Westinghouse WH2200iXLT, 4LB User manual

Westinghouse WH2200iXLT, 4LB User manual
California
Proposition 65 Warning
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.
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.
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 MWE Investments, LLC.
2
CONGRATULATIONS ON OWNING A WESTINGHOUSE
INVERTER
! DANGER
This manual contains important instructions for operating this inverter. For your safety and the
safety of others, be sure to read this manual thoroughly before operating the inverter. 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:
Inverter Model Number:
Purchased from Store/Dealer:
Inverter 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 inverter. You can register
your inverter by either:
1. Filling in the product registration form below and mailing to:
Product Registration
MWE Investments, LLC
777 Manor Park Drive
Columbus, OH 43228
2. Registering your product online at
www.westinghouseportablepower.com/register-your-product/
To register your inverter you will need to locate the model
number and serial number. The serial number tag is located
toward the bottom of the inverter housing on the opposite side of
the muffler.
Product Registration Form
PERSONAL INFORMATION
INVERTER 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:
3
TABLE OF CONTENTS
CONGRATULATIONS ON OWNING A WESTINGHOUSE INVERTER...............................................................3
For Your Records:..........................................................................................................................................3
Product Registration......................................................................................................................................3
Product Registration Form.............................................................................................................................3
SAFETY ....................................................................................................................................................................5
SAFETY DEFINITIONS ......................................................................................................................................5
SAFETY SYMBOL DEFINITIONS ......................................................................................................................5
GENERAL SAFETY RULES ...............................................................................................................................6
SAFETY LABELS AND DECALS .................. ....................................................................................................7
UNPACKING ............................................................................................................................................................9
UNPACKING THE INVERTER ...........................................................................................................................9
Components: ...............................................................................................................................................9
FEATURES ..............................................................................................................................................................9
GENERAL INVERTER FEATURES................... ............................................................................................... 9
CONTROL PANEL FEATURES .................. ......................................................................................................10
OPERATION ...........................................................................................................................................................11
BEFORE STARTING THE INVERTER..............................................................................................................11
INVERTER PARALLELING OPERATION .........................................................................................................12
INITIAL OIL FILL ...............................................................................................................................................13
ADDING / CHECKING ENGINE FLUIDS AND FUEL .......................................................................................15
Checking and / or Adding Engine Oil ..........................................................................................................15
Adding Gasoline to the Fuel Tank ...............................................................................................................15
STARTING THE INVERTER .............................................................................................................................16
Using Efficiency Mode ................................................................................................................................17
Resetting the Reset Breaker ......................................................................................................................17
STOPPING THE INVERTER............................................................................................................................. 18
Normal Operation .......................................................................................................................................18
During an Emergency .................................................................................................................................18
MAINTENANCE ......................................................................................................................................................19
MAINTENANCE ................................................................................................................................................19
Maintenance Schedule ...............................................................................................................................19
ENGINE OIL MAINTENANCE ..........................................................................................................................20
Engine Oil Specification..............................................................................................................................20
Checking Engine Oil ..................................................................................................................................20
Adding Engine Oil ......................................................................................................................................20
Changing Engine Oil...................................................................................................................................21
AIR FILTER MAINTENANCE ............................................................................................................................21
Cleaning the Air Filter ................................................................................................................................21
DRAINING THE FLOAT BOWL .........................................................................................................................22
SPARK PLUG MAINTENANCE ........................................................................................................................22
CLEANING THE SPARK ARRESTOR ..............................................................................................................24
CHECKING AND ADJUSTING VALVE LASH ...................................................................................................25
CLEANING THE INVERTER.............................................................................................................................25
STORAGE .........................................................................................................................................................25
SERVICE PARTS ..............................................................................................................................................26
TROUBLESHOOTING ............................................................................................................................................28
TROUBLESHOOTING ......................................................................................................................................28
4
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.
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
NOTICE
Indicates a situation which can cause damage to the
inverter, personal property and/or the environment, or
cause the equipment to operate improperly.
NNOTE: Indicates a procedure, practice or condition
that should be followed in order for the
inverter to function in the manner intended.
Fire Hazard
Lifting Hazard
Pinch-Point Hazard
Read Manufacturer’s Instructions
Read Safety Messages Before
Proceeding
Wear Personal Protective Equipment
(PPE)
5
SAFETY
GENERAL SAFETY RULES
! WARNING
! DANGER
Gasoline and gasoline vapors are
extremely flammable and explosive
under certain conditions.
• Always refuel the inverter outdoors,
in a well-ventilated area.
