Page 1
HPS12000HE/F
INSTALLATION AND
OPERATORS MANUAL
TRI-FUEL GENERATOR
Page 2
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
3240-10
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60706-236
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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
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Page 4
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
Page 5
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
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Page 6
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
Page 7
The fuel line used to connect the supply line to the
demand regulator must be a locally approved fl exible
fuel line. Products used will vary in different regions
depending on availability and local codes. Consult
with your local fuel supplier to ensure complete compliance with ALL codes.
1. Remove the plastic cover plug from the demand
regulator.
2. Connect the fl ex fuel line to the demand regulator
or the optional fuel solenoid..
DANGER: PERSONAL INJURY
Do not use galvanized pipe in the fuel line runs.
The galvanized coating will become eroded and
fl ake off, causing possible obstruction or damage
to the regulator or fuel valve. The obstruction could
cause an inoperative engine or an explosive fuel
leak.
Size of pipe required for generators operating on
natural gas/LP gas.
Length of Fuel Line* Fuel Line Size
less than 25 feet 3/4 inch black pipe
25 to 100 feet 1 inch black pipe
over 100 feet not recommended**
*allow an additional 3 feet for each standard elbow.
Do not use ‘street ells’ (restrictive)
** Consult factory for fuel runs over 100 feet.
DANGER! - FIRE - PERSONAL INJURY -
Be careful when sealing gas joints. Excessive
sealing compound can be drawn into the solenoid,
regulator or carburetor causing an engine malfunction or dangerous fuel leak.
Reference numbers 1 through 3 in the diagrams
above are system parts supplied by customer.
Reference number 4 is the engine generator set.
Below is a table of the fuel pressure reading at each
reference in the system.
Fuel Pressure Table
Single Regulator (L.P. Vapor only)
134
UNIT OFF TANKPSI 7-11 in 7-11 in
4-6 oz 4-6 oz
STARTING TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
FULL LOAD TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
FUEL CONSUMPTION (Full Load)
Gasoline 1.67 Gal/HR
LP Vapor 2.2 Gal/HR 200,932 BTU/HR
Natural Gas 200 cu ft/hr 200,000 BTU/HR
FUEL PRESSURE
Correct fuel pressure cannot be stressed enough.
The most common cause for inoperative systems is
an inadequate or incorrect fuel pressure. Power and
performance of the engine is in direct relation to the
correctness of the fuel system. Shown below is a
diagram of a typical L.P. or N.G. installation.
3240-10 60706-236
Two (2) Regulator System (L.P. Vapor only)
1234
UNIT OFF TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
STARTING TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
FULL LOAD TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
7
Page 8
Natural Gas
2 3 4
UNIT OFF LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
STARTING LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
FULL LOAD LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
CHANGING FUEL TYPES
These engine generator sets are designed to run
on three different fuels; gasoline, natural gas or LP
vapor. They may be easily changed from one fuel to
another.
FROM GASOLINE TO LP/NG
1. With the engine running turn off the gasoline
fuel valve.
2. Run the engine until it runs out of fuel.
3. Remove the plastic insert from the demand
regulator.
4. Install a locally approved fl exible fuel line.
5. Connect the LP/NG vapor fuel line to the fl ex-
ible fuel line. You can’t connect the black iron
pipe dir
6. All three units have two different hose fi ttings
on the top of the demand regulator. One is for
LP and one is for Natural Gas. Make sure the
hose is attached to the proper fi tting. See the
picture below.
7. Turn on the vapor fuel.
8. Start the engine.
9 . Apply the load to the generator.
Remember that whichever fuel delivery system or
type of vapor fuel used, the fuel pressure at the
demand regulator installed on the engine generator
must be between 4 and 6 oz. (7-11 inches of water
column). Any lower pressure and the unit will starve
for fuel under load. Any higher and the unit will ‘fl ood’
when attempting to start.
LP TANK SIZING
The tank sizes shown below are the smallest recommended tank sizes based on the outside temperature.
Once above this minimum acceptable size, the size of
L.P. tank used will generally depend on how long you
want the unit to run without refi lling. Keep in mind
the colder it gets the slower L.P. will vaporize. This
is the reason for the larger tanks at low temperature.
