Winco WC3000H User manual

INDUSTRIAL
GENERATORS
OPERATORS MANUAL
60706-128
WC3000H
W9500HE

Read and understand all instructions in the manual before
starting and operating the generator set.
USING THIS MANUAL
Congratulations on your choice of a Winco generator set.
You have selected a high-quality, precision-engineered
generator set designed and tested to give you years of
satisfactory portable service.
To get the best performance from your new engine
generator set, it is important that you carefully read and follow
the operating instructions in this manual.
Should you experience a problem please follow the
“Things To Check” near the end of this manual. The warranty
listed in this manual describes what you can expect from
WINCO should you need service assistance in the future.
TABLE OF CONTENTS
INTRODUCTION i
FEATURES BY MODEL TABLE 1
GUIDETOPRODUCTSAFETY 2
BASICINFORMATION
Intended Uses 3
Restricted Uses 3
Unit Capabilities 3
PREPARING THE UNIT
Unpacking the unit 4
Unit Preparation 4
LP/NG Installation 4
Battery Installation 4
Low Oil Shutdown 5
Automatic Idle 5
BASIC OPERATION
Starting 6
Starting Hints 6
Stopping And Storage 6
Operating Speed 7
Connecting The Load 7
INSTALLATION GUIDELINES
Wiring 7
OPERATOR CARE AND MAINTENANCE
Engine Care 8
Generator Care 9
Cleaning 9
Things To Check BEFORE
You Call For Service 9
24 MONTH WARRANTY 10
PROPER USE AND INSTALLATION
You must be sure your new engine generator set is:
* Properly serviced before starting
* Operated in a well ventilated area
* Exhaust gases are dispersed safely
* Wired by a qualified electrician
* Operated only for its designed purposes
* Used only by operators who understand its operation
* Properly maintained
COPY YOUR MODEL AND SERIAL NUMBER HERE
No other WINCO generator has the same serial number as
yours. It is important that you record the number and other
vital information here, if you should ever need to contact us
on this unit it will help us to respond to your needs faster.
MODEL____________________________________
SERIAL NUMBER____________________________
PURCHASE DATE____________________________
DEALER___________________________________

Page160706-128 WINCOPORTABLESERIES

WINCOPORTABLESERIES Page2 60706-128
This engine generator set has been designed and
manufactured to allow safe, reliable performance. Poor
maintenance, improper or careless use can result in
potential deadly hazards; from electrical shock, exhaust gas
asphyxiation, or 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.
ANSISAFETYDEFINITIONS
______________________________________________________
DANGER:
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
This signal word is to be limited to the most extreme
situations.
______________________________________________________
______________________________________________________
WARNING:
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
______________________________________________________
______________________________________________________
CAUTION:
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe
practices.
______________________________________________________
NOTE:
CAUTION is also used on the unit labels and in this
manual to indicate a situation that could result in serious
damage or destruction of the equipment and possible
personal injury.
______________________________________________________
1. ELECTRIC SHOCK- The output voltage present in this
equipment can cause a fatal electric shock. This
equipment must be operated by a responsible person.
a. Do not allow anyone to operate the generator
without proper instruction.
b. Guard against electric shock.
c. Avoid contact with live terminals or receptacles.
d. Use extreme care if operating this unit in rain or
snow.
e. Use only three-prong grounded plugs and
extension cords.
f. Be sure the unit is properly grounded to an
external ground rod driven into the earth.
2. FIRE HAZARD- Gasoline and other fuels always present a
hazard of possible explosion and/or fire.
a. Do not refuel when the engine is running or hot.
Allow the engine to cool at least two minutes before
refueling.
b. Keep fuel containers out of reach of children.
c. Do not smoke or use open flame near the
generator set or fuel tank.
GUIDE TO PRODUCT SAFETY
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.
3. DEADLYEXHAUSTGAS-Exhaustfumesfromany
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.
c. Never operate the unit in such a way as to
allow exhaust gases to seep back into closed
rooms (i.e. through windows, walls or floors).
4. NOISE HAZARD - Excessive noise is not only tiring, but
continual exposure can lead to loss of hearing.
a. Use hearing protection equipment when
working around this equipment for long periods
of time.
b. Keep your neighbors in mind when
permanently installing this equipment.
