Westinghouse WH7500v - Portable Generator Manual

DISCLAIMERS

SAVE THESE INSTRUCTIONS
Important safety instructions are included in this manual.

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.

All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and/or specifications to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Some images may vary depending upon which model is shown.

	This manual contains important instructions for operating this generator. For your safety and the safety of others, be sure to read this manual thoroughly before operating the generator. Failure to properly follow all instructions and precautions can cause you and others to be seriously hurt or killed.

TECHNICAL SPECIFICATIONS

Model Number	Running Watts	Peak Watts	Fuel Tank Rated Size Speed (L/G) (RPM)	Ignition Type	Spark plug	Engine Disp (cc)	Stroke X Bore	Oil Capacity (L)	Oil Type
WH7500v	6000	7500	25/6.6 3600	TCI	F7TC	420	66X90	1.10	10W30
NOTICE
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.

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

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.

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

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

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

GENERAL SAFETY RULES

	Never use the generator in a location that is wet or damp. Never expose the generator to rain, snow, water spray or standing water while in use. Protect the generator from all hazardous weather conditions. Moisture or ice can cause a short circuit or other malfunction in the electrical circuit.
	Never operate the generator in an enclosed area. Engine exhaust contains carbon monoxide. Only operate the generator outside and away from windows, doors and vents.
	Voltage produced by the generator could result in death or serious injury. Never operate the generator 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 generator to the utility circuit. Never touch an operating generator if the generator is wet or if you have wet hands. Never operate the generator 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 generator is operating. Be sure the generator is properly grounded before operating.
	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 generator 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 any other forms 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 generator, wipe up any spills immediately. Dispose of rag properly. Allow area of spilled fuel to dry before operating the generator. 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.
	Never operate the generator if powered items overheat, electrical output drops, there is sparking, flames or smoke coming from the generator, or if the receptacles are damaged.
	Never use the generator to power medical support equipment.
	Always remove any tools or other service equipment used during maintenance from the generator before operating.
NOTICE
Never modify the generator. Never operate the generator if it vibrates at high levels, if engine speed changes greatly or if the engine misfires often. Always disconnect tools or appliances from the generator before starting.

SAFETY LABELS AND DECALS

UNPACKING

	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. Remove the Wheel Kit Accessories cardboard box.
4. Carefully cut two sides of the carton to remove the generator.

WHAT COMES IN THE BOX

Manual
Quick Start Guide/Maintenance Schedule
1.1 Liter Bottle of SAE 10W30 Oil (1)
Spark Plug Socket Wrench (1)
Wheel Kit Accessories Box
Funnel (1)

WHEEL KIT ACCESSORIES BOX

Open the Wheel Kit Accessories box and verify the contents against the list right. If any parts are missing, please locate an authorized Westinghouse Generator dealer at service@wpowereq.com or call 1-855-944-3571.

Figure 1 - Wheel and Feet Kit Hardware

1. Washer (2 used)
2. Flange Bolt M8 x16mm (4 used)
3. Hairpin Cotter Pin (2 used)
4. Wheel Axle Pin (2)

ASSEMBLY

INSTALLING WHEELS AND FEET

BEFORE ASSEMBLING THE GENERATOR, REVIEW THE SAFETY SECTION.

	Never lift the generator without assistance. The generator is heavy and lifting without assistance could result in personal injury.
	Never use the handles as a lifting point to support the entire weight of the generator. Only use the handles to move the generator by lifting the handles and using the wheels to move the generator.
	Use caution when collapsing the handles. Hands and fingers could get caught and pinched.
NOTICE
Assembling the generator will require lifting the unit on one side. Make sure all engine oil and fuel are drained from the unit prior to assembling. Once assembled, the wheel kit is not intended for on-road use. The wheel kit is designed for use on this generator only.

INSTALLING FEET TO FRAME

1. Place generator on a flat surface.
2. Place a piece of cardboard or other soft material to tip the generator onto, to protect the frame paint and prevent the generator from sliding. Tip the generator onto the side.
3. Install the mounting foot to the frame using M8 flange bolts.
   
   Figure 1 - Assemble Mounting Feet to Frame
   1. Mounting Feet
   2. Flange Bolts M8

INSTALLING WHEELS TO FRAME

1. Insert axle pin through washer and wheel.
   
   Figure 2 - Wheel Assembly
2. Install the wheel with axle pin through the axle bracket on the frame. The eye of the bolt should be facing toward the inside of the generator.
3. Install the hairpin cotter through the axle pin to lock it in place.
   
