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Summary of Contents for Winco DE4040F4 /4 Series
- Page 1 DE4040F4-XX/4 GENERATOR INSTALLATION AND OPERATORS MANUAL 16200-030 16200-049 www.wincogen.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS SAVE THESE INSTRUCTIONS ENGINE MAINTENANCE SAFETY INFORMATION CHANGING THE OIL CHANGING OIL FILTER SAFETY DEFINITIONS REFILLING COOLANT SPECIFICATIONS CHANGING AIR FILTER DE4040F4 CHECKING WATER IN PRE-FILTER INTRODUCTION CLEANING RADIATOR TESTING POLICY REPLACING BLOW-BY FILTER Rated output of generator is based on engineering tests STORAGE of typical units, and is subject to, and limited by, the MAINTENANCE SCHEDULE... -
Page 3: Save These Instructions
COPY YOUR MODEL AND SERIAL NUMBER HERE No other WINCO generator has the same serial number as yours. If you should ever need to contact us on this unit, it will help us to respond to your needs faster. -
Page 4: Safety Information
SAFETY INFORMATION IMPORTANT SAFETY INSTRUCTIONS This engine generator set has been designed and DANGER: FIRE HAZARD manufactured to allow safe, reliable performance. Poor Gasoline and other fuels present a hazard of possible maintenance, improper or careless use can result in explosion and/or fire. -
Page 5: Specifications
SPECIFICATIONS DE4040F4 MODEL DE4040F4-3 DE4040F4-4 DE4040F4-17 DE4040F4-18 DE4040F4-21 GENERATOR Watts 40,000 40,000 40,000 40,000 40,000 Volts 120/240 120/208 120/240 277/480 346/600 Phase Single Three Three Three Three Amps Hertz GENERATOR RESISTANCE (all value at 22°C) Model Stamford UCI224C Winding Group Rotor 0.59 Ω... -
Page 6: Testing Policy
Rated output of generator is based on engineering tests Go to the WINCO website for a list of engine dealers of typical units, and is subject to, and limited by, the (wincogen.com) or contact the WINCO Service Department. -
Page 7: Preparing The Unit
This must be completed and If the generator was shipped on the fuel tank, use the returned to WINCO Inc. within 180 days of the factory lifting points located on the fuel tank to move the entire invoice date. -
Page 8: Installation
The flange should not be placed closer than 0.75 in. to the edge of the structure or other The WINCO installation manual OPM-112 contains solid surfaces. The radiator is mounted on rubber vibration additional information on indoor installations and isolators that allow it to move. -
Page 9: Exhaust Installation
EXHAUST INSTALLATION INSTALLING THE FUEL LINE DANGER: PERSONAL INJURY Engine-generator sets are properly adjusted before they leave the factory. Connecting a fuel supply with adequate Improper exhaust installation will allow dangerous gases supply volume is critical to reliable operation. Diesel units to seep into enclosed spaces causing a hazard to your with optional base mounted fuel tanks are pre-plumbed to health and/or death. -
Page 10: Generator Circuit Breaker
GENERATOR CIRCUIT BREAKER your application’s needs. Consult experts in this field for assistance in designing this part of the system. This unit DOES NOT come with a circuit breaker. The circuit DANGER breaker will provide overload protection for the generator. Only use ASME pressure vessels. -
Page 11: Grounding
DC WIRING VEHICLE-MOUNTED GENERATOR CAUTION Your WINCO generator ships with a bonded neutral. Never run the AC and DC wiring on the same conduit. When mounted to a vehicle to safely distribute power it is necessary that the generator frame is bonded to the vehicle REMOTE START frame. - Page 12 RS485. The ports are wired onto the back of the DSE7310. In order to finalize communication the program will need to be adjusted using the free DSE configuration software to enable the communication. Contact Winco service for a list of register values. OPM-171/B...
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Page 13: Installing The Battery
INSTALLING THE BATTERY CAUTION WARNING In the following battery installation procedure, check to be The electrolyte is diluted sulfuric acid that is harmful to the sure the engine control is in the “stop” position. This should skin and eyes. It is electrically conductive and corrosive. be your last step before initial start-up. - Page 14 Make sure all DC battery connections are tight and clean. Follow battery manufacturer’s recommendations. This charger is mounted under the customer connection on the control side of the generator. The charger will need to be plugged to a customer’s power source, using a customer supplied heavy duty, UL approved extension cord.
