Westinghouse WHXC3750 User manual

WHXC3750
WHXC3750-PRO
WHXC5000
WHXC7000
WHXC8500E
WHXC8500E-PRO
Portable Generator
Instruction Manual
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2
DISCLAIMERS:
All instructions, 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 or
specifications to explain or exemplify a product, service or maintenance improvement. We reserve the right
to make any change at any time without notice.Your generator may differ slightly from the models pictured,
including optional accessories.
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.

Congratulations on PurCHasing a WEstingHousE
gEnErator
Thank-you for purchasing a Westinghouse portable generator. It is a high quality power product that will provide
many years of safe and reliable service if properly operated and maintained.
!
DANGER
!
This manual contains important instructions for operating the generator. For your safety and
that 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. This manual should be considered a permanent part of the generator and
should remain with it if resold.
For Your Records:
Date of Purchase: Generator Model Number:
Purchased from Store/Dealer: Generator Serial Number:
Purchase Receipt: (Please retain your tax invoice or purchase receipt to ensure warranty coverage.)
3

4

CONTENTS
5
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.......................................................................................................................................................12
ASSEMBLY .............................................................................................................................................................13
WHEEL KIT ASSEMBLY...................................................................................................................................13
INSTALLING THE BATTERY (ELECTRIC START GENERATORS ONLY) .......................................................15
FEATURES .............................................................................................................................................................16
MAIN GENERATOR COMPONENTS ...............................................................................................................16
CONTROL PANEL ...........................................................................................................................................18
OPERATION ...........................................................................................................................................................19
BEFORE STARTING THE GENERATOR .........................................................................................................19
CHECKING / ADDING ENGINE OIL AND FUEL..............................................................................................20
Checking and Adding Engine Oil................................................................................................................20
Checking and Adding Fuel .........................................................................................................................20
STARTING THE GENERATOR .........................................................................................................................21
Manually Starting a Generator ...................................................................................................................21
Starting an Electric Start Generator ...........................................................................................................23
STOPPING THE GENERATOR ........................................................................................................................24
Normal Operation .......................................................................................................................................24
During an Emergency.................................................................................................................................24
APPLICATION AND DUTY CYCLE ..................................................................................................................24
AMBIENT CONDITIONS ..................................................................................................................................24
CONNECTING ELECTRICAL LOADS..............................................................................................................24
240-Volt AC Loads......................................................................................................................................24
12-Volt DC Loads .......................................................................................................................................25
Power Output and Demand ........................................................................................................................25
240-VOLT AC EXTENSION CORDS ................................................................................................................26
12 VOLT BATTERY CHARGING .......................................................................................................................27
Battery Charging by Direct Connection ......................................................................................................27
Battery Charging by a Mains-Powered Charger .........................................................................................27
TRANSPORTING THE GENERATOR ..............................................................................................................28
MAINTENANCE......................................................................................................................................................29
MAINTENANCE PRECAUTIONS .....................................................................................................................29
Maintenance Schedule ...............................................................................................................................29
ENGINE OIL MAINTENANCE ..........................................................................................................................30
Engine Oil Specification..............................................................................................................................30
Checking Engine Oil ...................................................................................................................................30
Adding Engine Oil.......................................................................................................................................31
Changing Engine Oil...................................................................................................................................31
AIR FILTER MAINTENANCE............................................................................................................................31
Cleaning the Air Filter (Models WHXC3750 & WHXC3750-PRO) ..............................................................32
Cleaning the Air Filter (Models WHXC5000, WHXC7000, WHXC8500E & WHXC8500E-PRO)................33
FUEL STRAINER MAINTENANCE...................................................................................................................34
FUEL SEDIMENT CUP MAINTENANCE..........................................................................................................35
SPARK PLUG MAINTENANCE ........................................................................................................................36
SPARK ARRESTER MAINTENANCE...............................................................................................................37
CLEANING THE GENERATOR ........................................................................................................................38
RCD SAFETY SWITCH TESTING (IF EQUIPPED)..........................................................................................39
12 VOLT BATTERY MAINTENANCE (IF EQUIPPED) ......................................................................................40
Charging the Battery ..................................................................................................................................40
Replacing the Battery .................................................................................................................................40
DRAINING THE FUEL ......................................................................................................................................41

