Generating Quality

Since 7925

GASOLINE ELECTRIC PLANT

AIR-COOLED

/
EGSMA
ELECTRICAL
GENERATING

MAAXEVNG

WINPOWER CORPORATION
NEWTON, IOWA 50208 U.S.A.
PHONE: (515) 792.1301 / CABLE: WINPOWER /TELEX II: 910-520-1557
 4
LIMITED WARRANTY
Winpower Corporation hereby warranties far a period o f one year as hereinofter
stated, the Winpower Alternator or Alternator Set described herein to be free
from defects i n material and workmanship i f properly installed, serviced and
operated under normal conditions according to our instructions.

The Winpower Alternator Set is equipped with on engine, far which the engine
manufacturer's warranty is attached to the engine manual, and is the only
warronty applicable t o the engine.

A l l ports not a part o f the engine andlor not manufactured by the engine manu-
facturer, w i l l be repaired or reploced by Winpower Corporation i f found by it,
or its authorized service outlet, to be defective i n material or workmanship
within one year from the purchase date. The equipment added to the engine by
Winpawer, such as natural or LP gas carburetion, and not furnished by the engine
I manufacturer, w i l l be replaced by Winpower i f found to be defective i n material
and workmanship w i t h i n one year from the purchase date.

A l l transportation charges on parts or units submitted far replacement or repair

under this warranty must be borne by the purchaser.

Winpower Corporation hereby disclaims any and a l l implied warranties, including,

but not limited to, warranties o f merchantability and fitness far any particular
purpose, i f and to the extent, but only i f and to the extent, that such disclaimer
is not forbidden b y any applicable law and any implied warranties, including, but
not limited to warranties o f merchantability and fitness far any particular purpose
which Winpower Corporation is so forbidden t o disclaim by any applicable law,
are warranted one year from dote o f purchase.

This is the exclusive remedy and l i a b i l i t y for c o n ~ e ~ u e n t i o lincidental

damages and/or expenses under any and a l l warranties are excluded to the extent
exclusion is permitted b y law.
, or special

%
xi Form WEA - 705

IMPORTANT!
I F o l l o w t h e i n s t r u c t i o n s i n t h e o w n e r ' s m a n u a l s p e c i f i c a l l y when p u t t i n g
t h i s alternator i n t o service. When w r i t i n g a b o u t s e r v i c e o r o r d e r i n g
r e p a i r s , a l w a y s show m o d e l number a n d s e r i a l number o f a l t e r n a t o r .

NOTICE
la a d e rt o etiminnte a needless w u t e of time to you. our customer. i t u best in case
of engine h u b l e t o conbet the local dealer or distributor of thnt pPrticular engine
within your area. H e can often diagnose a problem and correct the trouble without
m y difficulty. H e a h will have a stock of spare parts in u s e something has to be
rsplmd. AU of our engines have National and Internatioml distributors or dealers.
'Ihcra should be n o tiouble with getting our engine serviced within your m a .
We are always glad t o u s i s t you in obtaining f u l l satisfaction from any engine as-

-
t c m b k d t o a Generator o f our manufacture b u t we know that b y contacting the
local engine distributor or dealer. a more prompt correction of the engine malady
be achkwd-
 INTRODUCTION The commutator t y p e e x c i t o t - i o n s y s t e m i s u s e d w h e n . i t i s d e s i r e d t o
cronk t h e engine. t h r u t h e generoyor. T h e r e i s o DC w i n d i n g on t h e
T h i s monuol c o v e r s t h e i n s t a l l o t i o n , o p e r a t i n g and m a i n t e n a n c e o r m o t u r e i n a d d i t i o n to. AC w i n d i n g , t h u s g i v i n g a common m a g n e t i c
i n s t r u c t i o n s f o r t h e Winpower l i n e o f a i r - c o o l e d g e n e r a t o r s e t s . c i r c u i t f o r both windings.
I n c l u d e d a s o p o r t o f t h i s manual i s a p o r t s l i s t and w i r i n g
d i a g r o m c o v e r i n g t h e p a r t i c u l a r model you h a v e p u r c h a s e d . The The g e n e r o t o r i s e i t h e r 2 o r .4 p o l e d e p e n d i n g upon t h e s p e e d i t
e n g i n e m a n u f a c t u r e r ' s monual i s a l s o f u r n i s h e d w i t h t h e s e t and i s driven at. I t i s 2 p o l e f o r 3600 RPM and 3 0 0 0 RPM, a n d 4 p o l e f o r
g i v e s t h e n e c e s s a r y o p e r a t i n g and m a i n t e n a n c e i n f o r m a t i o n f o r 1800 RPM and 1500 RPM. There a r e c e r t a i n f e a t u r e s t h a t o r e s t a n d a r d
t h e engine. on some models b u t n o t on 011. They a r e : 1
1. Econ-0-Miser
GENERAL 2. T o t a l Power

The e n g i n e g e n e r a t o r s e t s c o v e r e d by t h i s monual a r e o f t h e s i n g l e The Econ-0-Mizer i s on e l e c t r o - m e c h a n i c 0 1 d e v i c e t h a t i s u s e d o n l y on

bearing type. The r o t a t i n g member o f t h e g e n e r a t o r i s mounted on 3600 RPM models f o r o u t o m o t i c o l l y r e d u c i n g t h e e n g i n e s p e e d t o a p p r o x .
a t a p e r e d e x t e n s i o n o f t h e e n g i n e c r o n k s h o f t e x c e p t on t h o s e models 2000 RPH when t h e r e i s no l o a d on t h e g e n e r a t o r . A t the instant the
h a v i n g a f o u r c y l i n d e r e n g i n e which h a v e a f l e x i b l e d i s c c o u p l i n g l o a d i s a p p l i e d t o t h e g e n e r o t o r t h e e n g i n e comes bock t o t h e g o v e r n e d
c o n n e c t i n g t h e r o t o t i n g g e n e r a t o r member a n d t h e e n g i n e s h a f t . s p e e d o f 3600 RPM.

