OWNERS MANUAL
MODELS PSS6HE\E
INSTALLATION, OPERATION,
and MAINTENANCE INSTRUCTIONS
Read and understand all instructions in the manual before starting and
operating the generator set.
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
* Operated so that 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 HERE
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.
TABLE OF CONTENTS
INTRODUCTION i
GUIDE TO PRODUCT SAFETY 1
BASIC INFORMATION
Intended Uses 2
Restricted Uses 2
Unit Capabilities 2
Description 2
Unpacking the unit 3
Unit Preparation 3
Battery Installation 4
Battery Charging 4
Low Oil Level Shutdown System 4
LP/NG INSTALLATION 4
Installing the Fuel Line 5
Fuel Pressure 5
Tank Sizing 6
Changing Fuel Types 6
STARTING INSTRUCTIONS
Initial Starting 6
Starting 6
Starting Hints 7
Stopping And Storage 7
Operating Speed 7
EMERGENCY TRANSFER SERVICE KIT
Preparation 8
Installation 9
Testing the System 10
Engine Care 11
Generator Care 12
Cleaning 12
Troubleshooting - Things To Check
BEFORE You Call For Service 12
WARRANTY 13
MODEL______________________________________
SERIAL NUMBER _________________________
PURCHASE
DATE_____________________________
DEALER_____________________________________
Page i
SAFETY INFORMATION
This engine generator set has been designed and
manufactured to allow safe, reliable performance.
Poor maintenance, improper or careless 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
labels and in the manuals.
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
onlyin a well-ventilated area.
f. Follow local codes for closeness to combustible
material.
ANSI SAFETY DEFINITIONS
************************************************************
DANGER:
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
This signal word is to be limited to the most extreme
situations.
***********************************************************
************************************************************
WARNING:
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
***********************************************************
***********************************************************
CAUTION:
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices.
************************************************************
NOTE:
CAUTION is also used on the unit labels and in this
manual to indicate a situation that could result in
serious damage or destruction of the equipment and
possible personal injury.
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 - Natural gas and L.P. 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
3. DEADLY EXHAUST GAS - Exhaust fumes from any
gasoline engine contain carbon monoxide, an
invisible, 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. Keep your neighbors in mind when permanently
installing this equipment.
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 clean up any gas or oil spills before
starting the unit.
d. Never allow leaves or other flammable material
to build up around the engine intake or 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. Use extreme caution when working on electrical
components. High output voltages from this
equipment can cause serious injury or death.
e. Always avoid hot mufflers, exhaust manifolds,
and engine parts. They all can cause severe
burns instantly.
f. Installing a generator set 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.
Page 160707-116
8201-00
INTENDED USES
UNIT CAPABILITIES
These engine generator sets have been designed
primarily for portable use. Both 120 and 240 volt AC
receptacles are provided in the 'control panel' to plug in
your loads (portable tools, and small appliances and
lights). These units are dual wound generators,
therefore the 120 Volt loads must be equally split with
1/2 of the rated capacity available on each of the two
120 Volt circuits. See unit capabilities for further
explanation.
These portable units require large quantities of fresh
air for cooling of both the engine and the generator.
Fresh air is drawn from both the engine end and the
generator end and is exhausted at the center of the
unit. For safety, long life and adequate performance,
these units should never be run in small compartments
or enclosed areas, without positive fresh air flow.
RESTRICTED USES
DO NOT remove from the cradle assembly. Removal
of the generator from the cradle assembly may cause
excessive vibration and damage to the engine
generator set.
DO NOT install and operate these portable
generators in a small compartment., i.e. generator
compartment of vehicles, motor homes or travel
trailers. These compartments will not allow enough
free flow fresh air to reach the engine generator set for
cooling and will cause the unit to overheat damaging
both the engine and the generator. Small
compartments will also develop hot spots where there
is very little air flow and may cause a fire.
Generator Connections - The diagram (figure A)
represents a 5500 watt generator. Loads A and B are
120 Volt loads. Up to 2750 watts at 120 volts (22.9
Amps) can be drawn from the generator at each of the
load points. This generator produces 120 and 240
volt, 60 Hz (Hertz), AC (Alternating Current).
CAUTION: EQUIPMENT DAMAGE
CAUTION MUST BE EXERCISED TO PREVENT
OVERLOADING EITHER OF THE GENERATORS 120
VOLT OUTPUT CIRCUITS (A OR B).
Check the appliance or tool nameplates for the current
and voltage to insure compatibility. Remember that
amperage utilized by the 240 volt load shown as C
reduces the power available at both A and B. Any
remaining 120 volt loads should be equally divided
between A and B. Failure to split the load will cause
permanent damage to the stator. Although circuit
breakers are provided, damage due to overloading
constitutes abuse and will not be warranted.
