DTI Dyna Technology WINPOWER DE20I4 User manual



INSTALLATION AND
OPERATIONS MANUAL
DE20I4
DE30I4
DE45I4
DE65I4
INSTALLATION AND
OPERATIONS MANUAL
MODELS:
DE20I4
DE30I4
DE45I4
DE65I4
DSE702 START MODULE
AND MANUAL KEY START

SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be fol-
lowed during installation and maintenance of the generator and
batteries.
Read and understand all instructions in the manual before starting
and operating the generator set.
USING THIS MANUAL
Congratulations on your choice of a Winpower generator set. You
have selected a high-quality, precision-engineered generator set
designed and tested to give you years of satisfactory standby
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 “Things To
Check” near the end of this manual. The warranty listed in this
manual describes what you can expect from WINPOWER should
you need service assistance in the future.
COPY YOUR MODEL AND SERIAL NUMBER HERE
No other WINPOWER 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________________________________
SERIAL NUMBER________________________
‘M” Spec. ______________________________
PURCHASE DATE_______________________
DEALER_______________________________
TABLE OF CONTENTS
INTRODUCTION i
GUIDE TO PRODUCT SAFETY 1
BASIC INFORMATION 2
Specication Table 2
Description 3
DSE702 Description 3
RECEIVING THE GENERATOR 3
Unpacking the unit 4
ENGINE GENERATOR INSTALLATION
Installation 4
Engine Generator Set Mounting 5
Fuel Installation 5
Lubrication 6
Coolant 6
Battery Installation 6
AC Electrical Connections 7
AC Wiring Diagram 8
Engine Control Layout 9
DSE702 Control 10
INITIAL START-UP DSE702 10
Manual Key Start Control 11
Initial Start-Up Manual Key Start 11
TROUBLESHOOTING INFORMATION 12
LAYOUT DIAGRAMS
DE20I4 13
DE30I4 13
DE45I4 14
DE65I4 14
DC SCHEMATIC - WIRING DIAGRAM DSE702
DE20I4 & DE30I4 DSE 702 16
DE45I4 & DE65I4 DSE 702 17
DC SCHEMATIC - WIRING DIAGRAM
MANUAL KEY START
DE20I4 & DE30I4 18
DE45I4 & DE65I4 19
AC WIRING - THREE PHASE
277/480 Volt 20
120/208 Volt 20
120/240 Volt 21
AC WIRING - SINGLE PHASE
120/240 Volt 21
12 MONTH WARRANTY 22
PROPER USE AND INSTALLATION
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
* Wired by a qualied electrician
* Operated only for its designed purposes
* Used only by operators who understand its operation
* Properly maintained

2080-10 60708-151
1
IMPORTANT SAFETY
INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that
should be followed during installation and maintenance
of the generator and batteries.
Read and understand all instructions in the manual
before starting and operating the generator set.
This engine generator set has been designed and
manufactured to allow safe, reliable performance. Poor
maintenance, improper or careless use can result in potential
deadly hazards; from electrical shock, exhaust gas asphyxiation,
or re. Please read all safety instructions carefully before
installation or use. Keep these instructions handy for future
reference. Take special note and follow all warnings on the unit
labels and in the manuals.
ANSI SAFETY DEFINITIONS
************************************************************
DANGER:
DANGER indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury. This signal word
is to be limited to the most extreme situations.
***********************************************************
************************************************************
WARNING:
WARNING indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
***********************************************************
***********************************************************
CAUTION:
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be
used to alert against unsafe practices.
************************************************************
NOTE:
CAUTION is also used on the unit labels and in this manual
to indicate a situation that could result in serious damage or
destruction of the equipment and possible personal injury.
1. 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 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 presents a hazard of possible
explosion and/or re.
a. Do not smoke or use open ame near the generator
set.
b. 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 diesel
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.
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 or oors).
4. NOISE HAZARD - Excessive noise is not only tiring, but
continual exposure can lead to loss of hearing.
a. Use hearing protection equipment when working
around this equipment for long periods of time.
b. Keep your neighbors in mind when permanently install-
ing 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 material that could create
potential re hazards.
c. Carefully wipe up any fuel or oil spills before starting the
unit.
d. Never allow leaves or other ammable material to build
up around the engine exhaust area.
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. Never remove the protective guards, cover, or recep-
tacle panels while the engine is running.
d. Use extreme caution when working on electrical compo-
nents. High output voltages from this equipment can
cause serious injury or death.
e. Always avoid hot mufers, exhaust manifolds, and
engine parts. They all can cause severe burns instantly.
f. Installing a generator set 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.
g. Always make sure unit is disabled before placing your
hands anywhere near the fan, belts, alternator or water
hoses.

