OWNERS MANUAL
INSTALLATION, OPERATION,
and MAINTENANCE INSTRUCTIONS
Modular Generator
& Lighting Systems
YLT6010DE LLT6012DE
MLS4Y MLS4L
MD6Y MD6L
60706-121
Read and understand all instructions in the manual
before starting and operating the generator set.
TABLE OF CONTENTS
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
PRODUCT SAFETY 1
SPECIFICATIONS 2
PREPARATION
UNPACKING 3
OIL REQUIREMENTS 3
FUEL REQUIREMENTS 3
BATTERY CONNECTIONS 4
INSTALLATION OF LIGHTS 4
OPERATIONS
FRONT PANEL DESCRIPTION 4
TOWER PROCEDURES 5
START-UP CHECKLIST 6
STARTING 6
UNIT STORAGE 7
MAINTENANCE
PREVENTIVE MAINTENANCE 7
ROUTINE MAINTENANCE 7
ENGINE 7
GENERATOR 8
TROUBLESHOOTING 9
RESISTANCE TABLES 1 0
DIAGNOSTIC TABLES 1 1
COPY YOUR MODEL AND SERIAL NUMBER
BELOW FOR FUTURE REFERENCE.
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 Mobile Lighting System has been designed and
manufactured to allow safe reliable performance.
Improper or careless use can result in potentially
deadly hazards; from electrocution or serious 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: 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.
************************************************************
************************************************************
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 electrical 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 - Engine 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 contains 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).
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 doors closed to reduce
the operational noise level.
5. CLEANLINESS - Keep the generator and surrounding area clean.
A. Remove all grease, ice, snow or materials that
create slippery conditions around the unit.
B. Remove any rags or other material that could
create potential fire hazards.
C. Carefully wipe up any gas or oil spills before
starting the unit.
D. Never allow leaves or other flammable material
to build up around the engine exhaust area.
6. SERVICING EQUIPMENT - All service, including
the installation or replacement of service parts, should
be performed only by a qualified technician.
A. Use only factory approved repair parts.
B. Do not work on this equipment when fatigued.
C. Never remove the protective guards, cover or
receptacle panels while the engine is running.
D. 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 that rigging is designed to lift unit
PAGE 160706-121
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.
D. Always retract the tower and lock it into the
horizontal retracted position before moving the unit.
E. Always put all jacks into (“foot up”) horizontal
position before moving the tower.
9. TOWER ERECTION - This equipment will become
top heavy very quickly as the tower is raised. Always
follow the proper sequence raising or lowering the
tower.
A. Always extend the leveling jacks and level the
unit before lifting the tower from its horizontal position.
B. Always lift the tower to the full vertical position
(or tilt position) and lock in place before removing the
pin to extend the tower.
C. Never attempt to lower the tower to the horizontal position without the tower FULLY RETRACTED and
locked.
D. Always check for proper overhead clearance
before attempting to erect the tower. Never raise in the
vicinity of overhead power lines.
E. Never allow anyone to walk under the tower
during the raising or lowering operation.
MODULAR GENERATOR/ LIGHT-
and an internal 20 gallon fuel tank.
This power unit can be used on the MSL4 light tower
mounted on a separate trailer, or operated as a
staionary power unit.
b. LLT6012DE power unit is powered by a Lister
12 h.p. diesel operating at 1800 rpm. It comes complete with a receptacle panel, running time meter and
an internal 35 gallon fuel tank.
This power unit can be used on the MSL4 light tower
mounted on a separate trailer, or operated as a
staionary power unit.
3. MD6 is an over-the-road trailer with one of the two
power units listed above mounted on it. The trailer is
equipped with a standard DOT trailer light package,
jack stand and safety chains.
SPECIFICATIONS
MLS4Y & MLS4L
TOWER
Height 30 Feet
Rotation 360 degrees
LIGHTS
Type Metal Halide
Number/Wattage 4/1000
TRAILER
Axle Capacity 2200lbs
Tires 215/75-15
Hitch Type 1-7/8 to 2 1/8" Ball
YLT6010DE
ENGINE/GENERATOR
Make/Model Yanmar - L100AE
Fuel/Cooling Diesel/Air
Displacement 406 c.c.
