WEN 56352 User Manual

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Page 1

MODEL 3500

Questions? Problems?

Please call our customer help line:

(800) 232-1195 M-F 8-5 CST

 HP Generator

Item # 56352

Owner’s Manual

Manual del Propietario

FEATURES

 3500 Surge Watt Output  3000 Rated Watt Output  Powerful Enough to Run Essential Appliances During Power Outages  120 and 240 Volt AC Outputs  Low Oil Automatic Shutoff  Circuit Breaker for Overload Protection  4 Gallon Fuel Tank Capacity  Engine Hour Counter  Cigarette Lighter Style 12V DC Outlet  Spark Arrester  Meets EPA Emission Standards

Page 2

Page 3

GENERATOR IDENTIFICATION

Date

Oil Change

Change spark plug

Clean Fuel Tank

Clean Filter Cup

Clean Air Cleaner

For information and questions, please contact the Customer Service Help Line by calling 800-232-

1195. Certain information will be requested by the Customer Service Representative and to facilitate that, please fill in the information below.

Refer to the illustration below for the location of Serial Number. Record generator information in the spaces provided below.

DATE OF PURCHASE: ______________________________________________

PURCHASED FROM: ______________________________________________

GENERATOR MODEL NUMBER: ____________________________________

ENGINE SERIAL NUMBER: _________________________________________

SERVICE RECORD

Record Service Dates:

ENGINE SERIAL NUMBER

Page 4

TABLE OF CONTENTS

GENERATOR IDENTIFICATION ................................................................................................ i

SERVICE RECORD ......................................................................................................................... i

INTRODUCTION ............................................................................................................................ 1

SAFETY INFORMATION .............................................................................................................. 2

GENERAL SAFETY PROCEDURES ........................................................................................... 3

IMPORTANT SAFETY INSTRUCTIONS ................................................................................... 5

PACKAGE CONTENTS ................................................................................................................. 8

GENERATOR COMPONENTS ..................................................................................................... 9

ASSEMBLY .................................................................................................................................... 10

Attach Feet ................................................................................................................................ 10

Attach Handles ......................................................................................................................... 11

Attach Wheels ........................................................................................................................... 11

GENERATOR PREPARATION .................................................................................................. 13

Using the Generator for the First Time ........................................................................................ 13

Step 1 - Fill Oil ......................................................................................................................... 13

Step 2- Add Gasoline ................................................................................................................ 14

Step 3- Ground the Generator ................................................................................................... 15

STARTING THE GENERATOR ................................................................................................. 16

SUBSEQUENT STARTING OF THE GENERATOR ............................................................... 17

Step 1- Check the Oil................................................................................................................ 17

Step 2 – Check the Fuel Level .................................................................................................. 18

Step 3- Ground the Generator ................................................................................................... 18

USING THE GENERATOR ......................................................................................................... 19

AC Usage ...................................................................................................................................... 19

DC Usage ...................................................................................................................................... 22

STOPPING THE GENERATOR.................................................................................................. 22

MAINTENANCE / CARE ............................................................................................................. 23

Cleaning the Generator ................................................................................................................. 23

Checking the Oil ........................................................................................................................... 23

Changing/ Adding Oil .................................................................................................................. 24

Air Cleaner Maintenance .............................................................................................................. 25

Fuel Filter Cup Cleaning .............................................................................................................. 25

Spark Plug Maintenance ............................................................................................................... 26

Draining the Fuel Tank ................................................................................................................. 26

STORAGE / TRANSPORT PROCEDURES .............................................................................. 27

SPECIFICATIONS ........................................................................................................................ 28

TROUBLESHOOTING ................................................................................................................. 29

EXPLODED VIEW AND PARTS LIST ...................................................................................... 30

WIRING DIAGRAM ..................................................................................................................... 34

WARRANTY STATEMENT ........................................................................................................ 36

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INTRODUCTION

Thank You for Purchasing a WEN Power TM Product.

. This manual provides information regarding the safe operation and maintenance of this product. Every effort has been made to ensure the accuracy of the information in this manual. WEN Power prior notice.

Please keep this manual available to all users during the entire life of the generator.

reserves the right to change this product and specifications at any time without

Special Messages

This manual contains special messages to bring attention to potential safety concerns, generator damage as well as helpful operating and servicing information. Please read all the information carefully to avoid injury and machine damage.

Questions? Problems?

In order to answer questions and solve problems in the most efficient and speedy manner, contact Customer Service at:

(800) 232-1195 M-F 8-5 CST

NOTICE REGARDING EMISSIONS

Engines that are certified to comply with U.S. EPA emission regulations for SORE (Small Off Road Equipment), are certified to operate on regular unleaded gasoline, and may include the following emission control systems: (EM) Engine Modifications and (TWC) Three-Way Catalyst (if so equipped).

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SAFETY INFORMATION

Before operating this generator read and observe all warnings, cautions, and instructions on

this sheet, on the generator, and in the Owner’s Manual.

NOTE: The following safety information is not meant to cover all possible conditions and

situations that may occur. Read the entire Owner’s Manual for safety and operating instructions. Failure to follow instructions and safety information could result in serious injury or death.

This safety alert symbol is used to identify safety information about hazards that can result in

personal injury.

A signal word (DANGER, WARNING, or CAUTION) is used

with the alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.

DANGER indicates a hazard, which, if not avoided, will result in death or serious

injury.

WARNING indicates a hazard, which, if not avoided, could result in death or

serious injury.

CAUTION indicates a hazard, which, if not avoided, might result in minor or

moderate injury.

CAUTION, when used without the alert symbol, indicates a situation that could

result in damage to the engine or generator.

