Winco HPS12000HE, HPS12000F Installation And Operator's Manual
HPS12000HE/F
INSTALLATION AND
OPERATORS MANUAL
TRI-FUEL GENERATOR
SAVE THESE INSTRUCTIONS
PROPER USE AND INSTALLATION
This manual contains important instructions that
should be followed during installation and maintenance of the generator and battery. Read and
understand all instructions in the manual before
starting and operating the generator set.
USING THE MANUAL
Congratulations on your choice of a Winco generator set. You have selected a high-quality, precision
engineered generator set designed and tested to
give you years of satisfactory service.
To get the best performance from your new engine
generator set, it is important that you carefully read
and follow the operating instructions in this manual.
Should you experience a problem please follow
the “Troubleshooting Tables” near the end of this
manual. The warranty listed in the manual describes
what you can expect from WINCO should you need
service assistance in the future.
You must be sure your new engine generator set is:
* Properly serviced before starting.
* Operated in a well ventilated area.
* Properly exhausted and gases safely
dispersed.
* Operated only for its designed purposes.
* Used only by operators who understand
its operation.
* Properly maintained.
COPY YOUR MODEL AND
SERIAL NUMBER HERE
No other WINCO generator has the same serial
number as yours. It is important that you record
the number and other vital information here. If you
should ever need to contact us on this unit it will help
us to respond to your needs faster.
MODEL
SERIAL NUMBER_________________________
HPS12000HE/F
TABLE OF CONTENTS
INTRODUCTION 2
BASIC INFORMATION
Specifi cations 2
SAFETY INFORMATION 3
UNIT CAPABILITIES 4
PREPARING THE UNIT
Unpacking the Unit 5
LP/NG Installation 6
Fuel Line Sizing 6
Fuel Consumption 7
Fuel Pressure 7
Tank Sizing for LP 8
Changing Fuel Types 8
Battery Installation 9
INITIAL START UP 10
Electric Starting for Gasoline 10
Electric Starting for LP/NG 11
Stopping & Storage 11
Operating Speed 11
CONNECTING THE LOADS 12
Wiring 13
ENGINE CARE 14
GENERATOR CARE 15
TROUBLESHOOTING 16
CONTROL PANEL WIRING DIAGRAM 17
WARRANTY INFORMATION 18
PURCHASE DATE_________________________
DEALER_________________________________
DEALER PHONE # ________________________
UNIT SPECIFICATIONS
GENERATOR MODEL HPS12000HE/F
Surge Watts (gasoline) 12,000
Continuous Watts 10,800
Volts 120/240
Amps 90/45
Engine Honda
GX630RH VXE1 NH1
Code GCAMH
Generator Mecc Alte Spa
S20FS-160/A
Fuel Capacity 15 Gallons
Fuel Consumption
Gasoline 1.67 gal/hr
LP 2.2 gal/hr
NG 200 cu ft/hr
200,000 btu/hr
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60706-236
SAFETY INFORMATION
This 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 fi re. Please
read all safety instructions carefully before installation or use. Keep these instructions handy for future
reference. Take special note and follow all warnings
on the unit labels and in the manuals.
ANSI SAFETY DEFINITIONS
***********************************************************
DANGER:
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This signal word is to be limited to the
most extreme situations.
***********************************************************
b. Keep fuel containers out of reach of children.
c. Do not smoke or use open fl ame near the
generator set or fuel tank.
d. Keep a fi re extinguisher nearby and know its
proper use. Fire extinguishers rated ABC by
NFPA are appropriate.
e. Store fuel only in an approved container, and
only in a well ventilated area.
f. Follow local codes for closeness to
combustible material.
3. DEADLY EXHAUST GAS Exhaust fumes from
any gasoline engine contain carbon monoxide, an invisible, odorless and deadly gas that must be mixed
with fresh air.
a. Operate only in well ventilated areas.
b. Never operate indoors including attached
garages
c. Never operate the unit in such a way as to
allow exhaust gases to seep back into closed
rooms (i.e. through windows, walls, fl oors).