HP @ 3600 10
Starting System 12 volt DC
Fuel Tank 20 gallons
ING SYSTEM DESCRIPTION
WINCO's uniquely designed MLS4 Modular Lighting
Sustem offers you three units in one. 1. MSL4 is an
Ultra Quiet light tower and trailer equipped with a 30 ft
tower, four 1000 watt metal Halide lamps and your
choice of two different Ultra Quiet power uints. The
power units are self contained and can be easily
removed or installed on the light tower trailer
2. a. YLT6010DE power unit is powered by a
Yanmar 10 h.p. diesel operating at 3600 rpm. It comes
complete with a receptacle panel, running time meter
Generator WINCO 6000
Continuous Watts 5500
Type Rotating Field
LLT6012DE
ENGINE/GENERATOR
Make/Model Lister - LPA3
Fuel/Cooling Diesel/Air
Displacement 1088 c.c.
HP @ 1800 12
Starting System 12 volt DC
60706-121PAGE 2
Fuel tank 35 gallons
Generator WINCO 6000
Continuous Watts 5500
Type Rotating Field
SAE20W/40
40 to 80 degrees F. SAE10W/40
SAE15W/40
5 to 40 degrees F. SAE 10W/30
Below 5 Defrees F. SAE5W20
For Addtional information see the Lister engine manual.
PREPARATION
NOTE: This booklet covers the entire unit, EXCEPT
THE ENGINE. See the engine manufacturer's operator
manual for specific maintenance and care information
regarding the engine. The engine information provided in
this manual is for your convenience only and in no way
supersedes the engine manufacture's instruction. If a
conflict should arise regarding engine instruction, the
engine manual should be considered the authority,
unless specifically instructed in this manual to ignore
an engine manual instruction.
Read ALL instructions in the manuals provided before
attempting to operate the generator set.
UNP ACKING
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 QUANTITY US Qts.
YLT6010DE 1.74 Qt/1.65 L
LLT6012DE 4.43 QT/4.20 L
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. When normal operating
temperatures are below 32 degrees F. (0 degrees C.), it
is acceptable to use a seasonal blend of No. 2 fuel. The
use of lighter fuel will reduce fuel economy. (SEE THE
ENGINE OPERATOR'S MANUAL FOR ADDITIONAL
FUEL INFORMATION.)
Filling the Fuel Tank
These units are equipped with a single internal fuel
tank. The YLT6010DE has a 20 gallon tank and the
LLT6012DE has a 35 Gallon tank. Use caution when
filling the tank to prevent it from overflowing.
BATTERY CONNECTION INSTRUCTIONS
CAUTION: EQUIPMENT DAMAGE
Insure the Selector Switch is in the OFF position before
connecting or disconnecting either of the battery
cables. Failure to turn the Selector switch OFF can
cause equipment damage when the battery cables are
connected or disconnected.
OIL REQUIREMENTS
Engine oil should be MIL-L-2104B or have properties of
API classification CC/CD grades. Change the type of
engine oil according to the ambient temperature.
YLT6010DE
-10 to 100 degrees F. SAE20W-40
-20 to 80 degrees F. SAE10W-30
below -20 or above 100 degrees F. ..Consult Yanmar
LLT6012DE
Above 86 degrees F. SAE15W/40
PAGE 360706-121
These units will require installation of a coustomer
purchased 12 volt battery for starting. The YLT6010DE
requires a group U1 235CCA battery and the
LLT6012DE requires a group 24F 600 CCA battery.
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
an 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.
c. “START” - This switch position engages the
engine starter and the pull-in coil on the fuel solenoid.
3. Alarm Light - This light will be lit if the unit has
shutdown on low oil pressure.
INSTALLA TION OF LIGHTS
The four flood lamps for the Mobile Lighting System
have been shipped on a separate pallet to prevent
damage during shipment. Carefully unpack and inspect
the lamps prior to installing them on the tower crossbar.
The individual lamps have been prewired and hardware
provided for their installation. Two lamps are installed on
the top of the crossbar and two are attached to the
bottom of the crossbar. The lights should be tipped
straight down and the swivel joints locked before
towing.