SAFETY SYMBOLS AND MEANINGS

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GENERAL SAFETY PROCEDURES

For any questions regarding the hazard and safety notices listed in this manual or on the

product, please call (800) 232-1195 M-F 8-5 CST before using the generator.

DANGER: CARBON MONOXIDE. Using a generator indoors CAN KILL

YOU IN MINUTES.

Generator exhaust contains carbon monoxide (CO). This is a poison gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.

 NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed

areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh air.

 ONLY use a generator outside and far away from windows, doors, and vents. These

openings can pull in generator exhaust. Even if you use a generator correctly, CO may leak into the home. ALWAYS use a batterypowered or battery-backup CO alarm in the home. If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

WARNING: The exhaust from this product contains chemicals known to the

State of California to cause cancer, birth defects, or other reproductive harm.

WARNING: This generator may emit highly

flammable and explosive gasoline vapors, which can cause severe burns or even death, if ignited. A nearby open flame can lead to explosion even if not directly in contact with gasoline.

 Do not operate near open flame.  Do not smoke near generator.  Always operate on a firm, level surface.  Always turn generator off before refueling. Allow generator to cool for at least 2

minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

 Do not overfill fuel tank. Gasoline may expand during operation. Do not fill to the

top of the tank. Allow for expansion.

 Always check for spilled fuel before operating.  Empty fuel tank before storing or transporting the generator.  Before transporting, turn fuel valve to off and disconnect spark plug wire.

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WARNING: This generator produces powerful voltage, which can

result in electrocution.

 ALWAYS ground the generator before using it (see the “Ground the Generator”

portion of the “GENERATOR PREPARATION” section).

 Generator should only be plugged into electrical devices, either directly or with an

extension cord. NEVER connect to a building electrical system without a qualified electrician. Such connections must comply with local electrical laws and codes. Failure to comply can create a back-feed, which may result in serious injury or death to utility workers.

 Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as

metal decking or steel work. GFCIs are available in-line with some extension cords.

 Do not use in rainy conditions.  Do not touch bare wires or receptacles (outlets).  Do not allow children or non-qualified persons to operate.

WARNING: This generator produces heat when running. Temperatures

near exhaust can exceed 150º F (65º C).

 Do not touch hot surfaces. Pay attention to warning labels on the generator identifying

hot parts of the machine.

 Allow generator to cool down after use before touching engine or areas of the generator

that become hot during use.

CAUTION: Misuse of this generator can damage it or shorten its life.

 Use generator only for its intended purposes.  Operate only on dry, level surfaces.  Allow generator to run for several minutes before connecting electrical devices.  Shut off and disconnect any malfunctioning devices from generator.  Do not exceed the wattage capacity of the generator by plugging in more electrical devices

than the unit can handle.

 Do not turn on electrical devices until after they are connected to the generator.  Turn off all connected electrical devices before stopping the generator.  Turn engine switch to “off” position when the engine is not running.

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IMPORTANT SAFETY INSTRUCTIONS

 SAVE THESE INSTRUCTIONS – This manual contains important instructions for WEN

3500 generator that should be followed during installation and maintenance of the generator.

 Generators vibrate in normal use. During and after the use of the generator, inspect the

generator as well as extension and power supply cords connected to it for damage resulting from vibration. Have damaged items repaired or replaced as necessary. Do not use plugs or cords that show signs of damage such as broken or cracked insulation or damaged blades.

 For power outages, permanently installed stationary generators are better suited for

providing backup power to the home. Even a properly connected portable generator can become overloaded. This may result in overheating or stressing the generator components, possibly leading to a generator failure.

 WARNING: When this generator is used to supply a building wiring system:

Generator must be installed by a qualified electrician and connected to a transfer switch as a separately derived system in accordance with the National Electrical Code, NFPA 70. The generator shall be connected to a transfer switch that switches all conductors other than the equipment grounding conductor. The frame of the generator shall be connected to an approved grounding electrode.

In addition to the previous safety notices, please become familiar with the safety and hazard markings on the generator.

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Page 11

Page 12

PACKAGE CONTENTS

Generator

Instruction manual and registration card

Rubber Foot (2pcs)

NEMA L14-30 plug

Set of four wrenches for assembly

Wheel (2pcs)

Threeprong plug

Vinyl Tool Pouch

Wheel kit hardware

Spark plug wrench

Handle (2pcs)

Your generator comes with the items listed below. Please check to see that all of the following items are included with your generator.

If there are any damaged or missing items, please call (800) 232-1195 M-F 8-5 CST for

customer service.

ITEM LIST

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GENERATOR COMPONENTS

(1) Fuel Cap- Access to the fuel tank for adding

fuel. (2) Voltage Selector-To switch between 120 and 240 Volt output. (3) Circuit Reset Buttons- Reset buttons that protect the generator from electrical overload. (4) Power Indicator-Green lights that turn on to indicate the output of power to each receptacle. (5) 240/120 Volt AC Receptacle- To connect electrical devices that run 120 and/or 240 Volt, 60 Hz, single phase, AC current. (6) Ground Terminal- Connect grounding wires here to properly ground unit.

(7) Engine hour counter. (8) 120 Volt AC Duplex Receptacle- To connect

electrical devices that run 120 Volt, 60 Hz, single phase, AC current.

(9) 12V Cigarette lighter Style DC Receptacle.

(10) Oil Fill and Dipstick- Location for checking and filling engine oil. (11) Engine Switch- To start/stop engine. (12) Recoil Starter- Pull-cord for starting engine. (13) Fuel Filter Cup- Traps dirt from fuel before it enters

the engine. (14) Air Cleaner- A removable, cleanable, sponge-like element that limits the amount of dirt pulled into the engine. (15) Choke Lever- Adjusts the amount of air let into the engine.

