WINCO DR12I4 (01) PDF Document

The WINCO DR12I4 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. 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.

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.

The output voltage present in this equipment can cause fatal electric shock. This equipment must be operated by a responsible person.

1. Do not allow anyone to operate the generator without proper instruction.

2. Guard against electric shock.

3. Avoid contact with live terminals or receptacles.

4. Use extreme care if operating this unit in rain or snow.

5. Use only three-pronged grounded receptacles and extension cords.

6. Be sure the unit is properly grounded for your application.

Exhaust fumes from any gasoline engine contain carbon monoxide, an invisible, odorless and deadly gas that must be mixed with fresh air.

1. Operate only in well ventilated areas.

2. Never operate indoors including attached garages.

3. 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).

Gasoline and other fuels present a hazard of possible explosion and/or fire.

1. Do not refuel when the engine is running or hot.

2. Keep fuel containers out of reach of children.

3. Do not smoke or use open flame near the generator set or fuel tank.

4. Keep a fire extinguisher nearby and know its proper use. Fire extinguishers rated ABC by NFPA are appropriate.

5. Store fuel only in an approved container, and only in a well ventilated area.

6. Follow local codes for closeness to combustible material.

The muffler becomes very hot during operation and for a period after the unit has been turned off. Do not touch the muffler until it has completely cooled off.

Excessive noise is not only tiring, but continual exposure can lead to loss of hearing.

1. Use hearing protection when working around this equipment for long periods of time.

2. Keep your neighbors in mind when using this equipment.

Keep the generator and surrounding area clean.

1. Remove all grease, ice, snow or materials that create slippery conditions around the unit.

2. Remove any rags or other materials that could create a potential fire hazard.

3. Carefully clean up any gas or oil spills before starting the unit.

All service, including the installation or replacement of service parts, should be performed only by a qualified technician.

1. Use only factory approved repair parts.

2. Do not work on this equipment when fatigued.

3. Never remove the protective guards, covers, or receptacle panels while the engine is running.

4. Use extreme caution when working on electrical components. High output voltage from this equipment can cause serious injury or death.

5. Always avoid hot mufflers, exhaust manifolds, and engine parts. They can cause severe burns instantly.

6. The use of the engine-generator set must comply with all national, state, and local codes.

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.

A Customer supplied 12 Volt battery is required to complete the installation. Battery requirements are listed later under the battery installation section.

The battery requirements for the WINCO DR12I4 model are:

This unit is 12 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.

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, disconnect the negative first and then the positive cable.

5. Be sure all connections are tight and coat the terminals and cable ends with dialectic grease.

The electrolyte is diluted sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. The following precautions must always be taken:

1. Always wear full eye protection and protective clothing.

2. Where electrolyte contacts skin, wash off immediately with water.

3. If electrolyte contacts the eyes, flush thoroughly and immediately with water and seek immediate medical attention.

4. Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of one pound of bicarbonate of soda (baking soda) to one gallon of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

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.

1. Never fill the battery above the fill line. Over filling above the upper level line may cause the electrolyte to overflow, resulting in corrosion to the engine or nearby parts.

2. Immediately wash off any spilled electrolyte following the procedure above.

NOTE: Always make sure that a new battery is fully charged before installing it on a generator set. Failure to do so can cause damage to the engine control module in the generator set.

CAUTION: Only change oil when the engine is not running and is at a low temperature in order to avoid the risk of burns.

1. Remove one of the oil caps to vent the engine crankcase and allow the oil to drain more easily.

2. Place a drip pan or suitable container for catching the oil. WINCO has supplied a valve on the skid frame to hook a customer supplied 5/8″ hose to conveniently run the oil to the drip pan.

3. Drain the oil.

4. Once the oil has fully drained, close the valve.

5. Top-off through the filler port using lubricant oil with the suitable oil table in the LUBRICATION section of this manual.

6. Use the dip stick to ensure the level of oil does not exceed the “MAX” limit.

7. Insert the dipstick and close the lubricant oil cap.

8. Dispose of oil in accordance to local codes. DO NOT dispose or allow oil to seep into the ground or sewer systems, doing so will cause environmental damage.

CAUTION: Only change oil when the engine is not running and is at a low temperature in order to avoid the risk of burns.

