INDUSTRIAL PORTABLE
INSTALLATION AND
OPERATORS MANUAL
W6010DE/G
WINCO INC.
225 S. CORDOVA AVE.
LE CENTER, MN 56057
507-357-6821
SERVICE DEPT.
507-357-6831
wincogen.com
SAVE THESE INSTRUCTIONS
PROPER USE AND INSTALLATION
This manual contains important instructions that
should be followed during installation and maintenance of the generator and battery. 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 set.
You have selected a high-quality, precision engineered
generator set designed and tested to give you years of
satisfactory 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
“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.
TABLE OF CONTENTS
INTRODUCTION 2
BASIC INFORMATION
Specifi cations 2
SAFETY INFORMATION 3
SPECIFICATIONS 4
UNIT CAPABILITIES 5
PREPARING THE UNIT
Unpacking the Unit 6
Unit Preparation 6
Battery Installation 7
OPERATION/INSTALLATION 8
INITIAL START UP 8
Manual Starting 8
Electric Starting 8
Operating Speed 9
CONNECTING THE LOADS 9
Wiring 9
ENGINE CARE 10
GENERATOR CARE 13
TROUBLESHOOTING 14
GENERA T OR TESTING RESISTANCES 14
ENGINE MAINTENANCE PARTS 14
CONTROL PANEL WIRING DIAGRAM 15
WARRANTY INFORMATION 16
You must be sure your new engine 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.
MODEL W6010DE/G
SERIAL NUMBER_________________________
PURCHASE DATE_________________________
DEALER_________________________________
DEALER PHONE # ________________________
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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 potentially deadly hazards; from electrical shock, exhaust gas
asphyxiation, 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.
***********************************************************
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 extreme care if operating this unit in rain
or snow.
e. Use only three-pronged 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 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
generator 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
combustible material.
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 including attached
garages
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, fl oors).
4. 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.
b. Keep your neighbors in mind when using 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 materials that could
create a potential fi re hazard.
c. Carefully clean up any gas or oil spills before
starting the unit.
6. SERVICING EQUIPMENT All service, including the
installation or replacement of service parts, should be
performed 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. se extreme caution when working on
electrical 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
comply with all national, state, and local
codes.
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SPECIFICATIONS
TESTING POLICY
MODEL W6010DE/G
Generator
Surge Watts 6000
Continuous Watts 5500
Volts 120/240
AMPs @ 240 Volts 22.9
AMPs @ 120 Volts 45.8
Engine
Size 9.9 HP
Model Yanmar L100V
Type - See Engine Shroud For
Fuel Capacity- 7 gal
Fuel Consumption .7 gal/hr
Starting System 12 Volt Electric/Key
Muffl er Low Tone
Stop System Key
Complete Unit
Weight (dry) 288 LBS
Dimensions LxWxH 32 X 22 X 23
Owner Must Provide
Fuel #2 Diesel
Oil Type 10W-30 CD or higher
for -4F to 80F
See engine manual for additional oil information.
Oil Capacity 1.7 Qts (1.6 L)
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.
INTENDED USES
This engine generator set has been designed primarily for
portable heavy duty commercial use. Both 120 volt and
240 volt receptacles are provided in the control panel to
plug in your loads (lights, portable tools, and small appliances).
This portable unit requires large quantities of fresh air for
cooling the engine and generator. For safety, long life and
adequate performance, these units should never be run in
small compartments without positive fresh air fl ow.
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 this generator in a small
compartment., i.e. generator compartments of vehicles,
motor homes or travel trailers. These compartments will
not allow enough free fl ow of fresh air to reach the engine
generator set for cooling and will cause the unit to overheat, damaging both the engine and generator. Small
compartments will also develop hot spots where there is
very little air fl ow and may cause a fi re.
PLEASE NOTE There are 3rd party companies making
enclosures for generators that have been properly engineered. The use of these 3rd party enclosures is acceptable as long as they have been certifi ed and meet current
code.
DO NOT attempt to operate at 50 cycles. These units
are designed and governed to operate at 60 cycles only.
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4150-0060706-245
UNIT CAPABILITIES
This generator is equipped with Switchless Full Power.
