Winco PSS60F4 1 Series Setup guide

www.wincogen.com
PSS60F4-XX/1
GENERATOR
INSTALLATION AND
OPERATORS MANUAL

2
OPM-160/B
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS 3
SAFETY INFORMATION 4
SAFETY DEFINITIONS
SPECIFICATIONS 5
PSS60F4
INTRODUCTION 6
TESTING POLICY
PRODUCT DESCRIPTION
PREPARING THE UNIT 7
START-UP CHECK LIST
UNPACKING
LIFTING THE GENERATOR SET
INSTALLATION 8
PRIME POWER
GENERAL INFORMATION
ENGINE-GENERATOR SET MOUNTING
VENTILATION REQUIREMENTS
EXHAUST INSTALLATION
FUEL INSTALLATION
INSTALLING THE FUEL LINE
LIQUID PROPANE VAPOR (LP)
NATURAL GAS (NG)
FUEL PRESSURE
FUEL PRESSURE TABLES
NG/LP FUEL CONVERSION
ELECTRICAL CONNECTIONS 12
AC ELECTRICAL CONNECTIONS
GROUNDING
DC ELECTRICAL CONNECTIONS
TRANSFER SWITCH
MOUNTING THE ATS
INSTALLING THE BATTERY 15
SERVICING BATTERIES
BATTERY CHARGING
BATTERY CHARGER & BLOCK HEATER
STARTING PROCEDURE 17
LUBRICATION
COOLANT
PRE-START CHECK LIST
CONTROL LAYOUT 18
MANUAL MODE
AUTO MODE
CONTROL POWER
VOLTAGE REGULATOR 20
OPERATING CONDITIONS 20
NORMAL OPERATION
HARSH ENVIRONMENTS OPERATIONS
COLD WEATHER OPERATIONS
CHANGING THE OIL
CHANGING OIL FILTER
FILLING COOLANT
MAINTENANCE 21
CHANGING COOLANT
COOLANT FILL & BURP INSTRUCTIONS
CLEANING RADIATOR
STORAGE
AUTOMATIC TRANSFER SWITCH
MAINTENANCE SCHEDULE
ENGINE-GENERATOR SET
TROUBLESHOOTING TABLES 25
AC WIRING 26
ENGINE HARNESS SCHEMATIC 27
DSE 7310 MKII WIRING DIAGRAM 28
WARRANTY STATEMENT 29

3OPM-160/B
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 # ____________________________________

4
OPM-160/B
SAFETY INFORMATION
IMPORTANT SAFETY INSTRUCTIONS
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 fire. 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.
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.
SAFETY DEFINITIONS
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death
or serious injury.
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.
DANGER: 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, installation
must meet the national electrical code.
DANGER: 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, floors).
DANGER: FIRE HAZARD
Gasoline and other fuels present a hazard of possible
explosion and/or fire.
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 flame near the generator
set or fuel tank.
D. Keep a fire 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.
CAUTION: 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.
CAUTION
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 fire hazard.
C. Carefully clean up any gas or oil spills before starting
the unit.
D. Do Not use the generator area as a storage closet.
CAUTION
All service, including the installation or replacement of
service parts, should be performed only by a qualified
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 mufflers, 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.

5OPM-160/B
SPECIFICATIONS
PSS60F4
LP Gas - Standby
Wattage 60,000 62,000 62,000 62,000 62,000
Volts 120/240 120/208 120/240 277/480 346/600
kvA 60.0 77.5 77.5 77.5 77.5
Phase Single Three Three Three Three
Amps 250 215 186 93 75
CB Size 250 225 225 100 80
Hertz 60 60 60 60 60
Natural Gas - Standby
Wattage 60,000 62,000 62,000 62,000 62,000
Volts 120/240 120/208 120/240 277/480 346/600
kvA 60.0 77.5 77.5 77.5 77.5
Phase Single Three Three Three Three
Amps 250 215 186 93 75
CB Size 250 225 225 100 80
Hertz 60 60 60 60 60
Engine
Model Ford 6.2L
Starting System 12 Volt
Muffler Standard
Fuel Consumption
LP
NG
Full Load
8.2 Gal/Hr - 750,685 BTU/Hr
760 Ft³/Hr - 797,416 BTU/Hr
Generator Testing Resistance
Note: Review the Stamford Newage nameplate on your
generator before selecting the correct information below.
Model Stamford UCI224F
Winding Group 06
Resistances:
Rotor 0.83 Ohms @22°C
Stator (L-L) 0.024 Ohms Per Ph @ 22°C
Exciter Rotor (L-L) 0.078 Ohms Per Ph @ 22°C
Exciter Stator (L-L) 20.0 Ohms @ 22°C
Voltage Regulator (L-l) AS440
Model Stamford UCI224F
Winding Group 311
Resistances:
Rotor 0.83 Ohms @22°C
Stator (L-L) 0.065 Ohms Per Ph @ 22°C
Exciter Rotor (L-L) 0.078 Ohms Per Ph @ 22°C
Exciter Stator (L-L) 20.0 Ohms @ 22°C
Voltage Regulator (L-L) AS440

