Winco EC6010DR/T Setup guide

WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057
SALES DEPT. 507-357-6821
SERVICE DEPT. 507-357-6831
www.wincogen.com
INSTALLATION AND
OPERATORS
EC6010DR/T
GENERATOR
MANUAL

2REV B
OPM-125
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS 2
TESTING POLICY 2
SPECIFICATIONS 3
GENERATOR
ENGINE
SAFETY 3
IMPORTANT SAFETY INSTRUCTIONS
CALIFORNIA PROPOSITION 65
ANSI SAFETY DEFINITIONS
INTRODUCTION 4
INTENDED USES
RESTRICTED USES
UNIT CAPABILITIES 4
GENERATOR CONNECTIONS
STARTING ELECTRIC MOTORS
LOAD TYPES
PREPARING THE UNIT 5
UNPACKING
LUBRICATION
BATTERY INSTALLATION
OIL RECOMMENDATIONS
DIESEL FUEL
CONTROL PANEL
INITIAL START UP 8
BASIC OPERATION
FUEL PUMP
STARTING HINTS
STOPPING
CONNECTING THE LOADS 9
APPLYING THE LOADS
GROUNDING
WIRING
YOURGEN 11
ENGINE CARE 13
MAINTENANCE SCHEDULE
CHANGING THE OIL
CHECKING THE OIL LEVEL
AIR FILTER
GENERATOR CARE 14
EXERCISING THE GENERATOR
GENERATOR MAINTENANCE
CLEANING
TROUBLESHOOTING 14
CONTROL PANEL WIRING DIAGRAM 15
24 MONTH LIMITED WARRANTY 16
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 concerning this unit, it will help us
to respond to your needs faster.
MODEL __________________________________________________
SERIAL NUMBER _________________________________________
PURCHASE DATE _________________________________________
DEALER NAME ___________________________________________
DEALER PHONE # ________________________________________
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed
during installation and maintenance of the generator. Read and
understand all instructions in the manual before starting and operating
the generator.
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.

3REV B OPM-125
SPECIFICATIONS
GENERATOR
Model EC6010DR/T
Starting Watts 6,010
Running Watts 5,160
Volts 120/240
Starting Amps 50/25
Running Amps 43/21.5
Generator Manufacturer Mecc Alte Spa
Generator Model Number ES16F-160
Part Number 16346-027
Rotor Resistance 8.378 Ohms
Stator Resistance 0.51 Ohms
Regulation AVR
ENGINE
Engine Manufacturer Kohler
Engine Model Number KD440
Fuel Type Diesel
Oil Capacity 41.6 oz. (1.3 qts)
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.

4REV B
OPM-125
SAFETY
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important information that should be understood
and followed before the installation, operation and maintenance of the
generator. Failure to follow the safety instructions in this manual could
result in serious injury or death. Keep this manual available for future
reference.
CALIFORNIA PROPOSITION 65
WARNING: This product contains crude oil, gasoline,
diesel fuel and other petroleum products, Antifreeze to
which can expose you to chemicals including toluene
and benzene, Ethylene glycol (ingested) which are
known to the State of California to cause cancer, birth defects or other
reproductive harm and developmental issues.
For more information go to www.P65Warning.ca.gov.
ANSI SAFETY DEFINITIONS
DANGER:
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations.
WARNING:
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION:
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may be used to alert
against unsafe practices.
NOTE: CAUTION is also used on the unit labels and in this manual to
indicate a situation that could result in serious damage or destruction of
the equipment and possible personal injury.
1. 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 or your application.
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.
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.

5REV B OPM-125
INTRODUCTION
INTENDED USES
This engine generator set has been designed primarily for portable
heavy duty commercial use. Both 120 volt and 240 volt receptacles
are provided in the control panel to plug in your loads (lights, portable
tools, and small appliances). These units are dual wound generators,
therefore the 120 volt loads must be equally split with 1/2 of the rated
capacity available on each of the two 120 volt circuits.
This portable unit requires large quantities of fresh air for cooling the
engine and generator. For safety, long life and adequate performance,
these units should never be run in small compartments without positive
fresh air ow.
RESTRICTED USES
DO NOT operate generator where it could get wet or have pooling
water near it. This generator is NOT weatherproof. Failing to keep
generator in a dry area may cause an electrical shock, resulting in
injury or death.
DO NOT operate and/or store the unit outside during inclement weather
without adequate protection from the elements. Failure to do so will
damage the unit.
DO NOT remove from the cradle assembly. Removal of the generator
from the cradle assembly may cause excessive vibration and damage
to the engine-generator set.
DO NOT install and operate this generator in a small compartment.,
i.e. generator compartments of vehicles, motor homes or travel
trailers. These compartments will not allow enough free ow of fresh
air to reach the engine generator set for cooling and will cause the
unit to overheat, damaging both the engine and generator. Small
compartments will also develop hot spots where there is very little air
ow and may cause a re.
PLEASE NOTE There are 3rd party companies making enclosures for
generators that have been properly engineered. The use of these 3rd
party enclosures is acceptable as long as they have been engineered
and meet applicable code.
DO NOT attempt to operate at 50 cycles. These units are designed and
governed to operate at 60 cycles only.