• Never remove the fuel cap with the
engine running.
• Never refuel the inverter while the
engine is running. Always turn
engine off and allow the inverter to
cool before refueling.
• Only fill fuel tank with gasoline.
• Keep sparks, open flames or other
form of ignition (such as match,
cigarette, static electric source) away
when refueling.
• Never overfill the fuel tank. Leave
room for fuel to expand. Overfilling
the fuel tank can result in a sudden
overflow of gasoline and result in
spilled gasoline coming in contact
with HOT surfaces. Spilled fuel can
ignite. If fuel is spilled on the inverter,
wipe up any spills immediately.
Dispose of rag properly. Allow area
of spilled fuel to dry before operating
the inverter.
• Wear eye protection while refueling.
• Never use gasoline as a cleaning
agent.
• Store any containers containing
gasoline in a well-ventilated area,
away from any combustibles or
source of ignition.
• Check for fuel leaks after refueling.
Never operate the engine if a fuel leak
is discovered.
Never use the inverter in a location
that is wet or damp. Never expose the
inverter to rain, snow, water spray or
standing water while in use. Protect
the inverter from all hazardous weather
conditions. Moisture or ice can cause a
short circuit or other malfunction in the
electrical circuit.
Never operate the inverter in an
enclosed area. Engine exhaust
contains carbon monoxide. Only
operate the inverter outside and away
from windows, doors and vents.
! WARNING
Voltage produced by the inverter could
result in death or serious injury.
• Never operate the inverter in rain or a
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 inverter to the utility
circuit.
• Never touch an operating inverter if
the inverter is wet or if you have wet
hands.
• Never operate the inverter in highly
conductive areas such as around
metal decking or steel works.
• Always use grounded extension
cords. Always use three-wire or
double-insulated power tools.
• Never touch live terminals or bare
wires while the inverter is operating.
• Be sure the inverter is properly
grounded before operating.
! WARNING
Never operate the inverter if powered
items overheat, electrical output drops,
there is sparking, flames or smoke
coming from the inverter, or if the
receptacles are damaged.
NOTICE
Never modify the inverter.
Never operate the inverter if it vibrates at high levels,
if engine speed changes greatly or if the engine
misfires often.
Always disconnect tools or appliances from the
inverter before starting.
6
!
Never use the inverter to power
medical support equipment.
Always remove any tools or other
service equipment used during
maintenance from the inverter before
operating.
SAFETY
SAFETY LABELS
The safety labels have specific placement and must be replaced if they are unreadable, damaged or missing.
3
2
1
1
3
2
FRONT
Figure 3
7
BACK
SAFETY
2
3
1
2
1
3
MWE Investments LLC
Columbus OH 43228 USA
Designed in Columbus, OH USA
Figure 4
8
UNPACKING
UNPACKING THE INVERTER
! CAUTION
Always have assistance when lifting
the inverter. The inverter 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. Remove the document and save it for reference.
3. Carefully cut two sides of the carton to remove the inverter.
Components:
Tool Bag (1)
Screwdriver (1)
Bottle of SAE 15W-40 Oil (1)
Oil Fill Bottle (1)
FEATURES
GENERAL INVERTER FEATURES
2
1
8
5
3
4
6
9
7
Figure 9
1- C
ontrol Panel: Contains the reset breaker,
outlets and warning lights.
2- 1
2-Volt DC Power Socket: Provides 12-volt
DC power up to 8 amps.
3 - Recoil Handle: Pull to start the engine.
4 - Engine/Fuel Control Switch: Turns the
engine and the fuel on and off.
5- S
park Plug Access Cover: Remove the
cover to service the spark plug.
9
6- E
ngine Oil Fill/Drain Plug Service Panel:
Remove the panel to access the engine oil fill/
drain plug for maintenance.
ir Cleaner Access Panel: Remove the panel
7- A
to access the air cleaner for maintenance.
8- F
uel Cap and Vent: Open vent to run the engine,
and close the vent when the engine is off.
9- M
uffler and Spark Arrestor: Avoid contact until
the engine is cooled down. The spark arrestor
prevents sparks from exiting the muffler. It must
be removed for servicing.
FEATURES
CONTROL PANEL FEATURES
3
2
1
7
6
8
5
4
Figure 10 – Control Panel Features
1- 1
20-Volt, 20-Amp Duplex Outlet (NEMA
5-20R): The outlet is capable of carrying a
maximum of 20 amps.
2 - Reset Breaker: If the inverter is overloaded,
the reset breaker will trip. The engine will
continue to run, but there will be no output
from the inverter. Unplug the devices and
reduce the load. Push in the reset breaker to
reset it.