CAUTION: LIGHT BULB DAMAGE
Never handle the metal halide bulbs with your bare
hands! Doing so will leave traces of normal body oil
deposits on the bulbs which will shorten the bulb life. In
addition, a hot bulb will cause severe burns instantly.
See the Maintenance section of this manual for the
proper procedures.
OPERATIONS
DESCRIPTION AND
IDENTIFICATION
CONTROL PANEL LAYOUT
4. Fuel Pump Primer Switch - (YLT6010DE only)
This switch can be used to prime the fuel system prior
to engaging the engine starter.
5. Preheat Switch - (LLT6012DE only) At temperatures below 14 degrees F. this switch is used to
activate the engine preheat system.
6. AC Receptacles and Circuit Breakers - All of the
receptacles on the panel are protected by circuit
breakers.
1. 120 Volt 15 Amp GFCI (Ground Fault
Circuit Interrupter) duplex receptacle , Nema Spec. 5-
15. This duplex receptacle is protected by the 15 amp
circuit breaker mounted on the center side of the
control panel.
2. 120 Volt 15 Amp Duplex receptacle
(NEMA 5-15R). This receptacle is installed down
stream of the GFCI receptacle. Therefore it has both
ground fault protection as well as circuit breaker
protection.
3. 120 Volt 50 Amp receptacle (NEMA 550R). This receptacle is protected by 45 amp single
pole breaker.
4. 120/240 Volt 30 Amp Twistlock (NEMA
L14-30R). This twistlock receptacle is also protected by
the 30 Amp two pole 240 volt breaker mounted on the
bottom front of the control panel.
A. GENERATOR CONTROL PANEL
1. Hour Meter - This D.C. powered meter records the
time that the engine has run. It is used to schedule
engine maintenance such as air, fuel and oil filter
changes.
2. Start Switch - This unit is equipped for manual
start only. A three position Selector Switch controls the
engine.
a. “OFF” - This switch position stops the engine.
With the Selector Switch in this position, the unit can
be safely serviced.
b. “RUN” - This switch position activates the fuel
gauge,running time meter, electric fuel pump and the
holding coil in the fuel solenoid.
7. GROUNDING THE UNIT - To comply with current
safety standards, this generator set must be properly
grounded. Ground the Mobile Lighting System by
driving an 8 ft. copper ground rod into the earth. Connect a #8 AWG copper ground cable from the grounding
lug on the control panel to the ground rod.
B. LAMP CONTROL AND BALLAST
ASSEMBLY
The ballast assembly is connected to the generator AC
control panel via (4) four wire cord and plug assembly
that plugs into the L14-30R receptacle in the control
panel. Each of the lamps and ballasts are protected by
an individual 15 amp circuit breaker located on the end
of the ballast assembly. The individual lamp switches
are located just above the circuit breakers on this
60706-121PAGE 4
panel. Two lights are connected to each 120 volt leg
(G1 and G3) of the generator.
TOWER PROCEDURES
**************WARNING************************
NEVER ATTEMPT TO RAISE THE TOWER WITH
THE ENGINE GENERATOR SET REMOVED FROM
THE TRAILER BED. RAISING THE TOWER WITHOUT THE ENGINE GENERATOR ON THE BED OF
THE TRAILER WILL CAUSE THE UNIT TO BECOME
TOP HEAVY AND TIP OVER VERY EASILY. IN
ORDER TO MAINTAIN STABILITY ,THE TRAILER
BED MUST HAVE A MINIMUM OF 600 POUNDS ON
IT ANY TIME THE TOWER IS RAISED.
A. RAISING THE TOWER
WARNING: PERSONAL DANGER
Always check your overhead clearance before raising
the tower and never raise in the vicinity of overhead
power lines.
tower for at least six inches of tower extension.
8. Release the pin and continue to extend the
tower to the desired height or until it is fully extended to
the tower stop.
9. Loosen the “T-handle” nut and rotate the tower
to aim the light and retighten the “T-handle” nut. NOTE:
DO NOT LOOSEN UNLESS THE TOWER IS IN THE
TRUE VERTICAL POSITION.
B. LOWERING THE TOWER
1. Loosen the “T-handle” nut, rotate the tower until
the winch cable is realigned on the tongue end of the
trailer. Retighten.
