Winco DE4040F4 Installation And Operator'S Manual Download Page 1

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INSTALLATION AND

OPERATORS MANUAL

DE4040F4-XX/3

GENERATOR

COPY YOUR MODEL AND SERIAL NUMBER HERE

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MODEL __________________________________________________

SERIAL NUMBER _________________________________________

PURCHASE DATE _________________________________________

DEALER NAME ___________________________________________

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INE

MPRESSO

Summary of Contents for DE4040F4

Page 1: ...ontact us on this unit it will help us to respond to your needs faster MODEL __________________________________________________ SERIAL NUMBER _________________________________________ PURCHASE DATE _________________________________________ DEALER NAME ___________________________________________ DEALER PHONE ________________________________________ www wincogen com ENGINE C O MPRESSO R ...

Page 2: ...HE OIL FILTER REPLACING FINE SEPARATOR CARTRIDGE REPLACING THE AIR INTAKE FILTER ENGINE MAINTENANCE 19 CHANGING THE OIL CHANGING OIL FILTER REFILLING COOLANT CHANGING AIR FILTER CHECKING WATER IN PRE FILTER CLEANING RADIATOR REPLACING BLOW BY FILTER STORAGE TROUBLE SHOOTING 22 ENGINE GENERATOR SET MAINTENANCE SCHEDULE 22 COMPRESSOR FLOW DIAGRAM ENGINE CODES 24 WIRING SIZE TABLE 30 ENGINE HARNESS 3...

Page 3: ... HAZARD Gasoline and other fuels present a hazard of possible explosion and or fire A Do not refuel when the engine is running or hot B Keep fuel containers out of reach of children C Do not smoke or use open flame near the generator set or fuel tank D Keep a fire extinguisher nearby and know its proper use Fire extinguishers rated ABC by NFPA are appropriate E Store fuel only in an approved conta...

Page 4: ...66 139 120 60 48 Hertz 60 60 60 60 60 ENGINE Model FPT F5 C Starting System 12 Volt Fuel Consumption full load 4 16 Gal hr Fuel ASTM D 975 2D Oil Type See Lubrication section in this manual Oil Capacity 10 Quarts Cooling System 50 50 mix See engine manual for additional fuel types and specifications GENERATOR RESISTANCE all value at 22 C Model Stamford UCI224D Winding Group 311 Rotor 0 64 Ω Stator...

Page 5: ...late information recorded inside the front cover of this manual for future reference and for identification whenever requesting field or factory assistance Primary fields needed for assistance are complete model number and serial number ENGINE This manual covers specific operation of the combined engine generator set The basic engine information provided in this manual is not suitable for all oper...

Page 6: ...tems shipped loose for on site installation f Optional accessories 3 Remove main frame hold down bolts 4 Unit can now be lifted from shipping rails LIFTING THE GENERATOR SET NOTICE PERSONAL INJURY To prevent injury to persons or equipment observe the following guidelines when lifting the generator CAUTION Do not attempt to lift the generator set by the means of the lifting eyes on the engine or ge...

Page 7: ...eteriorate and the unit mountings will come loose These units must be mounted to a steel or concrete base VENTILATION REQUIREMENTS WARNING EQUIPMENT DAMAGE It is the installer s responsibility to ensure that there is sufficient cooling air available to prevent the engine and generator from over heating Damage caused by overheating is not covered by warranty Providing proper air movement during you...

Page 8: ...e 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 The information in this manual is offered to assist you in providing the proper fuel for your engine However this information is only provided to inform you of the engine s requirements and assist in making you aware of the decisi...

Page 9: ... the vehicle frame The generator should only supply equipment that is cord and plug connected through customer installed receptacles mounted on the generator or the vehicle PERMANENTLY INSTALLED GENERATORS This WINCO portable generator ships with a bonded neutral NFPA 70 refers to this as a separately derived system When connecting it to a building a transfer switch specifically designed for GFCI ...

Page 10: ... Battery Battery E Stops SERIAL COMMUNICATION DSE provides a series of remote accessories that can help provide useful information to operators These accessories communicate over the DSE Net Terminal blocks are wired to the distribution panel to aid in installation Follow the instructions included with each accessory The generator controller can communicate with a variety of controls and monitorin...

Page 11: ...erflow resulting in corrosion to the engine or nearby parts 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 All connections must be clean and tight Check the electrolyte in the battery period...