   Figure 3 - Assemble Wheel to Frame
   1. Axle Bracket
   2. Hairpin Clip
   3. Axle Pin
4. Repeat previous steps on other wheel.

INSTALLING THE BATTERY

To avoid electric shock: ALWAYS connect the positive (+) battery cable (red boot) first when connecting battery cables. ALWAYS disconnect the negative (-) battery cable (black boot) first when disconnecting battery cables. NEVER connect the negative (-) battery cable (black boot) to the positive (+) post on the battery. NEVER connect the positive (+) battery cable (red boot) to the negative (-) post on the battery. NEVER touch both battery posts simultaneously. NEVER place a metal tool across both battery posts. ALWAYS use insulated or nonconducting tools when installing the battery.

1. Secure the positive (+) battery cable (red boot) tightly to the positive (+) battery post. Make sure boot is over battery post.
2. Carefully remove the protective wrapping around the lug of the negative (-) battery cable (black boot).
3. Locate negative (-) cable attached to alternator cable, remove tie and route to the negative (-) battery post. See figure 4 below for location of negative (-) cable.
   
   Figure 4 - (1) Negative Cable
4. Pull back the black boot and securely attach the negative (-) battery cable (black boot) to the negative (-) battery post as shown in Figure 5. Replace the black boot so it protects the cable lug and battery post.
   
   Figure 5 - Attaching the Negative (-) Battery Wire
   1. Positive (+) Battery Cable (Red)
   2. Negative (-) Battery Cable (Black)

FEATURES

1. Electric Start Switch: Hold in Start position for 1 second to start engine. Make sure to manually open choke prior to starting.
2. Fuel Cap: Close until clicking sound is heard.
3. Control Panel: Contains the circuit breakers and outlets.
4. Oil Fill Plug/Dipstick: Must be removed to add and check oil.
5. Oil Drain Plug: Must be removed to drain engine oil.
6. Never Flat Wheels: For easy portability.
7. Fuel Shut off Valve: Controls the flow of fuel to the engine.
8. Manual Choke: Choke must be set manually by adjusting choke lever.
9. Single Piece Handle: Includes rubber grip. Allows you to easily push or pull unit with one hand.

1. Fuel Gauge: Indicates fuel level.
2. Spark Plug Boot (Wire): Must be removed when servicing the engine or the spark plug.
3. Muffler and Spark Arrester: Avoid contact until engine is cooled down. Spark arrestor prevents sparks from exiting the muffler. It must be removed for servicing.

CONTROL PANEL FEATURES

1. Electric Start Switch: Hold in Start until engine starts. Make sure to manually open choke prior to starting.
2. Hour Meter: Displays how many hours the generator has been run when under load.
3. 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.
4. 20-Amp Circuit Breakers: Each circuit breaker limits the current that can be delivered through the 120-volt duplex outlets to 20amps.
5. 25-Amp Circuit Breakers: Each push button circuit breaker controls total output per leg to L14-30 receptacle.
6. 120/240-Volt, 30-Amp Twist Lock Outlet (NEMA L14-30R): Outlet can supply either 120V or 240V output.
7. Ground Terminal: The ground terminal is used to ground the generator.

OPERATION

BEFORE STARTING THE GENERATOR

BEFORE STARTING THE GENERATOR, REVIEW SAFETY SECTION.

Location Selection

Before starting the generator, avoid exhaust and location hazards by verifying:

• You have selected a location to operate the generator that is outdoors and well ventilated.
• You have selected a location with a level and solid surface on which to place the generator.
• 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 generator is located close to a building, make sure it is not located near any windows, doors and/or vents.

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.
	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 generator on a solid, level surface. Operating the generator on a surface with loose material such as sand or grass clippings can cause debris to be ingested by the generator that could: Block cooling vents Block air intake system

Weather

Never operate your generator 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 generator on a dry surface free of any moisture.

No Connected Loads

Make sure the generator 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 generator with loads already applied to it could result in damage to any appliance being powered off the generator 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. The most common application that requires a ground rod is when you are using the generator as a separately derived system to provide back up power to your house. Typically this is when a transfer switch has a switched neutral.

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.

	Be sure the generator is properly connected to earth ground before operating. The generator must be grounded to prevent electrical shock due to faulty appliances.

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: 140545

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

Using Westinghouse Power Cord

Use the extension cord chart to determine the size of the conductor for extension cord applications. Determine the distance of the generator to the appliance on the top line of the chart. Then select the rated amperage of the generator on the left side of the chart. Where the two meet is the size of the conductor required for the application.