2. Crank the tower extension winch (#2) to lower
the tower until the telescoping lock pin engages with an
audible click.
WARNING: PERSONAL DANGER
1. Extend both of the outriggers by removing the
locking pins to release the arms. Pull out the arm until
the outrigger holes line up in the extended position and
insert the locking pins.
2. Rotate all four of the jacks into the “foot-down”
vertical position and lock. Level the trailer using the
outriggers, bumper, and tongue jacks. All four jacks
must be in contact with the ground.
CAUTION: EQUIPMENT DAMAGE
Never attempt to raise the tower without all the
outriggers fully extended and the trailer properly leveled.
Failure to properly support the trailer may cause it to tip
over in a high wind with the tower raised.
3. Loosen the light at the trunnion pivots. Aim
(forward) 5 degrees to 30 degrees as desired, retighten.
4. Remove the mast travel locking pin.
5. Crank the winch to raise the tower to the full
vertical position, insert the vertical tower locking pin
through the vertical support and the tower. Insert the
safety pin in the vertical tower locking pin.
6. Reverse winch slightly to slacken cable.
Do not attempt to tilt the tower up or down unless the
tower is in the fully retracted position and the telescoping lock pin is fully engaged. Attempting to lift or lower
an extended tower may exceed cable strength leading
to possible cable or winch failure.
3. Remove the safety pin from the vertical tower
locking pin and pull the vertical tower locking pin. Crank
the tower tilt winch to lower the tower into the travel
position.
4. Install the mast travel locking pin.
5. Raise all the outrigger jacks to their fully
retracted position. Rotate all the jacks to the “foot-up”
vertical position. Pull the locking pins and slide the
outriggers into the fully retracted position, making sure
the locking pins are re-installed.
6. Rotate the trunnions to aim the lights down and
tighten securely for travel.
7. Before moving the trailer, fully retract the
tongue jack after hooking up to the towing vehicle. DO
NOT MOVE WITHOUT THE SAFETY CHAINS
HOOKED UP.
OPERATING THE UNIT
7. Pull the telescoping locking pin and hold while
operating the tower extension winch (#2) to extend the
PAGE 560706-121
A. START UP CHECKLIST
Before initial start-up and each subsequent start,
complete the following checklist:
Release both switches when the unit starts.
1. Check oil level, refill with proper grade oil.
2. Check for loose bolts or hardware.
3. Check tire pressure. (35 psi)
4. Trailer level to within 15 degrees.
5. Battery securely fastened, connections clean
and tight, and proper fluid level.
6. Fuel tank filled with the proper grade of diesel
fuel.
7. Check the air cleaner. Service only when
indicated. Do not over service.
B. STARTING INSTRUCTIONS
CAUTION: EQUIPMENT DAMAGE
DO NOT USE STARTING FLUIDS! Immediate engine
damage may result!
Note: This unit is equipped with engine safety shutdown
monitoring of low oil pressure. This shutdown is not
bypassed during start up. The engine will build sufficient oil pressure during cranking to open the safety
switch.
YLT6010DE
1. Depress the fuel pump primer switch for 10
seconds. This will charge the fuel system before
cranking.
2. Turn the Selector Switch to the “START” position. The starter will engage and the engine will start.
The Selector Switch is spring loaded so it can’t be
accidentally left in the “START” position. Releasing the
switch in the “START” position will automatically return
it to the “RUN” position.
3. Allow the engine to stabilize in speed and warm
up, then turn on the lights or other external loads
plugged into the receptacles.
4. When stopping the unit, first turn off the lights
and disconnect the external loads. Allow the engine to
cool down at no load for 5 minutes. Then turn the
selector switch to the OFF position.
LLT6012DE
1. If the temperature is below 14 degreees F. Put
the control switch in the run position. Depress the
preheat switch for 15 to 20 seconds. Continuing to
depress the preheat switch move, the selector switch to
the start postion.
2. If the temperature is above 14 degrees F. turn
the Selector Switch to the “START” position. The starter
will engage and the engine will start. The Selector
Switch is spring loaded so it can’t be accidentally left in
the “START” position. Releasing the switch in the
“START” position will automatically return it to the
“RUN” position.