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Page 15: Starting Procedure
We have partnered with a national lubrication oil manufacturer to give you access to Winco private branded AIR COMPRESSOR LUBRICATION premium oil available at comparable prices to conventional oils. -
Page 16: Dse7310 Mkii
DSE7310 MKII WARNINGS Warnings are non-critical alarm conditions. They do not affect the operation of the generator system, they serve to draw the operator’s attention to an undesirable CAUTION condition. Warning alarms are self-resetting when the If the DSE7310 is being replaced with a manual start panel, fault condition is removed. -
Page 17: Control Power
COMPRESSOR START UP 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 This unit has been equipped with an air compressor that of 59.5 to 60.5 hertz (Hz). uses an auxiliary shaft from the generator to provide 120 PSI @ 40 CFM. -
Page 18: Operating Conditions
OPERATING CONDITIONS Inspect the CV filters and 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 NORMAL OPERATION an engine seal failure. An optional CV hose heater kit is available to install and is recommended for units operating in temperatures below 14°F. -
Page 19: Adjusting Air Pressure
NOTE: The CAS R3 should be filled until the oil covers no more than 3/4 of the sight glass. Wait until the compressor If your application requires higher pressure contact Winco has been off for several minutes to allow the oil in the Service. -
Page 20: Changing The Compressor Oil Filter
REPLACING COMPRESSOR FINE 7. Refill with new oil at the filler neck to the maximum level. SEPARATOR CARTRIDGE NOTE: The compressor must be operated with an oil WARNING: PERSONAL INJURY suitable for special requirements. This oil must be approved by the manufacturer for screw compressors. It must even Rotating, pressurized, and hot components. -
Page 21: Checking The Compressor Pressure Safety Valve
3. Carefully remove dust from the filter housing. 4. Remove the old filter (Ref. 3). 5. Insert the new filter in the filter housing. 6. Securely screw the filter cover back on using the wing nut. 7. Switch on the compressor. 8. -
Page 22: Engine Maintenance
1. Place a drip pan or suitable container for catching the oil below the drain valve attached to the sump (5). WINCO has supplied a valve to hook a customer supplied 5/8” hose to conveniently run the oil to the drip pan. -
Page 23: Checking Water In Pre-Filter
1. Remove the air filter cover (4) after having released the 2. Unscrew the lower guard screws (2) and remove the two quick closing hooks (3). lower guard (1). 2. Remove the filter (5). During this operation, take care 3. Save the anti-vibration plugs (3). to ensure that no dust enters the sleeve. -
Page 24: Storage
MAINTENANCE SCHEDULE 6. Correctly position the guards inserting the anti- vibration plugs. 7. Secure the other guards. ENGINE Checks In Period of Use Frequency Check for water in the fuel Pre-Filter Daily Check Air-Restriction Indicator on Filter Daily Engine Oil Level Daily/Prior to Use Engine Coolant Level Daily/Prior to Use... -
Page 25: Trouble Shooting
TROUBLE SHOOTING ENGINE-GENERATOR SET COMPRESSOR Problem Possible Causes Problem Possible Causes Unit will not crank when Digital genset not in AUTO System does not start No electricity, verify voltage at power fails Transfer control switch not in solenoid AUTOMATIC position System difficult to start Verify engine speed is correct Incorrect wiring between ATS and... -
Page 26: Rotorcomp
stem is the The NK 31 may 1.7 Nameplate s or other media OTORCOMP. For the location of the nameplate, see Figure 3-1 ROTORCOMP d by specialized or 3-3. ng know-how. al data, limits, in- Should you have questions, please provide us In the event you will need technical support, please have ions for commis- with the data on the nameplate. -
Page 27: Engine Codes
ENGINE CODES FMI Test Translation The electrical Signal of the EGR Valve position sensor is monitored. In case of defect recognition a replacement value is 1B-3 taken. The electrical Signal of the EGR Valve position sensor is monitored. In case of defect recognition a replacement value is 1B-4 taken. - Page 28 FMI Test Translation The Fuel Rail pressure control is executed with a device: Metering Unit (MeUn) as feeding quantity control and an 9D-12 overpressure valve allocate in the rail (PRV). Dataset Interlock Feature is used to prevent the flashing of unintended datasets on to the ECU during any SW upgrades A6-2 in field.
