Westinghouse iPro4200 - Inverter Generator Manual
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Westinghouse iPro4200 - Inverter Generator Manual

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Table of Contents
Contents
Westinghouse iPro4200 - Inverter Generator Manual

TECHNICAL SPECIFICATIONS

Model Number Running Watts Peak Watts Fuel Tank Size (L/G) Rated Speed (RPM) Ignition Type Spark plug Engine Disp (cc) Stroke X Bore Oil Capacity (L) Oil Type THD
iPro4200 3500 4200 15L/4G 3600 CDI F7TC 212cc 55X70 .6 L 10W30 < 3%

NOTICE
This generator is NOT equipped with altitude carburetor modification. Even with a carburetor modification, engine horsepower will decrease about 3.5% for each 300 meter (1,000 foot) increase in altitude. The effect of altitude on horsepower will be greater if no carburetor modification is made. A decrease in engine horsepower will decrease the power output of the generator. Contact our service team to order altitude kits. See "BEFORE STARTING THE UNIT" for altitude kit number.

HAVE QUESTIONS?
Email us at service@wpowereq.com or call 1-855-944-3571

IMPORTANT: KEEP YOUR PURCHASE RECEIPT TO ENSURE TROUBLE-FREE WARRANTY COVERAGE.

PRODUCT REGISTRATION

To ensure trouble-free warranty coverage, it is important you register your Westinghouse inverter.
You can register your generator by either:

  1. Filling in the product registration form below and mailing to:
    Product Registration
    MWE Investments LLC
    777 Manor Park Drive
    Columbus, Ohio 43228
  2. Registering your product Online at www.westinghouseportablepower.com/register-your-product/
    To register your generator you will need to locate the following information:
    Model info and serial number location

SAFETY

SAFETY DEFINITIONS

The words DANGER, WARNING, CAUTION and NOTICE are used throughout this manual to highlight important information. Be certain that the meanings of these alerts are known to all who work on or near the equipment.

This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alerts symbol.

DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE
Indicates a situation which can cause damage to the generator, personal property and/or the environment, or cause the equipment to operate improperly.

NOTE: Indicates a procedure, practice or condition that should be followed in order for the generator to function in the manner intended.

SAFETY SYMBOL DEFINITIONS

SAFETY SYMBOL DEFINITIONS

GENERAL SAFETY RULES

California Proposition 65 Warning
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

California Proposition 65 Warning
Certain components in this product and its related accessories contain chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling.

DANGER
Never use the inverter in a location that is wet or damp. Never expose the inverter to rain, snow, water spray or standing water while in use. Protect the inverter from all hazardous weather conditions. Moisture or ice can cause a short circuit or other malfunction in the electrical circuit.


Never operate the inverter in an enclosed area. Engine exhaust contains carbon monoxide. Only operate the inverter outside and away from windows, doors and vents.

WARNING
Voltage produced by the inverter could result in death or serious injury.

  • Never operate the inverter in rain or a flood plain unless proper precautions are taken to avoid being subject to rain or a flood.
  • Never use worn or damaged extension cords.
  • Always have a licensed electrician connect the inverter to the utility circuit.
  • Never touch an operating inverter if the inverter is wet or if you have wet hands.
  • Never operate the inverter in highly conductive areas such as around metal decking or steel works.
  • Always use grounded extension cords. Always use three-wire or double-insulated power tools.
  • Never touch live terminals or bare wires while the inverter is operating.
  • Be sure the inverter is properly grounded before operating.

WARNING
Gasoline and gasoline vapors are extremely flammable and explosive under certain conditions.

  • Always refuel the generator outdoors, in a well-ventilated area.
  • Never remove the fuel cap with the engine running.
  • Never refuel the inverter while the engine is running. Always turn engine off and allow the generator to cool before refueling.
  • Only fill fuel tank with gasoline.
  • Keep sparks, open flames or other form of ignition (such as match, cigarette, static electric source) away when refueling.
  • Never overfill the fuel tank. Leave room for fuel to expand. Overfilling the fuel tank can result in a sudden overflow of gasoline and result in spilled gasoline coming in contact with HOT surfaces. Spilled fuel can ignite. If fuel is spilled on the inverter, wipe up any spills immediately. Dispose of rag properly. Allow area of spilled fuel to dry before operating the inverter.
  • Wear eye protection while refueling.
  • Never use gasoline as a cleaning agent.
  • Store any containers containing gasoline in a well-ventilated area, away from any combustibles or source of ignition.
  • Check for fuel leaks after refueling. Never operate the engine if a fuel leak is discovered.

