Wen GN4500 Instruction Manual

Download

MODEL GN4500

4500-WATT

PORTABLE GENERATOR

Instruction Manual

EPA III CERTIFIED CARB COMPLIANT

NEED HELP? CONTACT US!

Have product questions? Need technical support? Please feel free to contact us:

TECHSUPPORT@WENPRODUCTS.COM1-800-232-1195 (M-F 8AM-5PM CST)

IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest standards for dependability,

ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged, trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.

For replacement parts and the most up-to-date instruction manuals, visit WENPRODUCTS.COM

CONTENTS

WELCOME 3

Specifications ................................................................................................... 3

Introduction ..................................................................................................... 4

SAFETY 5

Safety Information ........................................................................................... 5

Generator Safety Warnings .............................................................................. 6

BEFORE OPERATING 8

Unpacking & Packing List ................................................................................ 8

Know Your Generator ....................................................................................... 9

Generator Preparation .................................................................................... 11

OPERATION & MAINTENANCE 14

Starting Your Generator ................................................................................. 14

Using Your Generator ..................................................................................... 16

Shutting Off Your Generator ........................................................................... 19

Maintenance ................................................................................................... 20

Transportation & Storage ............................................................................... 25

Troubleshooting Guide ................................................................................... 26

Wiring Diagram .............................................................................................. 27

Exploded View & Parts List ............................................................................ 28

Warranty Statement ....................................................................................... 33

To purchase accessories for your tool, visit WENPRODUCTS.COM

Wheel & Handle Kit (Model No. GNA410), Magnetic Oil Dipstick (Model No. 55201),

and Generator Cover (Model No. 56406).

CONTENTSSPECIFICATIONS

GENERATOR

Model Number GN4500

Surge (Starting) Wattage 4500 Watts

Rated (Running) Wattage 3600 Watts

Rated Voltage 120V AC

Rated Amperage 30A

Phase Single

Frequency 60Hz

Product Weight 97.9 lbs (without wheel kit), 104.5 lbs (with wheel kit)

Product Dimensions 23-1/4 in. × 18 in. × 18-3/4 in.

Rated output determined by PGMA Standard G300

ENGINE

Engine Type

Engine Displacement 212cc

Fuel Tank Capacity 4 US gallons (15 L), 87 octane minimum

Oil Capacity 20.3 fl. oz. (0.6 L)

Half-Load Run Time 13 hours

Lubrication System Splash

Spark Plug Type NGK BP7ES/Torch F7TC

Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.031 in.)

Spark Plug Torque

4 stroke, OHV, single cylinder with forced air cooling system

½ - ¾ turn after gasket contacts base or 15 ft-lbs (20.34 Nm)

INTRODUCTION

Thanks for purchasing the WEN 4500-Watt Portable Generator. Refer to the illustration below for the location of the serial number on the side of the engine. Record the generator information in the spaces provided below. If assistance for information or service is required, please contact customer service by calling 1-800-232-1195, M-F 8-5 CST; you will be asked to provide the following generator information when calling.

Generator Model Number: GN4500

Date of Purchase: ______________________________________________

Purchased From: _______________________________________________

Serial Number: ________________________________________________

Serial Number

SERVICE RECORD

Record the service dates of your generator in the chart below. Please perform maintenance checks and operations according to this manual. Refer to "Maintenance" on page 20.

Service Record Date Date Date Date Date Date

Change Oil

Change Spark Plug

Clean Fuel Tank

Clean Air Cleaner

Clean Spark Arrestor

TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your generator at least once a month for 20 to 30 minutes. Start the generator according to the instructions and plug a small load in to make sure the outlet is producing electricity.

SAFETY INFORMATION

WARNING: Before operating the generator, make sure to read all safety warnings and all instructions.

Failure to follow the warnings and instructions may result in electric shock, fire or serious injury.

SAFETY INTRODUCTION

Safety is a combination of common sense, staying alert, and knowing how your tool works. This manual contains important information regarding the generator’s potential safety concerns, as well as preparation, operation, and maintenance instructions. Before operating this generator, be sure to read and observe all warnings and instructions both on the generator labels and in this instruction manual. Failure to follow all instructions listed below may result in personal injury.

NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur. WEN reserves the right to change this product and specifications at any time without prior notice.

At WEN, we are continuously improving our products. If you find that your tool does not exactly match this manual, please visit wenproducts.com for the most up-to-date manual or contact customer service at 1-800-232-1195, M-F 8-5 CST.

Keep this manual available to all users during the entire life of the tool and review it frequently to maximize

safety for both yourself and others.

SAVE THESE SAFETY INSTRUCTIONS.

SAFETY SYMBOLS

The purpose of following safety symbols is to attract your attention to possible dangers. The safety symbols, and their explanations, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures.

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 machine.

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).

QUESTIONS? PROBLEMS?

In order to answer questions and solve problems in the most efficient and speedy manner, contact customer service at 1-800-232-1195, M-F 8-5 CST or email techsupport@wenproducts.com.

GENERATOR SAFETY WARNINGS

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, crawl spaces, or other partially 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 battery-powered 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: RISK OF EXPLOSION. HIGHLY FLAMMABLE: 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, heat, or any other ignition source. Do not smoke near the 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.

• If fuel spills, move the generator at least 30 feet away from the spill and wipe clean any spilled fuel before starting the engine.

• Empty fuel tank before storing or transporting the generator.

WARNING: If this generator is used as a supply for a building’s wiring system, the generator must be installed by a qualified electrician and connected to a transfer switch as a separately derived system in accordance with all applicable laws and electrical codes and the National Electrical Code, NFPA 70. The generator shall be connected to a transfer switch that switches all conductors excluding the equipment grounding conductor. The frame of the generator shall be connected to an approved grounding electrode.

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals and produces exhaust known to the State of California to cause cancer, birth defects and other reproductive harm.

GENERATOR SAFETY WARNINGS

WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury.

OPERATING ENVIRONMENT

1. Using a generator indoors can kill you in minutes. Only use a generator outside and far away from windows, doors and vents.

2. Do not smoke near the generator.

3. Do not operate near open flame, heat, or flam- mable materials. 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 an explosion even if it isn’t directly in contact with gasoline.

4. Do not expose the generator to rainy or wet con-

ditions; doing so significantly increases the risk of electrical shock. Never handle the generator, electronic

devices, or any cord while standing in water, while barefoot, or when hands or feet are wet.

5. Always operate the generator on a dry, firm, level

surface.

6. The generator should have at least 5 feet of clearance from buildings or other equipment during operation.

7. Do not allow children or non-qualified persons to operate the generator.

3. If any part of the generator, electrical device or power cord is broken, damaged, or defective, make sure it is repaired or replaced before operation. Ser-

vice should only be performed by a qualified technician. Do not use receptacles or cords that show signs of damage, such as broken or cracked insulation.

4. Use a ground fault circuit interrupter (GFCI) in high-

ly conductive areas such as metal decking or steel work. Extension cords with in-line GFCIs are recom-

mended for these operations to maximize safety.

5. If connecting the generator to a building’s electrical

system for standby power, you MUST consult a qualified electrician and install a transfer switch. 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.

6. Never modify the generator in any way. Modifying or using the machine for any other purpose for which it is not designed may result in serious injuries, machine damage and voiding of the warranty.

GENERATOR OPERATION

1. Only use the generator for its intended purposes. Modifying or using the generator for operations for which it was not designed may cause hazards and personal injury.

GENERATOR PREPARATION

1. Always ground the generator before using it to maximize safety (see “Ground the Generator” section).

2. Do not overfill fuel tank, as gasoline may expand during operation. Do not fill to the very top of the tank.

Leave room for gasoline expansion. Always check for spilled fuel before operating.

2. Do not touch bare wires or receptacles (outlets).

3. Do not exceed the wattage capacity of the generator

by plugging in more electrical devices than the unit can handle. This could damage the generator and/or

connected electrical devices. Check the operating voltage and frequency requirements of all electrical devices prior to plugging them into the generator.

Generator safety warnings continue on the next page.

GENERATOR SAFETY WARNINGS

WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury.