Minimum sizing is not based on running time.
Temp f. 60 deg 30 deg 0 deg -20 deg
150 gal 250 gal 500 gal 1000 gal
FROM LP/NG TO GASOLINE
1. With the engine running turn off the LP/NG
fuel supply.
2. Run the engine until it runs out of fuel.
3. Remove the fl exible fuel line from the demand
regulator.
4. Reinstall the plastic insert in the regulator.
5. Check to be sure the gasoline fuel valve is off.
6. Fill the gasoline fuel tank.
7. Turn on the gasoline fuel valve.
8. Start the engine.
3240-10
If the optional FUEL SOLENOID kit has been in
stalled on the unit all vapor fuel connection will be
made at the 12 volt gas valve.
8
60706-236
Page 9
BATTERY INSTALLATION
WARNING: PERSONAL INJURY
This engine generator set is shipped with a battery tie
down kit for customer installation. This kit consists of
a battery tie down and hardware for installation of the
customer supplied battery on the unit.
This engine generator set is designed for electric start
only, you will need to purchase and install a battery to
operate it. .
A 12-volt battery, BCI group U1 rated at 300 CCA
or larger is recommended for this electric start engine
generator set. Follow the battery manufacturers recommendations for servicing and charging prior to use.
Connect the battery to the electric start system using
the cables provided.
Lead acid batteries produce explosive hydrogen gas when charging. Keep sparks, fl ames, and
burning cigarettes away from the battery. Ventilate
the area when charging or using the battery in an
enclosed space. Lead acid batteries contain sulfuric
acid, which causes severe burns. If acid contacts
eyes, skin or clothing, fl ush well with water. For con-
tact with eyes, get immediate medical attention.
BATTERY CHARGING
Units equipped with electric start have a small fl y-
wheel charger built into the engine fl ywheel assembly
for recharging the starting battery. This fl ywheel
charger generates a small AC current that passes
through a diode assembly to produce a DC charging current of about 1 to 3 AMPS. This circuit is not
designed to be used as a battery charging circuit to
recharge dead batteries.
OIL ALERT SYSTEM
This WINCO generator is equipped with a low oil
shutdown system. This Honda engine uses an fl oat
switch mounted inside the engine. If the oil level
drops below a certain point the low oil module on the
engine will shut it down. This low oil warning system
will automatically stop the engine before the oil level
reaches a critical danger point. This feature is designed to prevent costly repairs and downtime.
CAUTION: EQUIPMENT DAMAGE
CAUTION: EQUIPMENT DAMAGE
These electric start engines are NEGATIVE
GROUND. Use extreme caution when connecting the
battery. Connect the NEGATIVE battery terminal to
GROUND. Connecting the positive battery terminal to
ground will damage the engines charging circuit.
For your safety always connect the positive battery
cable to the “bat+” terminal fi rst. Then connect the
negative battery cable to the “bat-” terminal. Make
sure all connections are clean and tight. Reverse the
sequence when disconnecting, disconnect the negative cable fi rst. These engines produce enough direct
current to keep a battery charged under normal operating conditions, but were not intended to be used as
a battery charger.
3240-10 60706-236
Allowing the engine to shutdown repeatedly on
low oil level may cause excessive wear which can be
cumulative.
STANDARD DOLLY KIT
An 4-wheel dolly kit come with this generator. The
dolly kit comes with instructions and parts list. After
installing the dolly kit, fi le the instructions and parts
list in the back of this manual for future reference.
OPTIONAL FUEL SOLENOID KIT
An optional 12 volt DC fuel solenoid kit is available
for this generator. This solenoid kit will automatically
shut off the fuel supply should the engine stop for any
reason will operating preventing fuel leaks. This kit
is recommended if you are going to be operating the
generator unattended.
9
Page 10
INITIAL START UP
MIN.
OPEN
CLOSED
ON
O
MIN.
MIN.
MIN.
MIN.
OON
OPEN
CLOSED
O
OOPPEEN
CCLLOOSSEED
The throttle control on these generators is preset and
locked to operate at 3600 RPM (nominal) with no
load speed set at 3690 RPM. Only a trained service
technician should be allowed to adjust this speed
setting.