Page 12: ... Fuel WINCO Broad Range 5W 40 Synthetic API CJ 4 ACEA E6 E9 15 ppm Premium 10W 40 Semi Synthetic API CJ 4 ACEA E6 E9 15 ppm Cold Climate 5W 30 Synthetic API CJ 4 ACEA E6 E9 15 ppm Not Authorized Monograde CAUTION PERSONAL INJURY Only check oil when the engine is not running and is at a low temperature in order to avoid the risk of burns 1 Remove the dipstick 1 and ensure the oil level is between t...

Page 13: ... 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...

Page 14: ...he initial start up or prior to start up it is most likely a false warning light Simply reset the ATS to start over Once you have completed testing of the ATS be sure you ALWAYS leave the system in the standby mode unless servicing the unit For standby operation press the AUTO button on the front of the control The green light should light up next to the AUTO button NOTE For setting the exerciser ...

Page 15: ...f dust and debris entering the housing and generator components COLD WEATHER OPERATIONS 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 can may be reduced at low temperatures due to the separation of the paraffin This results in the filters becoming clogged The ASTM D9...

Page 16: ...ly use genuine parts 3 All maintenance and repair work must only be carried out with the complete unit shut down and the power supply switched off Ensure the machine is secured against accidental switch on WARNING PERSONAL INJURY Before removing plugs filters and other pressurized parts the compressor must be cut off from all pressure sources and a pressure relief of the entire system must be carr...

Page 17: ...pres sor compact module see chapter 7 8 Mainte nance intervals 7 3 2 Oil drain points The system should be at operating temperature in this case Figure 7 2 Note Dispose of the used oil according to the appli cable regulations Switch off the screw compressor and then secure it against being switched on again by removing the main switch Completely release the pressure in the screw compressor system ...

Page 18: ... 7 5 2 Replacing ﬁne separator cartridge Figure 7 4 Note Dispose of the old ﬁne separator cartridge ac cording to the applicable regulations Unscrew the ﬁne separator cartridge 1 with a suitable tool e g oil ﬁlter strap wrench Oil the gasket on the new ﬁne separator car tridge 1 with oil of the same oil type as in the compressor module Tighten the new ﬁne separator cartridge by hand No tool is req...

Page 19: ...to avoid the risk of burns 1 Remove the cap 1 on the radiator 2 With the engine cold make sure the level of coolant in ENGINE MAINTENANCE CHANGING THE OIL CAUTION PERSONAL INJURY Only change oil when the engine is not running and is at a low temperature in order to avoid the risk of burns 1 Place a drip pan or suitable container for catching the oil below the drain valve attached to the sump 5 WIN...

Page 20: ...er cover 4 after having released the two quick closing hooks 3 2 Remove the filter 5 During this operation take care to ensure that no dust enters the sleeve 3 Position the filter 5 in its seat 4 Replace the cover 4 of the air filter and lock it in place using the two quick release hooks 3 CHECKING WATER IN PRE FILTER WARNING EQUIPMENT DAMAGE Clean the exhaust valve prior to checking the pre filte...

Page 21: ...tective oil in a quantity of approx 130 g 10 g per liter of displacement in the turbocharger intake inlet during the engine turning operation described in the previous paragraph 6 Close all of the engine s intake discharge ventilation and bleeding holes with plugs or seal them with adhesive tape 7 Drain the residual 30 M protective oil from the sump which can be used for an additional 2 preparatio...

Page 22: ...set Defective control relay in ATS Fuse s blown in the DSE 7310 Defective DSE 7310 Loose or dirty battery terminals Defective starter Defective start solenoid Low dead battery Engine won t crank Low dead battery Blown DC fuses Defective DSE 7310 Defective key switch Loose or dirty battery terminals Defective starter Defective start solenoid Locked up engine genset Defective engine harness Improper...

Page 23: ... with pre separation 6 Fine separator 7 Minimum pressure valve 8 Oil thermostat 9 Oil ﬁlter 10 Oil cooler 11 Air after cooler 12 Non return valve 13 Safety valve optional 2 1 1 2 4 5 3 3 1 13 6 7 11 9 8 10 12 Figure 3 2 3 2 Flow diagram of NK 31 electric control unit 3 3 Operating description for NK 31 Screw Compressor Compact Module electric The ﬂow diagram shows a schematic view of the operating...

Page 24: ... signal range check is performed on the signal Sensor is inside ECU 6C 3 108 4 Environmental pressure sensor is available and connected via hardware to the ECM Pressure is obtained through Analogic to Digital Converter and transformed to a physical value in EnvP_pSens A signal range check is performed on the signal Sensor is inside ECU 6C 4 110 3 Electrical Signal range check of Coolant temperatur...