3- E
fficiency Mode Switch: When turned to the
ON position, the engine will sense the load
needed and run at a slower RPM to save fuel.
hoke Knob: Pull out to the ON position
4- C
to start the engine, and push in to the OFF
position once the engine is running.
10
5- O
utput Ready LED: The light will be green
when the inverter is ready to be used.
6- O
verload LED: The red light will come on if
the inverter is overloaded. Decrease the load
before restoring inverter operations.
7- L
ow Oil LED: The red light will come on
and the engine will shut down if the oil level
becomes low. You must add oil to the correct
level before the inverter can be restarted.
8- G
round Terminal: The ground terminal is
used to externally ground the inverter.
OPERATION
BEFORE STARTING THE
INVERTER
Before starting the inverter,
review Safety section.
Location Selection – Before starting the inverter, avoid
exhaust and location hazards by verifying:
• You have selected a location to operate the inverter
that is outdoors and well ventilated.
• You have selected a location with a level and solid
surface on which to place the inverter.
• You have selected a location that is at least 6 feet
(1.8 m) away from any building, other equipment or
combustible material.
• If the inverter is located close to a building, make
sure it is not located near any windows, doors
and/or vents.
Weather – Never operate your inverter outdoors during
rain, snow or any combination of weather conditions
that could lead to moisture collecting on, in or around
the inverter.
Dry Surface – Always operate the inverter on a dry
surface free of any moisture.
No Connected Loads – Make sure the inverter
has no connected loads before starting it. To ensure
there are no connected loads, unplug any electrical
extension cords that are plugged into the control panel
receptacles.
NOTICE
Starting the inverter with loads already applied to
it could result in damage to any appliance being
powered off the inverter during the brief start-up
period.
Grounding the Inverter – Consult with your local
municipalities for your grounding codes.
! WARNING
Always operate the inverter on a level
surface. Placing the inverter on nonlevel surfaces can cause the inverter
to tip over, causing fuel and oil to spill.
Spilled fuel can ignite if it comes in
contact with an ignition source such as
a very hot surface.
NOTICE
Only operate the inverter on a solid, level surface.
Operating the inverter on a surface with loose
material such as sand or grass clippings can cause
debris to be ingested by the inverter that could:
• Block cooling vents
• Block air intake system
11
Figure 13 – Ground Terminal on the Control Panel
! WARNING
Be sure the inverter is properly
connected to earth ground before
operating.
OPERATION
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
INVERTER PARALLELING
OPERATION
! DANGER
Never connect the paralleling cord to
the inverters with the inverters running.
The inverters must not be running and
both the paralleling cord switches must
be off when connecting the cords.
! WARNING
Always ensure that both ends of the
paralleling cord are switched off before
connecting the inverters.
1. Using only the Westinghouse paralleling cord (Part
No. 260041) with both cord switches set to OFF
(O), connect one male plug to one inverter and
connect the remaining plug into the other inverter.
Either of the receptacles on the inverters can be
used (see Figure 15).
! WARNING
Do not attempt to parallel the
Westinghouse inverter with any other
manufacturers’ inverters. Do not use
the paralleling cord for any application
other than inverter paralleling. Do not
use this cord on other manufacturers’
inverters.
Figure 14 – Paralleling Cord ON/OFF Switches
12
OPERATION
2. Start one of the inverters and wait until the ready
light is on.
3. Turn both cord switches to ON (I).
4. Start the remaining inverter; wait until the ready
light is on before connecting the load.
5. When power is present, a light will illuminate in the
three-prong plug that is plugged into the inverter.
INITIAL OIL FILL
NOTICE
Engine oil must be added when the inverter is on
a flat, level surface, or an inaccurate reading may
result. Do not overfill. If the engine is overfilled with
oil, it can cause serious engine damage.
1. Loosen the screw and remove the engine oil fill/
drain plug service panel to access the oil fill/drain
plug (see Figure 21).
Figure 15 – Paralleling Cord Connected
6. To stop the inverters, unplug all connected loads,
turn both cord switches to OFF (O) and unplug the
cord on each inverter.
7. If during operation the inverters’ output is stopped
due to overloading, reduce the connected load by
unplugging appliances, and then push the reset
button and restart the inverter. When the ready light
is on, the load can be reconnected.
Figure 21 – Engine Service Panel
2. Clean the area around the oil fill/drain plug and
remove plug (see Figure 22).