WARNING
Never operate the inverter if powered items overheat, electrical output drops, there is sparking, flames or smoke coming from the inverter, or if the receptacles are damaged.


Never use the inverter to power medical support equipment.


Always remove any tools or other service equipment used during maintenance from the inverter before operating.

NOTICE
Never modify the inverter.
Never operate the inverter if it vibrates at high levels, if engine speed changes greatly or if the engine misfires often.
Always disconnect tools or appliances from the inverter before starting.

SAFETY LABELS AND DECALS

SAFETY LABELS AND DECALS - Part 1
SAFETY LABELS AND DECALS - Part 2

UNPACKING

CAUTION
Always have assistance when lifting the generator. The generator is heavy; lifting it could cause bodily harm.
Avoid cutting on or near staples to prevent personal injury.

Tools required – box cutter or similar device.

  1. Carefully cut the packing tape on top of the carton.
  2. Fold back top flaps to reveal the manual.
  3. Carefully cut two sides of the carton to remove the generator.

WHAT COMES IN THE BOX
Owners manual
Quick Start Guide/Maintenance Schedule
.6 Liter Bottle of SAE 10W30 Oil (1)
Spark Plug Socket Wrench (1)
Funnel (1)

FEATURES

BASIC PRODUCT FEATURES

FEATURES - BASIC PRODUCT FEATURES

  1. Open frame inverter design: Quiet, fuel efficient power provided by a digital inverter built in a rugged open frame design.
  2. Recoil Handle: Pull to start the engine.
  3. Choke lever: Pull to choke and push in to run once the engine has started.
  4. Muffler and Spark Arrestor: Avoid contact until the engine is cooled down. The spark arrestor prevents sparks from exiting the muffler. It must be removed for servicing.
  5. Oil Fill Plug/Dipstick: Must be removed to add and check oil.
  6. Air-filter Access Cover: Gain access to airfilter for maintenance.
  7. Fuel Gauge: Indicates fuel level.

CONTROL PANEL FEATURES

FEATURES - CONTROL PANEL FEATURES

  1. Pull Cord Starter: Pull to start engine.
  2. Choke Lever: Pull to set choke before starting and push in to run once the engine has started.
  3. Engine Control Switch: Switch to "Stop" to stop the engine. Switch to "Run" before starting engine.
  4. Indicator Lights:
    Low Oil LED:     Indicates low oil level.
    Overload LED: Indicates that the inverter is overloaded.
    Output Ready LED: Indicates the inverter is ready to be used.
  5. Efficiency Mode Switch: When turned to the ON position, the engine will sense the load needed and run at a slower RPM to save fuel.
  6. Reset Breaker: If the inverter is overloaded, the reset breaker will trip. The engine will continue to run, but there will be no electrical power output from the inverter. Unplug the devices and reduce the load. Push in the reset breaker to reset it.
  7. USB Duplex: 5V DC that come in 1 amps and 2.1 amps.
  8. 120-Volt, 20-Amp Duplex GFCI Outlets (NEMA 5-20R): Each outlet is capable of carrying a maximum of 20 amps on a single receptacle or a combination of both receptacles.
  9. Hour Meter: Displays how many hours the generator has been run when under load.
  10. 20-Amp Circuit Breakers: Each circuit breaker limits the current that can be delivered through the 120-volt duplex outlets to 20amps.
  11. Ground Terminal: The ground terminal is used to ground the generator.

OPERATION

BEFORE STARTING THE UNIT


BEFORE STARTING THE INVERTER, REVIEW SAFETY SECTION.

Location Selection – Before starting the inverter, avoid exhaust and location hazards by verifying:

  • You have selected a location to operate the inverter that is outdoors and well ventilated.
  • You have selected a location with a level and solid surface on which to place the inverter.
  • You have selected a location that is at least 6 feet (1.8 m) away from any building, other equipment or combustible material.
  • If the inverter is located close to a building, make sure it is not located near any windows, doors and/ or vents.
DANGER
Using a generator indoors
CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and vents.
Avoid other generator hazards.
READ MANUAL BEFORE USE

WARNING
Always operate the inverter on a level surface. Placing the inverter on non level surfaces can cause the inverter to tip over, causing fuel and oil to spill. Spilled fuel can ignite if it comes in contact with an ignition source such as a very hot surface.