DESCRIPTION
This package system consists of an electric 'key start'
engine generator set equipped to run any one of three
fuels; gasoline, vapor LP ( propane) or natural gas;
manual transfer load center rated for 60 amps and
wheel kit for the generator allowing you greater mobility;
generator cover and a battery tender (charger).
ENGINE/GENERATOR
DO NOT attempt to operate at 50 cycles. These units
are designed and governed to operate only at 60
cycles.
Figure A
The engine generator set consists of a Honda overhead valve, single cylinder, air cooled engine equipped
to run on gasoline, vapor LP (propane) or natural gas.
The engine operates at 3600 rpm and frequency
regulation is maintained by the engine governor within 4
cycle's variation (62.5 Hz to 58.5 Hz) from no load to full
rated load.
The generator is rated at 6000 watts surge, 5500 watts
(5.5 kW) continuous, it is a brushless, single bearing,
direct drive, rotating field design. The generator is
connected to the engine's tapered (quill) crankshaft
extension. The engine generator is mounted in a full
wrap around cradle assembly.
A four-wire 125/250 volt receptacle (NEMA L14-30R)
is provided on the generator receptacle panel for
connecting to the manual transfer load center. Two
additional 120 volt receptacles are also provided for
your convenience.
8201-00
Page 2 60707-116
The engine electric start function is handled by the key
start on the engine control panel. For LP or NG operation, a 12 volt fuel solenoid has been installed on the set,
with a 120 volt control relay. The control relay is wired
across the generator output and is used as a safety to
shut the vapor fuel off in case the engine should stop for
any reason. To start on vapor fuel, the bypass button on
the outside of the control relay box must be depressed.
Depressing the bypass engages the 12 volt fuel solenoid
until the generator can build output voltage. This powers
the 120 volt relay, closing the relay contacts to provide
12 volts to the fuel solenoid. A customer supplied 235
CCA (BCI Group U1) battery is required to operate the
unit electric start system.
EMERGENCY TRANSFER SERVICE
The Emergency Transfer Service kit includes a UL
Approved Square 'D' manual power isolation switch.
When properly installed it will safely disconnect the
normal power service from your home emergency
electrical circuits and reconnect them to a portable
generator. It is not designed to transfer your whole
electrical system, only selected circuits you need
powered during a power failure (i.e. furnace, refrigerator,
freezer and minimal lighting). This system is comprised
of three major parts. The manual transfer center, exterior
'J' (junction) box for connections and cord storage and
the 12' four wire cord set with the plug installed.
The manual transfer center is built around two 60 amp
backfeed Square "D" circuit breakers with a mechanical
interlock bar installed. Manual transfer center also has
additional space for the customer to install two 240 volt
breakers, or one 240 volt and two 120 volt breakers or
four 120 volt breakers. The load center uses standard
Square D circuit breakers type QO and Q1. The 120 volt
breakers may be replace with type QO-T circuit breakers,
providing up to eight 120 volt circuits.
Before beginning the installation process it is very
important to plan which circuits you want to move from
your main circuit breaker panel into the manual emergency transfer panel. That way you can purchase only
the breakers you need and will have room for everything
when you are completed.
BATTERY TENDER
A two-stage battery tender is provided with this system.
This battery tender charges at a rate of 750 mA until the
battery is fully charged and then automatically switches
to a 13.2 VDC float charger. The charger has an
indicator light on it, red indicates it is charging, and green
indicates it is in the storage mode (float charge).
WHEEL KIT & COVER
UNPACKING THE SYSTEM
CAUTION: EQUIPMENT DAMAGE
THIS UNIT HAS BEEN SHIPPED WITHOUT OIL.
Failure to maintain the engine oil at the proper level will
result in serious engine damage.
When you unpack your new ENGINE GENERATOR
be sure to remove all the information sheets and
manuals from the carton.
1. This power plant was in good order when shipped.
Inspect the power plant promptly after receiving it. If
damage is noted, notify the transportation company
immediately; request proper procedures for filing a
“concealed damage” claim. Title to the equipment and
responsibility for filing a claim rests with you when a
generator is sent F.O.B. shipping point. Only you can
legally file a claim.
2. Before proceeding with the preparation of your new
engine generator set for operation, take a couple of
minutes to insure that the unit you have received is the
correct model and review the specification pages in this
manual to insure that this unit fits your job
requirements.
3. After removing the engine generator from the
carton locate and remove the shipping strap attached
to the generator shock mount. See attached tag for
removal instructions.
UNIT PREPARATION
Before your engine generator was shipped from our
factory it was fully checked for performance. The
generator was load tested to its full capacity, and the
voltage and frequency were carefully checked and
adjusted.
Lubrication
Before starting the engine, fill the crankcase to the
proper level with a good quality oil. The recommended
grade of oil and quantity of oil required is listed in the
engine operator's manual. The necessity of using the
correct oil, and keeping the crankcase full cannot be
overemphasized. Engine failures resulting from
inadequate or improper lubricant are considered abuse
and are not covered by the generator or the engine
manufacturer's warranty.
