W6010DE/I, J & K
GENERATOR
INSTALLATION AND
OPERATORS
WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057
MANUAL
SALES DEPT. 507-357-6821
SERVICE DEPT. 507-357-6831
www.wincogen.com
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS 3
SPECIFICATIONS 3
GENERATOR
ENGINE
TESTING POLICY 3
SAFETY 4
IMPORTANT SAFETY INSTRUCTIONS
ANSI SAFETY DEFINITIONS
INTRODUCTION 5
INTENDED USES
RESTRICTED USES
UNIT CAPABILITIES 5
GENERATOR CONNECTIONS
STARTING ELECTRIC MOTORS
PREPARING THE UNIT 6
UNPACKING
LUBRICATION
OIL RECOMMENDATIONS
DIESEL FUEL
BATTERY INSTALLATION 7
LIFTING EYE INSTALLATION 8
SERVICING BATTERIES
BATTERY CHARGING
INITIAL START UP 9
BASIC OPERATION
STARTING HINTS
STOPPING
CONNECTING THE LOADS 10
APPLYING THE LOADS
GROUNDING
WIRING
ENGINE CARE 12
MAINTENANCE SCHEDULE
CHANGING THE OIL
CHECKING THE OIL LEVEL
AIR FILTER
GENERATOR CARE 13
EXERCISING THE GENERATOR
GENERATOR MAINTENANCE
CLEANING
TROUBLESHOOTING 14
CONTROL PANEL WIRING DIAGRAM 15
36 MONTH LIMITED WARRANTY 16
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COPY YOUR MODEL AND SERIAL NUMBER HERE
No other WINCO generator has the same serial number as yours.
If you should ever need to contact us on this unit, it will help us to
respond to your needs faster.
MODEL __________________________________________________
SERIAL NUMBER _________________________________________
PURCHASE DATE _________________________________________
DEALER NAME ___________________________________________
DEALER PHONE # ________________________________________
SAVE THESE INSTRUCTIONS
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.
SPECIFICATIONS
GENERATOR
Model W6010DE/I, J, & K
Starting Watts 6,010
Running Watts 5,160
Volts 120/240
Starting Amps 50/25
Running Amps 43/21.5
Generator Manufacturer Mecc Alte Spa
Generator Model Number S20FS-160/A
Part Number 351836-1
Rotor Resistance 6.57 Ohms
Stator Resistance 0.124 Ohms
Cap Winding Resistance 0.60 Ohms
Capacitors 31.5 mF
Capacitor Part Number 300323-112
ENGINE
Engine Manufacturer Kohler
Engine Model Number KD440
Fuel Type Diesel
Oil Capacity 51.2 oz. (1.6 qts)
USING THIS 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.
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 specied by the manufacturer of applicable engines.
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SAFETY
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important information that should be understood
and followed before the installation, operation and maintenance of the
generator. Failure to follow the safety instructions in this manual could
result in serious injury or death. Keep this manual available for future
reference.
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 be used to alert
against unsafe practices.
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 re hazard.
C. Carefully clean up any diesel or oil spills before starting the
unit.
5.SERVICING EQUIPMENT -
All service, including the installation or replacement of service parts,
should be performed only by a qualied technician.
A. Use only factory approved repair parts.
B. Do not work on this equipment fatigued.
C. Use extreme caution when working on electrical components.
High output voltages from this equipment can cause serious
injury or death.
D. Installing a generator is not a “do-it-yourself” project. Consult
a qualied, licensed electrician or contractor. The installation
must comply with all national, state, and local codes.
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 plugs and extension cords.
F. Be sure the unit is properly grounded to an external ground rod
driven into the earth.
2. FIRE HAZARD -
A. Keep a re extinguisher nearby and know its proper use. Fire
extinguishers rated ABC by NFPA are appropriate.
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.
B. Keep your neighbors in mind when permanently installing this
equipment.
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INTRODUCTION
UNIT CAPABILITIES
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). 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.
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 ow.
RESTRICTED USES
DO NOT operate generator where it could get wet or have pooling
water near it. This generator is NOT weatherproof. Failing to keep
generator in a dry area may cause an electrical shock, resulting in
injury or death.
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 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
ow and may cause a 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 engineered
and meet applicable code.
DO NOT attempt to operate at 50 cycles. These units are designed and
governed to operate at 60 cycles only.
GENERATOR CONNECTIONS
W6010DE: 120 Volt and 240 Volt receptacles are provided for
connection to various loads. The following diagram represents this
5,160 watt (rated output) generator. A & B represent the 120 volt output
legs of this generator. Up to 2,580 watts at 120 volts (43 Amps) can be
drawn from the receptacles attached to either A or B output legs. This
generator is capable of producing 21.5 Amps of 240 volt current at C.