5. CLEANLINESS- Keep the generator and surrounding
area clean.
a. Remove all grease, ice, snow or materials that
create slippery conditions around the unit.
b. Remove any rags or other material that could
create potential fire hazards.
c. Carefully wipe up any gas or oil spills before
starting the unit.
d. Never allow leaves or other flammable
material to build up around the engine exhaust
area.
6. SERVICINGEQUIPMENT-Allservice,includingthe
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, cover, or
receptacle panels while the engine is running.
d. Use extreme caution when working on
electrical components. High output voltages from
this equipment can cause serious injury or death.
e. Always avoid hot mufflers, exhaust manifolds,
and engine parts. They all can cause severe
burns instantly.
f. Installing a home-standby generator is not a
“do-it-yourself” project. Consult a qualified,
licensed electrician or contractor. The
installation must comply with all national, state,
and local codes.

Page360706-128 WINCOPORTABLESERIES
having to choose between powering them or a 240 Volt load.
There are no switches or connectors to change. Simply plug in
and use the power without being concerned about overloading
the generator winding as long as the load doesn't exceed the
size of the generator.
Check the appliance or tool nameplates for the current and
voltage to insure compatibility. Remember that power taken
from receptacle C reduces the power available at both A and
B and vice versa.
StartingElectricMotors
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 current to start them as to run them.
Capacitor motors are easier to start and usually require 2 to 4
times as much current to start them as to run them.
Repulsion Induction motors are the easiest to start and
usually require 1 1/2 to 2 1/2 times as much to start them as
to run them.
Most fractional horsepower motors take about the same
amount of current to run them whether they are of Repulsion-
Induction (RI), Capacitor (Cap), or Split-Phase (SP) type. The
chart below shows the approximate current required to start
and run various types and sizes of 120 volt 60 cycle electric
motors under average load conditions.
RUNNING STARTING AMPS
HP AMPS SP CAP RI
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 NOTMADE 14 TO 29 11 TO 18
1 13.0 NOTMADE 26 TO 52 20 TO 33
The figures given above 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.
Self-excited generators respond to severe overloading
differently than the power line. 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 might also be
damaged.
CAUTION: EQUIPMENT DAMAGE
RUNNING THE GENERATOR SET UNDER THESE
CONDITIONS MAY RESULT IN DAMAGING THE
GENERATOR STATOR AS WELL AS THE MOTOR
WINDING.
Because 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 difficulty is experienced in starting motors,
turn all other electrical loads off and if possible reduce the load
on the electric motor.
INTENDED USES
These engine generator sets have been designed primarily
for portable use. Both 120 and 240 volt AC 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. See unit capabilities for
further explanation.
These portable units require large quantities of fresh air for
cooling of both the engine and the generator. Fresh air is
drawn from both the engine end and the generator end and
is exhausted at the center of the unit. For safety, long life
and adequate performance, these units should never be
run in small compartments without positive fresh air flow.
RESTRICTED USES
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 these portable generators in a
small compartment., i.e. generator compartment of
vehicles, motor homes or travel trailers. These
compartments will not allow enough free flow fresh air to
reach the engine generator set for cooling and will cause
the unit to overheat, damaging both the engine and the
generator. Small compartments will also develop hot
spots where there is very little air flow and may cause a fire.
DO NOT attempt to operate at 50 cycles. These units are
designed and governed to operate at 60 Cycles only.
UNIT CAPABILITIES
GeneratorConnections
The diagram below represents a typical 4000 watt
generator. Receptacles A and B are the two 120 Volt
duplex receptacles. Up to 2000 watts at 120 volts (16.6
Amps) can be taken from the generator at each of the
receptacles. This generator produces 120 and 240 volt, 60
Hz (Hertz), AC (Alternating Current).
The WINCO Industrial series generators have the EXTRA
Heavy FULL POWER winding to allow the use of all the
power available from the engine at either 120 Volts, or 240
Volts or any combination of the 120 or 240 volts. You are
not restricted to splitting up your large 120 Volt loads or
BASIC INFORMATION

WINCOPORTABLESERIES Page4 60706-128
PREPARING THE UNIT
DIESEL FUEL
ASTM No.2 diesel fuel is recommended for these engines.
