Westinghouse WHL1000 User manual

WHL1000
WHL2500
WH3250 Series
WH5500 Series
WH6500E Series
WH7500E Series
WHL1000
WHL2500
WH3250 Series
WH5500 Series
WH6500E Series
WH7500E Series
Models:
June 2015
P/N 270027ES

2
DISCLAIMERS:
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.
ALL RIGHTS RESERVED:
No part of this publication may be reproduced or used in any form by any means – graphic, electronic or
mechanical, including photocopying, recording, taping or information storage and retrieval systems – without the
written permission of Westpro Power Systems, LLC.
California
Proposition 65 Warning
Certain components in this product and its
relatedaccessories contain chemicals
known to the state of California to cause
cancer, birth defects or other reproductive
harm. Wash handsafter handling.
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.

CONGRATULATIONS ON OWNING A WESTINGHOUSE
GENERATOR
!
DANGER
!
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.
For Your Records:
Date of Purchase: Generator Model Number:
Purchased from Store/Dealer: Generator Serial Number:
Purchase Receipt: (retain your purchase receipt to ensure trouble-free warranty coverage)
Product Registration
To ensure trouble-free warranty coverage, it is important you register your Westinghouse generator.You can register
your generator by either:
1. Filling in the product registration form below and mailing to:
Product Registration
Westpro Power Systems, LLC
W237 N2889 Woodgate Road, Unit B
Pewaukee, WI 53072
2. Registering your product online at www.westpropower.com
To register your generator you will need to locate the following information:
Model Number Serial Number
Product Registration Form
PERSONAL INFORMATION GENERATOR INFORMATION
First Name: Model Number:
Last Name: Serial Number:
Street Address: Date Purchased:
Street Address: Purchased From:
City, State, ZIP:
Country:
Phone Number:
E-Mail:

4
MODEL NUMBER REFERENCE
EPA (49 States)
WH3250
WH5500
WH6500E
WH7500E
EPA (49 States) and CARB (50 States)
WH3250C
WH5500C
WH7500EC
CSA (Canada)
WHC6500
WHC6500E
WHC7000EGC
Export
WHL1000
WHL2500
Suffix:
E – Electric Start
C – CARB Unit
GC – Generator Cord
Prefix:
WHC – CSA Certified

5
TABLE OF CONTENTS
CONGRATULATIONS ON OWNING A WESTINGHOUSE GENERATOR .........................................................3
For Your Records: .........................................................................................................................................3
Product Registration.....................................................................................................................................3
Product Registration Form............................................................................................................................3
MODEL NUMBER REFERENCE..............................................................................................................................4
SAFETY ....................................................................................................................................................................7
SAFETY DEFINITIONS ......................................................................................................................................7
SAFETY SYMBOL DEFINITIONS ......................................................................................................................7
GENERAL SAFETY RULES ...............................................................................................................................8
SAFETY LABELS AND DECALS .....................................................................................................................10
UNPACKING ...........................................................................................................................................................12
UNPACKING THE GENERATOR......................................................................................................................12
WHEEL KIT ACCESSORIES BOX ...................................................................................................................12
Components: ..............................................................................................................................................12
ASSEMBLY.............................................................................................................................................................13
ASSEMBLY .......................................................................................................................................................13
INSTALLING THE BATTERY (ELECTRIC START GENERATORS ONLY) .......................................................15
FEATURES .............................................................................................................................................................16
GENERAL GENERATOR FEATURES..............................................................................................................16
CONTROL PANEL FEATURES ........................................................................................................................18
OPERATION ...........................................................................................................................................................19
BEFORE STARTING THE GENERATOR .........................................................................................................19
POWER CORD.................................................................................................................................................20
Using Extension Cords...............................................................................................................................20
Using Westinghouse Power Cord ...............................................................................................................21
TRANSFER SWITCH CONNECTIONS............................................................................................................21
ADDING / CHECKING ENGINE FLUIDS AND FUEL.......................................................................................22
Checking and / or Adding Engine Oil..........................................................................................................22
Adding Gasoline to the Fuel Tank...............................................................................................................22
STARTING THE GENERATOR .........................................................................................................................23
Manually Starting a Generator ...................................................................................................................23
Starting an Electric Start Generator ...........................................................................................................25
STOPPING THE GENERATOR ........................................................................................................................26
Normal Operation .......................................................................................................................................26
During an Emergency.................................................................................................................................26
MAINTENANCE......................................................................................................................................................27
MAINTENANCE................................................................................................................................................27
Maintenance Schedule...............................................................................................................................27
ENGINE OIL MAINTENANCE ..........................................................................................................................28
Engine Oil Specification..............................................................................................................................28
Checking Engine Oil...................................................................................................................................28
Adding Engine Oil.......................................................................................................................................29
Changing Engine Oil...................................................................................................................................29
AIR FILTER MAINTENANCE............................................................................................................................29
Cleaning the Air Filter.................................................................................................................................29
SPARK PLUG MAINTENANCE ........................................................................................................................32
TESTING GFCI OUTLETS ...............................................................................................................................33
BATTERY SERVICE .........................................................................................................................................33
Battery Replacement..................................................................................................................................33
CLEANING THE SPARK ARRESTOR ..............................................................................................................34
CLEANING THE GENERATOR ........................................................................................................................35
STORAGE.........................................................................................................................................................36
TROUBLESHOOTING ............................................................................................................................................37
TROUBLESHOOTING ......................................................................................................................................37