6
OPM-160/B
INTRODUCTION
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 specified
by the manufacturer of applicable engines.
PRODUCT DESCRIPTION
The Package Standby System is designed to automatically
provide standby power to unattended loads during
electrical outages. Upon interruption of normal electrical
service, the Packaged Standby System electrical control
circuits will automatically start the engine. The generator
will produce electrical power and the Automatic Transfer
Switch (ATS) will automatically transfer the electrical loads
to the engine-generator set. Upon restoration of normal
electrical service the emergency transfer switch will sense
return of the normal commercial power. The Automatic
Transfer Switch will transfer the load back to the normal
commercial power source. The engine control circuits will
begin a cool-down cycle, after which the fuel supply will be
shut off and the engine ignition system disabled.
NOTICE
A Customer supplied 12 Volt battery is required to
complete the installation. Battery requirements are listed
later under the battery installation section.
The generator ships with an advanced DSE7310 digital
controller. The DSE7310 will electronically display useful
engine and generator performance information. The
controller starts and stops the generator and monitors
critical operating parameters and will shut the generator
down to protect the engine from damage.
GENERATOR SET:
Every WINCO generator set has its own unique identity
data plate. This data plate identifies 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 identification
whenever requesting field or factory assistance.
Primary fields needed for assistance are complete model
number and serial number.
ENGINE:
This manual covers specific 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
specified in the engine manual.
Engine service is available from a nearby authorized dealer
or distributor. Go to the WINCO website (wincogen.com)
for a list of engine dealers or contact the WINCO Service
Department.
The rated power of each engine-generator is limited by
the temperature, altitude, and all other ambient conditions
specified by the engine manufacturer.
Derates
Above Sea Level
> 2,000 FT 2% Every 500 Feet
Temperature
> 104°F 4% Every 10°F
Units should not be operated in ambient temperature
greater than 120° Fahrenheit.
GENERATOR:
The nameplate includes a standby and prime/continuous
rating. The standby rating is the maximum amount of
power the generator set can produce. For prime power
applications the load should be equal to or less than the
prime power rating and the load is assumed to be variable.
It is acceptable to occasionally reach the standby rating
during prime operation to start motors or other temporary
surges.
WINCO generator sets use a brushless, AVR (Auto-Voltage
Regulator) controlled broad-range generator ends. The
generator converts rotational mechanical energy into
electrical energy. These WINCO units are equipped
with generators manufactured by Cummins Generator
Technologies. 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.

7OPM-160/B
PREPARING THE UNIT
IMPORTANT
This engine is equipped with an O2 sensor. During the
break in period you may get engine codes and limited
output. After the engine operates for two to five hour
the O2 sensor is conditioned and will allow full output
without engine codes.
START-UP CHECK LIST
A Start-Up Completion & Warranty Validation Form was
sent along with this manual. This must be completed and
returned to WINCO Inc. within 180 days of the factory
invoice date.
If this form is not returned, the Warranty may be voided.
UNPACKING
1. As you receive your unit, it is critical to check it for any
damage. If any damage is noted, it is 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 file 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 specification pages in this manual to
ensure that this unit meets your job requirements.
CAUTION: EQUIPMENT DAMAGE
These units are shipped with oil and a 50/50 mix of
coolant. Be sure to check all fluid 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. Start-up and warranty validation form.
d. Battery hold-down brackets & hardware.
e. Unit components or accessory items shipped loose
for on-site installation.
f. Optional accessories.
3. Remove main frame hold-down bolts.
4. Unit can now be lifted from shipping rails.
LIFTING THE GENERATOR SET
CAUTION: PERSONAL INJURY:
To prevent injury to persons or equipment, observe the
following guidelines when lifting the generator.
Due to the different designs, configurations, options,
weights, site conditions, and available material handling
equipment, specific 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. Always use
forklifts of a proper rating and with long enough forks to
move the generator. As the distance from the forklift mast
increases the lifting capacity for the forklift decreases. When
lifting from the side the forks should extend the entire width
of the unit to the opposite side frame rail.
CAUTION
Do not attempt to lift the genset 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 and not the complete unit.

8
OPM-160/B
system installation. The information in this manual is offered
only as a guide to finalizing your installation plans.
WARNING: PERSONAL INJURY
The enclosures on these units can become very hot
adjacent to the exhaust areas. Special care must be taken
when installing these units to insure that the risk of
contact by people is minimized.
The unit’s main frame should be bolted to a pad that meets
local code. Various materials, including concrete and
composites, are acceptable as long as they are structurally
sound supporting the weight of the unit and preventing
movement during operation. The mounting holes on the
base of this unit is 0.625” in diameter. The engine-generator
is mounted on a sub-frame which is isolated with special
shock mounts on the main frame. This allows the engine-
generator to vibrate without affecting the control panel on
the main frame.
Do not install any shock mounts between the base frame
and the pad. Engine vibration will be transmitted to the
control panel causing erroneous start/stop cycles and
premature control failure.
These units should be mounted a minimum of 24” from a
structure. This will allow for ample room to maintain and
work on the generator set.
Units must be installed in accordance with all local, state,
and national codes. Consult your local agency for specific
requirements.
VENTILATION REQUIREMENTS
OPEN SKID
WARNING: EQUIPMENT DAMAGE
It is the installer’s responsibility to ensure that there is
sufficient 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 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
enclosure 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
and damage. If louvers are used in front of the hot air duct
to protect the unit from outside weather, the louvers should
be 1½ times as large as the area of the radiator face to
prevent back pressure.
Foam or other seals can be used to form a tight lip forcing
all of the air from the engine fan out of the enclosure.
In addition to a hot air discharge, you must plan a fresh air
intake opposite the radiator discharge. Their fresh air inlets
should be 1½ to 2 times larger than the radiator face. The
INSTALLATION
This unit should be installed in a well ventilated area,
ensuring the exhaust air cannot be recirculated back into
the engine.
CAUTION:
This unit will get hot while it is running and for some time
afterward.
WARNING
Before proceeding with the installation, be sure
the engine control is in the “stop” position and the
emergency stop depressed. Also, be sure the generator
MLCB (main line circuit breaker) is in the “off” position and
the unit starting battery is disconnected.
PRIME POWER
Some configurations of the PSS60F4 are available with
EPA Prime power certifications. These configurations are
outfitted with a catalyst to meet current regulations. When
operating prime power derate the load at least 10% for a
variable load. If the load is continuous at one current rating
ensure that it does not exceed 80% of the standby rating.
Prime power configurations can be installed in mobile
or stationary applications as long as sound engineering
practices are followed to accommodate the structural
and cooling considerations outlined in this manual.
Prime applications will require close observation of actual
conditions requiring a shortening of maintenance intervals.
GENERAL INFORMATION
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 is
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
finalizing your installation plans and does not substitute for
sound engineering judgment for the specific application.
ENGINE-GENERATOR SET MOUNTING
These engine-generator sets are designed to be mounted
on a pad where there is proper ventilation. The transfer
switch is mounted next to your electrical entrance or
distribution panel inside or outside the building. Consult
a qualified, licensed electrician or contractor to install and
wire the transfer switch. The installation must comply with
all national, state and local codes. Before beginning the
installation process check the rating of the generator set
and its transfer switch rating. Be certain they can handle
the intended load and are compatible with the entrance
voltage, phase and current ratings. Plans for installation
should be prepared with proper attention to mechanical
and electrical engineering detail to assure a satisfactory