60708-151 2080-10
2
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 outpdut of the generators 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 the applicable engines.
SPECIFICATIONS
MODEL DE20I4-A DE20I4-D DE20I4-J DE20I4-L
Generator
Wattage 20000 20000 20000 20000
Volts 120/240 120/208 120/240 277/480
Phase single three three three
PF 1.0 .80 .80 .80
AMPs 83.0 69.5 60.2 30.1
Hertz 60 60 60 60
Engine
Model Isuzu 4LE1
Starting System 12 Volt Manual Start
Mufer Standard
Stop System Key/Emergency
Fuel Consumption (full Load) 1.8 Gal/hour
Owner Must Provide
Fuel ASTM D-975 - 1D or 2D
EN590 or equivalent
See engine manual for additional
fuel types & specication
Oil Type 10W-30 CC/CD
See engine manual for additional oil information.
Oil Capacity 8.6 Quarts
Cooling System 50/50 Mix
MODEL DE30I4-A DE30I4-D DE30I4-J DE30I4-L
Generator
Wattage 30000 30000 30000 30000
Volts 120/240 120/208 120/240 277/480
Phase single three three three
PF 1.0 .80 .80 .80
AMPs 125 104 90 45
Hertz 60 60 60 60
Engine
Model Isuzu 4LE TurboCharged
Starting System 12 Volt Manual Start
Mufer Standard
Stop System Key/Emergency
Fuel Consumption (full Load) 2.6 Gal/hour
Owner Must Provide
Fuel ASTM D-975 - 1D or 2D
EN590 or equivalent
See engine manual for additional
fuel types & specication
Oil Type 10W-30 CC/CD
See engine manual for additional oil information.
Oil Capacity 8.6 Quarts
Cooling System 50/50 Mix
MODEL DE45I4-A DE45I4-D DE45I4-J DE45I4-L
Generator
Wattage 45000 45000 45000 45000
Volts 120/240 120/208 120/240 277/480
Phase single three three three
PF 1.0 .80 .80 .80
AMPs 187 156 135 68
Hertz 60 60 60
60
Engine
Model Iveco N45SM1
Starting System 12 Volt Manual Start
Mufer Standard
Stop System Key/Emergency
Fuel Consumption (full Load) 4.09 Gal/hour
Owner Must Provide
Fuel ASTM D-975 - 1D or 2D
EN590 or equivalent
See engine manual for additional
fuel types & specication
Oil Type 10W-30 CF-CH4
See engine manual for additional oil information.
Oil Capacity 13.5 Quarts
Cooling System 50/50 Mix
MODEL DE65I4-A DE65I4-D DE65I4-J DE65I4-L
Generator
Wattage 65000 65000 65000 65000
Volts 120/240 120/208 120/240 277/480
Phase single three three three
PF 1.0 .80 .80 .80
AMPs 271 226 195 98
Hertz 60 60 60 60
Engine
Model Iveco N45SM2 TurboCharged
Starting System 12 Volt Manual Start
Mufer Standard
Stop System Key/Emergency
Fuel Consumption (full Load) 4.57 Gal/hour
Owner Must Provide
Fuel ASTM D-975 - 1D or 2D
EN590 or equivalent
See engine manual for additional
fuel types & specication
Oil Type 10W-30 CF-CH4
See engine manual for additional oil information.
Oil Capacity 13.5 Quarts
Cooling System 50/50 Mix