6
TABLE OF CONTENTS

7
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 alert 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.
OTE:N Indicates a procedure, practice or condition
that should be followed in order for the
generator to function in the manner
intended.
SAFETY SYMBOL
DEFINITIONS
Symbol Description
!
Safety Alert Symbol
Asphyxiation Hazard
Burn Hazard
Burst/Pressure Hazard
Don’t leave tools in the area
Electrical Shock Hazard
Explosion Hazard
Fire Hazard
Lifting Hazard
Pinch-Point Hazard
Read Manufacturer’s Instructions
Read Safety Messages Before
Proceeding
Wear Personal Protective Equipment
(PPE)

8
SAFETY
GENERAL SAFETY RULES
!
DANGER
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.
!
WARNING
Voltage produced by the generator
could result in death or serious injury.
• Never operate the generator in
rain or a floodplain 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.
!
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 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 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 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.

9
SAFETY
!
WARNING
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.

10
SAFETY
SAFETY LABELS AND DECALS
1
1
2
4
3
5
23
4
5
Figure 1

11
SAFETY
1
1
3
4
25
2
5
3
4
Figure 2

12
UNPACKING
UNPACKING THE
GENERATOR
!
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. Remove the Wheel Kit Accessories cardboard box.
4. Carefully cut two sides of the carton to remove the
generator.
WHEEL KIT ACCESSORIES
BOX
Open the Wheel Kit Accessories box and verify the
contents against the list below. The wheel kit is optional
for the WHL2500 model and is not available for the
WHL1000 model. If any parts are missing, please
locate an authorized Westinghouse Generator dealer
at www.westpropower.com or call 1-855-WHHELP1
(1-855-944-3571).
Components:
Wheels (2)
Handles with Grips (2)
Tool Bag (1)
Spark Plug Socket
Wrench (1)
One 0.6 Liter Bottle
of SAE 10W30 Oil (1)
(WH3250 Model)
One Liter Bottle of
SAE 10W30 Oil (1)
Mounting Foot (1)
Oil Funnel (1)
1
2
3
4
5
Figure 3 – Wheel Kit Hardware
1 - Clevis Pin
55 x 8 mm
(2 used)
2 - Flange Bolt
M8 x 16 mm
(2 used)
3 - Wheel Axle Pin -
3250 Series Only
16 mm x 95 mm
(2 used)
Wheel Axle Pin -
5500 to 7500
Series Only
16 mm x 100 mm
(2 used)
4 - Locking Flange
Nut M8 (2 used)
5 - Hairpin Cotter
(4 used)

13
ASSEMBLY
ASSEMBLY
Before assembling the generator,
review Safety on page 7 and the
following safety messages.
!
CAUTION
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.
Tools required – tool bag (included).
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 its side as shown in Figure 4
(engine should be on the bottom).
Figure 4 – Tip the Generator onto its Side