9OPM-160/B
sure the rain flap faces to the rear of the vehicle so that it is
not blown open during transportation.
The generator ships with a critical grade muffler that should
be installed to decrease noise. It can be mounted either
internally or externally to the enclosure. The muffler cannot
increase back pressure to more than 0.725 psi.
FUEL INSTALLATION
The fuel supply should be as close as possible to the
engine. This will reduce the installation cost of fuel runs.
The information in this manual is offered to assist you in
providing the proper fuel for your engine. However, this
information is only provided to inform you of the engine’s
requirements and assist in making you aware of the
decisions you must make. In no case should the instructions
and information provided be interpreted to conflict with
any local, state or national codes. If in doubt, always consult
your local fire marshal, gas supplier or building inspector.
WARNING: FIRE HAZARD
All fuel runs should be installed by a licensed fuel supplier.
To connect the fuel line to the generator set you will
connect your incoming fuel line to the 1.25 inch NPT
fitting located on the left side of the engine-generator set.
This fitting is shipped with a plastic plug installed to insure
the fuel system stays clean. For all vapor fuel systems the
delivery pressure of the fuel to the fuel solenoid on the unit
must be four to six ounces psi (per square inch) or 7 to 11
inches W.C. (water column). These fuel pressures are critical;
failure to provide the proper pressure can cause many
problems including failure to start, inability to produce full
power, or damage to the equipment.
These generators have been tested with both natural gas
and LP at the factory. Before starting the engine you must
verify it is configured for the proper fuel. See additional
information in the NG/LP conversion section.
INSTALLING THE FUEL LINE
NOTICE: The engine generator sets are properly adjusted
before they leave the factory. The electronic control panel
will indicate if the LP mode is active
NATURAL GAS or LP VAPOR PIPE SIZE
Size of pipe normally required for generators operating on
natural gas or LP vapor. Unit location will determine the
size of fuel line that is required to supply the engine with a
constant fuel pressure and volume.
LIQUID PROPANE VAPOR (LP)
Refer to the tables on the following pages for fuel line size
and recommended tank size. For distances of 25 feet or
greater, a two regulator fuel system is recommended. This
is accomplished by installing a primary regulator at the tank
which will reduce the tank pressure down to 10 to 15 lbs.
A low pressure regulator is installed to further reduce the
fuel pressure to the required six (6) oz. operating pressure.
This low pressure regulator must be at least 10 feet from
the engine generator set; any closer installation will require
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 insufficient air flow to the engine for cooling. Installing
them opposite the hot air discharge will allow a sweeping
flow of cooling air across the engine, preventing hot spots.
WARNING: EQUIPMENT DAMAGE
Failure to seal the radiator output will result in hot air
recirculation that will result in equipment overheating
and damage.
The WINCO installation manual OPM-112 contains
additional information on indoor, open skid installations
and is available electronically through our website or by
requesting a copy from the factory.
EXHAUST INSTALLATION
DANGER: PERSONAL INJURY
Improper exhaust installation will allow dangerous gases
to seep into enclosed spaces causing a hazard to your
health and/or death.
All exhaust must be piped out of the enclosure. When
selecting a location to exhaust fumes make sure that the
potential for contact with people is controlled. Exhaust can
enter buildings through windows, ventilation systems and
other openings if proper precautions are not followed.
The exhaust must be isolated from the vibration of the
engine. If the exhaust is connected in a rigid system it will
result in damage to the engine. The generator comes
equipped with an engine mounted flex pipe to aid your
installation. Ensure proper alignment with the generator.
The flex can be eliminated if it is pushed to one side to make
a connection.
The most direct path possible should be used to get to the
outside of the enclosure. Each bend restricts the pipe and
increases back pressure. It may be necessary to increase the
exhaust pipe diameter in some applications.
The exhaust pipe is very hot. When passing through the
structure it is critical that a thimble or other appropriate
technique is used to dissipate the heat and prevent the
structure from catching on fire.
It is preferable to exhaust out the side of the enclosures.
Slope the pipe slightly downward away from the engine
to cause any water in the exhaust to run away from the
engine. Do not exhaust near intake. Once outside the
enclosure a rain cap or other technique must be used to
keep water out of the exhaust. In mobile applications make
Radiator
Discharge
Air Inlet
Duct
Exhaust
Thimble Flex
Piping