The use of No. 2 diesel fuel will result in optimum engine
performance. The use of a lighter fuel will reduce fuel
economy. See your engine operators manual for complete
fuel information.
WARNING:FIREDANGER
Gasoline, diesel fuel and its fumes are VERY explosive
when proper precautions are not taken.
Never use fuel that has been stored for an extended period
of time as the fuel will lose it's volatile properties and you
will be left with only the varnish residue. This varnish like
substance will clog the carburetor or injectors and 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
fuel tank and replace with fresh fuel before attempting to
start.
BATTERY INSTALLATION
All electric start engine generator sets are shipped with a
battery kit for customer installation. This kit consists of a
battery rack, battery tie down, battery cables, and instruction
sheet for installation. After installing the battery rack, file the
instruction sheet in the back of this manual for future
reference.
If you intend to use the power plant’s electric start system,
you will need to purchase and install a battery to operate it.
Units equipped with a recoil or rope start will operate
satisfactorily without a battery. A twelve volt battery, group
U1 rated at 235 CCA or larger is recommended for this
electric start engine generator set. Follow the battery
manufacturers recommendations for servicing and
charging prior to use. Connect the battery to the electric
start system using the cables provided.
CAUTION: EQUIPMENT DAMAGE
Theseelectric startengines areNEGATIVEGROUND. 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 first. Then connect the negative battery
cable to the “bat-” terminal. Make sure all connections are
clean and tight. Reverse the sequence when
disconnecting, disconnect the negative cable first. These
engines produce enough direct current to keep a battery
charged under normal operating conditions, but were not
intended to be used as a battery charger.
UNPACKING
CAUTION: EQUIPMENTDAMAGE
THIS UNIT HAS BEEN SHIPPED WITHOUT OIL. Failure
to maintain the engine oil at the proper level will result in
serious engine damage.
When you unpack your new ENGINE GENERATOR be sure to
remove all the information sheets and manuals from the
carton.
1. This generator set was in good order when shipped.
Inspect the power plant promptly after receiving it. If
damage is noted, notify the transportation company
immediately, request proper procedures for filing a
“concealed damage” claim. Title to the equipment
and responsibility for filing a claim rests with you
when a generator is sent F.O.B. shipping point. Only
you can legally file a claim.
2. Before proceeding with the preparation of your new
engine generator set for operation, take a couple of
minutes to insure that the unit you have received is
the correct model and review the specification pages
in this manual to insure that this unit fits your job
requirements.
3. After removing the engine generator from the carton
locate and remove the shipping strap attached to the
generator shock mount. See attached tag for
removal instructions.
UNIT PREPARATION
Before your engine generator was shipped from our factory it
was fully checked for performance. The generator was load
tested to its full capacity, and the voltage and frequency were
carefully checked and adjusted.
LUBRICATION
Before starting the engine, fill the crankcase to the proper
level with a good quality oil. The recommended grade of oil
and quantity of oil required is listed in the engine operator's
manual shipped with our unit. 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 are not
covered by the generator or the engine manufacturer's
warranty.
GASOLINE FUEL
Always use a good grade of unleaded fuel. Leaded gasoline
may be used if unleaded is not available. Gasoline
containing alcohol, such as gasohol is not recommended.
However, if gasoline with alcohol is used, it must not contain
more than 10 percent Ethanol and must be removed from the
engine during storage. DO NOT use gasoline containing
methanol. Always insure that the fuel is clean and free of all
impurities.

Page560706-128 WINCOPORTABLESERIES
WARNING: PERSONAL INJURY
Lead acid batteries produce explosive hydrogen gas
when charging. Keep sparks, flames, 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,
flush well with water. For contact with eyes, get
immediate medical attention
Battery Charging
Units equipped with electric start have a small flywheel
charger built into the engine flywheel assembly for
recharging the starting battery. This flywheel charger
generates a small AC current that passes through a diode
assembly to produce a DC charging current of about 1 AMP.
This circuit is not designed to be used as a battery charging
circuit to recharge dead batteries.
