Winco MDS45 User Manual

OWNERS
MANUAL

Mobile Diesel
Systems

MDS45

INSTALLATION AND OPERATION MANUAL

60706-154

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

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.

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
RECEPTACLE AND BREAKERS 5
FULL POWER CONNECTIONS 5
ENGINE CONTROL MODULE 5
VOLTAGE REGULATOR 6
SELECTING THE CORRECT

VOLTAGE 7
START-UP CHECKLIST 7
ELECTRIC STARTING 7
REMOTE STARTING 8
CONNECTING THE LOADS 8
UNIT STORAGE 9
50 CYCLE OPERATION 9

MAINTENANCE 9

PREVENTIVE MAINTENANCE 9

WIRING DIAGRAMS

DC ELECTRICAL SCHEMATIC 10
RECEPTACLE PANEL 11
CIRCUIT BREAKER PANEL 11
CONTROL PANEL 12
CONTROL PANEL WIRING DETAIL 13
AC SCHEMATIC 14
AC WIRING DIAGRAM 15
WARRANTY 16

MODEL____________________________________
SERIAL NUMBER____________________________
PURCHASE DATE____________________________
DEALER___________________________________

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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.
************************************************************

************************************************************
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.

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 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 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.

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).

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

MDS45

KILOWATT 35 kW
KILOVOLT-AMPS (.8 PF)43.5 KVA
AMPERAGE 277/480 VOLT 3 PHASE 52 AMPS*

120/240 VOLT 3 PHASE 105 AMPS*
120/208 VOLT 3 PHASE 121 AMPS*
120/240 VOLT 1 PHASE 146 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 RESISTANCE

MDS45

Main Stator 0.085 ohms
Main Rotor 3.2 ohms
Exciter Stator 0.35 ohms
Exciter Rotor 25 ohms
Exciter Voltage (F1-F2)

No Load 9.5 VDC
Full Load 36 VDC

Exciter Amperage (F1-F2)

No Load 0.4 Amps
Full Load 1.3 Amps

ENGINE SPECIFICATIONS

When receiving 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

This engine was filled at the factory. Before starting
check the oil level and ensure it is full. If not, fill to the
proper level with 15W-40 Cummins Premium Blue or
equivalent.

OIL QUANTITY US Qt. Liters

MDS45 8.0 7.5

FUEL REQUIREMENTS

See your engine operator's manual for complete type and
grade fuel information.

See Cummins Operation and Maintenance Manual for
complete engine specifications.

TRAILER/HOUSING

MDS45

Capacity 5000 lb.
Fuel Capacity 80 Gallons
Axles Single
Hitch Height Adjustable
Tires P225/75R-15
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 manufacturer’s 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.

Filling the Fuel Tank

Standard Trailer - The standard trailer is equipped with a
single 80 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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COOLANT REQUIREMENTS

The cooling system of this engine has been filled at the
factory with a 50% water and 50% ethylene-glycol
antifreeze and the proper amount of supplemental
coolant additives. This mixture provides protection to -37
degrees F.

The MDS45 requires a customer supplied 12 volt group
27 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.

When replenishing coolant or changing coolant refer to
your Cummins engine manual for the proper type and
mixture of water, antifreeze and supplemental coolant
additives.

WARNING: EQUIPMENT DAMAGE

Failure to properly follow Cummins requirements for
antifreeze and supplemental coolant additives can lead to
permanent damage to your engine cylinder liner walls.

COOLANT QUANTITY US Gal Liters

MDS45 6.67 25.3

BATTERY CONNECTION INSTRUCTIONS

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).

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.

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).

DESCRIPTION AND IDENTIFICATION

A. FRONT PANEL

1. Starting Controls (1)- This unit is equipped for
manual or automatic start. A three position switch controls
the engine starting.

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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 engine control
module goes into a 12 second start delay 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
MDS45 is used in a standby mode. With the switch in this
position a remote contact (i.e. Automatic Transfer Switch)
can be closed to engage the start circuitry. A terminal
block has been provided behind the customer connection
door for you to wire your remote contact into. This remote
contact must close to provide a path between the start
wire and battery negative.

2. DC Control Circuit Breaker (DCCB) (2)- 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. Emergency Stop Switch (3)- 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.

b. Field circuit breaker (FCB) (9)- Protects voltage
regulator and exciter field in the event of a load short
circuit or equipment malfunction.

c. Voltage selector power switch (10)- This heavy
duty three position switch allows the operator to quickly
and safely reconnect the 12 lead 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:

4. Engine Instruments
a. Oil pressure monitor gauge (OPG) (4)- 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) (5)-

The 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 (6)- 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 (7)- This DC meter records

the total hours the engine has run.

5. AC Generator Controls
a. Voltage adjust rheostat (8)- Controls the output

voltage of the generator by varying voltage regulators
reference voltage.

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.

6. AC Generator Instruments
a. VM/AM Selector Switch (11)- This selector switch

allows you to check the amperage being drawn from
each generator leg and your line to line voltage.

b. AC Voltmeter (VM) (12)- Monitors generator

output line to line voltage, for all voltage operations.

c. AC Ammeter (AM) (13)- Monitors the amperage

that is being drawn from each leg of the generator.

d. AC Frequency Meter (14)- Monitors the generator

frequency.

7. Warning Light Cluster (15)- 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.

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