NOTICE
Only operate the inverter on a solid, level surface. Operating the inverter on a surface with loose material such as sand or grass clippings can cause debris to be ingested by the inverter that could:

  • Block cooling vents
  • Block air intake system

Weather – Never operate your inverter outdoors during rain, snow or any combination of weather conditions that could lead to moisture collecting on, in or around the generator.

Dry Surface – Always operate the inverter on a dry surface free of any moisture.

No Connected Loads – Make sure the inverter has no connected loads before starting it. To ensure there are no connected loads, unplug any electrical extension cords that are plugged into the control panel receptacles.

NOTICE
Starting the inverter with loads already applied to it could result in damage to any appliance being powered off the inverter during the brief start-up period.

Grounding the Generator – The National Electric Code (NEC), as well as many local electrical codes, may require the generator to be connected to earth ground. As the generator application has many variables that cannot be determined by the manufacturer of the generator, a licensed electrician will need to determine if a grounding rod is needed.
If a licensed electrician has determine the application requires a ground rod, make sure it is connected to earth ground by connecting the ground terminal on the control panel to earth ground using copper wire (minimum 10 AWG). Consult a qualified electrician for local grounding requirements.
Neutral Bonded: There is a permanent conduct or between the generator (stator winding) and the frame.
Consult with your local municipalities for your grounding codes.

WARNING
Be sure the inverter is properly connected to earth ground before operating.

High Altitude Operation
Engine power is reduced the higher you operate above sea level. Output will be reduced approximately 3.5% for every 1000ft of increased altitude from sea level. This is a natural occurrence and cannot be adjusted by engine. Increased exhaust emissions can also result due to increased fuel mixture. Other issues include hard starting, increased fuel consumption and spark plug fouling. Contact our service team 1-855-944-3571 for altitude part kits.
High Altitude Carburetor Kit Part Number: 140540

POWERCORD

Using Extension Cords
Westinghouse Portable Power assumes no responsibility for the content within this table. The use of this table is the responsibility of the user only. This table is intended for reference only. The results produced by using this table are not guaranteed to be correct or applicable in all situations as the type and construction of cords are highly variable. Always check with local regulations and a licensed electrician prior to installing or connecting an electrical appliance
Extension Cord Wire Gauge Size

ADDING/CHECKING ENGINE FLUIDS AND FUEL


BEFORE ADDING/CHECKING ENGINE FLUIDS AND FUEL, REVIEW SAFETY SECTION.

DANGER
Filling the fuel tank with gasoline while the inverter is running can cause gasoline to leak and come in contact with hot surfaces that can ignite the gasoline.

Before starting the inverter, always check the level of:

  • Engine oil
  • Gasoline in the fuel tank

Once the inverter is started and the engine gets warm, it is not safe to add gasoline to the fuel tank or engine oil to the engine while the engine is running or the engine and muffler are hot.

CHECKING AND/OR ADDING ENGINE OIL

WARNING
Internal pressure can build in the engine crankcase while the engine is running. Removing the oil fill plug/ dipstick while the engine is hot can cause extremely hot oil to spray out of the crankcase and can severely burn skin. Allow engine oil to cool for several minutes before removing the oil fill plug/dipstick.

The unit as shipped does not contain oil in the engine. You must add engine oil before starting the inverter for the first time. See Checking Engine Oil and Adding Engine Oil for instructions on checking engine oil level and the procedure for adding engine oil.

NOTICE
The engine does not contain engine oil as shipped. Attempting to start the engine without adding engine oil will permanently damage internal engine components.
The engine is equipped with a low oil shutdown switch. If the oil level becomes low, the engine may shut down and not start until the oil is filled to the proper level.
The owner of the inverter is responsible to ensure the proper oil level is maintained during the operation of the generator. Failure to maintain the proper oil level can result in engine damage.

ADDING GASOLINE TO THE FUEL TANK

WARNING
Never refuel the inverter while the engine is running.


Always turn the engine off and allow the inverter to cool before refueling.

CAUTION
Avoid prolonged skin contact with gasoline. Avoid prolonged breathing of gasoline vapors.