Check the appliance or tool nameplates for the current and voltage to
insure compatibility. Remember that power taken from C reduces the
power available equally at both A and B and vice versa.
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 starting current as
running current. Capacitor motors are easier to start and usually require
2 to 4 times as much starting current as running current. Repulsion
Induction motors are the easiest to start and require only 1 1/2 to 2 1/2
times as much starting as running current.
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 following chart shows
the approximate current required to start and run various types
and sizes of 120 Volt 60 cycle electric motors under average load
conditions.
STARTING AMPS
Running
HP
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 Not Made 26 to 52 20 to 33
Amps
Split Phase
Motor
Capacitor
Motor
Repulsion
Induction Motor
The gures given in the previous chart 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.
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Self-exciting generators respond to severe overloading differently than
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 may also be damaged.
CAUTION: EQUIPMENT DAMAGE
Running the generator set under these conditions may result in
damage to the generator stator as well as the motor winding.
PREPARING THE UNIT
UNPACKING
CAUTION: EQUIPMENT DAMAGE
Always check oil level prior to use. Failure to maintain the engine oil at
the proper level will result in serious engine damage.
When you unpack your engine-generator set be sure to remove all the
information sheets and manuals from the carton.
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 difculty is experienced
in starting motors, turn all other electrical loads off and if possible
reduce the load on the electric motor.
Motor starting capacity - 2HP code ‘G’ capacitor start engine.
Trying to start a larger motor or higher code motor, i.e. ‘J’ or ‘K’,
may result in damage to both the generator and the electric motor,
especially 120 Volt motors.
1. As you receive your unit, it is critical to check it for any damage. If
any damage is noted, it is always easiest to refuse the shipment and
let WINCO take care of the freight claim. If you sign for the unit, the
transfer of the ownership requires that you le the freight claim
2. Before proceeding with the preparations of your new generator
for operation, take a couple of minutes to ensure the unit you have
received is the correct model and review the specication pages in this
manual to ensure that this unit meets your job requirements.
LUBRICATION
CAUTION: EQUIPMENT DAMAGE
Failure to maintain the engine oil at the proper level will result in
serious engine damage.
Before starting the engine, verify the crankcase is lled to the proper
level with a good quality oil. The recommended grade oil and quantity
of oil required is listed in the engine operator’s manual and under the
service tab in this manual. This unit was shipped with oil in it. The
engine normally holds 1.6 quarts (51.2 oz.) of oil. Use the dipstick to
ensure that you have the proper oil level in the crankcase. The full oil
level mark on the dipstick is depicted in the following image.
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Oil is added to the engine by removing the oil cap and adding oil at
this point. After lling the crankcase to the proper level, be sure you
properly tighten the oil ll cap. NOTE: This engine generator must be
on a level surface before you check or add oil to the system.
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 not covered by the
generator or engine manufacturer’s warranty.
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OIL RECOMMENDATIONS
BATTERY INSTALLATION
Outdoor temperatures determine the proper oil viscosity for the
engines. Use the chart to select the best viscosity for the outdoor
temperature range expected.
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 BioDiesel fuel. Never use gasoline or gasohol. Always ensure that the fuel
is clean and free of all impurities. Always be sure to keep the strainer in
place when lling the fuel tank.
WARNING: FIRE DANGER
Diesel fuel is ammable and can be ignited, causing or enlarging 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’ or
varnish residue. This varnish-like substance will clog the 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.
This engine generator set is shipped with a battery tie down for
customer installation.
A customer supplied 12 Volt battery, BCI group U1 rated at 300 CCA
or larger is recommended for this electric start engine-generator set.
Follow the battery manufacturers recommendations for servicing and
charging prior to use. Connect the battery to the electric start system
using the cables provided.
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 proper group/size starting
battery. The battery should be a maintenance free lead acidic design.
Deep cycle batteries will NOT work for this application.
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 rst. Then connect the negative battery cable to the “Bat-”
terminal. Make sure all connections are clean an tight. Reverse the
sequence when disconnecting, disconnect the negative cable rst.
These engines produce enough direct current to keep the battery
charged under normal operating conditions, but were not intended to
be used as a battery charger.
WARNING: PERSONAL INJURY
Lead acid batteries produce explosive hydrogen gas when charging.
Keep sparks, ames, 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, ush well with water. For
contact with the eyes, get immediate medical attention.
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.
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.
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5
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 rst and then connect the
battery negative cable. When removing the battery cables from
the battery reverse the procedure, disconnect the negative cable
rst and then the positive cable.