6REV B
OPM-125
Self-exciting generators respond to severe overloading differently than
utility power. When overloaded, the engine is not able to supply enough
power to bring the electric motor up to operating speed. The generator
responds with high initial starting current, but the engine speed drops
sharply. The overload may stall the engine. If allowed to operate at very
low speeds, the electric motor starting winding will burn out in a short
time. The generator winding may also be damaged.
CAUTION: EQUIPMENT DAMAGE
Running the generator set under these conditions may result in
damage to the generator stator as well as the motor winding.
The heavy surge of current required for starting motors is required for
only an instant. The generator will not be damaged if it can bring the
motor up to speed in a few seconds of time. If difculty is experienced
in starting motors, turn all other electrical loads off and if possible
reduce the load on the electric motor.
Motor starting capacity - 2HP code ‘G’ capacitor start engine.
Trying to start a larger motor or higher code motor, i.e. ‘J’ or ‘K’,
may result in damage to both the generator and the electric motor,
especially 120 Volt motors.
LOAD TYPES
This generator is designed and rated for general commercial use. The
running watts rating assumes a variable load. If your application has
a xed load that does not vary, an additional derate of 20% from the
running watts is recommended to ensure the longest useful life of the
engine and generator end.
UNIT CAPABILITIES
GENERATOR CONNECTIONS
EC6010DR: 120 Volt and 240 Volt receptacles are provided for
connection to various loads. The following diagram represents this
5,160 watt (rated output) generator. A & B represent the 120 volt output
legs of this generator. Up to 2,580 watts at 120 volts (43 Amps) can be
drawn from the receptacles attached to either A or B output legs. This
generator is capable of producing 21.5 Amps of 240 volt current at C.
Check the appliance or tool nameplates for the current and voltage to
insure compatibility. Remember that power taken from C reduces the
power available equally at both A and B and vice versa.
STARTING ELECTRIC MOTORS
Electric motors require much more current (amps) to start them than to
run them. Some motors, particularly low cost split-phase motors, are
very hard to start and require 5 to 7 times as much starting current as
running current. Capacitor motors are easier to start and usually require
2 to 4 times as much starting current as running current. Repulsion
Induction motors are the easiest to start and require only 1 1/2 to 2 1/2
times as much starting as running current.
Most fractional horsepower motors take about the same amount
of current to run them whether they are Repulsion Induction (RI),
Capacitor (Cap), or Split-Phase (SP) type. The following chart shows
the approximate current required to start and run various types
and sizes of 120 Volt 60 cycle electric motors under average load
conditions.
STARTING AMPS
HP Running
Amps
Split Phase
Motor
Capacitor
Motor
Repulsion
Induction Motor
1/6 3.2 16 to 22 6 to 13 5 to 8
1/4 4.5 22 to 32 9 to 18 7 to 12
1/3 5.2 26 to 35 10 to 21 8 to 17
1/2 7.2 Not Made 14 to 29 11 to 18
1 13 Not Made 26 to 52 20 to 33
The gures given in the previous chart are for an average load such
as a blower or fan. If the electric motor is connected to a hard starting
load such as an air compressor, it will require more starting current. If
it is connected to a light load, or no load such as a power saw, it will
require less starting current. The exact requirement will also vary with
the brand or design of the motor.

7REV B OPM-125
LUBRICATION
CAUTION: EQUIPMENT DAMAGE
Failure to maintain the engine oil at the proper level will result in
serious engine damage.
Before starting the engine, verify the crankcase is lled to the proper
level with a good quality oil. The recommended grade oil and quantity
of oil required is listed in the engine operator’s manual and under the
service tab in this manual. This unit was shipped with oil in it. The
engine normally holds 1.3 quarts (41.6 oz.) of oil. Use the dipstick to
ensure that you have the proper oil level in the crankcase. The full oil
level mark on the dipstick is depicted in the following image.
Oil is added to the engine by removing the oil cap and adding oil at
this point. After lling the crankcase to the proper level, be sure you
properly tighten the oil ll cap. NOTE: This engine generator must be
on a level surface before you check or add oil to the system.
The necessity of using the correct oil and keeping the crankcase full
cannot be overemphasized. Engine failures resulting from inadequate
or improper lubricant are considered abuse and not covered by the
generator or engine manufacturer’s warranty.
OIL RECOMMENDATIONS
Outdoor temperatures determine the proper oil viscosity for the
engines. Use the chart to select the best viscosity for the outdoor
temperature range expected.
PREPARING THE UNIT
UNPACKING
CAUTION: EQUIPMENT DAMAGE
Always check oil level prior to use. Failure to maintain the engine oil at
the proper level will result in serious engine damage.
When you unpack your engine-generator set be sure to remove all the
information sheets and manuals from the carton.
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.
COMPARTMENT INSTALLATION
When installing this generator in vehicle compartments it is essential
that proper care is taken to prevent overheating. The following
guidelines will help prevent these problems.
The easiest way to prevent overheating is to mount the generator on a
slide out tray. This will move the generator into open air whenever it is
in operation. A vertical opening door can also provide protection from
rain during operation.
If the generator must be installed in an enclosed compartment during
operation it is important to provide adequate cooling air ow.
This can cause air to recirculate and can result in generator
overheating. The windings will fail prematurely in this scenario.
Separate air intakes for the engine and generator can help reduce
heat. The design should be tested with measurements taken for engine
oil temperature and the generator stator windings. Contact WINCO for
help in evaluating your application.