4. Turn the engine switch to the “on” position
urn the engine switch to
he ON position.
ONN
NOTICE: ENGINE START LOCKOUT
This unit will not start if it is low on oil. The lu-
bricating oil level must be at the full mark before the
engine will start and run.
BASIC OPERATION
This engine is electric start only. The batteries must
be maintained in good condition to prevent hard starting or damage to the engine mounted starter.
GASOLINE STARTING
1. Check oil level, refi ll as needed
ENGINE
N
SWITCH
5.. Operating the starter. Rotate the key switch
briefl y to the START position. The starter life is
improved by using shorter starting cycles with
time to cool off between cranking cycles. Do
not operate the starter more than 5 seconds and
wait at least 10 seconds before operating the
starter again, Repeat cycle if necessary.
6. When the engine starts, release the key
switch, allowing it to return to the “on” position.
ONN
START
ENGINE
SWITCH
A
2. Turn on the fuel supply. Ref “A” Lever pointing
up is on, lever pointing down is off.
3. Pull the choke out to the full “closed” position. A
warm engine will require less choking than a
cold engine.
CHOKE KNOB
D
N
7. Gradually push the choke to the open position as
the engine warms up..
6. The engine should promptly come up to
operating speed.
CAUTION: EQUIPMENT DAMAGE
Never permit the choke to remain on after the
engine has run for a short time. It is not necessary
to choke the engine when it is warm. Avoid overchoking.
3240-10
10
60706-236
Page 11
LP/NG STARTING
MIN.
MIN.
OON
OPEN
CLOSED
O
MIN.
OPEN
CLOSED
ON
O
MIN.
MIN.
1. Check oil level, refi ll as needed.
2. Turn on the LP/NG fuel supply
3. NEVER USE THE CHOKE WHEN OPERATING
ON LP/NG..
4. Turn the engine switch to the “on” position
urn the engine switch to
he ON position.
ONN
ENGINE
N
5.. Operating the starter. Rotate the key switch
briefl y to the START position. The starter life is
improved by using shorter starting cycles with
time to cool off between cranking cycles. Do
not operate the starter more than 5 seconds and
wait at least 10 seconds before operating the
starter again, Repeat cycle if necessary.
6. When the engine starts, release the key
switch, allowing it to return to the “on” position.
SWITCH
2. Hot weather
a. Use the proper oil for the temperature
expected.
b. Use only summer blended gasoline. Using
gasoline left over from winter may cause the
unit to vapor lock.
STOPPING AND STORAGE
1. Move the key switch to the “OFF” position.
2. Turn off the fuel supply valve.
3. Before extended storage (over 30 days) certain
precautions must be taken to ensure the fuel
doesn’t deteriorate and clog the fuel system.
Note: The use of a fuel additive, such a STA-BIL or
equivalent will minimize the formation of gum deposits during storage. The additive may be added to
gasoline in the engines fuel tank or to gasoline in a
storage container.
a. Add the fuel stabilizer to the fuel in the tank
and run the unit for 2 minutes to circulate the
stabilizer throughout the fuel system.
b. If you choose to remove the remaining fuel
from the fuel tank, it must be drained into an
approved container.
c. Start the engine and allow it to run until all
the fuel in the carburetor and the fuel lines
has been used up and the engine stops.
ONN
START
ENGINE
SWITCH
7. The engine should promptly come up to
operating speed.
STARTING HINTS
1. Cold weather
a. Use the proper oil for the temperature
expected.
b. Use fresh winter grade fuel. Winter grade
gasoline is blended to improve starting. Do
not use summer grade gasoline.
Note: Running the engine to use up the fuel in the
lines and carburetor will still leave a small amount of
fuel in the carburetor. It is best for extended storage
to treat the fuel before draining.
d. While the engine is warm, drain the oil and
refi ll with fresh oil.
e. Clean dirt and chaff from cylinder, cylinder
head fi ns, blower housing, screen and
muffl er areas.
f. Store in a clean and dry area.
OPERATING SPEED
The engine-generator must be run at the correct
speed in order to produce the proper electrical voltage and frequency.
