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Westpro Westinghouse WH3250 Series, Service Manual, Page: 60 / 64

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Westpro Westinghouse WH3250 Series Service Manual Download Page 60

9-10 

SERVICE AND DISASSEMBLY 

FAN COVER

1

4

5

2

3

Figure 9-9

1 -   Cooling Fan:

 Install by aligning the holes on 

the fan with the holes on the fl ywheel. Inspect 
the fan blades for wear or damage. Replace the 
fan if any fi ns are damaged.

2 -   Starter Cup:

 When installing, align the hole in 

the starter cup with the lug on the cooling fan.

3 -   Flywheel Nut:

 Hold the fl ywheel from turning 

and tighten the nut to 77 ft-lb (105 N·m).

4 -  Blower Housing

5 -  Recoil Starter

Summary of Contents for Westinghouse WH3250 Series

Page 1: ......

Page 2: ...n 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 imag...

Page 3: ...ights and Obligations 2 3 Manufacturer s Warranty Coverage 2 3 Owner s Warranty Responsibilities 2 3 Defects Warranty Requirements 2 4 Warranted Parts 2 5 Questions 2 5 SPECIFICATIONS 3 1 Specifications 3 1 Bolt and Fastener Torque Information 3 2 Wiring Diagrams 3 3 WH3250 Series 3 3 WH4500 Series WH5500 Series 3 4 WH6000 Series 3 5 WH6500E Series 3 6 WH7000E Series 3 7 WH7500E Series 3 8 COMPONEN...

Page 4: ...ent Bowl 7 7 Spark Plug Service 7 7 Cleaning the Spark Arrestor 7 9 Checking and Adjusting Valve Lash 7 9 Governor Adjustment 7 10 Governor Range Adjustment 7 10 Battery Service 7 11 Battery Replacement 7 11 Cleaning the Generator 7 12 Storage 7 13 TROUBLESHOOTING 8 1 Troubleshooting 8 1 Electrical Diagnostics 8 2 Engine Diagnostics 8 5 SERVICE AND DISASSEMBLY 9 1 Control Panel 9 1 Alternator 9 2 ...

Page 5: ...ided 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 generat...

Page 6: ...wer 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 ...

Page 7: ... to contact eyes skin or clothing If contact or spillage of electrolyte occurs immediately flush the area with water Never use this product to power life support devices or life support appliances Never use this product to power medical devices or medical appliances Inform your electricity provider immediately if you or anyone in your household depends on electrical equipment to live Inform your el...

Page 8: ...1 4 SAFETY This Page Intentionally Left Blank ...

Page 9: ...in the operator s manual for your WESTPRO Westinghouse unit Should a product difficulty occur you must at your expense deliver or ship your WESTPRO Westinghouse unit to a WESTPRO Authorized Service Dealer for warranty repairs which must occur within the applicable warranty period and arrange for pick up or return of your unit after the repairs have been made For the WESTPRO Authorized Service Deale...

Page 10: ...art s x Failure due to misapplication x Telephone cellular phone facsimile internet access or other communication expenses x Expenses related to customer instruction or troubleshooting where no manufacturing defect is found x Overnight freight or special shipping costs for replacement part s x Overtime holiday or emergency labor x Starting batteries fuses light bulbs and engine fluids DISCLAIMER OF...

Page 11: ... including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This emission control system is warranted for two years If any emission related part on your outdoor equipment is defective the part will be repaired or replaced by Westpro Power Systems LLC OWNER S WARRANTY RESPONSIBILITIES As the outdoor equipment owner you are responsible for performance of the required maintenance listed in ...

Page 12: ...rt fails before the first scheduled replacement the part will be repaired or replaced by Westpro Power Systems LLC according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part 4 Repair or replacement of any warranted part under the warranty provisions herein must be perf...