8REV B
OPM-125
These engines produce enough direct current to keep the battery
charged under normal operating conditions, but were not intended to
be used as a battery charger.
WARNING: PERSONAL INJURY:
Lead acid batteries produce explosive hydrogen gas when charging.
Keep sparks, ames, and burning cigarettes away from the battery.
Ventilate the area when charging or using the battery in an enclosed
space. Lead acid batteries contain sulfuric acid, which causes severe
burns. If acid contacts eyes, skin, or clothing, ush well with water. For
contact with the eyes, get immediate medical attention.
CAUTION:
Do NOT open or mutilate the battery. Released electrolyte is known to
be harmful to the skin and eyes and to be very toxic.
A battery presents a risk of electrical shock and high short circuit
current. The following precautions must be observed when working
with batteries:
1. Remove watches, rings and other metal objects.
2. Use tools with insulated handles.
3. Check both the battery cable ends and the battery posts to be
sure they are free of corrosion.
4. Always connect the battery positive rst and then connect the
battery negative cable. When removing the battery cables from
the battery reverse the procedure, disconnect the negative cable
rst and then the positive cable.
5. Be sure all connections are tight and coat the terminals and cable
end with dialectic grease.
WARNING:
The electrolyte is diluted sulfuric acid that is harmful to the skin
and eyes. It is electrically conductive and corrosive. The following
precautions must be always be taken.
1. Always wear full eye protection and protective clothing.
2. Where electrolyte contacts skin, wash off immediately with water.
3. If electrolyte contacts the eyes, ush thoroughly and immediately
with water and seek immediate medical attention.
4. Spilled electrolyte is to be washed down with an acid neutralizing
agent. A common practice is to use a solution of one pound
of bicarbonate of soda (baking soda) to one gallon of water.
The bicarbonate of soda solution is to be added until the evidence
of reaction, foaming, has ceased. The resulting liquid is to be
ushed water and the area dried.
DANGER: EXPLOSIVE FIRE RISK
Never smoke when near batteries. Do not cause a ame or spark in the
battery area. Always discharge static electricity from your body before
touching batteries by rst touching a ground metal surface.
SERVICING BATTERIES
Batteries used on these units may over time lose water. This is
especially true if you are using a trickle charger to maintain your
battery. When relling the battery with water use only distilled water.
Tap water will shorten the service life of the battery.
DIESEL FUEL
Always use a good grade of # 2 diesel fuel. For cold weather, blended
#1 fuel may be used. Fuel cetane number should be 45 or higher
and the fuel MUST be low sulfur or ultra low sulfur fuel. See engine
operators manual for additional fuel recommendations including Bio-
Diesel fuel. Never use gasoline or gasohol. Always ensure that the fuel
is clean and free of all impurities. Always be sure to keep the strainer in
place when lling the fuel tank.
WARNING: FIRE DANGER
Diesel fuel is ammable and can be ignited, causing or enlarging res
when proper precautions are not taken.
Never use fuel that has been stored for an extended period of time.
Fuel will lose its volatile properties and you will be left with a ‘gum’ or
varnish residue. This varnish-like substance will clog the lters, fuel
lines, and injectors. Old, contaminated, stale fuel will not burn properly.
The use of a fuel additive, such as Sta-Bil, or an equivalent will
minimize the formation of fuel gum deposits. If a unit has been out of
operation for an extended period of time, it is best to drain old fuel from
the engine and replace with fresh fuel before attempting to start.
BATTERY INSTALLATION
You will need to connect this unit to a battery to operate it. Cables
have not been provided as length are going to vary depending on
your installation. These engines are all negative ground. The positive
battery cable must be connected to the open large terminal on the
start solenoid (This terminal may have a small 16 GA. wire on it for
the charging circuit). The negative cable should be attached to a good
ground on the engine. This is usually one of the engine mounts.
Start Solenoid terminals
A twelve volt battery, rated at 300 CCA or larger is recommended for
this electric start generator set. Follow the battery manufacturer’s
recommendations for servicing and charging prior to use.
CAUTION: EQUIPMENT DAMAGE:
These electric start engines are NEGATIVE GROUND. Use extreme
caution when connecting the battery. Connect the NEGATIVE battery
terminal to GROUND.
For your safety, always connect the positive battery cable to the “bat+”
terminal rst. Then connect the negative battery cable to the “Bat-”
terminal. Make sure all connections are clean an tight. Reverse the
sequence when disconnecting, disconnect the negative cable rst.