The Wheel Kit is shipped loose and comes with it's
own set of instructions. This wheel kit will allow greater
mobility with the generator as well as making it easier to
move inside for storage. Do not leave the generator
stored outside without protection. The cover will protect
the generator, but must must be romved from the unit
during operation
Page 360707-116
8201-00
Gasoline Fuel
WARNING: PERSONAL INJURY
When using gasoline always use a good grade of
unleaded fuel. Leaded gasoline may be used if
unleaded is not available. Gasoline containing alcohol,
such as gasohol is not recommended. However, if
gasoline with alcohol is used, it must not contain more
than 10 percent Ethanol and must be removed from the
engine during storage. DO NOT use gasoline
containing methanol. Always insure that the fuel is clean
and free of all impurities.
WARNING: FIRE DANGER
Gasoline and its fumes are VERY explosive when proper
precautions are not taken.
Never use gasoline that has been stored for an
extended period of time as the fuel will lose its volatile
properties and you will be left with only the varnish
residue. This varnish-like substance will clog the
carburetor and will not burn properly. The use of a fuel
additive, such as STA-BIL, or an equivalent will
minimize the formation of fuel gum deposits. If a unit
has been out of operation for an extended period of time
it is best to drain old fuel from the engine and replace
with fresh fuel before attempting to start.
BATTERY INSTALLATION
If you intend to use the power plant’s electric start
system (Required when using LP or NG), you will need
to purchase a battery to operate it. Units equipped with
a recoil or rope start will operate satisfactorily without a
battery on gasoline only. A twelve volt battery, group
U1 rated at 235 CCA or larger is recommended for this
electric start engine generator set. Follow the battery
manufacturer's recommendations for servicing and
charging prior to use.
Lead acid batteries produce explosive hydrogen gas
when charging. Keep sparks, flames, and burning
cigarettes away from the battery. Ventilate the area
when charging or using the battery in an enclosed
space. Lead acid batteries contain sulfuric acid, which
causes severe burns. If acid contacts eyes, skin or
clothing, flush well with water. For contact with eyes, get
immediate medical attention.
BATTERY CHARGING
Units equipped with electric start have a small
flywheel charger built into the engine flywheel assembly
for recharging the starting battery. This flywheel
charger generates a small AC current that passes
through a diode at the end of the charging lead to
produce a DC charging current of about 1 AMP. This
circuit is not designed to be used as a battery charging
circuit to recharge dead batteries.
LOW OIL LEVEL SHUTDOWN SYSTEM
Honda powered generators - These engine
generator sets come equipped standard with the Honda
Oil Alert System.
The Oil Alert system is designed to prevent damage
caused by an insufficient amount of oil in the
crankcase. Before the oil level in the crankcase falls
below a safe limit, the Oil Alert system will automatically
shut down the engine (the engine switch will remain in
the ON position).
If the Oil Alert system shuts down the engine, the Oil
Alert lamp will flash when you attempt to start the
engine and it will not run. If this occurs, check the
engine oil level.
CAUTION: EQUIPMENT DAMAGE
These electric start engines are NEGATIVE GROUND.
Use extreme caution when connecting the battery.
Connect the NEGATIVE battery terminal to GROUND.
For your safety always connect the positive battery
cable to the “bat+” terminal first. Then connect the
negative battery cable to the “bat-” terminal. Make sure
all connections are clean and tight. Reverse the
sequence when disconnecting, disconnect the negative
cable first. These engines produce only enough direct
current to keep a battery charged under normal
operating conditions, but were not intended to be used
as a battery charger.
8201-00
Use of the Oil Alert system on applications that are
subject to shock, bumping or severe angles of
operation (in excess of 15 degrees) should be avoided.
This is especially true if an unexpected shutdown
would cause a safety hazard or serious
inconvenience for the operator.
LP/NG FUEL INSTALLATION
The information in this instruction manual is offered to
assist you in providing the proper vapor fuel supply for
your engine. This information is only provided to advise
you of the engine’s requirements and the decisions you
must make. In no case should this information be
interpreted to conflict with any local, state or national
code. If in doubt, always follow local codes.
DANGER: FIRE - PERSONAL INJURY -
All fuel lines must be installed by a qualified fuel
supplier.
Page 4 60707-116
OPERATING LOCATION
The engine-generator models covered in this manual
were designed for portable use. DO NOT INSTALL OR
OPERATE THESE UNITS INDOORS. The unit should
be stored in a dry location. During a power outage
move the unit outdoors to a flat dry location such as a
driveway, concrete pad or sidewalk. We recommend
installing the optional wheel kit provided or equivalent
for ease of handling.
The fuel line used to connect the supply line to the
fuel solenoid must be a locally approved flexible fuel
line. Products used will vary in different regions
depending on availability and local codes. Consult with
your local fuel supplier to insure complete compliance
with ALL codes.