Page 13: ...ission warranty parts are covered if applicable 1 Fuel Metering System x Cold start enrichment system soft choke x Carburetor and internal parts or fuel injection system x Fuel pump x Fuel tank 2 Air Induction System x Air cleaner x Intake manifold 3 Ignition System x Spark plug s x Magneto ignition system 4 Exhaust System x Catalytic converter x SAI Reed valve 5 Miscellaneous Items Used in Above ...

Page 14: ...2 6 EMISSIONS CONTROL WARRANTY This Page Intentionally Left Blank ...

Page 15: ...NE Speed RPM 3600 Type OHV 4 cycle Displacement cc 208 292 357 357 357 420 420 Valve Lash in mm IN 0 005 0 001 0 125 0 025 EX 0 007 0 001 0 175 0 025 Fuel 87 octane or higher unleaded E10 Ethanol Fuel Tank Capacity gal L 6 6 25 Engine Oil SAE 10W 30 Engine Oil Capacity qt L 1 2 1 1 Spark Plug RN9YC Spark Plug Gap in mm 0 028 0 031 0 7 0 8 Air Filter 160006 Battery Electric Start Models Only 100024...

Page 16: ...d Bolts M10 x 1 25 x 80 35 48 Exhaust Pipe Bolts M8 x 32 13 18 Fuel Shutoff Valve Hex Fitting M10 x 1 25 17 24 Fuel Tank Mounting Bolts M6 x 1 0 x 25 7 10 Ignition Coil Bolts M6 x 1 0 x 25 7 10 Muffler Cover Bolts M6 x 1 0 x 14 3 4 Muffler Rear Mounting Bracket Bolts M8 x 1 0 x 16 13 18 Muffler Side Guard Bolts M6 x 1 0 x 14 3 4 Oil Drain Screw M12 x 1 5 24 32 Pivot Adjusting Nuts M6 x 0 75 9 12 Pivo...

Page 17: ...SPECIFICATIONS 3 3 WIRING DIAGRAMS WH3250 Series WH3250 Series Figure 3 1 WH3250 Series Wiring Diagram ...

Page 18: ...SPECIFICATIONS 3 4 WH4500 Series WH5500 Series WH4500 Series WH5500 Series Figure 3 2 WH4500 Series WH5500 Series Wiring Diagram ...

Page 19: ...SPECIFICATIONS 3 5 WH6000 Series WH600 0 Series Figure 3 3 WH6000 Series Wiring Diagram ...

Page 20: ...SPECIFICATIONS 3 6 WH6500E Series WH6500E Series Figure 3 4 WH6500E Series Wiring Diagram ...

Page 21: ...SPECIFICATIONS 3 7 WH7000E Series WH700 0E Series Figure 3 5 WH7000E Series Wiring Diagram ...

Page 22: ...SPECIFICATIONS 3 8 WH7500E Series WH750 0E Series Figure 3 6 WH7500E Series Wiring Diagram ...

Page 23: ... 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 ...

Page 24: ...er 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 Carbon Canister Model numbers followed by a C will be equipped with a carbon canister See Removing Fine Inside Air Filter on page 7 6 for more information 7 Spark Plug Boot Wire Must be removed when servicing the engine or th...

Page 25: ... Volt 20 Amp Duplex 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 f...

Page 26: ...4 4 COMPONENTS This Page Intentionally Left Blank ...

Page 27: ...eded are x Hammer x Torque wrench x Volt ohm meter x Frequency meter x Resistive load such as a load bank heaters light bulbs etc x Alternator removal tool x Wooden block for rotor support TRANSPORTING GENERATOR WARNING Hot engine or exhaust system can cause serious burns or fires Let generator cool completely before transporting When moving or transporting the generator x Move the engine control s...

Page 28: ...5 2 PREPARING FOR SERVICE This Page Intentionally Left Blank ...

Page 29: ...ion Coil 50 50 50 50 Meters Circuit Breakers 45 45 45 45 Oil Shutdown Switch 40 40 40 40 Oil Alert Sender 40 40 40 40 Receptacles Ports 50 50 50 50 Recoil Starter Assembly 30 30 30 30 Spark Plug 30 30 30 30 Electric Starter 45 Starter Solenoid 35 Voltage Regulator 60 60 60 60 ENGINE Air Filter 30 30 30 30 40 40 40 40 Carburetor 50 50 50 50 Choke 45 45 45 45 Cylinder Head Cover 45 45 45 45 Cylinder...