Required Gasoline – Only use gasoline that meets the following requirements:

  • Unleaded gasoline only
  • Gasoline with maximum 10% ethanol added
  • Gasoline with an 87 octane rating or higher

Filling the Fuel Tank – Follow the steps below to fill the fuel tank:

  1. Shut off the inverter.
  2. Allow the inverter to cool down so all surface areas of the muffler and engine are cool to the touch.
  3. Move the inverter to a flat surface.
  4. Clean area around the fuel cap.
  5. Remove the fuel cap by rotating counterclockwise.

NOTICE
Do not overfill the fuel tank. Spilled fuel will damage some plastic parts.

  1. Slowly add gasoline into the fuel tank. Be very careful not to overfill the tank. The gasoline level should NOT be higher than the red ring (see Figure 1).
    OPERATION - Filling the Fuel Tank
  2. Install the fuel cap by rotating clockwise.

STARTING THE UNIT


BEFORE STARTING THE INVERTER, REVIEW SAFETY SECTION.

For proper starting and operation of the inverter, make sure you review the inverter control panel features and their descriptions.

Before attempting to start the inverter, verify the following:

  • The engine is filled with engine oil (see Engine Oil Correct Level).
  • The inverter is situated in a proper location (see Location Selection).
  • The inverter is on a dry surface (see Weather and Dry Surface).
  • All loads are disconnected from the inverter (see No Connected Loads).
  • The inverter is properly grounded (see Grounding the Inverter)

DANGER
Never use the inverter in a location that is wet or damp. Never expose the inverter to rain, snow, water spray or standing water while in use. Protect the inverter from all hazardous weather conditions. Moisture or ice can cause a short circuit or other malfunction in the electrical circuit.


Never operate the inverter in an enclosed area. Engine exhaust contains carbon monoxide. Only operate the inverter outside and away from windows, doors and vents.

Starting iPro4200

  1. Move inverter to a flat surface outside in a well ventilated area away from open doors or windows.
  2. Check oil levels. If it is the first time starting make sure to add oil (see Adding Engine Oil).
  3. Disconnect all electrical loads from the generator.
  4. Make sure the circuit breakers are properly set (see Figure 2 below).

    Figure 2: Breaker position
    1. 120V Breaker Operating Position
    2. 120V Breaker Tripped Position Figure 2: Breaker position
  5. Move the fuel shut off valve to the ON position (see Figure 3).
  6. Push the engine control switch into the RUN position (see Figure 4).
  7. Pull the choke lever on the control panel (see Figure 5).
  8. Firmly grasp and pull the recoil handle slowly until you feel increased resistance. At this point, apply a rapid pull while pulling up and slightly away from the generator.
  9. As the engine starts and stabilizes, push the choke lever in (see Figure 6).

STOPPING THE UNIT

Normal Operation
During normal operation, use the following steps to stop your inverter:

  1. Remove any connected loads from the control panel receptacles.
  2. Allow the inverter to run at "no load" to reduce and stabilize engine and alternator temperatures.
  3. Push the engine control switch to the STOP position (see Figure 7).
    OPERATION - STOPPING THE UNIT

During an Emergency
If there is an emergency and the inverter must be stopped quickly, move the engine control switch to the STOP position immediately (see Figure 7).

USING EFFICIENCY MODE

The inverter is equipped with an efficiency mode switch to minimize fuel consumption. In efficiency mode, the inverter will sense the load and adjust the engine RPM to the current load requirements. Efficiency mode should be used only after the inverter has been warmed up to operating temperature.

  1. To turn on the efficiency mode, press the switch to the ON position).
  2. If no load is present, the inverter RPM will drop down to an idle speed.
  3. As a load is applied, the inverter will sense the load and engine RPM will increase according to the load applied.
  4. To run the inverter at maximum power and RPM, press the efficiency mode switch to the OFF position.

RESETTING THE RESET BREAKER

The inverter will trip the breaker and automatically disconnect from the load when the controls sense a predetermined overload condition. The inverter engine will continue to run, but there will not be any electrical output.

  1. Turn off all devices and unplug them from the inverter.
  2. Determine the wattage required from the devices being powered by the inverter. Make sure the wattage required does not exceed the maximum output of the inverter.
  3. Press in the reset breaker to reset it (see Figure 8).
    OPERATION - RESETTING THE RESET BREAKER
  4. Plug the devices in to the inverter.
  5. Turn on the devices as needed.

MAINTENANCE


BEFORE PERFORMING MAINTENANCE ON THE INVERTER, REVIEW THE SAFETY SECTION, AS WELL AS THE FOLLOWING SAFETY MESSAGES.