CAUTION: EQUIPMENT DAMAGE
The output voltage should be checked to ensure
the generator is working properly prior to connecting
a load to the generator. Failure to do so could result
in damage to equipment plugged into the unit and
possible injury to the individual.
3240-10 60706-236
11
Page 12
All engines have a tendency to slow down when a
load is applied. When the electrical load is connected
to the generator, the engine is more heavily loaded,
and as a result the speed drops slightly. This slight
decrease in speed, together with the voltage drop
within the generator itself, results in a slightly lower
voltage when the generator is loaded to its full capacity than when running no load. The slight variation
in speed also affects the frequency of the output
current. This frequency variation has no appreciable
effect in the operation of motors, lights and most appliances. However, electronic equipment and clocks
will be affected if correct RPM is not maintained. See
Load vs. Output chart.
Although individual units and models vary slightly, the
normal voltage and frequency of the engine-generator described in this manual are approximately as
follows, under varying loads:
CAUTION: EQUIPMENT DAMAGE
SPEED ADJUSTMENTS SHOULD ONLY BE
MADE BY A QUALIFIED SERVICE TECH.
Whenever making any speed adjustments, check
the unit with a voltmeter and a frequency meter
or tachometer and be sure the voltage and speed
are correct.
Lower voltage may damage both the generator and
any load connected to it. Running the engine at excessively high speeds results in high voltage, which
may signifi cantly shorten the life of appliances being
used.
Output voltage should be checked periodically to
ensure continued proper operation of the generating plant and appliances. If the generator is not
equipped with a voltmeter, it can be checked with a
portable meter.
LOAD VS. OUTPUT
Generator
Load
None 3690 61.5 125V
Half 3600 60.0 120V
Full 3510 58.5 115V
The speed of the engine was carefully adjusted at
the factory so that the generator produces the proper
voltage and frequency. For normal usage, the speed
setting should not be changed. If the generator
is being run continuously on a very light load, it is
often advisable to lower the operating speed slightly.
Reference “D” below is the speed adjustment for this
engine.
Speed
(RPM)
Frequency
(Hz)
Voltage
D
CONNECTING THE LOADS
APPLYING THE LOADS
Allow the engine to warm up for two or three minutes
before applying any load. This will allow the engine to
reach normal operating temperature and oil to circulate throughout the engine. A short warm-up time will
permit the engine to work more effi ciently when the
load is applied and will reduce the wear in the engine,
extending its life.
Receptacles have been provided to allow loads to
be connected to the generator. The loads should be
added one at a time. If a large motor is being started;
or multiple motors are being started, they should be
started individually and the largest should be started
fi rst.
CAUTION: EQUIPMENT OVERLOAD
Keep the generator load within the generator and
receptacle nameplate rating. Overloading may cause
damage to the generator and/or the loads .
3240-10
Most electric tools and appliances will have the voltage and amperage requirements on their individual
nameplates. When in doubt, consult the manufacturer
or a local electrician. The nameplate amperage rating
for electric motors can be misleading. See “Starting
Electric Motors” in Unit Capabilities (page 4).
These engine-generator sets are inherently self regulating based on engine speed. The engine governor
will automatically adjust itself to the load. No harm
to the generator will result if it is operated with no
load connected. Proper utilization of the receptacles
located on the control panel is necessary to prevent
damage to either the receptacles or the generator.
12
60706-236
Page 13
The generator is a limited source of electrical power,
therefore, pay special attention to the receptacle
and generator ratings. The nameplate rating can be
obtained through a single receptacle as long as the
receptacle amperage rating is not exceeded.
GROUNDING
All units must be grounded. Drive a 3/4 or 1” copper pipe or rod into the ground close to the enginegenerator set. The pipe must penetrate moist earth.
Connect an approved ground clamp to the pipe.
Run a no. 10 Awg wire from clamp to the generator
ground lug on the receptacle panel. Do not connect to
a water pipe or to a ground used by a radio system.
The engine-generators covered in this manual were
designed primarily for portable use. If you are connecting into a building wiring system that is already
grounded using the 14-60 4 wire plug, you do not
have to ground the unit.
WARNING: PERSONAL DANGER
DO NOT OPERATE THIS GENERATOR INDOORS.
