Wanco WI6000 User manual

Inverter Series Generator
Operator Manual
Model WI6000
May 2017 P/N 220884 Rev. A

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PREFACE
Thank you for purchasing a Wanco portable inverter generator set. This manual contains important
safety and operating information - please read the complete manualbefore attempting to operate
the generator.
All information in this publication is based on the latest product information available at the time of
approval for printing. We reserve the right to make changes atany time without notice.
No part of this publication may be reproduced without written permission.
Throughout this manual pay special attention to statements preceded by the following signal
words:
Failure to properly follow these precautions is likely to result in
property damage, serious injury or death
Failure to properly follow these precautions can result in property
damage, serious injury or death
Indicates a possibility of personal injury or equipment damage if
instructions are not followed
Gives helpful information.
If you need assistance with your generator set, please contact our service department:
Wanco Inc.
5870 Tennyson Street
Arvada, Colorado 80003
303-427-5700
fax [phone]
www.wanco.com
[email protected]

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CONTENTS
1. SAFETY INSTRUCTIONS ..........................................4
2. UNBOXING AND ASSEMBLY....................................6
3. COMPONENT LOCATIONS.......................................7
4. PRE-OPERATION CHECK.......................................10
5. GENERATOR USE...................................................12
6. MAINTENANCE........................................................17
7. TRANSPORTING/STORAGE ...................................19
8. TROUBLESHOOTING..............................................20
9. SPECIFICATIONS....................................................21
10.WIRING DIAGRAMS.................................................22
Read and understand this Operator Manual before starting the generator.
Failure to do so could result in personal injury or equipment damage

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SAFETY INSTRUCTIONS
Exhaust gas contains invisible but poisonous carbon monoxide. Never run the generator in an
enclosed area.
Gasoline vaporis invisible butextremely flammable andexplosive under certain conditions. Shut the
engine OFF and allow the generator to cool for two minutes before refueling. Never refuel while the
engine is running.
Keep away from smoking materials, sparks and other sources of combustion when refueling the
generator.
Neverattemptto“backfeed”orpowerabuildingthroughaninstalledreceptacle.Backfeedingcreates
a dangerous shock hazard for the user and for utility personnel working on power lines.

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Engine exhaust is very hot. Place the generator at least three feet or one meter away from buildings
or other equipment during operation.
The muffler becomes very hot during operation and remains hot for several minutes after stopping
the engine. Be careful not to touch the muffler while it is hot.
Let the engine cool before storing the generator indoors.
Always make a pre-operation inspection before you start the engine.
Operate the generator on a level surface to prevent fuel spillage or oil starvation.
Know how to stop the generator quickly and understand operation of all controls.
Never permit anyone to operate the generator without proper instructions. Keep children and pets
away from the generator when it is in operation.
Do not operate the generator in rain or snow and do not operate when wet.

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UNBOXING AND ASSEMBLY
1. WI6000H Chassis- installed
2. Support Bracket- (4)
3. Front Stabilizer (2)
4. AxleAssembly
5. 10” Wheel
6. Wheel Washer (4)
7. Wheel Clip
Assembly:
Install the four support brackets and secure with bolts.
Attach the front stabilizers to the chassis (below the handles)
Attach the axle assembly.
Install one washer on the axle against each welded stop.
Install the two wheels.
Install the two remaining washers and secure with the wheel clips.
The handles are preassembled before packaging. To raise the handles, simply raise the handle
assemblyto a horizontal position.To retract the handles,slidethechrome collars toward you toclear
the sleeve and lower them to the starting position.

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COMPONENT LOCATIONS

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Control Panel
OUTPUT
INDICATOR
THERMAL
CIRCUIT
BREAKERS
SMART
THROTTLE
HOURMETE
R
CHOKE
START
SWITCH
GFCI
RECEPTACLES
DC RECEPTACLE
LOCKING
RECEPTACLE
GROUND
LUG
VOLTAGE
SELECT
SWITCH
OVERLOAD
RESET
SWITCH FUEL VALVE

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Fuel Valve (located inside the generator service door)
Serial Number Identification
The generator serial number identifies your particular unit and isimportant when ordering parts and
accessories. The number is engraved on the engine blockleft of the oil drain port (inside the
service door). We recommend recording the following information in case you need to contact
Wanco Technical Support:
Model Number: WI______________
Serial Number: _________________
Date of Purchase: _________________
Place of Purchase: _______________________________

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PRE-OPERATION CHECK
Be sure to check the generator on a level surface with the engine stopped.Allow the engine to cool
to avoid burns.
Check The Engine Oil Level.
Use a premium-quality 4-stroke engine oil certified to meet or exceed theAPI Service Classification
SJ or higher. Select the appropriate viscosity for the expected temperature in your area. 10W – 30
oil is suitable for most climates.
DO NOT use synthetic oil in Wanco inverter generators. Use of synthetic oil
can interfere with break-in and can lead to excessive oil consumption.
SAE Viscosity Grades vs Temperature
Remove and wipe the oil dipstick with a clean rag.
Insert the dipstick in the filler hole – but do not screw it in.
Remove and carefully read the oil level.
Add oil if necessary until the oil level is at the top of the dipstick marking.
Reinstall the dipstick, securely screwing it until tight.