CONTENTS
6
LONG-TERM STORAGE ..................................................................................................................................41
Storage Procedure for 1 – 3 Months...........................................................................................................42
Storage Procedure for Greater than 3 Months ...........................................................................................42
Removal from Storage................................................................................................................................42
DISMANTLING AND DISPOSAL......................................................................................................................42
TROUBLESHOOTING ............................................................................................................................................43
SPECIFICATIONS...................................................................................................................................................47
WIRING DIAGRAMS...............................................................................................................................................48
WHXC3750 WIRING DIAGRAM .......................................................................................................................48
WHXC3750-PRO WIRING DIAGRAM ..............................................................................................................49
WHXC5000 WIRING DIAGRAM .......................................................................................................................50
WHXC7000 WIRING DIAGRAM .......................................................................................................................51
WHXC8500E WIRING DIAGRAM.....................................................................................................................52
WHXC8500E-PRO WIRING DIAGRAM............................................................................................................53
WARRANTY............................................................................................................................................................54
WARRANTY AGAINST DEFECTS ...................................................................................................................54
Proof of Purchase ......................................................................................................................................54
Warranty Conditions ..................................................................................................................................54

SAFETY
7
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)

SAFETY
8
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 system.
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 flood.
• Never use worn or damaged
extension cords.
• Always have a licensed electrician
connect the generator to any fixed
electrical installation.
• 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 earthed 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
earthed before operating..
• Keep animals and children away
from the generator at all times.
!
WARNING
Fuel and fuel vapours 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 refuelling.
• Only fill fuel tank with unleaded
petrol.
• Keep away from sparks, open
flames or other forms of ignition
such as matches, cigarettes, CB
radios and mobile phones when
refuelling.
• Never overfill the fuel tank. Leave
room for fuel to expand. Overfilling
the fuel tank can result in a sudden
overflow of fuel and result in spilled
fuel coming in contact with hot
surfaces. Spilled fuel can ignite. If
fuel is spilled on the generator, wipe
it up immediately and dispose of
rags properly. Allow area of spilled
fuel to dry before operating the
generator.
• Wear eye protection while refuelling.
• Never use fuel as a cleaning agent.
• Store any fuel containers in a well-
ventilated area, away from any
combustibles or source of ignition.
• Check for fuel leaks after refuelling.
Never operate the engine if a fuel
leak is discovered.
• Equip the operating area with a
Class ABE or BE portable fire
extinguisher.

SAFETY
9
!
WARNING
Never operate the generator if:
powered items overheat; electrical
output drops; there are sparks, flames
or smoke coming from the generator;
or if the receptacles are damaged.
Never attempt to connect more than
one generator to the same electrical
device, extension cord or fixed
electrical installation.
!
Never use the generator to power
medical support equipment.
Always remove any tools or other
service equipment used during
maintenance before operating the
generator.
!
WARNING
Do not operate in a hazardous
location, e.g. where there may be a
risk of explosion of fumes, leaking fuel
or explosive dusts.
Do not operate in a confined area
where exhaust gases, smoke or
fumes could reach dangerous
concentrations.
Do not refuel while engine is running.
!
WARNING
!
You must take reasonable care for
the health and safety both of yourself
and any others who may be affected
by your actions. You must understand
and follow all of the safety rules and
working instructions described herein.
You must also use your own good
judgement and common sense.
NOTICE
Never modify the generator.
Never operate the generator if it vibrates at high
levels, if the engine speed changes greatly or if the
engine misfires often.
Always disconnect electric tools or appliances from
the generator before starting.

SAFETY
10
Figure 1 - Safety Labels and Decals (Front, Left Side & Top)
saFEtY laBEls anD DECals
5
13
2
4
6
1
2
4 65
3

SAFETY
11
Figure 2- Safety Labels and Decals (Rear & Right Side)
51
53
4
2
RUN
STOP
START
RUN
STOP
4
2
1
3

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.
1. Carefully cut the packing tape on top of the carton.
2. Fold back top flaps to reveal the Instruction
Manual lying on top of the unit. Remove the
manual and save it for reference.
3. Remove the Wheel Kit (if included).
4. Carefully cut down along the four vertical corners
of the carton and fold the sides flat onto the
ground.
5. Locate and remove the oil bottle, oil funnel and
tool bag (with spark plug socket wrench enclosed)
that are packed in together with the generator.
6. Proceed with attachment of the wheel kit
components, if included (see page 13).
7. Lift and move the generator off the carton and
then recycle or dispose of the packaging materials
properly.
WHEEl Kit
(Included with some models or may be purchased
separately.)
Check the wheel kit and verify its components against
those shown in Figure 3. If any parts are missing,
please contact your local Westinghouse dealer.
A– Wheel (Qty 2)
B– Handle with Grip (Qty 2)
C– Mounting Foot (Qty 1)
D– Axle (Qty 2)
E– Clevis Pin (Qty 2)
F– Bolt M6 x 18 mm (Qty 2)
G– Nut M6 (Qty 2)
H– Bolt M8 x 16 mm (Qty 2)
I – Nut M8 (Qty 2)
J– Rubber Pad (Qty 2)
K– Cotter Pin (Qty 4) Figure 3 - Wheel Kit Components
(Enlarged for clarity)
D
J
EF I
G H
K
A
B
C