Figure 22 – Oil Fill/Drain Plug
NOTE: The oil capacity for the 2200iXLT is
400 ml.
13
OPERATION
3. Using the supplied oil fill container and oil, fill the
container to the 2.0 mark on the container. Do not
overfill (see Figure 23).
2.0
1.5
1.0
0.5
Figure 23 – Oil Fill Container
NOTICE
Do not tilt the inverter to add oil. It must be filled on a
flat, level surface.
4. Add the 200 ml of oil to the engine (see Figure 24).
Figure 24 – Adding Engine Oil
5. Fill the container with oil again to the 2.0 mark.
6. Add the 200 ml of oil to the engine. The oil should
now be at the correct level (see Figure 25).
14
Figure 25 – Engine Oil Correct Level
7. Do not overfill. If oil level is too high, oil will drain out
through the fill plug.
OPERATION
ADDING / CHECKING ENGINE
FLUIDS AND FUEL
Before adding/checking engine
fluids and fuel, review Safety
section.
Adding Gasoline to the Fuel Tank
! WARNING
Never refuel the inverter while the
engine is running.
Always turn the engine off and allow
the inverter to cool before refueling.
! DANGER
Filling the fuel tank with gasoline
while the inverter is running can cause
gasoline to leak and come in contact
with hot surfaces that can ignite the
gasoline.
Before starting the inverter, always check the level of:
• Engine oil
• Gasoline in the fuel tank
Once the inverter is started and the engine gets warm,
it is not safe to add gasoline to the fuel tank or engine
oil to the engine while the engine is running or the
engine and muffler are hot.
Checking and / or Adding Engine Oil
! WARNING
Internal pressure can build in the
engine crankcase while the engine
is running. Removing the oil fill plug/
dipstick while the engine is hot can
cause extremely hot oil to spray out
of the crankcase and can severely
burn skin. Allow engine oil to cool for
several minutes before removing the oil
fill plug/dipstick.
Required Gasoline – Only use gasoline that meets the
following requirements:
• Unleaded gasoline only
• Gasoline with maximum 10% ethanol added
• Gasoline with an 87 octane rating or higher
Filling the Fuel Tank – Follow the steps below to fill the
fuel tank:
1. Shut off the inverter.
2. Allow the inverter to cool down so all surface areas
of the muffler and engine are cool to the touch.
3. Move the inverter to a flat surface.
4. Clean area around the fuel cap.
5. Remove the fuel cap by rotating counterclockwise.
NOTICE
Do not overfill the fuel tank. Spilled fuel will damage
some plastic parts.
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 red ring (see Figure
26).
7. Install the fuel cap by rotating clockwise.
The unit as shipped does not contain oil in the
engine. You must add engine oil before starting the
inverter for the first time. See Engine Oil
Maintenance for instructions on checking engine oil
level and the procedure for adding engine oil.
NOTICE
The inverter does not contain engine oil as shipped.
Attempting to start the engine without adding
engine oil will permanently damage internal engine
components.
Figure 26 – Maximum Gasoline Fill Level
15
OPERATION
! CAUTION
!
Avoid prolonged skin contact with
gasoline. Avoid prolonged breathing of
gasoline vapors.
STARTING THE INVERTER
For proper starting and operation of the inverter,
make sure you review the inverter features and
their descriptions.
Before starting the inverter,
review Safety Section.
Before attempting to start the inverter, verify the
following:
NOTICE
The engine is equipped with a low oil shutdown
switch. If the oil level becomes low, the engine will
shut down and will not start until the oil is filled to the
proper level.
Be sure the engine has the proper oil level before
using. Failure to verify that the engine has the proper
oil level could result in engine damage.
Disconnect all loads from the inverter before starting.
Failure to verify all loads are disconnected prior to
starting the inverter could result in damage to the
connected appliances.
NNOTE: There are key areas that need to be
addressed when starting the inverter. These
key areas are highlighted in yellow.
1. Turn the fuel tank vent to the ON position (see
Figure 27).
• The inverter is situated in a proper location (see
Location Selection.
• The inverter is on a dry surface (see Weather and
Dry Surface.
• All loads are disconnected from the inverter (see No
Connected Loads).
• The inverter is properly grounded (see Grounding
the Inverter).
! DANGER
Never use the inverter in a location
that is wet or damp. Never expose the
inverter to rain, snow, water spray or
standing water while in use. Protect
the inverter from all hazardous weather
conditions. Moisture or ice can cause a
short circuit or other malfunction in the
electrical circuit.
Figure 27 – Fuel Tank Vent
2. Turn the engine/fuel control switch to the ON
position (see Figure 28).