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Running the engine with insufficient oil can cause serious engine damage.
The Low OilAlarm Shutdown will automatically stop the engine before the
oil level fallsbelow a safe limit. However it is still advisable to visually inspect the oil level regularly.
Fuel
Use regular automotive gasoline with no more than 10% ethanol.
Never use an oil/gasoline mixture or dirty gasoline.
Avoid getting dirt, dust or water in the fuel tank.
After refueling, tighten the fuel filler cap securely
Gasolinevaporisinvisiblebutisextremelyflammableand isexplosiveunder
certain conditions.
Refuel in a well-ventilated area with the engine stopped. Keep all smoking
materials, sparks, and any other source of combustion away from the generator during refueling.
Do not overfill the fuel tank, and allow for fuel to expand as it warms.After refueling, make sure the
tank cap is closed properly and securely.
Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite, If any fuel is spilled,
wipe the area is dry before starting the engine.
Avoid repeated or prolonged contact with skin or breathing of vapor.
KEEP OUT OF REACH OF CHILDREN.
Air Cleaner
Check the air cleaner element to be sure it is clean and in good condition.
Open the generator service door. Remove the air
cleaner cover, remove the foam element from the air
cleaner cover. If the elementappears dirty, wash it in
warm soapy water, rinse and squeeze dry. Apply a
small amount of clean engine oil before reinstalling.
Never run the engine without the air cleaner. Rapid
engine wear will result from contaminants such as
dustanddirtbeingdrawnthroughthecarburetorinto
the engine.

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GENERATOR USE
Starting the Engine:
When starting the engine after adding fuel for the first time, after long term storage or after running
outof fuel,turn thefuelvalvelevertothe"ON"position,thenwaitfor10 to20secondsbeforestarting
the engine.
Turn the fuel valve to the ON position.
Pull the choke knob out to the START position.
Do not use the choke if the engine is already warm or the ambient air
temperature is high.
Insert the key into the Start Switch on the panel
Turnthe control panelswitchto the START position(full clockwise) until the engine hasstarted, then
release. Do not engage the starter for more than 10 seconds. If the engine does not start, wait 10
seconds before attempting another start.
Push the choke lever in to the RUN position as the engine warms up.
If the engine stops and will not restart, check the engine oil level before
further troubleshooting.
Shutting Down the Engine.
To stop the engine in an emergency, turn the engine switch to the OFF (O) position.
1. Switch off the connected equipment and pull the inserted plug out.
2. Turn the engine switch to the OFF (O) position
3. Turn the fuel valve to the OFF position
Voltage Selection Switch
The voltage selection switch has two positions:AC120V andAC120/240V.
When thevoltage selection switch isin the 120/240V position, the generator supplies both 120V and
240V AC power. If you operate the generator with the switch in this position, the electric current is
limited to 15 amps to the 120V receptacles although it can provide 15 amps at 240V from the
120/240V receptacle.
When the voltage selection switch in the 120V position, the generator supplies 120VAC only. It can
supply a full 30 amps to the 30Amp receptacle or 20Ato the GFCI receptacle.

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Connecting Loads to the Generator.
Never connect a portable generator directly to any building service wiring
throughan installedreceptacle. “Backfeeding”createsariskofsevere shock
for the user and for utility personnel who may be working on power lines.
DO NOT connect a Wanco inverter generator to a building through a Double
Throw Transfer Switch as it may damage the inverter. Only connect loads
directly to the generator using extension cords.
Limit operation at maximum power to 30 minutes or less.
The neutral conductor in this generator is bonded to the generator frame (“bonded neutral”). Follow
local codes regarding grounding of portable generator sets, depending on how it isused.
The total wattage of all appliances connected must be considered.
Do not exceed the current limit specified for any one receptacle.
Do not exceed the total power available from the generator.
When an extension cord is required, make sure you use the proper size and length.
•16 gauge cords up to 100 feet long will adequately handle loads up to 10 amps.
•14 Gauge Cords up to 50 feet long will adequately handle loads up to 15 amps.
•12 Gauge Cords up to 100 feet long will adequately handle loads up to 15 amps.
Start the engine and make sure only the output indicator light (green) comes on.
Confirm that the appliance to be used is switched off, and plug in the appliance.
Before connecting an appliance to the generator, check that its electrical
rating does not exceed that of the generator.
Be sure that all appliances are in good working order before connecting them to the generator. If an
appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn off the generator
immediately. Disconnect the appliance and examine it for signs of malfunction.