The WCG25 power cord is connected to the generator at the 120/240 plug. The opposite end of the power cord is a fan tail receptacle with 2 green receptacles and 2 red receptacles. Each receptacle is rated at 120 volts AC. To balance the load on the generator's alternator, use the red and green identifiers on the fan tail receptacle. To keep the load balanced, connect the loads so that both color receptacles are used. An example is one in red and one in green. Do not connect 2 in red and none in green, or 2 in green and none in red. If only one color receptacle is used with multiple loads, the alternator may experience an unbalanced load, causing undue vibration to generator.

WCG25 Extension Cord

TRANSFER SWITCH CONNECTIONS

The Westinghouse generator is wired with the neutral bonded to ground. If you are connecting your generator to a panel board transfer switch, a licensed electrician will need to consider removing the bonded neutral to ensure proper operation of household GFCI circuits. This is done by removing the jumper wire that connects the alternator ground to the alternator neutral.

If the bonded neutral is removed the generator must be relabeled as floating neutral on the control panel.

If your generator is equipped with GFCI receptacles, removing the bonded neutral may not allow proper operation of the GFCI receptacles. Keep the jumper wire with the owner's manual in case it is needed for future use when not connected to a transfer switch.

Figure 5

ADDING / CHECKING ENGINE FLUIDS AND FUEL

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

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

Before starting the generator, always check the level of:

• Engine oil
• Gasoline in the fuel tank

Once the generator 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

	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 generator 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 can damage engine components. The owner of the generator 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

	Never refuel the generator while the engine is running.
	Always turn the engine off and allow the generator to cool before refueling.

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 generator.
2. Allow the generator to cool down so all surface areas of the muffler and engine are cool to the touch.
3. Move the generator to a flat surface.
4. Clean area around the fuel cap.
5. Remove the fuel cap by rotating counterclockwise.
6. Slowly add gasoline into the fuel tank. Be very careful not to overfill the tank. The gasoline level should NOT be higher than the filler neck (see Figure 6).
   
   Figure 6 - Maximum Gasoline Fill Level
7. Install the fuel cap by rotating clockwise until you hear a click, indicating the cap is completely installed.

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

BEFORE STARTING THE GENERATOR

BEFORE STARTING THE GENERATOR, REVIEW SAFETY SECTION.

Before attempting to start the generator, verify the following:

• The engine is filled with engine oil. See Checking Engine Oil.
• The generator is situated in a proper location (Location Selection).
• The generator is on a dry surface (Weather and Dry Surface).
• All loads are disconnected from the generator (No Connected Loads).
• The generator is properly grounded the Generator.

	Never use the generator in a location that is wet or damp. Never expose the generator to rain, snow, water spray or standing water while in use. Protect the generator from all hazardous weather conditions. Moisture or ice can cause a short circuit or other malfunction in the electrical circuit.
	Never operate the generator in an enclosed area. Engine exhaust contains carbon monoxide. Only operate the generator outside and away from windows, doors and vents.
NOTICE
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. Poor oil quality may interfere with the operation of the low oil shutdown switch. The owner of the generator 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.

STARTING THE GENERATOR

1. Move generator to a flat surface outside in a well ventilated area.
2. Check oil levels (see Adding Engine Oil).
3. Verify the battery is installed and both battery cables are attached to their corresponding polarity. (See Installing the Battery)
4. Disconnect all electrical loads from the generator.
5. Make sure the circuit breakers are properly set (see Figure 7 below).
   
   Figure 7 - Breakers
   1. Operating Position
   2. Tripped Position
6. Move the fuel shut off valve to the ON position (see Figure 8 below).
   
   Figure 8 - Fuel Shut Off - ON
7. Move the choke lever to the ON position (see Figure 9 below).
   
   Figure 9 - Choke Lever - ON
8. Electric Start: Push and hold the engine control switch in the START position until the engine starts. Once the engine starts, release the engine control switch; the switch will automatically move into the RUN position (see Figure 10 below).
   
   Figure 10 - Engine Control Switch - START

   NOTICE

   Failure to release the engine control switch once the engine starts could result in damage to the generator. Never push the engine control switch to the START position while the engine is running' this could damage the generator.

   Note: If the engine fails to start after 5 seconds, release the engine control switch. Let the generator sit idle for 15 seconds and then repeat step 8. If the cranking speed drops after each unsuccessful attempt, then the battery may not be adequately charged. Manually start the generator in step 9.
9. Manual Start: Make sure the engine control switch is in the RUN position. 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 (see Figure 11).
   
   Figure 11 - Engine Control Switch - RUN
   Recoil Handle - PULL
10. As the engine starts and stabilizes, gradually move the choke lever back to the OFF position (see Figure 12 below).
    
