Winco DE4040 Setup guide

WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057
SERVICE DEPT. 507-357-6831 • SALES DEPT. 507-357-6821
www.wincogen.com
INSTALLATION AND
OPERATORS
DE4040/2
GENERATOR
MANUAL
MANUAL KEY START AND DSE4510 ELECTRIC START

2OPM-106
REV B
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS 2
SAFETY INFORMATION 3
ANSI SAFETY DEFINITIONS
TESTING POLICY 3
SPECIFICATIONS 4
DE4040F4
INTRODUCTION 4
PRODUCT DESCRIPTION
PREPARING THE UNIT 5
UNPACKING
LIFTING THE GENERATOR SET
INSTALLATION 5
GENERAL INFORMATION
ENGINE GENERATOR SET MOUNTING
VENTILATION REQUIREMENTS
INSTALLING THE FUEL LINE
LUBRICATION
COOLANT
INSTALLING THE BATTERY
SERVICING BATTERIES
A.C. ELECTRICAL CONNECTIONS 7
CURRENT TRANSFORMERS
NEUTRAL AND GROUND LUGS
GENERATOR CIRCUIT BREAKER
ENGINE CONTROL PANEL LAYOUT 8
MANUAL KEY START
INITIAL START UP
DSE4510 ELECTRONIC START 9
STARTING PROCEDURE
INITIAL START UP
FRONT PANEL CONFIGURATION 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 to
respond to your needs faster.
MODEL __________________________________________________
SERIAL NUMBER _________________________________________
PURCHASE DATE _________________________________________
DEALER NAME ___________________________________________
DEALER PHONE # ________________________________________
DSE4510 DEFAULT CODES 11
DE4040 TROUBLESHOOTING TABLE 12
AIR COMPRESSOR 12
AIR COMPRESSOR SPECIFICATIONS
CONNECTING TO COMPRESSOR
START UP
ADJUSTING AIR PRESSURE
ADJUSTING THE BELT
AIR COMPRESSOR MAINTENANCE
CHECKING THE OIL LEVEL
CHANGING THE OIL
CHANGING THE OIL FILTER
REPLACING FINE SEPARATOR CARTRIDGE
REPLACING THE AIR INTAKE FILTER
TROUBLESHOOTING
FLOW DIAGRAM
AIR COMPRESSOR TROUBLESHOOTING TABLE 16
DSE4510 WIRING SCHEMATIC 17
KEY START PANEL SCHEMATIC 18
ENGINE HARNESS SCHEMATIC 18
THREE PHASE AC WIRING- DELTA 19
THREE PHASE AC WIRE HIGH AND LOW WYE 19
SINGLE PHASE 311 WINDING 19
12 MONTH LIMITED WARRANTY 20

3OPM-106 REV B
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 using this equipment.
5. CLEANLINESS -
Keep the generator and surrounding area clean.
A. Remove all grease, ice, snow or materials that create
slippery conditions around the unit.
B. Remove any rags or other materials that could create a
  potential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. Never remove the protective guards, covers, or receptacle
panels while the engine is running.
D. Use extreme caution when working on electrical components.
High output voltage from this equipment can cause serious
injury or death.
 E.Alwaysavoidhotmufers,exhaustmanifolds,andengineparts.
They can cause severe burns instantly.
F. The use of the engine-generator set must comply with all
national, state, and local codes.
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speciedbythemanufacturerofapplicableengines.
This unit comes factory set for either key start or manual start. With
the DSE 4510 controller used in the manual start option it is possible
to wire the control for remote start. Wiring instructions can be found
further in this manual. The key start version does not have this option.
SAFETY INFORMATION
This engine generator set has been designed and manufactured to
allow safe, reliable performance. Poor maintenance, improper or
carelessusecanresultinpotentiallydeadlyhazards;fromelectrical
shock,exhaustgasasphyxiation,orre.Pleasereadallsafety
instructions carefully before installation or use. Keep these instructions
handy for future reference. Take special note and follow all warnings on
the unit labels and in the manuals.
ANSI SAFETY DEFINITIONS
DANGER:
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations.
WARNING:
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION:
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be used to
alert against unsafe practices.
1. ELECTRICAL SHOCK -
The output voltage present in this equipment can cause fatal electric
shock. This equipment must be operated by a responsible person.
A. Do not allow anyone to operate the generator without proper
instruction.
B. Guard against electric shock.
C. Avoid contact with live terminals or receptacles.
D. Use extreme care if operating this unit in rain or snow.
E. Use only three-pronged grounded receptacles
and extension cords.
F. Be sure the unit is properly grounded to an
external ground rod driven into the earth.
2. FIRE HAZARD -
Gasolineandotherfuelspresentahazardofpossibleexplosionand/
orre.
A. Do not refuel when the engine is running or hot.
B. Keep fuel containers out of reach of children.
 C.Donotsmokeoruseopenamenearthegeneratorsetorfuel
tank.
 D.Keepareextinguishernearbyandknowitsproperuse.
Fire extinguishers rated ABC by NFPA are appropriate.
E. Store fuel only in an approved container, and only in a well
ventilated area.
F. Follow local codes for closeness to combustible material.
3. DEADLY EXHAUST GAS -
Exhaust fumes from any gasoline engine contain carbon monoxide, an
invisible, odorless and deadly gas that must be mixed with fresh air.