A l l s e t s h a v e been t h o r o u g h l y t e s t e d o t t h e f o c t o r y . The n e c e s s a r y The T o t a l Power f e a t u r e i s u s e d on some 120/240 v o l t p o r t a b l e s i n g l e

c a r b u r e t o r and e n g i n e s p e e d a d j u s t m e n t s h a v e been mode. The s e t p h a s e g e n e r o t o r s where 90% o f t h e f u l l KW r a t i n g o f t h e s e t maybe t a k e n
h a s been t e s t e d w i t h t h e t y p e o f f u e l s p e c i f i e d by t h e c u s t o m e r . from o n e o f t h e 1 2 0 v o l t l e g s .

The s e t s h o u l d be c a r e f u l l y i n s p e c t e d on d e l i v e r y f o r e v i d e n c e o f INSTALLATION
p o s s i b l e s h i p p i n g damoge. I f damoge h a s o c c u r r e d , a n o t a t i o n s h o u l d
be mode on t h e f r e i g h t b i l l , and you s h o u l d f i l e a c l a i m i f n e c e s s a r y .
I f t h e damage o p p e o r s t o be o f a m o j o r n o t u r e t h e s e t s h o u l d n o t be
-
NOTE

o p e r a t e d u n t i l t h e f a u l t h a s been c o r r e c t e d .
The model number a n d t h e s e r i a l number o f t h e s e t must be g i v e n when
contacting the d e a l e r o r the foctory.
If o u r s e t i s a p o r t a b l e u n i t t h e s e i n s t a l l a t i o n i n s t r u c t i o n s d n
n o t a p p l y e x c e p t f o r l o o d c o n n e c t i o n s , g r o u n d i n g and w i r e s i z e .
Check l o c a l and s t a t e r e g u l a t i o n s f o r i n s t o l l a t i o n o f e n g i n e g e n e r a t o r
s.et 5.

GENERAL

ELECTRICAL DESCRIPTION T h e r e o r e two prime r e q u i r e m e n t s i n t h e i n s t a l l a t i o n o f on o i r c o o l e d

engine generator s e t . They a r e :
T h e r e o r e b a s i c a l l y two t y p e s o f g e n e r o t o r s u s e d i n t h e Winpower 1. Adequate c o o l i n g a i r f o r t h e e n g i n e .
l i n e o f a i r c o o l e d e n g i n e g e n e r a t o r s e t s . They o r e r e v o l v i n g a r m a t u r e 2. P r o p e r d i s c h a r g e o f e x h o u s t g o s
and r e v o l v i n g f i e l d . Other f o c t o r s of importance ore:
1. L o c a t i o n
The e x c i t o t i o n s y s t e m f o r t h e r e v o l v i n g o r m o t u r e t y p e g e n e r o t o r s maybe 2. Mounting
e i t h e r s t a t i c o r c o n n u t a t o r type. The e x c i t a t i o n s y s t e m f o r t h e 3. F u e l c o n n e c t i o n
revolving f i e l d type generator i s s t o t i c . 4. Load c o n n e c t i o n

The s t o t i c , o r e l e c t r o n i c e x c i t o t i o n s y s t e m , u s e s r e c t i f i e r s t o
c h a n g e p o r t o f t h e o u t p u t o f t h e AC g e n e r o t o r t o DC f o r e x c i t o t i o n o f
t h 6 f i e l d . ' On most m o d e l s . u s i n g s t o t i c e x c i t o t i o n t h i s s y s t e m i s
e x t e n d e d s t i l l f u r t h e r by u s i n g c u r r e n t f e e d b a c k t h r u r e c t i f i e r 8 i n
o r d e r t o o b t a i n i n c r e o s i n g f i e l d s t r e n g t h with lood i n c r e a s e t o g i v e
better voltage regulation.
LOCATION
The p l o n t s h o u l d be l o c a t e d i n on o t m o s p h e r e t h a t i s f r e e from e x c e s s i v e
d u s t , wind biown particles, e x c e s s i v e h i g h a n d / o r low t e m p e r a t u r e , ond
c o r r o s i v e fumes. Allowance must be mode f o r a minimum o f o two f o o t
c l e o r a n c e around t h e p l o n t f o r s e r v i c e o c c e s s i b i l i t y .
 BOLT SIZE

MOUNTING

A p e r m a n e n t l y i n s t a l l e d e n g i n e g e n e r a t o r s e t s h o u l d be mounted on
a base, p r e f e r o b l y c o n c r e t e , w i t h t h e m o u n t i n g b o l t s b e i n g embedded
i n t h e c o n c r e t e bose. A l l 3 6 0 0 RPM u n i t s , ond 3.75 KW, ond s m o l l e r
1 8 0 0 RPM u n i t s , a r e f u r n i s h e d w i t h s p r i n g v i b r a t i o n i s o l o t o r s . They
c a n be u s e d f o r p e r m a n e n t l y m o u n t i n g t o o bose a s shown i n F i g u r e 1.