10
OPM-160/B
interfere with each other. This regulator must be sized to
accommodate the demand of the generator set and any
other appliance connected to it. See the following table for
the correct size of pipe to be installed.
Feet* Size of pipe
Up to 25 ft 1.25” pipe
Over 25 ft* 1.25” pipe
*Allow an additional 3 feet for each standard elbow.
DO NOT use ‘street ells’ (restrictive).
WARNING: PERSONAL DANGER
Do not use galvanized pipe in fuel line runs. The
galvanized coating can become eroded and flake off,
causing possible obstructions in the regulator or fuel
valve. The results could range from inoperative engine to
hazardous fuel leaks.
CAUTION
Be careful when sealing gas joints. Excessive sealing
compound can be drawn into the solenoid, regulator or
carburetor causing an engine malfunction.
FUEL PRESSURE
Correct fuel pressure cannot be stressed enough. The most
common cause for inoperative systems is an inadequate
or incorrect fuel pressure. Performance of the engine is in
direct relation to the correctness of the fuel system. Shown
below is a diagram of a typical LP vapor fuel installation.
Notice the following tables give two different units of
measuring fuel pressure. The first and most accurate is
the use of a simple water manometer. A manometer is
calibrated in inches of water column . The second is with a
pressure gauge calibrated in ounces per square inch.
a larger line be installed to provide a fuel reservoir. This is
also true for the single low pressure regulator, it should
also be a minimum of 10 feet from the unit. If this is not
done, the demand regulator on the unit and the pressure
regulator in the fuel line will interfere with each other.
When the two (2) regulator system is used on LP, a fuel line
size of 3/4 to 1 inch is generally adequate for distances up
to 300 feet from the primary to the low pressure regulator.
Consult your local fuel supplier for your exact requirements.
The appropriate line size from the following table is then
installed from the low pressure regulator to the generator
set.
Feet* Size of pipe
Up to 25 ft ¾” pipe
25 - 100 ft 1” pipe
Over 100 ft Use a two regulator system
*Allow an additional 3 feet for each standard elbow.
DO NOT use ‘street ells’ (restrictive).
LP TANK SIZING
Tank size is based off of 75% load, tank level has more
than 20% capacity, and tank is dedicated for the generator
supply.
Tank Temperature Tank Size
32° F (0° C) 1000 Gallons
0° F (18° C) 2000 Gallons
-20° F (-29° C) 3000 Gallons
LIQUID WITHDRAWAL SYSTEMS
When installing a unit equipped with the LP liquid
withdrawal, a primary regulator is not required on the
supply tank. The supply line is connected to a liquid
withdrawal valve on the supply tank and runs directly to
the fuellock strainer mounted on the engine generator
set. Normally a 3/8 to 1/2 inch copper line is acceptable
for this type of fuel installation. You must be sure that the
valve you have connected to on the supply tank is in fact a
liquid supply valve and has a drop tube inside the tank that
is pulling fuel from the bottom of the supply tank. Before
starting the unit, you must confirm that you have a good
liquid supply at the unit. Engine generator sets equipped for
liquid withdrawal will not run properly when supplied with
vapor fuel.
NATURAL GAS (NG)
The primary regulator (fuel meter) on the building should
deliver the correct volume and pressure to the generator
set. This regulator must be sized to deliver the required
BTU’s to the generator set and all other appliances in the
building. If the primary regulator (fuel meter) is a high
pressure regulator, then a low pressure regulator must be
installed to bring the pressure down to 4-6 oz. (7-11 inches
water column) of pressure. This low pressure regulator must
be at least 10 feet from the engine generator set; any closer
installation will require a larger line be installed to provide
a fuel reservoir. If this is not done, the demand regulator
on the unit and the pressure regulator in the fuel line will

11 OPM-160/B
Reference in both diagrams: numbers 1 through 3 in the
diagram above are system parts supplied by the customer.
Reference number 4 is on the generator.
The following diagram is of a natural gas (NG) installation.
Reference numbers 2 through 4 in the previous diagram
are system parts supplied by the customer. Reference
number 4 is on the generator.
FUEL PRESSURE TABLES
The following tables are the fuel pressure readings at each
reference in the system.
SINGLE LOW PRESSURE REGULATOR (LP vapor only)
Ref# 1 3 4
Unit off Line PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
Starting Line PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
No load Line PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
Full load Line PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
TWO REGULATOR SYSTEM (LP vapor only)
Ref# 1234
Unit off Line PSI 10-15 lbs 7-11 in
4-6 oz
7-11 in
4-6 oz
Starting Line PSI 10-15 lbs 7-11 in
4-6 oz
7-11 in
4-6 oz
No load Line PSI 10-15 lbs 7-11 in
4-6 oz
7-11 in
4-6 oz
Full load Line PSI 10-15 lbs 7-11 in
4-6 oz
7-11 in
4-6 oz
NATURAL GAS
Ref# 234
Unit off 2 PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
Starting 2 PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
No load 2 PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
Full load 2 PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
NG/LP FUEL CONVERSION
This generator set was tested on both LP and NG at the
factory. Ensure proper fuel configuration before operating.
CAUTION: EQUIPMENT DAMAGE
Do not make any fuel adjustments or governor
adjustments until all pressure readings are in compliance
with specification.
These engine/generator sets are easy to convert between
LP or NG. As the engine timing is controlled by the ECU on
the engine you only need to tell it what fuel you want to
operate on. A small rocker switch has been provide on the
underside of the engine control cabinet for this purpose.
Opening the rocker switch will tell the ECU mounted on
the engine that you are operating on NG Fuel. Closing the
rocker switch will tell the ECU that the fuel being supplied is
LP. The Advance Power Controller has an indicator light for
LP. When this light is on, the engine is set-up for LP, when
the LP light is out the engine is set up for NG. The ECU will
then reprogram the engine to operate on the proper fuel.

