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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coolant temperature gauge indicates engine coolant
temperature. The gauge serves a dual function. In
addition to displaying the water temperature it also
provides the shutdown signal to the engine control
module if the water temperature gets too high. The
shutdown signal is preset to operate at 225 f (407 k)
c. Battery Voltage Meter - This DC voltmeter monitors
the VOLTAGE of the battery under static (at rest)
conditions, and under cranking and charging conditions.
The voltmeter indicates not only the condition of the
charging system, but also indicates the battery reserve
under cranking load in cold weather.
d. Running Time Meter - This DC meter records the
total hours the engine has run.
6. A.C. Generator Controls
a. Voltage adjust rheostat - Controls the output voltage
of the generator by varying voltage regulators reference
voltage.
b. Field circuit breaker (FCB) - Protects voltage regulator and exciter field in the event of a load short circuit or
equipment malfunction.
c. Voltage selector power switch - This heavy duty three
position switch allows the operator to quickly and safely
reconnect the 12 wire generator to any one of three
output voltages. Once the output voltage is selected, the
switch may be locked to prevent it from accidentally
being changed during operation. Three output voltage
combinations are available with this selector switch:
1. 120/240 Three Phase* (series Delta configuration)
2. 120/208 Three Phase (Low or Parallel WYE configuration)
3. 277/480 Three Phase (High or series WYE configuration)
*This selector position is also used for single phase 120/
240 output by using only the L1 and L2 leads. The three
phase L3 output lead is the wild leg in the delta
configuration.
5. AC Generator Instruments
a. VM/AM Selector Switch - This selector switch allows
you to check the amperage being drawn from each
generator leg and your line to line voltage.
a. AC Voltmeter (VM) - Monitors generator output line to
line voltage, for all voltage operations.
b. AC Ammeter (AM) - Monitors the amperage that is
being drawn from each leg of the generator.
7. Warning Light Cluster - This light cluster contains
the indicator lamps for the four engine shutdowns
controlled by the engine control module. The lamps will
stay lit after a shutdown until the selector switch has
been moved to the off position. All the shutdowns are
reset when the selector switch is turned off or the DC
circuit breaker is turned off.
a. Low Oil Pressure Lamp (LOP) - Indicates that the
unit did not maintain a minimum oil pressure of 15 psi.
b. High Water Temperature Lamp (HWT) - Indicates
the coolant temperature in the engine exceeded upper
coolant temperature limits.
c. Overspeed Lamp (OS) - Indicates the engine speed
exceeded the allowable speed limit while operating. An
OS light may also indicate that the ECM has lost its
frequency sensing signal (from the engine alternator)
during the last run period.
d. Overcrank Lamp (OC) - Indicates the engine tried to
start and went through five (5) twelve (12) second crank
cycles without starting. Before attempting to restart the
unit, first investigate why it didnt start.
e. Lamp Test Switch - The lights can be tested by
pressing the lamp test switch. When depressed all four
lights will come on. As soon as the switch is released the
light will go out.
8. Panel Light - A panel light is provided for your
convenience. It is activated by the panel light switch.
9. Receptacles and Circuit Breakers - All of the
receptacles on the panel are protected by circuit breakers.
a. 120 Volt 20 Amp Ground Fault Interputer Duplex.
This duplex receptacle is protected by a 20 Amp circuit
breaker mounted just above the duplex. With the T
slot design both 15 and 20 amp 120 volt cords can be
plugged in.
b. 120 Volt 20 Amp 3 wire twist lock, Nema Spec L5-20.
This twistlock receptacle is also protected by a 20 Amp
circuit breaker. This receptacle is wired in series with
the GFCI receptacle which provides it with GFCI
protection.
c. 240 Volt 20 Amp 3 wire twist lock, Nema Spec L6-20.
This twistlock receptacle is protected by a two pole 240
volt circuit breaker.
d. 120/240 Volt 50 Amp 4 wire twistlock. This receptacle
is rated for dual voltage, 120 or 240 volt use. It is a four
wire receptacle, with a center grounding pin. Four wire
c. AC Frequency Meter - Monitors the generator frequency.
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60706-120
drop cords plugged into this receptacle may be split into
120 volt receptacles at a distribution box. This receptacle
is protected by a two pole 50 amp circuit breaker
mounted just above it. THIS RECEPTACLE UTILIZES
A SPECIAL HUBBELL PLUG.(HUBBELL PART
NUMBER CS 6365.)