Page 25: ... switch input For the idle shut down a state machine is used The state in which the state machine is at the moment is shown in the message CoEng_stIdlShDwnStM_mp Assuming the conditions to enable the engine shut off then the engine will shut down after a countdown timer The status signal indicates when the countdown timer is below a timer calibrated CoEng_stIdlShDwnStM_mp 1 252 1F 623 6 The Power ...

Page 26: ... trigger appropriate substitute reaction The behavior pattern describes in a 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 28E 5 654 6 Hardware errors in the injectors and respective ECM power stages are investigated Diagnostic procedure ...

Page 27: ...hardware connected sensor The raw voltage signal is acquired in the message Exh_uRawPTrbnUs This signal is checked for the Signal Range Errors and then transformed into physical value Exh_pSensPTrbnUs 4B9 3 1209 4 The turbine upstream pressure is acquired via hardware connected sensor The raw voltage signal is acquired in the message Exh_uRawPTrbnUs This signal is checked for the Signal Range Erro...

Page 28: ...s the LowLevel Chipdriver for the Powerstage Chips R2S25200kfp The R2S25200 is a chip with 18 powerstages and an additional module for the monitoring of the ECU internal 5V Supply Voltage It is possible to configure max 4 R2S2 B18 C 2840 14 Calibrated parameters for baud rate cannot be read from EEPROM B18 E 2880 2 A range and plausibility check for the value of PTO switch are performed The source...

Page 29: ...rcuit is monitored separately A plausibility check is made in case a failure Short circuit to Battery SCB or Short circuit to Ground SCG is detected Therefore the switch Low side in case of SCB High side in case of SCG is closed If the Short Circuit failure disappears it is cleared and the Overload failure activated 152B 6 5419 7 The Throttle Valve actuator gives a feedback with a position sensor ...

Page 30: ... THHW THW 2 XHH XHHW XHHW 2 ZW 2 SIZE AWG OR KCMIL Wire Type RHW THHW THW THWN XHHW USE Wire Type TBS SA SIS THHN THW 2 THWN 2 RHH RHW 2 USE 2 XHH XHHW XHHW 2 ZW 2 50 65 85 100 115 130 150 175 200 230 255 285 310 335 380 420 460 475 490 520 545 590 625 650 655 55 75 95 115 130 145 170 195 225 260 290 320 350 380 430 475 520 535 555 585 615 665 705 735 750 8 6 4 3 2 1 1 0 2 0 3 0 4 0 250 300 350 40...

Page 31: ...31 OPM 141 E ENGINE HARNESS ...

Page 32: ...5 7 50 1 2 6 211 725 211 725 66 86 86 86 86 86 36 1 2 8 1387 20021 6 5 1 1 6 5 1 1 1 1 1 36 32 5 6 7 66 0 5 1 6723 6 7 66 8 6 7 21 6 7 9 5 92 7 8670 17 5 267 7 9 5 ƺ 1 855 17 66 7 50 1 2 803 56 6 2 1 29 25 2 7 5 255 6321 1 7 50 1 6 2 22 17 02 8 25 1 7 6 7 5 9 6 216 5 9 51 6 5 37 21 7 33 3 25 1 5 83 7 7 5 3 27 5 6 33 25 1 3 57 5 83 7 5 21 21752 5 8 72 5 1 335 7 7 8 1 1 21752 5 7 7 7 5 1 02 3 57 7 6...

Page 33: ...33 OPM 141 E THREE PHASE AC WIRE HIGH AND LOW WYE WIRING DIAGRAMS THREE PHASE AC WIRING DELTA SINGLE PHASE 311 WINDING ...

Page 34: ...or for your failure to ensure the performance of all scheduled maintenance As the off road engine owner you should however be aware that FPT Industrial S p A may deny your warranty coverage if your off road engine or part has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on diesel only Use of any other fuel may result in your engine...

Page 35: ...iginal equipment Fuel injection system Fuel injection part Fuel injectors Fuel injection lines Air induction system Intake manifold Turbocharger system includes exhaust manifold Charger air cooler Positive Crankcase Ventilation PCV system if applicable PCV valve Oil cap filler Exhaust after treatment devices if applicable Diesel Oxidation Catalyst DOC Diesel Particulate Filter DPF Selective Cataly...

Page 36: ...at requires replacement of engine part or component of the product that is no longer manufactured or available Additionally WINCO Inc will not be liable for any engine replacement that may require an emissions tier level change THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE DESCRIBED HEREIN THERE ARE NO OTHER WARRANTIES EXPRESSED OR IMPLIED OR OTHERWISE CREATED UNDER THE UNIFORM COMMERCIAL CODE ...

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