1. Use an oil filter wrench to unscrew and remove the oil filter (2) and recover the gasket.

2. Lightly coat the gasket on the new oil filter with engine oil.

3. Install the new engine oil filter manually by turning it clockwise until it contacts the mounting surface. Tighten to 14 – 17 ft-lb or one additional turn using the oil filter wrench.

4. Warm up the engine by running it for 5 minutes and check for any oil leaks.

5. Recheck the oil level using the dipstick.

6. Add engine oil to engine oil filler port as needed until the level is between the maximum and minimum lines shown on the dipstick.

The filter must be replaced when the lubricant oil is changed. Only use filters with a filtering degree equal to the original filter.

CAUTION: Only fill coolant when the engine is not running and is at a low temperature in order to avoid the risk of burns.

1. Ensure the radiator plug located at the bottom of the radiator and the plug on the engine block are secure.

2. Remove the cap (1) and slowly pour the coolant into the radiator until it is even with the lip of the filler port. Ensure no air bubbles develop.

3. Reinstall radiator cap.

4. Or close the drain valve in the radiator. Reinstall and tighten the engine block drain plug.

5. Fill radiator and engine with engine coolant.

Engine coolant contaminated with rust or water scale reduces the cooling effect. Even when extended life engine coolant is properly mixed, the engine coolant gets contaminated as its ingredients deteriorate. Drain, flush and refill the cooling system with new coolant every 1000 hours or once a year, whichever comes first.

CAUTION: Only proceed when the engine is not running and is at a low temperature in order to avoid the risk of burns.

1. Remove the cap (1) on the radiator.

2. Remove the drain plug (2) at the bottom of the radiator and drain the coolant into an approved container. Reinstall plug.

3. Remove the coolant drain plug from the engine block. (see (1) in the following figure)

4. After draining the engine coolant, flush the radiator and engine block to remove any rust, scale and contaminants. Then reinstall and tighten the drain plug

The surfaces of the radiator come into contact with the outside air and can be subject to deposits and impurities. Clean in accordance to the maintenance schedule with compressed air or steam.

CAUTION: Always wear eye protection when servicing the engine and when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.

1. Blow off dirt and dust from fins and radiator with 28PSI or less compressed air. Be careful not to damage the fins with the compressed air (1).

2. If there are larger amount of contamination on fins, apply detergent, thoroughly clean and then rinse with tap water.

The engine performance is adversely affected when the air cleaner element is clogged with dust.

WARNING: Never operate the engine with the air cleaner element removed. This may allow foreign material to enter the engine and damage it. Do NOT remove filter while engine is running.

1. Unlatch and remove the air cleaner cover (1).

2. Remove the element (2).

3. Blow air (Figure 13, (3)) through the element from the inside out using 42 – 71 PSI compressed air to remove the particulates. Use the lowest possible air pressure to remove the dust without damaging the element.

4. Replace the element with a new one if the element is damaged, excessively dirty or oily.

5. Clean inside of the air cleaner cover.

6. Reinstall the element into the air cleaner case (4).

Note: If there is a red line (2) in the outer element, reinsert the element until the overlap position of red line and end face of the air cleaner case.

7. Reinstall the air cleaner cover making sure you match the arrow (5) on the cover with the arrow on the case (6).

8. Latch the air cleaner cover to the case.

WARNING: Diesel fuel is flammable and explosive under certain conditions.

Drain the water separator whenever there are contaminants, such as water, collected in the bottom of the cup. Never wait until the scheduled periodic maintenance if contaminants are discovered.

1. Position an approved container under the water separator (1) to collect the contaminants.

2. Close (2) the fuel valve (3).

3. Turn the retaining ring (4) to the left (9).

4. Carefully remove the cup (1). Remove the retaining spring (6) and float (7) from the cup. Pour the fuel into an approved container and dispose of waste properly. Hold the bottom of the cup with a shop towel to prevent the fuel from dripping. Wipe up any spills immediately.

5. Clean the inside of the cup.

6. Inspect the condition of the mesh filter (10). Clean the mesh filter if necessary.

7. Inspect the condition of the O-ring (11). Replace the O-ring if necessary.

8. Put the float (7) and retaining spring (6) inside the cup.

9. Reinstall the cup to the mounting flange (8) and turn the retaining ring (4) to the right (5). hand-tighten only.

10. Open the fuel valve (3).

11. Be sure to prime the diesel fuel system when you are done.

12. Check for fuel leaks.

Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility. Never dispose of hazardous materials irresponsibly by dumping them into a sewer, on the ground, or into ground water or waterways.