1. Remove the pipe plug from the solenoid valve.
2. Connect the flex fuel line to the solenoid valve.
DANGER: PERSONAL INJURY
The fuel source should be as close as possible to the
outdoor operating location. This will reduce the
installation cost of fuel runs. Connect the fuel supply
line to the inlet of the fuel demand regulator on the unit
using a locally approved flexible fuel line (see table for
recommended line size). The pressure supplied to
the demand regulator must be FOUR TO SIX
OUNCES or 7 to 11 INCHES W.C. (water column).
The primary regulator at the fuel supply must be
capable of delivering the proper volume of fuel at this
pressure.
Have your local fuel supplier install a protected fuel
connection at the outside operating location. He should
also install a lockable fuel shutoff valve at the
connection point. Have your fuel supplier permanently
install a flexible fuel line to the demand regulator on the
engine generator set.
INSTALLING THE FUEL LINE
DANGER: PERSONAL INJURY
Units that are intended to be run unattended MUST
have an electric fuel solenoid installed. This solenoid
MUST be wired to AUTOMATICALLY turn off the fuel
whenever the engine stops. See page 9 for additional
information.
Unit location will determine the size of fuel line that is
required to supply the engine with a constant fuel
pressure. Refer to the tables below for fuel line size,
and recommended tank size. For distances of 100 feet
and over, a two regulator fuel system is recommended.
This system consisting of a primary 10-15# regulator at
the tank and a 6 ounce secondary regulator installed
about 10 feet from the generator. You need to run a 3/4
inch line or larger from the secondary regulator to the
engine-generator set. When a two (2) regulator fuel
system is used, a fuel line size of 3/8 inch is generally
adequate for distances up to 300 feet. The line size
from the following table applies to the distance from the
second regulator to the fuel solenoid valve.
Do not use galvanized pipe in the fuel line runs. The
galvanized coating will become eroded and flake off,
causing possible obstruction or damage to the regulator
or fuel valve. The obstruction could cause an inoperative engine or an explosive fuel leak.
Size of pipe required for generators operating on
natural gas/LP gas.
Length of Fuel Line* Fuel Line Size
less than 25 feet 3/4 inch black pipe
25 to 100 feet 1 inch black pipe
over 100 feet not recommended
*allow an additional 3 feet for each standard elbow.
Do not use ‘street ells’ (restrictive)
DANGER! - FIRE - PERSONAL INJURY -
Be careful when sealing gas joints. Excessive sealing
compound can be drawn into the solenoid, regulator or
carburetor causing an engine malfunction or dangerous
fuel leak.
FUEL PRESSURE
Correct fuel pressure cannot be stressed enough.
The most common cause for inoperative systems is an
inadequate or incorrect fuel pressure. Power and
performance of the engine is in direct relation to the
correctness of the fuel system. Shown below is a block
diagram of a typical L.P. or N.G. installation.
Reference numbers 1 through 3 in the block
diagrams above are fuel lines supplied by customer.
Reference number 4 & 5 are already installed on your
engine generator set.
Page 560707-116
8201-00
Remember that whichever fuel delivery system or type
of vapor fuel used, the fuel pressure at the fuel solenoid
valve installed on the engine generator must be
between 4 and 6 oz. (7-11 inches of water column).
Any lower pressure and the unit will starve for fuel
under load. Any higher and the unit will ‘flood’ when
attempting to start.
Wheel Kit
The wheel kit is shipped loose and must be
assembled. The wheel kit comes with instructions and
parts list. After installing the wheel kit, file the
instructions and parts list in the back of this manual for
future reference.
LP TANK SIZING
Once above the minimum acceptable size, the size of
LP tank used will generally depend on how long you
want the unit to run without refilling. The tank sizes
shown below are the smallest recommended tank sizes
based on the outside temperature. Keep in mind the
colder it gets the slower L.P. will vaporize. This is the
reason for the larger tanks at low temperature.
Minimum sizing is not based on running time.
Temp 60 deg f. 30 deg f. 0 deg f. -20 deg f.
PSS6HE 40 gal 50 gal 125 gal 350 gal
CHANGING FUEL TYPES
These engine generator sets are designed to run on
three different fuels; gasoline, natural gas or LP vapor.
They may be easily changed from one fuel to another.
FROM GASOLINE TO LP/NG
1. With the engine running, turn off the gasoline fuel
valve.
2. Run the engine until it runs out of fuel.
3. Remove the plastic plug from the fuel solenoid
valve.
4. Install locally approved flexible fuel line.
5. Connect the LP/NG vapor fuel line.
6. Units have two different hose fittings on the top of
the demand requlator. One is for LP and one is for
Natural Gas. Make sure the hose is attached to the
proper fitting.