12
OPM-160/B
For additional information on wire sizing refer to table 310-
16 of the National Electrical Code ANSI/NFPA 70.
C - Ground Lug, These ground lugs are bonded to ground
and are provided for you to connect your ground wire
from the transfer switch to. The lugs on the 60kW will
accommodate #1 AWG to 250 MCM and should be
torqued to 250 in. lbs.
D. 120 Volt Terminal Block. These terminals are for shore
power. For a power line with one lead, plug into either
terminals, ensuring the jumper is still connected. To isolate
two leads for use of two separate circuit breakers, the
jumper must be removed.
WARNING: EQUIPMENT DAMAGE
When installing a three-phase 240 Volt system, be sure
you know which lead is the high voltage “wild” leg (208
Volt to neutral). The generator normally carries the high
voltage on the G2 lead.
The load current carrying wires (L) and (T) must be sized
to handle the maximum load current without excessive
voltage drop. By code, the wire must be heavy enough to
handle the full current rating of the mainline circuit breaker
(or fuse) in the entrance (or sub-panel) protecting the
contactor switch.
All wires should be installed in rigid or flexible conduit.
(knockouts are provided in the control box).
GROUNDING
A grounding lug has been provided on the engine
generator set. 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. .
DC ELECTRICAL CONNECTIONS
CAUTION
Never run the AC and DC wiring on the same conduit.
NOTE: There are various DC connectors on the engine
that have nothing connected to them. This was done
intentionally, the connectors are for END OF THE LINE
TESTING and other diagnostic tests. They are not used
during normal operations and can just be ignored.
All DC connections are completed on the terminal strip just
AC ELECTRICAL CONNECTIONS
NOTICE: CLASS 1 WIRING METHODS ARE TO BE USED
FOR ALL FIELD WIRING CONNECTIONS TO TERMINAL OF
A CLASS 2 CIRCUIT.
WARNING
A mainline circuit breaker has been provided inside the
generator housing. During all wiring installation, make
sure the breaker is in the off position and the generator
operators switch is in the off position.
A - Neutral Lugs, These neutral lugs are isolated from
ground and provided for you to connect your neutral wire
from the transfer switch. The lugs on the 60 kW will handle
wire sizes #4 AWG to 300 MCM and should be torqued to
250 in lbs.
B - Generator Circuit Breaker, This circuit breaker provides
overload protection for the generator. Your power feeds
from the transfer switch will connect to the bottom lugs on
the circuit breaker. The generator power feeds have already
been wired into the upper lugs.
The table below gives you the circuit breaker size, lug wire
sizes and torque specification. (see the actual breaker for
additional information and restrictions)
Volts PH Amp Wire Capability
120/240 1250 (1) #1 AWG-600 kcmil or
(2) #1 AWG-250 kcmil
120/208 3225 (1) 4 AWG-300 kcmil
120/240 3225 (1) 4 AWG-300 kcmil
277/480 3100 (1) #14 - #3/0 AWG
346/600 380 (1) #14 - #3/0 AWG
The following table shows the minimum conductor sizes
between the generator and the ATS, based on wire type
and temperature rating. Wire has been derated 40° C
ambient temperatures.
Wire Temperature Rating
Cu Conductor Al Conductor
Volts PH Amp 75°C 90°C 75°C 90°C
120/240 1250 300 4/0 500 350
120/208 3225 250 4/0 400 300
120/240 3225 250 4/0 400 300
277/480 3100 2 3 1/0 1
346/600 380 3 4 2 3
A
C
B
D
ELECTRICAL CONNECTIONS

13 OPM-160/B
below the engine control cabinet.
A - Customer Remote Start CONNECTIONS TERMINALS. The
two remote start leads from the Automatic Transfer Switch
are connected to the two terminals marked 1 & 23. The
wire in terminal labeled #1 is Battery Negative/Ground and
the wire in the terminal labeled #23 is your Remote Start
lead. Closing these two leads together will signal the DSE
7310 MKII to go into an autostart mode and start up the
engine generator.
Depending on the distance, 14 to 16 gauge stranded wire
should be used. It is suggested that these wires be labeled
S1 and S23.
Note: Any relay closure can be used to start and stop this
generator. As long as the contact stays closed the engine
generator set will continue to run. Once the relay is opened
the unit will shut down and remain in the standby mode
until the remote start relay is closed again.
B - ESTOP- & ESTOP+. Remote Emergency Stop terminals.
These two terminals are shipped with a jumper installed.
If your application requires the installation of a Remote
Emergency Stop switch, remove the jumper and wire your
switch to these terminals. This unit will not start and run
without either the jumper installed or a remote N/C switch
installed..
C - Battery Charger Failure. Battery charger failure relay
input from remote battery charger to DSE7310 MKII
controller.
D - Remote Display Panel Interface Terminals. These
interface terminals are pre-wired to allow for the connection
of a remote display. This display allows for the remote
annunciation of alarms at a location such as a nurses station
or a control room.
E - Battery Positive and Ground ( battery negative). These
terminals are dedicated for any accessory that will be
installed. There is a maximum of 7 Amps combined.
DC INTERCONNECTIONS TO ATS
Two control wires are required between the ATS panel
and the generator control terminal box. Depending on the
distance, 14 and 16 gauge stranded wire should be used.
These wires should be labeled S1 and S23.
WARNING
Be sure engine generator is in the OFF position before
you make any DC interconnections.
D
C
B
A
E
TRANSFER SWITCH
NOTICE
For full service switching of the entire load, the ATS must
be ‘SE’ (Service Entrance) rated or must have a properly
rated fusible disconnect installed before the ATS to
protect the contacts.
ASCO 185 UL SWITCH
Your DC connection points in the ASCO 185 UL ATS are on
the terminal block on the bottom of the controller in the
lower left hand corner of the ATS panel. The terminal block
(TB7) is numbered 1 through 9. These terminals will accept
# 22 - # 14 AWG stranded wire. It is recommended that you
use # 16 AWG for distances up to 200 feet. You need to run
two (2) wires from the engine generator set to the transfer
switch. You will be using terminals 4 and 5, wire Start # 23
will connect to terminal # 5 and wire Battery Negative #
1 will connect to terminal # 4. See the following table and
illustration.
Your DC connection points in the ASCO 185 ATS are
terminals “4” and “5” on the interface terminal block. As this
is a “DRY” unpowered contract set it set, it makes difference
which lead (battery negative #1 or start #23) connect to
which terminal.
ASCO 300 UL SWITCH
When Normal
Source Fails
Terminals On
Transfer Switch
Contact Closes TB1 and TB2
Contact Opens TB1 and TB3
Engine start and
auxiliary circuit
terminal block TB
located on 3ATS
&3NTS transfer
switch.