The unit should be stored in a warm dry location. During a power outage, move the unit outdoors to a fl at
dry location such as a driveway or sidewalk. Never
attempt to operate this generator in direct rain
or snow. It must be protected during inclement
weather.
WIRING
Plug your tools such as drills, saws, blowers, sump
pump and other items to be powered directly into
the generator receptacles. Before plugging in all the
tools and cord sets, recheck the rating of the generator set. Be sure it can handle the intended load and
is compatible with the voltage, phase, and current ratings. ‘Hard Wiring’ this unit directly into a home or a
temporary construction site electrical system is NOT
A SIMPLE DO-IT-YOURSELF JOB. For your safety,
all wiring must be done by a qualifi ed electrician and
conform to the National Electric Code and comply
with all state and local codes and regulations. Check
with local authorities before proceeding.
WARNING: PERSONAL DANGER
A fully isolated, double pole double throw manual
transfer switch must be installed any time a generator
is being connected to an existing distribution system.
note that the 4-wire 240 volt receptacle on these units
are designed to power both 120 or 240 volt loads.
The plug for this receptacle can be wired for either
120 volt, 240 volt, or a combination of 120 and 240
volt loads depending on how the plug is wired. A full
power 4-wire receptacle (two hot, one ground, and
one neutral) has been provided on the control panel
for use in temporary power applications requiring
120/240 volt power. Consult a licensed electrician
for wiring the TemPower plug and connecting it as
temporary service.
To connect these units directly to an un-powered,
isolated construction site TemPower panel, have
your electrician connect to the control panel using a
120/240 volt, 4-wire plug (14-60P).
2. If the generator set is be connected to an existing
distribution system, a fully isolated manual transfer switch must be installed. The transfer switch
prevents damage to the generator and other circuit
components if main line power is restored while the
generator is connected. Installing a transfer switch
also permits the use of normal fusing.
3. Many homes and construction sites are wired
for at least 60 to 100 Amp entrance service, much
greater than the capacity of this portable generator. When installing the generator at these sites, a
secondary emergency distribution panel may have to
be installed, such as the Emergency Transfer/Service
(ET/S) system available through your WINCO dealer.
The emergency distribution panel must be installed
by a licensed electrician according to all applicable
codes. The electrician will move the critical circuits
to be powered during the outage to the emergency
panel. Keep in mind only a limited amount of amperage is available from the generator set. Some circuit
breakers may still have to be turned off to prevent an
overload on the generator during the initial start up.
See the nameplate on your generator for the amperage capabilities of your unit.
CAUTION: EQUIPMENT DAMAGE
Failure to properly limit and balance the load applied to the generator will cause the generator to
produce low voltage and may damage the engine
generator set. It may also cause severe damage to
the loads connected to the generator at that time. Improper loading of the generator set constitutes abuse
and will not be covered by warranty.
1. These engine generator sets are designed for
portable use. Receptacles are provided on the
control panel to permit 120 volt portable appliances
and tools to be plugged directly into them. Please
3240-10 60706-236
13
Page 14
ENGINE CARE
If major engine service or repair is required, contact
an authorized engine service center. The manufacturer of these engines has established an excellent
world-wide engine service organization. Engine service is very likely available from a nearby authorized
dealer or distributor. Check the yellow pages of your
local telephone directory under “Engines-Gasoline”
for the closest engine repair center or ask the dealer
from whom you purchased the power plant.
b. Remove oil drain bolt at base of the engine
and drain the oil into an approved container.
c. Remove the oil fi lter and dispose of it properly.
SEAL
MAINTENANCE SCHEDULE
REGULAR SERVICE PERIOD (3)
Perform at every
indicated month or
operating hour interval,
whichever com es first.
ITEM
Engine oil
Engine oil filter
Air cleaner
Spark plug
Spark arrest er
()
applicable types
Idle speed
Valve clearance
Combustion
chamber
Fuel filter
Fuel tube
Replace the paper filter element only.
＊
Refer to the Shop Manual.
＊＊
(1)
Service more frequently when used in dusty areas.
These items should be serviced by your Honda servicing
(2)
dealer, unless you have the proper tools and are mechanically
proficient. Refer to the Honda shop manual for service
procedures.