6 KW s e t s a n d h i g h e r a t 1 8 0 0 RPM o r e mounted on o r i g i d s k i d . For

permonent i n s t a l l a t i o n s i t i s o d v i s o b l e t o b o l t t h e s k i d t o t h e
f l o o r o r b a s e w i t h v i b r o t i o n dampening pads p l o c e d b e t w e e n t h e s k i d
and f l o o r .

--
COOLING AIR

I t i s i m p e r a t i v e t h o t t h e e n g i n e have an adequate s u p p l y o f c o o l i n g
air. I f t h e u n i t i s i n s t a l l e d i n s i d e o b u i l d i n g o r enclosure, i t
means t h a t t h e r e m u s t be o n a d e q u a t e a i r i n l e t and on a d e q u a t e a i r
outlet. See F i g u r e 3 f o r a t y p i c 0 1 l a y o u t .

The F o l l o w i n g i s a s u g g e s t e d f o r m u l o f o r u s e i n d e t e r m i n i n g t h e
minimum s i z e o f t h e o i r i n l e t ond a i r o u t l e t :
S i z e i n sq. f t . = 0.5 + ( 0 . 5 x K W )
S i z e i n sq. f t . = 1.25 ( 0 . 5 + (0.5 x K W ) ) w i t h l o u v e r s

When t h e u n i t i s i n s t o l l e d i n s i d e o b u i l d i n g , meons m u s t be p r o - ALTERNATE METHOD

v i d e d f o r e x h a u s t i n g t h e p o i s o n o u s goses from t h e e n g i n e e x h a u s t BOLT W/FLAT WASHER
system. I f a m u f f l e r i s used, t h e p r e f e r a b l e l o c o t i o n i s i n s i d e FIGURE 1 MOUNTING OF SPRING TYPE VIBRATION
the building. I f t h e e x h o u s t p i p e passes t h r u o w a l l w i t h combust- ISOLATORS TO CONCRETE BASE
i b l e material, i t must be s h i e - l d e d b y o m e t 0 1 t h i m b l e . See F i g u r e
2. The end o f t h e e x h a u s t p i p e s h o u l d be l o c a t e d o d i s t a n c e oway
from t h e a i r i n l e t t o t h e engine. Use o f l e x i b l e t u b i n g t o c o n n e c t
EXHAUST P I P E
t h e engine exhaust f i t t i n g t o the r i g i d pipe o r m u f f l e r .

CONNECTION - Gasoline
7
A l l m a n u a l and e l e c t r i c . s t a r t s h o v e i n t e g r a l f u e l t a n k s . Remote
s e t s a r e e q u i p p e d w i t h f u e l pumps when t h e y a r e t o u s e , g a s o l i n e
METAL VENTILATED
as a fuel. The f u e l pump i n l e t i s t o be c o n n e c t e d t o t h e f u e l
THIMBLES AS SHOWN ARE TO
s u p p l y by meons o f a f l e x i b l e c o n n e c t i o n . BE 1 2 INCHES LARGER I N
DIAMETER THAN THE EXHAUST
U n d e r g r o u n d f u e l t a n k s o r e r e q u i r e d i n some l o c a l i t i e s . Local
PIPE
regulations s h o u l d be c h e c k e d o n d t h o r o u g h l y c o m p l i e d w i t h .

FIGURE 2
"9"
EXHAUST PIPE PASSING THROUGH WALL
OR PARTITION
L
17
 A day tank ( s o m e t i m e s c o l l e d p r i m i n g t a n k ) i s recommended f o r o u t o -
motic, unottendcd s t o r t i n g i n s t o l l o t i o n s . When t h e s e t h o s s t o o d
i d l e f o r o p e r i o d , t h e f u e l l i n e a n d c o r b u r e t o r may h o v e l o s t t h e i r
gosoline thru evaporation. There i s then a d e l a y i n s t a r t i n g due t o
t h e f u e l pump h a v i n g t o pump t h e l i q u i d f r o m t h e t o n k .

10 RAIN C A P
The d o y t o n k i s a s m a l l g r a v i t y f e e d t a n k o n d m u s t h o v e a r e t u r n l i n e
LOAO t o t h e main t o n k . A t y p i c a l i n s t a l l a t i o n i s shown i n F i g u r e 4.

n I f t h e g o s o l i n e supply i s l o c a t e d obove t h e l e v e l o f t h e c a r b u r e t o r ,
t h e r e m u s t b e p o s i t i v e means o f s h u t t i n g o f f t h e f u e l when t h e p l a n t
is not operoting.

FUEL CONNECTION -
- Gaseous F u e l s

G a s e o u s f u e l s a r e o f two k i n d s :
1. N a t u r o l o r m a n u f a c t u r e d g a s , o r a c o m b i n o t i o n o f b o t h ,
w h i c h comes t h r u t h e g a s company m a i n s .
2. LPG ( L i q u e f i e d P e t r o l e u m G a s ) w h i c h comes b o t t l e d i n
s t e e l tanks.