B. Full Power Load Connections and
Breakers
This Mobile Diesel Power System is equipped with both
high voltage (480) and low voltage (208/240) main line
breakers. The breakers are interlocked with a lockable
bar to insure that only one breaker can be turned on at
a time.
A full power output terminal block is provided. This
terminal block is located below the main power breakers
and is accessible through the access door located just
below the main line breakers. If this access door is
opened with the unit running a safety switch will
disable the 12 volt system shutting the unit down. This
door must remain closed and latched at all times during
normal operations.
DANGER: PERSONAL INJURY
This unit will start as soon as the door is closed if the
start switch is in the run position. Do not use the
switch on this door to shutdwon a unit to connect to
the full load terminal block , this is a safty switch only.
C. ENGINE CONTROL MODULE (ECM)
The ECM is a microprocessor based module that controls
the complete unit. It monitors all the engine safety
sensors such as oil pressure, water temperature, overspeed., overcrank and shuts the unit down should any
one of the sensor circuits show a fault.
1. Control switch inputs
The following front panel controls and instruments are
wired into the microprocessor through the ECM terminal blocks.
2. Safety inputs:
a. Low oil pressure shutdown -(LOP)- Monitoring of oil
pressure begins 12 seconds after the unit starts, and
remains in effect until unit is shutdown by normal
control circuits (except as noted in loss of frequency
input below). The LOP signal is derived from an oil
pressure gauge mounted in the engine control panel.
b. High water temperature shutdown -(HWT)- The
engine coolant sensor temperature monitoring begins
immediately with the start signal. If water temperature
is excessive at time of start, (i.e. heat soak after shutdown), the unit is still permitted to start. The HWT
condition is permitted to exist for up to 60 seconds after
the unit initially starts before a shutdown WITH
ALARM occurs. If the excessive water temperature
condition is corrected within the initial 60 second period,
the HWT circuit begins normal monitoring of the
engine temperature and the safety shutdown circuit is
reactivated. The HWT signal is derived from a temperature gauge mounted in the engine control panel.
c. Overspeed adjustment -(OS)- Overspeed protection is
provided by a frequency sensing network within the
controller. The trip point of the frequency network is
adjustable via a rheostat located in the center of the
controller. The adjustment is accessed through the
small hole in the center of the engine control module.
NOTE: Use a plastic or non-metallic screwdriver when
making any adjustment to the overspeed. Clockwise
(CW) rotation increases the tip frequency, and thereby
raises the shutdown speed. The frequency input is
obtained from the engine battery charging alternator.
d. Overcrank -(OC)- The MD25 is designed to use cycle
cranking. This feature provides a series of five cranking
cycles lasting 12 seconds with a 12 second rest period
between each. Failure of the engine to start by the end
of the fifth crank period results in an overcrank
shutdown and alarm indication.
3. Cranking disconnect signal
a. Run-Off-Auto switch:
1). Run - This is your local operation position. In this
position the engine will start immediately.
2). Off - position prevents unit operation by disconnecting all power to the ECM.
3). Auto - position powers up the ECM in a standby
mode. A remote switch closure is required to activate the
start circuits.
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PAGE 5
The cranking disconnect signal is obtained from the
frequency sensing network within the controller. The
trip point of the crank disconnect is not directly adjustable but is a percentage of the overspeed adjustment.
4. E.C.M. - Program notes
a. Loss of frequency input - In the event the input
frequency goes to zero (engine runs out of fuel, battery
charging alternator fails, etc), the L.O.P. shutdown
circuit is by-passed, and a 12 second wait period is
initiated. If frequency returns within this time period,
L.O.P. monitoring resumes and operation continues
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normally. If frequency has not returned at the end of
this time period, the engine oil pressure status is
observed to determine whether the engine is actually
running or stopped. If the engine has stopped (i.e.- air in
fuel, (etc), the unit is shut down with an overspeed
indication and alarm.
b. Overspeed indicator light can mean a loss of control
signal during the previous run period (i.e.- bat. charging
alternator belt broken).
TROUBLE SHOOTING HINT: This is of particular
note since the tendency is to pursue only overspeed
faults. The overspeed signal source (battery charging
alternator) is a key component in this system and must
be checked out thoroughly whenever an OS shutdown
occurs.
Please note: The controller does not provide protection
against loss of signal during start-up. A shutdown with
alarm due to any of the above conditions will prevent
any subsequent operation of the generator set. The
control switch on the control panel must be momentarily
placed in the off position to reset.