3. Allow the engine to stabilize in speed and warm
up, then turn on the lights or other external loads
plugged into the receptacles.
4. When stopping the unit, first turn off the lights
and disconnect the external loads. Allow the engine to
cool down at no load for 5 minutes. Then turn the
selector switch to the OFF position.
C.UNIT STORAGE
Certain precautions must be taken if a Mobile Light
System 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
Yanmar or Lister engine dealer. They have certain
procedures that must be followed in order to prevent
engine damage, i.e. cylinder rust and injector, injector
pump deterioration.
MAINTENANCE
The ultimate aim of any 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.
60706-121PAGE 6
B. Old equipment requires more frequent inspection, and possibly servicing, than similar equipment that
has seen less service.
Every 500 hoursReplace air cleaner element.
See Yanmar operator's manual for complete mainte-
nance schedule for the Engine.
C. Time spent in cleaning, inspecting and correcting minor defects before they become major troubles
means time saved in overhaul and repair.
PREVENTIVE MAINTENANCE
A. Daily Maintenance Checklist
**Oil level is maintained 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.
**Air cleaner checked regularly. Change the filter
element only as required.
**Inspect for any fluid leaks.
**Look for any loose or damaged parts.
**Trailer hitch and safety chains checked for fitness.
**Tires checked for proper pressure.
**Battery checked for proper fluid level.
**Generator control panel checked for loose or damaged parts.
**Unit checked for general appearance and cleanliness.
**Tower cable checked for broken strands or frays.
**Insure floodlights are securely fastened.
B. Engine Routine Maintenance
A good preventive maintenance program begins with a
good day-to-day maintenance check and continues with
a rigid routine maintenance program at the proper
service intervals. The chart below is to be used as a
guide for your maintenance program. Shorter maintenance intervals are required if the engine is operated in
a dusty environment or if frequent stops are made. If the
engine is operated in consistent ambient temperatures
below 0 or above 100 degrees F., maintenance should
be performed at shorter intervals. Consult your Yanmar
authorized repair location for recommended intervals.
YLT6010DE
LLT6012DE
INTERVAL ITEM
Every 125 hoursChange oil and filter if you're
operating regularly above 95
degrees F or high duty factors.
Clean air cleaner.
Check for fuel and oil leaks.
Check serviceability of
battery.
Every 250 hoursChange oil and filter if you're
operating regularly below 95
degress F.
Clean fuel injectors if the
exhaust is dirty.
Replace the fuel filter element.
See Lister operator's manual for complete maintenance
schedule for the Engine.
C. Generator Routine Maintenance
Very little routine maintenance is required on the
generator itself as it contains no consumable parts. The
generator and control panel should be kept free of oil
and dirt. The generator air intake and exhaust must be
kept clear of all debris.
1. The generator frequency should be checked
periodically to insure that the engine is maintaining the
correct operating speed. The voltage should be checked
with an external voltmeter.
2. Inspecting generator insulation - Routine
nondestructive testing of the stator windings may be
required where the unit is subjected to excessive
humidity, and/or dirty environment. This is especially
important when the Generator Set is used for prime
power.
INTERVAL ITEM
Every 100 hoursChange engine oil and oil filter
Check air cleaner element
Check fuel filter
Check injector nozzles
Check fuel lines
Check battery electrolyte
CAUTION: EQUIPMENT DAMAGE
When making an insulation test on the main field,
disconnect all diodes. This is done to protect diode
elements from high voltage breakdown during megger
test.
Measure insulation resistance with a megger. If reading
of less than 200 megohm is obtained at 75 degrees F.
PAGE 760706-121
(297k) ambient temperature and moisture is suspected,
dry the insulation as described later in this section.
Note: Measurement of insulation resistance is an
important part of an adequate program for the maintenance of electric equipment. The measured values of
insulation resistance serve as a useful guide in determining whether or not insulation is defective. Drying,
revarnishing, or overhauling may be necessary to
prevent failure.
a) Check windings, connections, load
cables, and other components for
excessive dirt and grime. Clean if
applicable.
b) Make sure all mounting bolts have
been installed and are tight. Refer to
applicable portions of the text for
torque specifications.
c) Make certain no foreign objects are
lodged in the generator. Remove all
tools and shop clothes from the
vicinity of the Generator Set.
d) Be sure that all covers and guards
are reinstalled.