9REV B OPM-125
3. Place the panel on the other side of the generator (receptacle facing
out). Secure the panel to the skid mount using the pre-installed rivet
nuts.
4. Replace the control cover. Push the rubber grommet with the wires
through it, back onto the genend cover. Place the cover back on
the genend with the grommet on the same side of the control panel.
Secure the wires with new zip ties.
FUEL PUMP
Like the control panel, the fuel pump can also be placed on either side
of the generator.
1. Snip the zip ties around wires/lines that will be moved. Detach the
ground wires from the skid base (green wire) and in front of the
engine (black wire). Locate the two bolts on the fuel pump mounting
bracket.
2. Carefully, to ensure diesel fuel does not leak, move the fuel pump to
the other side of the unit. The fuel line will be longer than needed and
will need to be shortened. Secure the fuel pump mounting bracket to
the skid mount using the pre-installed rivet nuts.
3. Reconnect the ground wires. The green wire connects to the skid
base. There may already be a ground wire screwed down, add the
green wire and re-secure the screw. The black, longer wire will connect
to the front of the engine.
Rivet Nuts
Mounting Bracket Remove
Fuel Pump
Rivet Nuts
Attach black
ground wire here
depending on
placement side.
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.
All connections must be clean and tight. Check the electrolyte (uid) in
the battery periodically to be sure it is above the plates. Never allow the
battery to remain in a discharged condition.
BATTERY CHARGING
Units have a small ywheel charger built into the engine ywheel
assembly for recharging the starting battery. This ywheel charger
generates a small AC current that passes through a diode assembly
to produce DC charging current of about 1 to 3 Amps. This circuit is
not designed to be used as a battery charging circuit to recharge dead
batteries.
CONTROL PANEL
The control panel can be installed on either side of the genend.
Placement will be determined on the installation of the unit.
1. Snip off the zip ties around the wires that will be getting moved.
Remove the front cover of the control panel. Locate the two bolts
inside the panel that are securing the panel to the skid. Remove
these two bolts. Make sure to keep track of all hardware being taken
off and keep in an area where they won’t get lost.
2. Remove the 4 screws around the top of the genend and remove the
cover. There is a rubber grommet that secures the wires in place,
gently remove it by pulling it down, keeping the wires through it.
Remove
Rubber Grommet
Remove

10 REV B
OPM-125
INITIAL START UP
The throttle control on these generators is preset and locked to operate
at 3600 RPM (nominal) with no load speed set at 3690 RPM. Only
a trained service technician should be allowed to adjust this speed
setting.
NOTICE: ENGINE START LOCKOUT
This unit will not start if it is low on oil. The lubricating oil level must be
at the full mark before the engine will start and run. This engine will not
start without a battery. The fuel shut-off solenoid requires 12V DC to
operate.
BASIC OPERATION
If the engine is cold and stiff or if the battery is not fully charged,
starting can be made easier by slowly hand cranking the engine
through the compression stroke before pushing the starter switch. This
permits the starter to gain momentum before the heavy load of the
compression stroke occurs. This minimizes the drain on the battery
and improves the possibility of starting under such adverse conditions.
Always keep the battery charged, especially during cold weather
operation.
1. Check oil level, rell as needed.
2. Make sure the fuel solenoid valve lever is in the down position. This
lever should never be put in the up position. The lever is located
under the key switch as pictured.
3. Turn key to 1st position (Ref A).
4. Turn key to the 2nd position - starting (Ref B).
5. Return key to 1st position when engine is running (Ref A).
A
B
CONNECTING THE FUEL SUPPLY
Fuel Pump Specications:
Voltage 12
PSI 9.0 to 11.5
Amps 1.6 average
Average Lift 6 feet
The fuel pump is self-priming and self-regulating.
Tank size,tank location, hose size, hose routing, and hot spots all play
a role in a successful fuel tank installation. Preferred fuel installations
use 1/4” hose that run straight to the engine with no drops or twists
from an adequately sized fuel tank.
Connect a 1/4” fuel hose to the hose tting located on the fuel pump.
Use a hose clamp to secure the hose to the tting.
Connect fuel line to the fuel source.
A 1/4” fuel return hose will connect to the T-tting located above the
engine.
Secure the return hose with a hose clamp. Connect the return line to
the fuel source.
1/4” Hose Fitting
Fuel Return
T-tting

11REV B OPM-125
NOTE: While the engine is running, all warning lights should be off
except the OK light.
STARTING HINTS
1. COLD WEATHER
Use the proper oil for the temperature expected.
CAUTION: EQUIPMENT DAMAGE
Never use ether or any other starting aides. Serious engine damage or
personal injury may result from ignoring this simple warning.
2. HOT WEATHER
Use the proper oil for the temperature expected.
STOPPING
1. Move the key to the “OFF” position.
2. Make sure the fuel solenoid valve lever is in the down position. The
lever is located under the key switch as pictured. The generator will
not shutdown if this lever is in the up position.
3. Before extended storage (over 30 days) certain precautions must be
taken to ensure the fuel doesn’t deteriorate and clog the fuel system.
NOTE: Running the engine to use up the fuel in the lines, fuel pumps
and injectors will still leave a small amount of fuel in the system. It is
best extended storage to treat the fuel before draining.
A. While the engine is warm, drain the oil and rell with fresh oil.
B. Clean dirt and chaff from cylinder, cylinder head ns, blower
housing, screen, and mufer areas.
C. Store in a clean and dry area.
A
0