This feature allows the full output of the unit to be drawn
from either the 120 volt receptacles or the 240 volt receptacle without reconnecting the generator. This feature is
extermly helpful when powering larger 120 volt loads. The
diagram below represents the 5500 watt (rated output)
generator
RUNNING STARTING AMPS
HP AMPS SP CAP RI
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
The fi gures given above are for an average load such as
a blower or fan. If the electric motor is connected to a
hard starting load such as an air compressor, it will require
more starting current. If it is connected to a light load,
or no load such as a power saw, it will require less starting current. The exact requirement will also vary with the
brand or design of the motor.
Self-excited generators respond to severe overloading differently than the utility power. When overloaded,
the engine is not able to supply enough power to bring
the electric motor up to operating speed. The generator
responds with high initial starting current, but the engine
speed drops sharply. The overload may stall the engine. If
allowed to operate at very low speeds, the electric motor
starting winding will burn out in a short time. The generator winding might also be damaged.
Reference A = 120 Volt Full Power Receptacle
NEMA 5-50 (120V-50A)
Reference B & C = 120 Volt Receptacle
B - NEMA 5-20 (120V-20A)
C - NEMA 5-20 (120V-20A)
Reference D = 120/240 Volt Twistlock Receptacle
NEMA L14-30 (120/240V-30A)
With the receptacles wired in this confi guration the opera-
tor can use up to the nameplate rating of unit (5500 Watts)
using any combination of the 120 Volt receptacles and still
have the 240 volt power available. Remember no matter
what combination of 120 volt or 240 volt power utilized you
can not exceed the 5500 watt rating of the unit..
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 usually 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 of 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.
CAUTION: EQUIPMENT DAMAGE
RUNNING THE GENERATOR SET UNDER THESE
CONDITIONS MAY RESULT IN DAMAGING THE
GENERATOR STATOR AS WELL AS THE MOTOR
WINDING.
Because the heavy surge of current required for starting
motors is required for only an instant, the generator will
not be damaged if it can bring the motor up to speed in a
few seconds of time. If diffi culty is experienced in starting
motors, turn all other electrical loads off and if possible
reduce the load on the electric motor.
Motor Starting Capacity - listed below you will fi nd the mo-
tor starting capability of your engine generator set.
Generator Motor Size
Model (code “G” capacitor start)
W6010DE 3.0 HP
Trying to start a larger motor or higher code (ie. J or K)
motor may result in damage to both the generator and the
electric motor especially 120 volt motors.
54150-00
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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.
UNPACKING
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 fi ling a “concealed damage”
claim. Title to the equipment and responsibility for fi ling
claim rests with you when a generator is sent F.O.B. Shipping point. Only you can legally fi le 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 specifi cation pages in this manual to
insure that this unit fi ts 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.
1. Lubrication - Before starting the engine, fi ll the crank-
case to the proper level with a good quality oil. The recommended grade of oil and quantity of oil required is listed
below. 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 manufacturers warranty.
a. Make sure the engine is level
b. Remove the oil cap/dipstick (1) from either side
of the engine and wipe off with a clean cloth.
c. Fully re-insert oil cap/dipstick, but do not screw
in.
d. Remove oil cap/dipstick. The oil level should be
between the upper mark (2) and the lower mark
(3) on the oil cap/dipstick.
e. Fill engine with proper grade and weight of oil.
f. Fully reinsert oil cap/dipstick and hand tighten.
Over-tightening the oil cap/dipstick will damage it.
g. Never overfi ll. Overfi lling may result in white
exhaust smoke, engine overspeed or internal
damage
Oil should be change after the fi rst 50 hours of operation
and every 200 hours there after. It should be checked
daily.
YANMAR recommends A. P. I. engine service classifi ca-
tion of CD or higher oil. Always use oil with the right viscosity or the ambient temperature in which your engine is
being operated. USE the chart above when choosing you
engine oil. The YANMAR engine operators manual has
addition information on oil requirements.
2. Diesel Fuel - Always use a good grade of # 2 diesel
fuel. For cold weather, blended # 1 fuel may be used
Fuel cetane number should be 45 or higher and the fuel
MUST be low sulfur or ultra low sulfur fuel. See engine
operators manual for additional fuel recommendations
including Bio-Diesel fuel. Never use gasoline or gasohol.