D. VOLT/HERTZ VOLTAGE
REGULATOR
Some minor changes must be made for 50 cycle operation. Refer to 50 Hz operation later in this section for
set-up procedures.
a. During periods of operation at reduced speed use the
field circuit breaker to remove the power from the
regulator.
b. If the exciter field voltage exceeds 95 VDC, the regulator senses overexcitation and automatically removes the
field current after a time delay. This time delay is
inversely proportional to the magnitude of the detected
overvoltage condition. At approximately 140 VDC, the
field voltage is removed instantaneously.
Upon detection of overexcitation and the resulting field
voltage shutdown, the regulator will not reset or return
to an operational condition until the generator output
voltage drops to less than 6 VAC for ten seconds (minimum). TO ACCOMPLISH THIS ON A MOBILE DIESEL GENERATOR SET THE FIELD CIRCUIT
BREAKER MUST BE TURNED OFF FOR TEN SECONDS.
For additional information on the Basler Voltage regulator model APR125-5X see Basler Electric publication
number: 9 1688 00 992.
The purpose of the voltage regulator is to maintain the
voltage output of the Generator Set within a specified
percentage of its rated output from no load to full load.
The voltage regulator controls the voltage output of the
main generator by regulating the amount of current
delivered to the exciter field.
1. Location -Access to the voltage regulator assembly is
gained by removing the control panel access door located
through the left rear housing door.
2. Description - The Basler model VR63-4C voltage
regulator is a completely encapsulated unit. The regulator controls the DC exciter field voltage on brushless
generators to regulate the output voltage. Regulation is
provided by sensing the generator output voltage,
converting it to a DC signal and comparing the signal to
a reference voltage signal. An error signal is developed
and used to control the DC field power in order to
maintain a constant generator output.
3. Operation of voltage regulator - The voltage regulator
has been installed in the Mobile Diesel Generator set
and tested at the factory prior to shipment. No additional set-up is required when changing from one voltage
to another. The only adjustment required is to fine tune
the exact voltage you want using the voltage adjustment
rheostat located on the front panel. The adjustment
range is 10% of the nominal voltage.
OPERATING THE UNIT
A. SELECTING THE CORRECT
VOLTAGE
A variety of voltages are available from the three position selector switch. The three basic connection patterns
are, Delta (120/240), Low or Parallel WYE (120/208),
and High WYE (277/480). Single phase 120/240 is
available with the switch in the 120/240 (Delta) position.
Before connecting this unit to a distribution panel or any
other loads, be sure you have the selector switch set for
the right voltage and locked. If you have any doubts as
to the voltage in your area compare your incoming
power or load name plates to the voltage table below.
1. 120/240 Three Phase* (Delta/Series configuration) -
This configuration will produce the following line-to-line
and line-to-neutral voltage. In this selector switch
position, all of the receptacles on the front panel are
powered.
L1 - L2 - L3 240 Volts three phase
L1 - L2 240 volts single phase
L2 - L3 240 volts single phase
L1 - L3 240 volts single phase
L1 - N 120 Volts
L2 - N 120 Volts
L3 - N 208 volts
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60706-120
*This selector position is also used for single phase 120/
240 output, using only the L1 and L2 leads. The L3
three phase output lead is the wild leg in the delta
configuration and is used only for three phase loads.
9. Check hoses and clamps for leakage.
10. Check the air cleaner indicator. Service only when
indicated. Do not over-service.
11. Clean out dust cup on the air cleaner.
2. 120/208 Three Phase (Low/Parallel WYE configura-
tion) This configuration will produce the following lineto-line and line-to-neutral voltage. Use of this selector
switch position allows utilization of the 120 volt receptacle only. The 240 volt receptacles cannot be used as
the voltage at them will be 208 volts, the line to line
voltage.
L1 - L2 - L3 208 Volts three phase
L1 - L2 208 volts single phase
L2 - L3 208 volts single phase
L1 - L3 208 volts single phase
L1 - N 120 Volts
L2 - N 120 Volts
L3 - N 120 volts
3. 277/480 Three Phase (High/Series WYE configura-
tion) This configuration will produce the following lineto-line and line-to-neutral outputs. None of the front
panel receptacles are powered in this voltage configuration.
L1 - L2 - L3 480 Volts three phase
L1 - L2 480 volts single phase
L2 - L3 480 volts single phase
L1 - L3 480 volts single phase
L1 - N 277 Volts
L2 - N 277 Volts
L3 - N 277 volts
C. ELECTRIC STARTING
(Normal portable use)
CAUTION: EQUIPMENT DAMAGE
DO NOT ATTEMPT TO JUMP/BOOST START THIS
UNIT. TO DO SO MAY DAMAGE THE ELECTRONIC
MICROPROCESSOR IN THE ENGINE CONTROL.