13
ASSEMBLY
WHEEl Kit 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
lift one end of the generator and then
move it around on its wheels.
Use caution when collapsing the
handles. Hands or 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
towing the generator either on or off-road. The
wheel kit is designed for use on this generator only.
Tools required (not included) – 10 mm spanner
(Qty 2) and 13 mm spanner (Qty 2).
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 with
the engine at the bottom.
3. Attach the rubber pads onto the mounting foot
using the M6 bolts and nuts as shown in Figure 5.
Figure 4 - Tip the Generator onto its Side

14
ASSEMBLY
4. Attach the mounting foot to the frame using the
M8 bolts and nuts.
Figure 5 – Attaching Mounting Foot to Frame
A - Rubber Pads
B - Mounting Foot
C - M8 Flange Bolt
and Nut
5. Insert an axle through one of the wheels from the
recessed hub side. Then insert the protruding axle
through one of the axle brackets on the frame
beside the engine.
6. Insert the straight leg of one cotter pin through the
hole in the end of the axle.
Figure 6 – Attaching Wheel to Frame
A - Axle B - Cotter Pin
7. Repeat steps 5 and 6 using the other axle, wheel
and cotter pin.
8. Install each handle using a clevis pin and cotter
pin as shown in Figure 7.
Figure 7 – Attaching Handle to Frame
A - Clevis Pin
B - Handle
C - Cotter Pin
B
AB
A
C
B
C C
5A

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 (+) terminal on the battery.
• NEVER connect the positive (+)
battery cable (red boot) to the
negative (-) terminal on the battery.
• NEVER touch both battery terminals
simultaneously.
• NEVER place a tool or other metal
object across both battery terminals.
• NEVER place a tool or other metal
object between either of the battery
terminals and any part of the
generator.
• 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.
Tools required (not included) – 10 mm spanner.
1. Verify the positive (+) battery cable (red boot)
is securely tightened to the positive (+) battery
terminal. Ensure boot is properly fitted over battery
terminal.
2. Carefully remove the protective wrapping around
the lug of the negative (-) battery cable (black
boot).
3. Remove the temporary cable tie on the negative
(-) cable and then route the cable towards the
negative (-) battery terminal.
4. Pull back the black boot and securely attach the
negative (-) battery cable (black boot) to the
negative (-) battery terminal as shown in Figure 8.
Replace the black boot so it protects the cable lug
and battery terminal.
1
2
Figure 8 – Attaching the Negative (-) Battery Cable
(Black) to the Negative (-) Battery Terminal
1 - Positive (+)
Battery Cable
(Red)
2 - Negative (-)
Battery Cable
(Black)

16
FEATURES
Main gEnErator CoMPonEnts
Figure 9 - Main Generator Components (Front, Left Side & Top)
1 - Fuel Cap
2- Fuel Tank
3- Fuel Gauge
4- Frame
5- Control Panel
6- Battery (if equipped)
7- Oil Fill Plug/Dipstick
8- Wheel (if equipped)
9- Engine
10 - Recoil Starter Handle
11 - Fuel Shutoff Valve
12 - Air Filter
13 - Choke Lever
1
23
4
5
6
8
7
12
13
11
10
9

17
FEATURES
Figure 10 - Main Generator Components (Rear & Right Side)
1- Handle (if equipped)
2- Muffler
3- Spark Arrester
4- Mounting Foot (if equipped)
5- Alternator
6- Spark Plug
7- Carburettor
1
5
2
3
7
6
4