***********************************************************
WARNING:
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
***********************************************************
***********************************************************
CAUTION:
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against
unsafe practices.
***********************************************************
1. ELECTRICAL SHOCK The output voltage present in this equipment can cause fatal electric shock.
This equipment must be operated by a responsible
person.
a. Do not allow anyone to operate the generator
without proper instruction.
b. Guard against electric shock.
c Avoid contact with live terminals or
receptacles.
d Use extreme care if operating this unit in rain
or snow.
e. Use only three-pronged grounded receptacles
and extension cords.
f. Be sure the unit is properly grounded to an
external ground rod driven into the earth.
2. FIRE HAZARD Gasoline and other fuels present a hazard of possible explosion and/or fi re.
a. Do not refuel when the engine is running or
hot.
4. NOISE HAZARD Excessive noise is not only
tiring, but continual exposure can lead to loss of
hearing.
a. Use hearing protection when working around
this equipment for long periods of time.
b. Keep your neighbors in mind when using this
equipment.
5. CLEANLINESS Keep the generator and surrounding area clean.
a. Remove all grease, ice, snow or materials that
create slippery conditions around the unit.
b. Remove any rags or other materials that could
create a potential fi re hazard.
c. Carefully clean up any gas or oil spills before
starting the unit.
6. SERVICING EQUIPMENT All service, including the installation or replacement of service parts,
should be performed only by a qualifi ed technician.
a. Use only factory approved repair parts.
b. Do not work on this equipment when fatigued.
c. Never remove the protective guards, covers,
or receptacle panels while the engine is
running.
d. Use extreme caution when working on
electrical components. High output voltage
from this equipment can cause serious injury
or death.
e. Always avoid hot muffl ers, exhaust manifolds,
and engine parts. They can cause severe
burns instantly.
f. The use of the engine-generator set must
comply with all national, state, and local
codes.
3240-10 60706-236
3
TESTING POLICY
UNIT CAPABILITIES
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.
Rated output of generator is based on engineering
tests of typical units, and is subject to, and limited
by, the temperature, altitude, fuel, and other conditions specifi ed by the manufacturer of the applicable
engines.
INTENDED USES
This engine generator set has been designed primarily for portable heavy duty commercial use. Both
120 volt and 240 volt receptacles are provided in the
control panel to plug in your loads (lights, portable
tools, and small appliances). These units are dual
wound generators, therefore the 120 volt loads must
be equally split with 1/2 of the rated capacity available on each of the two 120 volt circuits.
This portable unit requires large quantities of fresh
air for cooling the engine and generator. For safety,
long life and adequate performance, these units
should never be run in small compartments without
positive fresh air fl ow.
GENERATOR CONNECTIONS
HPS12000HE: 120 volt and 240 volt receptacles
are provided for connection to various loads. The
diagram below represents this 10,800 watt (rated
output) generator. A & B represent the 120 volt output legs of this generator. Up to 5400 watts at 120
volts (45 Amps) can be drawn from the receptacles
attached to either A or B output legs. This generator
is capable of producing 45 Amps of 240 volt current
at C. Check the appliance or tool nameplates for the
current and voltage to ensure compatibility. Remember that power taken from C reduces the power
available at equally both A and B and vice versa.
RESTRICTED USES
DO NOT remove from the cradle assembly. Re-
moval of the generator from the cradle assembly
may cause excessive vibration and damage to the
engine-generator set.
DO NOT install and operate this generator in a small
compartment., i.e. generator compartments of vehicles, motor homes or travel trailers. These compartments will not allow enough free fl ow of fresh
air to reach the engine generator set for cooling and
will cause the unit to overheat, damaging both the
engine and generator. Small compartments will also
develop hot spots where there is very little air fl ow
and may cause a fi re.
PLEASE NOTE There are 3rd party companies
making enclosures for generators that have been
properly engineered. The use of these 3rd party
enclosures is acceptable as long as they have been
certifi ed and meet current code.