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Turn on the appliance and observe the generator for any abnormal operation.
When an electric motor is started, both the overload indicator light (red) and
the output indicator light (green) may go on simultaneously. This is normal
but if the overload indicator light (red) stays on more than about four seconds, consult a service
center.
Output and Overload Indicators
The output indicator light (green) will remain on during
normal operating conditions. If the generator is overloaded
or if there is a short in the connected AC appliance the
outputindicatorwill go out, the overload indicator light (red)
will illuminate and all output current will be shut off.
Repeated overloading of that lights the overload indicator
light (red) may shorten the service life of the generator.
All Wanco inverter generators include GFCI-protected duplex receptacles. The
GFCI protection will trip if there is any fault current to ground, which is usually
caused by faulty appliances or water entering into electrical devices –If the GFCI
breaker trips, it is very important to locate and resolve the ground fault before
resetting. Press the extended reset button located in the center of the receptacle
to reset.
AGFCI trip will only affect one receptacle – voltage will still be present at the other
receptacles.
GFCI protects against ground faults and is completely unrelated to overloads.
The generator also includes thermal type circuit breakers to protect the
AC receptacles from excessive current. These breakers have a small
round button that extends when an overload condition is detected.
Overload Reset Switch
Should the generator maximum load capacity be exceeded,AC power will be cut off but the engine
will stay running. Reduce the load and then press the Overload Reset Switch on the front panel.AC
power will be restored immediately.

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Low-Oil Protection System
The low oil protection system is designed to prevent engine damage caused by an insufficient
amount of oil in the crankcase. Before the oil level in the crankcase falls below a safe limit, the low
oil alarm system will automatically shut down the engine.
If the low oil alarm system shuts down the engine, the low oil alarm indicator light (red) willcome on
when you operate the starter and the engine will not run. If this occurs add engine oil before
restarting. Damage caused by running the engine with insufficient oil is not covered under warranty.
Air Conditioning Operation
Forbestresults,theSmartThrottleswitch should be inthe offposition.Bringthegeneratorto normal
operatingtemperaturesbeforeapplyingtheairconditioningload.Alwaysallowa2minutewait period
when manually cycling an air conditioner off and on. A longer wait period may be required under
unusually hot weather conditions. Additionally, all other loads should be turned off until the air
conditioner has started and is performing normally. It is also important to follow the air conditioner
manufacturer's instructions for starting and restarting for proper operation. Some air conditioner
manufacturers offer a start capacitor or rapid start kit as an extra cost option. The lack of a start
capacitor can cause the air conditioner to draw too high a starting current and overload the
generators. Contact your air conditioner dealer if you consistently have problems starting your air
conditioner with the generators in parallel.
Smart Throttle System
When the SmartThrottle switch is placed in the ONposition, engine speed iscontrolled to matchthe
electrical load.The engine will idle at no load and will increase speed as more load is applied.
The Smart Throttle system does not operate effectively if the
electrical appliance requires constant fluctuations in power.
When high electrical loads are connected simultaneously, turn the
Smart Throttle switch to the OFF position to reduce voltage
fluctuation or shutdown.
In DC operation, turn the Smart Throttle switch to the OFF position.
DC voltage may be too low when the Smart Throttle isON.
Whenthe SmartThrottleswitch isplacedintheOFFposition,theenginethrottleisfixedatmaximum
speed, improving the ability of the generator to accept large or fluctuating loads.
High Altitude Operation
The reduced oxygen available athigher altitudes willreduce the maximum power available from the
engine.Highaltitude performance can be improved somewhat by installingaspecialhigh-altitude jet
in the carburetor. If you operate the generator at altitudes higher than about 5000 feet above sea
level for extended periods, have your authorized dealer installa high altitude main jet.