WARNING: Diesel fuel is flammable and explosive under certain conditions. Do NOT perform while the engine is running.

1. Position an approved container under the cup (1) of the water separator to collect the contaminants.

2. Close (2) the fuel valve (3).

3. Loosen the drain valve (4) and drain the contaminants.

4. Turn the cup (1) to the left (10), remove the cup (1).

5. Carefully hold the cup to prevent fuel from spilling. If you spill any fuel, clean up the spill completely.

Never attempt to adjust the low or high idle speed limit screw. This may impair the safety and performance of the machine and shorten its life. If adjustment is ever required, contact your Isuzu Distributor.

1. Check that the governor lever (1) makes firm contact with the high idle stop (2) and the low idle speed limit screw (3) when the engine speed control is in the full speed or low idle speed positions.

2. If the governor lever does not make proper contact with the high idle stop or the low idle speed limit screw, adjust the throttle cable or linkage as necessary.

To prevent the interior parts of the engine and some components of the injection system from oxidizing, prepare the engine as follows:

1. Perform the next Preventive Maintenance procedure. For example, if there are 10 hours remaining before the 250 hour maintenance, you should do the maintenance before you place the engine in storage.

2. Flush the radiator and refill with Long Life Engine Coolant.

3. Clean the exterior of the engine so it is free of grease and oil.

4. Drain the fuel tank or make sure it is completely full.

5. Lubricate exposed parts of the engine speed control system.

6. Protect the air cleaner, muffler and electrical components (alternator, starter motor, switches, controller) from water and dust.

7. Disconnect the negative (-) battery cable to prevent the battery from discharging. Charge the battery once a month during storage.

8. Rotate the engine without starting, every four to six months.

1. Perform the Daily Checks.

2. The engine should be pre-oiled before startup. Crank the engine, leaving the fuel system shut off so the engine will not start, for 15 seconds. Then pause for 30 seconds. Repeat the procedure until you have cranked the engine for a total of one minute. This will circulate the oil in the engine’s lubrication system.

3. Prime the fuel system.

4. Start the engine. Allow the engine to idle for approximately 15 minutes while you check for:

a. Proper oil pressure

b. Fuel, engine oil, or coolant leaks

c. Proper operation of the indicators and/or gauges.

5. Avoid prolonged operation at minimum or maximum engine speeds and loads for the remainder of the first hour of operation.

The maintenance schedule for the COOLING SYSTEM is:

The maintenance schedule for ELECTRICAL EQUIPMENT is:

The maintenance schedule for ENGINE OIL is:

The maintenance schedule for ENGINE SPEED CONTROL is:

The maintenance schedule for FUEL is:

The maintenance schedule for HOSES is:

The maintenance schedule for INTAKE & EXHAUST is:

The maintenance schedule for the COMPLETE ENGINE is:

Note: Some operating conditions may require more frequent maintenance intervals.

The possible causes are:

1. Digital genset not in AUTO

2. Transfer control switch not in AUTOMATIC position

3. Incorrect wiring between ATS and genset

4. Defective control relay in ATS

5. Fuse(s) blown in the DSE 7310

6. Defective DSE 7310

7. Loose or dirty battery terminals

The possible causes are:

1. Defective starter

2. Defective start solenoid

3. Low/dead battery

The possible causes are:

1. Low/dead battery

2. Blown DC fuses

3. Defective DSE 7310

4. Defective key switch

5. Loose or dirty battery terminals

6. Defective starter

7. Defective start solenoid

8. Locked up engine genset

9. Defective engine harness

10. Improper battery voltage to start solenoid, fuel pump, or fuel solenoid

The possible causes are:

1. Improper fuel delivery to the unit

2. Fuel supply shut off

3. Fuel tank empty

4. Air in the fuel system

5. Engine fuel solenoid has not opened

6. Defective fuel pump

7. Defective fuel solenoid

8. Defective engine harness

9. Improper battery voltage to fuel pump or fuel solenoid

10. Engine oil pressure is low

11. Engine has high water temperature

12. Engine has overspeed

13. Engine has gone into overcrank

14. No output from AC generator

15. Loss of speed signal

16. Loss of run signal

The possible causes are:

1. Insufficient fuel volume getting to the unit

a. Too small of fuel line

b. Fuel racks not open properly

2. Governor is defective

3. AC short in generator components

The possible causes are:

1. No AC generator output

2. Defective ATS control board. See ATS manual

3. Circuit breaker open or defective

The possible causes are:

1. Proper power line not available at line terminals in ATS panel

2. Defective ATS control board. See ATS manual

The possible causes are:

1. Defective diode

2. Defective voltage regulator

3. Defective rotor

4. Defective stator

5. Defective exciter rotor

6. Defective exciter stator

7. AC short in the output leads

8. Defective/open generator output breaker

9. Wiring error

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.

1. As you receive your unit, it is critical to check it for any damage. If any damage is noted, it is always easiest to refuse the shipment and let WINCO take care of the freight claim. If you sign for the unit, the transfer of the ownership requires that you 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.

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.

To prevent injury to persons or equipment, observe the following guidelines when lifting the generator:

1. 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.

2. 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 generator set by the means of the lifting eyes on the engine or generator end. These lifting points are only for the use during the manufacturing process and are designed for lifting of the individual generator set components and not the complete unit.

WARNING: NEVER attempt to lift the fuel tank filled with fuel. Sloshing of the fuel can cause a shift in the balance of the fuel tank, making for a DANGEROUS, unbalanced lifting load. If the generator was shipped on the fuel tank, use the lifting points located on the fuel tank to move the entire generator set into place. DO NOT PLACE FUEL IN THE TANK PRIOR TO LIFTING.

The max continuous coolant temperature for this unit is 113°F. This unit should be installed in a well ventilated area, ensuring the exhaust air cannot be recirculated back into the engine.

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) in is the “off” position and the unit starting battery is disconnected.

The unit’s main frame must be bolted securely to a solid base. The engine-generator is mounted on channels which are attached with special shock mounts to the main frame. This allows the engine-generator free movement without affecting the base or surrounding equipment.

WARNING: Never mount these engine-generator sets to a wooden base/structure. Over time, the wood will deteriorate and the unit mountings will come loose. These units must be mounted to a steel or concrete base.

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 1/2 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 1 1/2 to 2 times larger than the radiator face. The extra air inlet area is required to minimize restriction and to provide combustion air for the engine. Do not block fresh air intakes with other equipment as this will result in 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.

Improper exhaust installation will allow dangerous gases to seep into enclosed spaces causing a hazard to your health and/or death.

1. 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.

2. 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.

3. 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.

4. 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.

5. 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 sure the rain flap faces to the rear of the vehicle so that it is not blown open during transportation.

6. 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.

WARNING: All fuel runs should be installed by a licensed fuel supplier.

The fuel supply should be as close to the engine as possible. This will reduce the installation cost of fuel runs and minimize line losses. The diesel fuel supply should be no more than 3 feet below the fuel inlet pump. If your fuel supply is lower than 3 feet, you may have to install an additional lift pump to bring the fuel up to the mechanical fuel pump on the engine.

Engine-generator sets are properly adjusted before they leave the factory. Connecting a fuel supply with adequate supply volume is critical to reliable operation. Diesel units with optional base mounted fuel tanks are pre-plumbed to the fuel pump on the engine.

Open skid mounted diesel units are often supplied with capped inlet and return lines. The use of a suitable customer supplied flexible fuel lines is essential between the engine and fuel supply to provide a vibration break between your fuel supply and the engine.

WARNING: Connecting rigid fuel line (i.e. steel or copper line) directly to the inlet fuel filter or fuel pump may cause the fuel line to crack during operation creating a serious fire hazard.

NOTICE: CLASS 1 WIRING METHODS ARE TO BE USED FOR ALL FIELD WIRING CONNECTIONS TO TERMINALS OF A CLASS 2 CIRCUIT.

NOTE: The symbol always indicates ground where shown. All wiring must be completed in accordance with the National Electric Code as well as any state and local codes.