DO NOT attempt to operate at 50 cycles. These
units are designed and governed to operate at 60
cycles only.
STARTING ELECTRIC MOTORS
Electric motors require much more current (amps) to
start than to run. Some motors, particularly low cost
split-phase motors, are very hard to start and require
5 to 7 times as much starting current as running current. Capacitor motors are easier to start and usually require 2 to 4 times as much starting current as
running current. Repulsion Induction motors are the
easiest to start and require only 1 1/2 to 2 1/2 times
as much starting as running current.
Most fractional horsepower motors take about the
same amount of current to run whether they are
Repulsion Induction (RI), Capacitor (Cap), or SplitPhase (SP) type.
If the electric motor is connected to a hard starting
load such as an air compressor, it will require more
starting current. If it is connected to a light load,
or no load such as a power saw, it will require less
starting current. The exact requirement will also
vary with the brand or design of the motor.
3240-10
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60706-236
Self-exciting generators respond to severe overloading differently than utility power. When overloaded,
the engine is not able to supply enough power to
bring the electric motor up to operating speed. The
generator responds with high initial starting current,
but the engine speed drops sharply. The overload
may stall the engine. If allowed to operate at very
low speeds, the electric motor starting winding will
burn out in a short time. The generator winding may
also be damaged.
CAUTION: EQUIPMENT DAMAGE
RUNNING THE GENERATOR SET UNDER
THESE CONDITIONS MAY RESULT IN DAMAGE
TO THE GENERATOR STATOR AS WELL AS THE
MOTOR WINDING.
The heavy surge of current required for starting
motors is required for only an instant. The generator will not be damaged if it can bring the motor up
to speed in a few seconds of time. If diffi culty is
experienced in starting motors, turn all other electrical loads off and if possible reduce the load on the
electric motor.
PREPARING THE UNIT
UNPACKING
CAUTION: EQUIPMENT DAMAGE
THIS UNIT HAS BEEN SHIPPED WITHOUT OIL.
Failure to maintain the engine oil at the proper level
will result in serious engine damage.
When you unpack your new engine-generator set be
sure to remove all the information sheets and manuals from the carton.
1. This generator-set was in good order when
shipped. Inspect the generator-set promptly after
receiving it. If any damage is noted, notify the transportation company immediately; request proper procedures for fi ling a “concealed damage” claim. Title
to the equipment and responsibility for fi ling a claim
rests with you when a generator-set is sent F.O.B.
shipping point. Only you can legally fi le a claim.
2. Before proceeding with the preparations of your
new generator-set for operation, take a couple of
minutes to ensure the unit you have received is the
correct model and review the specifi cation pages in
this manual to ensure that this unit meets your job
requirements.
LUBRICATION
Before starting the engine, fi ll the crankcase to the
proper level with a good quality oil. The recommended grade of oil and quantity of oil required is
listed in the engine operator’s manual and under
oil recommendations below. This unit was shipped
with most of the oil removed. The engine normally
holds 57 and 58 ounces of oil. Since there is some
trapped oil in the engine, when fi lling the crankcase
the fi rst time use the dipstick to ensure that you do
not over fi ll the crankcase. The picture below shows
the full oil level mark on the dipstick.
OIL FILLER
CAP
OIL LEVEL DIPSTICK
UPPER LIMIT
LOWER LIMIT
Oil is added to the engine by removing the oil fi ller
cap and adding oil at this point. After fi lling the
crankcase to the proper level be sure you properly
tighten the oil fi ll cap. NOTE: This engine generator
must be on a level surface before you check or add
oil to the system.
The necessity of using the correct oil, and keeping
the crankcase full cannot be overemphasized. Engine failures resulting from inadequate or improper
lubricant are considered abuse and not covered by
the generator or engine manufacturer’s warranty.
Oil Recommendations
Outdoor temperatures determine the proper oil
viscosity for the engines. Use the chart to select the
best viscosity for the outdoor temperature range
expected.