Always insure that the fuel is clean and free of all impurities. Always be sure to keep the strainer in place when
fi lling the fuel tank.
6
4150-0060706-245
WARNING: FIRE
Diesel fuel is fl ammable and can be ignited to cause or
enlarge fi res when proper precautions are not taken.
Never use fuel that has been stored for an extended
period of time. Fuel will lose its volatile properties and you
will be left with a ‘gum’ / varnish residue. This varnish-like
substance will clog the fi lters, fuel lines and injectors. Old,
contaminated, stale fuel 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.
INSTALLING THE BATTERY
A customer supplied twelve-volt battery is required to
complete the installation. The battery rack on this unit is
designed to handle a U1 12 Volt battery, minimum 300
CCA. Installation of the highest CCA rated battery, within
the correct BCI group, will increase cold weather starting
performance.
CAUTION - DO NOT open or mutilate the battery.
Released electrolyte is known to be harmful to the skin
and eyes and to be very toxic.
These engine generator sets are all NEGATIVE ground.
Be very careful not to connect the battery in reverse
polarity, as this may short circuit the battery charging
system on the engine.
CAUTION – A battery presents a risk of electrical shock
and high short circuit current. The following precautions
must be observed when working with batteries.
1. Remove watches, rings and other metal objects.
2. Use tools with insulated handles.
3. Check both the battery cable ends and the battery
posts to be sure they are free of corrosion.
4. Always connect the battery positive cable fi rst and
then connect the battery negative cable. When
removing the battery cables from the battery reverse
the procedure, disconnect the negative cable fi rst and
then the positive cable.
5. Be sure all connections are tight and coat the
terminals and cable end with dialectic grease.
Installation and servicing of batteries must be performed
or supervised only by personnel knowledgeable
of batteries and the required precautions. Keep
unauthorized personnel away from batteries.
When installing or replacing batteries, use the proper
group/size starting battery. The battery should be a
Maintenance Free lead acid design. Deep cycle batteries
will not work for this application.
WARNING – The electrolyte is a diluted sulfuric acid that
is harmful to the skin and eyes. It is electrically conductive
and corrosive. The following precautions must always be
taken.
* Always wear full eye protection and protective clothing.
* Where electrolyte contacts the skin, wash off
immediately with water.
* If electrolyte contacts the eyes, fl ush thoroughly and
immediately with water and seek immediate medical
attention.
* Spilled electrolyte is to be washed down with an acid
neutralizing agent. A common practice is to use
a solution of one pound of bicarbonate of soda (baking
soda) to one gallon of water. The bicarbonate of soda
solution is to be added until the evidence of reaction,
foaming, has ceased. The resulting liquid is to be
fl ushed with water and the area dried.
DANGER – Explosive Fire Risk
* Never smoke when near batteries.
* Do not cause a fl ame or spark in the battery area.
* Always discharge static electricity from your body
before touching batteries by fi rst touching a grounded
metal surface.
SERVICING BATTERIES
CAUTION – PERSONAL DANGER
CAUTION - NEVER dispose of a battery in a fi re. The
battery is capable of exploding.
Batteries used on these units may over time lose water.
This is especially true if you are using a trickle charger to
maintain your battery. When refi lling the battery with water
use only distilled water. Tap water will shorten the service
life of the battery.
74150-00
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Never fi ll the battery above the fi ll line. Over fi lling above
the upper level line may cause the electrolyte to overfl ow,
resulting in corrosion to the engine or nearby parts.
Immediately wash off any spilled electrolyte following the
procedure above.
NOTE: Always make sure that a new battery is fully
charged before installing it on a generator set.
All connections must be clean and tight. Check the
electrolyte (fl uid) in the battery periodically to be sure it is
above the plates. Never allow the battery to remain in a
discharged condition.
1. Manual starting - Provision for manual starting is not
provided - If the battery is dead or defective, recharge or
replace it. Refer to the engine manual for additional starting, operating, and stopping instructions.
Note: The recoil can be used to assist in starting a
unit with a weak battery- but the battery must be strong
enough to pull in the fuel soleniod.
2. Electric Starting - Always keep the battery charged,
but especially during cold weather operation.
a. Turn on the fuel supply and prime the fuel line up
to the injector pump.