4OPM-106
REV B
SPECIFICATIONS
DE4040F4
MODEL DE4040F4-3 DE4040F4-4 DE4040F4-17 DE4040F4-18
Generator
Wattage 33,500 40,000 40,000 40,000
Volts 120/240 120/208 120/240 277/480
Phase Single Three Three Three
PF 1.0 .80 .80 .80
Amps 138 139 120 60
Hertz 60 60 60 60
Engine
Model FPT N45SM2 Turbocharged
Starting System 12 Volt Manual
Mufer Standard
FuelConsumption(fullload) 4.57Gal/hr
Generator Testing Resistance
Model Stamford UC1224D
Winding Group 311
Resistances Ohms
Rotor 0.59
Stator   0.181@22°C
Exciter Rotor 0.071
Exciter Stator 21.0
Voltage Regulator SX460
EngineFluidSpecications
Fuel ASTM D-975 -1D or 2D
EN590 or equivalent
Oil Type 10W-30 CF-CH4
Oil Capacity 13.5 Quarts
CoolingSystem  50/50mix
INTRODUCTION
PRODUCT DESCRIPTION
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
from no load to rated load for standard mechanical governors. 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.
NOTICE: These engine generator sets have only basic engine
protections. The manual key start panel only provides low-oil pressure,
high compressor oil temperature, and high-coolant temperature
protection. The DSE 4510 electronic start panel displays a voltage
and frequency reading. Based on this information, it also provides
basicover/underspeedandvoltageprotection.Low-oilpressureand
high-coolanttemperaturereading/shutdownsareprovidedbysenders
mounted on the engine. No other control options are available. If your
application requires additional safety devices or signals, consider
upgrading to the DR series generators manufactured by WINCO.
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 come standard with a manual key start
system.Thiskeystartsystemutilizesasafetylatchingrelaythatshuts
the unit down if the oil pressure gets low or if the water or compressor
oil temperatures get too high. The safety latching relay must be
depressed during cranking. The optional DSE4510 digital controller
is available and electronically starts the generator set.
GENERATOR SET:
Every WINCO 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 data plates providing additional
information to document build data for warranty and replacements
parts. Be sure to have the main WINCO unit data plate information
recorded inside the front cover of this manual for future reference
andforidenticationwheneverrequestingeldorfactoryassistance.
Primaryeldsneededforassistancearecompletemodelnumberand
serial number.
ENGINE:
Thismanualcoversspecicoperationofthecombinedengine
generator set. The basic engine information provided in this manual is
not suitable for all operating conditions. Refer to the engine operators
manual for more detailed operation and maintenance information.
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.GototheWINCOwebsiteforalistof
enginedealers(http://wincogen.com/Engine_Support)orcontactthe
WINCO Service Department.
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 may decrease 3½% for each
1000 feet above sea level, and will decrease an additional 1% for each
10degreesFahrenheitabove60°Fahrenheit.Unitsshouldnotbe
operatedinambienttemperaturegreaterthan125°Fahrenheit.
GENERATOR:
WINCOgeneratorsetsusebrushless,AVR(Auto-VoltageRegulator)
controlled broad-range generator ends. The generator converts
rotational mechanical energy into electrical energy. These WINCO units

5OPM-106 REV B
are equipped with generators manufactured by Cummins Generator
Technology. Each generator ‘end’ has its own data tag. A unique serial
number is on the data plate and the data label is affixed to the main
frame on the generator on the left side.
PREPARING THE UNIT
UNPACKING
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specicationpagesinthis
manual to ensure that this unit meets your job requirements.
CAUTION: EQUIPMENT DAMAGE:
This unit is 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.
Once generator set 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. Installation and Operator’s 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 generator
line. It is the responsibility of the installing party to follow the lifting
equipment’s operator’s 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 the use
during the manufacturing process and are designed for lifting of the
individual generator set components.
WARNING:
NEVER attempt to lift the fuel tank 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. Also, be sure the generator MLCB (main line
circuit breaker) in is the “off” position and the unit starting battery is
disconnected.
GENERAL INFORMATION
This engine-generator set is designed and built as an open power unit,
meaning no weather protection has been provided. This unit must be
installed inside of an enclosure that will provide proper protection from
the elements and ventilation.
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.
ENGINE GENERATOR SET MOUNTING
The unit’s main frame must be bolted solidly to a solid base. The en-
gine-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.
WARNING: EQUIPMENT DAMAGE:
Never mount these engine-generator sets to a wooden base/structure.
Over time, the wood will deteriorate and the unit mountings will come
loose. These units must be mounted to a steel or concrete base.
The unit should be mounted to allow ample working room around it.
A general rule to follow is to allow 24 inches or more of clearance
for maintenance. Follow local codes for clearance from combustible
surfaces.

6OPM-106
REV B
VENTILATION REQUIREMENTS
WARNING: EQUIPMENT DAMAGE:
It is the installer’s responsibility to ensure that there is sufcient cooling
air available to prevent the engine and generator from over heating.
Damage caused by overheating is not covered by warranty.
Providing proper air movement during your installation planning is
absolutely essential. You will need to provide a fresh air inlet as well as
ahotairoutlet(totheoutsideofprotectionhousing)forproperengine
performance. These engine-generator sets 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 enclo-
sure to ensure 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, the louvers should be 1½times
as large as the area of the radiator face to prevent back pressure.
In addition to a hot air discharge, you must plan a fresh air intake
opposite the radiator discharge. There fresh air inlets should also be
1½to 2 times larger than the radiator face. The extra air inlet area is
requiredtominimizerestrictionandtoprovidecombustionairforthe
engine. Do not block fresh air intakes with other equipment as this will
resultininsufcientairowtotheengineforcooling.Installingthem
oppositethehotairdischargewillallowasweepingowofcoolingair
across the engine, preventing hot spots.
INSTALLING THE FUEL LINE
This unit comes standard with a 54 gallon fuel tank. A larger tank that is
supplied by the customer may be used to fuel the generator.
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.
DE44 FUEL CONNECTIONS
Fuel Inlet
Connection
Fuel Return
Line Connection
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.
Fiat Oil Viscosity Table
COOLANT
WARNING: PERSONAL INJURY:
Never open a hot radiator cap.
Before starting the engine, check the coolant level in the radiator
overow.Ifitislow,rellasneeded.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 12 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
Model Voltage BCI Group Min. CCA Rating
DE4040F4 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.
42
-35 -30 -25 -20
SAE 10W
SAE 20W
SAE 30
SAE 40
SAE 10W -30
SAE 10W -40
SAE 10W -60
SAE 15W -40
mineral base
SAE 15W -40
semisynthetic base
SAE 20W -60
semisynthetic base
SAE 5W -30
synthetic base
SAE 0W -30
synthetic base
-15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 °C
°F
-31 -22 -13 -4 5 14 23 32 41 50 59 68 77 86 95 104 113 122

7OPM-106 REV B
Installation and servicing of batteries must only be preformed or
supervised 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:
NEVER dispose a battery in a re. The battery is capable of exploding.
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
rst and then the positive cable.
5. Be sure all connections are tight and coat the terminals and cable
ends 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 always be taken.
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 with water and the area dried.
DANGER: EXPLOSIVE FIRE RISK:
1. Never smoke when near batteries.
2. Do not cause a ame or spark in the battery area.
3. 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. Different types of batteries require various types
ofmaintenance.Refertothebatterymanufacturerforspecic
recommendations.
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. Depending on your battery
type, check the electrolyte 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: The symbol always indicates ground where shown. All
wiring must be completed in accordance with the National Electric
Code as well as any state and local codes.
Youmustpayparticularattentiontowiresizerequirementforthe
amperage of service you are dealing with. Wire amperages have
been derated for 40° C ambient temperatures operation.
WARNING:
Make sure the generator is disconnected from the battery to prevent
accidental starting.
CURRENT TRANSFORMERS
Currenttransformers(CT)havebeenshippedloosewiththegenerator.
The CTs will be labeled G1, G2, and G3 on the black wire next to the
CT. Ensure these are corresponding with the correct leads. Run the
wires through the CT so that the white wire is facing the generator and
the side with the black wire facing towards the load. Zip tie the CTs
tightly in place to prevent them from rubbing through the lead wires or
against the generator end. If power readings are negative, check CT
orientation.
G3CT
G2CT
G1CT
G3Wires
G2Wires
G1Wires