5. Be sure all connections are tight and coat the terminals and cable
end with dialectic grease.
WARNING:
The electrolyte is diluted sulfuric acid that is harmful to the skin
and eyes. It is electrically conductive and corrosive. The following
precautions must be always be taken.
LIFTING EYE INSTALLATION
1. Always wear full eye protection and protective clothing.
2. Where electrolyte contacts skin, wash off immediately with water.
3. If electrolyte contacts the eyes, ush thoroughly and immediately
with water and seek immediate medical attention.
4. 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
ushed water and the area dried.
DANGER: EXPLOSIVE FIRE RISK
Never smoke when near batteries. Do not cause a ame or spark in the
battery area. Always discharge static electricity from your body before
touching batteries by rst touching a ground metal surface.
SERVICING BATTERIES
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 relling the battery with water use only distilled water.
Tap water will shorten the service life of the battery.
Never ll the battery above the ll line. Overlling above the upper level
line may cause the electrolyte to overow, resulting in corrosion to the
engine or nearby parts. Immediately wash off any spilled electrolyte
following the procedure above.
In the bag of parts for the lifting eye, ensure all of the required materials
are included: 2 qty - 5/16-18 x 2.25 button head socket screws (#1); 4
qty - washers (#2); 2 qty - .3125-18 ange (#3); 1 qty - lifting eye (#4).
1. Place the bottom of the lifting eye (#4) under the cross bar (#5).
CAUTION: EQUIPMENT DAMAGE
Ensure the lifting eye is NOT installed on top of the cross bar.
2. In each hole, place 1 washer (#2) between the top of the cross bar
and the button head screw (#1). Place 1 washer (#2) between the base
of the lifting eye and ange (#3). Secure the screw and ange, ensuring
it is torqued.
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 (uid) in
the battery periodically to be sure it is above the plates. Never allow the
battery to remain in a discharged condition.
BATTERY CHARGING
Units have a small ywheel charger built into the engine ywheel
assembly for recharging the starting battery. This ywheel charger
generates a small AC current that passes through a diode assembly
to produce DC charging current of about 1 to 3 Amps. This circuit is
not designed to be used as a battery charging circuit to recharge dead
batteries.
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INITIAL START UP
STARTING HINTS
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.
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 and run. This engine will not
start without a battery. The fuel shut-off solenoid requires 12V DC to
operate.
BASIC OPERATION
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 minimizes the drain on the battery
and improves the possibility of starting under such adverse conditions.
Always keep the battery charged, especially during cold weather
operation.
1. Check oil level, rell as needed.
2. Turn on the fuel supply. Lever pointing up is on, lever
pointing down is off.
3. Turn key to 1st position (Ref A).
A
1. COLD WEATHER
Use the proper oil for the temperature expected.
CAUTION: EQUIPMENT DAMAGE
Never use ether or any other starting aides. Serious engine damage or
personal injury may result from ignoring this simple warning.
2. HOT WEATHER
Use the proper oil for the temperature expected.
STOPPING
1. Move the key to the “OFF” position.
2. Turn off the fuel supply valve.
3. Before extended storage (over 30 days) certain precautions must be
taken to ensure the fuel doesn’t deteriorate and clog the fuel system.
NOTE: Running the engine to use up the fuel in the lines and
carburetor will still leave a small amount of fuel in carburetor. It is best
extended storage to treat the fuel before draining.
D. While the engine is warm, drain the oil and rell with fresh oil.
E. Clean dirt and chaff from cylinder, cylinder head ns, blower
housing, screen, and mufer areas.
F. Store in a clean and dry area.
OPERATING SPEED
The engine-generator must be run at the correct speed in order to
produce the proper electrical voltage and frequency.
4. Turn key to the 2nd position - starting (Ref B).
B
5. Return key to 1st position when engine is running (Ref A).
A
NOTE: While the engine is running, all warning lights should be off
except the OK light.
CAUTION: EQUIPMENT DAMAGE
The output voltage should be checked to ensure 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 vary slightly, the normal voltage
and frequency of the engine-generator described in this manual are
approximately as follows, under varying loads:
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LOAD vs. OUTPUT
Generator
Load
None 3690 61.5 125V 258V
Half 3600 60.0 120V 240V
Full 3510 58.5 115V 230V
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.
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 signicantly
shorten the life of light bulbs and appliances being used, as well as
possibly damaging the engine.
CAUTION: EQUIPMENT DAMAGE
SPEED ADJUSTMENTS SHOULD ONLY BE MADE BY A QUALIFIED
SERVICE TECH. Whenever making any speed adjustments, check the
unit with a voltmeter and a frequency meter or a tachometer and be
sure the voltage and speed are correct.