With g a s e o u s f u e l we a r e d e a l i n g w i t h . g o s u n d e r p r e s s u r e . The g a s
p r e s s u r e must be reduced t o a t m o s p h e r i c p r e s s u r e a t t h e e n t r a n c e t o
the carburetor. The f i n a l s t e p o f p r e s s u r e r e d u c t i o n i s d o n e by t h e
s e c a n d o r y r e g u l a t o r which i s mounted on t h e e n g i n e . A primary
r e g u l a t o r i s u s e d f o r t h e c o a r s e r e g u l a t i n g o n LP g a s , a n d a l s o o n
n o t u r a l g a s i f t h e p r e s s u r e from t h e mains e x c e e d s 4 oz.

A t y p i c a l n a t u r a l g a s i n s t a l l a t i o n c o m p o n e n t l a y o u t i s shown i n F i g u r e
5 , a n d o typical LPG i n s t a l l a t i o n c o m p o n e n t l a y o u t i s shown i n F i g u r e
6.

T h e s e c o n d a r y r e g u l a t o r m u s t n o t be u s e d a s t h e o n l y s h u t o f f when
t h e e n g i n e is n o t running. T h e r e must be a hand v a l v e w i t h manual
s t o r t models and an e l e c t r i c s o l e n o i d f u e l v a l v e t h a t i s .energized
when t h e e n g i n e s t a r t i n g c i r c u i t i s e n e r g i z e d , a n d ' b e c o m e s d e -
e n e r g i z e d when t h e e n g i n e i s s h u t down w i t h t h e e l e c t r i c a n d r e m o t e
s t a r t models.

F o r c o m p l e t e p r o t e c t i o n , i t i s recommended t h a t a vacuum s w i t c h s u c h
a s G a r r e t s o n No. 4 8 0 t o g e t h e r w i t h G a r r e t s o n r e l a y s w i t c h b e u s e d , s o
FIG. 3 t h a t i f t h e e n g i n e becomes n o n - o p e r a t i v e w i t h t h e i g n i t i o n s w i t c h o n ,
t h e s o l e n o i d v a l v e w i l l c l o s e and s h u t o f f t h e gas.
typical installation
S t a t e a n d l o c a l c o d e s s h o u l d be c h e c k e d a n d c o m p l i e d w i t h i n r e g a r d s
t o use o f gaseous fuels. National Fire Protection Association
S t ' a n d a r d s No. 5 4 s h o u l d b e c o m p l i e d w i t h f o r n a t u r a l g a s . National
F i r e P r o t e c t i o n Association S t a n d a r d s No. 5 8 s h o u l d b e c o m p l i e d w i t h
f o r l i q u e f i e d petroleum gas.
 CARBURETOR
nmml L I U
LOAD CONNECTIONS

The meons f o r l o a d c o n n e c t i o n v a r i e s d e p e n d i n g on o r d e r r e q u i r e m e n t s ,
c a p a c i t y , and t y p e o f use. Receptacles a r e u s u a l l y p r o v i d e d on models
f o r p o r t a b l e use. S e t s f o r permanent i n s t a l l a t i o n s a r e n o r m a l l y
provided w i t h t e r m i n a l s t r i p s f o r l o a d connection. Permanent c o n n e c t i o n s
s h o u l d be made by a q u a l i f i e d e l e c t r i c i a n w i t h f i l l 1 k n o w l e d g e 0.f c o d e
requirements. I

TYPICAL CONNECTIONS / C208~i::::q'

FIG. 4

120/240 V 120/208 V
S i n g l e Phase T h r e e Phase
-- TO CARBURETOR
N l e a d s a r e grounded. R o t a t i o n on 3 p h a s e m o t o r s m u s t be c h e c k e d f o r
FUEL SOLENOID c o r r e c t r o t a t l o t , a f t e r connecting. I f r o t a t i o n i s wrong, r e v a r s n t w o .
o f t h e i n p u t l e a d s t o t h e motor.
Fig 5
GROUNDING

The g e n e r a t o r f r a m e m u s t be g r o u n d e d t o a g r o u n d i n g s t a k e d r i v e n i n t o
m o i s t e a r t h o r t o a water pipe.

BATTERY

I f t h e s e t i s a e l e c t r i c o r r e m o t e s t a r t s e t , o 12 v o l t b a t t e r y o f
TYPICAL ASSEMBLY: NATURAL
-. ...-- . . -.. - .-
- --
GAS (SINGLE9LtNOtR ENGINES)
a t l e a s t 7 0 ampere h o u r s , o r 2 s i x v o l t b o t t e r i e s o f a t l e a s t 7 0
NOTE: FUEL SOLENOID IS REPLACED BY MANUAL SHUTOFF VALVE
ON MANUAL START U N I I S , ampere h o u r s pach, s h o u l d be used. Observe c o r r e c t p o l a r i t i e s i n
SMALLER SINCLC CYLINDER ENGINES MAY USE THE TYPE making t h e connections.
O F SECONDARY REGULATOR SHOWN IN FIG. 6 .
ELECTRIC AND REMOTE START

PRIMARY REGULATOR E l e c t r i c and r e m o t e s t a r t s e t s have t w o d i f f e r e n t t y p e s o f s t a r t i n g .