4. Allow generator to run for several minutes before connecting electrical devices. Do not start or stop engine with electrical devices plugged in to the receptacles. Failure to do so could damage the generator and/ or connected electrical devices.

5. Do not turn on electrical devices until after they are

connected to the generator.

6. Generators vibrate in normal use. During and after the use of the generator, inspect both the generator as well as extension and power supply cords for damage resulting from vibration.

7. Do not touch hot parts. This generator produces heat when running. Temperatures near exhaust can exceed 150ºF (65ºC). Allow generator to cool down after use before touching engine or areas of the generator that become hot during use.

8. Turn off all connected electrical devices before stopping the generator.

9. 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.

10. Turn the engine switch to “OFF” position when the

engine is not running.

11. Empty fuel tank before storing or transporting the generator. Do not store generator or gasoline near fur-

naces, water heaters, or any other appliances that produce heat or have automatic ignitions. Store the generator and fuel away from sparks, open flames, pilot lights, heat and other sources of ignition.

12. Always wash hands after handling generator.

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

UNPACKING & PACKING LIST

UNPACKING

With the help of a friend or trustworthy foe, carefully remove the generator from the packaging and place it on a sturdy, flat surface. Make sure to take out all contents and accessories. Do not discard the packaging until everything is removed. Check the packing list below to make sure you have all of the parts and accessories. If any part is missing or broken, please contact customer service at 1-800-232-1195 (M-F 8-5 CST), or email techsupport@

wenproducts.com. See included insert for instructions on removing the shipping brackets.

PACKING LIST

A. Generator ..................................................1

B. Spark Plug Wrench ...................................1

C. Engine Oil Bottle .......................................1

TIP: A Wheel & Handle Kit (Model No. GNA410) is available for purchase from wenproducts.com. This kit allows for easier transportation of your generator.

KNOW YOUR GENERATOR

Refer to the following diagrams to become familiarized with all the parts and controls of your generator. The components will be referred to later in the manual for assembly and operation instructions.

GENERATOR

Fuel Cap

Fuel Gauge

Control

Choke Lever

ON/OFF

Fuel Valve

Switch

Panel

Air Filter

Recoil Starter

• Fuel Gauge Indicates amount of fuel inside the fuel tank. E indicates empty, F indicates full.

• Choke Lever Adjusts the amount of air allowed into the engine during startup.

• Fuel Valve Allows fuel to enter the engine from the fuel tank.

• Air Filter A case with a sponge-like element that filters the air entering the engine.

• Recoil Starter Pull the cord to start the engine.

Oil Fill &

Dipstick

• Fuel Cap Access to the fuel tank to add gasoline.

• Control Panel Refer to the next page for more information.

• ON/OFF SWITCH Use to turn the engine ON and OFF.

• Oil Fill and Dipstick Access to the oil tank to check oil levels and add oil.

NOTE: You can purchase a wheel kit separately for easier transportation. Visit wenproducts.com and search Model No. GNA410.

CONTROL PANEL

KNOW YOUR GENERATOR

ENGINE

SWITCH

OFF

2 5 3

MAIN

BREAKER

OFF

GROUNDING

NUT

IMPORTANT BEFORE STARTING

1. Make sure the generator is properly grounded.

2. Check that the crankcase is sufficiently filled with oil.

3. Turn off and unplug all devices connected to generator.

OPERATION SUMMARY

1. Move the switch to the ON position.

2. Turn the fuel valve to the ON position.

3. Move the choke lever to the START position.

4. Pull the start cord to start the engine.

5. If the engine fails to start, adjust the choke and try again.

6. Allow the generator to run for several minutes before connecting devices.

AC 120V 20A

5-20R

4 4

BREAKER

ON OFF

BREAKER

ON OFF

AC 120V 20A

5-20R

AC 120V 30A

TT-30R

Rv ready

AC 120V 30A

L5-30R

transfer

switch ready

86 7

1. Engine ON/OFF Switch

Use to turn the engine ON and OFF.

2. Data Meter

Displays voltage, frequency, total runtime (HHHH) and session runtime (HH:MM). Press the MODE button to switch between displays.

3. AC Main Breaker

Push the button to reset the circuit.

