Winco ULTB4000C User Manual

TWO-BEARING
GENERATOR

INSTALLATION AND
OPERATORS MANUAL

ULTB4000C

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SAVE THESE INSTRUCTIONS

PROPER USE AND

This manual contains important instructions that
should be followed during installation and main­tenance of the generator. Read and understand
all instructions in the manual before starting and
operating the generator set.

USING THE MANUAL

Congratulations on your choice of a Winco genera­tor. You have selected a high-quality, precision
engineered generator designed and tested to give
you years of satisfactory service.

To get the best performance from your new genera­tor, it is important that you carefully read and follow
the operating instructions in this manual.

Should you experience a problem please follow
the “Troubleshooting Tables” near the end of this
manual. The warranty listed in the manual describes
what you can expect from WINCO should you need
service assistance in the future.

INSTALLATION

You must be sure your new generator set is:
* Properly serviced before starting.
* Operated in a well ventilated area.
* Properly exhausted and gases safely
dispersed.
* 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

BASIC INFORMATION
Specifi cations 2
GUIDE TO PRODUCT SAFETY 3
UNIT CAPABILITIES 4
PREPARING THE UNIT 5
Unit Installation 5
CONNECTING THE LOADS 6
TROUBLESHOOTING 8
WIRING SCHEMATIC 8
ILLUSTRATED PARTS LIST 9
OUTLINE DRAWING 10
END COVER ASSEMBLY 11
WARRANTY INFORMATION 12

MODEL__________________________________

SERIAL NUMBER_________________________

PURCHASE DATE_________________________

DEALER_________________________________

DEALER PHONE # ________________________

UNIT SPECIFICATIONS

GENERATOR

Surge Watts 4000
Continuous Watts 4000
Volts 120/240
Amps 33.3/16.6
Receptacles 2 - NEMA 5-15R
1 - NEMA L14-30R
UL Listed UL STD 1004-1
UL STD 1004-4

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SAFETY INFORMATION

This generator 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,
or fi re. 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.

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. ELECTRICAL SHOCK The output voltage pres­ent in this equipment can cause 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 only three-pronged grounded receptacles
and extension cords.
e. Be sure the unit is properly grounded.

2. FIRE HAZARD Gasoline and other fuels pres­ent a hazard of possible explosion and/or fi re.

a. Do not refuel when the engine is running or
hot.
b. Keep fuel containers out of reach of children.
c. Do not smoke or use open fl ame near the gen-
erator set or fuel tank.
d. Keep a fi re 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.
f. Follow local codes for closeness to combust­ ible material.

3. NOISE HAZARD Excessive noise is not only
tiring, but continual exposure can lead to loss of
hearing.

a. Use hearing protection when working around
this equipment for long periods of time.

4. 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 materials that could
create a potential fi re hazard.
c. Carefully clean up any gas or oil spills before
starting the unit.

5. SERVICING EQUIPMENT All service, includ­ing the installation or replacement of service parts,
should be preformed only by a qualifi ed technician.

a. Use only factory approved repair parts.
b. Do not work on this equipment when fatigued.
c. Never remove the protective guards, covers, or
receptacle panels while the engine is running.
d. Use extreme caution when working on electri­ cal components. High output voltage from this
equipment can cause serious injury or death.
e. Always avoid hot muffl ers, exhaust manifolds,
and engine parts. They can cause severe
burns instantly.
f. The use of the engine-generator set must com­ ply with all national, state, and local codes.

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TESTING POLICY

Before any generator is shipped from the factory, it
is fully checked for performance. The generator is
loaded to its full capacity, and the voltage, current
and frequency are carefully checked.

Rated output of generator is based on engineering
tests of typical units, and is subject to, and limited
by, the temperature, altitude, fuel, and other condi­tions specifi ed by the manufacturer of the applicable
engines.

DESCRIPTION

The generator is a 3600 rpm two bearing, belt driv­en, brushless, revolving fi eld design. The generator
is self excited and inherently regulated to +/- (plus or
minus) 7% - no load to full rated load. It can be op­erated under any load within its rating without being
damaged. The frequency regulation is determined
by the sensitivity of the customer supplied prime
movers’ governor. It is desirable to maintain this
speed to within 3 cycles variation (61.5 Hz - 58.5 Hz)
no load to full rated load (3690 rpm - 3510 rpm).

Check the appliance or tool nameplate for the cur­rent and voltage to insure compatibility. Although a
circuit breaker is provided, damage due to overload­ing constitutes abuse and will not be warranted. Re­fer to the generator nameplate for unit’s capabilities.

The diagram below represents a 4,000 watt genera­tor. Only 2,000 watts at 120 volts (16.6 Amps) can
be taken from the generator at receptacle A and up
to 2,000 watts at 120 volts from receptacle C. On
an ordinary generator, CAUTION MUST BE EXER­CISED TO PREVENT OVERLOADING EITHER OF
THE 120 VOLT CIRCUITS (A OR C).

UNIT CAPABILITIES

GENERATOR CONNECTIONS

This generator is designed for 120/240 volt alter­nating current (AC). Two circuit breaker protected
duplex outlets and one 240 volt twist lock receptacle
are provided for connection to various loads. This
generator can be spun in either direction.

FULL POWER 120 VOLT ONLY

This generator can be converted to full power 120
volt only. Replacement of the circuit breaker and
receptacle is required. A 30 amp 1-pole circuit
breaker and a 3-wire 30 amp twist-lock receptacle is
recommended for full power applications. See wir­ing schematic below.

STARTING ELECTRIC MOTORS

Electric motors require much more current (amps) to
start them than to run them. Some motors, par­ticularly low cost split-phase motors, are very hard
to start and require 5 to 7 times as much current
to start them as to run them. Capacitor motors are
easier to start and usually require 2 to 4 times as
much current to start them as to run them. Repul­sion Induction motors are the easiest to start and
require 1 1/2 to 2 1/2 times as much to start them as
to run them.

Most fractional horsepower motors take about the
same amount of current to run them whether they
are Repulsion Induction (RI), Capacitor (Cap), or
Split-Phase (SP) type. The chart below shows the
approximate current required to start and run various
types and sizes of 120 volt 60 cycle electric motors
under average load conditions.

HP AMPS

RUNNING

1/6 3.2 16 to 22 6 to 13 5 to 8
1/4 4.5 22 to 32 9 to 18 7 to 12
1/3 5.2 26 to 35 10 to 21 8 to 17
1/2 7.2 not made 14 to 29 11 to 18

1 13.0 not made 26 to 52 20 to 33

ST ARTING AMPS

SP CAP RI

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