(16) Fuel Valve- Allows fuel to enter engine. (17) Fuel Gauge- Indicates the amount of fuel in the tank. (18) Spark Plug- Provides proper engine ignition. (19) Muffler- Reduces engine noise.

Please familiarize yourself with the locations and functions of the various components and controls of your generator.

Page 14

ASSEMBLY

In order to best protect the generator while in the package, this product comes with some components disassembled. Please complete the following assembly steps before proceeding to use the generator. For ease of assembly, we recommend attaching the components in the order listed in this manual.

If after reading this section, you are unsure about how to perform any of the steps, please call (800) 232-1195 M-F 8-5 CST for customer service.

WARNING: This generator is heavy. Some assembly procedures may require

lifting equipment or two people.

Attach Feet

To attach the feet to the generator, perform the following steps:

1. Stack the two generator wheels on top of each other. Lift the end of the generator that has

the recoil starter onto the stack of wheels (see figure 1). Be careful not to obstruct any holes on the generator frame.

2. Place one leg onto the frame as shown in figure 2. Line up the holes on the generator

frame with the holes on the bracket portion of the leg. Tighten using two M6x40 bolts, two M6 nuts, and the included wrench.

3. Repeat step 2 for the other generator leg.

Figure 1- Stacking the wheels

a b

Figure 2- foot assembly

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Attach Handles

The handles attach to the same end of the generator as the feet. To attach the handles to the generator, perform the following steps:

1. Place one handle onto the upper portion of the generator frame as shown in figure 3.

2. Slide handle with M8×40 bolt attached through the hole and secure using an M8 nut.

3. Repeat steps 1 and 2 for the other side.

At this point, gently remove the two wheels from underneath the generator.

a b

Figure 3- handle assembly

Attach Wheels

To attach the wheels to the generator, perform the following steps:

1. Find a wood block or similar item that is 3 inches thick or greater and rest the exhaust end

of the generator on the block as shown in figure 4.

2. Take one wheel shaft, and one M12 nut as shown. Slide the wheel shaft, with the threaded

part facing inward, through the frame. Secure using an M12 nut and the included wrench as shown in figure 5.

3. Slide the wheel onto the axle and secure in place using a large cotter pin as shown in figure

6. Spread the pin legs apart slightly to help secure the pin in place.

4. Repeat steps 2 and 3 for the other wheel.

At this point, the generator assembly is complete. Gently remove the generator from the wood block.

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a b

Figure 4- supporting the generator Figure 5- axle assembly

a b

Figure 6- wheel installation

Page 17

GENERATOR PREPARATION

Using the Generator for the First Time

The following section describes steps necessary to prepare the generator for use. If after

reading this section, you are unsure about how to perform any of the steps please call (800)

232-1195 M-F 8-5 CST for customer service. Failure to perform these steps properly can

damage the generator or shorten its life.

Step 1 - Fill Oil

The generator is shipped without oil. User must add the proper amount of oil before operating the generator for the first time. The oil capacity of the engine crankcase is 20 fluid oz.

Select good quality detergent oil bearing the American Petroleum Institute (API) service classifications SJ, SL, or SM. (Synthetic oils may be used.) Use the SAE viscosity grade of oil from the following chart that matches the starting temperature anticipated before the next oil changes.

Figure 7- Engine oil recommendations

To fill oil to the crankcase, follow these steps:

1. Make sure the generator is on a level surface. Tilting the generator to assist in filling will

cause oil to flow into engine areas and will cause damage. Keep generator level!

2. Remove the oil filler/dipstick cap from the engine as shown in figure 8.

3. Using a funnel, add the appropriate type and amount of oil into the crankcase. The

crankcase is full when the oil level has reached the second thread from the lip of the opening (see figure 9).

4. Check for oil leaks. Reinstall oil filler cap before starting engine.

Figure 8- Unscrewing the oil cap Figure 9- filling oil

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Model number

3500

Fuel tank

capacity

15 L (4 gallons)

Step 2- Add Gasoline

WARNING: This generator may emit highly

flammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A nearby

open flame can lead to explosion even if not directly in contact with gasoline.

minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

 Do not overfill fuel tank. Gasoline may expand during operation. Do not fill to the

top of the tank. Allow for expansion.

 Always check for spilled fuel before operating. Clean up any spilled fuel before

starting.

 Empty fuel tank before storing or transporting the generator.  Before transporting, turn fuel valve to off position and disconnect spark plug wire.

Use fresh (within 30 days from purchase), unleaded gasoline with a minimum 87 octane rating. Do not use gasoline which contains Methanol. Do not mix oil with gasoline.

To add gasoline, follow these steps:

1. Make sure the generator is on a level surface.

2. Unscrew fuel cap and set aside (NOTE: the fuel cap may be tight and hard to unscrew).

3. Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill. Please refer to the

chart in figure 10 for the fuel capacity. The fuel gauge on the top of the generator indicates how much gasoline is in the generator fuel tank. NOTE: Do not fill the fuel tank to the very top. Gasoline will expand and spill over during use even with the fuel cap in place.

4. Reinstall fuel cap and wipe off any spilled gasoline with a dry cloth.

IMPORTANT:

 Never use an oil/gasoline mixture.  Never use old gasoline.  Avoid letting dirt or water into the fuel tank.  Gasoline can age in the tank and make it hard to start up the generator in the future. Never

store generator for extended periods of time with fuel in the tank.

Figure 10- Fuel Tank Capacity

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Step 3- Ground the Generator

WARNING: Failure to properly ground the generator can result in

electrocution.

Ground the generator by tightening the grounding nut against a grounding wire (see figure 11). A generally acceptable grounding wire is a No. 12 AWG (American Wire Gauge) stranded copper wire. This grounding wire should be connected at the other end to a copper or brass grounding rod that is driven into the earth. Wire and grounding rod are not included in generator contents.