Page 30: ...0 Operation WH3250 Series WH4500 Series min WH5500 Series WH6000 Series min WH7000 Series min Electric Start Models min FUEL EXHAUST Carbon Canister with bracket CARB Emission Equipment 45 45 45 45 Carbon Canister T ube CARB Emission Equipment 30 30 30 30 Exhaust Pipe CARB Emission Equipment 40 40 40 40 Fuel Gauge 30 30 30 30 OTE N Repair times represent generally accepted intervals for conducting...

Page 31: ...or Every Year Engine Oil Check Level Change Change Cooling Features Check Clean Air Filter Check Clean1 Replace Spark Plug Check Clean Replace Spark Arrestor Check Clean Fuel Sediment Bowl Clean Cylinder Cooling Fins Clean Valve Lash Check Adjust Fuel Line Check Replace Idle Speed Check Adjust 1 Service more frequently if operating in dry and dusty conditions CAUTION Avoid skin contact with engine...

Page 32: ...e paint and plastic Be careful not to spill fuel when filling the fuel tank Damage caused by spilled fuel is not covered under warranty Oxygenated Fuel Types Ethanol Ethyl or Grain Alcohol Do not use gasoline containing more than 10 ethanol by volume as this may cause starting or performance problems Gasoline containing ethanol may be marketed under the name Gasohol Not all pumps are required to di...

Page 33: ...30 Figure 7 2 Recommended Oil Low Oil Protection The generator engine is protected from low lubrication failure by an oil shutdown switch This switch prevents the ignition system from operating until sufficient oil is added to the crankcase When the engine shuts down due to low oil level x The engine control switch will remain in the RUN position x The ignition system will be inoperable x The engin...

Page 34: ...dipstick 5 Remove oil fill plug dipstick and wipe clean 6 Select the proper engine oil as specified in Figure 7 2 7 Using the supplied funnel and tube slowly add engine oil to the engine Stop frequently to check the level to avoid overfilling see Figure 7 5 Figure 7 5 Adding Engine Oil 8 Continue to add oil until the oil is at the correct level See Checking Engine Oil on page 7 3 Changing Engine Oil ...

Page 35: ... detergent soap to clean the air filter Cleaning the Air Filter 2 1 3 4 5 6 7 8 Figure 7 7 Air Cleaner Assembly 1 Gasket 2 Nuts 3 Air Filter Baffle 4 Gray Fine Inside Filter 5 Black Coarse Outside Filter 6 Air Filter Cover 7 Air Filter Gasket 8 Air Filter Housing 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 en...

Page 36: ...tion used to clean the air filter by dumping the solution into a sewer on the ground or into groundwater or waterways Always be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for proper disposal of hazardous materials Consult local authorities or reclamation facility 8 Dispose of used soap cleaning solution properly 9 Dry the air filter elements by again ...

Page 37: ...e Figure 7 15 3 2 1 Figure 7 15 1 Sediment Bowl 2 O Ring 3 Screen 6 Wipe the pieces clean with clean dry cloth 7 Install the screen O ring and sediment bowl 8 Turn the fuel shutoff valve to the ON position and check for any fuel leaks SPARK PLUG SERVICE 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 St...

Page 38: ...he spark plug fails any one of the conditions listed above replace the plug with a Champion RN9YC plug or equivalent NOTICE Only use the recommended spark plug Champion RN9YC or equivalent Using a non recommended spark plug could result in damage to the engine Figure 7 18 Spark Plug Gap Requirements 8 Install the spark plug by carefully following the steps outlined below a Carefully insert the spa...