8OPM-106
REV B
NEUTRAL AND GROUND LUGS
Each DE unit comes with a neutral lug from the factory to provide
a connection point from the generator to the transfer switch or load
distribution center. The generator ships from the factory with a
bonded neutral.
Ground lugs are provided to connect to the distribution center. The
Generator ships from the factory with a bonded neutral.
Model Lug AMP Wire Capability Torque
DE4040 225 #4 AWG to 300 MCM 250 in. lbs.
WARNING: EQUIPMENT DAMAGE:
When installing a three phase 240 Volt system, be sure you know
which lead is high voltage ‘wild’ leg (208 Volt to neutral). The generator
normally carries the high voltage on the G2 lead.
GENERATOR CIRCUIT BREAKER
This unit does not come with circuit breaker protection. This gives
exibilityforinstallationasthecircuitbreakercanbemountedremotely.
A circuit breaker is required in the system
Thefollowingtablesarerecommendedcircuitbreakersize,lugwire
sizesandtorquespecications.Seeactualbreakerforadditional
information and restrictions.
kW Voltage PH AMP Wire Capability Lug Torque
33.5 120/240 1 150 #4 AWG - 300 MCM 250 in lbs
40 120/208 3 150 #4 AWG - 300 MCM 250 in lbs
40 120/240 3 125 #4 AWG - 300 MCM 250 in lbs
40 277/480 3 60 #8-3/0AWG 120 in lbs
Foradditionalconductorsizesbetweenthegeneratorandtheload.
Based on wire type and temperature rating.
Wire Temperature Rating
CB
AMP
Cu Conductor AI Conductor
kW Voltage PH 75°C 90°C 75°C 90°C
33.5 120/240 1 150 3/0AWG 1/0AWG 4/0AWG 3/0AWG
40 120/208 3 150 2/0AWG 1/0AWG 4/0AWG 3/0AWG
40 120/240 3 125 1/0AWG #1 AWG 3/0AWG 2/0AWG
40 277/480 3 60 #4 AWG #6 AWG #3 AWG #4 AWG
Wirehasbeenderatedfor40°Cambienttemperature.Foradditional
informationonwiresizingrefertotable310.16oftheNationalElectrical
CodeANSI/NFPA70.
ENGINE CONTROL PANEL LAYOUT
MANUAL KEY START
A. Three position start switch
1. Off - In this position all power to the engine is turned off and the
engine is stopped.
2. 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.
3. 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 come on when you go to start the engine.
This will also come on when you go to start 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 the meter
This meter records the actual hours of the engine operation.
D. 15 Amp fuse
This fuse protects all the DC wiring in the engine control panel and on
the engine. If this fuse is 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, a high water
temperature fault, or a high compressor oil temperature fault, this relay
will trip, disconnecting the furl 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.
A
B
C
D
E

9OPM-106 REV B
DSE4510 ELECTRONIC START
NOTE: See DSE4510 Wiring Schematic in this manual for proper
wiring procedure.
STARTING PROCEDURE
WARNING: EQUIPMENT DAMAGE:
Before attempting to start this unit, complete your pre-start checklist
and ensure 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.
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.
INITIAL START UP
Use the following check list to verify correct installation before starting
the engine.
□Engineoil.Fillasrequiredwithpropergrade/qty.
□Engine coolant. Fill as required with proper mixture.
□Unit mounting base properly bolted down.
□Clearance for service and maintenance on all sides.
□Properfuellinematerialandsize.
□All fuel line connections tight.
□Battery connections clean and tight
□Battery fully charged.
□All AC and DC wiring installed and properly protected.
□Compressoroil.Fillasrequiredwithpropergrade/qty.
CONTROL LAYOUT
A. Deep Sea 4510 Engine control
B. 2 Amp fuses
These fuses are in the AC input line from the generator that provide the
AC Voltage reading on the display. If the fuse is blown, the DSE4510
will not display a voltage or frequency reading and will shutdown on low
voltageorfrequency.(ReplacementfuseATO-ATC-2A-250Volt)
B
A
C
INITIAL START UP
Use the following check list to verify correct installation before starting
the engine.
□Engineoil.Fillasrequiredwithpropergrade/qty.
□Engine coolant. Fill as required with proper mixture.
□Unit mounting base properly bolted down.
□Clearance for service and maintenance on all sides.
□Properfuellinematerialandsize.
□All fuel line connections tight.
□Battery connections clean and tight
□Battery fully charged.
□All AC and DC wiring installed and properly protected.
 □Compressoroil.Fillasrequiredwithpropergrade/qty.
After completing the previous checklist, the engine-generator set is
ready for the initial start-up test.
STARTING PROCEDURE
1.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.
2. 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 sufficient oil pressure to operate
properly and the high coolant temperature has not been exceeded.
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.
3. After the engine is up and 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 minutes before applying load.
4. When stopping the unit, it is best to turn off all of 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 any reason during operation the oil pressure should drop below
the 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 find the unit stopped with the relay button popped out,
it could have been caused by either low oil pressure or high water
temperature.