WARNING
Avoid accidentally starting the inverter during maintenance by removing the spark plug boot from the spark plug. For electric start inverters, also disconnect the battery cables from the battery (disconnect the black negative (-) cable first) and place the cables away from the battery posts to avoid arcing.


Allow hot components to cool to the touch prior to performing any maintenance procedure.


Internal pressure can build in the engine crankcase while the engine is running. Removing the oil fill plug/ dipstick while the engine is hot can cause extremely hot oil to spray out of the crankcase and can severely burn skin. Allow engine oil to cool for several minutes before removing the oil fill plug/dipstick.


Always perform maintenance in a wellventilated area. Gasoline fuel and fuel vapors are extremely flammable and can ignite under certain conditions.

CAUTION
Avoid skin contact with engine oil or gasoline. Prolonged skin contact with engine oil or gasoline can be harmful. Frequent and prolonged contact with engine oil may cause skin cancer. Take protective measures and wear protective clothing and equipment. Wash all exposed skin with soap and water.

WARNING
Failure to perform periodic maintenance or not following maintenance procedures can cause the inverter to malfunction and could result in death or serious injury.

NOTICE
Periodic maintenance intervals vary depending on inverter operating conditions. Operating the inverter under severe conditions, such as sustained highload, high-temperature, or unusually wet or dusty environments, will require more frequent periodic maintenance. The intervals listed in the maintenance schedule should be treated only as a general guideline.

Following the maintenance schedule is important to keep the inverter in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals.

TABLE 1: MAINTENANCE SCHEDULE - OWNER PERFORMED

Maintenance Item Before Every Use After First 20 Hours or First Month of Use After 50 Hours of Use or Every 6 Months After 100 Hour of Use or Every 6 Months After 300 Hours of Use or Every Year
Engine Oil Check Level Change Change - -
Cooling Features Check/Clean - - - -
Air Filter Check - Clean* - Replace
Spark Plug - - - Check/Clean Replace
Spark Arrestor - - - Check/Clean -

*Service more frequently if operating in dry and dusty conditions

ENGINE OIL MAINTENANCE

Engine Oil Specification

  1. Only use the engine oil specified in Figure 9.
    MAINTENANCE - CHOOSING THE ENGINE OIL
  2. Only use 4-stroke/cycle engine oil.NEVER USE 2-STROKE/CYCLE OIL. Synthetic oil is an acceptable substitute for conventional oil.

CHECKING ENGINE OIL

NOTICE
Always maintain proper engine oil level. Failure to maintain proper engine oil level could result in severe damage to the engine and/or shorten the life of the engine.
Always use the specified engine oil. Failure to use the specified engine oil can cause accelerated wear and/ or shorten the life of the engine.

Engine oil level should be checked before every use.

  1. Always operate or maintain the inverter on a flat surface.
  2. Stop engine if running.
  3. Let engine sit and cool for several minutes (allow crankcase pressure to equalize).
  4. With a damp rag, clean around the oil fill plug.
  5. Remove the oil fill plug/dipstick (see Figure 10).
    CHECKING ENGINE OIL - Step 1 - Remove oil dipstick
  6. Check oil level: When checking the engine oil, remove the oil fill plug/dipstick and wipe it clean. Thread the oil fill plug/dipstick all the way back in and then remove and check the oil level on the oil fill plug/dipstick.
    • Acceptable Oil Level – Oil is visible on the crosshatches between the H and L lines on the oil fill plug/dipstick (see Figure 11).
      CHECKING ENGINE OIL - Step 2
    • Low Oil – Oil is below the L line on the oil fill plug/ dipstick.

NOTICE
Engine oil must always be checked and added when the inverter is on a flat, level surface, or an inaccurate reading may result, causing serious engine damage.

ADDING ENGINE OIL

  1. Always operate or maintain the inverter on a flat surface.
  2. Stop engine if running.
  3. Let engine sit and cool for several minutes (allow crankcase pressure to equalize).
  4. Thoroughly clean around the oil fill plug/dipstick.
  5. Remove the oil fill plug/dipstick (see Figure 10).
  6. Select the proper engine oil as specified in Figure 9.
  7. Using the supplied oil funnel, slowly add engine oil to the engine. Stop frequently to check the oil level and avoid overfilling.
  8. Continue to add oil until the oil is at the correct level then replace oil fill plug/dipstick.