Grounding codes can vary by location. Please contact a local electrician to check the grounding regulations for your area.

Figure 11- Grounding nut location

NOTE: After completing the 3-step Generator Preparation, the generator is ready to be

started.

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STARTING THE GENERATOR

Before starting the generator, make sure you have read and performed the steps in the

“Generator Preparation” section of this manual. If you are unsure about how to perform any of the steps in this manual please call (800) 232-1195 M-F 8-5 CST for customer service.

DANGER: CARBON MONOXIDE. Using a generator indoors CAN KILL

YOU IN MINUTES.

 NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed

areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh air.

 ONLY use a generator outside and far away from windows, doors, and vents. These

openings can pull in generator exhaust.

Even if you use a generator correctly, CO may leak into the home. ALWAYS use a batterypowered or battery-backup CO alarm in the home.

If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

WARNING: This generator produces powerful voltage, which can result in

electrocution.

 ALWAYS ground the generator before using it (see the “Ground the Generator”

portion of the “GENERATOR PREPARATION” section).

 Generator should only be plugged into electrical devices, either directly or with an

 Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as

metal decking or steel work. GFCIs are available in-line with some extension cords.

 Do not use in rainy or wet conditions.  Do not touch bare wires or receptacles (outlets).  Do not allow children or non-qualified persons to operate.

CAUTION: Disconnect all electrical loads from the generator before

attempting to start.

Page 21

To start your generator, perform the following steps:

Figure 12- Fuel Valve in the “on” position

Figure 14- Pulling the start cord

Figure 13- Pull choke out for closed position.

Push `in for open position.

1. No electrical devices should be connected to the generator during starting. Devices can

make it difficult for the engine to start.

2. Check that the generator is properly grounded (see “Ground the Generator”).

3. Check the oil and fuel levels.

4. Turn the fuel valve to the “on” position (see figure 12).

5. Move the choke lever to the “closed” position (see figure 13).

6. Set the engine switch to the “on” position.

7. Pull on the recoil starter handle slowly until a slight resistance is felt (see figure 14). Then

pull quickly to start the engine. Return cord gently into the machine. Never allow the cord to snap back.

8. If engine fails to start, repeat step 7. NOTE: After repeated failed attempts to start the

engine, please consult the troubleshooting guide before attempting again. If problems persist please call (800) 232-1195 M-F 8-5 CST.

9. Once the engine has started, slowly return the choke lever all the way to the “open”

position.

10. Allow the generator to run for several minutes before attempting to connect any electrical

devices. This allows the generator to stabilize its speed and temperature.

SUBSEQUENT STARTING OF THE GENERATOR

If this is not the first time using the generator, user should take the following steps to prepare it for operation.

IMPORTANT: At this point the user should be familiar with the procedures described in the

section titled “Using the Generator for the First Time.” If the user has not yet read this section, go back and read it now.

Step 1- Check the Oil

Oil consumption is normal during generator usage. The generator is equipped with a low-oil shutoff to protect it from damage. The oil level in the engine should be checked before each use to ensure that the engine crankcase contains sufficient lubricant.

Page 22

To check or add oil, follow these steps:

1. Make sure the generator is on a level surface. Clean around oil fill.

2. Remove the oil filler/dipstick cap and check oil level.

3. If oil level is below the second thread from the lip of the oil fill opening, slowly add oil

until the engine crankcase is filled.

4. Reinstall and tighten oil filler cap before starting the engine. .

Step 2 – Check the Fuel Level

Before starting the generator, check to see that there is sufficient gasoline in the fuel tank. The fuel gauge on top of the generator will indicate the fuel level in the tank. Add gasoline if necessary but leave sufficient room in tank for expansion.

WARNING: This generator may emit highly

flammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A nearby

open flame can lead to explosion even if not directly in contact with fuel.

minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

 Do not overfill fuel tank. Gasoline may expand during operation. Do not fill to the

top of the tank. Allow for expansion.

 Always check for spilled fuel before operating. Clean up any spilled fuel before

starting.

 Empty fuel tank before storing or transporting the generator.  Before transporting, turn fuel valve to off and disconnect spark plug wire.

IMPORTANT:

 Use only UNLEADED gasoline with an octane rating of 87 or higher.  Do not use old gasoline.  Never use an oil/gasoline mixture.  Avoid letting dirt or water into the fuel tank.

Step 3- Ground the Generator

WARNING: Failure to properly ground the generator can result in

electrocution.

Ground the generator by tightening the grounding nut on the front control panel against a grounding wire. (Figure 11) A generally acceptable grounding wire is a No. 12 AWG (American Wire Gauge) stranded copper wire. This grounding wire should be connected at the other end to a copper or brass rod that is driven into the earth. Wire and grounding rod are not included in generator contents.

Grounding codes can vary by location. Contact a local electrician for area codes.

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USING THE GENERATOR

Model Number

Rated(Running) Wattage

Surge Wattage

3500

3000

3500

WARNING: When this generator is used to supply a building wiring system:

Generator must be installed by a qualified electrician and connected to a transfer switch

as a separately derived system in accordance with the National Electrical Code, NFPA 70. The generator shall be connected to a transfer switch that switches all conductors other than the equipment grounding conductor. The frame of the generator shall be connected to an approved grounding electrode.

For power outages, permanently installed stationary generators are better suited for providing backup power to the home. Even a properly connected portable generator can become overloaded. This may result in overheating or stressing the generator components, possibly leading to a generator failure.

Before connecting electrical devices, allow the generator to run for a few minutes to stabilize the speed and voltage output.

CAUTION: Become familiar with the markings on the panel before connecting electrical devices.