14
OPM-160/B
MOUNTING THE ATS
See the ASCO installation manual for additional details on
proper wiring of the Automatic Transfer Switch.
WARNING: FIRE HAZARD
All wiring must be done by a licensed electrician, and
must conform to the National Electrical Code and comply
with all the local codes and regulations. Check with the
local authorities before proceeding.
INSTALLATION NOTES:
Because of the many different types of service, feeder,
and distribution equipment, no specific wiring instructions
can be provided. It is recommended that only copper
wire be used. In all cases it is essential that while the load
is connected to the generator, there can be absolutely
no feedback from the generator to the power line or the
power line to the generator. When properly installed, the
normal A.T.S. Control and safety systems will eliminate all
paths for feedback.
To wire the automatic transfer switch into the existing
wiring, first determine which circuits will be on the
emergency load circuit. If the entire load is to be transferred,
the transfer switch can be wired in directly after the watt-
hour meter and the service entrance, providing the service
entrance ampere rating is within the transfer switch’s rated
capability.
If only specific circuits are to be powered under emergency
power failure conditions, an additional distribution panel
designated “emergency distribution panel” must be
installed.
All selected emergency circuits are removed from main
distribution panels and installed in the emergency
distribution panel. The A.T.S. is then installed between
the main panel and the emergency distribution panel.
Suggested circuits: freezer, refrigerator, furnace, emergency
lights, sump pump, emergency outlet circuits, etc. Total
running load must not exceed generator rating.
WARNING
A service disconnect must be installed in front of the
ATS panel if the ATS is not service entrance rated. This
will allow you to test the generator under load. Should
you ever have to work on the switch, you will be able
to disconnect the power and work on the switch cold
without having the power company pull your meter.
To wire the automatic transfer switch into the existing
wiring, first determine which circuits will be on the
emergency load circuit. If the entire load is to be transferred,
the transfer switch can be wired in directly after the watt-
hour meter and the service entrance, providing the service
entrance ampere rating is within the transfer switch’s rated
capability.
If only specific circuits are to be powered under emergency
power failure conditions, an additional distribution panel
designated “emergency distribution panel” must be
installed. All selected emergency circuits are removed from
main distribution panels and reinstalled in the emergency
distribution panel. Suggested circuits: freezer, refrigerator,
furnace, emergency lights, sump pump, emergency outlet
circuits, etc. Total running load must not exceed generator
rating

15 OPM-160/B
WARNING
The electrolyte is a diluted sulfuric acid that is harmful
to the skin and eyes. It is electrically conductive and
corrosive, The following precautions must always be
taken.
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, flush immediately and
thoroughly with water. 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 biocarbonate of soda (baking
soda) to one gallon of water. The biocarbonate of soda
is to be added until the evidence of reaction, foaming,
has ceased the resulting liquid is to be flushed with
water and the area dried.
DANGER: EXPLOSIVE FIRE RISK
Never smoke near batteries. Do not cause a flame
or spark in the battery area. Always discharge static
electricity from your body before touching batteries by
first 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 refilling the battery with
water, use only distilled water. Tap water will shorten the
service life of the battery.
Never fill the battery above the fill line. Over filling above
the upper level line may cause electrolyte to overflow,
resulting in corrosion to the engine or nearby parts.
Immediately wash off any spilled electrolyte following the
procedure above.
BATTERY CHARGING
This generator is equipped with an engine mounted
alternator that will recharge the battery during operation.
It is not necessary to have the battery charger circuit on the
emergency distribution circuit.
CAUTION: EQUIPMENT DAMAGE
Always connect the positive cable first and the negative
cable last. When disconnecting, remove the negative
cable first and the positive cable last. Failure to connect
and disconnect in the proper sequence can cause
equipment damage.
Observe polarities: connect the positive (+) battery
terminal to the (+) cable from the engine starter; the
negative (-) battery terminal is connected to the negative
cable (ground) from the engine generator assembly. All
connections must be clean and tight. Check the electrolyte
(fluid) in the battery periodically to be sure it is above the
plates. Never allow the battery to remain in a discharge
condition.
INSTALLING THE BATTERY
CAUTION
In the following battery installation procedure, check to
be sure the engine control is in the “stop” position. This
should be your last step before initial start-up.
A customer supplied twelve-volt battery is required to
complete the installation. Installation of the highest CCA
rated battery, within the correct BCI group (size), will
increase cold weather starting performance. Gel batteries
should not be used with the battery tender installed in the
generator enclosure.
Voltage BCI Group MIN. CCA Rating
12 24 650
WARNING: EQUIPMENT DAMAGE
This unit is12 Volt and is negative ground. Permanent
damage will occur if they are connected to a 24 Volt
system or a positive ground system. If you are using
the truck batteries to start these units, you may have to
disable the charging system to keep it from interfering
with the vehicle charging system.
Installation and servicing of batteries must be performed
or supervised only by persons knowledgeable of batteries
and the required precautions. Keep unauthorized persons
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 of a battery in a fire. 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 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
and damage electronic components.
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 first and then
connect the battery negative cable. When removing
the battery cables from the battery, reverse the
procedure and disconnect the negative cable first and
then the positive cable.
5. Be sure all connections are tight and coat the terminals
and cable ends with dielectric grease.