10 OPM-106
REV B
attention to an undesirable condition. Warning alarms are self-resetting
when the fault condition is removed. The icon will appear steady in the
display.
SHUTDOWN
Shutdowns are critical alarm conditions that stop the engine and draw
the operator’s attention to an undesirable condition. Shutdown alarms
arelatching.ThefaultmustberemovedandtheSTOP/RESETbutton
pressedtoresetthemodule.Theiconwillbeashinginthedisplay.
Example of DSE home page display
FRONT PANEL CONFIGURATION
1. Press the and the buttons together to enter the editor
mode.
2. Press the or navigation buttons to cycle through the front
paneleditortoselecttherequiredpageinthecongurationtables.
3. Press the to select the next parameter or to select the
previous parameter within the current page.
4. When viewing the parameter to be edited, press the button,
thevaluebeginstoash.
5. Press the or buttons to adjust the value to the required
setting.
6. Press the button to save the current value, the value ceases
 ashing.
7. Press thebuttontosaveandexittheeditor,theconguration
icon is removed from the display.
NOTES:
Pressing and holding the or buttons will give auto-repeat
functionality. Values can be changed quickly by holding the
buttons for a prolonged period of time.
The editor automatically exits after 5 minutes of inactivity to
ensure security.
The PIN number is not set by WINCO when the module leaves the
factory. If the code has been ‘lost’ or ‘forgotten’, the module must
be returned to the DSE factory to have the module removed. A
charge will be made for this procedure.
NB - This procedure cannot be performed away from the factory.
The PIN number is automatically reset when the editor is exited
(manually or automatically) to ensure security.
C. 10 Amp fuse
This fuse supplies the 12 Volt DC to power the DSE 4510 controller
circuits on the boards. If this fuse is blown, the DSE 4510 will not
functionatall.(ReplacementforATO-ATC2A-250Volt)
After completing the previous checklist, the engine-generator set is
ready for initial start-up.
 1.PressandreleasetheredStop/Resetbutton
2. Press and release the green Start Engine button. The engine-
generator set will crank and start automatically. If the engine fails
to start, it will display a fault code and the common alarm
indicator will start blinking. See the fault code appendix portion of
this manual.
3. With the unit running smoothly, check the no load voltage and
frequency of the generator output.
4. Once the unit is running and the safety on time has elapsed, the
engine monitoring switches are active for low oil pressure and
high water temperature.
5. After the engine is up and 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 minutes before
applying the load. See Air Compressor section in this manual for
starting the air compressor.
6. When stopping the unit, it is best to turn off all the loads before
pressing the stop button. This prevents your loads from getting
low voltage while still running during shutdown.
STOP/RESET(redbutton)-Thisbuttonplacesthemodule
intoitsStop/Resetmode.Thiswillclearanyalarmconditions
for which the triggering criteria have been removed. The fuel
supplyde-energizesandtheenginecomestoastandstill.
Should a remote start signal be present while operating in
this mode, a remote start WILL NOT occur.
AUTO(whitebutton)-Thisbuttonplacesthemoduleinto
its Automatic mode. This mode allows the module to control
the function of the generator automatically. The module will
monitor the remote start input and once a start request is
made, the set will be automatically started and placed on
load. The module will then wait until the next start event.
START(greenbutton)-PressingthisbuttonfromSTOP/
RESET will start the engine and run the load.
MENU NAVIGATION - Used for navigating the
instrumentation,eventlog,andcongurationscreens.
PROTECTIONS
Whenanalarmispresent,thecommonalarmLEDifcongureswill
illuminate. The LCD display will show an icon to indicate the failure.
WARNINGS
Warnings are non-critical alarm conditions and do not affect the
operation of the generator system, they serve to draw the operator’s

11OPM-106 REV B
Auxiliary Inputs - Auxiliary inputs can be be user
conguredandwilldisplaythemessageaswrittenby
the user.
FailtoStart-Theenginehasnotredafterthepreset
number of start attempts.
Low Oil Pressure - The module detects that the engine
oil pressure has fallen below the low oil pressure
pre-alarm setting level after the Safety On timer has
expired.
Engine High Oil Temperature - The module detects
that the engine oil temperature has exceeded the high
engine temperature pre-alarm setting level after the
Safety On timer has expired.
Underspeed - The engine speed has fallen below the
underspeed pre-alarm setting.
Overspeed - The engine speed has risen above the
overspeed pre-alarm setting.
Generator Under Voltage - The generator output
voltage has fallen below the pre-set pre-alarm setting
level.
Generator Over Voltage - The generator output voltage
has risen above the pre-set pre-alarm setting after the
Safety On timer has expired.
Generator Under Frequency - The generator frequency
has fallen below the pre-set pre-alarm setting after the
Safety On timer has expired.
Generator Over Frequency - The generator output
frequency has risen above the pre-set alarm setting
AnalogueInputConguredAsDigital-Theanalogue
inputscanbeconguredtodigitalinputs.Themodule
detectsthataninputconguredtocreateafault
condition has become active.
Charge Failure - The auxiliary charge alternator voltage
islowasmeasuredfromtheW/Lterminal.
Low Fuel Level - The level detected by the fuel level
sensor is below the low fuel level pre-set alarm setting.
High Fuel Level - The level detected by the fuel level
sensor is above the high fuel level pre-set alarm
setting.
Delayed Over Current - The measured current has
risenabovetheconguredtriplevelforacongured
duration.
kW Overload - The measured kW has risen above the
conguredtriplevelforaconguredduration
CAN ECU Fault - The engine ECU has detected an
alarm – CHECK ENGINE LIGHT Contact Engine
Manufacturer for support.
CANDataFail-ThemoduleisconguredforCAN
operation and does not detect data on the engine Can
data link
Emergency Stop -The emergency stop button has been
depressed. This failsafe (normally closed to emergency
stop)inputandimmediatelystopsthesetshouldthe
signal be removed.
Oil Sender Open Circuit - The oil pressure sensor has
been detected as being open circuit.
Coolant Temperature Sender Open Circuit - The
coolant temperature sensor has been detected as
being open circuit
Oil Filter
MaintenanceAlarmMaintenancedueforoillter.
Air Filter - Maintenance Alarm Maintenance due for air
lter.
Fuel Filter - Maintenance Alarm Maintenance due for
fuellter.
DSE4510 DEFAULT CODES