CHANGING ENGINE OIL

  1. Stop the engine.
  2. Let engine sit and cool for several minutes (allow crankcase pressure to equalize).
  3. Place oil pan (or suitable container) under the oil drain plug (see Figure 12).
    MAINTENANCE - CHANGING ENGINE OIL
  4. With a damp rag, thoroughly clean around the oil drain plug.
  5. Remove the oil drain plug (see Figure 12). Once removed, place the oil fill plug/dipstick on a clean surface.
  6. Allow oil to completely drain.
  7. Replace oil drain plug.
  8. Fill crankcase with oil following the steps outlined in Adding Engine Oil.
  9. Dispose of used engine oil properly.

NOTICE
Never dispose of used engine oil by dumping the oil into a sewer, on the ground, or into groundwater or waterways. Always be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for proper disposal of hazardous materials. Consult local authorities or reclamation facility.

AIR FILTER MAINTENANCE

WARNING
Never use gasoline or other flammable solvents to clean the air filter. Use only household detergent soap to clean the air filter.

Cleaning the Air Filter
The air filter must be cleaned after every 50 hours of use or 3 months (frequency should be increased if inverter is operated in a dusty environment).

  1. Turn off the inverter and let it cool for several minutes if running.
  2. Unscrew the air cleaner cover and set aside (see Figure 13).
  3. Remove the foam element from the air cleaner housing.
  4. Wash the foam air filter element by submerging the element in a solution of household detergent soap and warm water. Slowly squeeze the foam to thoroughly clean.

NOTICE
NEVER twist or tear the foam air filter element during cleaning or drying. Only apply slow but firm squeezing action.

  1. Rinse in clean water by submerging the air filter element in fresh water and applying a slow squeezing action (see Figure 14).

NOTICE
Never dispose of soap cleaning solution used to clean the air filter by dumping the solution into a sewer, on the ground, or into ground water or waterways. Always be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for proper disposal of hazardous materials. Consult local authorities or reclamation facility.

  1. Dispose of used soap cleaning solution properly.
  2. Dry the air filter elements by again applying a slow firm squeezing action.
  3. Once the air filters are dry, coat the air filters with clean engine oil (see Figure 15 below).
  4. Squeeze the filters to remove any excess oil.
  5. Install the filters back into the unit.
  6. Install the air filter cover and secure the air filter assembly.

DRAINING THE FLOAT BOWL

  1. Locate carburetor float bowl above air filter (see Figure 16).
    DRAINING THE FLOAT BOWL - Step 1
  2. Locate the clear plastic hose from the float that is exiting out the bottom of the inverter, and place a suitable container under it to catch the drained fuel (see Figure 17).
    DRAINING THE FLOAT BOWL - Step 2
  3. Loosen the float bowl drain screw (see Figure 18) until fuel is seen draining from the float bowl.
    DRAINING THE FLOAT BOWL - Step 3
  4. Allow fuel to drain into the container, and then tighten the float bowl drain screw.

NOTICE
Never dispose of fuel by dumping fuel into a sewer, on the ground, or into groundwater or waterways. Always be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for proper disposal of hazardous materials. Consult local authorities or reclamation facility.

SPARK PLUG MAINTENANCE

The spark plug must be checked and cleaned after every 100 hours of use or 6 months and must be replaced after 300 hours of use or every year.

  1. Stop the inverter and let it cool for several minutes if running.
  2. Remove the spark plug boot by firmly pulling the plastic spark plug boot handle directly away from the engine. (see Figure 19)

NOTICE
Never apply any side load or move the spark plug laterally when removing the spark plug. Applying a side load or moving the spark plug laterally may crack and damage the spark plug boot.

  1. Clean area around the spark plug.
  2. Using the spark plug socket wrench provided, remove the spark plug from the cylinder head.
  3. Place a clean rag over the opening created by the removal of the spark plug to make sure no dirt can get into the combustion chamber.
  4. Inspect the spark plug for:
    • Cracked or chipped insulator
    • Excessive wear
    • Spark plug gap (the acceptable limit of 0.027–0.032 in. [0.70 – 0.80 mm]).
  5. If the spark plug fails any one of the conditions listed above, replace the plug.

NOTICE
Only use the recommended spark plug. See chart below. Using a non- recommended spark plug could result in damage to the engine.