2080-10 60708-151
3
INTRODUCTION AND
DESCRIPTION
PRODUCT DESCRIPTION:
This engine-generator set is designed for manual key start
operation. The engine-generator set is fully tested at the factory
prior to shipment to insure proper operation of each individual
component as well as the total system’s performance and
reliability.
The engine generator set consists of a multi-cylinder, liquid cooled
engine nominally operating at 1800 rpm. The generator frequency
regulation is maintained by the engine governor to within +/- 1.5
hertz (cps), from no load to rated load for standard mechanical
governors. The generator is a single bearing, direct drive, rotating
eld brushless design. The generator is connected to the engine
ywheel via exible drive disks. The Generator Set is skid
mounted with isolation mounts between the engine and base on
all units.
Unit Orientation Note: All references used in this manual for unit
familiarization, access and component locations on the Generator
Set are oriented from a TOP (plan) VIEW with engine at the
FRONT and generator to the REAR.
A customer supplied 12 Volt battery is required to complete the
installation. Battery requirements are listed later under the battery
installation section.
These engine generator sets are available in two key start
versions. In the rst version the engine is controlled and
monitored for safe operation by a manual operation Electronic
Engine Control Module (ECM) with an LCD digital display. The
generator set ECM control can be mounted on either the left or
right hand side of the unit. All units are shipped with it mount
on the same side of the unit as the oil dipstick for single side
accessibility. The ECM is a DSE702 genset start controller.
The second is a key switch with a Safety Latching Relay for
protection. This safety latching relay is connected to both a low
oil pressure switch and a high water tempature switch. if either
should fail the safety latching relay will trip shutting the engine
down. Both systems are discussed later in detail.
GENERATOR SET:
Every WINPOWER Generator Set has its own unique identity
data plate. This data plate identies the complete unit model
number, the system serial number and has links to the individual
components that form the generator set in our factory records.
Several of the major components also have their own individual
identity plates providing additional information to document build
data for warranty and replacement parts.
Be sure to have the main WINPOWER unit data plate information
recorded inside the front cover of this manual for future reference
and for identication whenever requesting eld or factory technical
assistance. Primary elds needed for assistance are complete
model number, serial number and especially the M-Spec number.
The M-Spec number (if provided) is recorded in the ‘TYPE NO.’
block on the lower right of the plate.
ENGINE:
This manual covers specic operation of the combined engine
generator set. Refer to engine operating and maintenance
instructions for specic instruction on the care and maintenance
of the engine. Oil and fuel requirements along with maintenance
schedules and engine warranty information are provided by the
individual engine manufactures.
** CAUTION **
EQUIPMENT DAMAGE - Be sure to check the engine oil level
frequently as specied in the engine manual.
The engine manufacturer has established an excellent worldwide
engine service organization; engine service is available from a
nearby authorized dealer or distributor; check the Yellow Pages
of the telephone directory under “engines,” or ask the dealer from
whom you purchased the power plant.
The rated power of each engine-generator is limited by the
temperature, altitude and all other ambient conditions specied
by the engine manufacturer. Engine power will decrease 3-1/2%
for each 1000 ft. above sea level, and will decrease an additional
1% for each 10 degrees Fahrenheit above 60 degrees Fahrenheit.
Units should not be operated in ambient temperature greater than
125 degrees Fahrenheit.
GENERATOR:
WINPOWER Generators Sets use totally brushless, AVR (Auto-
Voltage Regulator) controlled broad-range generator ends. The
generator converts rotational mechanical energy into electrical
energy. These WINPOWER units are equipped with generators
manufactured by MECC ALTE SPA. Each generator ‘end’ has its
own data tag. A unique serial number is stamped on the data plate
and the data label is afxed to the main frame of the generator on
the left side.
ENGINE CONTROL MODULE (DSE702)
The DSE702 start control module is a basic push button manual
start controller. It has a removable key for additional security.
The controller has three safety shutdowns built into it for engine
protection along with a glow plug circuit for engines requiring that
feature.
Engine protection features include low oil pressure and high
coolant temperature monitoring. As well as overspeed shutdown
protection. It also comes with a starter lock out that prevents
the starter from being engaged or staying engaged once the
generator achieves 20% of desired frequency.

60708-151 2080-10
4
RECEIVING THE GENERATOR
The generator set will generally be shipped by a commercial
‘common freight carrier’. Routing is determined by the bulk, size,
and a means available to unload the generator at the receiving
end. WINPOWER recommends units that are shipped by
common carrier be delivered to a commercial dock to allow the
Generator Set to be unloaded in a safe, efcient manner and to
minimize handling damage to the unit.
Locate the packing slip on the side of the crate or request it from
the truck driver. When receiving the unit take special care in
examining the unit for damage during shipment. Avoid signing for
the equipment until a full visual assessment and inventory have
been made. Verify that you have received the right equipment
and the proper amount by matching up the equipment to the
packing list.
UNPACKING INSTRUCTIONS:
When unpacking the generator set, be sure to inspect it carefully
for freight loss or damage. If loss or damage is noted at the time
of delivery, require that the person making the delivery make note
of the loss or damage on the freight bill, or afx his signature
under the consignee’s memo of the loss or damage. Contact the
carrier for claim procedures.
When loss or damage is noted after delivery, segregate the
damaged material, and contact the carrier for claim procedures.
“Concealed Damage” is understood to mean damage to the
contents of a package which is not in evidence at the time of
delivery by the carrier, but which is discovered later. The carrier
or carriers are responsible for merchandise lost or damaged
in transit. The title to goods rests with the consignee when
generators are shipped fob factory, and only the consignee can
legally le a claim.
***** CAUTION ****
EQUIPMENT DAMAGE - These units are shipped with oil,
and a 50/50 mix of coolant. Be sure to check all uid
levels before operating. See engine manufacturer’s
instruction manual for recommended oil requirements
before initial starting.
UNPACKING:
(Not recommended until the unit is on-site)
1. Carefully remove the crate.
2. After inspecting the engine-generator for external physical
damage, locate and check the following items packed with
the unit.
a. Owner’s operators manual.
b. Engine manufacturer’s instruction manual.
c. Battery hold-down brackets & hardware.
d. Unit components or accessory items shipped loose
for on-site installation.
e. Optional accessories.
3. Remove main frame hold down bolts.
4. Unit can now be lifted from shipping rails.
LIFTING THE GENERATOR SET
NOTICE - Personal Injury
To prevent injury to persons or equipment, observe the
following guidelines when lifting the generator:
Due to the different designs, congurations, options, weights,
site conditions, and available material handling equipment,
specic lifting instructions are not provided for each individual
generator set model. General guidelines provided are applicable
to the entire standby generator line. It is the responsibility of the
installing party to follow the lifting equipment’s operators manual
to prevent injury to personnel and damage to the generator.
Smaller Generator Sets may not require use of overhead lifting
equipment and may be placed on the pad with basic material
handling equipment, i.e. a forklift.
CAUTION: - Do not attempt to lift the generator set by the means
of the lifting eyes on the engine or generator end.
These lifting points are only for use during the manufacturing
process and are designed for lifting of the individual Generator
Set component.
***************
***** WARNING ****
***************
NEVER - attempt to lift the fuel tank while lled with fuel.
Sloshing of the fuel can cause a shift in the balance of the
fuel tank, making for a DANGEROUS, unbalanced lifting load.
If the generator was shipped on the fuel tank, use the lifting
points located on the fuel tank to move the entire Generator
Set into place. DO NOT place fuel in the tank prior to lifting.
INSTALLATION
***************
***** WARNING ****
***************
PERSONAL INJURY - Before proceeding with the installation,
be sure the engine control is in the “stop” position. Before
proceeding with the installation, be sure the Generator MLCB
(Main Line Circuit Breaker) is in the ‘OFF’ position and the
unit starting battery is disconnected.
GENERAL INFORMATION
This series of engine/generator sets are designed and built
as open power unit, meaning no weather protection has been
provided. These unit must be installed inside of an enclosure that
will provide proper protection from the elements.