12 REV B
OPM-125
CAUTION: EQUIPMENT OVERLOAD
Keep the generator load within in the generator and receptacle
nameplate rating. Overloading may cause damage to the generator
and/or the loads.
Most electric tools and appliances will have the voltage and amperage
requirements on their individual nameplates. When in doubt, consult
the manufacturer or a local electrician. The nameplate amperage rating
for electric motors can be misleading. See “Starting Electric Motors” in
the Unit Capabilities.
This generator end is controlled by an AVR. The engine governor will
automatically adjust itself to the load. No harm to the generator will
result if it is operated with no load connected.
CAUTION: EQUIPMENT DAMAGE
Diesel engines should never be run for an extended period of time with
a very light load or no load on them, it may do permanent damage to
the engine if run under these conditions.
Proper utilization of the receptacles located on the control panel
is necessary to prevent damage to either the receptacles or the
generator. The generator is a limited source of electrical power,
therefore, pay special attention to the receptacle and generator ratings.
The nameplate rating can be obtained through a single receptacle as
long as the receptacles amperage rating is not exceeded.
GROUNDING
Proper grounding of your generator is application dependent. Carefully
evaluate your planned use of your generator to understand which
grounding you require. If you are not sure what to do, contact a
competent professional to assist you. The NFPA 70 250:34-35 are good
technical references.
STANDARD PORTABLE GENERATOR
Your WINCO portable generator ships with a bonded neutral. You can
safely use this generator without external grounding as long as all
loads are powered through the receptacle panel.
VEHICLE-MOUNTED GENERATOR
Your WINCO portable generator ships with a bonded neutral. When
mounted to a vehicle to safely distribute power it is necessary that
the generator frame is bonded to the vehicle frame. The generator
should only supply equipment that is cord and plug connected through
receptacles mounted on the generator or the vehicle.
PERMANENTLY INSTALLED GENERATORS
This WINCO portable generator ships with a bonded neutral and
overcurrent protection. NFPA 70 refers to this as a “separately derived
system.” When connecting it to a building a transfer switch specically
designed for GFCI and bonded neutral generators is required.
CONNECTING THE LOADS
The engine-generator covered in this manual was designed for portable
use. Do NOT operate indoors. The unit should be stored in a warm, dry
location. Move the unit outdoors to a at, dry location for use.
WARNING: PERSONAL DANGER:
Operating any engine driven generator without proper air ow can
result in personal injury or death. DO NOT operate this unit inside a
home or garage, near vents or windows, or anywhere carbon monoxide
gas could accumulate.
Failure to properly limit and balance the load applied to the generator
will cause the generator to produce low voltage and may damage
the engine generator set. It may also cause severe damage to the
loads connected to the generator at the time. Improper loading of the
generator set constitutes abuse and will not be covered by warranty.
A 30 Amp receptacle (NEMA L14-30) has been provided to allow
the connection of loads to the generator. This receptacle is a full load
receptacle protected by a 30 Amp hydrolic magnetic breaker. The
breaker toggle switch is located on the control panel, located next to
the receptacle.
Your individual loads must be protected by individual circuit breakers
mounted in some type of distribution panel. This location will also be
where you will install your neutral to ground bond. You must wire four
separate wires from the generator (2-hot, 1- neutral, and 1-ground) to
the distribution panel.
APPLYING THE LOADS
Allow the engine to warm up for two or three minutes before applying
any load. This will allow the engine to reach normal operating
temperature and oil to circulate throughout the engine. A short warm-
up time will permit the engine to work more efciently when the load
is applied and will reduce the wear in the engine, extending its life.
Receptacles have been provided to allow loads to be connected to the
generator.
The loads should be added one at a time. If a large motor is being
started: or multiple motors are being started, they should be started
individually and the largest should be started rst.