Page 39: ...een 8 Install the spark arrestor components in the following order a Place spark arrestor screen over the muffler exhaust pipe Push on the screen until it fully bottoms out b Place the spark arrestor band clamp over the screen and tighten with a flathead screwdriver CHECKING AND ADJUSTING VALVE LASH CAUTION Checking and adjusting valve lash must be done when the engine is cold 1 Loosen the clamp and...

Page 40: ...Start the engine and run the engine at full throttle with no load 2 Attach a frequency meter to the engine The frequency should be 62 5 0 5 Hz 3 Turn the limiting screw on the governor stop to adjust the frequency 4 If the frequency is out of range see Governor Range Adjustment on page 7 10 5 If frequency still cannot be adjusted see Engine Diagnostics on page 8 5 Governor Range Adjustment 1 Remov...

Page 41: ... slightly to access battery cables 4 Disconnect the black negative battery cable from the battery first 5 Disconnect the red positive battery cable second and remove the battery 1 2 Figure 7 25 1 Red Positive Battery Cable 2 Black Negative Battery Cable NOTICE Dispose of the used battery properly according to the guidelines established by your local or state government 6 Install the new battery int...

Page 42: ...remove all dirt on or around the engine s cooling fins see Figure 7 27 Figure 7 27 Engine 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 see Figure 7 28 and Figure 7 29 Fi...

Page 43: ...e generator as outlined in Cleaning the Generator on page 7 12 2 Drain all gasoline from the fuel tank as best as possible 3 With the fuel shutoff 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 4 Close the fuel shutoff valve 5 Change the oil see Changing Engine Oil on page 7 4 6 Remov...

Page 44: ...7 14 MAINTENANCE This Page Intentionally Left Blank ...

Page 45: ...cumstances leading to death serious injury and property damage TROUBLESHOOTING DANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or smell NEVER use inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far away from windows doors and vents OTE N For all dealer service inquiries call 855 944 ...

Page 46: ...s and Connections from 120V Duplex to 240V Receptacle If a Connection is Loose or Disconnected Reestablish a Tight Connection and Recheck Continuity If a Wire or Connection is Damaged Replace Electrical Panel 120V Circuit Check No Output OR Voltage Out of Spec General Electrical Check Check Output Voltage X toY of the 240V Receptacle 246 252V If Voltage Still Out of Range Replace Voltage Regulator...

Page 47: ...ings or Slip Ring Terminals Fuel Cutout 1 3 1 8 If a Winding Resistance is Out of Spec Replace Alternator If Using an Ohmmeter with Kelvin Bridge Clips Measure Resistance at the Slip Ring Wire Terminals for Best Results WH3250 Series only Brown White Red Blue White Blue Green Brown Blue Yellow Blue Yellow WH5500 Series WH6000 Series WH7000 Series WH4500 Series WH3250 Series Electric Start Models 0...

Page 48: ...looking into female connector from alternator VOLTAGE REGULATOR STATOR X WINDING STATOR Y WINDING White Gray Red Black TERMINAL BLOCK Red 2 wires Black 2 wires Blue Blue Green White EXCITER WINDING AVR TAP WINDING EXCITER AVR TAP CONNECTOR view looking into female connector from alternator BRUSH ASSEMBLY Red White 5 9 mm Figure 8 3 ...

Page 49: ... Pull Coil Check Resistance Primary Coil 0 8 1 0 Ohms Secondary Coil 5 9 7 1 Ohms measure at spark plug lead Replace Coil if Necessary Reinstall Coil with Proper Coil Flywheel Air Gap Set gap to 008 016 in 2 4mm Reinstall Plug Recoil Not Operating Recoil Locked Replace Recoil Assembly see Manual Section Recoil Starter Check Recoil for Mechanical Binding Rope Not Retracting see Manual Section Recoi...

Page 50: ...8 6 TROUBLESHOOTING This Page Intentionally Left BlanK ...

Page 51: ...trol Panel Assembly 3 Hour Meter If equipped 4 Main Circuit Breaker 5 120 240 VAC 30 Amp Twist Lock Outlet 6 120 VAC 20 Amp Duplex Outlets 7 Pushbutton Circuit Breakers 8 Engine Control Switch RUN STOP Manual Start Models START RUN STOP Electric Start Models 9 Diode 10 Fuse 5 Amp Electric Start Models 11 Wire Harness 12 Wire Harness Shutdown ...