They a r e :
APPROVED TYPE 1. A DC ' u i n d i n ~i n t h e a r m a t u r e o f t h e AC g e n e r a t o r
FLEXIBLE HOSE e n a b l e s t h e g e n e r a t o r t o be u s e d a s a n e l e c t r l c
motor f o r t h e purpose o f c r a n k i n g t h e engine.
2. The e n g i n e i s e q u i p p e d w i t h o s t o r t i n g m o t o r . Electric
s t a r t m o d e l s c o n be s t a r t e d a n d s t o p p e d a t t h e s e t .
Remote s t a r t c a n be s t a r t e d a n d s t o p p e d a t t h e s e t o r
a t a remote l o c a t i o n . T h e r e m u s t be some i n d i c a t i o n
FIG. 6 o f e n g i n e s t a r t i n g a t t h e remote l o c a t i o n so t h a t t h e
SECONDARV REGULATOR . e n e r g i z a t i o n o f t h e c r a n k i n g c i r c u i t maybe m a n u a l l y
terminated. Refer t o t h e w i r i n g diagram f o r the
c o n n e c t i o n o f t h e remote switch.

*u*r(u*~._SnuToFF VALVE-QI
MANUAL START UNITS.
 MODELS : GR6W4-C GR6W4-D
BATTERY CHARGING GRlOW4-C GRlOW4-D
GR15W4-C GR15W4-D
A l l e l e c t r i c . a n d r e m o t e s t o r t u n i t s hove o s o u r c c o f p s u e r l o r
battery chorging. U n i t s which cronk o f f the moin generator u t i l i z o
t h e DC w i n d i n g on t h e g e n e r a t o r as t h e s o u r c e f o r c h o r g i n g t h c
battery. U n i t s w h i c h hove o s e p o r a t e s t a r t i n g m o t o r o r e c h o r g r d
f.rom a r e c t i f i e d o u t p u t o f t h e m o i n g e n e r a t o r . A r e s i s t o r i s grnc.ro!ly
used i n the b a t t e r y chorging c i r c u i t .
START STOP OR
WIRE SIZE
(push b u t t ~ n (momentary
Wire S i z e Maximum Amperes V o l t a g e D r o p P e r 10G F t . o r momentary toggle switch o r WINPOWER SWITCH
A t Max. Amps toggle switch ~ u s hb u t t o n P/N EE-166
n o r m a l l y open) normally closed)
4 105 2.6
6 8C 3.2
MODELS : GR20W4-C GR20W4-D
8 55 3.42
10 40 4.0
21 24 23 21 24 23
12 25 4.0
14 20 6.4

As c o n be s e e n f r o m above, a w i r e s i z e c h o s e n on c u r r e n t c a r r y i n g
o b i l i t y o n l y can g i v e o h i g h l i n e d r o p i f t h e l e n g t h i s l o n g . Tit:
START STOP
v o l t a g e d r o p f i g u r e s g i v e n obove i s f o r a s i n g l e 100 f o o t c o n d u c t o r
w h i c h w o u l d be t h e same a s t w o 5 0 f o o t l e n g t h s i n s e r i e s . Therefore, 4 1
t h e v o l t a g e d r o p s g i v e n above o r e what y o u w i l l hove when you o r e
( p u s h b u t t o n (TWO p o s i t i o n LO- - - - --
o r momentarv On-Off I I
c o r r y i n g moximl!m amperes a t o d i s t a n c e o r 5 0 f e e t f r o m t h e s e t .
t o g g l e s w i t c h Toggle switch) WINPOWER SWITCH
n o r m a l l y open) P/N EE-166
---
REMOTE SWITCH WIRING

Use No. 1 8 o r l a r g e r w i r e f o r w i r i n g I stween t h e s w i t c h ond t h e s r t .

AUTOMATIC LINE TRANSFER CONTROL
C e r t o i n m o d e l s o f f e r t h e c h o i c e b e t w e e n u s i n g two s t o n d o r d s w i t c h e s
o r one s p e c i a l s w i t c h a s shown i n t h e f o l l o w i n g d i a g r a m s . A l o a d t r a n s f e r s w i t c h i s r e q u i r e d f o r s t a n d b y o r emergency p l a n t s .
M o s t i n s t a l l a t i o n s u s e an a u t o m a t i c l i n e t r a n s f e r s w i t c h r a t h e r t h a n
MODELS : GR5B2-A d GR4B2-A5X a manuol.
GR4B2-A d GR303B2-AX5
The W i n p o w e r A u t o m a t i c L i n e T r a n s f e r C o n t r o l a l s o incorporates
protection against overcranking, cranking shut o f f on engine s t a r t ,
and a s e l e c t o r s w i t c h f o r s e l e c t i n g t h e f o l l o w i n g modes: automatic,
t e s t , hand and s t o p . Refer t o t h e Automatic L i n e T r a n s f e r Contro!
Start Stop manual f o r i n f o r m a t i o n on it.