16
OPM-160/B
CAUTION: EQUIPMENT DAMAGE
NEVER JUMP START these units. Doing so will destroy
the engine control module, rendering the unit non-
operational. Remove and fully recharge the battery
before attempting to start.
BATTERY CHARGER & BLOCK HEATER
BATTERY CHARGER
A three-stage, on-board marine battery charger is provided
standard on this unit. The charger is a 5 amp dual use
maintainer and charger designed to keep your batteries
fully charged by maintaining them automatically.
Make sure all DC battery connections are tight and clean.
Follow battery manufacturer’s recommendations.
This charger is mounted under the customer connection
on the control side of the generator. The charger will
need to be plugged to a customer’s power source, using
a customer supplied heavy duty, UL approved extension
cord. The receptacle is to be powered by a GFCI circuit and
installed in accordance to the US National Electric Code. It is
suggested that this circuit be fused to 20 Amps.
Low/Charge Mode:
The illuminated blue power LED and red low/charging LED.
This indicates the Low/Charge mode is in process. When
completed the RED Low/Charge LED will turn off.
Auto Maintain Mode:
The illuminated Green auto maintain LED. This indicates
your 12 volt battery is fully charged. During short or long
term storage periods, Auto Maintain (Energy Saver) mode
will monitor and auto maintain a battery only when needed
to maintain a full state of charge. This feature significantly
reduces AC Power consumption, lowers operating costs
and maximizes reserve power performance.
BLOCK HEATER
The block heater on this unit is a 1500 watt heater and
can use the same 20 Amp GFCI fused circuit. The circuit
will terminate on the 120 Volt terminal block mount in the
customer connection cabinet. The engine block heater
installed on this unit should also be plugged into this
receptacle. The block heater is thermostatically controlled
when plugged in will maintain the engine coolant
temperature between 100 and 120 degrees F.

17 OPM-160/B
STARTING PROCEDURE
CAUTION
For the first 10 seconds of operation all of the oil, coolant,
and electrical shutdowns are disabled. This is enough
time to cause catastrophic damage to the equipment
if the pre-start checklist is not properly completed and
proper maintenance isn’t consistently followed.
LUBRICATION
Before starting the engine, check the oil level in the
crankcase. If it is low, refill 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 do so will cause excessive
engine wear and shorten its useful life.
Winco recommends our 5W-30 fully synthetic heavy duty
engine oil to give you maximum cold weather protection
while maintaining excellent performance in warmer
weather. We have partnered with a national lubrication oil
manufacturer to give you access to Winco private branded
premium oil available at comparable prices to conventional
oils. See your dealer for additional information.
COOLANT
Before starting the engine, Check the coolant level in
the radiator. If it is low, refill as specified in the engine
manufacturer’s maintenance instructions.
PRE-START CHECK LIST
F-153 Pre-Start & Warranty Form was sent with your
generator. This form must be filled out by an Authorized
WINCO Service Center and submit it to our WINCO Service
Department for your warranty to become valid. After
completing the checklist, the engine-generator set is ready
for initial start-up.
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.
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.
IMPORTANT
This engine is equipped with an O2 sensor. During the
break in period you may get engine codes and limited
output. After the engine operates for two to five hour
the O2 sensor is conditioned and will allow full output
without engine codes.

18
OPM-160/B
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 flashing in
the display.
MANUAL MODE
1. Press and release the Manual Mode button. The small
LED light next to it should come on.
Note: There is no start delay in this mode of operation.
2. Press and release the green Start Engine button. The
DSE 7310 will send two signals to the engine. The first
signal wire #21 will engage the fuel solenoid, the second
wire, #22, will engage the starter on the engine. At this
point the DSE 7310 will start the cranking cycle (10
seconds on and 10 seconds off).
If the engine fails to start during this cranking period, the
starter motor is disengaged and goes into a rest mode
after which a second attempt is made to start the engine.
Should this sequence continue through 3 cranking cycles
the start sequence will be stopped and the display will
show ‘FAILED TO START’.
3. During manual operation, the load will not normally be
applied to the generator. But caution must be used, if the
line power should fail or be turned off the transfer switch
during manual operation the load may be applied to the
generator.
With the engine running smoothly check the no load
voltage and frequency on the digital display. The voltage
should match the nameplate and a frequency of 59.5 to
60.5 hertz (Hz).
If you have the proper voltage at the generator the next
step is to check the voltage at the generator terminals
in the Automatic Transfer Switch. The voltage between
the G1 and the G3 terminals should be the same as it
was on the generator front panel. The voltage should
also be checked between the hot terminals (G1 and G3)
and the G-N to be certain of a balanced voltage output
and a solid neutral connection. The voltage between G1
and G-N should be about 120 volts AC (277 on 480
units). The same approximate voltage should be found
between terminals G3 and G-N (120 volts AC).
On three phase panels the G2 voltage level should also
be checked. ON 240 VOLT (DELTA) SYSTEMS BE SURE
YOU KNOW WHERE THE HIGH VOLTAGE “WILD” LEG IS.
IT MUST BE IN THE SAME LOCATION ON THE LINE SIDE
AS IT IS ON THE GENERATOR SIDE. (i.e. if it’s on L-3 on
the line side it must be on G-3 on the generator side. Also
on three phase systems make sure that the rotation is the
same on the generator as it is on your line power.
CONTROL LAYOUT
STOP/RESET - 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.
MANUAL MODE - This button places the
module into its Manual Mode. Once in
Manual Mode, the model responds to the
Start button to start the generator and run it
off load.
START - Pressing this button from STOP/RESET
will start the engine and run the load.
AUTO MODE - This button places the
module into its Auto Mode. This mode allows
the module to control the function of the
generator automatically.
ALARM/LAMP TEST - This button silences the
audible alarm in the controller, deactivates
the Audible Alarm output (if configured) and
illuminates all of the LEDs on the module’s
face as a lamp test function.
MENU NAVIGATION - Used for navigating the
instrumentation, event log, and configuration
screens.
A small rocker switch is located on the
underside of the engine control cabinet.
On gaseous models, the engine timing is
controlled by the ECU on the engine and you
need to tell it what fuel you want to operate
on; LP or NG.
On diesel models, this switch has been
disconnected and will do nothing.
PROTECTIONS
When an alarm is present, the common alarm LED, if
configured, will illuminate. The LCD display will show an
icon to indicate the failure.
WARNINGS
Warnings are non-critical alarm conditions. They do not
affect the operation of the generator system, they
serve to draw the operator’s attention to an undesirable
condition. Warning alarms are self-resetting when the