You must pay particular attention to wire size requirement for the amperage of service you are dealing with. The table below provides you guidance on wire sizing based on both wire type and amperage. Wire amperages have been derated for 40° C ambient temperatures operation.

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.

This Winco generator ships with either a bonded or floating neutral depending upon the configuration. The distribution panel will be labeled indicating the configuration. A competent electrician or other professional should be consulted on the proper neutral configuration for the specific application. Generally a floating neutral is used when the generator is connected to a buildings electrical system as a back up. Mobile or remote applications often require a bonded neutral. If the neutral configuration is changed in the field be sure to relabel the panel to its current condition.

The table below is based on Table 310.15 (B) (16) in the National Electric Code 2014 edition. Allowable ampacities of insulated conductors rated 0 through 2000V, 75°C through 90°C. Not more than three current-carrying conductors in Raceway, Cable, or Earth (direct buried). Adjust for 40°C (104°F) ambient temperature.

Wire Type: RHW, THHW, THW, THWN, XHHW, USE, ZW uses ratings from the “Copper 75°C” column with types TBS, SA, SIS, FEP, FEPB, MI, RHH, RHW-2, THHN, THHW, THW-2, XHH, XHHW, XHHW-2, ZW-2.

Wire Type: RHW, THHW, THW, THWN, XHHW, USE uses ratings from the “Aluminum Copper Clad Aluminum 75°C” column with types TBS, SA, SIS, THHN, THW-2, THWN-2, RHH, RHW-2, USE-2, XHH, XHHW, XHHW-2, ZW-2.

A. NEUTRAL LUGS: These lugs are isolated from ground and provided for you to connect your neutral wire from the transfer switch to the generator. The 100 Amp terminal block lugs will handle wire sizes #4 to 300 MCM and should be torqued to 75in. lbs.

B. GENERATOR CIRCUIT BREAKER: This circuit breaker provides overload protection for the generator. Your power feeds from the transfer switch will connect the bottom lugs on the circuit breaker. The generator power feeds have already been wired into the upper lugs. Refer to the circuit breaker installed on your unit for breaker lug capacities and proper toque specifications.

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 and will accommodate #10 AWG to 2/0 AWG and should be torqued to 200 in. lbs.

D. 120V GFCI CIRCUIT TERMINAL BLOCK: These terminals are rated for 20 Amps and will handle wire sizes #4 AWG to 18AWG. They should be torqued to 16 in. lbs. This circuit must be fed from a fused circuit in the distribution panel and it provides power for the block heater and the battery charger.

E. 120V/20 AMP DUPLEX RECEPTACLE: This convenience receptacle is used to power both battery charger and block heater. This circuit must be fed from a GFCI fused circuit in the distribution panel.

F. NEUTRAL TO GROUND LEAD LUG: This lug is provided on the neutral terminal block to allow you to run a neutral to ground lead if you are using the generator in a stand alone application. This would be an application where there is not a distribution panel and no other ground to neutral bond in the wiring system. If a grounding wire is attached here, remove the floating neutral label in the panel. This will not be used when you are wiring a generator and transfer switch into an existing power system.

WARNING: A mainline circuit breaker has been provided inside the generator housing. During all wiring installations, make sure the breaker is in the OFF position and the generator operating switch is in the OFF position.

WARNING: When installing a three-phase 240 Volt system, be sure you know which lead is the high voltage “wild” leg (208 Volt line to neutral). The generator normally carries the high voltage on the G2 lead.

All wires should be installed in rigid or flexible conduit (knockouts are provided in the control box).

All communication and DC wiring should be run in separate conduit from AC wiring.

To install the wires, reference the following picture. Use a small flat head screwdriver to push the release spring inside the square hole (A). While the release is being pushed, insert the wire into the larger circular hole (B). Remove the screwdriver to secure the wire into place.

The DSE7310 is able to start the generator when it receives a remote signal from any dry contact. This makes the system compatible with a wide range of control mechanisms including two-wire start automatic transfer switches. When the contact closes the controller will automatically start. When the contact is opened the generator will go through a cool-down cycle and turn off. Connect the remote start leads to the Remote Start + and Remote Start – terminal blocks in the door behind the DSE 7310 controller.