Never operate the inverter in an
enclosed area. Engine exhaust
contains carbon monoxide. Only
operate the inverter outside and away
from windows, doors and vents.
Figure 28 – Engine/Fuel Control Switch
16
OPERATION
3. Pull the choke knob out to the ON position (see
Figure 29).
Using Efficiency Mode
The inverter is equipped with an efficiency mode switch
to minimize fuel consumption. In efficiency mode, the
inverter will sense the load and adjust the engine RPM
to the current load requirements. Efficiency mode
should be used only after the inverter has been warmed
up to operating temperature.
1. To turn on the efficiency mode, press the switch to
the ON position (see Figure 31).
Figure 29 – Choke Knob
4. Firmly grasp and pull the recoil handle slowly until
you feel increased resistance. At this point, apply
a rapid pull while pulling out from the inverter (see
Figure 30).
Figure 31 – Efficiency Mode Switch
2. If no load is present, the inverter RPM will drop
down to an idle speed.
3. As a load is applied, the inverter will sense the load
and engine RPM will increase according to the load
applied.
4. To run the inverter at maximum power and RPM,
press the efficiency mode switch to the OFF
position.
Resetting the Reset Breaker
The inverter will trip the breaker and automatically
disconnect from the load when the controls sense a
predetermined overload condition. The inverter engine
will continue to run, but there will not be any electrical
output.
1. Turn off all devices and unplug them from the
inverter.
Figure 30 – Recoil Handle
5. As the engine starts and stabilizes, gradually push
the choke knob back in to the OFF position.
2. Determine the wattage required from the devices
being powered by the inverter. Make sure the
wattage required does not exceed the maximum
output of the inverter.
3. Press in the reset breaker to reset it.
4. Plug the devices in to the inverter.
5. Turn on the devices as needed.
17
OPERATION
STOPPING THE INVERTER
Normal Operation
During normal operation, use the following steps to stop
your inverter:
1. Remove any connected loads from the control
panel receptacles.
2. Allow the inverter to run at “no load” to reduce and
stabilize engine and alternator temperatures.
3. Move the engine control switch to the OFF position.
4. Turn the fuel tank vent to the OFF position.
During an Emergency
If there is an emergency and the inverter must be
stopped quickly, move the engine control switch to the
OFF position immediately.
18
MAINTENANCE
MAINTENANCE
! CAUTION
Before performing maintenance
on the inverter, review Safety
section and the following safety
messages.
Avoid skin contact with engine oil or
gasoline. Prolonged skin contact with
engine oil or gasoline can be harmful.
Frequent and prolonged contact with
engine oil may cause skin cancer.
Take protective measures and wear
protective clothing and equipment.
Wash all exposed skin with soap and
water.
! WARNING
Avoid accidentally starting the inverter
during maintenance by removing
the spark plug boot from the spark
plug. For electric start inverters, also
disconnect the battery wires from the
battery (disconnect the black negative
(-) wire first) and place the wires away
from the battery posts to avoid arcing.
!
Allow hot components to cool to
the touch prior to performing any
maintenance procedure.
Internal pressure can build in the
engine crankcase while the engine
is running. Removing the oil fill plug/
dipstick while the engine is hot can
cause extremely hot oil to spray out
of the crankcase and can severely
burn skin. Allow engine oil to cool for
several minutes before removing the oil
fill plug/dipstick.
Always perform maintenance in a wellventilated area. Gasoline fuel and fuel
vapors are extremely flammable and
can ignite under certain conditions.
Maintenance Schedule
! WARNING
Failure to perform periodic
maintenance or not following
maintenance procedures can cause the
inverter to malfunction and could result
in death or serious injury.
!
NOTICE
Periodic maintenance intervals vary depending on
inverter operating conditions. Operating the inverter
under severe conditions, such as sustained highload, high-temperature, or unusually wet or dusty
environments, will require more frequent periodic
maintenance. The intervals listed in the maintenance
schedule should be treated only as a general
guideline.
Following the maintenance schedule is important to
keep the inverter in good operating condition. The
following is a summary of maintenance items by
periodic maintenance intervals.
Table 1: Maintenance Schedule - Owner Performed
Maintenance
Item
Before Every
Use
After First 20
Hours or First
Month of Use
After 50 Hours
of Use or Every
3 Months
After 100 Hours
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
–
Clean1
–
Replace
Spark Plug
–
–
–
Check/Clean
Replace
Spark Arrestor
–
–
–
Check/Clean
–
1
Service more frequently if operating in dry and dusty conditions.