14
ASSEMBLY
3. Install the mounting foot to the frame using M8
flange bolts and nuts.
1
33
2
Figure 5 – Assemble Mounting Foot to Frame
1 - Rubber Pads
2 - Mounting Foot
3 - M8 Flange Bolt
and Nut
4. Install the 16 mm x 105 mm axle pin through the
axle bracket on the frame.
5. Install the hairpin cotter through the axle pin.
1
2
Figure 6 – Assemble Wheels to Frame
1 - Axle Pin 2 - Hairpin Cotter
6. Install the handles using the clevis pin and hairpin
cotter as shown in Figure 7.
1
3
4
2
Figure 7 – Attaching the Handles
1 - Clevis Pin
2 - Handle
3 - Hairpin Cotter
4 - Negative Battery
Cable

15
ASSEMBLY
INSTALLING THE BATTERY
(ELECTRIC START
GENERATORS ONLY)
!
WARNING
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 non-
conducting tools when installing the
battery.
OTE:N The generator comes equipped with the
positive battery cable (red boot) already
attached.
1. Verify the positive (+) battery cable (red boot) is
securely tightened 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.
4. Pull back the black boot and securely attach
the negative (-) battery cable (black boot) to the
negative (-) battery post as shown in Figure 8.
Replace the black boot so it protects the cable lug
and battery post.
2
1
Figure 8 – Attaching the Negative (-) Battery Cable
(Black)
1 - Positive (+)
Battery Cable
(Red)
2 - Negative (-)
Battery Cable
(Black)

16
FEATURES
GENERAL GENERATOR FEATURES
1
23
4
65
7
Figure 9
1 - Engine Control Switch: Turns the engine on
and off.
2 - Fuel Cap: Close until clicking sound is heard.
3 - Control Panel: Contains the circuit breakers
and outlets.
4 - 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.
5 - Battery: For electric start models only.
6 - Oil Fill Plug/Dipstick: Must be removed to
add and check oil.
7 - Oil Drain Plug: Must be removed to drain
engine oil.

17
FEATURES
1
2
3
4
5
7
6
Figure 10
1 - Fuel Gauge: Indicates fuel level.
2 - Fuel Shutoff Valve: Controls the flow of fuel
to the engine.
3 - Recoil Handle: Must pull to start engine for
manual start units.
4 - Air Cleaner Cover: Must remove to service
the air cleaner.
5 - Choke Lever: Must be put in the ON position
to start the engine and returned to the OFF
position once the engine is running.
6 - CARB Canister: Model numbers followed
by a “C” will be equipped with a carbon
canister.
7 - Spark Plug Boot (Wire): Must be removed
when servicing the engine or the spark plug.

18
FEATURES
CONTROL PANEL FEATURES
2
834
7
5
6
1
Figure 11 – Control Panel Features
1. Engine Control Switch (RUN/STOP for
Manual Start Units):
• RUN - In the RUN position, the switch
allows the generator to be started (for
manual start models).
• STOP - In the STOP position, the switch
stops the engine.
2. Hour Meter: Displays how many hours the
generator has been run when under load.
3. Main Circuit Breaker: The main circuit
breaker controls total output of all outlets to
protect the generator.
4. 120/240-Volt, 30-Amp Twist Lock Outlet
(NEMA L14-30R): Outlet can supply either
120V or 240V output.
5. 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.
6. 20-Amp Circuit Breakers: Each circuit
breaker limits the current that can be
delivered through the 120-volt duplex outlets
to 20 amps.
7. Ground Terminal: The ground terminal is
used to ground the generator.
8. Engine Control Switch (START/RUN/STOP
for Electric Start Units):
• START - When the switch is momentarily
depressed and held in the START position,
the electric start motor engages and starts
the engine. Once the engine starts, release
the switch. (The switch will automatically go
to the RUN position.)
• RUN - Once started, the switch will remain
in the RUN position.
• STOP - To stop the engine, move the switch
to the STOP position.

19
OPERATION
BEFORE STARTING THE
GENERATOR
Before starting the generator, review
Safety on page 7.
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.
!
WARNING
Always operate the generator on a level
surface. Placing the generator on non-
level surfaces can cause the generator
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,
require the generator to be connected to earth ground
before operating. Before starting the generator, make
sure it is connected to earth ground by connecting
the ground terminal on the control panel (see Figure
12) to earth ground using copper wire (minimum 10
AWG). Consult a qualified electrician for local grounding
requirements.
Figure 12 – Ground Terminal on the Control Panel

20
OPERATION
!
WARNING
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.
POWER CORD
Using Extension Cords
Westpro Power Systems 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