AC Usage

Connect electrical devices running on AC current according to their wattage requirements. The chart in figure 15 shows the rated and surge wattage of your generator.

NOTE: Although the overall rated wattage of the machine is 3000 Watts, it is not recommended that you attempt to draw more than 2400 Watts (20 A) from any ONE of the 120 Volt receptacles.

The rated wattage corresponds to the maximum wattage the generator can output on a continuous basis.

The surge wattage corresponds to the maximum amount of power the generator can output for a short period of time. Many electrical devices such as refrigerators require short bursts of extra power, in addition to the rated wattage listed by the device, to stop and start their motors. The surge wattage ability of the generator covers this extra power requirement.

Figure 15- generator wattage by model number.

The total running wattage requirement of the electrical devices connected to the generator should not exceed the rated wattage of the generator itself. To calculate the total wattage requirement of the electrical devices you wish to connect, find the rated (or running) wattage of each device. This number should be listed somewhere on the device or in its instruction manual. If you cannot find this wattage, you may calculate it by multiplying the Voltage requirement by the Amperage drawn:

Watts= Volts x Amperes

If these specifications are not available, you may estimate the Watts required by your device using the chart in figure 16.

Page 24

When the rated wattage requirement of each electrical device has been determined, add these

tool or appliance

rated (running) Watts

additional surge Watts

electric water heater (40 gal)

4000

hot plate

2500

saw- radial arm

2000

electric stove (each element)

1500-2800

saw- circular

1500

air compressor (1 HP)

1500

3000

window air conditioner

1200

1800

saw- miter

1200

microwave

1000

well water pump

1000

reciprocating saw

960

1040

sump pump

800

1200

refrigerator freezer

800

1200

furnace blower

800

1300

computer

800

electric drill

600

900

television

500

deep freezer

500

garage door opener

480

stereo

400

box fan

300

600

clock radio

300

security system

180

DVD player/ VCR

100

common light bulb

numbers to find the total rated wattage needed. If this number exceeds the rated wattage of the generator, DO NOT connect all these devices. Select a combination of electrical devices, which has a total rated wattage lower than or equal to the rated wattage of the generator.

CAUTION: The generator can run at its surge wattage capacity for only a short time. Connect electrical devices requiring a rated (running) wattage equal to or less than the rated wattage of the generator. Never connect devices requiring a rated wattage equal to the surge wattage of the generator. This can trip the circuit protectors (circuit breakers).

NOTE: The above wattage figures are estimates. Try to check the wattage listed on your electrical device before consulting this chart.

Once you have determined what electrical devices you will be powering with the generator, connect these devices according to the following procedure:

1. Plug in each electrical device with the device turned off. NOTE: Be sure to attach

appliances to the correct receptacles (outlets). Connect standard 120 Volt, single phase, 60 Hz loads only to the 120 Volt receptacles. Connect 240/120 Volt, single phase, 60Hz loads with a NEMA L14-30 plug only to the 240/120 Volt receptacle See Figure 17 for a depiction of each of these receptacles.

Figure 16- Estimated wattage requirements of common electrical devices.

Page 25

2. Push in the circuit reset buttons to the “on” position (NOTE: They may be pushed in

already).

3. Move the voltage selector to the desired position. Move the switch to the left to use the

standard 120 Volt receptacles. Move the switch to the right to use the 240/120 Volt NEMA receptacle.

4. The power indicator lights will light accordingly as the Volt Selector is selected. They light

up when the receptacles receive power. In the case of the 240/120 Volt receptacle, both lights MUST light up for 240/120 Volts of power. If only one light comes on, DO NOT USE the receptacle. Press the circuit reset buttons and see if both lights come on. If both lights will still not illuminate, call the customer service number for instructions.

CAUTION: Do not connect 50Hz or 3-phase loads to the generator.

Figure 17- Receptacles available on the generator

CIRCUIT RESET BUTTONS

The circuit reset buttons help to prevent the generator from electrical overload. If your receptacle short circuits or becomes overloaded by an electrical device or devices with too great a wattage rating, the circuit protector may shut off power to the receptacle. If this happens, you will see the voltage indicator light or lights turn off and you will not be able to draw power from the overloaded receptacle. In the event of such an overload, disconnect all electrical devices from the generator and press the circuit reset buttons. If power still does not return to the receptacle, call our customer service line.

SOME NOTES ABOUT POWER CORDS

Long or thin cords can drain the power provided to an electrical device by the generator. When using such cords, allow for a slightly higher rated wattage requirement by the electrical device. See Figure 18 for recommended cords based on the power requirement of the electrical device.

Page 26

Device Requirements

Max. Cord Length (ft) by Wire Gauge

Amps

Watts (120V)

Watts (240 V)

#8 wire

#10 wire

#12 wire

#14 wire

#16 wire

2.5

300

600

1000

600

375

250

600

1200

500

300

200

125

7.5

900

1800

350

200

125

100

1200

2400

250

150

100

1800

3600

150

100

2400

4800

175

125

3000

6000

150

100

3600

7200

125

4800

9600

*NR= not recommended

Figure 18- Maximum Extension Cord Lengths by Power Requirement

DC Usage

This Generator is equipped with a cigarette lighter style 12V DC receptacle. The maximum draw for this DC outlet is 8.3 Amps. The 12V DC receptacle is not intended for use to charge automotive batteries.

The cigarette lighter style receptacle permits the use of any electrical device designed for use in a 12V DC cigarette style outlet similar to ones found in automobiles. The electrical device has a power cord with a metal pin on the bottom and two leaf springs on the sides. Some common automotive type electrical devices are inflators, vacuum cleaners, chargers of various types and more.