Check level
Change
Replace
Check
Clean
Replace
Check-adjust
Replace
Clean
Check-adjust
Check-adjust
Clean
Replace
Check
Each
Use
Every 2 years (Replace if necessary) (2)
Every 6
First
Months
Month
or
or
100 Hrs
20 Hrs
Every 200 Hrs.
(1)
After every 1000 Hrs . (2)
Every
Year
or
300 Hrs
(2)
(2)
(2)
Every 2
Years
or
500 Hrs
＊
Refer
to
Page
8
8
9
9
9
10
11
＊＊
＊＊
＊＊
＊＊
＊＊
1. Change the oil after the fi rst 5 hours of operation
and yearly or 100 hours thereafter under normal operating conditions. Change engine oil every 50 hours
of operation if the engine is operated under heavy
load, or in high ambient temperatures.
a. Start the engine and warm it up, stop the engine
and remove the spark plug wire to prevent it
from accidently being started.
OIL FILLER CAP OIL LEVEL DIPSTICK
UPPER
LIMIT
LOWER
LIMIT
OIL FILTER
FILTER MOUNTING BASE OIL FILTER SOCKET
d. Before you install the new oil fi lter, clean the fi lter
mounting base and coat the seal of the new oil
fi lter will clean engine oil.
e. Install the oil fi lter by hand until the gasket
contacts the oil fi lter adapter, then tighten the oil
fi lter 1/2 to 3/4 turns.
f. Replace oil drain bolt making sure the sealing
washer is in place..
g. Remove oil cap plug and refi ll with new oil.
Refer to the table on page 5 for the proper
grade of oil based on your operating
temperature.
NOTE: This engine requires 57 to 58 ounces of oil
if it is completely drained. Use caution when refi lling
the engine as some residual oil may have remained
in the engine. Always use the dipstick when fi lling
the engine with oil to prevent overfi lling.
h. Replace fi ller cap.
i. Start the engine up and warm it up.
j. After warming up the engine, recheck the oil
level and refi ll as necessary to bring it to the
proper level. See page 5 for proper oil level.
2. Checking the Oil Level: The oil level must always be checked before the engine is started. Take
care to remove any dirt or debris from around the
oil fi ll plug before removing. Be sure the oil level is
maintained. Fill to the “FULL” mark on the dipstick.
3. Dual Element Air Filter: Clean and/or replace
foam pre-cleaner and air fi lter annually or every 100
hours. Service more often under dusty conditions.
WARNING: EQUIPMENT DAMAGE
SEALING WASHER
DRAIN BOLT
3240-10
Never start or run the engine with the air fi lter re-
moved
a. Unsnap the air cleaner cover latches and
remove cover
14
60706-236
Page 15
AIR CLEANER COVER LATCH
AIR CLEANER
FOAM FILTER
ELEMENT
AIR CHAMBER
PACKING
COVER
WING NUT
PAPER FILTER
ELEMENT
AIR CLEANER CASE
b. Remove the wing nut.
c. Remove the paper fi lter element and the foam
element from the air cleaner case.
d. Remove the foam fi lter elements from the paper
fi lter element.
e, Inspect both fi lter elements, and replace them
if they are damaged. Always replace the paper
fi lter element at the scheduled interval.
See page 14.
f. To loosen debris, gently tap the air fi lter on a
hard surface. If the air fi lter is excessively dirty
replace with a new fi lter. You can use pres-
surized air (not to exceed 30 psi.) to clean the
fi lter. Always blow the compressed air from
inside to the outside.
g. Wash the foam fi lter element in liquid detergent
and water. Then allow it to thoroughly air dry.
Dip the foam fi lter element in clean engine oil
and squeeze out all the excess before rein
stalling it. The engine will smoke when started if
too much oil is left in the foam.
h. Clean the dirt from the inside of the air cleaner
body and cover. Reinstall the air fi lter in
housing making sure the packing is in place
beneath the fi lter element. Tighten the wing nut
securely.
I Install and secure the cover.