12 OPM-106
REV B
AIR COMPRESSOR
This unit has been equipped with an air compressor that uses an
auxiliary shaft from the generator to provide counter-clockwise 120 PSI
@40CFM
AIR COMPRESSOR SPECIFICATIONS
Model Rotorcomp NK 31
Max.OperatingPressure  218PSI(15bar)
Max.GaugePressure   239PSI(16.5bar)
OilCapacity     101.4oz.(3.17qts)
CONNECTING TO COMPRESSOR
Locatethe3/4”NPTontheaircooler(referencefollowingimage)and
attach your air hose.
START UP
Follow the starting procedure found previously in this manual.
Once the engine is running at speed, engage the air compressor toggle
switch to the ‘on’ position.
WARNING: EQUIPMENT DAMAGE
Always start and stop engine with the air compressor OFF.
ADJUSTING AIR PRESSURE
Adjustment of the maximum pressure of the compressor is done
through the switch that it mounted near the outlet of the compressor.
3/4”NPT
DE4040 TROUBLESHOOTING TABLE
Problem Possible Causes
Engine won’t crank Low/deadbattery
Blown DC fuses
Defective DSE4510
Defective key switch
Loose or dirty battery terminals
Defective starter
Defective start solenoid
Locked up engine genset
Defective engine harness
Improper battery voltage to start solenoid,
fuel pump, or fuel solenoid
Engine cranks but will not start Improper fuel delivery to the unit
Fuel supply shut off
Fuel tank empty
Air in the fuel system
Engine fuel solenoid has not opened
Defective fuel pump
Defective fuel solenoid
Defective engine harness
Improper battery voltage to fuel pump or fuel
solenoid
Engine starts, then stops and
alarm light comes on
Engine oil pressure is low
Engine has high water temperature
Refer to fault code on DSE4510
Engine will not come up to speed
after it starts
Insufcientfuelvolumegettingtotheunit
1. Too small of fuel line
2. Fuel racks not open properly
Governor is defective
AC short in generator components
No AC output from generator Defective diode
Defective voltage regulator
Defective rotor
Defective stator
Defective exciter rotor
Defective exciter stator
AC short in the output leads
Defective/opengeneratoroutputbreaker
Wiring error
Negativecurrent/kWonDSE
display
Reverse CT direction
Noairoutput/lowoutput See Air Compressor Trouble Shooting Table
Air compressor
toggle switch

13OPM-106 REV B
AIR COMPRESSOR MAINTENANCE
All maintenance, assembly, and repair work should be carried out by
anauthorized,qualied,speciallytrainedpersonnel.Theseprecautions
must be followed:
1. Only use suitable tools for maintenance and repair parts.
2. Only use genuine parts.
3. All maintenance and repair work must only be carried out with the
complete unit shut down and the power supply switched off.
Ensure the machine is secured against accidental switch-on.
WARNING: PERSONAL INJURY
Before removing plugs, lters, and other pressurized parts, the
compressor must be cut off from all pressure sources and a pressure
relief of the entire system must be carried out.
 4.Neveruseammablesolventsorcarbontetrachloridetoclean
parts.
5. Always ensure the area is clean and free from dirt when
conducting maintenance or repair work. Cover parts and exposed
openings with a clean cloth, paper, or adhesive tape.
6. Do not conduct any welding or other heat producing work around
the oil system.
7. Ensure no tools, loose parts, or cloths are left on or on the
system.
 8.Priortousingtheunit,checkwhethertheoperatingpressure,
temperatures, time settings, and the oil levels are correct. Also
check that the control and switch-off devices function properly.
MAINTENANCE SCHEDULE CHART
Before operation
• Check oil level
Once after 50 hours
• Check oil level
•Tightenallscrewpipettings&electricalscrewterminalttings
•Checkallotherconnectionsforrmseating
Every 100 hours
• Check oil level, top off if low
Every 1,000 - 6,000 hours or annually
•Replaceneseparatorcartridge
• Change oil and replace
•Replaceoillter
•Replacelterelementinintakeairlter
• Check system for leaks and inspect system
There is an approximate 30PSI difference between the cutout pressure
and the point at which the switch loads the compressor again. In order
to reach the adjustment nut, unscrew the acorn nut on the top of the
gray switch housing and lift the housing off of the switch. To increase
thecutoutpressure,turnthenutclockwise;tolowerthecutoutpressure
turn.
ADJUSTING THE BELT
NOTE: When adjusting or replacing the belt on the unit, care must
be taken to ensure that the pulleys are properly aligned and that the
belt is properly tensioned. Failure to do this may result premature
wear and failure of the drive belts, damage to the equipment, or poor
performance. There are several things to keep in mind when adjusting
the compressor.
There are four bolts that bolt into the base of the compressor that can
be loosened to adjust the compressor front to rear and help with minor
tweakstotheangle.Adjusttheseboltsrstinordertodoanymajor
front to rear adjustment. Torque those bolts to 32 FT-LBS. There are
fourcornerboltsthatsecuretheslidingbaseintoplace;thesemustbe
loosened before the tension can be set on the belt. Once the four bolts
are loosened, the two bolts on the right side of the compressor base
can be turned clockwise in order to tighten the belt or counter clockwise
in order to allow the belt to be loosened. Tighten the belt until there is
2-3lbs of tension in the belt that can be checked with a gauge or about
.3inchesofdeectionatthemidpointofthebelt.Itisrecommendedto
use a proper pulley alignment too when making any adjustments to the
pulley in order to keep the alignment accurate so as to prevent excess
wear on the belts. Once the belt tension has been set, tighten the four
corner screws to lock the tension and alignment into place. Verify after
tightening all four corner bolts that the pulley alignment has not shifted.