4. AC 120V NEMA 5-20R Duplex Receptacles (20A)

Standard household outlets provide 120V 60Hz power.

5. AC Circuit Breaker

Push the button to reset the circuit.

6. AC 120V NEMA TT-30R Receptacle (30A)

RV ready outlet provides 120V 60Hz power.

7. AC 120V NEMA L5-30R Receptacle (30A)

Transfer switch ready outlet provides 120V 60Hz power.

8. Grounding Nut

Ground the generator to reduce the risk of electric shock. Refer to "Step 3 - Ground The Generator" on page 13.

GENERATOR PREPARATION

The following section describes the necessary steps to prepare the generator for use. If you are unsure about how to perform any of the steps please call 1-800-232-1195 (M-F 8-5 CST) for customer service. Failure to perform these steps properly can damage the generator or shorten its life.

STEP 1 - ADD/CHECK OIL

The user must add the proper amount of oil before operating the generator for the first time. The oil capacity of the engine crankcase is 20.3 fl. oz. (0.6 L).

ENGINE OIL RECOMMENDATIONS - Select good quality detergent oil bearing the American Petroleum Institute (API) service classifications SJ, SL, or SM (synthetic oils may be used). Select the SAE viscosity grade of oil that matches the expected operating temperature. For general use (above 40° F), we recommend using 30W engine oil.

• 30W Engine Oil Temperatures above 40°F.

• 10W-30 Engine Oil Temperatures between 0°F - 40°F.

• Synthetic 5W-30 Engine Oil All temperature ranges.

TO ADD OIL:

1. Place the generator on a level surface. Make sure the engine is OFF before adding or checking oil.

CAUTION! Keep the generator level. Tilting the generator to assist in filling will cause oil to flow into the wrong areas of the engine and cause damage.

Dipstick

Fig. 1

Fig. 2

2. Unscrew the oil dipstick (Fig. 2) from the engine.

3. Using an oil funnel or appropriate dispenser, slowly add oil into the oil fill, being careful not to overfill the unit. Fill the crankcase to the upper fill line so you can visually see the oil coming halfway up the oil fill threads. See Fig. 3.

4. Reinstall the oil dipstick and firmly tighten it. Wipe clean any spilled oil.

CAUTION! For subsequent operation, the oil level should be checked before each use, or after every 8 hours of operation. The generator is equipped with a low-oil sensor and will not start without a sufficient amount of oil. Follow the instructions on the next page to check the oil level.

Upper Fill Line

Lower Fill Line

Fig. 3

Dipstick

1110

GENERATOR PREPARATION

TO CHECK OIL LEVEL (before every subsequent start):

1. Place the generator on a level surface. Make sure the engine is OFF before adding or checking oil.

2. Remove and wipe the dipstick with a clean rag.

3. Insert the dipstick into the oil fill without screwing it in. Remove the dipstick to check the oil mark.

4. If the oil mark covers less than one half of the dipstick, slowly add oil until the oil mark reaches the top of the dipstick (or when you can see the oil coming halfway up the oil fill threads). See Fig. 4.

OIL LEVEL SHUTDOWN

To protect the unit from damage, the generator is equipped with a low-oil-pressure shutoff that will automatically shut down the engine when the oil level is too low. The oil level of the engine should be checked before each start to ensure that the engine crankcase contains sufficient lubricant.

STEP 2 - ADD/CHECK FUEL

Fig. 4

Upper Limit

Lower Limit

TIP: Your WEN generator is compatible with the WEN 55201 Magnetic Oil Dipstick (not included),

available for purchase at wenproducts.com. The dipstick’s industrial-strength magnetic tip will collect metal shavings from your generator’s oil tank to help preserve the engine and extend your generator’s lifespan.

• Do not operate near open flame, heat, or any other ignition source. Do not smoke near the 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.

• If fuel spills, move the generator at least 30 feet away from the spill and wipe clean any spilled fuel before starting the engine.

• Empty fuel tank before storing or transporting the generator.

ONLY use fresh (within 30 days from purchase), lead-free gasoline with a minimum of 87 octane rating. The generator performs best with ethanol-free gasoline. DO NOT use gasoline with over 10% ethanol.

