Winco W6010DEG User Manual

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 # ________________________

4150-0060706-245

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.

34150-00

60706-245

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.

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

60706-245

+ 11 hidden pages