INSTALLING THE EXHAUST DEFLECTOR
The exhaust defl ector shown above was shipped loose
with your unit. It is installed by sliding it over the exhaust
pipe coming out of the muffl er and tightening the locking
ring. The exhaust can be direct in any direction.
OPERATION/INSTALLATION
This engine generator set consists of a Yanmar 9.9 hp diesel engine and a 6 kw generator end. The Yanmar engine
is an electric key start engine with low oil level protection
b. Operate the key switch. Position #I will turn on
the fuel solenoid and position #II will engage the
Starter. The switch is spring loaded to the #I position,
so when you release the key the switch returns to
this position.
c. The engine will start and come up to operating
speed.
d. To shut the unit off rotate the key switch to the O
position and the unit is stopped by shutting off the fuel
solenoid.
INITIAL START UP
Use the following checklist to verify the correct preparation
of the engine generator before starting.
D Engine oil, fi ll as required with correct grade and
quantity.
D Fuel level, fi ll as required with clean fresh fuel.
D Visually check unit for loose parts.
STARTING and STOPPING
The throttle control on these generators is preset and
locked to operate at 3600 RPM (nominal) with no load
speed set at 3690 RPM. Only a trained service technician
should be allowed to adjust this speed setting. See “Operating Speed” section for additional information.
This engine has one additional emergency stop lever
mounted on the side of the engine below the electric fuel
solenoid. If this lever is tripped to the stop position it must
be manually reset before the engine can be started.
To reset, move the lever (1) back to the run position. This
lever and associated mounting brackets also set your engine speed, so no adjustment should ever be made to this
speed control/emergency stop device.
8
4150-0060706-245
STARTING HINTS
Cold Weather
1. Use the proper oil for the temperature expected.
2. Use fresh winter grade fuel. Winter grade fuel is
blended to improve starting. Do not use old or straight
summer blend fuel.
CAUTION: EQUIPMENT DAMAGE
Never use ether or any other starting aides. Serious engine damage or personal injury may result from ignoring
this simple warning.
Hot Weather
1 Use the proper oil for the temperature expected.
2. Use only summer blended fuel. Using old fuel left over
from winter may cause damage to the engine or
clogging of the fuel fi lters and injection pump.
See Engine Manufacturers instructions.
OPERATING SPEED
The engine-generator must be run at the correct speed in
order to produce the proper electrical voltage and frequency.
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:
LOAD vs. OUTPUT
**************************************************************
Generator Frequency Generator voltage
Load Speed (Hz) 120V 240V
Applied* (RPM) Recpt. Recpt.
————————————————————————
None 3690 61.5 129V 258V
Half 3600 60.0 120V 240V
Full 3510 58.5 115V 230V
**************************************************************
*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 tachometer and be sure
the speed is correct.
The engine will govern itself at full speed. Intentionally
overriding the governor and operating the generator at
low 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 signifi cantly
shorten the life of light bulbs and appliances being used,
as well as possibly damaging the engine.
Output voltage should be checked periodically to ensure
continued proper operation of the generating plant and appliances. If the generator is not equipped with a voltmeter,
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.
CONNECTING THE LOADS
The engine-generators covered in this manual were designed for portable use. DO NOT OPERATE INDOORS.
The unit should be stored in a warm dry location. Move the
unit outdoors to a fl at dry location for use.
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 effi ciently 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 fi rst.
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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. See “Starting Electric Motors”
in Unit Capabilities (page 5).
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 for short periods of time with
no load connected to warm it up.
CAUTION: EQUIPMENT DAMAGE
Diesel engines should never be run for an extended
period of time with a very light load or no load on
them, it may do permanent damage to the engine if
run under these conditions.
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. The nameplate rating
can be obtained through a single receptacle as long as the
receptacle amperage rating is not exceeded.
Grounding
All units must be grounded. Drive a 3/4 or 1” copper pipe
or rod into the ground close to the engine-generator set.
The pipe must penetrate moist earth. Connect an approved ground clamp, to the pipe. Run a no. 10 Awg wire
from clamp to the generator ground lug on the “receptacle
panel”. Do not connect to a water pipe or to a ground
used by a radio system.
WIRING
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.