The capacity of the fuel tank is 4 gallons. Do not mix oil with gasoline.

Follow the instructions on the next page to add gasoline.

IMPORTANT:

• Avoid getting dirt or water into the fuel tank.

• Keep gasoline away from sparks, open flames, pilot lights, heat, and other sources of ignition.

• Gasoline can age in the tank and make starting difficult. Never store the generator for more than 2 months with fuel in the tank.

• Never use an oil/gasoline mixture.

• Never use old gasoline.

GENERATOR PREPARATION

TO ADD GASOLINE:

1. Place the generator on a level surface. Make sure the engine is OFF before adding or checking the fuel.

2. Unscrew the fuel cap (Fig. 5) and set it aside. The fuel cap may be tight and hard to unscrew.

3. Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill. Reinstall fuel cap and wipe clean any spilled gasoline with a dry cloth.

NOTE: Do not fill the fuel tank to the very top. If you do so, gasoline will expand and spill during use, even with the fuel cap in place.

TO CHECK GAS LEVEL (before every subsequent start):

1. Before starting the generator, check the fuel gauge (Fig.

5) to see if there is sufficient fuel inside the tank:

• E = Empty

• F = Full

2. If the tank is empty add gasoline to the gas tank. See above section, "To Add Gasoline".

Fuel Cap

Control Panel

ENGINE SWITCH

IMPORTANT BEFORE STARTING

1. Make sure the generator is properly grounded.

2. Check that the crankcase is sufficiently filled with oil.

3. Turn off and unplug all devices connected to generator.

OFF

OPERATION SUMMARY

1. Move the switch to the ON position.

2. Turn the fuel valve to the ON position.

3. Move the choke lever to the START position.

4. Pull the start cord to start the engine.

5. If the engine fails to start, adjust the choke and try again.

6. Allow the generator to run for several minutes before connecting devices.

Fuel Gauge

AC 120V 20A

5-20R

BREAKER

ON OFF

BREAKER

ON OFF

Grounding Nut

AC 120V 20A

5-20R

AC 120V 30A

TT-30R

Rv ready

AC 120V 30A

L5-30R

transfer

switch ready

Fig. 5

Fig. 6

MAIN

BREAKER

OFF

GROUNDING

NUT

STEP 3 - GROUND THE GENERATOR

To reduce the risk of electric shock and to maximize safety, the generator should be properly grounded.

1. Attach one end of the grounding wire to the grounding nut (Fig. 6). Tighten the nut to secure the grounding wire.

2. Connect the other end of the grounding wire to a copper, brass, or steel-grounding rod that is driven into the earth.

WARNING! Failure to properly ground the

generator increases your risk of electric shock.

NOTE: Grounding wire and grounding rods are not included with the generator. A generally acceptable grounding wire is a No. 12 AWG (American Wire Gauge) stranded copper wire. Grounding codes can vary by location. Contact a local electrician to check the area codes.

STARTING YOUR GENERATOR

Before starting the generator, make sure you have read and performed the steps in the “Generator Preparation” section of this manual, pages 11-13. If you are unsure about how to perform any of the steps in this manual please call 1-800-232-1195 (M-F 8-5 CST) for customer service.

DANGER: CARBON MONOXIDE

WARNING: The exhaust from this product contains chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

WARNING: Do not operate generator near open flame or flammable materials 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 it isn’t directly in contact with gasoline. Do not smoke near the generator.

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

WARNING: 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.

WARNING: Generator should only be connected to electrical devices, either directly or with an extension cord. NEVER connect to a building electrical system without a qualified electrician and connected to a transfer switch as a separately derived system. 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.

To maximize safety, ALWAYS ground the generator before using it. Refer to "Step 3 - Ground The Generator" on page 13.

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.

CAUTION!

Disconnect all electrical loads from the generator before attempting to start.

Follow the instructions on the next page to start your generator.

STARTING YOUR GENERATOR

CHOKE LEVER

START RUN

OPEN

FUEL VALVE

OFF

BEFORE STARTING THE GENERATOR

1. Verify that the generator is outside on a dry, level surface. Allow at least two feet of clearance on all sides of the generator.