13REV B OPM-125
WIRING
Plug your tools such as drills, saws, blowers, sump pump, and
other items to be powered directly into the generator receptacles.
Before plugging in all the tools and cord sets, recheck the rating
of the generator set. Be sure it can handle the intended load and
is compatible with the voltage, phase, and current ratings. ‘Hard
wiring’ this unit directly into a temporary construction site electrical
system is NOT A SIMPLE DO-IT-YOURSELF JOB. For your safety,
all wiring must be done by a qualied electrician and conform to the
National Electric Code and comply with all state and local codes and
regulations. Check with local authorities before proceeding.
WARNING: PERSONAL DANGER
A fully isolated, double pole double throw manual transfer switch must
be installed any time a generator is being connected to an existing
distribution system.
1. These engine-generator sets are designed for portable heavy duty
commercial use. Receptacles are provided on the control panel to
permit 120 and 240 Volt portable appliances and tools to be
plugged directly into them. A 4-wire receptacle (two hot, one
ground, and one neutral) has been provided on the control panel
for use in temporary power applications requiring 120/240 Volt
power.
2. If the generator set is connected to an existing distribution
system, a fully isolated manual transfer switch must be installed.
The transfer switch prevents damage to the generator and
the other circuit components if main line power is restored while
the generator is connected. Installing a transfer switch also
permits the use of normal fusing.
3. Many homes and construction sites are wired for at least 60 to
100 Amp entrance service, much greater than the capacity of this
portable generator. When installing the generator at these sites, a
secondary emergency distribution panel may have to be installed.
The emergency distribution panel must be installed by a licensed
electrician according to all applicable codes. The electrician
will move the critical circuits to be powered during the outage to
the emergency panel. Keep in mind only a limited amount of
amperage is available from the generator set. Some circuit
breakers may still have to be turned off to prevent an overload
on the generator during the initial start up. See the nameplate on
your generator for the amperage capabilities of your unit.
CAUTION: EQUIPMENT DAMAGE
Failure to properly limit and balance the load applied to the generator
will cause the generator to produce low voltage and may damage
the engine generator set. It may also cause severe damage to the
loads connected to the generator at that time. Improper loading of the
generator set constitutes abuse and will not be covered by warranty.

14 REV B
OPM-125
The speed of the engine was carefully adjusted at the factory so that
the generator produces the proper voltage and frequency. For normal
usage, the speed setting should not be changed. If the generator is
being run continuously on a very light load, it is often advisable to lower
the operating speed slightly.
The engine will govern itself at full speed. Intentionally overriding the
governor and operating the generator at low voltage may damage both
the generator and any load connected to it. Running the engine at
excessively high speeds results in high voltage, which may signicantly
shorten the life of light bulbs and appliances being used, as well as
possibly damaging the engine.
CAUTION: EQUIPMENT DAMAGE
SPEED ADJUSTMENTS SHOULD ONLY BE MADE BY A QUALIFIED
SERVICE TECH. Whenever making any speed adjustments, check the
YourGen meter and be sure the voltage and speed are correct.
Output voltage should be checked periodically to ensure continued
proper operation of the generating plant and appliances.
Hz -
This is the measured frequency of the generator set. See the table in
the RPM section above for an explanation of voltage and frequency
ranges under load.
V1 -
Output voltage of Line 1 (L1 on panel) to neutral. See the Load vs.
Output table for an explanation of voltage and frequency ranges under
load.
V2 -
Output voltage of Line 2 (L2 on panel) to neutral. See the Load vs.
Output table for an explanation of voltage and frequency ranges under
load.
V1-V2 -
Output voltage of Line 1 (L1) and Line 2 (L2). See the Load vs. Output
table for an explanation of voltage and frequency ranges under load.
Hours -
This displays the total running hours of the generator set. When the
generator is turned off, the hours will remain displayed. The display is
run on a CR2032, ten-year battery. Once the unit is running, the battery
connected to the unit will then supply the power to the YourGen meter.
Load Bars -
These bars indicate how much load is being used on Line 1 (L1) and
Line 2 (L2).
= 1-25% = 25-50% = 50-75% = 75-100%
It is good practice to monitor the YourGen Meter when applying load.
This will ensure the generator is balanced.
Balanced Unbalanced
YOURGEN
The WINCO YourGen meter allows you to see useful information about
your generator from the front panel by displaying RPMs, Voltage,
frequency, load, hours, and maintenance reminders. It also has the
ability to display warnings if any parameter gets outside of normal
operation range.
Cycle Button ( ) -
During normal operation, the display will toggle through on xed delay.
If you want to see any specic item, you can press the cycle button
to move it to that setting. Once the display is selected, the delay is
approximately 5 seconds before it starts toggling. This button is also
used to reset maintenance reminders.
RPM -
The meter will display the RPMs of the engine. This number is
calculated based upon frequency and is not directly measured from the
engine. The engine-generator must be run at the correct speed in order
to produce the proper electrical voltage and frequency.
CAUTION: EQUIPMENT DAMAGE
The output voltage should be checked to ensure the generator is
working properly prior to connecting a load to the generator. Failure to
do so could result in damage to equipment plugged into the unit and
possible injury to the individual.
Operating Speed
All engines have a tendency to slow down when a load is applied.
When the electrical load is connected to the generator, the engine is
more heavily loaded, and as a result, the speed drops slightly. This
slight decrease in speed, together with the voltage drop within the
generator itself, results in a slightly lower voltage when the generator
is loaded to its full capacity than when running no load. The slight
variation in speed also affects the frequency of the output current.
This frequency variation has no appreciable effect in the operation of
motors, lights, and most appliances. However, electronic equipment
and clocks will be affected if correct RPM is not maintained. See Load
vs. Output chart.
Although individual units and models vary slightly, the normal voltage
and frequency of the engine-generator described in this manual are
approximately as follows, under varying loads:
LOAD vs. OUTPUT
Generator
Load
Speed
(RPM)
Frequency
(Hz)
Voltage
None 3690 61.5 120V
Half 3600 60.0 120V
Full 3510 58.5 120V

