Winco WL22000VE/A Installation And Operator's Manual

WL22000VE/A

GENERATOR

INSTALLATION AND

OPERATORS

MANUAL

WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057 507-357-6821

SERVICE DEPT. 507-357-6831

www.wincogen.com

TABLE OF CONTENTS

SAVE THESE INSTRUCTIONS 2
SPECIFICATIONS 3

GENERATOR
ENGINE

TESTING POLICY 3
SAFETY 4

IMPORTANT SAFETY INSTRUCTIONS
CALIFORNIA PROPOSITION 65
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
OIL ALERT SYSTEM
GASOLINE
BATTERY INSTALLATION
BATTERY CHARGING
LIFTING EYE INSTALLATION
OPTIONAL DOLLY KIT

INITIAL START UP 8

BASIC OPERATION
STARTING HINTS

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.

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.

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 respond
to your needs faster.

MODEL __________________________________________________

SERIAL NUMBER _________________________________________

PURCHASE DATE _________________________________________

DEALER NAME ___________________________________________

CONNECTING THE LOADS 9

APPLYING THE LOADS
GROUNDING
WIRING

YOURGEN 10
ENGINE CARE 12

MAINTENANCE SCHEDULE
CHECKING THE OIL LEVEL
CHANGING THE OIL
DUAL ELEMENT AIR FILTER
SPARK PLUG
CARBON CANISTER

VOLTAGE REGULATOR WIRING 13
GENERATOR CARE 14

EXERCISING THE GENERATOR
GENERATOR MAINTENANCE
CLEANING

TROUBLESHOOTING 14
RECEPTACLE WIRING DIAGRAM 15
36 MONTH LIMITED WARRANTY 16

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DEALER PHONE # ________________________________________

2

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SPECIFICATIONS

TESTING POLICY

GENERATOR

Model WL22000E/A
Surge Watts 22,000
Continuous Watts 19,000
Volts 120/240
Amps 166.6/83.3
Generator Manufacturer Mecc Alte
Generator Model Number AME3
Part Number 16346-031

Rotor Resistance 9.743 Ohms @ 20°C
Stator Resistance 0.366 Ohms @ 20°C
Exciter Rotor Resistance 1.453 Ohms @ 20°C
Exciter Stator Resistance 15.71 Ohms @ 20°C
AVR DSR

ENGINE

Engine Manufacturer Briggs & Stratton
Engine Model Number 613477-0238-J1
Spark Plugs 792015
Air Filter 692519
Pre-Cleaner Filter 692520
Oil Filter 842921
Fuel Filter 845125
Spark Plug Gap 0.030 in
Intake Valve Clearance 0.004 - 0.006 in
Exhaust Valve Clearance 0.007 - 0.009 in
Oil Capacity 73.6 oz (2.3 qts)

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 specied by the manufacturer of applicable engines.

3REV A

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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.

CALIFORNIA PROPOSITION 65

WARNING: This product contains crude oil, gasoline,
diesel fuel and other petroleum products, Antifreeze to
which can expose you to chemicals including toluene

and benzene, Ethylene glycol (ingested) which are
known to the State of California to cause cancer, birth defects or other
reproductive harm and developmental issues.
For more information go to www.P65Warning.ca.gov.

ANSI SAFETY DEFINITIONS

2. FIRE HAZARD -

A. Keep a re extinguisher nearby and know its proper use. Fire

extinguishers rated ABC by NFPA are appropriate.

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,

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 permanently installing this
equipment.

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.

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 or your application.

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 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 qualied technician.

A. Use only factory approved repair parts.
B. Do not work on this equipment when 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 qualied, licensed electrician or contractor. The installation

must comply with all national, state, and local codes.

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4

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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 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 certi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.

GENERATOR CONNECTIONS

WL22000VE: 120 Volt and 240 Volt receptacles are provided for
connection to various loads. The following diagram represents this
19,000 watt (rated output) generator. A & B represent the 120 volt
output legs of this generator. Up to 9500 watts at 120 volts (79 Amps)
can be drawn from the receptacles attached to either A or B output
legs. This generator is capable of producing 79 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.

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-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 might 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.

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 difculty is experienced

in starting motors, turn all other electrical loads off and if possible
reduce the load on the electric motor.

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