‘Hard Wiring’ this unit directly into a temporary construction site electrical system is NOT A SIMPLE DO-IT-YOURSELF JOB. For your safety all wiring must be done by a
qualifi ed electrician and conform to the National Electric
Code and comply with all state and local codes and regulations. Check with local authorities before proceeding.
WARNING: PERSONAL DANGER
A fully isolated, double pole double throw manual
transfer switch must be installed any time a generator is
being connected to an existing distribution system.
1. These engine generator sets are designed for portable
heavy duty commercial use. A 4 wire receptacle (2 hot, 1
ground, and 1 neutral) has been provided on the control
panel for use in temporary power applications requiring
120/240 volt power. Consult a licensed electrician for
wiring the TemPower plug and connecting it as temporary
service.
To connect these units directly to an un-powered, isolated
construction site TemPower panel, have your electrician
connect to the control panel using a 120/240 volt, four wire
twist-lock plug (L14-30P). The use of locking receptacles
and locking plugs provides the convenience of quick disconnect, for moving, while allowing non electrical workers
to safely reconnect the power. In addition they prevent
the plug from being accidentally removed by bumping or
vibration.
2. If the generator set is be connected to existing distribution system a fully isolated manual transfer switch must
be installed. The transfer switch prevents damage to the
generator and other circuit components if main line power
is restored while the generator is connected. Installing a
transfer switch also permits the use of normal fusing.
3. Many homes and construction sites are wired for at
least 60 to 100 Amp entrance service, much greater than
the capacity of these portable generators. When installing the generator at these sites, a secondary emergency
distribution panel may have to be installed, such as the
Emergency Transfer/Service (ET/S) system available
through your WINCO dealer. The emergency distribution
panel must be installed by a licensed electrician according to all applicable codes. The electrician will move the
critical circuits to be powered during the outage to the
emergency panel. Keep in mind only a limited amount
of amperage is available from the generator set. Some
circuit breakers may still have to be turned off to prevent
an overload on the generator during the initial start up.
See the nameplate on your generator for the amperage
capabilities of your unit.
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.
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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. A listing of service centers is included
with the engine operators literature package. Engine
service is very likely available from a nearby authorized
dealer or distributor. Check the yellow pages of your local
telephone directory under “Engines-Diesel” for the closest engine repair center or ask the dealer from whom you
purchased the power plant. You can also locate a engine
service center by accessing the Winco web site at www.
wincogen.com, click on Service Support and then engine
support. Page down to Yanmar engine and access their
web site and dealer locator.
114150-00
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1. CHANGING THE OIL
Change the oil as recommended in the engine operators
manual. It is usually required to change oil after the fi rst 50
hours of operation and every 200 hours thereafter under
normal operating conditions. If the engine is not used frequently, change the oil every 12 months, regardless of the
actual number of hours of operation.
Before refi lling the engine with oil, the oil fi lter must be
remove and cleaned or replaced.
a. Remove the oil fi lter retaining bolt (1).
b. Pull the oil fi lter cap (2) out and remove the oil
fi lter (3).
c. Clean the oil fi lter or replace if damaged.
d. Install the oil fi lter.
e. Make sure the oil fi lter cap is fully seated (2).
f. Install and tighten the oil fi lter retaining bolt (1).
a. Make sure the unit is level.
b. Start the engine and bring it up to operating tem-
perature.
c. Stop the engine.
d. Remove the oil cap/dipstick (1) to allow the en-
gine to drain more easily.
e. Position a container under the engine to collect
the old oil.
f. Remove the drain plug located on the bottom of
the cylinder block (either side) (2). Allow the oil to
drain completely.
g. Refi ll the engine with new oil. Run the engine for
about 5 minutes checking for any oil leaks. After the
engine is warm, shut it off and let it sit for 10 minutes.
h. Recheck the oil level in the engine and refi ll as
required.
Replacement engine oil fi lter part number 114250-35070
or 114299-35110.
2. Servicing Air Cleaners
Check the engine air fi ler check and cleaned after the
fi rst 100 hour of operation and every 200 hour after that.
Consult engine operators manual for additional recommendations. Service more often if it isvery dirty. Replace
the cartridge using only original equipment parts available
at any engine service center.
g. After all the oil has been drained from the engine,
install the drain plug (2) and tighten to 14-17 ft. lbs.
h. Dispose of used oil properly.