7. Turn on the vapor fuel.
8. Start the engine.
9. Apply the load to the generator.
INITIAL START UP
Use the following checklist to verify the correct
preparation of the engine generator before starting.
Before Starting always Check:
1. Engine oil, fill as required with correct grade and
quantity.
2. Fuel level, fill as required with clean fresh fuel.
3. Visually for loose parts.
STARTING
NOTICE: TRI-FUEL STARTING
Tri-Fuel generators operating on vapor fuel, (either
LP or NG) must be started using the electric start system
provided. You cannot hand crank the unit fast enough to
develop the proper vacuum to make the vapor fuel
system work. In addition the electric fuel solenoid valve
requires a battery to operate. For starting the black
button on the fuel control relay panel must be depressed.
WHEN USING VAPOR FUEL NEVER USE THE
CHOKE. Use of the choke will prevent the air and fuel
from properly mixing.
The throttle control on these generators is preset and
locked to operate at 3600 RPM (nominal) with no load
speed set at 3750 RPM. Only a trained service technician should be allowed to adjust this speed setting. See
“Operating Speed” section for additional information.
NOTICE: ENGINE START LOCKOUT
This unit will not start if it is low on oil. The lubricating oil
level must be at the full mark before the engine will start.
FROM LP/NG TO GASOLINE
1. With the engine running turn off the LP/NG fuel
supply.
2. Run the engine until it runs out of fuel.
3. Remove the flexible fuel line from the fuel solenoid
valve.
4. Reinstall the plastic plug in the fuel valve.
5. Check to be sure the gasoline fuel valve is off.
6. Fill the gasoline fuel tank.
7. Turn on the gasoline fuel valve.
8. Start the engine.
9. No adjustment should be necessary as the engine
has been tested on gasoline.
8201-00
MANUAL STARTING - (For Gasoline Only)
Refer to the engine manual for additional starting,
operating, and stopping instructions.
1. Turn on the GASOLINE supply.
2. Move the choke to the full "on" position. A warm
engine will require less choking than a cold engine.
3. Grasp starter grip and pull slowly until starter
engages, then pull cord rapidly to overcome
compression, prevent kickback and start the engine.
Repeat if necessary.
4. When the engine starts, open the choke gradually.
5. The engine should promptly come up to operating
speed.
Page 6 60707-116
Electric Starting - If the engine is cold and stiff or if the
battery is not fully charged, starting can be made easier
by slowly hand cranking the engine through the
compression stroke before pushing the starter switch.
This permits the starter to gain momentum before the
heavy load of the compression stroke occurs. This also
minimizes the drain on the battery and improves the
possibility of starting under adverse conditions. Always
keep the battery charged, but especially during cold
weather operation.
1. Turn on the fuel supply.
2. Move the choke to the full "on" position (for gaso-
line only). A warm engine will require less choking
than a cold engine.
3. Engage the engine start switch briefly to the START
position. The starter life is improved by using
shorter starting cycles with time to cool off between
cranking cycles. Do not operate the starter more
than 15 seconds during each minute. Repeat if
necessary. Remember when starting the
PSS6HE on vapor fuel the solenoid bypass
button must also be depress on the control
panel.
4. When the engine starts, open the choke gradually.
5. The engine should promptly come up to operating
speed.
CAUTION: EQUIPMENT DAMAGE
auctions must be taken to ensure the fuel doesn’t
deteriorate and clog the fuel system.
a. Remove the remaining fuel from the fuel tank.
b. Start the engine and allow it to run until all
the fuel in the carburetor and the fuel lines has
been used up and the engine stops.
c. While the engine is warm, drain the oil and
refill with fresh oil.
d. Remove the spark plug, pour approximately
1/2 ounce (15 cc) of engine oil into the cylinder
and crank slowly to distribute oil. Replace spark
plug.
e. Clean dirt and chaff from cylinder, cylinder
head fins, blower housing, rotating screen and
muffler areas.
f. Store in a clean and dry area.
Note:
The use of a fuel additive, such as STA-BIL, or an
equivalent, will minimize the formation of gum
deposits during storage. Such an additive may be added
to gasoline in the engine’s fuel tank or to gasoline in a
storage container.
OPERATING SPEED
The engine-generator must be run at the correct
speed in order to produce the proper electrical voltage
and frequency.
Never permit the choke to remain on after the engine
has run for a short time. It is not necessary to choke the
engine when it is warm. Avoid over-choking.
STARTING HINTS
1. Cold weather
a. Use the proper oil for the temperature expected.
b. Use fresh winter grade fuel. Winter grade
gasoline is blended to improve starting. Do not
use summer gasoline.
c. A slightly richer fuel mixture will usually improve
cold starting.
2. Hot weather
a. Use the proper oil for the temperature expected.
b. Use only summer blended gasoline. Using
gasoline left over from winter may cause the
unit to vapor lock.
c. DO NOT over-choke the unit.