2080-10 60708-151
5
Before beginning the installation process, recheck the voltage,
phase and amperage rating of the Generator Set. Be certain
it can handle the intended load and are compatible with the
intended loads. Plans for installation should be prepared with
proper attention to mechanical and electrical engineering detail
to assure a satisfactory system installation. The installation must
comply with all national, state, and local codes.
The information in this manual is offered only as a guide to
nalizing your installation plans.
NOTICE
For full service switching of the entire load, the ATS must be ‘SE’
(Service Entrance) rated or must have a properly rated fusible
disconnect installed before the ATS to protect the contacts.
ENGINE GENERATOR SET MOUNTING
The unit’s main frame must be bolted solidly to a solid base. The
engine-generator is mounted on channels which are attached
with special shock mounts to the main frame. This allows the
engine-generator free movement without affecting the base or
surrounding equipment
The unit should be mounted to allow for ample working room
around it. A general rule to follow is ve (5) feet of clearance from
an ammable surface ( NFPA 37 code). These distances may be
reduced for nonammable surfaces but sufcient access should
be provided for servicing the equipment.
VENTILATION REQUIREMENTS
Providing proper air movement during your installation planning
is absolutely essential, You will need to provide fresh a air inlet
as well as a hot air outlet for proper engine performance. These
engine generator set are equipped with unit mount radiators and
the engine is equipped with a pusher type fan. The hot air from
the face of the radiator must be ducted out of the enclosure to
insure proper cooling. Failing to do so will allow the hot air to
recirculate around the radiator causing the engine to overheat
resulting in an engine shutdown. If louvers are used in front of the
hot air duct to protect the unit from outside weather, these louvers
should be 1 1/2 time as large as the area of the radiator face to
prevent back pressure.
In addition to a hot air discharge you must plan for a fresh air
intake opposite the radiator discharge. These fresh air inlets
should also be 1 1/2 to 2 times large that the radiator face. The
extra air inlet area is required to minimize restriction and to
provide combustion air for the engine. Installing them opposite
the hot air discharge will allow a sweeping ow of cooling air
across the engine preventing hot spots.
FUEL INSTALLATION
The fuel supply should be as close to the engine as possible.
This will reduce the installation cost of fuel runs and minimize
line losses. The diesel fuel supply should be no more than 3 feet
below the fuel inlet on the pump. If your fuel supply is lower than
three feet you may have to install an additional lift pump to bring
the fuel up to the mechanical fuel pump on the engine.
The information in this manual is offered to assist you in providing
the proper fuel for your engine. However, this information is only
provided to inform you of the engine’s requirements and assist in
making you aware of the decisions you must make. In no case
should the instructions or information provided be interpreted to
conict with any local, state or national codes. If in doubt, always
consult your local re marshal or fuel supplier.
INSTALLING THE FUEL LINE
Engine generator sets are properly adjusted before they leave the
factory. Connecting a fuel supply with adequate supply volume
is critical to reliable operation. Diesel units with optional base
mounted fuel tanks are pre-plumbed to the mechanical fuel pump
on the engine.
Open skid mounted Diesel units are often supplied with capped
inlet and return lines. The use of a suitable customer supplied
exible fuel line is essential between the engine and fuel supply
to provide a vibration break between your fuel supply and the
engine.
***************
***** WARNING ****
***************
FIRE DANGER - Connecting rigid fuel line (i.e. steel or copper
line) directly to the inlet fuel lter or fuel pump may cause
the fuel line to crack during operation creating a serious re
hazard.
FUEL RETURN
LINE CONNECTION
FUEL INLET
CONNECTION
DE45 & DE65 FUEL LINE CONNECTIONS