14 OPM-106
REV B
NOTE: The compressor must be operated with an oil suitable for
special requirements. This oil must be approved by the manufacturer
for screw compressors. It must even be suitable under unfavorable
operating conditions, such as soiling of the intake air with gases,
solvent vapors and exhaust gases and at high ambient temperatures.
Suitableoiltypesandoilmanufacturerscanbespeciedforscrew
compressor on request.
Renedoils(mineraloils)syntheticoilsandbiooils(biodegradable)
can be used as screw compressor oil. The materials and gaskets used
in the screw compressor system must be taken into account when
selecting the oil type. Corrosion and other material damage may not
occur. It is not permissible to mix different oils.
Thiscompressorrequires101.4ounces(3.17quarts)ofoilifitis
completelydrained.Usecautionwhenrelling.
 8.Turnonthecompressorandallowtorunfor3minutes.
9. Check oil level. Top off to the maximum level if needed.
CHANGING THE OIL FILTER
WARNING: PERSONAL INJURY
Rotating, pressurized, and hot components. The oil change can only
be changed at a standstill and with the compressor system completely
discharged.
1. Switch off the compressor and disconnect the battery to prevent
the engine from starting.
 2.Removetheoilltercartridge(Ref.1)withasuitabletool,i.e.oil
  lterstrapwrench.
 3.Oilthegasket(Ref.2.)onthenewltercartridgewiththesameoil
type in use with the compressor.
 4.Screwthenewoilltercartridgeon(Ref.3)andtightenbyhand.
5. Switch on the compressor.
 6.Checkthelterforleakswhilethesystemisrunning.
7. Turn off compressor and check oil level. Top off to the maximum
level if needed.
REPLACING FINE SEPARATOR CARTRIDGE
WARNING: PERSONAL INJURY
Rotating, pressurized, and hot components. The ne separator
cartridge can only be changed at a standstill and with the compressor
system completely discharged.
NOTE: Heavily soiled intake air or a poor oil quality will result in early
replacementoftheneseparatorcartridge.
7.4 [en] 02/2014
Installation and operating manual - NK 31ROTORCOMP VERDICHTER
7.3.3 Filling with oil
Attention
Observe the oil recommendation, see “Lubricants
and Operating Materials”. Add oil of the same oil
type from the same manufacturer.
Switching over to another oil type can require the
compressor module to be flushed.
ROTORCOMP recommends also replacing the
oil filter during an oil change.
• Replace the oil filter if necessary
• Pour oil into the filler neck on the separator
tank up to the maximum level and screw the
screw plug 1onto the filler neck by hand
(see Figure 7-2).
• Switch on the screw compressor and allow it to
run for approx. three minutes.
• Oil level check:
Top up the missing oil quantity again up to the
maximum level.
• Check sheet entry (see chapter 7.7 “Mainte-
nance check sheet”).
7.4 Oil filter
Warning
Rotating, pressurized and hot components,
DANGER OF INJURY
– The unit parts, oil and oil filler plug may be
over 80°C/176°F; danger of burns!
– Wear personal safety equipment!
The oil filter replacement may only be carried
out at a standstill and with the screw compressor
system completely discharged.
7.4.1 Oil filter replacement intervals
According to the specifications of the system
manufacturer.
For the reference values for the screw compres-
sor compact module, see chapter 7.8 “Mainte-
nance intervals”.
7.4.2 Oil filter replacement
Figure 7-3
• Switch off the system and completely release
the pressure in the system.
• Remove the oil filter cartridge 1with a suitable
tool, e.g. oil filter strap wrench.
• Oil the gasket 2on the new oil filter cartridge 1
with oil of the same oil type as in the compres-
sor module.
Note
Dispose of the old oil filter cartridge according to
the applicable regulations.
• Screw the new oil filter cartridge onto the con-
nection nipple 3and tighten by hand. No tool is
required.
• Switch on the screw compressor.
• The oil filter must then be checked for leaks
with the system running.
• Oil level check:
Top up the missing oil quantity again up to the
maximum level.
• Check sheet entry (see chapter 7.7 “Mainte-
nance check sheet”).
1
2
3
CHECKING THE OIL LEVEL
Oillevelcanonlybecheckedattheoillleropening.
NOTE: The screw cap has a safety hole on the side, oil or air escapes
if there is any residual pressure in the tank.
1. Switch off the compressor and disconnect the battery to prevent
the engine from starting.
2. Wait one minute at standstill.
 3.Screwoffplugofthellerneckbyhandwiththeoillevel
  depressurized.
4. Check the oil level. Reference the previous diagram.
5. If necessary, top off oil to the maximum level.
 6.Screwontheplugrmlybyhand.
7. Switch on the system.
 8.Checktheplugforanyleaks,replacetheo-ringifnecessary.
9. Carefully remove escaped, excess oil.
CHANGING THE OIL
Refer to the maintenance schedule chart for required oil change
intervals.
WARNING: PERSONAL INJURY
Rotating, pressurized, and hot components. The oil change can only
be changed at a standstill and with the compressor system completely
discharged.
NOTE: Dispose of the used oil according to applicable regulations.
1. Switch off the compressor and disconnect the battery to prevent
the engine from starting.
2. Completely release the pressure in the system.
 3.Slowlyscrewoffthescrewplugontheoilllerneck.
 4.Unscrewtheoildrainscrew(ref.1)anddraintheusedoilintoan
approved container.
5. Clean the oil drain screw and screw back in.
 6.Replacetheoillterifnecessary.SeeChangingOilFilterofthe
Air Compressor section of this manual.
 7.Rellwithnewoilatthellernecktothemaximumlevel.
7.2 [en] 02/2014
Installation and operating manual - NK 31ROTORCOMP VERDICHTER
7.2 Oil level
An important factor for the operating safety of the
system is the oil level in the oil reservoir.
The oil level check must be carried out before
commissioning the screw compressor module
and then repeated every 100 operating hours..
The exact oil level check can only be carried out
via the oil filler opening.
Warning
Rotating, pressurized and hot components,
DANGER OF INJURY!
7.2.1 Oil level check via oil filler opening
Warning
– The unit parts, oil and oil filler plug 1may be
over 80°C/176°F; danger of burns!
Wear personal safety equipment!
– With hot oil, the oil level can be approx. 10 mm
higher than with cold oil shortly after discharg-
ing.
As a result, oil may escape when the oil filler
plug is opened at the maximum oil level. In
this case, close the oil filler plug again imme-
diately and carefully remove the oil which has
escaped.
Figure 7-1
Note
The screw cap of the oil filler neck is provided
with a safety hole on the side from which oil or air
escapes if there is any residual pressure in the
separating tank. Wait briefly in this case.
• Switch off the system and secure it against
unauthorized switch-on.
• Wait for one minute at standstill.
• Screw off the screw plug 1of the filler neck by
hand with the oil level depressurized.
• Check the oil level.
• If necessary, top up oil of the same oil type and
the same brand up to the maximum level.
MAX
MIN
1
7.3
[en] 02/2014
Installation and operating manual - NK 31
Note
The oil filler neck is positioned so that overfilling
of the screw compressor system is not possible.
Excess oil runs out of the filler neck again.
• Screw on the screw plug 1firmly by hand.
• Switch on the system.
• Check the oil filler plug for leaks and replace
the O-ring if necessary.
• Carefully remove escaped, excess oil.
7.3 Oil change
Warning
Rotating, pressurized and hot components,
DANGER OF INJURY
The oil change may only be carried out at a
standstill and with the screw compressor system
completely discharged.
7.3.1 Oil change intervals
According to the specifications of the system
manufacturer.
For the reference values for the screw compres-
sor compact module, see chapter 7.8 “Mainte-
nance intervals”.
7.3.2 Oil drain points
The system should be at operating temperature
in this case.
Figure 7-2
Note
Dispose of the used oil according to the appli-
cable regulations.
• Switch off the screw compressor and then
secure it against being switched on again by
removing the main switch.
• Completely release the pressure in the screw
compressor system.
• Slowly screw off the screw plug on the oil filler
neck.
• Carefully unscrew the oil drain screw 1and
catch the used oil in a suitable container.
• Clean the oil drain screw 1and screw in again.
1