Synthetic 5W-30
AMBIENT TEMPERATURE
SAE 10W-30 or 5W-30 is recommended for general use. Use a full
synthetic 5W-30 for starting/operating temperatures between 5°F
−−−
( 15°C) and 13°F ( 25°C). Other viscosities shown in the chart
may be used when the average temperature in your area is within
the indicated range.
3240-10 60706-236
5
GASOLINE
When using gasoline, always use fresh, clean,
unleaded fuel. This engine is certifi ed to operate on
unleaded gasoline with a minimum octane rating of
87 or higher. Gasoline containing no more than 10%
ethanol is acceptable.
CAUTION: EQUIPMENT DAMAGE
Do not use unapproved gasolines, such as E15 or
E85. Do not mix oil in the gasoline. Use of unapproved fuels will damage the engine components and
void the engine warranty.
Use of fuels with content of ethanol greater than
shown above may cause starting and/or performance
problems. Always ensure that the fuel is clean and
free of all impurities.
WARNING: FIRE DANGER
Gasoline and its fumes are VERY explosive when
proper precautions are not taken.
The fuel source should be as close as possible to
the outdoor operating location. This will reduce the
installation cost of fuel runs. Connect the fuel supply
line to the inlet of the fuel demand regulator on the
unit using a locally approved fl exible fuel line (see
table for recommended line size). The pressure
supplied to the demand regulator must be FOUR
TO SIX OUNCES or 7 to 11 INCHES W.C. (water
column). The primary regulator at the fuel supply
must be capable of delivering the proper volume of
fuel at this pressure.
Have your local fuel supplier install a protected fuel
connection at the outside operating location. They
should also install a lockable fuel shut off valve at the
connection point. An approved fl exible fuel line must
be installed between the engine generator set and
the supply line.
DANGER: FIRE - PERSONAL INJURY -
The LP/NG fuel supply line must always be shut off
when the engine is not running. Failure to do so may
allow fuel to leak at the unit.
Never use gasoline that has been stored for an extended period of time as the fuel will lose its volatile
properties and you will be left with varnish residue.
The varnish like substance will clog the carburetor
and will not burn properly.
The use of fuel additives, such as STA-BIL, or an
equivalent will minimize the formation of fuel gum
deposits. If a unit has been out of operation for an
extended period of time, it is best to drain old fuel
from the engine and replace with fresh fuel before
attempting to start.
See the engine manual for special instruction for
operating this unit at over 5000 feet
LP/NG FUEL INSTALLATION
The information in this instruction is offered to assist
you in providing the proper vapor fuel supply for your
engine. This information is only provided to advise
you of the engine’s requirements and the decisions
you must make. In no case should this information be
interpreted to confl ict with any local, state or national
code. If in doubt, always follow local codes.
DANGER: FIRE - PERSONAL INJURY -
All fuel lines must be installed by a qualifi ed fuel
supplier.
INSTALLING THE FUEL LINE
DANGER: PERSONAL INJURY
Units that are intended to be run unattended
MUST have an electric fuel solenoid installed. This
solenoid MUST be wired to AUTOMATICALLY turn off
the fuel whenever the engine stops.
Unit location will determine the size of fuel line that
is required to supply the engine with a constant fuel
pressure. Refer to the tables below for fuel line size,
and recommended tank size. For distances of 100
feet and over, a two regulator fuel system is recommended. This system consisting of a primary 10-15#
regulator at the tank and a 6 ounce secondary regulator installed about 10 feet from the generator. You
need to run a 3/4 inch line or larger from the secondary regulator to the engine-generator set. When a
two (2) regulator fuel system is used, a fuel line size
of 3/8 inch is generally adequate for distances up to
300 feet. The line size from the table below applies
to the distance from the second regulator to the
demand regulator. A positive fuel shut-off device
must be installed in the fuel line close to the
engine generator set. This manual shut-off valve is
require by code even if the 12 volt fuel solenoid kit is
installed. This optional 12 volt DC valve is available
through your local Winco dealer and can be used to
shut the fuel off during normal periods of operation
with-out having to shut off the manual valve.
3240-10
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60706-236
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