60708-151 2080-10
6
LUBRICATION
Before starting the engine, check the oil level in the crankcase.
If it is low, rell to the full mark with the proper weight/grade of
oil as recommended by the engine manufacturer’s maintenance
instructions. The necessity of using the correct oil, and keeping
the crankcase full cannot be over emphasized. Failure to use
the proper oil and keep the crankcase properly lled will cause
excessive engine wear and shorten its useful life.
COOLANT
Before starting the engine, check the coolant level in the radiator.
If it is low, rell as specied in the engine manufacturer’s
maintenance instructions. The radiator should be lled to about
1 inch below the ller neck. For additional information on engine
coolant requirements see engine manufacturer’s maintenance
instructions.
INSTALLING THE BATTERY
**** CAUTION ****
In the following battery installation procedure, check to be
sure the engine control is in the “stop” position. This should
be your last step before initial start-up.
A customer supplied twelve-volt battery is required to complete
the installation. Installation of the highest CCA rated battery,
within the correct BCI group, will increase cold weather starting
performance.
BATTERY REQUIREMENTS
MINIMUM
Model Voltage BCI Group CCA Rating
DR20I4 12 24 650
DE30I4 12 24 650
DE45I4 12 24 650
DE65I4 12 24 650
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE- All of these units are 12 Volt and they
are all negative ground. Permanent damage will occur if
they are connected to a 24 volt system or a positive ground
system. If you are using the truck batteries to start these
units you may have to disable the charging system to keep it
from interfering with the vehicle charging system.
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.
CAUTION – PERSONAL DANGER
CAUTION - NEVER dispose of a battery in a re. The battery is
capable of exploding.
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 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.
DE30 FUEL CONNECTIONS
FUEL INLET
CONNECTION
FUEL RETURN
LINE CONNECTION
FUEL RETURN
LINE CONNECTION
FUEL INLET
CONNECTION
DE20 FUEL CONNECTIONS

2080-10 60708-151
7
5. Be sure all connections are tight and coat the terminals and
cable ends with dialectic grease.
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, ush thoroughly and
immediately with water and seek immediate medical attention
* Spilled electrolyte is to be washed down with an acid neutral
izing 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 with 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 grounded 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 relling 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. Over lling above the
upper level line may cause the electrolyte to over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. Failure to do so can cause
damage to the engine control module in the 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.
A.C. ELECTRICAL
CONNECTIONS
NOTICE - CLASS 1 WIRING METHODS ARE TO BE USED FOR
ALL FIELD WIRING CONNECTIONS TO TERMINALS OF A
CLASS 2 CIRCUIT
Note: This symbol always indicates ground where shown.
All wiring must be completed in accordance with the Nation
Electric Code as well as any state or local codes.
You must pay particular attention to wire size requirement for
the amperage of service you are dealing with. The table below
provides you guidance on wire sizing based on both wire type
and amperage. Wire amperage’s have been derated for 40o
C ambient temperatures operation. See page 8 for wiring
schematic.
*************
***** WARNING *****
*************
A main line circuit breaker has been provided inside the
generator housing. During all wiring installations make
sure the breaker is in the OFF position and the generator
operation switch is in the OFF position.
Neutral Lugs - DE20 has 100 amp neutral lugs. These lugs are
isolated from ground and provided for you to connect your neutral
wires to, from the transfer switch or load distribution center. The
lugs will accommodate #12 AWG to #1/0 Awg and should be
torqued to 50 in. lbs. The DR30 and larger have 225 AMP neutral
lugs and will accommodate #4 AWG to 300 MCM and should be
torqued to 250 in. lbs. The exception is the DE65 single phase
unit which has a 400 amp neutral block. The 400 amp terminal
block lugs will handle wire sizes #1 AWG to 400 MCM and should
be torqued to 300 in. lbs.
Generator Circuit Breaker, This circuit breaker provides overload
protection for the generator. Your power feeds from the load
panel will connect to the open lugs on the circuit breaker. The
generator power feeds have already been wired into one set of
lugs.
The table below gives you the circuit breaker size, lug wire sizes
and torque specication. (see the actual breaker for additional
information and restrictions)
kW Voltage PH Amp Wire Capability Lug Torque
20 120/240 1 85 #12 AWG -2/0 AWG 50 in lbs
20 120/208 3 70 #12 AWG -2/0 AWG 50 in lbs
20 120/240 3 60 #12 AWG -2/0 AWG 50 in lbs
20 277/480 3 30 #14 - #1/0 AWG 80 in lbs
kW Voltage PH Amp Wire Capability Lug Torque
30 120/240 1 125 #12 AWG -2/0 AWG 50 in lbs
30 120/208 3 100 #12 AWG -2/0 AWG 50 in lbs
30 120/240 3 90 #12 AWG -2/0 AWG 50 in lbs
30 277/480 3 45 #14 - #1/0 AWG 80 in lbs
kW Voltage PH Amp Wire Capability Lug Torque
45 120/240 1 175 #4 AWG - 300 MCM 250 in lbs
45 120/208 3 150 #4 AWG - 300 MCM 250 in lbs
45 120/240 3 125 #4 AWG - 300 MCM 250 in lbs
45 277/480 3 60 #14 - #1/0 AWG 80 in lbs
kW Voltage PH Amp Wire Capability Lug Torque
65 120/240 1 250 #1 AWG - 600 MCM 375 in lbs
65 120/208 3 225 #4 AWG - 300 MCM 250 in lbs
65 120/240 3 200 #4 AWG - 300 MCM 250 in lbs
65 277/480 3 100 #14 - #3/0 AWG 120 in lbs