15OPM-106 REV B
TROUBLESHOOTING
In the event you will need technical support, please have the following
information ready:
1. Order number
2. Model number
3. Serial number
4. Year of manufacture
5. Max. RPM
 6.Max.operatingpressure(PSI)
 7.Max.operatingtemperature(˚F)
 8.Max.operatingtemperature(˚C)
9. Max. operating pressure in bar
FLOW DIAGRAM
1.Intakelter      2.Intakevalve
2.1No-loadnozzle     3.Controlunit(electric)
3.1 Solenoid valve 4. Screw compressor
5. Separator tank with pre-separation 6. Fine separator
7.Minimumpressurevalve   8.Oilthermostat
9.Oillter      10.Oilcooler
11. Air after-cooler 12. Non-return valve
13.Safetyvalve(optional)
1.2 [en] 02/2014
Installation and operating manual - NK 31ROTORCOMP VERDICHTER
1.5.2 Purpose
The NK 31 is a screw compressor compact mod-
ule designed for installation in a compressed-air
generating station.
The sole intended use of the system is the
compression of atmospheric air. The NK 31 may
only be used to compress gases or other media
following written approval by ROTORCOMP.
The NK 31 may only be installed by specialized
companies with the corresponding know-how.
The safety precautions, technical data, limits, in-
stallation guidelines and regulations for commis-
sioning and operation specified in this operating
manual must be observed and complied with.
1.5.3 Standard delivery scope
With the NK 31, ROTORCOMP offers a com-
pletely equipped, compact compressor module.
The components of the standard delivery scope
are described in the following chapters.
Optionally available components are marked with
(optional).
1.6 Warranty information,
liability disclaimer
ROTORCOMP is a manufacturer of screw com-
pressor components and not of ready-to-operate
compressor systems.
RC shall only be answerable for any defects of
these individual components for which it is re-
sponsible within the scope of the warranty condi-
tions.
Failure to comply with the following instructions
and information shall void any and all liability.
This liability disclaimer also results in the loss of
claims for damages. This applies in particular in
case of:
– Installation not approved by RC
– Improper use
– Operation of the compressor outside the speci-
fied limits
– Failure to observe the safety precautions and
the usual care and caution
– Unsuitable operating materials (gases, oils)
– Condensate in the screw compressor
– Corrosion as subsequent damage
– Improper operation
– Insufficient maintenance, missing proof of
maintenance
– Use of unsuitable tools
– Failure to use genuine spare parts
– Unauthorized modifications to the screw com-
pressor module and/or its components–
1.7 Nameplate
For the location of the nameplate, see Figure 3-1
or 3-3.
Should you have questions, please provide us
with the data on the nameplate. This ensures that
you receive the correct information.
Figure 1-1
Stamping for customers outside Germany
(Europe)
1. Order No.
2. Model
3. Serial No.
4. Year of manufacture
5. Max. rpm
6. Max. operating pressure in psi
7. Max. operating temperature °F
8. Max. operating temperature °C
9. Max. operating pressure in bar
1 2 3 4
5
6
7
9 8
3.2 [en] 02/2014
Installation and operating manual - NK 31ROTORCOMP VERDICHTER
1. Intake filter
2. Intake valve
2.1 No-load nozzle
3. Control unit (electric)
3.1 Solenoid valve
4. Screw compressor
5. Separator tank with pre-separation
6. Fine separator
7. Minimum pressure valve
8. Oil thermostat
9. Oil filter
10. Oil cooler
11. Air after-cooler
12. Non-return valve
13. Safety valve (optional)
2.1
1
2
45
3
3.1
13
6
711
9
8
10
12
Figure 3-2
3.2 Flow diagram of NK 31
(electric control unit)
3.3 Operating description for NK 31
Screw Compressor Compact Module
(electric)
The flow diagram shows a schematic view of the
operating principle and the arrangement of the
main components of the NK 31 screw compres-
sor module with electrical control unit, regardless
of any other equipment.
3.3.1 Standstill
At standstill the solenoid valve 3.1 is deener-
gized, the relief line is open and the downstream
devices are depressurized. The minimum pres-
sure valve 7set to approx. 5.5 bar at the factory
is tightly closed. The intake valve 2is slightly
open at standstill.
1. Switch off the compressor and disconnect the battery to prevent
the engine from starting.
 2.Unscrewtheneseparatorcartridge(Ref.1)withasuitabletool,
  i.e.anoillterstrapwrench.
 3.Oilthegasketonthenewneseparatorcartridgewiththesame
oil type as in the compressor module.
 4.Tightenthenewneseparatorcartridgebyhand.
5. Switch on the system.
6. Check for any leaks.
REPLACING THE AIR INTAKE FILTER
NOTE: Theairltermustnotbecleanedandthenreused,always
replacetheairlter.
WARNING: EQUIPMENT DAMAGE
No dirt or dust particles may get into the air inlet of the air compressor.
1. Switch off the compressor and disconnect the battery to prevent
the engine from starting.
 2.Screwoffthenut(Ref1)andremovetheltercover(Ref.2).
 3.Carefullyremovedustfromthelterhousing.
 4.Removetheoldlter(Ref.3).
 5.Insertthenewlterinthelterhousing.
 6.Securelyscrewtheltercoverbackonusingthewingnut.
7. Switch on the compressor.
 8.Conductatestrunandoperatingtest.
7.5
[en] 02/2014
Installation and operating manual - NK 31
7.5 Fine separator cartridge
Warning
Rotating, pressurized and hot components,
DANGER OF INJURY
– The unit parts and oil may be over 80°C/176°F;
danger of burns!
– Wear personal safety equipment!
The fine separator cartridge may only be re-
placed at a standstill and with the screw com-
pressor system completely discharged.
7.5.1 Maintenance intervals
According to the specifications of the system
manufacturer.
For the reference values for the screw compres-
sor compact module, see chapter 7.8 “Mainte-
nance intervals”.
With heavily soiled intake air or a poor oil quality,
the cartridge is heavily soiled, making premature
replacement necessary.
7.5.2 Replacing fine separator cartridge
Figure 7-4
Note
Dispose of the old fine separator cartridge ac-
cording to the applicable regulations.
• Unscrew the fine separator cartridge 1with a
suitable tool, e.g. oil filter strap wrench.
• Oil the gasket on the new fine separator car-
tridge 1with oil of the same oil type as in the
compressor module.
• Tighten the new fine separator cartridge by
hand. No tool is required.
• Switch on the screw compressor system.
• The fine separator must be checked for leaks
with the system running.
• Check sheet entry (see chapter 7.7 „Mainte-
nance check sheet“).
1
7.6 [en] 02/2014
Installation and operating manual - NK 31ROTORCOMP VERDICHTER
7.6 Intake air filter
7.6.1 Maintenance intervals
According to the specifications of the system
manufacturer.
For the reference values for the screw compres-
sor compact module, see chapter 7.8 „Mainte-
nance intervals“.
In case of heavily soiled intake air, an earlier
replacement of the filter element is necessary
when the optical or electric maintenance indica-
tor (optional) indicates this (perm. vacuum up to
50 mbar).
7.6.2 Replacing air filter element
Figure 7-5
Attention
No dirt or dust particles may get into the air inlet
of the screw compressor.
Note
It is not permissible to clean the filter element;
the filter element must always be replaced in
case of soiling!
Dispose of the old air filter element according to
the applicable regulations.
3
1
2
• Switch off the system and secure it against
unauthorized switch-on.
• Screw off the nut 1and remove the filter
cover 2.
• Carefully remove dust from the filter housing.
• Remove the old filter element 3.
• Insert the new filter element in the filter hous-
ing.
• Lay on the filter cover, ensuring proper posi-
tioning during assembly.
• Tighten the wing nut.
• Switch on the screw compressor system.
• Conduct a test run and an operating test.