OPTIONAL DOLLY KIT
An optional dolly kit is available for most of these engine
generator sets. The dolly kit comes with instructions and
parts list. After installing the dolly kit, file the instructions and
parts list in the back of this manual for future reference.
LOW OIL LEVEL SHUTDOWN SYSTEM
All Winco Industrial generators are equipped standard with
low oil shutdown systems. The Honda and Briggs &
Stratton IP engines all use a float switch system. This low oil
warning system will automatically stop the engine before the
oil level reaches an critical danger point. This feature is
designed to prevent costly repairs and downtime.
CAUTION: EQUIPMENT DAMAGE
Allowing the engine to shutdown repeatedly
on low oil level may cause excessive wear
which can be cumulative.
This system uses a float in the engine crankcase to sense
the oil level. If a low oil level condition should occur during
operation, the float will ground out the magneto impulse,
“killing” the engine. In addition, there is an indicator light
mounted on the engine shroud near the recoil starter. This
light will blink on and off to indicate a low oil level condition
when you are attempting to start the unit. To get the engine
started, you must add the required amount of oil to the
engine crankcase.
Use of the float system on applications that are subject to
shock, bumping or severe angles of operation (in excess of
15 degrees) should be avoided. This is especially true if an
unexpected shutdown would cause a safety hazard or
serious inconvenience for the operator.
The Yanmar diesel, Kohler Commander and the Briggs &
Stratton Vanguard all use a pressurized oil system. The oil
pressure is monitored by an oil pressure sensor mounted on
the engine. If the oil pressure gets low during operation the
engine ignition is grounded out and the engine will shutdown.
On the Yanmar the oil pressure sensor opens the power feed
to the run solenoid, allowing the fuel rack to close shutting
the engine down. If during starting the oil system doesn’t
build sufficient pressure to close the oil sensor switch the
engine will not continue to run. This can be caused by a low
oil level or by using the wrong grade of oil for the ambient air
temperature.
AUTOMATIC CONSERVER®CONTROL
(WC Series Only)
The automatic Conserver® control is a gas saving, solid state
system, designed to reduce engine speed whenever the
electrical load is removed from the generator. Without a slow
down control, the engine would run at full speed at all times,
regardless of the electrical load. With the automatic
Conserver® control switch in the 'Auto' position, the throttle
control lever is electrically released when the load is turned
on so it in no way interferes with the normal governor
operation. When the load is turned off, the idle magnet
energizes and reduces the engine speed. It does not cause
incorrect operation of the carburetor or governor, but neither
does it correct them.
The automatic Conserver® control consists of a solid state
module mounted in the generator end cover, a switch,
resistor and transformer located in the generator control box,
and an electromagnet mounted on the engine near the
throttle lever. The automatic Conserver® control is only
offered as a factory installed feature. It is not available for
field installation.
With the automatic Conserver® switch in the “automatic”
position, the system operates as follows:
1. After the engine has been started, and no electrical
load is applied, the transformer senses and signals the
solid state module to turn on the electromagnet. This will
pull and hold the throttle lever, closing the throttle on the
carburetor reducing the engine speed.
2. When a load is applied to the generator, the
transformer senses it and sends a signal to the solid
state module to turn off the electromagnet. This allows
the throttle to release and allows the governor spring to
open the throttle. The engine will respond and come up
to the governed speed (3600 rpm).
3. When the electrical load is turned off, no power will
flow through the transformer, and as a result, the
automatic idle control will once again energize the
magnet, pulling and holding the throttle.
When the automatic Conserver® switch is in the “off”
position, the engine will run at full governed speed regardless
of the generator load.
PREPARING THE UNIT

WINCOPORTABLESERIES Page6 60706-128
CAUTION: EQUIPMENT DAMAGE
Never permit the choke to remain on after the engine
has run for a short time. It is not necessary to choke
the engine when it is warm. Avoid over-choking.
STARTING HINTS
1. Cold weather
a. Use the proper oil for the temperature
expected.
b. Use fresh winter grade fuel. Winter grade
gasoline is blended to improve starting. Do
not use summer gasoline.
c. A slightly richer fuel mixture will usually
improve cold starting.