4. Spark Plug: Replace annually or every 300 hours
of operation. Always replace spark plugs with the
original manufacturers recommendations, and check
gap before installing. Spark plug gap is 0.030”. Poor
spark will also occur if spark plug wire does not fi t
fi rmly on spark plug. If this happens, reform the terminal to fi t fi rmly on spark plug tip.
5. Carbon Canister: Designed to collect, store, and
dispose of fuel vapors created in the fuel tank / fuel
system. The canister should last the life of the unit as
long as it stays dry.
GENERATOR CARE
Proper care and maintenance of the generator is
necessary to ensure a long trouble free life.
1. Exercising The Generator - The generator
should be operated every three to four weeks. It
should be operated for a period of time suffi cient to
warm the unit up and to dry out any moisture that has
accumulated in the windings. If left, this moisture can
cause corrosion in the winding. Frequent operation
of the engine generator set will also ensure that the
set is operating properly should it be needed in an
emergency.
2. Generator Maintenance - Any major generator service, including the installation or replacement
of parts, should be performed only by a qualifi ed
electrical service technician. USE ONLY FACTORY
APPROVED REPAIR PARTS.
a. Bearing - The bearing used in these generators
is a heavy duty double sealed ball bearing.
They require no maintenance or lubrication.
b. Receptacles - Quality receptacles have been
utilized. If a receptacle should become cracked
or otherwise damaged, replace it. Using dam-
aged or cracked receptacles can be both dan gerous to the operator and destructive to the
equipment.
CLEANING
Remove dirt and debris with a cloth or brush. DO
NOT use high pressure spray to clean either the
engine or the generator. This high pressure spray
could contaminate the fuel system and the generator
components.
1. Keep the air inlet screen on both the engine and
generator free of any dirt or debris to ensure proper
cooling. At least yearly, remove the blower housing
on the engine and clean the chaff and dirt out of the
engine cooling fi ns and fl ywheel. Clean more often
if necessary. Failure to keep these areas clean may
cause overheating and permanent damage to the
unit.
2. Periodically clean muffl er area to remove all grass,
dirt and combustible debris to prevent a fi re.
3. On engine muffl ers equipped with spark arresters,
the spark arrester must be removed every 50 hours
for cleaning and inspection. Replace if damaged
3240-10 60706-236
15
Page 16
TROUBLESHOOTING
PROBLEM (SYMPTOMS) POSSIBLE
CAUSES
———————————————————————
Won’t Start *Low Oil Level.
*Fouled spark plug.
*Out of fuel.
*Start switch in Off position.
*Fuel valve turn off.
*Plugged fuel fi lter.
*Blown fuse in key switch
———————————————————————
Voltage too low *Engine speed is too low.
*Generator overloaded.
*Defective stator.
*Defective rotor (fi eld).
*Defective Capacitor.
———————————————————————
Circuit Breaker *Defective load.
Trips *Defective receptacle.
*Excessive Load.
———————————————————————
Voltage too high *Engine speed is too high.
———————————————————————
Generator *Overloaded.
overheating *Insuffi cient ventilation.
———————————————————————
No output voltage *Short in load (disconnect).
*Tripped or defective circuit
breaker.
*Broken or loose wire.
*Defective receptacle.
*No residual magnetism
(in generator).
*Defective stator.
*Defective rotor (fi eld).
*Shorted capacitor.
*Shorted diodes on rotor.
*GFCI Receptacle tripped.
———————————————————————
GENERATOR SPECIFICA TIONS
Generator manufacturer MECC Alte Spa
Generator model number S20FS-160A
Part number 351836-1
Rotor resistance 6.57 Ohms
Stator resistance 0.124 Ohms
Cap winding resistance 0.60 Ohms
Capacitors 31.5 mF
Capacitor part number 300323-112
ENGINE SPECIFICATIONS
Engine manufacturer HONDA
Engine model number GX630RH
Type VXE1 NH1
Code GCAMH
Spark plugs ZFR5F (NGK)
Air fi lter 17210-Z6L-010
Air fi lter pre-cleaner 17218-Z6L-000
Oil fi lter 15400-PLM-A01
Fuel Filter 16910-Z6L-003
Spark plug gap 0.030 in
Intake valve clearance 0.006 - 0.010 in
Exhaust valve clearance 0.010 - 0.012 in
Oil capacity 57 - 58 oz.