To Use: Simply plug the electrical device power cord into the 12V DC outlet and ensure the power cord is securely in place. Use the device as instructed. Remove after use by simply pulling the power cord out of the receptacle. The 12V DC receptacle is protected against overloads by an inline fuse located behind the control panel.

STOPPING THE GENERATOR

To stop the generator:

1. Turn off all electrical devices prior to unplugging them from the generator. Unplugging

running devices can cause damage to the generator.

2. Turn the engine switch to the “OFF” position.

3. Turn the fuel valve to the “OFF” (horizontal) position.

CAUTION: Allowing gasoline to sit in the generator tank for long periods of time without use can make it difficult to start the generator in the future. Never store generator for extended periods of time with fuel in the tank.

WARNING: Allow the generator to cool for several minutes before touching

areas that become hot during use.

Page 27

MAINTENANCE / CARE

Recommended Maintenance Schedule

each use

first month

then every

20 hrs

every 3

months or

50 hrs

every 6

months or

100 hrs

every year

or 300 hrs

Engine oil

check level

replace x

Air cleaner

check x

clean x

fuel filter cup

clean x

spark plug

check/ clean

fuel tank

check fuel level

clean

Proper routine maintenance of your generator will help prolong the life of your machine. Please perform maintenance checks and operations according the schedule in figure 19.

If you have questions about any of the maintenance procedures listed in this manual, please

call (800) 232-1195 M-F 8-5 CST.

CAUTION: Never perform maintenance operations while the generator is running.

Figure 19- Recommended maintenance schedule

Cleaning the Generator

Never clean the generator when it is running! Never clean with a bucket of water or a hose. Water can get inside the working parts of the generator and cause a short circuit or corrosion. Always try to use the generator in a cool, dry place. If the generator becomes dirty, clean the exterior with a damp cloth, a soft brush, vacuum or pressurized air.

Checking the Oil

Check the oil level of the generator according to the Recommended Maintenance Schedule in Figure 19. The generator is equipped with an automatic shutoff to protect it from running with low oil pressure. The generator should be checked before each use for proper oil level. This is a critical step for proper engine starting.

To check or add oil, follow these steps:

1. Make sure the generator is on a level surface. Clean around oil fill.

2. Remove the oil filler/dipstick cap and check oil level.

3. If oil level is below the second thread from the lip of the oil fill opening, slowly add oil

until the engine crankcase is filled.

4. Reinstall and tighten oil filler cap before starting the engine. .

Page 28

Figure 20- Checking the oil

Changing/ Adding Oil

Change the oil according to the maintenance schedule in figure 19. Change the oil when the engine is warm. This will allow for complete drainage. Change oil more often if operating under heavy load or high ambient temperatures. It is also necessary to drain the oil from the crankcase if it has become contaminated with water or dirt.

The oil capacity of the engine in this generator is 20 fluid oz. Add oil when the oil level is low.

Drain the oil from the generator according to the following steps:

1. Place a container underneath the engine to catch oil as it drains.

2. Using a 10 mm hex wrench, unscrew the oil drain plug (see figure 21). Allow all the oil to

drain from the engine.

3. Reinstall the oil drain plug and tighten with a 10 mm hex wrench.

To fill the crankcase with oil, follow these steps:

1. Make sure the generator is on a level surface. Tilting the generator to assist in filling will

cause oil to flow into engine areas and will cause damage. Keep generator level!

2. Remove the oil filler/dipstick cap from the engine as shown in figure 20 above.

3. Using a funnel, add the appropriate type and amount of oil into the crankcase. The

crankcase is full when the oil level has reached the second thread from the lip of the opening (see figure 22).

4. Check for oil leaks. Reinstall oil filler cap before starting engine.

NOTE: Never dispose of used motor oil in the trash or down a drain. Please call your local

Figure 21- Draining oil Figure 22- Adding oil

recycling center or auto garage to arrange oil disposal.

Page 29

Air Cleaner Maintenance

Routine maintenance of the air cleaner helps maintain proper air flow to the carburetor. Check that the air cleaner is free of excessive dirt.

1. Unhinge the clasps at the top and bottom of the air cleaner cover (see figure 23).

2. Remove the sponge-like element from the casing.

3. Wipe the dirt from inside the empty air cleaner casing

4. Wash the sponge-like element in household detergent and warm water. Allow to dry.

5. Reinstall the sponge-like element in the air cleaner casing and reinstall the cover.

Figure 23- Removing the air cleaner casing.

Fuel Filter Cup Cleaning

The fuel filter cup is a small well underneath the fuel valve. It helps to trap dirt and water that may be in the fuel tank before it can enter the engine. To clean the fuel filter cup:

1. Turn the fuel valve to the “off” position.

2. Unscrew the fuel filter cup from the fuel valve using a wrench. Turn the valve toward you

to unscrew (see figure 24).

3. Clean the cup of all sediment using a rag or brush.

4. Reinstall the fuel filter cup.

Figure 24- Removing the Fuel Filter Cup

Page 30

Spark Plug Maintenance

0.7-0.8 mm

(0.028-0.031 in)

The spark plug is important for proper engine operation. A good spark plug should be intact, free of deposits, and properly gapped. To inspect the spark plug:

1. Pull on the spark plug cap to remove it.

2. Unscrew the spark plug from the generator using the spark plug wrench included with this

product (see figure 25).

3. Visually inspect the spark plug. If it is cracked or chipped, discard and replace with a new

spark plug.

4. Measure the plug gap with a gauge (see figure 26). The gap should be 0.7-0.8mm (0.028-

0.031in).

5. If you are re-using the spark plug, use a wire brush to clean any dirt from around the spark

plug base and then re-gap the spark plug.

6. Screw the spark plug back into its place on the generator using the spark plug wrench. Do

not over-tighten spark plug. Recommended tightening of spark plug is ½ to ¾ of a turn after spark plug gasket contacts spark plug hole. Reinstall the spark plug cap.