Page 52: ...9 2 SERVICE AND DISASSEMBLY ALTERNATOR 1 2 3 4 A 5 6 7 9 10 11 13 14 15 16 17 18 View A 19 20 5 6 12 8 Figure 9 2 ...

Page 53: ...ree from engine crankshaft with rotor removal tool properly tightened tap the end of the removal tool with a brass hammer to separate rotor from crankshaft 1 Bolts 2 End Cover 3 Bolt 4 Bolt 5 Voltage Regulator 6 Brush Assembly Before removing rotor and stator remove the brush assembly When installing the brush assembly tighten to 18 in lb 2 N m 7 Negative Battery Cable Electric Start Models 8 Brac...

Page 54: ...AND ALTERNATOR OIL 1 2 3 5 4 6 7 8 9 9 Figure 9 3 1 Rotor Bolt Apply oil to threads before installing 2 Lock Washer 3 Flat Washer 4 Rotor Assembly 5 Stator Assembly 6 Front Engine Adapter 7 Engine Assembly 8 Frame Assembly 9 Shock Mounts ...

Page 55: ... cap securely Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled the area must be dry before starting the engine Avoid repeated or prolonged contact with skin or breathing of vapor 1 2 3 4 5 6 7 Figure 9 4 1 Fuel Tank Mounting Hardware Tighten to 89 in lb 10 N m 2 Fuel Gauge When installing check float for proper operation 3 Fuel Cap Check cap g...

Page 56: ... after stopping the engine Never touch hot surfaces and avoid hot gases Let engine cool before storing the generator indoors 2 3 4 5 6 6 1 to tank Figure 9 5 1 Spark Arrester Tighten to 8 in lb 1 N m 2 Muffler and Heat Shield 3 Muffler Back Plate 4 Exhaust Pipe Tighten to 159 in lb 18 N m 5 Pulse Air Valve 6 Carbon Canister If equipped ...

Page 57: ...el cap securely Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled the area must be dry before starting the engine Avoid repeated or prolonged contact with skin or breathing of vapor 1 2 3 4 5 6 7 9 10 8 Figure 9 6 1 Intake Gasket 2 Insulator 3 Carburetor Gasket 4 Inlet Needle Check for wear on the tip and a weak spring 5 Float Check that float ...

Page 58: ... 1 2 3 4 5 6 Figure 9 7 1 Starter Mounting Bolts 2 Starter Solenoid Tighten solenoid terminal nut to 53 in lb 6 N m 3 Electric Starter Move the engine control switch to the START position to operate starter 4 Battery 5 Red Positive Battery Cable 6 Black Negative Battery Cable ...

Page 59: ...1 2 3 Figure 9 8 OTE N There are no serviceable components for the recoil starter Replace the recoil as an assembly 1 Blower Housing 2 Recoil Starter Install the recoil handle in the position shown 3 Bolts Remove the bolts to replace the starter ...

Page 60: ... the holes on the flywheel Inspect the fan blades for wear or damage Replace the fan if any fins are damaged 2 Starter Cup When installing align the hole in the starter cup with the lug on the cooling fan 3 Flywheel Nut Hold the flywheel from turning and tighten the nut to 77 ft lb 105 N m 4 Blower Housing 5 Recoil Starter ...

Page 61: ... DISASSEMBLY WHEEL LEG AND HANDLE ASSEMBLY 1 2 2 3 4 5 6 7 8 10 9 Figure 9 10 1 Handle Bumper 2 Shock Mount 3 Battery Electric Start Models 4 Wheel 5 Axle Pin 6 Hairpin Clips 7 Foot Pad 8 Foot 9 Handle Grips 10 Handles ...

Page 62: ...9 12 SERVICE AND DISASSEMBLY This Page Intentionally Left Blank ...

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