(push b u t t o n (push b u t t o n A customer b u y i n g an Automatic L i n e T r a n s f e r Switch from a n o t h e r

o r momentary o r momentary s o u r c e t h a n Winpower, f o r u s e w i t h a W i n p o w e r A i r C o o l e d E n g i n e
toggle switch toggle switch G e n e r a t o r , w i l l r e q u i r e a d d i t i o n a l components f o r p r o t e c t i o n a g a i n s t
n o r m a l l y open) n o r m a l l y open) o v e r c r o n k i n g and f o r d e e n e r g i z a t i o n o f t h e s t a r t i n g c i r c u i t upon
engine s t a r t i n g .
 The u n i t s h o u l d be s t a r t e d m a n u a l l y and t h e s a n d p a p e r o p p l i e d a s
OPERATION

---
INITIAL START UP

T h e e n g i n e man'ual s h o u l d b e t h o r o u g h l y r e a d i n r e g a r d s t o o p e r a t i o n .
T h e e n g i n e c r a n k c a s e m u s t b e f i l l e d w i t h a n o i l r e c o m m e n d e d by t h e I f t h e ' c o m m u t a t o r i s e x c e s s i v e l y worn and rough, t h e s e t s h o u l d , b e
engine manufacturer. The f u e l s h o u l d be r e g u l a r g r a d e o u t o m o t i v e
s e n t t o o s e r v i c e shop t o have t h e commutator t u r n e d and undercut.
gasoline. When f i l l i n g t h e t a n k o l l o w f o r f u e l e x p a n s i o n .
The c o l l e c t o r r i n g s sho"1d be c l e a n e d w i t h s a n d p a p e r i f d i r t y .
MANUAL STARTING
The g e n e r o t o r b e a r i n g is a s e a l e d b e a r i n g and r e q u i r e s no r e l u b r i -
The c a r b u r e t o r c h o k e s h o u l d be a d j u s t e d a s r e q u i r e d by t e m p e r a t u r e
cution.
conditions. P u l l t h e s t a r t r o p e w i t h a q u i c k , smooth p u l l t o c r ~ n k
t h e engine. A f t e r t h e engine s t a r t s , r e t u r n choke t o i t s normal
D i r t , and t h e moisture it w i l l hold, a r e d e t r i m e n t a l t o g e n e r a t o r s .
position. I n c o l d t e m p e r a t u r e s i t maybe n e c e s s a r y t o k e e p t h e c h o k e
I f d u s t and d i r t accumulate t h e g e n e r a t o r should be cleoned
i n t h e choke p o s i t i o n longer. T h e r e i s no c a r b u r e t o r choke on sets
periodically.
made f o r u s e w i t h g o s e o u s f u e l s .
The l e v e l o f t h e b a t t e r y e l e c t r o l y t e s h o u l d b e c h e c k e d w e e k l y u n d e r
ELECTRIC. START
c o n s t a n t u s e ond monthly w i t h i n t e r m i t t e n t u s e . Refill t o proper
l e v e l , i f down, w i t h d i s t i l l e d w a t e r . Never ollow t h e b a t t e r y t o
The c a r b u r e t o r c h o k e s h o u l d b e a d j u s t e d a s f o r monual s t o r t i n g . Push
stand for a long period i n a discharged condition.
t h e s t a r t , o r t h e s t a r t - s t o p s w i t c h , t o i t s s t a r t p o s i t i o n and r e l e a s e
s w i t c h immediately on e n g i n e s t a r t i n g .
TROUBLE SHOOTING CHART

--
REMOTE START TROUBLE CAUSE REMEDY

No o u t p u t v o l t a g e Loss o f r e s i d u a l See instruction f o r

R e m o t e s t a r t p l a n t s h a v e a n a u t o m a t i c , c h o k e a n d a f u e l pump. Push restoring residual
magnetism
t h e s t a r t - s t o p s w i t c h t o t h e s t a r t p o s i t i o n ond r e l e a s e immediately magnetism
upon e n g i n e s t a r t i n g .
Defective diode i n Replace diode o r
MAINTENANCE r e c t i f i e r assembly
r e c t i f i e r bridges (see
instructions for testing
ENGINE
r e c t i f i e r bridges)
R e f e r t o e n g i n e s t a r t i n g manual.
Poor brush contact Free brush i f stuck.
( b r u s h c a n be s t u c k i n R e p l a c e w i t h new b r u s h i f
GENERATOR
h o l d e r , worn o r s p r i n g worn. R e 2 l a c e b r u s h s p r i n g
C h e c k b r u s h l e n g t h s a f t e r 5 0 0 h o u r s o f r u n n i n g , a n d e v e r y 100 h o u r s c a n be weak) i f weak. ..
thereafter. I f b r u s h l e n g t h i s less t h a n 1/2" t h e b r u s h s h o u l d be
Open c i r c u i t ( s e e Complete c i r c u i t i f i n
r e p l a c e d w i t h a new o n e .
instructions for external wiring.
On u n i t s w i t h a c o m m u t a t o r , a n e v e n b r o w n f i l m o n t h e c o m m u t a t o r t e s t i n g o f open
d e n o t e s a d e s i r a b l e c o n d i t i o n a n d i t s h o u l d n o t b e removed. I f the
c o m m u t a t o r becomes rough a n d / o r d i r t y i t c a n be c l e a n e d by s a n d p a p e r .