2. Hot weather
a. Use the proper oil for the temperature
expected.
b. Use only summer blended gasoline. Using
gasoline left over from winter may cause the
unit to vapor lock.
c. DO NOT over-choke the unit.
STOPPING AND STORAGE
1. Depress the stop switch.
2. Close the fuel shut-off valve. Always shut the
fuel off whenever the engine is stopped to prevent
fuel leakage from carburetor.
3. Before extended storage (over 30 days) certain
precautions must be taken to ensure the fuel
doesn’t deteriorate and clog the fuel system.
a. Remove the remaining fuel from the fuel
tank.
b. Start the engine and allow it to run until all
the fuel in the carburetor and the fuel lines
has been used up and the engine stops.
c. While the engine is warm, drain the oil and
refill with fresh oil.
d. Remove the spark plug, pour approximately
1/2 ounce (15 cc) of engine oil into the
cylinder and crank slowly to distribute oil.
Replace spark plug.
e. Clean dirt and chaff from cylinder,
cylinder head fins, blower housing, rotating
screen and muffler areas.
f. Store in a clean and dry area.
Note: The use of a fuel additive, such as STA-BIL, or an
equivalent, will minimize the formation of gum deposits
during storage. Such an additive may be added to gasoline
in the engine’s fuel tank or to gasoline in a storage
container.
INITIAL START UP
Use the following checklist to verify the correct preparation of
the engine generator before starting.
Before Starting always Check:
1. Engine oil, fill as required with correct grade and
quantity.
2. Fuel level, fill as required with clean fresh fuel.
3. Automatic Conserver® is in the 'Off' position
4. Visually check for loose or broken parts.
STARTING
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. See “Operating Speed”
section for additional information.
NOTICE: ENGINE
These units will not start if it is low on oil. The lubricating oil
level must be at the full mark before the engine will start.
MANUALSTARTING
Refer to the engine manual for additional starting, operating,
and stopping instructions.
1. Turn on the fuel supply.
2. For gasoline move the choke to the full "on"
position. A warm engine will require less choking
than a cold engine.
3. Grasp starter grip and pull slowly until starter
engages, then pull cord rapidly to overcome
compression, prevent kickback and start the
engine. Repeat if necessary.
4. When the engine starts, open the choke
gradually.
5. The engine should promptly come up to
operating speed.
ELECTRIC STARTING
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. Turn on the fuel supply.
2. For gasoline move the choke to the full "on"
position. A warm engine will require less choking
than a cold engine.
3. Engage the engine start switch briefly to the
START position. The starter life is improved by
using shorter starting cycles with time to cool off
between cranking cycles. Do not operate the starter
more than 15 seconds during each minute. Repeat
if necessary.
4. When the engine starts, open the choke
gradually.
5. The engine should promptly come up to
operating speed.
BASIC OPERATION

Page760706-128 WINCOPORTABLESERIES
OPERATING SPEED
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 insure 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.
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 may vary slightly, the
normal voltage and frequency of the engine-generators
described in this book are approximately as follows, under
varying loads:
LOAD vs. OUTPUT
__________________________________________________________________________________________________________________
Generator Frequency Voltage
Load Speed 120V
Applied* (RPM) (HZ) Recpt.
__________________________________________________________________________________________________________________
None 3690 61.5 125V
Half 3600 60.0 120V
Full 3510 58.5 115V
__________________________________________________________________________________________________________________
*Portion of plant’s rated output current.
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. Whenever making any speed adjustments
check the unit with a voltmeter or tachometer and be sure the
speed is correct.
Lower 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 significantly
shorten the life of appliances being used.
Output voltage should be checked periodically to ensure
continued proper operation of the generating plant and
appliances. If the generator is not equipped with a voltmeter,
it can be checked with a portable meter. Frequency can be
checked by using an electric clock with a sweep second
hand. Timed against a wrist watch or a stop watch the clock
should be correct within +/- 2 seconds per minute.
CONNECTING THE LOADS
Applying The Load
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 efficiently 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 first.
CAUTION: EQUIPMENT OVERLOAD
Keep the generator load within 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 Unit Capabilities
(page 3).
These engine generator sets are inherently self regulating
based on engine speed. 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.