Figure 25- Removing the spark plug cap Figure 26- Measuring the spark plug gap

Spark plug: NGK BP7ES

Draining the Fuel Tank

Clean fuel tank each year or before storing the generator for extended periods of time. To drain the fuel tank and carburetor:

1. Turn the fuel valve to the “off” position.

2. Remove the fuel line between the fuel valve and carburetor. Caution: a small amount of

fuel may leak from the hose during removal.

3. Attach a fuel line (not included with the generator) to exposed end of the fuel valve.

4. Position fuel line into an appropriate container and open the fuel valve allowing fuel to

flow into the container.

5. Once fuel is drained, shut off the fuel valve.

6. Start and run the engine until fuel runs out.

7. Remove the fuel filter cup (see “Fuel Filter Cup Cleaning” earlier in this section).

8. Empty the fuel filter cup of any fuel and clean

9. Reinstall the fuel filter cup.

10. Store the emptied gasoline in a suitable place.

CAUTION: Do not store fuel for more than 3 months.

Page 31

STORAGE / TRANSPORT PROCEDURES

CAUTION: Never place any type of storage cover on the generator

while it is still hot.

If the generator is being stored for short periods of time (30 – 60 days), add stabilized fuel to the fuel tank until full. NOTE: Filling the tank reduces the amount of air in the tank and helps reduce deterioration of fuel. Run the engine for 2 – 3 minutes allowing stabilized fuel mixture to circulate through the carburetor.

When transporting or storing the generator for extended periods of time:

 Drain the fuel tank (see “Draining the Fuel Tank” in the “Maintenance” section).  Disconnect the spark plug cap from the spark plug.  Do not obstruct any ventilation openings.  Keep the generator in a cool dry area.

Page 32

SPECIFICATIONS

Generator

AC Output

Rated Wattage

3000 W

Surge Wattage

3500 W

Rated Voltage

240V/120 V

Rated Amperage

12.5A/25A

Rated Frequency

60 Hz

Phase

Single

Dimensions(in):

length= 24.4 width= 17.7 height= 18.5

Weight

111.2 lbs

Engine

Engine type

4-stroke OHV single cylinder with forced air cooling system

Ignition system

non-contact transistor

Displacement

208 cc

Fuel tank capacity:

15 L (4 US gal.)

Oil capacity

0.6 L (20 fl oz.)

Run time on 50% load

11 hrs

Noise rating at 22 feet

67 dB idle

74 dB fully loaded

Spark Plug

NGK BP7ES

Page 33

TROUBLESHOOTING

Problem

Cause

Solution

Engine will not start

Engine switch is set to "OFF".

Set engine switch to "ON".

Fuel valve is turned to "OFF".

Turn fuel valve to "ON" position.

Choke is open.

Close the choke

Engine is out of fuel.

Add gasoline.

Engine is filled with contaminated or old gasoline.

Change the gasoline in the gas tank.

Spark plug is dirty.

Clean spark plug.

Spark plug is broken.

Replace spark plug.

Generator is not on level surface.

Move generator to a level surface to prevent low oil shutdown from triggering.

Oil is low.

Add or replace oil.

Engine runs but there is no electrical output

Circuit reset button is off.

Wait for 2 minutes and push the circuit reset button to the "ON" position.

Bad connecting wires/cables.

If you are using an extension cord, try a different one.

Bad electrical device connected to generator.

Try connecting a different device.

Generator runs but does not support all electrical devices connected.

Generator is overloaded.

Perform these steps:

1. Turn off all electrical devices.

2. Unplug all electrical devices.

3. Turn off generator.

4. Wait several minutes.

5. Restart generator.

6. Try connecting fewer electrical loads to the generator.

Short in one of the connected devices.

Try disconnecting any faulty or short-circuited electrical loads.

Air cleaner is dirty.

Clean or replace air cleaner.

DC No Power

Power cord plug not securely in place

Twist and push power cord plug into receptacle until contact is made with bottom of receptacle.

Protective fuse is blown

Contact our customer service help line at (800) 232-1195.

IMPORTANT: If trouble persists please call our customer help line at (800) 232-1195 M-F 8-5 Central Time.

Page 34

Engine exploded view

EXPLODED VIEW AND PARTS LIST

Page 35

Engine parts list

Item

Order #

Qty

Description

Item

Order #

Qty

Description

P54000

Oil drain plug

P54122

Woodruff key

P54002

Washer

P54123

Crankshaft assembly

P54004

Bearing 6205

P54128

Lock nut

P54008

Crankshaft oil seal

P54130

Sleeve

P54011

Crankcase

P54132

Valve rocker

P54014

Regulating sway bar

P54134

Adjusting bolt for valve gap

P54016

Washer

P54136

Valve rocker assembly

P54018

Split pin

P54138

Pusher guide

P54020

Oil sensor

P54140

Pusher

P54024

M6×14 bolt

P54142

Tappet

P54026

Regulating shaft

P54146

Camshaft assembly

P54028

Washer

P54150

Exhaust valve

P54031

Regulator gear assembly

P54152

Intake valve

P54032

Snap ring

P54154

Valve spring

P54034

Washer

P54156

Intake valve spring seat

P54036

Sleeve

P54158

Exhaust valve spring seat

P54040

M6×12 bolt

P54160

Cap

P54043

Air duct

P54162

Inlet gasket

P54044

Wind cover

P54164

Connecting block

P54047

M6×96 bolt

P54166

Carburetor gasket

P54048

Set pin 10×16

P54168

Air cleaner gasket

P54051

Cylinder head gasket

P54178

Carburetor assembly

P54054

Cylinder head Assembly

P54175

Air cleaner

P54058

M8×34 bolt

P54186

M6×22 bolt

P54060

Spark plug

P54596

Crankcase side plate assembly

P54062

Bolt

P54598

M6×8 bolt

P54064

Cylinder head cover gasket

P54668

Fan hood assembly (black)