19
ENGINE OIL MAINTENANCE
Engine Oil Specification
1. Only use the engine oil specified in Figure 32.
2. Only use 4-stroke/cycle engine oil. NEVER
USE 2-STROKE/CYCLE OIL. Synthetic oil is an
acceptable substitute for conventional oil.
0°C
SAE 5W-30
25°C
SAE 10W-30
A
Engine oil must always be checked and added when
the inverter is on a flat, level surface, or an inaccurate
reading may result, causing serious engine damage.
7. Check oil level:
When checking the engine oil, remove the oil fill/
drain plug.
• The oil level is acceptable if oil is visible at the
bottom of the threads of the oil fill plug.
SAE 15W-40
C
B
32°F
NOTICE
80°F
Figure 32 – Recommended 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.
• If oil level is low, add to the correct level using
the supplied oil fill bottle. Do not overfill the oil
crankcase.
Adding Engine Oil
1. Always operate or maintain the inverter on a flat
surface.
2. Stop engine if running.
3. Let engine sit and cool for several minutes (allow
crankcase pressure to equalize).
4. Remove the engine service panel to gain access to
the oil fill/drain plug.
5. Thoroughly clean around the oil fill/drain plug.
6. Remove the oil fill/drain plug.
7. Select the proper engine oil as specified in Figure
32.
8. Using the supplied oil fill container, slowly add
engine oil to the engine. Stop frequently to check
the oil level and avoid overfilling (see Figure 38).
1. Always operate or maintain the inverter on a flat
surface.
2. Stop engine if running.
3. Let engine sit and cool for several minutes (allow
crankcase pressure to equalize).
4. Remove the engine service panel to access the oil
fill/drain plug.
5. With a damp rag, clean around the oil fill/drain plug.
6. Remove the oil fill/drain plug (see Figure 35).
Figure 38 – Adding Engine Oil
9. Continue to add oil until the oil is at the correct
level. See Checking Engine Oil
20
Figure 35 – Oil Fill/Drain Plug
MAINTENANCE
Changing Engine Oil
Cleaning the Air Filter
1. Stop the engine.
The air filter must be cleaned after every 50 hours of
use or 3 months (frequency should be increased if
inverter is operated in a dusty environment).
2. Let engine sit and cool for several minutes (allow
crankcase pressure to equalize).
3. Remove the engine service panel to gain access to
the oil fill/drain plug.
1. Turn off the inverter and let it cool for several
minutes if running.
4. Place oil pan (or suitable container) under the oil fill/
drain plug.
2. Remove the air cleaner access panel to gain
access to the air filter.
5. With a damp rag, thoroughly clean around the oil
fill/drain plug.
3. Remove the screw for the air cleaner cover and
remove the cover (see Figure 43).
6. Tilt the inverter so the oil drains down the trough
into the container (see Figure 40).
Figure 43 – Air Cleaner Cover
Figure 40 – Draining Engine Oil
4. Remove the foam element from the air cleaner
housing (see Figure 44).
7. Allow oil to completely drain.
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 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.
9. Dispose of used engine oil properly.
Figure 44 – Foam Element
21
MAINTENANCE
5. Wash the foam air filter element by submerging
the element in a solution of household detergent
soap and warm water. Slowly squeeze the foam to
thoroughly clean.
NOTICE
NEVER twist or tear the foam air filter element
during cleaning or drying. Only apply slow but firm
squeezing action.
6. Rinse in clean water by submerging the air filter
element 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 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.
Figure 47 – Float Bowl Drain Screw
4. Allow fuel to drain into the container, and then
tighten the float bowl drain screw.
NOTICE
Never dispose of fuel by dumping fuel into a sewer,
on the ground, or into groundwater or waterways.
Always be environmentally responsible. Follow the
guidelines of the EPA or other governmental agencies
for proper disposal of hazardous materials. Consult
local authorities or reclamation facility.
5. Install the engine service panel.
7. Dispose of used soap cleaning solution properly.
8. Dry the air filter element by again applying a slow
firm squeezing action.
9. Return the air filter element to its position in the air
cleaner housing.
10. Install the air cleaner cover, making sure the tabs
lock into place.
11. Install the air cleaner access panel.
DRAINING THE FLOAT BOWL
1. Remove the engine service panel to access the
float bowl drain.
SPARK PLUG MAINTENANCE
The spark plug must be checked and cleaned after
every 100 hours of use or 6 months and must be
replaced after 300 hours of use or every year.
1. Stop the inverter and let it cool for several minutes
if running.