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.
Speed
(RPM)
Frequency
(Hz)
120V
Recpt
Voltage
240V
Recpt
CONNECTING THE LOADS
The engine-generator covered in this manual was designed for portable
use. Do NOT operate indoors. The unit should be stored in a warm, dry
location. Move the unit outdoors to a at dry location for use.
APPLYING THE LOADS
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 efciently 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 rst.
CAUTION: EQUIPMENT OVERLOAD
Keep the generator load within in 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
the Unit Capabilities.
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.
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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 receptacles 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 the 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. The engine-generators covered in this manual were
designed primarily for portable use. If you are connecting into a building
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wiring system that is already grounded using the 14-30 4 wire plug, you
do not have to ground the unit.
WARNING: PERSONAL DANGER
DO NOT OPERATE THIS GENERATOR INDOORS, The unit should
be stored in a warm, dry location. During a power outage, move the
unit outdoors to a at, dry location such as a driveway or sidewalk.
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 qualied electrician and conform to the National
Electric Code and comply with all state/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.
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 a[[lied 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.
1. These engine-generator sets are designed for portable heavy duty
commercial use. Receptacles are provided on the control panel to
permit 120 and 240 Volt portable appliances and tools to be plugged
directly into them. Please note that the 3-wire 240 Volt receptacle(s) on
these units are designed to power only 240 Volt tools. There are two
hot leads and a ground wire, but no neutral connection, in the 3-wire
240Volt receptacle. A 4-wire receptacle (two hot, one ground, and one
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, 4-wire twist-lock plug (L14-30P).
2. If the generator set is connected to an existing distribution system,
a fully isolated manual transfer switch must be installed. The transfer
switch prevents damage to the generator and the other circuit
components if main line power is restored while the generator is
connected. This generator is GFCI protected, so the transfer switch
needs to be GFCI compatible. If the transfer switch is not GFCI
compatible, the breaker on the generator will always trip.
3. Many homes and construction sites are wired for at least 60 to 100
Amp entrance service, much greater than the capacity of this portable
generator. When installing the generator at these sites, a secondary
emergency distribution panel may have to be installed. 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.
11REV C
OPM-107
ENGINE CARE
MAINTENANCE SCHEDULE
C. Replace oil drain plug.
D. Remove oil ll cap.
Daily or
Every 10 hrs
Check Oil
Check oil lter
Check dry air cleaner
Fuel tank cleaning
Clean cooling ns
Replace engine oil
Replace oil lter
Replace fuel lter
Set and clean injectors
Rocker arm adjustment
* If engine use is infrequent; every year
**If engine use is infrequent; every 2 years
If you are using oil of a quality lower than the recommended one then
you will have to replace it every 150 hours
ü
ü
ü
Every
250* hrs
ü
ü
Every
500** hrs
ü
ü
ü
ü
ü
E. Fill to correct level with oil. Reinstall cap.
F. Remove the oil lter and dispose of it properly.
If major engine service or repair is required, contact an authorized
engine service center. The manufacturer of these engines has
established an excellent world-wide engine service organization.
Engine service is very likely available from a nearby authorized dealer
or distributor.
CHANGING THE OIL
Change the oil after the rst 50 hours of operation and yearly or 250
hours thereafter under normal operating conditions.
A. Change oil while the engine is still warm, the oil will ow more
freely.
B. Remove the oil drain bolt at base of the engine and drain the oil
into an approved container.
NOTE: This engine requires 51.2 oz. (1.6 qts) of oil if it is completely
drained. Use caution when relling the engine as some residual oil may
have remained in the engine. Always use the dipstick when lling the
engine with oil to prevent overlling.
H. Replace oil lter and lter plug.
I. Start the engine and warm it up.
J . After warming up the engine, recheck the oil level and rell as
necessary to bring it to the proper level.
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 plug before
removing. Be sure the oil level is maintained. Fill to the “FULL” mark on
the dipstick.
AIR FILTER
drain bolt
OPM-107
Clean the ltering element with air blast. Air must be blown from inside
to outside the cartridge at a distance of at least 6 inches from the
paper. Lightly and repeatedly tap the element on a hard surface to
eliminate all excess dirt.
12
REV C
WARNING: EQUIPMENT DAMAGE
Never start or run the engine with the air lter removed.
GENERATOR CARE
A. Remove the cover.
B. Remove the wing nut.
C. Remove the lter element.
D. Check the rubber seal is undamaged.
Proper care and maintenance of the generator is necessary to ensure a
long trouble free life.