3. Cleaning - Cleanliness is of primary importance
in preventive maintenance. Do not allow dust, moisture,
oil, or other substances to remain in or on the equipment. The importance of keeping all insulation clean
cannot be over emphasized. Dust, dirt and other foreign
materials tend to block ventilating ducts and retard
dissipation of heat, which in turn, leads to local overheating. If the particles are allowed to build up, the
windings may eventually be short circuited or grounded.
Abrasive particles may puncture insulation. Iron dust is
especially harmful because the particles are continually
agitated by magnetic pulsations. For these reasons,
equipment must be kept clean, both externally and
internally, and particularly, all air ducts must be kept
clean and unobstructed.
There are four (4) acceptable methods of cleaning
insulation associated with electrical equipment:
a) Clean with a vacuum cleaner with
suitable plastic attachments.
b) Wipe clean with a cloth.
c) Blow off with direct stream of filtered,
oilless low pressure compressed air.
d) Clean with solvent and soft bristle
brush.
Of the methods listed above, the vacuum cleaner
method is the most practical for removing loose, dry
particles because it does not redeposit them on other
parts of the equipment as is done when compressed air
is used. Also, a vacuum cleaner is capable of removing
dust from coils and from grooves between wires that is
otherwise inaccessible to a wipe cloth.
Substances such as grease and oil can best be
removed by wiping whenever possible with a cloth or a
brush, and flushing inaccessible windings and other
areas with a minimum volume of trichloroethane*
solvent. Flush windings with trichloroethane beginning
at the top or 12 o’clock position and proceeding to the
bottom or 6 o’clock position, on either side. After
cleaning and drying (which is rapid with trichloroethane), take megger readings to determine whether
resistance has increased to above the acceptable 200
megohm level. If resistance is still low, clean the
affected areas again.
*WARNING: PERSONAL DANGER
The explosive and fire hazards of trichloroethane are
negligible and it has the least toxic effect of all the
chlorinated hydrocarbons; however, avoid prolonged
skin contact with the solvent and perform cleaning
operations in a well ventilated area. If the solvent is
splashed on the skin, wash off with soap and water. If
splashed into the eyes, flush with water and get medical
help. Avoid prolonged breathing of fumes.
4. Drying insulation - It is sometimes necessary
to dry insulation in order to recondition electrical
equipment that has been submerged or splashed with
water. It may also be necessary to dry equipment that
has absorbed moisture from the air after standing idle
for an extended period of time.
Heat and circulation of dry air, or the application of a
vacuum, is required in order to effectively remove
moisture from insulation. Heat may be provided by
either of 2 methods or a combination of both.
a) By external application of heat.
b) By circulation of electrical current at low
voltage through the conductors.
The best method to use on a specific case depends
upon local conditions and the facilities/equipment
available. Do not use the second method until after
insulation has been partially dried by the first method.
Regardless of heating method used, keep a close
check on temperature of the insulation. This can be
done by means of temperature detectors, either
permanently or temporarily installed, or by thermometers so placed that they can be easily read at the
60706-121PAGE 8
hottest areas on the equipment. Heat applications
should be continuous. Interruption of the heating
operation to the extent that the equipment cools and
approaches ambient temperature, may allow moisture
to condense in the insulation and retard the drying
process. Drying cannot be hurried. Many hours, or even
days, may be required to achieve satisfactory results.
5. Revarnishing insulation - In some cases, after
long periods of operation, or if repeated cleaning and
drying has been necessary, the results of insulation
resistance tests may indicate that revarnishing of
insulation is necessary. However, the application of
varnish will not permanently increase the insulation
resistance or dielectric strength of the insulating
material and should not be done in lieu of repairing
defective insulation.
TROUBLESHOOTING
2. Generator - including excitation capacitors,
winding, and rectifiers.
3. Control panel - switches and wiring
4. Light tower - lamps, ballasts, or wiring
5. Other external influences - such as load, fuel,
battery, accessory equipment (remote control panels,
exhaust system, etc).