  1. Install the spark plug by carefully following the steps outlined below:
    1. Carefully insert the spark plug back into the cylinder head. Hand-thread the spark plug until it bottoms out.
    2. Using the spark plug socket wrench provided, turn the spark plug to ensure it is fully seated.
    3. Replace the spark plug boot, making sure the boot fully engages the spark plug's tip.

Recommended Spark Plug Replacement:
AC Delco: 4EXLS
Autolite: 52
Champion: N9YC
Bosch: W7DC
Torch: F7TC

CLEANING THE SPARK ARRESTOR

Check and clean the spark arrestor after every 100 hours of use or 6 months.

  1. Stop the inverter and let it cool for several minutes if running.
  2. Move the inverter to a flat, level surface.
  3. Remove the screws holding the muffler cover as well as the screws holding the inverter cover (see Figure 21).
    CLEANING THE SPARK ARRESTOR - Step 1
  4. Once the screws are removed and the inverter cover is off, slide the muffler cover to the right and pull out to remove.
  5. Loosen the clamp holding the spark arrestor onto the muffler (see Figure 22).
    CLEANING THE SPARK ARRESTOR - Step 2
  6. Slide the spark arrestor band clamp off the spark arrestor screen.
  7. Pull the spark arrestor screen off the muffler exhaust pipe (see Figure 23).
  8. Using a wire brush, remove any dirt and debris that may have collected on the spark arrestor screen (see Figure 24).
    CLEANING THE SPARK ARRESTOR - Step 3
  9. If the spark arrestor screen shows signs of wear (rips, tears or large openings in the screen), replace the spark arrestor screen.
  10. Install the spark arrestor components in the following order:
    1. Place spark arrestor screen over the muffler exhaust pipe. Push on the screen until it fully bottoms out.
    2. Place the spark arrestor band clamp over the screen and tighten with a flathead screwdriver
  11. Replace the muffler cover and the inverter cover that you removed in step 4.

CHECKING AND ADJUSTING VALVE LASH

CAUTION
Checking and adjusting valve lash must be done when the engine is cold.

  1. Remove the rocker arm cover and carefully remove the gasket. If the gasket is torn or damaged, it must be replaced.
  2. Remove the spark plug so the engine can be rotated more easily.
  3. Rotate the engine to top dead center (TDC) of the compression stroke. Looking through the spark plug hole, the piston should be at the top.
  4. Both the rocker arms should be loose at TDC on the compression stroke. If they are not, rotate the engine 360°.
  5. Insert a feeler gauge between the rocker arm and the push rod and check for clearance (see Figure 25). See table below for valve lash specifications
    1. Push Rod,
    2. Feeler Gauge Area
    3. Rocker Arm,
    4. Jam Nut,
    5. Adjusting Nut
Standard Valve Lash
Intake Valve Exhaust Valve
Valve Lash 0.0035 ± 0.0043 in (0.09 ± 0.11 mm) 0.0043 ± 0.0051 in (0.11 ± 0.13 mm)
Bolt Torque 8-12N.m 8-12N.m
  1. If an adjustment is required, hold the adjusting nut and loosen the jam nut.
  2. Turn the adjusting nut to obtain the correct valve lash. When the valve lash is correct, hold the adjusting nut and tighten the jam nut to 106 in-lb (12 N•m).
  3. Recheck the valve lash after tightening the jam nut.
  4. Perform this procedure for both the intake and exhaust valves.
  5. Install the rocker arm cover, gasket and spark plug.

TESTING GFCI OUTLETS

  1. Start the generator and allow it to warm up.
  2. Press the test button on the GFCI outlet.
  3. The reset button should pop out and there will be no power from the outlets. If the reset button does not pop out, the GFCI outlet is not working correctly and must be repaired before the generator can be operated.
  4. Press the reset button to restore power to the outlet.

CLEANING THE DEVICE

It is important to inspect and clean the inverter before every use.

Clean All Engine Air Inlet and Outlet Ports – Make sure all engine air inlet and outlet ports are clean of any dirt and debris to ensure the engine does not run hot.

STORAGE

WARNING
Never store an inverter with fuel in the tank indoors or in a poorly ventilated area where the fumes can come in contact with an ignition source such as a:

  1. pilot light of a stove, water heater, clothes dryer or any other gas appliance; or
  2. spark from an electric appliance.

NOTICE
Gasoline stored for as little as 60 days can go bad, causing gum, varnish and corrosive buildup in fuel lines, fuel passages and the engine. This corrosive buildup restricts the flow of fuel, preventing an engine from starting after a prolonged storage period.