15REV B OPM-125
1. The battery is located in the control box near potentially live
AC terminals. To prevent electrocution while changing the
battery disable the unit by disconnecting the main battery and
then open the receptacle panel. Locate the backside of the
YourGen meter. Gently pry the back plate off using the slot
located on top.
2. Once open, the battery will be located at the top. Using a
needle nose plier, carefully pull out the battery.
3. Replace the battery having the POSITIVE (+) side down.
Ensure the battery is secured between the battery connections.
4. Replace the back plate of the meter and close the receptacle
panel using the screws to secure it. Reconnect the unit’s main
battery.
Battery
Install Battery Between These Two Points
120 Volt and 240 Volt receptacles are provided for connection to
various loads.
The following diagram represents this 5,160 watt (rated output)
generator. A & B represent the 120 volt output legs of this generator.
Up to 2,580 watts at 120 volts (43 Amps) can be drawn from the
receptacles attached to either A or B output legs. This generator is
capable of producing 21.5 Amps of 240 volt current at C. Check the
appliance or tool nameplates for the current and voltage to insure
compatibility. Remember that power taken from C reduces the power
available equally at both A and B and vice versa.
Change Oil Warning -
After the rst 50 hours, the engine oil should be changed. The YourGen
meter will light up the oil icon ( ) and the word ‘change’ will ash.
Once the oil has been changed, press and hold the cycle button for
approximately 5 seconds until the warning has been removed from
the display to reset the warning. The meter will then remind you of oil
changes on the appropriate schedule for your generator. It is important
to remember that the engine manufacturer recommends changing the
oil on a calendar schedule even if the total number of operational hours
have not been reached. Certain operating environments may also
require more frequent oil changes.
Alarms -
The display will start blinking and toggle to the rst parameter that
is out of specication. The panel will remain ashing until the fault
condition returns to within the acceptable range, see following table.
Acceptable Range
Frequency 57-63 Hz
Voltage 110VAC-130VAC
VAC1-VAC2 220VAC-260VAC
Battery -
When the unit is off, the YourGen meter will display the hours
continuously using a coin cell back-up battery inside the meter. Once
the unit is running, the meter will get power from the main unit battery.
Voltage 3.0V DC
Battery Type CR2032
Lifetime 10 Years
The battery has a 10 year lifetime, in the event you need to change the
battery, follow these instructions:

16 REV B
OPM-125
C. Replace the adapter by pushing in and turning to the right to lock
.
D. Remove oil ll cap.
E. Fill to correct level with oil. Reinstall cap.
F. Remove the oil lter and dispose of it properly.
NOTE: This engine requires 41.6 oz. (1.3 qts) of oil if it is completely
drained. Use caution when relling the engine as some residual oil may
have remained in the engine. Always use the dipstick when lling the
engine with oil to prevent overlling.
H. Replace oil lter and lter plug.
I. Start the engine and warm it up.
J . After warming up the engine, recheck the oil level and rell as
necessary to bring it to the proper level.
CHECKING THE OIL LEVEL
The oil level must always be checked before the engine is started.
Take care to remove any dirt or debris from around the oil plug before
removing. Be sure the oil level is maintained. Fill to the “FULL” mark on
the dipstick.
AIR FILTER
Clean the ltering element with air blast. Air must be blown from inside
to outside the cartridge at a distance of at least 6 inches from the
paper. Lightly and repeatedly tap the element on a hard surface to
eliminate all excess dirt.
WARNING: EQUIPMENT DAMAGE
Never start or run the engine with the air lter removed.
A. Remove the cover.
ENGINE CARE
MAINTENANCE SCHEDULE
* If engine use is infrequent; every year
** If engine use is infrequent; every 2 years
If you are using oil of a quality lower than the recommended one then
you will have to replace it every 150 hours
If major engine service or repair is required, contact an authorized
engine service center. The manufacturer of these engines has
established an excellent world-wide engine service organization.
Engine service is very likely available from a nearby authorized dealer
or distributor.
CHANGING THE OIL
Change the oil after the rst 50 hours of operation and yearly or 250
hours thereafter under normal operating conditions.
A. Change oil while the engine is still warm, the oil will ow more
freely.
B. Push in the yellow adapter slightly and turn to the left, unlocking
the oil drain. Drain the oil into an approved container.
Daily or
Every 10 hrs
Every
250* hrs
Every
500** hrs
Check Oil ü
Check oil lter ü
Check dry air cleaner ü
Fuel tank cleaning ü
Clean cooling ns ü
Replace engine oil ü
Replace oil lter ü
Replace fuel lter ü
Set and clean injectors ü
Rocker arm adjustment ü
Adapter