C. Eliminate external causes of malfunction
1. Installation - restrictions in exhaust, ventilation,
fuel, low battery etc.
2. Load - two basic checks regarding apparent
overload.
a. Verify load is within nameplate capacity
using a clamp-on ammeter.
A. General - Check for loose wires, connections, and
hardware whenever the engine or generator control
panels are opened. If the troubleshooting chart indicates a particular component discrepancy, proceed to
that portion of the test procedure.
To properly check out electronic components and
generator wiring, they must be isolated from associated
circuitry. Always mark leads disconnected to insure
correct reconnection after testing.
Test equipment required to accomplish the static and
operational tests:
1. Volt-ohmmeter - 20,000 ohms per volt (or
higher).
2. Frequency meter - 58 to 62 hertz (cycles per
second).
3. Clamp-on ammeter 0-600 ampere range.
B. Problem isolation - Malfunctions are generally
classified and described by symptoms, with the
symptoms pointing to causes.
b. If within nameplate capacity on all legs,
determine if speed drops below specifications.
1. If speed drops, engine/fuel etc.,
problem.
a. Fuel filters plugged.
b. Tank empty.
c . Water in system.
d. Lines broken or disconnected.
e. Air filter plugged
2. If speed is OK, there is a genera
tor/electrical problem.
Efficient troubleshooting will rapidly narrow the number
of possible causes of malfunction with the minimum of
checks. To do this, a general understanding of the total
system operation is necessary. Each system component has unique input and output characteristics that
provide clear messages that properly interpreted will
point directly to the cause of malfunction. Verify defect
and repair or replace as required.
For resolution of specific failure symptoms, isolate to
system or component and refer to section of this
manual covering the suspected system.
Start failure, poor speed regulation, high voltage, low
voltage, etc., are only SYMPTOMS. To find and correct
CAUSES of these malfunctions, it is necessary to
isolate the problem to one of the basic system components.
1. Engine - including fuel and cranking systems.
PAGE 960706-121
WINDING RESISTANCES
YLT6010DE LLT6012DE Main
Rotor 2.0 .67
Stator
G1-N .13 .25
G3-N .26 .35
Q-Windings
(Capcitor Leads) .35 .85
60706-121PAGE 10
DIAGNOSTIC TABLE
GENERATOR
SYMPTOM
POSSIBLE CAUSE CORRECTION
LOW VOLTAGE (UNDER 220 VOLTS LOADED)
Engine Speed too Slow Check the no-load engine speed with a frequency meter and adjust
the governor to 61.5 Hertz at no-load. Troubleshoot engine and deter- mine why it will not hold the
proper speed.
Generator Overloaded Measure load being run and compare with nameplate rating. The load
on each leg should be as evenly balanced as possible and should not exceed the rated current on
any leg.
LOW VOLTAGE (UNDER 230 VOLTS NO LOAD)
Engine Speed too Slow Check the no-load engine speed with a frequency meter and adjust the
governor to 61.5 Hertz at no-load.
Generator Overloaded Measure load being run and compare with nameplate rating. The load
on each leg should be as evenly balanced as possible and should not exceed the rated current on
any leg.
Defective Main Rotor Measure rotor resistance (Rotating Fields). Check for grounds. Replace
if defective.
Defective Capacitor Test and replace if defective.
LOW VOLTAGE (3 TO 40 VOLTS)
Loose or Shorted Wires in Check all wiring and repair as needed.
Control Cabinet
Defective Diode Follow test procedure and replace if defective.
(Rotating Excitation)
Defective Excitor Winding Measure the resistance of the two leads connected to the capacitor,
Repair or replace as required. Check for grounds.
Defective Capacitor Test for opens and shorts. Replace if defective.
(Excitor)
Defective Main Rotor Measure rotor resistance (Rotating Field). Check for grounds. Replace
if defective.
PAGE 1160706-121
LOW VOLTAGE (0 VOLTS)
Loss of Residual Magnetism Flash the exciter stator with a small 9 volt battery. Consult factory for
procedure.
Defective Main Stator Measure stator resistance (G1 TO N & G3 TO N ). Check for ground
shorts. Replace if defective.