TURN THE DC BREAKER OFF AND RECHARGE
THE BATTERY WITH A BATTERY CHARGER.
1. Select the desired voltage on the voltage selector
switch and lock in place.
2. Turn off both main line circuit breakers.
3. Turn the control switch to the run position. In this
position the unit will go into an automatic start routine.
First the glow plugs will come on and 12 seconds later
the starter will engage. The starter will automatically
disengage as the engine comes up to proper operating
speed.
8. After the engine is running at proper speed, adjust
the voltage to the desired level using the external voltage
rheostat.
9. Turn on the proper main line breaker (either high or
low voltage) and padlock the lock bar to prevent the
incorrect breaker from being turned on.
D. REMOTE STARTING AND
CONNECTION
(Standby applications)
After you have selected the correct voltage for your
application and locked the selector switch, do the same
with the main line circuit breakers. Be sure to secure
the lock bar in place. This will prevent the incorrect
breaker from being turned on.
B. STARTUP CHECKLIST
Before initial start up and each subsequent start complete the following checklist:
1. Check oil level, refill with proper grade oil.
2. Check coolant level, refill with 50/50 mix of demineralized water and a permanent ethylene-glycol antifreeze.
3. Check for loose bolts or hardware.
4. Check tire pressure. (35 psi)
5. Trailer level to within 15 degrees.
6. Battery securely fastened, connection clean and tight,
and proper fluid level.
7. Fuel tank filled with the proper grade of diesel fuel.
8. Check the fan belt for tightness and excessive wear.
1. Complete the manual starting procedure above to
insure the system is set up properly.
2. Insure the start switch is in the off position during
installation of the remote start connections.
3. Locate the remote start terminal block. This terminal block is located next to the full power connections,
behind the access door at the bottom of the control panel.
4. Locate the remote start terminals in your remote
automatic transfer switch (ATS). The ATS terminal
block and wire numbers will vary with each ATS
manufacturer. The MD25 requires a contact closure for
start.
WARNING: EQUIPMENT DAMAGE
THE REMOTE SIGNAL MUST BE A DRY (NONPOWERED) CONTACT CLOSURE. USING A POWER
CONTACT WILL CAUSE PERMANENT DAMAGE TO
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THE ENGINE CONTROL MODULE.
switch to be in for automatic start operation.
5. For most installations sixteen gauge wire is sufficient
to handle the control signal. On extremely long runs
increase wire size to minimize voltage drop.
6. Locate the neutral and full power output load connection terminal on the generator.
7. Locate and identify the "neutral" and "generator"
connections in the automatic transfer switch.
8. Connect the load block to the transfer switch using
the proper wire sizes. Refer to the National Electric
Code Handbook (NFPA 70) for proper wire type and
sizing. Use Table 310-16 for wiring run through conduit
and table 310-17 for free air wiring.
Use extreme caution when installing the delta voltage
pattern. One power leg of this 3 phase pattern produces
208 volts measured from line to neutral. Be sure to
match the location of the generator wild leg to the
location of the wild leg on the incoming power service.
Failure to do so will cause equipment damage to any 120
volt load incorrectly connected to this line.
9. Connect the neutral to the transfer switch using the
same wire size.
10. For isolated neutral operation remove the jumper
wire between the ground lug and neutral connection
block.
11. Ground the Mobile Diesel generator set using an 8 ft
copper ground rod or other approved grounding system.
Connect #4 Awg Copper cable from the ground lug on
the generator to the ground rod.
12. Set the selector switch on the transfer switch to the
off position.
13. Move the start switch on the MD25 to the RUN
position. The generator set will now start.
14. Check the voltage at the transfer switch. Verify that
it matches the incoming power line voltage line-to-line
and line-to-neutral on each leg.
15. Check the three phase rotation pattern. Insure that
you have the same rotation, with both the generator and
the normal power source.
18. Use the test switch on the transfer switch or shut
off the incoming power to test the complete system. The
MD25 should start up and the transfer switch should
transfer the load to the generator.
19. Compare the amperage reading from each leg on the
generator and insure that none of the legs is exceeding
the nameplate rating on the generator.
20. Upon completion of the test, leave all control mode
switches in the AUTO position.
21. The system is now ready to start and power the
loads should the power fail.
E. CONNECTING THE LOADS
There are two ways the loads may be connected to a
Mobile Diesel Generator.