19 OPM-160/B
WARNING: EQUIPMENT DAMAGE
Failure to insure proper rotation will cause three phase
motors to spin backwards, possibly causing damage to
the equipment.
NOTICE
If for any reason during the check out procedure the
voltage and frequency are not correct, depress the STOP/
RESET button and correct the trouble before proceeding.
4. Stopping - There are two ways to stop the unit when it is
in the manual mode. Pressing the STOP/RESET button will
stop the unit immediately. Pressing the AUTO mode
button will stop the unit but only after the cool down
timers have timed out and there is no remote start signal
being sent to the unit.
WARNING: EQUIPMENT DAMAGE
Always make sure the generator runs under no load for
five minutes before stopping to allow the engine and
components to cool down. Don’t use the E-Stop as the
standard.
AUTO MODE
To activate the automatic start mode you will just need to
depress the AUTO button, the LED indicator beside the
button confirms that the unit is in automatic mode.
To test the Automatic Transfer Switch, follow the instruction
on the operator’s manual that came with the transfer
switch. If you get a fault during the initial start up or prior
to start up, it is most likely a false warning light. Simply reset
the ATS to start over.
Once you have completed testing of the ATS, be sure you
ALWAYS leave the system in the standby mode,unless
servicing the unit. For standby operation, press the AUTO
button on the front of the control. The green light should
light up next to the AUTO button.
NOTE: For setting the exerciser circuit, for all ATS, see the
operator’s manual shipped with the ATS.
CONTROL POWER
The DSE7310 controller consumes small amounts of battery
power when it is in use. The controller comes with a power
switch that disconnects battery power when it is not in use.
The switch is designed with a safety relay that prevents it
from removing power to the controller while the generator
is operating. If the switch is turned off while the engine is
running it will continue operating until the engine shuts
down and then the controller will power down.
This switch should be used when the generator is not
going to be used over the course of several days and the
generator is not connected to a battery charger.
A solar charger kit is the easiest way to always maintain the
battery during storage in mobile applications. The supplied
battery charger can be plugged in to an extension cord on
mobile applications.

20
OPM-160/B
VOLTAGE REGULATOR
The following is a list of connections on the AVR. These
have been factory set and other than voltage adjustment,
should never be changed.
AS440 AVR
1. VOLTS - Adjust generator output voltage.
Clockwise to increase voltage.
2. LINK: HAND TRIMMER
1-2: NO TRIMMER
NONE: TRIMMER FITTED
Adjust alternator output voltage
Clockwise to increase voltage by AVR voltage adjustment.
3. STABILITY - To prevent voltage hunting.
Clockwise to increase dampening effect.
4. LINK: POWER: RESPONSE
A-B: > 550kW : Fast
B-C: 100-550kW : Fast
A-C: < 100kW : Fast
B-D: < 100kW : Slow
5. UFRO - Under Frequency Roll Off
Clockwise decreases ‘KNEE’ point.
6. SWITCH - Select alternator frequency for UFRO
SWITCH LEFT: 60Hz
SWITCH RIGHT: 50Hz
7. LED Indicator Light - LED light on in UFRO or O/EXC
condition.
8. DROOP - Adjust alternator droop to 5% at zero power
factor.
Clockwise to increase increase droop.
9. TRIM - Adjust analog input sensitivity.
Clockwise to increase sensitivity.
10. O/EXC - Adjust over-excitation trip.
Clockwise to increase trip voltage.
11. LINK: SUPPLY
8-Z2: Main stator
None: Auxiliary winding
Select AVR supply source.
1
9
10
11
2
7
6
4
3
8
5
OPERATING CONDITIONS
NORMAL OPERATION
This generator-engine set needs load and should not idle
for long periods of time.
If the generator application is for emergency standby the
generator should be exercised at least monthly ideally
under load. Load banking the generator at least annually
will help keep the engine in good condition.
HARSH ENVIRONMENTS
OPERATIONS
Some applications require the generator to operate in
harsh environments. One of the most common hazards are
extremely dusty conditions. In harsh conditions it is often
necessary to take additional steps to keep the equipment
clean and operating at its peak. Maintenance intervals on
lubricant and filter changes may need to be shortened. An
oil quality testing program can also provide early warnings
or oil degradation. Efforts may need to be made to reduce
the amount of dust and debris entering the housing and
generator components.
COLD WEATHER OPERATIONS
The minimum starting temperature with block heater is
-13°F.
The degree of fluidity of the engine oil may be reduced at
low temperatures due to the separation of the paraffin. This
results in the filters becoming clogged.
Oil companies must respect these standards, which provide
for the distribution of fuels adapted to the climatic and
geographical conditions in various countries.
This generator-engine set needs load and should not idle
for long periods of time.
If the generator set will be run in extremely cold
environments it may be beneficial to provide means to
reduce air circulation to increase the temperature of the
enclosure.
Inspect the hoses regularly during cold operation looking
for signs of freezing. If the line freezes it will cause pressure
to build in the crankcase and may cause an engine seal
failure. If the engine operates below optimal temperatures
for long periods of time damage may occur.