16 OPM-106
REV B
AIR COMPRESSOR TROUBLESHOOTING TABLE
PROBLEM POSSIBLE CAUSES REMEDY
Incorrect direction of rotation Phase reversed Reconnect 2 supply line
System does not start No electricity
Combistat switches off due to excessively high temp
Check electrical connections
Check oil level, cooling, thermo-bypass
Systemdifculttostart Motoroutputinsufcient
Drive gear ratio ‘too fast’
Star-delta switchover incorrect
Compressorisoodedwithoil
System has not been discharged yet
Oilisllingtoviscous
Check
Check
Set
Check
Check
Check viscosity
Differential pressure Pressure in separator cartridge too high with
clogged or full separator cartridge
Replace separator cartridge
Combistat switches off due to excessively high temp Oil shortage
Oilltersoiled
Thermostat defective
Oil cooler soiled
Incorrect installation
1. Room ventilation
2. Exhaust air blocked
3. Thermal short circuit
Combistat faulty or incorrectly adjusted
Fan has failed
Check oil level, top off if necessary
Replaceoillter
Replace thermostat
Clean oil cooler on air side and oil side
See Air Compressor Manual
Adjust combistat or replace
Check fan
Safety valve blows Safety valve defective
Fine separator cartridge soiled
System does not relieve continuous operation
System does not switch off automatically
 (drop-outmode)
Replace safety valve
Replace cartridge
Oil in compressed air Oilextractionlinewithnozzleinoilsightglasssoiled
Fine separator cartridge defective
Oillevelinoilreservoirtoohigh;possiblyexcessive
condensate
Clean oil extraction system
Check cartridge and replace if necessary
Observeoillevelmarking;drainand
replace if necessary
System is not discharged during continuous operation,
system does not switch off automatically in case of
intermittent operation, i.e. safety valve blows off
Upper switching point of network pressure monitor
set too high
Solenoid or relief valve defective
Minimum pressure valve jammed
Readjust network pressure monitor
Replace solenoid or relief valve
Check minimum pressure valve for
 smoothmovement;ensuresmooth
movement if necessary
System continually discharges, low feed quantity Solenoid or relief valve defective
Break in electric supply line to solenoid valve
Replace solenoid or relief valve
Eliminate break
Noorinsufcientfeedquantity Intakeltersoiled
Oil shortage
Intake control valve does not open
Leaks in system
Replacelterinsert
Check oil level and top off if necessary
Check control valve
Check, seal off
Control valve does not close Pressure switch or control valve Check setting
Oil exits through intake control valve during stop Sealing surface on intake control valve damaged,
spring in intake control valve broken
Check parts and replace if necessary
System does not relieve Solenoidvalve/electricalsystem
Impulse-pressure relief valve
Check
Check and replace parts if necessary
Control valve constantly discharges Solenoidvalve/electricalsystem Check
Oil escapes during discharging
(oilfoaminneseparatorcartridge)
Oil type incorrect
Oil foam forms during stop
Oil level too high
Oil change
Install discharge delay valve, replace
 withdifferentnozzlediameter
Drain off oil

17OPM-106 REV B
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ENGINE HARNESS SCHEMATIC
NOTE: LOW COOLANT SWITCH IS OPTIONAL. OIL PRESSURE AND COOLANT
TEMPERATURE SENDERS INCLUDED ON MODELS WITH ELECTRONIC ENGINE
CONTROLS. FUEL LEVEL IS FOR UNITS WITH TANKS AND LEAK DETECTION FOR
UNITS WITH SECONDARY CONTAINMENT.

19OPM-106 REV B
THREE PHASE AC WIRING- DELTA SINGLE PHASE 311 WINDING
THREE PHASE AC WIRE HIGH AND LOW WYE

20 OPM-106
REV B
12 MONTH LIMITED WARRANTY
WINCO,Incorporatedwarrantstotheoriginalpurchaserfor12monthsor1000hourswhichever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.
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 12 months or 1000 hours which ever occurs
rstfromthedateofpurchase,transportationchargesprepaid,toyournearestWINCOAuthorizedServiceCenterorto
WINCO, Inc. at Le Center Minnesota.
THERE IS NO OTHER EXPRESS WARRANTY.
Totheextentpermittedbylaw,anyandallwarranties,includingthoseofmerchantabilityandtnessforaparticular
purpose,arelimitedto12monthsor1000hourswhicheveroccursrst,fromdateofpurchase.InnoeventisWINCO
liable for incidental or consequential damages.
Note: Some states do not allow limitation on the duration of implied warranty and some states do not allow the exclusion
or limitation of incidental or consequential damages, so the above limitations may not apply in every instance. This
warrantygivesyouspeciclegalrightswhichmayvaryfromstatetostate.
WINCO reserves the right to change or improve its products without incurring any obligations to make such changes or
improvement on products purchased previously.
EXCLUSIONS:
WINCO does not warrant Engines. Engines are covered exclusively by the warranties of their respective manufacturers,
see enclosed warranties.
WINCO does not warrant Component Parts that are warranted by their respective manufacturers.
WINCOdoesnotwarrantmodicationsoralterationswhichwerenotmadebyWINCO,Inc.
WINCOdoesnotwarrantproductswhichhavebeensubjectedtomisuseand/ornegligenceorhavebeeninvolvedinan
accident.
This warranty does not include travel time, mileage, or labor for removal or re-installation of WINCO product from its
application.
WINCO INC. • 225 S. CORDOVA AVE. • LE CENTER, MN 56057 • 507-357-6821