In some applications additional emergency stops may be desired or necessary. The controller has terminals designed allowing the addition of multiple remote emergency stops. E-stops must be normally closed to work properly in this system. The e-stop circuit supplies power to the fuel solenoid and the starter circuit. Opening any switch in the series prevents the engine from cranking or from receiving fuel to run.

To wire additional emergency stop switches first remove the orange jumper between the two Emergency Stop terminal blocks. Failure to remove the jumper will prevent the remote switches from working properly. Add wires between the terminal block to the new switch(s). The switches must be wired in series for proper function. Test each e-stop after wiring to ensure they function properly.

WARNING: Use a properly installed transfer switches when isolating the generator set from utility power. Failure to do so could result in backfeeding, which is illegal and dangerous. Backfeeding cause serious injury or death.

WARNING: Be sure Engine/Generator is in the OFF position before you make any DC interconnections.

CAUTION: Never run the AC and DC wiring in the same conduit.

For the ASCO 185 UL SWITCH, refer to Table A for Generator Start Connections:

For the ASCO 300 UL SWITCH:

Engine start and auxiliary circuit terminal block TB located on 3ATS &3NTS transfer switch. For 3ADTS & 3NDTS the terminal block TB is located in the upper right side of the enclosure.

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). Note: Wire #93 is energized to turn on the glow plugs for 15 seconds first and then the starter and fuel solenoid are engaged.

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).

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: 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.

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.

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.

The following is a list of connections on the AVR. These have been factory set and other than voltage adjustment, should never be changed.

VOLTS: To adjust generator output voltage. Clockwise to increase voltage.

STABILITY: To prevent voltage hunting. Clockwise to increase the dampening effect.

UFRO – Under Frequency Roll Off: Terminal S1 is connected to the C.T., S2 on the AVR.

O/Exc – Adjust over-excitation trip

LED Indicator Light – indicates over excitation condition or under speed running.

This generator set is designed to be operated under load and the accumulation of operating hours without load can cause unburned fuel from the combustion chamber to build up in the exhaust system. This is called wet stacking and can result in fouled injectors and carbon buildup in the exhaust pipes, turbo and exhaust valves.

To avoid wet stacking the operating temperatures must be kept high enough. The best way to do this is to ensure that the generator set has adequate load during operation. If the engine is cold at start up run it for 2-5 minutes and then load the generator. Idling longer than this is more likely to damage the engine than extend its life.

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.

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 of oil degradation. Efforts may need to be made to reduce the amount of dust and debris entering the housing and generator components.

The minimum natural starting temperature with glow plugs is -5°F. The minimum starting temperature with glow plugs and block heater is -13°F.

The degree of fluidity of the diesel oil may be reduced at low temperatures due to the separation of the paraffin. This results in the filters becoming clogged.

The ASTM D975 specifications distinguish different classes of diesel fuel, identifying the characteristics of those that are best adapted to low temperatures.

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.

WARNING: Place controller in manual mode, e-stop applied first. If an auto start signal comes on during maintenance, it may result in injury, death and equipment damage.

CAUTION: Only change oil when the engine is not running and is at a low temperature in order to avoid the risk of burns.

1. Remove one of the oil caps to vent the engine crankcase and allow the oil to drain more easily.

2. Place a drip pan or suitable container for catching the oil. WINCO has supplied a valve on the skid frame to hook a customer supplied 5/8″ hose to conveniently run the oil to the drip pan.

3. Drain the oil.

4. Once the oil has fully drained, close the valve.

5. Top-off through the filler port using lubricant oil with the suitable oil table in the LUBRICATION section of this manual.

6. Use the dip stick to ensure the level of oil does not exceed the “MAX” limit.

7. Insert the dipstick and close the lubricant oil cap.

8. Dispose of oil in accordance to local codes. DO NOT dispose or allow oil to seep into the ground or sewer systems, doing so will cause environmental damage.

CAUTION: Only change oil when the engine is not running and is at a low temperature in order to avoid the risk of burns.

1. Use an oil filter wrench to unscrew and remove the oil filter (2) and recover the gasket.

2. Lightly coat the gasket on the new oil filter with engine oil.

3. Install the new engine oil filter manually by turning it clockwise until it contacts the mounting surface. Tighten to 14 – 17 ft-lb or one additional turn using the oil filter wrench.