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Even with suitable carburetor jetting, engine horsepower will decrease approximately 3.5% for each
1000 feet or 305 meter increase in altitude. The effect of altitude on the horsepower will be greater
than this if the carburetor is not re-jetted.
Be sure to restore the original jet before operating at lower elevation or engine damage due to an
excessively lean fuel mixture may occur.
Ambient Temperature
Generator power generally degrades 1% for every 10° F (5.5° C) above 85° F (29° C). The normal
operating range of the generator is -20° to 113° F (-29° to 45° C).
Do not operate the generator when the ambient temperature is above 113° F (45° C)
12VDC Power Operation
The DC receptacle may be used for charging 12 volt batteries only. The no load voltage is 15V-30V.
Turn the Smart Throttle switch to the OFF position when using the DC receptacle.
1.ConnectthechargingcabletotheDCreceptacleofthegeneratorandthentothebatteryterminals.
To prevent the possibility of creating a spark near the battery, connect the
chargingcablefirstto the generatorthentothe battery.Disconnectthe cable
first at the battery.
Connect the positive battery terminal to the positive charging cord. Do not reverse the charging
cables, or serious damage to the generator and/or battery may occur.
The battery gives off explosive gases; keep spark, flames and cigarettes
away. Provide adequate ventilation when charging.
The battery may contain sulfuric acid (electrolyte). Contact with skin or eyes
may cause severe burns. Wear protective clothing and a face shield.
If electrolyte gets on your skin,flush with water.
If electrolyte gets in your eyes, flush with water for at least 15
minutes and call a physician.
KEEP OUT OF REACH OF CHILDREN.
2. Start the engine
The DC receptacle may be used while theAC power is in use.
An overloaded DCcircuit will triptheDCcircuit fuse located behindthegenerator panel.Replace the
fuse with one of the same size and rating (6.3Aslow-blow 5x20mm). Use of a higher rated fuse may
lead to generator damage.

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MAINTENANCE
The purpose of the maintenance and adjustment schedule is to keep the generator in optimum
operating condition.
Shut off the engine before performing any maintenance.
Maintenance Schedule
REGULAR SERVICE PERIOD Perform at
every indicated monthly
or operating hour
interval whichever occurs first
EACH
USE
1ST
MO
or
20H
3 MO
or
50H
6 MO
or
100H 300H
ITEM
Engine oil
Check
○
Change
○
Air cleaner
Clean
○
Replace
○
Spark plug
Clean/Gap
○
Spark arrester
Clean
○
Fuel sediment cup
Clean
○
Valve clearance
Check/adjust
○
Fuel tank and strainer
Clean
○
Fuel lines
Check
Every 2 years (Replace as necessary)
NOTE: Service filters more frequently when used heavily or in dusty areas.
Valve clearance is best adjusted by a qualified small-engine mechanic.
Changing Engine Oil
Drain the oil while the engine is still warm to assure rapid and complete drainage.
1. Open the generator service door.
2. Remove the oil dipstick and wipe the oil dipstick with a clean rag.
3. Remove the drain bolt and drain the oil into a suitable container.
There is a rubber plug in the bottom of the generator pan to facilitate draining
the oil. The generator willhave to be raised off the ground while the oil drains.
4. Retighten the drain bolt securely.
5. Refill with the recommended oil.
6. Insert the dipstick in the filler hole – but do not screw it in.
7. Unscrew, remove and carefully read the oil level.
8. Add oil if necessary until the oil level is at the top of the dipstick marking.
9. Reinstall the dipstick, securely screwing it until tight.
Dispose of used motor oil in a responsible manner. Do not throw it in the trash or pour it on the
ground.

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Air Cleaner Service
A dirty air cleaner will restrict airflow to the carburetor and allow dirt into the engine. Service more
frequently when operating the generator in extremely dusty areas.
Never run the generator without the air cleaner. Rapid engine wear may
result.
Spark Plug Service
To ensure proper engine operation, the spark plug must be the correct part, properly gapped and
free of deposits.
1. Open the generator service door.
2. Remove the spark plug cap.
3. Clean any dirt from around the spark plug base.
4. Use the wrench to remove the spark plug.
5. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped.
Clean the spark plug with a wire brush if it is to be reused.
6. Measure the plug gap with a feeler gauge. The gap should be 0.024-0.028in (0.6-0.7mm).
Correct as necessary by carefully bending the side electrode.
7. Install the spark plug carefully by hand to avoid cross-threading.
8. After a new spark plug has been seated by hand, it should be tightened 1/2 turn with a
wrench to compress the sealing washer. If a used plug is being reinstalled, it should only
require 1/8 to 1/4 turn after being seated.
9. Reinstall the spark plug cap.
The spark plug must be securely tightened.
Use only resistor-type spark plugs. Use of non-resistor-type spark plugs will
result in noAC output.
Spark Arrester Maintenance
1. Remove the generator rear cover to access the spark arrestor.
2. Remove the spark arrestor from the muffler by unscrewing the clamp.
3. Clean the spark arrestor with a stiff wire brush.
4. Replace if the wire mesh is perforated or torn.
5. Reinstall the spark arrester.
6. Reinstall rear cover.
If the generator has been running, the muffler will be very hot.Allow it to cool before proceeding.
The spark arrester must be serviced every 100 hours to maintain its efficiency.
Inspect the spark arrester screen for holesor tears.