EXERCISING THE GENERATOR
The generator should be operated every three to four weeks. It should
be operated for a period of time sufcient 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 ensure that the set is operating properly
should it be needed in an emergency.
GENERATOR MAINTENANCE
Any major generator service, including the installation or replacement
of parts, should be performed only by a qualied electrical service
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 both
dangerous to the operator and destructive to the equipment.
E. To loosen debris, gently tap the air lter on a hard surface. If the
air lter is excessively dirty replace with a new lter. You can use
pressurized air (not to exceed 30 psi) to clean the lter. Always
blow the compressed air from inside to the outside.
F. Clean the dirt from the inside of the air cleaner body and cover.
Reinstall the lter in housing. Tighten the wing nut securely.
G. Install and secure the cover.
H. Remove and clean the pre-lter if clogged.
CLEANING
Remove dirt and debris with a cloth or brush. DO NOT use high
pressure spray to clean either the engine or the generator. The 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 ensure proper cooling. At least yearly, remove
the blower housing on the engine and clean the chaff and dirt out of
the engine cooling ns and y wheel. Clean more often if necessary.
Failure to keep these areas clean may cause overheating and
permanent damage to the unit.
2. Periodically clean mufer area to remove all grass, dirt, and
combustible debris to prevent a re.
3. On engine mufers equipped with spark arresters, the spark arrester
must be removed every 50 hours for cleaning and inspection. Replace
if damaged.
13REV C
OPM-107
TROUBLESHOOTING
Problem Possible Causes
Won’t start Low oil level
Out of fuel
Start switch in OFF position
Fuel Valve turned off
Plugged fuel lter
Blown fuse in key switch
Battery required to open solenoid
Voltage too low Engine speed is too low
Generator overloaded
Defective stator
Defective rotor (eld)
Defective capacitor
Circuit breaker trips Defective load
Defective receptacle
Excessive load
GFCI type of load i.e. a building with
bonded neutral
Voltage too high Engine speed is too high
Generator overheating Overloaded
Insufcient ventilation
No output voltage Short in load (disconnect)
Tripped or defective circuit breaker
Broken or loose wire
Defective receptacle
No residual magnetism (in generator)
Defective stator
Defective rotor (eld)
Shorted capacitor
Shorted diodes on rotor
GFCI receptacle tripped
OPM-107
14
REV C
CONTROL PANEL WIRING DIAGRAM
0867%(5(029((':+(1&211(&7,1*72(;,67,1*%8,/',1*:,5,1*
0867%(,167$//(')25$//67$1'$/21(3257$%/(86(
$0392/7
1(0$)25
$036,1*/(32/(
386+%87721
&,5&8,7%5($.(56
*
72
*
*(1(5$725
*
$03*)&,32/(
0$,1/,1(&,5&8,7%5($.(5
1
1
*
*
*
*)&,&,5&8,7%5($.(5
1(875$/:,5(
*
*
*1'
$0392/7
1(0$/
1
1
$0392/7
1(0$/
*
1
*1'
1
1(0$
*
*
*
**
*1'
*1'
1(875$/72*5281'-803(5
15REV C
OPM-107
36 MONTH LIMITED WARRANTY
WINCO warrants to the original purchaser for 36 months or 1000 hours, whichever occurs rst, 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 and applicable codes.
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 the warranty period, to your nearest WINCO Authorized Service Center or to WINCO in Le Center Minnesota.
Duration Consumer, Commercial and Rental
Parts & Labor: 24 Months
Parts Only: 24-36 Months
EXCLUSIONS:
• Normal maintenance consumables or labor.
• This warranty does not cover travel time, mileage or labor for removal or re-installation of WINCO product from
its application.
• Normal wear and tear.
• Costs of rental equipment.
• WINCO does not warrant engines. Engines are covered exclusively by the warranties of their respective
manufacturers.
• WINCO does not warrant component parts that are warranted by their respective manufacturers.
• WINCO does not warrant modications or alterations which were not made by WINCO.
• WINCO does not warrant products which have been subjected to misuse and/or negligence or have been
involved in an accident. Proof of proper maintenance must be furnished upon request.
THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE DESCRIBED HEREIN. THERE ARE NO OTHER WARRANTIES,
EXPRESSED OR IMPLIED, OR OTHERWISE CREATED, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY, OR
WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE.
WINCO is liable for the repair or replacement of the product only and is not liable for incidental or consequential damages as permitted by your
state. This warranty gives you specic legal rights which may vary from state to state.
WINCO INC. • 225 S. CORDOVA AVE. • LE CENTER, MN 56057 • 507-357-6821
OPM-107
16
REV C
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