- Page 29 FMI Test Translation Hardware errors in the injectors and respective ECM power stages are investigated. Diagnostic procedure uses pattern detection to identify specific errors and trigger appropriate substitute reaction. The behavior pattern describes in a 28C-5 bit mask different detected problem (overcurrent, command collision, RAM error,short circuit,..) when the expected combination of errors is detected (measured and reference pattern are matching) a failure is detected.
- Page 30 FMI Test Translation Engine Starter is controlled by two relays actuators one for Low Side and one for High Side. Both power stages are 2A4-6 monitored by Hardware for electric failures. The Engine Position Management module is responsible for signals from camshaft and crankshaft sensor evaluation: angle and speed determination, signal plausibility and quality are monitored by this module.
- Page 31 FMI Test Translation The Power stage of EGR Valve actuator is monitored by Hardware for electric failures. The Power stage of electric EGR Valve actuator (H-Bridge) is monitored by Hardware for electric failures. The H-Bridge has 2 switches (High side and Low side). Each circuit is monitored separately. The Power stage of electric EGR Valve actuator (H-Bridge) is monitored by Hardware for electric failures.
- Page 32 FMI Test Translation 4009 The Power stage of Fuel Filter heater is monitored by Hardware for electric failures. FA9-5 4009 The Power stage of Fuel Filter heater is monitored by Hardware for electric failures. FA9-6 The electrical Signal of the Oxi Cat temperature upstream sensor is monitored. In case of defect recognition a substitute 4765 129D-3 value is taken.
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Page 33: Wiring Size Table
WIRING SIZE TABLE The table below is based on Table 310.15 (B) (16) un the National Electric Code 2014 edition. Allowable ampacitier 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. -
Page 34: Engine Harness
ENGINE HARNESS OPM-171/B... -
Page 35: Engine Harness
ENGINE HARNESS OPM-171/B... -
Page 36: Dse7310 Wiring Diagram
DSE7310 WIRING DIAGRAM OPM-171/B... -
Page 37: Compressor Wiring Diagram
COMPRESSOR WIRING DIAGRAM OPM-171/B... -
Page 38: Fan Harness
FAN HARNESS OPM-171/B... -
Page 39: Wiring Diagrams
WIRING DIAGRAMS THREE PHASE AC WIRE HIGH AND LOW WYE THREE PHASE AC WIRING- DELTA SINGLE PHASE 311 WINDING OPM-171/B... -
Page 40: California Emission Control Warranty Statement
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS California Air Recourses Board and FPT Industrial S.p.A. are pleased to explain the emission control system warranty on 2021 to 2023 off-road engines. In California, new heavy-duty off-road engines must be designed, built, and equipped to meet the state’s stringent anti-smog standards. -
Page 41: Us Environmental Warranty Statement
(12) months afterwards for a maximum of 33 months from engine manufacture date for warranty coverage to be available, and provide written confirmation to WINCO Inc that the engine was revalidated. Warranty will be exhausted if the unit is still in the seller’s inventory after revalidation cycle. -
Page 42: Limited Warranty
Air cooled units purchased for stock have 1 year to be sold. The warranty to the original retail customer commences on the date of sale of the product to them. All liquid cooled units have 180 days from the Winco invoice to submit a start up date. If no startup form is submitted, then warranty period starts on the Winco invoice date unit was sold. - Page 43 Note 2: 3rd Year warranty coverage is parts only/no labor. Note 3: Round trip mileage is limited to 200 miles per trip and a total of 2 trips per repair unless authorized in writing by the WINCO Service Dept.
- Page 44 225 S. CORDOVA AVE • LE CENTER, MN 56057 Sales: 507-357-6821• sales@wincogen.com Service: 507-357-6831 • service@wincogen.com www.wincogen.com OPM-171/B...
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