2. Move the inverter to a flat, level surface.
3. Slide the spark plug access cover off the housing
(see Figure 48).
Figure 46 – Engine Service Panel
2. Locate the clear plastic hose from the float that is
exiting out the bottom of the inverter, and place a
suitable container under it to catch the drained fuel.
3. Loosen the float bowl drain screw until fuel is seen
draining from the float bowl (see Figure 47).
Figure 48 – Spark Plug Access Cover
4. Remove the spark plug boot by firmly pulling the
plastic spark plug boot handle directly away from
the engine (see Figure 49).
22
MAINTENANCE
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.
8. Inspect the spark plug for:
• Cracked or chipped insulator
• Excessive wear
• Spark plug gap of 0.032 in. (0.80 mm) (see
Figure 51).
If the spark plug fails any one of the conditions
listed above, replace the plug.
NOTICE
Only use the recommended spark plug (Torch
A5RTC or equivalent). See chart below. Using a nonrecommended spark plug could result in damage to
the engine.
Figure 49 – Removal of Spark Plug Boot
5. Clean area around the spark plug.
6. Using the spark plug socket wrench provided,
remove the spark plug from the cylinder head (see
Figure 50).
Figure 51 – Spark Plug Gap Requirements
8. Install the spark plug by carefully following the steps
outlined below:
a - Carefully insert the spark plug back into the
cylinder head. Hand-thread the spark plug until
it bottoms out.
b - Using the spark plug socket wrench provided,
turn the spark plug to ensure it is fully seated.
c - Replace the spark plug boot, making sure the
boot fully engages the spark plug’s tip.
d - Install the spark plug access cover.
Recommended Spark Plug Replacement:
Figure 50 – Removing Spark Plug
7. 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.
23
AutoLite
4194
Denso
6010
NGK
CR4HJB
Torch
A5RTC
MAINTENANCE
CLEANING THE SPARK
ARRESTOR
Check and clean the spark arrestor after every 100
hours of use or 6 months.
1. Stop the inverter and let it cool for several minutes
if running.
2. Move the inverter to a flat, level surface.
3. Remove the four screws holding the muffler cover in
place (see Figure 52).
6. Pull the spark arrestor screen off the muffler
exhaust pipe.
7. Using a wire brush, remove any dirt and debris that
may have collected on the spark arrestor screen.
8. If the spark arrestor screen shows signs of wear
(rips, tears or large openings in the screen), replace
the spark arrestor screen.
9. 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. Remove the rocker arm cover and carefully remove
the gasket. If the gasket is torn or damaged, it must
be replaced.
Figure 52 – Muffler Cover
4. Loosen the clamp holding the spark arrestor onto
the muffler (see Figure 53).
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°.
Figure 53 – Spark Arrestor Clamp
5. Slide the spark arrestor band clamp off the spark
arrestor screen.
24
MAINTENANCE
5. Insert a feeler gauge between the rocker arm and
the push rod and check for clearance (see Figure
54). See Table 2 for valve lash specifications.
3
1
CLEANING THE INVERTER
It is important to inspect and clean the inverter before
every use.
Clean All Engine Air Inlet and Outlet Ports – Make
sure all engine air inlet and outlet ports are clean of any
dirt and debris to ensure the engine does not run hot.
2
STORAGE
4
5
Figure 54
1 - Push Rod
4 - Jam Nut
2 - Rocker Arm
5 - Adjusting Nut
3 - Feeler Gauge
Area
Table 2: Standard Valve Lash
Intake
Exhaust
0.0035 – 0.0043 in.
(0.09 – 0.11 mm)
0.0043 – 0.0051 in.
(0.11 – 0.13 mm)
6. If an adjustment is required, hold the adjusting nut
and loosen the jam nut.
7. Turn the adjusting nut to obtain the correct valve
lash. When the valve lash is correct, hold the
adjusting nut and tighten the jam nut to 106 in-lb
(12 N·m).
8. Recheck the valve lash after tightening the jam nut.
9. Perform this procedure for both the intake and
exhaust valves.
10. Install the rocker arm cover, gasket and spark plug.
25
! WARNING
Never store an inverter with fuel in the
tank indoors or in a poorly ventilated
area where the fumes can come in
contact with an ignition source such
as a: 1) pilot light of a stove, water
heater, clothes dryer or any other gas
appliance; or 2) spark from an electric
appliance.
NOTICE
Gasoline stored for as little as 60 days can go bad,
causing gum, varnish and corrosive buildup in fuel
lines, fuel passages and the engine. This corrosive
buildup restricts the flow of fuel, preventing an engine
from starting after a prolonged storage period.
