check the nameplate to be
sure it is what you ordered (proper KW, voltage, fuel,
etc.). If you have questions, contact your local authorized
dealer. If you see evidence of loss or damage at the time
of delivery, have the driver sign and describe the loss or
damage in the memo of loss or damage section on the
freight bill. Then contact the carrier to get instructions
on filing a claim.
When loss or damage is discovered after the equipment
is delivered, but not seen at the time of delivery, it is
referred to as concealed damage. Separate any damaged material and contact the carrier for proper procedures to file a concealed damage claim.
OIL REQUIREMENTS
The use of a multi-grade lubricating oil has been found
to improve oil consumption control and improve engine
cranking in cold temperatures while maintaining
lubrication at high operating temperatures. A multigraded oil 10W-30 or 10W-40 is recommended, meeting
API Classification CC/CD/CE. See your engine operators
manual for recommended oil grades when operating in
extreme cold conditions (ambients under -10 deg. C.) and
Arctic conditions.
OIL QUANTITY US Qts. Liters
MD25 10.1 9.5
See Kubota Operation and Maintenance Manual for
complete engine specifications.
TRAILER/HOUSING
MD25
Capacity 3500 lbs
Fuel Capacity 45 gals
Axles Single
Hitch Height Fixed
Tires P215/75B15 4 Ply Tread
Tire Pressure 35 psi
Sound Attenuated ULTRA QUIET
Housing Housing Standard
PREPARATION
NOTE: This booklet covers the entire unit, EXCEPT
THE ENGINE. See the engine manufacturers operator
manual for specific maintenance and care information
regarding the engine. Read ALL instructions in the
manuals provided before attempting to operate the
generator set.
FUEL REQUIREMENTS
ASTM No.2 diesel fuel is recommended for these engines. The use of No. 2 diesel fuel will result in optimum
engine performance. The use of lighter fuel will reduce
fuel economy. See your engine operators manual for
complete fuel information.
Filling the Fuel Tank
Standard Trailer - The standard trailer is equipped with
single a 45 gallon fuel tank. Use caution when filling the
tank not to overflow the tank into the trailer.
WARNING PERSONAL DANGER
Never refuel a running engine,. Always stop the engine
and allow to cool before refueling.
Never allow the fuel tank to run completely empty, as
air may enter the fuel system making it necessary to
bleed the engine when restarting.
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60706-120
COOLANT REQUIREMENTS
OPERATIONS
Antifreeze should be used during all seasons to protect
the engine cooling system from corrosion as well as
freezing damage.
The cooling system of the engine has been filled at the
factory with a 50% water and 50% ethylene-glycol
antifreeze mixture. This mixture provides protection to 34 degrees F. Never exceed a 50/50 antifreeze/water mix
ratio and never use 100% antifreeze for makeup coolant.
COOLANT QUANTITY US Gal Liters
MD25 2.14 8.1
BATTERY CONNECTION
INSTRUCTIONS
The MD25 requires a customer supplied 12 volt group 26
battery with minimum 675 CCA. A battery mounting
kit has been supplied loose with the unit. When connecting the battery, ALWAYS CONNECT THE POSITIVE CABLE FIRST and THE NEGATIVE CABLE
LAST! Disconnecting the battery is done in reverse,
disconnecting the negative cable first and then the
positive cable.
WARNING - POTENTIAL BATTERY
EXPLOSION
THIS UNIT USES A NEGATIVE GROUND. CONNECTING THE NEGATIVE CABLE FIRST MAKES
THE BATTERY POSITIVE TERMINAL HOT. CONNECTING THE POSITIVE CABLE LAST MAY RESULT IN ACCIDENTAL SHORT CIRCUIT OF THE
POSITIVE BATTERY TERMINAL TO ANY OF THE
SURROUNDING METAL SURFACES. (I.E. DROPPING A TOOL, WRENCH SWING ETC.) USE EXTREME CAUTION WHENEVER MAKING OR
BREAKING THE BATTERY CONNECTIONS AND
FOLLOW THE CORRECT SEQUENCE CAREFULLY.
DESCRIPTION AND IDENTIFICATION
A. FRONT PANEL
1. Starting Controls - This unit is equipped for
manual or automatic start. A three position switch
controls the engine starting.
a. Off - This switch position stops the engine and
disconnects the power from the engine control module. It
is intended to safely allow service and maintenance
checks on the engine
b. RUN - This switch position engages the start
circuitry in the engine control panel. The glow plugs
are turned on for 12 seconds and then the starter is
engaged. The engine control module in the control panel
will disengage the starter when the unit starts and
engage the engine monitoring sensors.
c. AUTO - This switch position is used when the
MD25 is used in a standby mode. With the switch in
this position a remote contact must be made to engage
the start circuitry. A terminal block has been provided
behind the customer connection door for you to wire your
remote contact to. This remote contact will be a dry
contact that will provide a ground on the start circuit to
engage the engine control module and start the unit .
2. DC control Circuit Breaker (DCCB) - The 15 amp
DC Circuit Breaker protects the engine controller and
wiring harness against faults in wiring or control
equipment. The DCCB also prevents a discharge of the
battery due to a circuit fault.
3. Glow Plug Indicator - This indicator light glows
red when the glow plug circuit is active.
NEVER ATTEMPT TO JUMP START
THIS ENGINE.
If the battery should accidentally become discharged
disconnect the battery cables and recharge the battery
before attempting to start the unit. Boost/jump starting
this unit improperly will result in PERMANENT
DAMAGE TO THE ENGINE CONTROL MODULE
(ECM).
WARNING! EQUIPMENT DAMAGE
FAILURE TO PUT THE ENGINE CONTROL
SWITCH IN THE OFF POSITION PRIOR TO CONNECTING THE BATTERY CABLE(S) MAY RESULT
IN DAMAGE TO THE ECM. (SOLID STATE ENGINE
CONTROL MODULE).
60706-120
4. Emergency Stop Switch - When depressed this
switch will disconnect all the 12 volt power to the engine
control panel shutting the engine down. The lamp in
the emergency stop switch will light up when the switch
is depressed showing that the power to the panel has
been disconnected.
5. Engine instruments
a. Oil pressure monitor gauge (OPG) - The oil pressure
gauge is mounted on the front control panel and indicates the engine oil pressure. The gauge serves a dual
function. In addition to displaying the oil pressure it
also provides the shutdown signal to the engine control
module if the pressure should drop too low. The shutdown signal is factory preset at 15 psi (103 kPa/m sq).
b. Coolant temperature monitor gauge (CTG) - The
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