Proper care should be taken to prepare the inverter for any storage

  1. Clean the inverter as outlined in Cleaning the Inverter.
  2. Siphon all gasoline from the fuel tank as best as possible.
  3. Start the engine and allow the inverter to run until all the remaining gasoline in the fuel lines and carburetor is consumed and the engine shuts off.
  4. Drain any remaining fuel from the float bowl. See Draining the Float Bowl.
  5. Change the oil (see Changing Engine Oil).
  6. Remove the spark plug (see Spark Plug Maintenance) and place about 1 tablespoon of oil in the spark plug opening. While placing a clean rag over the spark plug opening, slowly pull the recoil handle to allow the engine to turn over several times. This will distribute the oil and protect the cylinder wall from corroding during storage.
  7. Replace the spark plug (see Spark Plug Maintenance).
  8. Move the inverter to a clean, dry place for storage.

TROUBLESHOOTING

WARNING
Before attempting to service or troubleshoot the generator, the owner or service technician must first read the owner's manual and understand and follow all safety instructions. Failure to follow all instructions may result in conditions that can lead to voiding of the EPA certification or product warranty, serious personal injury, property damage or even death.

PROBLEM POTENTIAL CAUSE SOLUTION

Engine is running but no electrical output
  1. Reset breaker is tripped.
  1. Reset the reset breaker (see Resetting the Reset Breaker).
  1. The power cord's plug connector is not fully engaged in the inverter's outlet.
  1. Verify plug connector is firmly engaged in the inverter's outlet.
  1. Faulty or defective power cord.
  1. Replace power cord.
  1. Faulty or defective electrical appliance.
  1. Try connecting a known good appliance to verify the inverter is producing electrical power.
  1. GFCI outlet is tripped.
  1. Press the reset button on the GFCI outlet (see Testing GFCI Outlets).
  1. If trying 1-5 above does not solve the problem, the cause might be the inverter has a fault.
  1. Take the generator to your nearest authorized service dealer.
Engine will not start or remain running while trying to start.
  1. Inverter is out of gasoline.
  1. Add gasoline to the inverter (see Adding Gasoline to the Fuel Tank).
  1. Fuel flow is obstructed or fuel shutoff valve is in the OFF position.
  1. Inspect and clean fuel delivery passages and make sure fuel shut off is ON.
  1. Dirty air filter.
  1. Check and clean the air filter (see Air Filter Maintenance).
  1. Low oil level shutdown switch is preventing the unit from starting.
  1. Check oil level and add oil if necessary (see Checking Engine Oil).
  1. Spark plug boot is not fully engaged with the spark plug tip.
  1. Firmly push down on the spark plug boot to ensure the boot is fully engaged.
  1. Spark plug is faulty.
  1. Remove and check the spark plug. Replace if faulty (see Spark Plug Maintenance).
  1. Dirty/plugged spark arrestor.
  1. Check and clean the spark arrestor (see Cleaning the Spark Arrestor).
  1. Stale fuel.
  1. Drain fuel and replace with fresh fuel.

The unit suddenly stops running
  1. Inverter is out of fuel.
  1. Check fuel level (see Starting the Unit). Add fuel if necessary.
  1. The low oil shut down switch has stopped the engine.
  1. Check oil level and add oil if necessary (see Checking Engine Oil).
  1. Too much load.
  1. Restart the inverter and reduce the load.

Engine runs erratic/does not hold a steady RPM
  1. Choke was left in the CHOKE position.
  1. Move choke to the RUN position.
  1. Dirty air filter.
  1. Clean the air filter (see Air Filter Maintenance).
  1. Applied loads maybe cycling on and off.
  1. As applied loads cycle, changes in engine speed may occur; this is a normal condition.

PRODUCT EXPLODED VIEW

PRODUCT EXPLODED VIEW

PRODUCT EXPLODED VIEW PART NUMBERS

PRODUCT EXPLODED VIEW PART NUMBERS

ENGINE VIEW

ENGINE VIEW - Part 1
ENGINE VIEW - Part 2

ENGINE VIEW PART NUMBERS

ENGINE VIEW PART NUMBERS

SCHEMATIC

SCHEMATIC

WestinghousePortablePower.com
Service Hotline: (855) 944-3571
777 Manor Park Drive
Columbus, OH 43228

Documents / Resources

References

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Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.

Download Westinghouse iPro4200 - Inverter Generator Manual

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