Proper care should be taken to prepare the inverter for
any storage.
1. Clean the inverter as outlined in Cleaning the
Inverter
2. Siphon all gasoline from the fuel tank as best as
possible.
3. Start the engine and allow the inverter to run until
all the remaining gasoline in the fuel lines and
carburetor is consumed and the engine shuts off.
4. Drain any remaining fuel from the float bowl.
5. Change the oil
6. Remove the spark plug and place about 1
tablespoon of oil in the spark plug opening. While
placing a clean rag over the spark plug opening,
slowly pull the recoil handle to allow the engine to
turn over several times. This will distribute the oil
and protect the cylinder wall from corroding during
storage.
7. Replace the spark plug.
8. Move the inverter to a clean, dry place for
storage.
MAINTENANCE
Service Parts
3
4
5
27
2
21 22
25
16
17
18
19
6
14
15
7 8
26
20
9
10
13
11
12
Figure 56
26
23
MAINTENANCE
Item
27
Description
WH#
Qty
2
260005
Reset Breaker
1
3
260014
Efficiency Mode Switch
1
4
260021
Choke Cable
1
5
260039
12-volt DC Power Socket
1
6
260020
Recoil Starter
1
7
260019
Spark Plug Cover (Blue)
1
8
260003
A5RTC (Torch) Spark Plug
1
9
260017
Oil Filling Cover (Blue)
1
10
260015
Oil Filler Plug
1
11
260018
Draining Fuel Cover, Carburetor (Blue)
1
12
260026
Rubber Support Feet
4
13
260016
Air Cleaner Element
1
14
260007
Fuel Tank Cap Assy.
1
15
260028
Fuel Strainer
1
16
260025
Muffler Outer Cover
1
17
260024
Hose Clamp
1
18
260023
Lock Cap, Spark Arrestor Element
1
19
260022
Spark Arrestor Element
1
20
260040
Air Intake Cover
1
21
260043
Fuel Valve
1
22
260044
Engine/Fuel Control Knob
1
23
140083
Carburetor
1
25
260051
Front Housing
1
26
260052
Rear Housing
1
27
260027
Indicator Lights
1
TROUBLESHOOTING
TROUBLESHOOTING
! WARNING
Before attempting to service or
troubleshoot the inverter, 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
Engine is running, but no
electrical output.
Engine will not start or
remain running while trying
to start.
Inverter suddenly stops
running.
Engine runs erratic; does
not hold a steady RPM.
28
POTENTIAL CAUSE
SOLUTION
1.
Reset breaker is tripped.
1.
Reset the reset breaker
2.
The power cord’s plug
connector is not fully engaged
in the inverter’s outlet.
2.
Verify plug connector is firmly engaged in the
inverter’s outlet.
3.
Faulty or defective power cord
3.
Replace power cord.
4.
Faulty or defective electrical
appliance
4.
Try connecting a known good appliance to verify the
inverter is producing electrical power.
1.
Inverter is out of gasoline.
1.
Add gasoline to the inverter
2.
Fuel flow is obstructed.
2.
Inspect and clean fuel delivery passages.
3.
Unit is overchoked.
3.
Move the choke knob halfway between the ON and
OFF positions.
4.
Dirty air filter
4.
Check and clean the air filter
5.
Low oil level shutdown switch
is preventing the unit from
starting.
5.
Check oil level and add oil if necessary
6.
Spark plug boot is not fully
6.
engaged with the spark plug tip.
Firmly push down on the spark plug boot to ensure
the boot is fully engaged.
7.
Spark plug is faulty.
Remove and check the spark plug. Replace if faulty
8.
Dirty/plugged spark arrestor
8.
Check and clean the spark arrestor
9.
Stale fuel
9.
Drain fuel and replace with fresh fuel.
7.
10. Fuel system needs priming
10. Prime the fuel system
1.
Inverter is out of fuel.
1.
Check fuel level . Add fuel if
necessary.
2.
The low oil shutdown switch
has stopped the engine.
2.
Check oil level and add oil if necessary
3.
Too much load
3.
Restart the inverter and reduce the load.
1.
Choke was left in the ON
position.
1.
Move choke to the OFF position.
2.
Dirty air filter
2.
Clean the air filter
3.
Applied loads may be cycling
on and off
3.
As applied loads cycle, changes in engine speed
may occur; this is a normal condition.
MAINTENANCE NOTES
MAINTENANCE NOTES
MAINTENANCE NOTES
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