Short in AC Wiring. Turn off all circuit breakers for the lights and disconnect all external
loads. Check all the AC wiring in the control cabinet for shorts. Repair or replace as required.
FLUCTUATING VOLTAGE
Erratic Engine Speed Refer to the Engine manufacturer’s maintenance manual.
Loose Terminal or Load Check all AC wiring connections.
HIGH VOLTAGE
Engine Speed too High Check engine speed, reset to 61.5 HZ no-load.
GENERATOR OVERHEATING
Air Vents Obstructed Clear obstruction.
High Intake Air Improve ventilation. Allow at least two feet clearance around generator.
Temperature
ENGINE OVERHEATING
Engine Exhaust Leaking Repair exhaust system.
into Housing
Generator Overloaded Measure load being run and compare with nameplate rating. The load or
Unbalanced on each leg should be as evenly balanced as possible and should not
exceed the rated current on any leg.
Shorted Turns in Either the Measure rotor and stator resistance for shorted turns.
Rotor or Stator Replace if defective.
GENERATOR NOISY AND/OR VIBRATES
Loose Sheet Metal Check nuts, bolts and doors for tightness.
Rotor Rubbing Repair or replace defective part.
Bearing Defective Replace bearing.
Rotor Unbalanced Rotors are factory spin balanced on special computer controlled ma-
chines before assembly. Small washers or bars are used as balancing weights. Check inside the
generator for loose or missing parts. If any ` balance weights have broken loose, do not run the unit. Consult
your Winco dealer or the factory.
60706-121PAGE 12
Engine Unbalanced Consult local engine dealer.
ENGINE
DIESEL ENGINE WILL NOT CRANK.
Corroded Battery Cable Remove cables from battery and clean.
Connections
Battery Dead Check battery with a hydrometer. Recharge or replace as required.
CAUTION: SEE BATTERY CONNECTION ON PAGE 4
Defective Starter or Test start solenoid and starter. Refer to engine manufacturer's manual.
Solenoid
Selector Switch Defective Check selector switch for proper continuity. Replace.
CRANKS BUT WILL NOT START.
Out of Fuel Fill fuel tank.
Air in the Fuel Lines Bleed air out of fuel system. See engine manual.
Misadjusted or Defective Troubleshoot and Replace. See engine manual for details.
Fuel Solenoid
Water/Fuel Separator Full Drain water from separator.
of Water
Fuel Filter Plugged Replace filter(s).
STARTS BUT WILL NOT RUN.
Defective Holding Coil in Troubleshoot and replace.
Fuel Solenoid
Low Battery Test and recharge or replace. Be sure to check battery charging circuit
for proper charge operation.
CAUTION: SEE BATTERY CONNECTION ON PAGE 4
ENGINE SPEED DROPS TOO LOW UNDER LOAD
Air Cleaner Plugged Replace.
Generator Overloaded Remove external load and troubleshoot generator.
Water/Fuel Separator Full Drain water from separator.
of Water
Fuel Filter Plugged Replace filter(s).
Injector Pump Defective Repair or replace.
LIGHT TOWER
PAGE 1360706-121
Lamp Switches/ Circuit Breaker
No Generator Output Troubleshoot generator.
Circuit Breaker Trips Troubleshoot and replace if defective.
Defective Transformer or Troubleshoot and replace if defective.
Capacitor (Ballast)
Short Circuit in Trace and repair as required.
Tower Wiring
Defective Breaker Troubleshoot and replace if defective.
Short Circuit in Troubleshoot and repair or replace as required.
Lamp Fixture
Defective Transformer or Troubleshoot and repair or replace as required.
Capacitor (Ballast)
LAMPS START TO LIGHT AND THEN GO OUT.
Incorrect Generator Output Troubleshoot generator.
Incorrect Engine Speed Check engine speed reset to 61.5 HZ no-load.
Defective Transformer or Troubleshoot and repair or replace as required.
Capacitor (Ballast)
Defect in Ballast Wiring Trace and repair as required.
Defect in Tower Wiring Trace and repair as required.
60706-121PAGE 14
PAGE 1560706-121
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’s 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, 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.
60706-121 - 4115
225 South Cordova Avenue
Le Center, Minnesota 56057
612-357-6821
Loading...