STOPPING AND STORAGE
1. Remove the load.
2. Turn off the key switch on the engine to ‘ground out’
the spark or turn off the fuel.
3. Before extended storage (over 30 days) certain
CAUTION: EQUIPMENT DAMAGE
The output voltage should be checked to insure the
generator is working properly prior to connecting a load
to the generator. Failure to do so could result in damage
to equipment plugged into the unit and possible injury to
the individual.
All engines have a tendency to slow down when a
load is applied. When the electrical load is connected to
the generator, the engine is more heavily loaded, and
as a result the speed drops slightly. This slight
decrease in speed, together with the voltage drop within
the generator itself, results in a slightly lower voltage
when the generator is loaded to its full capacity than
when running no load. The slight variation in speed
also affects the frequency of the output current. This
frequency variation has no appreciable effect in the
operation of motors, lights and most appliances.
However, electronic equipment and clocks will be
affected if correct RPM is not maintained. See Load vs.
Output chart.
Although individual units and models may vary slightly,
the normal voltage and frequency of the engine
generators described in this book are approximately as
follows, under varying loads:
Page 760707-116
8201-00
LOAD vs. OUTPUT
__________________________________________________________________________________________________________________
Generator Frequency Voltage
Load Speed 120V
Applied* (RPM) (Hz) Recpt.
__________________________________________________________________________________________________________________
None 3750 62.5 129V
Half 3600 60.0 120V
Full 3540 59.0 115V
__________________________________________________________________________________________________________________
*Portion of plant’s rated output current.
The speed of the engine was carefully adjusted at the
factory so that the generator produces the proper
voltage and frequency. For normal usage, the speed
setting should not be changed. If the generator is
being run continuously on a very light load, it is often
advisable to lower the operating speed slightly.
Whenever making any speed adjustments check the
unit with a voltmeter or a tachometer and be sure the
speed is correct.
Lower voltage may damage both the generator and
any load connected to it. Running the engine at
excessively high speeds results in high voltage, which
may significantly shorten the life of appliances being
used.
WARNING - PERSONAL INJURY
All wiring must be done by a licensed electrician, and
must conform to the national electrical code and comply
with all state and local codes and regulations. Check
with your local electrical inspectors before proceeding!
PREPARATION
Before doing any wiring you must decide which circuits
you want to back up. As discussed earlier you will have
a limited number of circuits that can be moved from your
primary distribution panel to the Emergency Load
Distribution Panel.
The primary thing to remember when you are selecting
your circuits is that the generator has a very limited
amperage capability. The PSS6H/E generator is limited
to 22.9 amp of output at 240 volts. What this means is
that your combined load on the generator cannot exceed
22.9 on either power feed from the generator.
Also take into account any electric motors that you are
going to operate. Motor loads have a very high amperage inrush when the motors first start up. If you don't
have sufficient generator capability with your other loads
running, the motor will stall and possibly do damage to
the motor or other connected loads.
Output voltage should be checked periodically to
ensure continued proper operation of the generating
plant and appliances. The generator is not equipped
with a voltmeter, but it can be checked with a portable
meter. Frequency can be checked by using an electric
clock with a sweep second hand. Timed against a
wrist watch or a stop watch the clock should be correct
within +/- 2 seconds per minute.
WIRING THE EMERGENCY TRANSFER
SERVICE KIT
8201-00
COMPLETE SYSTEM LAYOUT
Page 8 60707-116
INSTALLATION
The first step will be to install the 'J' box on the outside
of the house and the Emergency Load Distribution Panel
next to your existing distribution panel. Remember the
circuits you take out of the main panel will be reinstalled
in the emergency panel, so these should be as close
together as possible.
Next you need to install a two pole (240 Volt) circuit
breaker in the current distribution panel. This circuit
breaker should be sized according to the load you are
going to wire into the emergency panel. But in no case
can it exceed the 60 amp breaker rating in the Emergency panel.
Next you will need to pull four wires from the main
panel to the emergency panel. The wire size will depend
on what amperage breaker you are using. The two Hot
leads will attach to the right hand 60 amp breaker. The
neutral and ground will be attached to the appropriate
bars in the emergency panel.
You will also need to install four leads from the 'J' box
to the emergency panel. These leads should be
attached to the cord set provided with the Emergency
Transfer Service Kit. The cord set is color coded the red
and black leads are hot , white is neutral and green is
ground. Be sure to mark your leads before installation to
insure that they get attached in the Emergency panel
correctly. All connections in the 'J' box should be
watertight. The red and black leads will attach to the left
hand 60 amp circuit breaker in the emergency panel.
The white will be routed to the neutral bar and the green
to the ground bar.
Next you will need to install your load circuit breakers
in the emergency panel. Again you can use any
combination of breakers that you want. The emergency
panel uses Square "D" circuit breakers type QO, if you
need to use the tandem breakers on the 120 circuit they
are type QO-T.