4. Warm up the engine by running it for 5 minutes and check for any oil leaks.

5. Recheck the oil level using the dipstick.

6. Add engine oil to engine oil filler port as needed until the level is between the maximum and minimum lines shown on the dipstick.

The filter must be replaced when the lubricant oil is changed. Only use filters with a filtering degree equal to the original filter.

CAUTION: Only fill coolant when the engine is not running and is at a low temperature in order to avoid the risk of burns.

1. Ensure the radiator plug located at the bottom of the radiator and the plug on the engine block are secure.

2. Remove the cap (1) and slowly pour the coolant into the radiator until it is even with the lip of the filler port. Ensure no air bubbles develop.

3. Reinstall radiator cap.

4. Or close the drain valve in the radiator. Reinstall and tighten the engine block drain plug.

5. Fill radiator and engine with engine coolant.

Engine coolant contaminated with rust or water scale reduces the cooling effect. Even when extended life engine coolant is properly mixed, the engine coolant gets contaminated as its ingredients deteriorate. Drain, flush and refill the cooling system with new coolant every 1000 hours or once a year, whichever comes first.

CAUTION: Only proceed when the engine is not running and is at a low temperature in order to avoid the risk of burns.

1. Remove the cap (1) on the radiator.

2. Remove the drain plug (2) at the bottom of the radiator and drain the coolant into an approved container. Reinstall plug.

3. Remove the coolant drain plug from the engine block. (see (1) in the following figure)

4. After draining the engine coolant, flush the radiator and engine block to remove any rust, scale and contaminants. Then reinstall and tighten the drain plug

CAUTION: Always wear eye protection when servicing the engine and when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.

1. Blow off dirt and dust from fins and radiator with 28PSI or less compressed air. Be careful not to damage the fins with the compressed air (1).

2. If there are larger amount of contamination on fins, apply detergent, thoroughly clean and then rinse with tap water.

WARNING: Never operate the engine with the air cleaner element removed. This may allow foreign material to enter the engine and damage it. Do NOT remove filter while engine is running.

1. Unlatch and remove the air cleaner cover (1).

2. Remove the element (2).

3. Blow air (Figure 13, (3)) through the element from the inside out using 42 – 71 PSI compressed air to remove the particulates. Use the lowest possible air pressure to remove the dust without damaging the element.

4. Replace the element with a new one if the element is damaged, excessively dirty or oily.

5. Clean inside of the air cleaner cover.

6. Reinstall the element into the air cleaner case (4).

Note: If there is a red line (2) in the outer element, reinsert the element until the overlap position of red line and end face of the air cleaner case.

7. Reinstall the air cleaner cover making sure you match the arrow (5) on the cover with the arrow on the case (6).

8. Latch the air cleaner cover to the case.

WARNING: Diesel fuel is flammable and explosive under certain conditions.

Drain the water separator whenever there are contaminants, such as water, collected in the bottom of the cup. Never wait until the scheduled periodic maintenance if contaminants are discovered.

1. Position an approved container under the water separator (1) to collect the contaminants.

2. Close (2) the fuel valve (3).

3. Turn the retaining ring (4) to the left (9).

4. Carefully remove the cup (1). Remove the retaining spring (6) and float (7) from the cup. Pour the fuel into an approved container and dispose of waste properly. Hold the bottom of the cup with a shop towel to prevent the fuel from dripping. Wipe up any spills immediately.

5. Clean the inside of the cup.

6. Inspect the condition of the mesh filter (10). Clean the mesh filter if necessary.

7. Inspect the condition of the O-ring (11). Replace the O-ring if necessary.

8. Put the float (7) and retaining spring (6) inside the cup.

9. Reinstall the cup to the mounting flange (8) and turn the retaining ring (4) to the right (5). hand-tighten only.

10. Open the fuel valve (3).

11. Be sure to prime the diesel fuel system when you are done.

12. Check for fuel leaks.

WARNING: Diesel fuel is flammable and explosive under certain conditions. Do NOT perform while the engine is running.

1. Position an approved container under the cup (1) of the water separator to collect the contaminants.

2. Close (2) the fuel valve (3).

3. Loosen the drain valve (4) and drain the contaminants.

4. Turn the cup (1) to the left (10), remove the cup (1).

5. Carefully hold the cup to prevent fuel from spilling. If you spill any fuel, clean up the spill completely.