2. To maximize safety, check that the generator is properly grounded. Refer to "Step 3 - Ground The Generator" on page 13.

3. Check that there is a sufficient level of oil in the crankcase. Add oil if necessary. Refer to "Step 1 - Add/Check Oil" on page 11.

4. Check that there is a sufficient level of fuel in the fuel tank. Add gas if necessary. Refer to "Step 2 - Add/Check Fuel" on page 12.

5. Make sure all electrical devices are unplugged from the generator during ignition. Otherwise it will be difficult for the engine to start.

STARTING THE GENERATOR

1. Turn the fuel valve to the ON position (Fig. 7).

Fig. 7

2. Move the choke lever to the CLOSE/START position (Fig.

7).

3. Flip the engine ON/OFF switch (page 9) to the ON position.

4. Pull on the recoil starter handle (page 9) slowly until a slight resistance is felt, then pull quickly to start the engine. Return cord gently into the recoil starter. Never allow the cord to snap back.

5. If engine fails to start, repeat this step.

6. Once the engine has started, slowly return the choke lever all the way to the OPEN/RUN position.

7. Allow the engine to run for several minutes before attempting to connect any electrical devices. This allows the generator to stabilize its speed and temperature. Follow the instructions in the next section for properly connecting your electrical devices.

NOTE: In case you have had repeated failed attempts to start the engine, please consult the troubleshooting guide before attempting to start the generator. If problems persist please call 1-800-232-1195, M-F 8-5 CST.

1514

USING YOUR GENERATOR

CALCULATING THE WATTAGE OF YOUR DEVICE(S)

Connect electrical devices running on AC current according to their wattage requirements. Calculate the total running wattage and starting wattage of the device(s) you wish to connect, and MAKE SURE that they are within the capacity of your generator and the capacity of each individual outlet.

GENERATOR RUNNING (RATED) WATTS GENERATOR STARTING (SURGE) WATTS

3600W 4500W

Generator

Wattage

Capacity

Electronic

Device

Wattage

Calculation

What this means:

The generator can produce a maximum of 3600W on a continuous basis to supply ongoing power to your electronic devices.

NOTE: Also check the rated amperage for each outlet and make sure not to overload the individual outlets.

Find the wattage information of each device you plan to connect. The information should

be listed on the device or in its instruction manual, or you may refer to page 17, Table

2 - Estimated Wattages of Common Electrical Appliances.

The wattage can be calculated using this equation: Watts = Volts x Amperes

To calculate the total running watts of your devices:

+ Add up the running wattages of all the

device(s) you plan to connect.

= The total running (rated) wattage.

This wattage should NOT exceed the running wattage of 3600W.

It is recommended to maintain a load at or below 3240W (90% of the rated output) to ensure steady voltage output and to prolong the generator’s lifespan.

What this means:

Some devices such as box fans require short bursts of extra power in addition to the rated wattage listed by the device to start their motors.

The generator can produce a maximum wattage of 4500W for a short period of time (seconds) to cover the extra starting power required by your electronic devices.

To calculate the total starting watts of your devices:

+ Add up the total running wattage of all the

device(s) you plan to connect.

+ Add the single highest ADDITIONAL starting wattage out of the device(s) you plan to connect.

= The total starting (surge) wattage.

This wattage should NOT exceed the starting wattage of 4500W.

If any of either of the total calculated running watts or starting watts is higher than the capacity of your generator, adjust the load until both wattage requirements are met. Otherwise you will overload the generator, and cause damage to the engine and your electrical device(s).

Table 1 - How to Calculate Wattages

USING YOUR GENERATOR

CALCULATING THE WATTAGE OF YOUR DEVICE(S) - CONTINUED

The chart below serves as a reference for the estimated wattage requirements of common electrical devices. However, do not solely rely on this chart - all electronics and appliances are built differently. Always check the wattage listed on the electrical device before consulting this chart.