TROUBLE
No o u t p u t v o l . t a g e
Low o u t p u t v o l t a g e
a t no l o a d
V o l t a g e OK a t no
load but drops o f f
r a p i d l y on l o a d
application
High o o t p u t v o l t a g e
Excessive generator
heating
Arcing a t brushes
TROUBLE SHOOTING CHART
I CAUSE
Shorted armature c o i l s
in revolving armature
u n i t o r shorted c o i l s
i n s t a t o r on r e v o l v i n g
field units.
E n g i n e s p e e d t o o low
- - -
Low e n g i n e s p e e d
Shorted diode (see
instructions for test-
ing r e c t i f i e r bridge)
Shorted diode i n s e r i e s
f i e l d bridge (see
instructions for test-
ing r e c t i f i e r bridge)
Engine speed d r o p s o f f
rapidly
Excessive engine speed
O v e r l o a d on g e n e r a t o r
Clogged v e n t i l a t i n g
i n l e t s and/or o u t l e t s
Rough o r d i r t y
commutator
Brushes not s e a t e d
properly
TESTING RECTIFIERS A N D DIODES
1 REMEDY DEFINITIONS
I
Replace armature o r A diode i s o s i n g l e r e c t i f y i n g element represented g r a p h i c a l l y a s
stator. shoun below:
-+
When a d i o d e i s used a l o n e s u c h a s i n h a l f wave r e c t i f i c a t : o n
i t con a l s o be c a l l e d a r e c t i f i e r . Two d i o d e s a r e u s e d i n f u l l
Ad j u s t e n g i n e s p e e d t o wove r e c t i f i c a t i o n . a s shown:
c o r r e c t value.
Ad j u s t e n g i n e s p e e d t o
c o r r e c t value F o u r d i o d e s o r e u s e d i n a s i n g l e p h a s e r e c t i f i e r b r i d g e a s shown:
Replace diode o r
r e c t i f i e r assembly
TESTING
Replace d i o d e o r
r e c t i f i e r assembly An ohmmeter i s r e q u i r e d f o r t e s t i n g a d i o d e o r r e c t i f i e r a s s e m b l y .
I t i s n e c e s s a r y t o remove t h e l e a d s g o i n g t o t h e r e c t i f i e r f o r
t e s t i n g i t . A s i n g l e d i o d e w i l l shoun a v e r y h i g h r e s i s t a n c e i n
o n e d i r e c t i o n and low r e s i s t a n c e i n t h e o t h e r d i r e c t i o n .
+f2
See e n g i n e manual
METER
METER
Adjust engine speed t o
-- -01 -- . ..
c o r r e c t value Low R e a d i n g Very High R e a d i n g
A s h o r t e d d i o d e w i l l h a v e a low r e a d i n g i n b o t h d i r e c t i o n s . An
Reduce l o a d open d i o d e - w i l l have a high r e a d i n g i n both d i r e c t i o n s . Each d i o d e
i n on a s s e m b l y , c a n be t e s t e d a s shown below:
C l e a n i n l e t s 'and o u t l e t s
Sand commutotor. Some
c a s e s may r e q u i r e t u r n -
ing in lathe.
Low R e a d i n g Very High R e a d i n g
See i n s t r u c t i o n s f o r
sanding brushes
T h i s r e o d i n g h a s t o be r e p e a t e d on e v e r y d i o d e . I f the r e c t i f i e r
o s s e m b l y i s a molded a s s e m b l y t e s t + - - AC
AC - --
between + and b o t h o f t h e AC t e r m i n a l s . The r e a d i n g a g a i n s h o u l d
be 1o.w i n one d i r e c t i o n and v e r y h i g h i n t h e o t h e r d i r e c t i o n . The
r e o d i n g s s h o u l d be r e p e a t e d between t h e n e g o t i v e t e r m i n a l and t h e
two AC t e r m i n a l s .
 SANDING BRUSHES

SANDING

I t i s i m p o r t a n t t h o t t h e brushes
make good c o n t a c t ' w i t h t h e c o l l e c t o r
r i n g s and w i t h t h e c o m m u t o t o r i f
used. When i n s t a l l i n g u new s e t The f u n c t i o n o f t h e e c o n o m i z e r i s t o r e d u c e t h e s p e e d o f t h e e n g i n e
o f b r u s h e s , t h e y s h o u l d be sanded when t h e a l t e r n a t o r i s o p e r a t i n g a t n o - l o o d i n ' o r d e r t o r e d u c e e n p i n .
i n b y u s i n g 0 0 sandpaper. wear and f u e l c o n s u m p t i o n .
I
The s a n d p a p e r s h o u l d be p u l l e d i n t h e d i r e c t i o n o f r o t a t i o n . When When t h e s e t i s o p e r a t e d a t n o - l o a d a v o l t a g e i s a p p l i e d t o t h e
p u l l e d i n t h e o p p o s i t e d i r e c t i o n t o s t a r t o new s t r o k e t h e b r u s l ' e l e c t r o m a g n e t c o i l w h i c h o t t r o c t s a l e v e r o t t . o c h e d :u t h e t h - o t t l e .
s h o u l d be r a i s e d . Continue t h e sanding u n t i l t h e brushes ore f t . 1 1 ~ T h i s l e v e r a c t i o n o v e r r i d e s t h e e n g i n e g o v e r n o r and r e d u c e s t h e e n g i r
seated. Do n o t u s e emery c l o t h . speed t o a p p r o x i m a t e l y 6 0 p e r c e n t o f t h e r a t e d speed. As s o o n a s a
l o a d i s a p p l i e d t h e v o l t a g e i s removed f r o m t h e e l e c t r o m a g n e t c o i l
TESTING FOR OPEN CIRCUITS and t h e e n g i n e g o v e r n o r ossumes f u l l c o n t r o l .