    Figure 12 - Choke Lever - OFF

STOPPING THE GENERATOR

Normal Operation

During normal operation, use the following steps to stop your generator:

1. Remove any connected loads from the control panel receptacles.
2. Allow the generator to run at "no load" to reduce and stabilize engine and alternator temperatures.
3. Position the engine control switch to STOP or if you plan to store the generator after use, turn the fuel shutoff valve to the OFF position and allow the fuel to be consumed from the carburetor. (see figure 13)
   
   Figure 13 - Move engine switch to STOP

During an Emergency

If there is an emergency and the generator must be stopped quickly, position the engine control switch to the STOP position immediately.

MAINTENANCE

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

	Avoid accidentally starting the generator during maintenance by removing the spark plug boot from the spark plug. For electric start generators, 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 well-ventilated area. Gasoline fuel and fuel vapors are extremely flammable and can ignite under certain conditions.

MAINTENANCE SCHEDULE

		Failure to perform periodic maintenance or not following maintenance procedures can cause the generator to malfunction and could result in death or serious injury.
NOTICE
Periodic maintenance intervals vary depending on generator operating conditions. Operating the generator under severe conditions, such as sustained high-load, 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.
		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.

Following the maintenance schedule is important to keep the generator 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

TABLE 2: MAINTENANCE SCHEDULE - AUTHORIZED WESTINGHOUSE SERVICE DEALER 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
Valve Clearance	-	-	-	-	Check/Adjust
Fuel Filter	-	-	-	Check/Clean	-

ENGINE OIL MAINTENANCE

Engine Oil Specification

1. Only use the engine oil specified in Figure 14.
   
   Figure 14 - Recommended 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 generator 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/dipstick.
5. Remove oil fill plug/dipstick (see Figure 15 below).
   
   Figure 15 - Oil Fill Plug/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 16).
     
     Figure 16 - Checking Oil Level
   • Low Oil – Oil is below the L line on the oil fill plug/dipstick.

ADDING ENGINE OIL

1. Always operate or maintain the generator 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 oil fill plug/dipstick and wipe clean.
6. Select the proper engine oil as specified in Figure 14.
7. Using the supplied funnel and tube, slowly add engine oil to the engine. Stop frequently to check the level to avoid overfilling.
8. Continue to add oil until the oil is at the correct level (see Figure 16).

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 17).
4. With a damp rag, thoroughly clean around the oil drain plug.
5. Remove the oil drain plug (see Figure 17). Once removed, place the oil drain plug on a clean surface.
   
   Figure 17 - Oil Drain Plug
6. Allow oil to completely drain.
7. Replace oil drain plug.
8. Fill crankcase with oil following the steps outlined in Adding Engine Oil.

NOTICE

Never dispose of used engine oil by dumping the oil 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.

AIR FILTER MAINTENANCE

	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 generator is operated in a dusty environment).

1. Turn off the generator and let it cool for several minutes if running.
2. Move the generator to a flat, level surface.
3. Unclip the clips on the top and bottom of the air filter cover (Figure 18).
   
   Figure 18 - Clips on air filter
4. Remove the black coarse air filters.
5. Wash the foam air filter elements by submerging the elements 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.

6. Rinse in clean water by submerging the air filter elements in fresh water and applying a slow squeezing action

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 19 below).
   
   Figure 19
4. Squeeze the filters to remove any excess oil.
5. Install the filters back into the unit. If there are two filters make sure the gray (fine) air filter goes in first followed by the black (coarse) air filter on the outside.
6. Install the air filter cover and secure the air filter assembly.

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 generator and let it cool for several minutes if running.
2. Move the generator to a flat, level surface.
3. Remove the spark plug boot by firmly pulling the plastic spark plug boot handle directly away from the engine (see Figure 20).
   
   Figure 20 - Remove Spark Plug Boot

   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.

4. Clean area around the spark plug.
5. Using the 13/16" spark plug socket wrench provided, remove the spark plug from the cylinder head.
6. 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.
   • Inspect the spark plug for:
   • Cracked or chipped insulator
   • Excessive wear
   • Spark plug gap (the acceptable limit of 0.027–0.032 in. Figure 21 [0.70 – 0.80 mm]) (see Figure 21).
     

     NOTICE

     Use only recommended spark plugs when servicing. The manufacturer is not responsible for engine damage when using spark plugs not recommended by the manufacturer.

