Winco MDS50E3B User Manual
OWNERS
MANUAL
Mobile Diesel
Systems
MDS50E3/B
INSTALLATION AND OPERATION MANUAL
60706-137
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 2
OIL REQUIREMENTS 2
FUEL REQUIREMENTS 2
COOLANT REQUIREMENTS 3
BATTERY CONNECTIONS 3
OPERATIONS
FRONT PANEL DESCRIPTION 4
RECEPTACLE AND BREAKERS 4
FULL POWER CONNECTIONS 5
VOLTAGE REGULATOR 5
SELECTING THE CORRECT
VOLTAGE 5
START-UP PROCEDURE 6
CONNECTING THE LOADS 6
UNIT STORAGE 7
50 CYCLE OPERATION 7
MAINTENANCE 8
PREVENTIVE MAINTENANCE 8
WARRANTY 9
WIRING DIAGRAMS
DC ELECTRICAL SCHEMATIC 10
RECEPTACLE PANEL 11
CIRCUIT BREAKER PANEL 11
AC SCHEMATIC 12
AC WIRING DIAGRAM 13
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___________________________________
Page i
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.
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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.
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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.
Page 1
SPECIFICATIONS
UNPACKING
GENERATOR SPECIFICATIONS
MDS50R3/B
KILOWATT 40 kW
KILOVOLT-AMPS (.8 PF)50 KVA
AMPERAGE 277/480 VOLT 3 PHASE 60 AMPS*
120/240 VOLT 3 PHASE 120 AMPS*
120/208 VOLT 3 PHASE 138 AMPS*
120/240 VOLT 1 PHASE 166 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
MDS50R3/B
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
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 with John Deere
Engine Break-In Oil. This break-in oil should be drained
and the oil filter changed after the first 100 hours of
operation.
During the break-in period, add John Deere Engine
Break-In Oil as needed to maintain the specified oil level.
A second 100-hour service interval with John Deere
Engine Break-In Oil may be required if the engine is
operated under light loads during the first 100 hours.
ENGINE SPECIFICATIONS
See John Deere Operation and Maintenance Manual for
complete engine specifications.
TRAILER/HOUSING
MDS50R3/B
Capacity 5000 lb.
Fuel Capacity 80 gals
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.
After the break-in period, use John Deere Torq-Grad
Supreme Plus-50 or other heavy -duty diesel engine oil
as recommended in the John Deere Engine manual. See
your engine operator's manual for recommended oil
grades and types under different operating temperatures.
OIL QUANTITY US Qt. Liters
MDS50R3/B 9.0 8.5
FUEL REQUIREMENTS
See your engine operator's manual for complete type and
grade fuel information.
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.
Page 2
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.
When replenishing coolant or changing coolant refer to
your John Deere engine manual for the proper type and
mixture of water, antifreeze and supplemental coolant
additives.
WARNING: EQUIPMENT DAMAGE
Failure to properly follow John Deere’s requirements for
antifreeze and supplemental coolant additives can lead to
permanent damage to your engine cylinder liner walls.
COOLANT QUANTITY US Gal Liters
MDS50R3/B 6.67 25.3
BATTERY CONNECTION INSTRUCTIONS
The MDS50R3/B 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.
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.
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).
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 key start only. A three position key switch controls
the engine starting.
Page 3
a. “OFF” - This switch position stops the engine and
disconnects the power to the engine controls. It is intended to safely allow service and maintenance checks
on the engine
b. “RUN” - This switch position engages the ignition
circuitry on the engine and powers up the engine control
panel and the engine sensors.
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