60708-151 2080-10
8
CONTROL BOX AC WIRING
WARNING THESE GENERATORS ARE WIRED WITH A FLOATING NEUTRAL

2080-10 60708-151
9
Minimum Conductor Sizes between the Generator and the load.
Based on wire type and temperature rating. Wire has been
derated for 40o C ambient temperatures.
Cu Conductor Al Conductor
C/B Wire Temperature Rating
kW Voltage PH Amp 750C 900C 750C 900C
20 120/240 1 85 #3 AWG #4 AWG #1 AWG #2 AWG
20 120/208 3 70 #4 AWG #6 AWG #3 AWG #4 AWG
20 120/240 3 60 #4 AWG #6 AWG #3 AWG #4 AWG
20 277/480 3 30 #8 AWG #8 AWG #8 AWG #8 AWG
30 120/240 1 125 1/0 AWG #1 AWG 3/0 AWG 2/0 AWG
30 120/208 3 100 #2 AWG #3 AWG 1/0 AWG #1 AWG
30 120/240 3 90 #2 AWG #3 AWG 1/0 AWG #2 AWG
30 277/480 3 45 #6 AWG #8 AWG #4 AWG #6 AWG
45 120/240 1 175 3/0 AWG 2/0 AWG 250 MCM 4/0 AWG
45 120/208 3 150 2/0 AWG 1/0 AWG 3/0 AWG 2/0 AWG
45 120/240 3 125 1/0 AWG #1 AWG 3/0 AWG 2/0 AWG
45 277/480 3 60 #4 AWG #6 AWG #3 AWG #4 AWG
65 120/240 1 250 300 MCM 250 MCM 500 MCM 350 MCM
65 120/208 3 225 250 MCM 4/0 AWG 400 MCM 300 MCM
65 120/240 3 200 4/0 AWG 3/0 AWG 300 MCM 250 MCM
65 277/480 3 100 #2 AWG #3 AWG 1/0 AWG #1 AWG
For additional information on wire sizing refer to table 310-16 of
the National Electrical Code ANSI/NFPA 70..
For additional information on wire sizing refer to table 310-16 of
the National Electrical Code ANSI/NFPA 70.
Ground Lug, These ground lugs are bonded to ground and are
provided for you to connect your ground wire from the transfer
switch to. The lugs on the 65 kW will handle wire sizes #6 AWG to
300 MCM and should be torqued to 250 in. lbs. The lugs on the
20 through 45 kW will accommodate #10 AWG to 2/0 AWG and
should be torqued to 200 in. lbs.
*************
***** WARNING *****
*************
PERSONAL DANGER - These unit are shipped with a
FLOATING NEUTRAL. If you not connecting to an existing
power system you must install a neutral to ground bond in
the generator connection box. If your system already has a
neutral to ground bond then you must run a separate ground
lead to that location. For additional questions refer to the
current National Electric Code on grounding.
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE - When installing a Three Phase 240
volt system be sure you know which lead is the high voltage
“wild” leg (208 Volt line to neutral). The generator normally
carries the high voltage on the G2 lead.
All wires should be installed in exible conduit. ( A knockout
covered by a rubber plug is provided in the control box).
ENGINE CONTROL PANEL
LAYOUT DSE702
A - 2 AMP FUSE This fuse supplies the DSE702 controller
120 Volt AC. This tells the controller that the unit is running.
(Replacement AGC-2A-250V)
B - 2 AMP FUSE -This fuse is in the 12 volt DC power supply for
the DSE702 controller circuitry on the board. It also supplies the
voltage for the two or three control relay in the control cabinet.
(Replacement AGC-2A-250V)
C - 25 AMP FUSE- This fuse provides the 12 volt DC voltage
for the relay controlling the starting, fuel, and glow plugs.
(Replacement AGC-25A-250V)
D - DSE702 Start Controller - See Description Later
ABD
C