3240-10
16
60706-236
Page 17
CONTROL PANEL WIRING DIAGRAM
3240-10 60706-236
17
Page 18
24 MONTH LIMITED WARRANTY
WINCO, Inc. warrants to the original purchaser for 24 months that goods manufactured or supplied by it will
be free from defects in workmanship and material, provided such goods are installed, operated and maintained in accordance with WINCO’s written instructions.
* NOTE: Units used in prime power are warranted for 120 day Units that are resold are not covered under
this warranty. Any further warranty whether expressed or implied, rest solely with the reseller.
WINCO, Inc. warrants to the ultimate purchaser and each subsequent purchaser that the evaporative emission control system is designed, built, and equipped so as to conform at the time of original sale to the then
current evaporative emission requirements. In addition it is free from defects in materials and workmanship
that may keep it from meeting these requirements. This evaporative emission control system is warranted
for two years. If an evaporative emission related part on your equipment is defective, the part will be repaired or replaced by WINCO Inc.
WINCO’s sole liability, and Purchaser’s sole remedy for a failure under this warranty, shall be limited to
the repair of the product. At WINCO’s option, material found to be defective in material or workmanship
under normal use and service will be repaired or replaced. For warranty service, return the product within
24 months from the date of purchase, transportation charges prepaid, to your nearest WINCO Authorized
Service Center or to WINCO Inc. at Le Center, Minnesota.
THERE IS NO OTHER EXPRESS WARRANTY.
To the extent permitted by law, any and all warranties, including those of merchantability and fi tness for a
particular purpose, are limited to 24 months from date of purchase. In no event is WINCO liable for incidental or consequential damages.
Note: Some states do not allow limitation on the duration of implied warranty and some states do not allow
the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply in
every instance. This warranty gives you specifi c legal rights which may vary from state to state.
WINCO reserves the right to change or improve it products without incurring any obligations to make such
changes or improvements on products purchased previously.
EXCLUSIONS:
WINCO does not warrant Engines. Engines are covered exclusively by the warranties of their respective
manufacturers.
WINCO does not warrant Batteries, or Other Component Parts that are warranted by their respective
manufacturers.
WINCO does not warrant modifi cations or alterations which were not made by WINCO Inc.
WINCO does not warrant products which have been subjected to misuse and/or negligence or have been
involved in an accident.
This warranty does not include travel time, mileage or labor for removal or reinstallation of a WINCO prod-
uct from its application.
3240-10
18
60706-236
Page 19
CALIFORNIA EVAPORATIVE EMISSION CONTROL
WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board is pleased to explain the evaporative emission control system’s warranty
on your model 2013 or later generator. In California, new equipment that uses small off-road engines must
be designed, built, and equipped to meet the State’s stringent anti-smog standards. WINCO must warrant
the evaporative emission control system on your generator for the period listed below provided there has
been no abuse, neglect or improper maintenance of your equipment.
Your evaporative emission control system may include parts such as: carburetor, fuel tanks, fuel lines, fuel
caps, valves, canisters, fi lters, vapor hoses, clamps, connectors and other associated components.
MANUFACTURER’S WARRANTY COVERAGE
The evaporative emission control system is warranted for two years. If any evaporative emission related
parts on your equipment are defective, the parts will be repaired or replaced by WINCO.
OWNER’S WARRANTY RESPONSIBILITIES:
As the generator owner, you are responsible for performance of the required maintenance listed in your
owner’s manuals. WINCO recommends that you retain all receipts covering maintenance on your generator,
but WINCO cannot deny warranty solely for lack of receipts.
As the generator owner, you should be aware that WINCO may deny you warranty coverage if your generator or a part has failed due to abuse, neglect, or improper maintenance or unapproved modifi cations.
You are responsible for presenting your generator to a WINCO service center as soon as the problem exists.
The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you
have a question regarding your warranty coverage, you should contact WINCO at 507-357-6831.
3240-10 60706-236
19
Page 20
WINCO INC.
225 S. CORDOVA AVE.
LE CENTER, MN 56057
507-357-6821
SERVICE DEPT.
507-357-6831
www.wincogen.com
3240-10
20
60706-236
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