1. FRONT PANEL - A variety of receptacles have been
provided for your convenience on the front panel. The
120 volt receptacles are powered when the voltage
selector switch is in the 120/240 or 120/208 volt position.
The 240 volt receptacles (although powered in both
positions) are only usable in the 120/240 volt position. In
the 120/208 volt position the 240 volt receptacles have
only 208 volts at them.
2. FULL POWER LOAD CONNECTION TERMINAL
BLOCK - For remote connections and connecting load
distribution boxes, heavy duty terminal blocks have
been provided. These terminal blocks are located on the
rear of the unit just below the main line circuit breakers. The neutral and ground are connected together at
this panel. For use with an isolated neutral, remove the
jumper strap between the neutral connection block and
the ground lug. This will isolate the neutral from the
ground and allow you single point grounding at a
distribution panel.When using these terminal blocks be
sure to use wire rated large enough to carry your full
load or the full rated load of the generator.
3. GROUNDING THE UNIT - To comply with current
safety standards this generator set must be properly
grounded. Ground the Mobile Diesel generator set by
driving an 8 ft copper ground rod into the earth. Then
connect a #4 AWG ground cable from the grounding lug
on the generator to the ground rod.
16. Move the start switch on the MD25 to the STOP
position. Let the unit stop and then move the switch to
the AUTO position. This is the normal position for the
switch to be in for automatic start operations.
17 Move the selector switch on the transfer switch to
the AUTO position. This is the normal position for the
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60706-120
F. UNIT STORAGE
Certain precautions must be taken if a mobile Diesel
Generator set is to be stored for a long period of time.
The unit must be stored in a dry location to prevent the
generator winding from drawing moisture. The unit
should also be thoroughly cleaned prior to storage.
For engine storage procedures consult your local Kubota
engine dealer. They have certain procedures that must
be followed in order to prevent engine damage, i.e.
cylinder rust and injector deterioration.
50 CYCLE (HZ) OPERATION
With a couple of minor changes these Mobile Diesel
Generators are capable of producing 50 hz power. Two
changes must be made.
A. The engine must be reduced to 1500 RPM governed
speed. Consult your local Kubota Service center for the
proper procedure for reducing the engine speed and
setting up the governor to operate at 1500 RPM.
PREVENTIVE MAINTENANCE
A. Daily Maintenance Checklist
** Oil level is between the L Low mark and the H
high mark on the dipstick. ** Fuel tank full of proper
grade of diesel fuel. ** Water and sediment drained from
water separator. ** Radiator filled with the proper
coolant mixture. ** Check air cleaner service indicator.
Change the filter element when the red indicator flag is
at the raised position ** Inspect for any fluid leaks
** Look for any loose or damaged parts
** Check belts for cracks or frays
** Check trailer hitch and safety chains for fitness
** Check tires for proper pressure
** Battery for proper fluid level.
** Generator control panel for loose or damaged parts.
** Unit for general appearance and cleanliness.
B. The automatic volt/hertz regulator must also be reset
to operate at 50 HZ instead of the standard 60 HZ. This
is done by cutting the two leads marked HZ that come
out of the regulator. This will change the regulator for
60 HZ operation to 50 HZ operation. If it should become
necessary to change it back to 60 HZ, you would need to
splice the leads together again.
MAINTENANCE
The ultimate aim of a preventive maintenance program
is to maintain the equipment in optimum condition,
either in service or ready for service, for the maximum
amount of time during the useful life of the equipment.
The detection of faults before they develop into major
sources of difficulty will decrease the incidence of repair.
To this end, a regular schedule of cleaning and inspection will go far toward assuring trouble-free operation.
Personnel responsible for maintenance should set up a
schedule for inspection, and cleaning at intervals
calculated to keep the equipment in good condition. In
making up a schedule, keep the following in mind:
A. New equipment must be carefully monitored until
extended operation has demonstrated that it is performing satisfactorily.
B. Old equipment requires more frequent inspection
(and possibly servicing) than similar equipment that has
seen less service.
C. Time spent in cleaning, inspecting and correcting
minor defects before they become major troubles means
time saved in overhaul and repair.
60706-120
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41821
WINCO, INC.
12 Month Limited Warranty
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.
WINCOs sole liability, and Purchasers sole remedy for a failure under this warranty, shall be limited to
the repair of the product. At WINCOs 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 no
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, batteries, or other component parts that are warranted by their respective manufacturers.
WINCO does not warrant modifications or alterations which were not made by the 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.
60706-120- 41821
225 South Cordova Avenue
Le Center, Minnesota 56057
1-800-433-8123 / 612-357-6821
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