60708-151 2080-10
10
DSE702 CONTROL
A - KEY SWITCH -Turns the controller on and off.
B - STOP/RESET - With key in this position the unit is shut off.
This position also resets the controller if it has gone into fault.
C - RUN POSITION - The key in this position will allow the glow
plugs to be turned on and the unit to be started.
D - START BUTTON - When this button is depress the starter is
engaged and will stay engaged until the button is released.
E - GLOW PLUG SWITCH - When this button is depress the glow
plug circuit is activated, operating the glow plugs on the engine.
When it is released the glow plug circuit is disconnected.
F - GLOW PLUG INDICATOR LED - When the glow plug switch
is depressed this LED will light up indicating the circuit has been
activated.
G - RUNNING TIME METER - This digital display will track the
hours of operation of the engine generator set. This meter runs
any time the key is in the run position.
H - OVERSPEED/UNDERSPEED LED - Overspeed: This light
will illuminate if the engine speed exceed the preset trip point
(14% above nominal frequency or about 68 Hz) and a shutdown
is initiated. The overspeed is not delayed, it is an immediate
shutdown. Underspeed: This light will ash if the engine speed
falls below 20Hz after the Safety On* time has expired and a
shutdown is initiated.
J - FAIL TO START - Not used on the manual start controller.
K - LOW OIL PRESSURE - This light will illuminate if the module
detects that the engine oil pressure has fallen below the oil
pressure switch setting (15 psi) after the Safety On* time has
expired and a shutdown is initiated.
M - BATTERY CHARGE FAILURE - Not used in this application.
N - HIGH WATER TEMPERATURE - This light will illuminat if the
module detects that the engine coolant temperature has exceeded
the limit the coolant temperature switch after the Safety On* timer
has expired and a shutdown is initiated.
NOTE: All warnings are reset but turning the key to off
position.
* SAFETY ON TIMER - The safety on delay on this controller is
10 seconds. Should and fault condition still be detected after this
10 second delay the engine will shutdown and fault code will be
illuminated.
INITIAL START UP
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE - DO NOT jump start these engine
generator sets. Starting these units on a low battery or
jump starting them will cause damage to the engine control
module.
Use the following check list to verify correct installation before
starting the engine:
1. Engine oil. Fill as required with proper grade/qty.
2. Engine coolant. Fill as required with proper mixture.
3. Unit mounting base properly bolted down.
4. Clearance for service and maintenance on all sides.
5. Proper fuel line material and size.
6. All fuel line connections tight.
7. Battery connections clean and tight.
8. Battery fully charged.
9. All AC and DC wiring installed and properly protected.
After completing the above checklist, the engine-generator set is
ready for the initial start-up test.
STARTING PROCEDURE
MANUAL MODE
****************
***** WARNING *****
****************
EQUIPMENT DAMAGE -BEFORE ATTEMPTING TO START
THIS UNIT COMPLETE YOUR PRE-START CHECKLIST AND
INSURE THE GENERATOR MAINLINE CIRCUIT BREAKER IS
IN THE PROPER POSITION PRIOR TO STARTING. STARTING
THIS UNIT WITHOUT IT PROPERLY CONNECTED CAN
CAUSE SERIOUS PERSONAL INJURY OR EQUIPMENT
DAMAGE.
1. Rotate the key (A) to the run position (C).
2. If your unit is equipped with glow plugs depress the glow plug
button (E) for about 10 seconds.
3. Depress the start button (D) to engage the start circuit. The
starter should engage and the unit will start. Once the unit has
started release the start button to disengage the starter.
H
J
K
D
G
N
M
FB
AC
E