18
FEATURES
Figure 11 – Control Panel Features
Voltage
Frequency
Run Time
CONTROL PANEL
1A. Engine Control Switch (RUN/STOP for Manual
Start Units):
•RUN - In the RUN position, the switch allows the
generator to be started.
•STOP - In the STOP position, the switch stops
the engine.
1B. 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 starter motor engages and starts the
engine. Once the engine starts, release the
switch. The switch will then automatically return
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.
2. 12-Volt DC Accessory Socket: Can be used for
12-Volt DC powered devices. Maximum output 8.3
Amps (100 Watts).
3. Main 240-Volt AC Circuit Breaker: Protects
the generator against overload or short circuit of
the 240-Volt AC system, and can also be used
to switch the generator’s entire AC output on
or off. The switch will automatically move to the
OFF position in the event of a fault and must be
manually reset when safe to do so after reducing
the applied load or rectifying the electrical fault.
4. 240-Volt AC, 15-Amp Circuit Breakers (if
equipped): Protect each 240-Volt AC outlet from
overload current above 15 Amps, and can also
be used to switch the individual AC outlets on
or off. The switch will automatically move to the
OFF position in the event of a fault and must be
manually reset when safe to do so after reducing
the applied load or rectifying the electrical fault.
5. Residual Current Device (RCD) Safety Switch
(if equipped): Designed to protect the operator
against electric shock by disconnecting all 240-
Volt AC outlets in the event of a detected current
leakage. The switch will automatically move to the
OFF position in the event of a fault and must be
manually reset when safe to do so after rectifying
the electrical fault.
6. 240-Volt AC, 15-Amp Outlet(s): Each outlet is
capable of delivering the generator’s full output or
15 Amps (3,600 Watts), whichever is the lesser.
7. Earth Terminal: The earth terminal is used to earth
the generator for electrical safety.
8. VFT Meter: Continuously displays the generator’s
AC output voltage, AC output frequency and
cumulative running hours in a repetitive sequence
when the generator is running.
9. 12-Volt DC Circuit Breaker: Protects the generator
against overload or short circuit of the 12-Volt DC
system. The push button will automatically extend
out from the control panel in the event of a fault
and must be manually pushed back in to reset
when safe to do so after reducing the applied load
or rectifying the electrical fault.
1A
5
45 6
1B
52 3
9 7
8

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 1.8 m
away from any building, other equipment or
combustible material.
• If the generator is located close to a building, 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
cords or devices from the 240-Volt AC and 12-Volt DC
receptacles on the control panel. The main 240-Volt
AC circuit breaker and the individual 240-Volt, 15 Amp
circuit breakers (if equipped) should also be switched
to the OFF position.
NOTICE
Starting the generator with loads already connected
to it could result in damage to any device being
powered by the generator during the brief start-up
period.
Earthing the Generator – When used as an isolated
power supply not connected to a fixed electrical
installation, the generator should be connected to
the general mass of earth by connecting an insulated
copper earthing wire of at least 4 mm2size between
the earth terminal on the control panel and an earth
electrode (stake). Vertical-type earth electrodes should
be driven to a minimum depth of 1.2 m in Australia and
comply with all of the other requirements as specified
in the Australian / New Zealand Wiring Rules (AS/
NZS 3000:2007). When used as a power supply to a
fixed electrical installation, the generator should only
be connected and earthed by a licensed electrician in
accordance with the applicable regulations.
Figure 12 – Earth Terminal on the Control Panel
!
WARNING
Be sure the generator is properly
earthed before operating to reduce
the possibility of electric shock.
Generators equipped with a RCD
Safety Switch offer much better
protection against electric shock as
mandated by Australian Workplace
Health and Safety Regulations.

20
OPERATION
CHECKing / aDDing EnginE
oil anD FuEl
Before checking or adding engine oil
and fuel, review Safety on page 7.
!
DANGER
Filling the fuel tank with fuel while the
generator is running can cause fuel
to spill and come in contact with hot
surfaces that can ignite the fuel.
Before starting the generator, always check the engine
oil and fuel levels.
After starting the generator, it is not safe to add fuel
to the fuel tank or engine oil to the engine while the
engine is running or immediately after stopping while
the engine and muffler are still hot.
Checking and Adding Engine Oil
!
WARNING
Internal pressure can build up 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 on page 30 and Adding Engine Oil on page
31 for instructions on checking engine oil level and
the procedure for adding engine oil.
NOTICE
The generator does not contain engine oil as
shipped. Attempting to start the engine before
adding engine oil can permanently damage internal
engine components.
Checking and Adding Fuel
!
WARNING
Never refuel the generator while the
engine is running.
Always turn the engine off and allow
the generator to cool before refuelling.
With the generator switched off and stationary on a
horizontal surface, check the fuel level as indicated on
the fuel gauge. It is good practice to always fill the fuel
tank before operating the generator.
Required Fuel – Use only unleaded petrol with an
octane rating not less than 87 and ethanol content not
greater than 10%. Where possible it is preferable to
use regular unleaded petrol without ethanol.
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 unscrewing it anti-
clockwise.
6. Slowly add fuel into the fuel tank. Be very careful
not to overfill the tank. The fuel level should NOT
be higher than the bottom of the filler neck (see
Figure 13).
7. Replace the fuel cap by screwing it clockwise until
a click is heard, indicating the cap is completely
installed.
Figure 13 – Maximum Fuel Fill Level
!
CAUTION
!
Avoid prolonged skin contact with
fuel. Avoid prolonged inhalation of
fuel vapours.