Altitude Kit Installation - iGen4500, iGen4500DF

By Jackie Green on Fri Nov 06, 20

HIGH ALTITUDE REPLACEMENT KIT

Engine performance decreases as altitude increases. Proper operation can be ensured by installing an altitude kit when required. See the table below to determine when an altitude kit is required. Operating this generator without the proper altitude kit installed may increase the engine’s emissions and decrease fuel economy and performance.

ALTITUDE KIT iGen 4500 and 4500DF INVERTER – Westinghouse Part No.
iGen4500 - 140573
iGen4500DF - 140569

  Altitude Range   Jet Number
  0-2000ft   Not required
  2000-3000ft   A
  3000-5000ft   B
  5000-6000ft   C
  6000-7000ft   D

Please note:

  • This high-altitude kit is to be used at elevations above 2000 feet.
  • At elevations above 7000 feet, the engine may experience decreased performance, even with the high altitude kit.
  • If the carburetor is replaced, the proper high-altitude kit jet will need to be installed into the replacement carburetor.
  • The warranty may be void if necessary adjustments are not made for high altitude use.
  • DO NOT throw away any carburetor jets. You may need them again if you change altitude of operation.

 

WARNING! TO PREVENT SERIOUS INJURY FROM FIRE:

Perform kit procedures in a well ventilated area away from ignition sources. If the engine is hot from use, shut the engine off and wait for it to cool before proceeding. Do not smoke near generator.
It is recommended to completely drain all the gasoline from the fuel tank and carburetor float. See owners manual for proper instructions on how to safely drain fuel.

To install a high altitude kit, follow these Operation Steps:

Step 1: Make sure the engine is “off” and the generator is cold.
 Step 2: Make sure the fuel valve is in the off or Propane (DF) position.
 Step 3: Remove the battery access cover and disconnect the battery.
 Step 4: Remove the left side engine service panel.
 Step 5: Remove the spark plug boot from the spark plug.
 Step 6: (DF models only) Remove the rubber plug and screw in the middle of the fuel knob and remove the valve.
 Step 7: (DF models only) Remove the screws and pull out the control panel. Do not disconnect any wires.
 Step 8: (DF models only) Disconnect the propane hose at the junction.
 Step 9: Remove the screws from the front panel and pull it away from the chassis. Pull the propane hose through the boot (DF models).
 Step 10: Place container under to carburetor to catch fuel in the bowl. Loosen the carburetor drain screw and empty the float bowl into a suitable container.
 Step 11: Remove the two bolts in the silencer box cover and remove the foam element.
 Step 12: Remove the crankcase breather tube and vapor tube from the airbox housing.
 Step 13: Remove the two nuts and remove the inner air box housing and gasket.
 Step 14: Remove the electrical connectors for the choke, throttle and fuel solenoid (DF models only).
 Step 15: Remove the gasoline fuel line from the carburetor.
 Step 16: Remove the carburetor from the unit.
 Step 17: Remove bolt at bottom of carburetor float bowl.
 Step 18: Refer to tables on page 1, install the proper high-altitude jet in the carburetor.
 Step 19: Make sure to replace O-ring (provided) where the bowl meets the carburetor. Also replace the bolt seal (provided) on the bottom of the carburetor. and assemble the carburetor properly, the torque of bolt on carburetor is: 8 lb/ft 10N.m. DO NOT DISCARD OLD CARBURETOR JET.
 Step 20: Inspect the insulator gasket and slide the carburetor back onto the stud bolts.
 Step 21: Reinstall the gasoline fuel hose on to the carburetor.
 Step 22: (DF models only) Route the propane hose through the rubber boot and into the front panel. Leave the panel loose currently.
 Step 23: Reconnect the electrical connections from step 14 for the throttle, choke and fuel solenoid (DF models only). Verify proper cable routing through the clips above the recoil assembly.
 Step 24: Replace the inner air box and gasket. Tighten the two nuts securing the assembly.
 Step 25: Place foam element back in the air box and replace the lid with the two bolts.
 Step 26: Reinstall the breather tube and vapor tube.
 Step 27: Install the front panel. Make sure not to pinch any hoses or wires behind the panel.
 Step 28: Install the propane hose onto the fitting inside the panel. Make sure the gasket is in good condition.
 Step 29: (DF models only) Install the control panel.
 Step 30: (DF models only) Install the fuel knob. Do not forget to replace the rubber cover on the knob.
 Step 31: Install the spark plug boot.
 Step 32: Install the maintenance panel using the four screws and bolt.
 Step 33: Reconnect the battery connector and replace the cover.
 Step 34: Test the unit for function in a well-ventilated area.

 

NOTE: If you move the generator back to a location below the elevation for which it is jetted, you will need to replace the carburetor jet with the one appropriate for that altitude. Failing to do so may result in poor performance and potential engine damage. PLEASE KEEP ALL PARTS YOU REMOVED FOR FUTURE USE.