The final step will be to move your load leads from the
main distribution panel to the emergency panel.
Switch Shown With Both Breakers Open
Page 960707-116
8201-00
24 MONTH
TESTING THE SYSTEM
1. Your first step in testing the Emergency panel will
be to close the circuit breaker in the main panel
feeding the Emergency panel. Check your voltage in
the emergency panel to insure you have the correct
voltage in all locations. Then close the utility circuit
breaker in the emergency panel.
INTERLOCKING BREAKER IN THE
UTILITY POSITION
2. Close your load breakers and make sure everything that you have wired to the Emergency panel is
working properly on utility power.
3. Start the engine generator set and plug the power
cord into the generator. Check your voltages at the
bottom lugs on the generator circuit breaker (left 60
amp breaker).
4. If the voltages are correct shut the utility breaker
off and move the generator breaker to the on position. The generator should now be powering your
connected loads. Monitor the voltage coming from
the generator and make sure that it stays at the
proper level.
CONNECTING THE LOADS
Applying The Load
Allow the engine to warm up for two or three minutes
before applying any load. This will allow the engine to
reach normal operating temperature and oil to circulate
throughout the engine. A short warm-up time will permit
the engine to work more efficiently when the load is applied
and will reduce the wear in the engine, extending its life.
Receptacles have been provided to allow loads to be
connected to the generator. The loads should be added
one at a time. If a large motor is being started or multiple
motors are being started, they should be started
individually and the largest should be started first.
Plug your tools such as drills, saws, blowers, sump pump
and other items to be powered directly into the generator
receptacles. Before plugging in all the tools and cord sets,
recheck the rating of the generator set. Be sure it can
handle the intended load and is compatible with the
voltage, phase, and current ratings.
CAUTION: EQUIPMENT OVERLOAD
Keep the generator load within the generator and receptacle
nameplate rating. Overloading may cause damage to the
generator and/or the loads .
Most electric tools and appliances will have the voltage
and amperage requirements on their individual nameplates.
When in doubt consult the manufacturer or a local
electrician. The nameplate amperage rating for electric
motors can be misleading, because of higher starting
current.
These engine generator sets are inherently self regulating
based on engine speed. The engine governor will
automatically adjust itself to the load. No harm to the
generator will result if it is operated with no load connected.
INTERLOCKING BREAKER IN THE
GENERATOR POSITION
5. If the voltage from the generator should drop too
far, turn the generator side breaker off. This will
remove the load from the generator. At this point you
are going to have to determine why the voltage
dropped. Either you have it overloaded (over 22.9
amps per leg on LP or 20 amps on NG) or the engine
is not getting enough fuel to carry the load.
6. After correcting the problem, retest the system
starting at step 3.
7. If everything tests ok, you can turn the generator
breaker off and turn the utility breaker back on. This
is how the system is left until you need the generator.
8201-00
Proper utilization of the receptacles located on the control
panel is necessary to prevent damage to either the
receptacles or the generator. The generator is a limited
source of electrical power, therefore pay special attention
to the receptacle and generator ratings.
CAUTION: EQUIPMENT DAMAGE
Caution must be used when loading the generator, overloading either of the 120 volt sides will cause the breaker to
trip disconnecting all the loads
Page 10 60707-116
CAUTION: EQUIPMENT DAMAGE
Failure to properly limit and balance the load applied to
the generator will cause the generator to produce low
voltage and may damage the engine generator set. It
may also cause severe damage to the loads connected
to the generator at that time. Improper loading of the
generator set constitutes abuse and will not be covered
by warranty.
Grounding
All units must be grounded. Drive a 3/4 or 1" copper
pipe or rod into the ground close to the enginegenerator set. The pipe must penetrate moist earth.
Connect an approved ground clamp to the pipe. Run a
#10 AWG wire from clamp to the generator ground lug
on the “end cover”. Do not connect to a water pipe or to
a ground used by a radio system.
ENGINE CARE
If major engine service or repair is required contact an
authorized engine service center. The manufacturer of
these engines has established an excellent worldwide
engine service organization. Engine service is very likely
available from a nearby authorized dealer or distributor.
Check the yellow pages of your local telephone directory
under “Engines-Gasoline” for the closest engine repair
center or ask the dealer from whom you purchased the
power plant.
1. Change the oil after the first five hours of operation
and every 50 hours thereafter under normal
operating conditions. Change engine oil every 25
hours of operation if the engine is operated under
heavy load, or in high ambient temperatures.
a. Remove oil drain plug at base of the engine
and drain the oil with the engine warm.
b. Replace oil drain plug.
c. Remove oil filler plug and refill with new oil.
Refer to the table in the engine manual for the
proper grade of oil based on your operating
temperature.
d. Replace filler plug.
3. Cartridge Air Cleaner - Remove and clean cartridge yearly or after every 25 hours, whichever occurs
first. Service more often if necessary. Clean by tapping
gently on flat surface. If very dirty, replace the cartridge
using only original equipment parts available at any
engine service center.