TESTING The p r o p e r AC v o l t a g e o u t p u t a t t h e 1 2 0 v o l t t e r m i n a l s o r r e c e p t a c l e
i s 55 t o 65 v o l t s when t h e s e t i s i n t h e i d l i n g mode. I f the voltag
The m o s t l i k e l y p l a c e f o r a n open c i r c u i t t o o c c u r i s t h e s h u n t f i e l d i s h i g h e r t h a n ' 6 5 t h e e c o n o m i z e r m u s t be r e a d j u s t e d .
circuit. The s h u n t f i e l d i s c o n n e c t e d t o t h e r e c t i f i e r o u t p u t o r t o
t h e b r u s h e s o n a c o m m u t a t o r t y p o machine. One end o f t h e s h u n t f i e l d The e c o n o m i z e r s h o u l d be t u r n e d o f f d u r i n g t h e f i r s t few m i n u t e s o f ,

s h o u l d be d i s c o n n e c t e d . An ohmmeter r e a d i n g s h o u l d be t o k e n b e t w e e n r u n n i n g a s an e n g i n e w i l l n o t i d l e w e l l when i t i s c o l d .
t h e d i s c o n n e c t e d e n d a n d t h e o t h e r end t o d e t e r m i n e c o n t i n u i t y . I f
no r e a d i n g i s o b t a i n e d t h e r e i s an open c i r c u i t . I t s exact location I f t h e economizer i s n o t performing, o r n o t performing properly, the
s h o u l d t h e n be d e t e r m i n e d ond t h e open s h o u l d be r e p a i r e d . f o l l o w i n g o r e t h e p o s s i b l e c a u s e s o.f t h e d i f f i c u l t y :
1. D e f e c t i v e m o d u l e
The o u t p u t - l e a d s s h o u l d be c h e c k e d f o r c o n t i n u i t y . On t h r e e phase 2. Open o r s h o r t e d e l e c t r o m a g n e t c o i l
m a c h i n e s a l l t h r e e c o m b i n a t i o n s s h o u l d be c h e c k e d f o r c o n t i n u i t y 3. Improper mechanical adjustment
that i s L1 - L2, L 1 - L3 and L 2 - L3.
Instructions covering the adjustment o f t h e e c o n o m i z e r a r e q j . v r n on .
RESTORING RESIDUAL MAGNETISM t h e n e x t page.

PROCEDURE - The i d l e a d j u s t m e n t s c r e w o n t h e c a r b u r e t o r m u s t n o t o v e r - r i d e t h e
economizer. T h i s s c r e w h a s been s e t a t t h e f a c t o r y a n d s h o u l d n o t '
The r e s t o r i n g o f r e s i d u a l m a g n e t i s m s h o u l d be done b y someone who be a d j u s t e d u n l e s s t h i s s c r e w makes c o n t a c t w i t h t h e s t o p when i n
i s f a m i l i a r w i t h e l e c t r i c a l equipment. I t c a n b e s t be done b y o p p l y - t h e i d l i n g mode.
i n g DG v o l t a g e ( 6 - 2 4 v o l t s ) o c r o s s t h e t e r m i n o l s o f t h e s h u n t f i e l d .
C a r e must be t o k e n t h a t t h e p o l o r i t y i s c o r r e c t . Incorrect polarity
w i l l destroy the diodes i n the r e c t i f i e r bridge i f o l i m i t i n g r e s i s t o r
i s n o t used.
 OWNER'S SERVICE RECORD
CNXILT W I N E PYIKW. FOR SU%ESTED
M4INTEtWKE AN) SERVJCE 1NlEfWAL.S
cCNSlL.1 GPERATU7 SET OPERATOR'S ML\NWL
KXI GEt€RATOR SERVICE AH) MAINIP(ANCE
I

DATE .-

INSTRUCTIONS FOR ADJUSTING ECON-0-MIZER

S t o p #1 Remove crown n u t (A) ond mognot c o v e r (8)

Stop #2 (a) To i n c r e o a e c o i l v o l t o g o 6 o n g i n o apood move mognot (E)

down f r o m b r o c k e t (F) by ad j u a t i n g .jam n u t s (c) and (D)

CAUTION! Core muat be t a k e n n o t t o oxcood opprox. 2400 RPH o n g i n o apeod

o r 30 v o l t s a c r o a a mognot c o i l whon o d j u a t i n g o n g i n o speed.
Secure magnot i n p o a i t i o n d o a i r o d by t i g h t e n i n g jom n u t (D)
t o b o t t o m o f m o u n t i n g b r o c k e t (F). N o t e t h o t t h o w i r e s on t h e
magnet muat be p o s i t i o n e d t o v d r d t h e open a i d e o f t h e c o v e r t o
p r e v e n t t h e p o a a i b i l i t y o f s h o r t i n g t h e l o o d a t o t h o covor.

(b) To decreoae c o i l v o l t a g e ond e n g i n e apeod move mognot

t o w a r d b r o c k e t (F) by adjusting jam n u t s (c) ond (D).
Secure mognot i n p o s i t i o n d e a i r e d by tightening jam n u t
(c) t o t o p o f m o u n t i n g b r o c k e t (F). C o i l v o l t o g o s h o u l d
r,
n o t be o d ' j u a t o d below 25 v o l t * . GENERATOR SET: ENGINE:
P
Stop #3 R e t u r n magnet c o v e r (8) t o s t u d on t o p o f mognot ond aocuro Model No. Model
w i t h crown n u t (A). S e r i a l No. S e r i a l No.

P u r c h a s e d From

-Placed I n Service