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
receptacle amperage rating is not exceeded.
Grounding
All units must be grounded. Drive a 3/4 or 1" copper pipe or
rod into the ground close to the engine-generator set. The
pipe must penetrate moist earth. Connect an approved
ground clamp, to the pipe. Run a no. 10 Awg wire from
clamp to the generator ground lug on the “receptacle panel”.
Do not connect to a water pipe or to a ground used by a
radio system.
The engine-generators covered in this manual were
designed for portable use.DO NOT OPERATE INDOORS.
The unit should be stored in a warm dry location. Move the
unit outdoors to a flat dry location for use.
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.
BASIC OPERATION

WINCOPORTABLESERIES Page8 60706-128
BASIC OPERATION
‘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 qualified
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.
Please note that the 3 wire 240 volt receptacle(s) on these
units are designed to power only 240 volt tools. There is 2
hots and a ground wire, but no neutral connection, in the 3
wire 240 volt receptacle. Split 120/240 volt ‘TemPower’
service requires the use of the L14-30R, 4 wire
receptacle (2 hot, 1 ground, and 1 neutral) provided on
the control panel. Consult a licensed electrician for wiring
the TemPower plug and connecting it as temporary
service.
To connect these units directly to an un-powered, isolated
construction site TemPower panel, have your electrician
connect to the control panel using a 120/240 volt, four
wire twist-lock plug (L14-30P). The use of locking
receptacles and locking plugs provides the convenience
of quick disconnect, for moving, while allowing non
electrical workers to safely reconnect the power. In
addition they prevent the plug from being accidentally
removed by bumping or vibration.
2. If the generator set is connected to existing (electrical)
wiring circuits it is permitted only through a fully isolated
manual transfer switch. The transfer switch prevents
damage to the generator and 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 these portable generators. When installing
the generator at these sites, a secondary emergency
distribution panel may have to be installed, such as the
Emergency Transfer/Service (ET/S) system available
through your Winco dealer. 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.
ENGINE CARE
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.
Check the yellow pages of your local telephone directory
under “Engines-Gasoline” for the closest engine repair
center or ask the dealer from whom you purchased the
power plant.
Change the oil
After the first five hours of operation and every 25 hours (50
hours for engines with oil filters) thereafter under normal
operating conditions. Change engine oil more often if the
engine is operated under heavy load, or in high ambient
temperatures.
a. Remove oil drain plug at base of the engine and
drain the oil with the engine warm.
b. Replace oil drain plug.
c. Change the oil filter if applicable
d. Remove oil filler plug and refill with new oil.
e. Replace filler plug.
Refer to the table in the engine manual for the
proper grade of oil based on your operating
temperature.
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 fill plug before removing. Be sure the oil level is
maintained. FILL TO POINT OF OVERFLOWING or on units
with the extended oil fill to the “FULL” mark on the dipstick.
Cartridge Air Cleaner
Remove and clean cartridge yearly or after every 25 hours,
whichever occurs first. Service more often if necessary.
Clean by tapping gently on flat surface. If very dirty, replace
the cartridge using only original equipment parts available at
any engine service center.
Do not use petroleum solvents, such as kerosene, to
attempt to clean the cartridge. They may cause
deterioration of the cartridge. DO NOT OIL CARTRIDGE,
DO NOT USE PRESSURIZED AIR TO CLEAN OR DRY
CARTRIDGE.

Page960706-128 WINCOPORTABLESERIES
Dual Element Air Cleaner
Clean and re-oil foam pre-cleaner at three month intervals or
every 25 hours, whichever occurs first. Service more often
under dusty conditions.
a. Remove knob and cover.
b. Remove foam pre-cleaner by sliding it off the
paper cartridge.
c. Wash foam pre-cleaner in kerosene or liquid
detergent and water
d. Wrap foam pre-cleaner in cloth and squeeze
dry.
e. Saturate foam pre-cleaner in engine oil.
Squeeze to remove excess oil.
f. Install foam pre-cleaner over paper cartridge.
Reassemble cover and screw down tight.
Replace the cartridge included with Dual Element Air Cleaner
yearly or every 100 hours. Service more often if necessary.