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4150-0060706-245
a. Remove the wing nut (1).
b. Remove the air cleaner cover (2).
c. Remove the wing nut (3).
d. Remove the air cleaner element (4) and the outer
foam element (5).
e. Blow air through both elements using 42-71 psi
compressed air to remove the particulates. Use the
lowest possible air pressure to remove the dust without damaging the elements.
f. If either element is damaged replace both of them
(they are not sold individually). Replacement element
part number is 114210-12590.
g. Clean the inside of the air cleaner cover (2).
h. Install the air cleaner element (4) into the air
cleaner case. Check accurately that the air fi lter car-
tridge is properly fi tted and aligned with its own seat of
the air fi lter box.
i. Install the wing nut (3) and hand tighten. Overtightening the wing nut will damage the air cleaner
assembly.
j. Slide the outer foam element (5) over the air
cleaner element (4).
k. Install the air cleaner cover (2). Install the wing
nut (1) and hand tighten. Overtightening the wing nut
will damage the air cleaner assembly.
LOW OIL LEVEL SHUTDOWN SYSTEM
This low oil warning system will automatically stop the
engine before the oil pressure reaches an operational danger point. This feature is designed to prevent costly repairs
and downtime.
Use of the oil safety shutdown 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.
GENERATOR CARE
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 suffi cient 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 winding. 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 qualifi ed electrical technician. USE
ONLY FACTORY APPROVED 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 dangerous both to the operator and 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.
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 fi ns and
fl ywheel. Clean more often if necessary. Failure to keep
these areas clean may cause overheating and permanent
damage to the unit.
2. Periodically clean muffl er area to remove all grass, dirt
and combustible debris to prevent a fi re.
3. On engine muffl ers equipped with spark arresters, the
spark arrester must be removed every 50 hours for cleaning and inspection. Replace if damaged.
134150-00
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TROUBLESHOOTING TABLE
GENERATOR SPECIFICATIONS
—————————————————————————-PROBLEM (SYMPTOMS) POSSIBLE CAUSES
————————————————————————-—
Won’t Start (electric) *Fouled fuel injector.
*Out of fuel.
*Dead battery.
*Defective start switch.
*Defective start solenoid.
*Defective fuel solenoid.
*Defective fuel pump.
*Defective control relay
—————————————————————————
Voltage too low *Engine speed is too low.
*Generator overloaded.
*Defective stator.
*Defective rotor (fi eld).
*Defective capacitor.
—————————————————————————
Circuit Breaker Trips *Defective load.
*Defective receptacle.
*Defective circuit breaker
—————————————————————————
Voltage too high *Engine speed is too high.
—————————————————————————
Generator overheating *Overloaded.
*Insuffi cient ventilation.
—————————————————————————
No output voltage *Short in load.
*Broken or loose wire.
*Defective receptacle.
*No residual magnetism in
generator.
*Defective stator.
*Defective rotor (fi eld).
*Shorted capacitor.
*Defective diode.
————————————————————————----
Generator manufacturer WINCO Inc.
Part number 15532-009
Rotor part number 15522-002
Rotor resistance 11.5 Ohms
Stator part number 15528-002
Stator resistance G1-N 0.11 Ohms
Stator resistance G3-N 0.18 Ohms
“Q” winding resistance 0.80 Ohms
Rectifi er part number 91452-000
ENGINE SPECIFICATIONS
Engine manufacturer Yanmar Diesel
Engine model number L100V6EJ1CHAS1
Air fi lter & pre-cleaner 114210-12590
Oil fi lter 1 14250-35070
or 114299-35110
Oil capacity 52 - 54 oz.
14
4150-0060706-245
RECEPTACLE PANEL WIRING DIAGRAM
ENGINE WIRING HARNESS
154150-00
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WINCO, Incorporated warrants to the original purchaser for 24 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 24 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 24 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. Engines are covered exclusively by the warranties of their
respective manufacturers, see enclosed warranties.
WINCO does not warrant 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.
This warranty does not include travel time, mileage, or labor for removal or reinstallation of
WINCO product from its application.
225 SOUTH CORDOVA
LE CENTER, MN 56057
507-357-6831
16
4150-0060706-245
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