Do not use petroleum solvents, such as kerosene, to
attempt to clean the cartridge. They may cause
deterioration of the cartridge. DO NOT OIL CARTRIDGE, DO NOT USE PRESSURIZED AIR TO CLEAN
OR DRY CARTRIDGE.
4. Dual Element Air Cleaner - Clean and re-oil foam
pre-cleaner at three month intervals or every 25 hours,
whichever occurs first. Service more often under dusty
conditions.
a. Remove knob and cover.
b. Remove foam pre-cleaner by sliding it off the
paper cartridge.
c. Wash foam pre-cleaner in kerosene or liquid
detergent and water
d. Wrap foam pre-cleaner in cloth and squeeze
dry.
e. Saturate foam pre-cleaner in engine oil.
Squeeze to remove excess oil.
f. Install foam pre-cleaner over paper cartridge.
Reassemble cover and screw down tight.
Replace the cartridge included with Dual Element Air
Cleaner yearly or every 100 hours. Service more often
if necessary.
5. Spark Plug - Clean and reset gap at .030" every
100 hours of operation. Do not blast clean spark plug.
Clean by scraping or wire brushing and washing with a
commercial solvent. Poor spark will occur if terminal
does not fit firmly on spark plug. If this happens reform
the terminal to fit firmly on spark plug tip.
2. Checking the Oil Level: The oil level must always
be checked before the engine is started. Take care to
remove any dirt or debris from around the oil fill plug
before removing. Be sure the oil level is maintained.
FILL TO POINT OF OVERFLOWING or on units with
the extended oil fill to the “FULL” mark on the dipstick.
Page 1160707-116
8201-00
GENERATOR CARE
TROUBLESHOOTING HINTS
Proper care and maintenance of the generator is
necessary to insure a long trouble free life.
1. Exercising The Generator - The generator should
be operated every three to four weeks. It should be
operated for a period of time sufficient to warm the unit
up and to dry out any moisture that has accumulated in
the windings. If left, this moisture can cause corrosion in
the windings. Frequent operation of the engine generator set will also insure that the set is operating properly
should it be needed in an emergency.
2. Generator Maintenance - Any major generator
service including the installation or replacement of parts
should be performed only by a qualified electrical
service technician. USE ONLY FACTORY AP-
PROVED REPAIR PARTS.
a. Bearing - The bearing used in these generators
is a heavy duty double sealed ball bearing.
They require no maintenance or lubrication.
b. Receptacles - Quality receptacles have been
utilized. If a receptacle should become cracked
or otherwise damaged, replace it. Using
damaged or cracked receptacles can be both
dangerous to the operator and destructive to
the equipment.
CLEANING
Remove dirt and debris with a cloth or brush. DO
NOT use high pressure spray to clean either the engine
or the generator. This high pressure spray could
contaminate the fuel system and the generator
components.
PROBLEM (SYMPTOMS) POSSIBLE CAUSES
—————————————————————————
Won’t Start *Low Oil Level.
*Fouled spark plug.
*Out of fuel.
*Stop switch in stop position.
————————————————————————-
Voltage too low *Engine speed is too low.
*Generator overloaded.
*Defective rectifier.
*Defective stator.
*Defective rotor (field).
—————————————————————————
Circuit Breaker *Defective load.
Trips *Defective receptacle.
—————————————————————————
Voltage too high *Engine speed is too high.
—————————————————————————
Generator *Overloaded.
overheating *Insufficient ventilation.
—————————————————————————
No output voltage *Short in load (disconnect).
*Broken or loose wire.
*Defective receptacle.
*No residual magnetism
(in generator).
*Defective stator.
*Defective rotor (field).
*Shorted capacitor.
*Defective rectifier.
—————————————————————————
1. Keep the air inlet screen on both the engine and
generator free of any dirt or debris to insure proper
cooling. At least yearly remove the blower housing on
the engine and clean the chaff and dirt out of the engine
cooling fins and flywheel. Clean more often if necessary. Failure to keep these areas clean may cause
overheating and permanent damage to the unit.
2. Periodically clean muffler area to remove all grass,
dirt and combustible debris to prevent a fire.
3. On engine mufflers equipped with spark arresters,
the spark arrester must be removed every 50 hours for
cleaning and inspection. Replace if damaged.
8201-00
Page 12 60707-116
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.
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 WINCO, Inc.
WINCO does not warrant products which have been subjected to misuse and/or negligence or have
been involved in an accident.
225 SOUTH CORDOVA AVE
LE CENTER MN 56057
Phone: 507-357-6831
Page 1360707-116
8201-00
Phone - (507) 357-6831
FAX - (507) 357-4857
www.wincogen.com
225 S. Cordova Ave.
LeCenter, Mn 56057
P/N 60707-116
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