Spark Plug
Clean and reset gap at .030" every 100 hours of operation.
Do not blast clean spark plug. Clean by scraping or wire
brushing and washing with a commercial solvent. Poor
spark will occur if terminal does not fit firmly on spark plug. If
this happens reform the terminal to fit firmly on spark plug
tip.
GENERATOR CARE
Proper care and maintenance of the generator is necessary
to insure 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 sufficient to warm
the unit up and to dry out any moisture that has accumulated
in the windings (15 to 20 minutes). If left, this moisture can
cause corrosion in the winding. Frequent operation of the
engine generator set will also insure 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
qualified electrical service technician. USE ONLY FACTORY
APPROVEDREPLACEMENTPARTS.
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. This 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 insure proper
cooling. At least yearly remove the blower housing
on the engine and clean the chaff and dirt out of the
engine cooling fins and flywheel. Clean more often
if necessary. Failure to keep these areas clean may
cause overheating and permanent damage to the
unit.
2. Periodically clean muffler area to remove all grass,
dirt and combustible debris to prevent a fire.
3. On engine mufflers equipped with spark arresters,
the spark arrester must be removed every 50 hours
for cleaning and inspection. Replace if damaged.
TROUBLESHOOTING HINTS
PROBLEM(SYMPTOMS)POSSIBLECAUSES
——————————————————————————
Won’t Start *Low Oil Level.
*Fouled spark plug.
*Out of fuel.
*Stop switch in stop
position.
*Engine won't turn over.
*Fuel supply turned off.
*Plugged air cleaner
——————————————————————————
Voltagetoo low *Engine speed is too low.
*Generator overloaded.
*Defective rectifier.
*Defective stator.
*Defective rotor (field).
——————————————————————————
Voltagetoohigh *Engine speed is too high.
——————————————————————————
Circuit Breaker *Defective load.
Trips *Defective receptacle.
*Overloaded circuit breaker
——————————————————————————
Generator *Overloaded.
overheating *Insufficient ventilation.
——————————————————————————
Nooutputvoltage *Short in load (disconnect).
*Broken or loose wire.
*Defective receptacle.
*No residual magnetism
(in generator).
*Defective stator.
*Defective rotor (field).
*Shorted capacitor.
*Defective rectifier.
*Circuit breaker tripped
*Engine RPM below 3600 RPM
——————————————————————————
OPERATOR CARE AND MAINTENANCE

WINCO, Inc.
Limited Warranty
P/N 60706-128
225 South Cordova Avenue
Le Center MN 56057
507-357-6831
WINCO, Incorporated warrants to the original purchaser for the warranty period that goods
manufactured or supplied by it will be free from defects in workmanship and material, provided such
goods are installed, operated and maintained in accordance with WINCO written instructions.
WINCO’s sole liability, and Purchaser’s sole remedy for a failure under this warranty, shall be limited
to the repair of the product. At WINCO’s option, material found to be defective in material or
workmanship under normal use and service will be repaired or replaced. For warranty service, return
the product within the warranty period from the date of purchase, transportation charges prepaid, to
your nearest WINCO Authorized Service Center or to WINCO, Inc. at Le Center Minnesota.
THERE IS NO OTHER EXPRESS WARRANTY.
To the extent permitted by law, any and all warranties, including those of merchantability and fitness
for a particular purpose, are limited to the warranty period from date of purchase. In no event is
WINCO liable for incidental or consequential damages.
Note: Some states do not allow limitation on the duration of implied warranty and some states do not
allow the exclusion or limitation of incidental or consequential damages, so the above limitations may
not apply in every instance. This warranty gives you specific legal rights which may vary from state
to state.
WINCO reserves the right to change or improve its products without incurring any obligations to
make such changes or improvement on products purchased previously.
EXCLUSIONS:
WINCO does not warrant engines, batteries, receptacles, or other component parts that are
warranted by their respective manufacturers.
WINCO does not warrant modifications or alterations which were not made by WINCO, Inc.
WINCO does not warrant products which have been subjected to misuse and/or negligence or have
been involved in an accident.
This warranty does not include travel time, mileage, or labor for removal or reinstallation of WINCO
product from its application.