P54066

Cylinder head cover assembly

P54604

Recoil starter (black)

P54075

Crankcase cover

P54040

M6×12 bolt

P54004

Bearing 6205

P54610

Plastic clip

P54080

Crankcase gasket

100

P54612

Diode

P54082

Set pin

102

P54616

Back spring

P54086

Oil dipstick assembly

103

P54618

Regulating spring

P54088

Crankshaft oil seal

104

P54620

Pulling rod

P54092

M8×32 bolt

105

P54622

Lock bolt

P54105

Piston ring assembly

106

P54624

Regulating arm

P54106

Piston pin clip

107

P54176

M6 nut

P54109

Piston

108

P54628

M6×25 screw

P54112

Piston pin

109

P54630

M14×1.5 nut

P54114

Connecting rod

110

P54632

Starting flange

P54116

Connecting rod cover

111

P54634

Flywheel fan

P54118

Bolt

112

P54636

Flywheel

P54121

Connecting rod assembly

113

P54638

Ignition coil assembly

Page 36

Generator exploded view

Page 37

Generator parts list

Item

Order #

Qty

Description

Item

Order #

Qty

Description

P54868

Gasoline engine

P54360

Stator ＆rotor assembly

P54237

Frame comp

P54369

Fuel tank (Black)

P54242

Bottom rubber A

P54368

Fuel cap

P54244

Bottom rubber B

P54372

Fuel filter

P54246

Flange nut M8

P54374

Fuel gauge assembly

P54258

Frame rubber pad

P54376

Screw M5×10

P54262

Earth terminal set

P54186

Flange bolt M6×22

P54830

Wire harness assembly

P54384

Washer

P54831

Switch wire

P54386

Cushion

P54272

Receptacle(30A)

P54388

Outlet pipe φ 9×φ 4.5×130

P54276

Bolt M4×10

P54390

Tube clip

P54283

Control panel assembly

P54392

Fuel cock

P54834

Control panel case

P54396

Fitting brush, fuel tank

P54291

Panel switch mark, RH

P54401

Muffler

P54293

Panel switch mark, LH

P54402

Muffler guard

P54296

Ignition switch

P54404

Flange bolt M8×16

P54826

Voltage selector

P54406

Exhaust pipe comp

P54838

Circuit breaker(13A)

P54408

Muffler gasket

P54304

Circuit bolt M6×25

P54410

Supporting plate

P54308

Nut M4

P54412

Muffler stay

P54454

Duplex receptacle

P54414

Bolt M8×25

P54316

AC output wire boot

P54246

Nut M8

P54318

Main wire harness boot

P54422

Flange bolt M6×12

P54325

Stator assembly

P54426

Exhaust pipe gasket

P54324

Stator cover

P54828

Power indicator

P54329

Rotor comp

P54451

Rectifier

P54332

Brush assembly

P54870

Decorating stripe, fuel tank

P54336

Generator stay

P54871

Rubber foot assembly

P54337

Generator end cover (Black)

P54872

Wheel assembly

P54340

Bolt M5×12

P54873

Nut

P54342

Voltage regulator

P54874

Bolt M6×40

P54346

Bearing 6202-2RS

P54875

Nut M6

P54348

Plain washer

P54876

Handle assembly

P54350

Flange bolt M6×160

P54877

Engine hour counter (E)

P54354

Bolt M8×210

P54878

12V Cigarette lighter style DC receptacle

P54358

Generator fan

P54879

Wheel shaft assembly

P54360

Bolt M5×14

P54254

Rubber bottom

Page 38

WIRING DIAGRAM

Page 39

NOTES:

Page 40

WARRANTY STATEMENT

WEN Power™ generators are warranted (to the original purchaser) to be free from defects in materials and workmanship for a period of two (2) years from the date of original purchase. Generators used for commercial or for rental have a warranty period of 90 days from date of original purchase. Please fill out and mail the enclosed warranty card and mail it to Power Pro Technology along with a copy of the receipt. The information is required to process warranty claims.

WEN Power™ will repair or replace, at its discretion, any part that is proven to be defective in materials or workmanship under normal use during the two (2) year warranty period. Warranty repairs or replacements will be made without charge for parts or labor. Parts replaced during warranty repairs will be considered as part of the original product and will have the same warranty period as the original product.

TO EXERCISE WARRANTY COVERAGE:

Do not return to retailer! For warranty and technical support call the toll-free

Customer Service Number: (800) 232-1195 and you will be informed of the nearest authorized service center. We will prearrange the repair with the center.

WARRANTY COVERAGE: This warranty is conveyed to the original purchaser and is not transferable. Generators contain parts that will wear out with usage and parts that need maintenance. The warranty does not cover wear or maintenance parts. Specifically, the warranty does not cover replacement of air filter, spark plug, brush and recoil starter rope. Warranty does not extend to generators damaged or affected by accidents, neglect, misuse, contaminated fuel, unauthorized alterations, use in applications beyond product design and any other modification or abuse.

WEN Power™ is not liable for any indirect, incidental or consequential damages from the sale or use of this product. Any implied warranties are limited to two (2) years as stated in this written limited warranty. Some states do not allow limitation on the length of an implied warranty. Some states do not allow the exclusion or limitation of incidental or consequential damages. This warranty gives you the specific legal right, and you may have other rights that vary by state.

FOR WEN POWERTM GENERATORS

Wen Power

. Elgin, IL 60123. www.wenproducts.com.