2080-10 60708-151
11
4. If the start button is release before the engine starts or the unit
does not stay running the key switch (A) has to be turn to the off
position and back to the run position before the starter can be
reengage using the start button (D). This protects the starter from
accidently being engage with the unit running.
5. Once the unit is running and the safety on time has elapsed the
engine monitoring switches are active.
6. If the unit should shut down and display a fault light (H,K or N)
clear the fault before attempting to restart the unit.
7. After the engine is up an running the circuit breaker can be
closed to power your loads. During periods of very cold operation
it is best to let the engine warm up for a few seconds before
applying the load.
8. When stopping the unit it is best to turn off all the loads before
turning the key switch to the off (B) position. This prevents your
loads from getting low voltage while still running during unit
shutdown.
ENGINE CONTROL PANEL
LAYOUT MANUAL KEY START
A- FOUR POSITION START SWITCH
1. Preheat - This position is used on the DE20 and DE30
only. With the switch in this position the glow plugs on the
engine are activated.
2. OFF - In this position all power to the engine is
turn off and the engine is stopped.
3. RUN - With the switch in this position the fuel solenoid
and the fuel pump on the engine are activated. A 12 Volt
signal is also being sent to the voltage regulator on the
engine alternator to activate it.
4. START - This position on the switch will activate the
starter on the engine to start it.
B. CHECK ENGINE LIGHT - This light will come on when the
low oil pressure switch or the high water temperature sensor
switches have been activated on the engine. This light will also
come on when you go to start the engine, and stay on until the
engine has built sufcient oil pressure to open the low oil pressure
switch.
C. RUNNING TIME METER - This meter records the actual
hours of engine operation.
D. 25 AMP FUSE - This fuse protect all the DC wiring in the
engine control panel and on the engine. If this Fuse if blown
nothing will work on the engine.
E. SAFETY LATCHING RELAY - This safety latching relay
provides the 12 volt DC power to the fuel solenoid and the engine
alternator eld circuit during normal operation. If the system
experiences a low oil pressure fault or a high water temperature
fault this relay will trip disconnecting the fuel solenoid and shutting
down the engine. When tripped the button on the panel will
extend out about 1 inch. This button must also be held in during
starting until the check engine light goes out.
INITIAL START UP
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE - DO NOT jump start these engine
generator sets. Starting these units on a low battery or
jump starting them will cause damage to the engine control
module.
Use the following check list to verify correct installation before
starting the engine:
1. Engine oil. Fill as required with proper grade/qty.
2. Engine coolant. Fill as required with proper mixture.
3. Unit mounting base properly bolted down.
4. Clearance for service and maintenance on all sides.
5. Proper fuel line material and size.
6. All fuel line connections tight.
7. Battery connections clean and tight.
8. Battery fully charged.
9. All AC and DC wiring installed and properly protected.
After completing the above checklist, the engine-generator set is
ready for the initial start-up test.
STARTING PROCEDURE
1. Rotate start switch (A) to the preheat position and hold for 10
seconds. NOTE: This step applies to the DE20 & DE30 ONLY.
2. Rotate the Start Switch (A) to the Run position. Then while
depressing the Safety Latching Relay button (E) rotate the switch
to the Start position. At this point the starter should engage and
the unit will start.
3. As the unit starts release the Start Switch and it will return to
the run position. You must continue to depress the Safety Latch
Relay button until the Check Engine light goes out. When this
light goes out, it indicates that the engine has built sufcient oil
pressure to operate properly and the high coolant temperature
has not been exceeded.

60708-151 2080-10
12
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE - DO NOT DEPRESS THE SAFETY
LATCHING RELAY BUTTON FOR OVER 10 SECONDS. IF THE
LIGHT HAS NOT GONE OUT IN 10 SECONDS IT INDICATES
THAT EITHER THE ENGINE HAS NOT BUILT OIL PRESSURE
OR THE COOLANT TEMPERATURE HAS EXCEEDED THE
ALLOWABLE MAXIMUM.
4. After the engine is up an running the circuit breaker can be
closed to power your loads. During periods of very cold operation
it is best to let the engine warm up for a few seconds before
applying the load.
5. When stopping the unit it is best to turn off all the loads before
turning the Start Switch to the off position. This prevents your
loads from getting low voltage while still running during unit
shutdown.
If for some reason during operation the oil pressure should drop
below the allowable oil pressure or the water temperature should
exceed allowable level the Safety Latching Relay button will pop-
out and the unit will shutdown. You will also get a check engine
light at this time.
If you nd the unit stopped with the relay button popped-out, it
could have been caused by either low oil pressure or high water
temperature.
TROUBLESHOOTING TABLES
ENGINE WILL NOT CRANK WITH GENERATOR
RUN PUSH-BUTTON DEPRESSED.
1. Low/dead battery.
2. Blown DC fuses 2 amp or 25 amp.
3. Defective DSE702.
4. Loose or dirty battery terminals.
5. Defective starter.
6. Defective start solenoid.
7. Locked up engine genset.
ENGINE CRANKS BUT WILL NOT START
1. Improper fuel delivery to the unit.
2. Fuel supply shut off.
3. Fuel tank empty.
4. Air in the fuel system.
5. Engine fuel solenoid has not opened.
6. Defect fuel pump.
ENGINE STARTS AND THEN STOPS AND ALARM LIGHT
COMES ON
1. Engine oil pressure is low.
2. Engine has high water temperature.
3. Engine has overspeed.
ENGINE WILL NOT COME UP TO SPEED AFTER IT
STARTS
1. Insufcient fuel volume getting to the unit.
a. Too small of fuel line.
b. Fuel racks not opened properly.
2. Governor is defective.
3. AC short in generator components.
NO AC OUTPUT FROM GENERATOR
1. Defective diode.
2. Defective voltage regulator.
3. Defective rotor.
4. Defective stator.
5. Defective exciter rotor.
6. Defective exciter stator.
7. AC short in the output leads.
8. Defective/open generator output breaker.
9. Wiring error.

2080-10 60708-151
13
DE30 OUTLINE DRAWING
DE20 OUTLINE DRAWING

60708-151 2080-10
14
DE45 & DE60 OUTLINE DRAWING

2080-10 60708-151
15
DE20 & DE30 DC SCHEMATIC FOR DSE702

60708-151 2080-10
16
DE45 & DE65 DC SCHEMATIC FOR DSE702

2080-10 60708-151
17
START CONTROL PANEL
ENGINE WIRING HARNESS
DE20 & DE30 KEY START SCHMATIC

60708-151 2080-10
18
START CONTROL PANEL
ENGINE WIRING HARNESS
DE45 & DE65 KEY START SCHMATIC