7. 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 13/16" 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

CHECKING AND ADJUSTING VALVE LASH

	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 23). See Table 2 for valve lash specifications
   
   Figure 23
   1. Push Rod,
   2. Feeler Gauge Area,
   3. Rocker Arm,
   4. Jam Nut,
   5. Adjusting Nut
      (Table 2) 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

6. If an adjustment is required, hold the adjusting nut and loosen the jam nut.

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 GENERATOR

It is important to inspect and clean the generator 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.

Clean All Engine Cooling Fins

Use a damp rag and a brush to loosen and remove all dirt on or around the engine's cooling fins.

Clean All Alternator Cooling Air Inlets and Exhaust Ports

Make sure the cooling air inlets and exhaust ports of the alternator are free of any debris and obstructions. Use a vacuum cleaner to remove dirt and debris stuck in the cooling air inlets and exhaust ports.

General Cleaning of the Generator

Use a damp rag to clean all remaining surfaces.

STORAGE

STORING GENERATOR

	Never store a generator 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: pilot light of a stove, water heater, clothes dryer or any other gas appliance; or 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 generator for any storage.

1. Make sure the Engine Switch is switched to STOP.
2. Disconnect the battery.
3. Clean the generator as outlined in Cleaning the Generator.
4. Drain all gasoline from the fuel tank as best as possible.
5. With the fuel shut off valve open, start the engine and allow the generator to run until all the remaining gasoline in the fuel lines and carburetor is consumed and the engine shuts off.
6. Close the fuel shut off valve.
7. Change the oil (see Changing Engine Oil).
8. 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 there coil handle to allow the engine to turn over several times. This will distribute the oil and protect the cylinder wall from corroding during storage.
9. Replace the spark plug (see Spark Plug Maintenance).
10. Move the generator to a clean, dry place for storage.

TROUBLESHOOTING

	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	Circuit breakers are tripped.	Reset the circuit breakers and check for overload condition.
	The power cord's plug connector is not fully engaged in the generator's outlet.	Verify plug connector is firmly engaged in the generator's outlet. If using the 240V outlet, make sure plug connector is rotated 1/4 turn in the clockwise direction.
	Faulty or defective power cord	Replace power cord.
	Faulty or defective electrical appliance	Try connecting a known good appliance to verify the generator is producing electrical power.
	GFCI outlet is tripped	Press the reset button on the GFCI outlet.
	If trying 1-5 above does not solve the problem, the cause might be the generator has a fault.	Take the generator to your nearest authorized service dealer.
Engine will not start or remain running while trying to start.	Fuel shutoff valve is in the OFF position.	Move the fuel shut off valve to the ON position (see Figure 8).
	Generator is out of gasoline.	Add gasoline to the generator.
	Fuel flow is obstructed.	Inspect and clean fuel delivery passages.
	Unit is over choked.	Move the choke lever halfway between the ON and OFF positions.
	Starting battery may have insufficient charge	On electric start models only. Check battery output and charge battery as necessary.
	Dirty air filter	Check and clean the air filter.
	Low oil level shut down switch is preventing the unit from starting.	Check oil level and add oil if necessary.
	Spark plug boot is not fully engaged with the spark plug tip.	Firmly push down on the spark plug boot to ensure the boot is fully engaged
	Spark plug is faulty.	Remove and check the spark plug. Replace if faulty.
	Dirty/plugged spark arrestor	Check and clean the spark arrestor.
	Stale fuel	Drain fuel and replace with fresh fuel.
	If trying 1-11 above does not solve the problem, the cause might be the generator has a fault.	Take the generator to your nearest authorized service dealer.
Generator suddenly stops running.	Generator is out of fuel.	Check fuel level. Add fuel if necessary.
	The low oil shut down switch has stopped the engine.	Check oil level and add oil if necessary.
	Too much load	Restart the generator and reduce the load.
	If trying 1-3 above does not solve the problem, the cause might be a fault in the generator.	Take the generator to your nearest authorized service dealer.
Engine runs erratic; does not hold a steady RPM.	Choke was left in the ON position.	Move choke to the OFF position
	Dirty air filter	Clean the air filter.
	Applied loads maybe cycling on and off	As applied loads cycle, changes in engine speed may occur; this is a normal condition.
	If trying 1-3 above does not solve the problem, the cause might be a fault in the generator	Take the generator to your nearest authorized service dealer.

WH7500v EXPLODED VIEW

WH7500v EXPLODED VIEW PART NO.

WH7500v ENGINE VIEW

WH7500v SCHEMATIC

WestinghousePortablePower.com

Service Hotline: (855) 944-3571

777 Manor Park Drive
Columbus, OH 43228

Documents / Resources

References

• Westinghouse Outdoor Power Equipment | Westinghouse Outdoor Equipment

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