17REV B OPM-125
GENERATOR CARE
Proper care and maintenance of the generator is necessary to ensure a
long trouble free life.
EXERCISING THE GENERATOR
The generator should be operated every three to four weeks. It should
be operated for a period of time sufcient to warm the unit up and to
dry out any moisture that has accumulated in the windings. If left, this
moisture can cause corrosion in the winding. Frequent operation of the
engine-generator set will also ensure that the set is operating properly
should it be needed in an emergency.
GENERATOR MAINTENANCE
Any major generator service, including the installation or replacement
of parts, should be performed only by a qualied electrical service
technician. USE ONLY FACTORY APPROVED REPAIR PARTS.
A. Bearing - The bearing used in these generators is a heavy duty,
double sealed ball bearing. They require no maintenance or
lubrication.
B. Receptacles - Quality receptacles have been utilized. If a
receptacle should become cracked or otherwise damaged,
replace it. Using damaged or cracked receptacles can be both
dangerous to the operator and destructive to the equipment.
CLEANING
Remove dirt and debris with a cloth or brush. DO NOT use high
pressure spray to clean either the engine or the generator. The high
pressure spray could contaminate the fuel system and the generator
components.
1. Keep the air inlet screen on both the engine and generator free of
any dirt or debris to ensure proper cooling. At least yearly, remove
the blower housing on the engine and clean the chaff and dirt out of
the engine cooling ns and y wheel. Clean more often if necessary.
Failure to keep these areas clean may cause overheating and
permanent damage to the unit.
2. Periodically clean mufer area to remove all grass, dirt, and
combustible debris to prevent a re.
3. On engine mufers equipped with spark arresters, the spark arrester
must be removed every 50 hours for cleaning and inspection. Replace
if damaged.
B. Remove the wing nut.
C. Remove the lter element.
D. Check the rubber seal is undamaged.
E. To loosen debris, gently tap the air lter on a hard surface. If the
air lter is excessively dirty replace with a new lter. You can use
pressurized air (not to exceed 30 psi) to clean the lter. Always
blow the compressed air from inside to the outside.
F. Clean the dirt from the inside of the air cleaner body and cover.
Reinstall the lter in housing. Tighten the wing nut securely.
G. Install and secure the cover.
H. Remove and clean the pre-lter if clogged.

18 REV B
OPM-125
TROUBLESHOOTING
Problem Possible Causes
Won’t start Low oil level
Out of fuel
Start switch in OFF position
Fuel Valve turned off
Plugged fuel lter
Blown fuse in key switch
Battery required to open solenoid
Voltage too low Engine speed is too low
Generator overloaded
Defective stator
Defective rotor (eld)
Defective AVR
Circuit breaker trips Defective load
Defective receptacle
Excessive load
GFCI type of load i.e. a building with
bonded neutral
Voltage too high Engine speed is too high
Generator overheating Overloaded
Insufcient ventilation
No output voltage Short in load (disconnect)
Tripped or defective circuit breaker
Broken or loose wire
Defective receptacle
No residual magnetism (in generator)
Defective stator
Defective rotor (eld)
Shorted capacitor
Shorted diodes on rotor
GFCI receptacle tripped
Will not shutdown Fuel solenoid valve lever is in up position

19REV B OPM-125
CONTROL PANEL WIRING DIAGRAM
G1
G1
G1
G2
G
N
N
G
G
G2
G2

20 REV B
OPM-125
WINCO INC. • 225 S. CORDOVA AVE. • LE CENTER, MN 56057 • 507-357-6821
24 MONTH LIMITED WARRANTY
WINCO warrants to the original purchaser for 24 months, that goods manufactured or supplied by it will be free from defects in workmanship and
material, provided such goods are installed, operated and maintained in accordance with WINCO written instructions and applicable codes.
WINCO’s sole liability, and Purchaser’s sole remedy for a failure under this warranty, shall be limited to the repair of the product. At WINCO’s
option, material found to be defective in material or workmanship under normal use and service will be repaired or replaced. For warranty service,
return the product within the warranty period, to your nearest WINCO Authorized Service Center or to WINCO in Le Center Minnesota.
Duration Consumer, Commercial and Rental
Parts & Labor: 24 Months
EXCLUSIONS:
• Normal maintenance consumables or labor.
• This warranty does not cover travel time, mileage or labor for removal or re-installation of WINCO product from its application.
• Normal wear and tear.
• Costs of rental equipment.
• WINCO does not warrant engines. Engines are covered exclusively by the warranties of their respective manufacturers.
• WINCO does not warrant component parts that are warranted by their respective manufacturers.
• WINCO does not warrant modications or alterations which were not made by WINCO.
• WINCO does not warrant products which have been subjected to misuse and/or negligence or have been involved in an accident.
Proof of proper maintenance must be furnished upon request.
THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE DESCRIBED HEREIN. THERE ARE NO OTHER WARRANTIES,
EXPRESSED OR IMPLIED, OR OTHERWISE CREATED, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY, OR
WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE.
WINCO is liable for the repair or replacement of the product only and is not liable for incidental or consequential damages as permitted by your
state. This warranty gives you specic legal rights which may vary from state to state.