Tool or Appliance Rated (Running) Watts Surge (Starting) Watts

Hot Plate 2500 0

Saw - Radial Arm 2000 2000

Electric Stove (Each Element) 1500-2800 0

Saw - Circular 1500 1500

Air Compressor (1 HP) 1500 3000

Window Air Conditioner 1200 1800

Saw - Miter 1200 1200

Microwave 1000 0

Well Water Pump 1000 1000

Sump Pump 800 1200

Refrigerator Freezer 800 1200

Furnace Blower 800 1300

Computer 800 0

Electric Drill 600 900

Television 500 0

Deep Freezer 500 500

Garage Door Opener 480 0

Stereo 400 0

Box Fan 300 600

Clock Radio 300 0

Security System 180 0

DVD Player / VCR 100 0

Common Light Bulb 75 0

Table 2 - Estimated Wattages of Common Electrical Appliances

NOTE: Become familiar with the functions and capacity of each component on the control panel before connecting electrical devices. See page 10 for more information about the components of the control panel. Do not overload generator or individual panel receptacles. Do not connect 50Hz or 3-phase loads to the generator.

1716

USING YOUR GENERATOR

CONNECTING ELECTRICAL DEVICES

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

2. Select the device with the highest wattage, and make sure it is turned off. Plug the device into the matching generator outlet and then turn the device on. Allow the engine to stabilize.

3. Repeat step 2 to plug in each additional device. Do not attempt to plug in or start multiple devices at the same time.

SOME NOTES ABOUT POWER CORDS

Long or thin extension cords can drain the power provided to your electrical devices. Refer to the following chart in determining the necessary gauge extension cord for each of your devices. Round up to the higher amperage in the chart to maximize safety.

Device Requirements Max. Cord Length (ft) by Wire Gauge

Amps Watts (120V) #8 wire #10 wire #12 wire #14 wire #16 wire

2.5 300 NR NR NR 375 250

5 600 NR NR 300 200 125

7.5 900 NR 350 200 125 100

10 1200 NR 250 150 100 50

15 1800 NR 150 100 65 NR

20 2400 175 125 75 50 NR

25 3000 150 100 60 NR NR

30 3600 125 65 NR NR NR

40 4800 90 NR NR NR NR

Table 3 - Power Cord Requirement Guide*NR = Not Recommended

FUEL VALVE

OFF

USING YOUR GENERATOR

WARNING! NEVER CONNECT TO A BUILDING'S ELECTRICAL SYSTEM without using a transfer switch, installed by a qualified electrician, as a separately derived system.

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

SHUTTING OFF YOUR GENERATOR

CAUTION! Unplugging running devices can cause damage to the generator. Never stop the engine with electrical devices connected and running.

WARNING! Allow the generator to cool down before touching areas that become hot during use.

CAUTION! Allowing gasoline to sit in the fuel tank for long periods of time can make it difficult to start the gen-

erator in the future. Never store the generator for extended periods of time (over 2 months) with fuel in the fuel tank. Refer to "Storing The Generator" on page 25.

MANUAL SHUTOFF

1. Turn off all electrical devices prior to unplugging them from the generator. Unplugging running devices can cause damage to the generator. Never start or stop the generator with electrical devices plugged in or turned on.

2. Let engine run at no-load for several minutes to stabilize internal temperatures of engine and generator.

3. Turn the fuel valve to the OFF position (Fig. 8). Let the generator run until the fuel is used up.

4. Flip the engine ON/OFF switch (page 9) to the OFF position.

5. Drain the carburetor. Refer to "Draining The Carburetor" on page 22.

IMPORTANT: Always ensure that the fuel valve and the engine switch are in the OFF position when the generator is not in use.

Fig. 8

NOTE: If for some reason (e.g. refueling, moving the generator, etc.) you need to shut down the generator quickly, simply flip the engine switch to OFF. However, doing this will allow fuel to remain in the carburetor, and will lead to problems if the carburetor is not drained after use.

1918

MAINTENANCE

RECOMMENDED MAINTENANCE SCHEDULE

Proper routine maintenance of the generator will help prolong the life of the machine. Please perform maintenance checks and operations according to the maintenance schedule below, Table 4. If there are any questions about the maintenance procedures listed in this manual, please contact customer service at 1-800-232-1195 (M-F 8-5 CST), or email techsupport@wenproducts.com.

WARNING! Never perform maintenance operations while the generator is running. Before maintaining or servicing the generator, turn OFF the generator, disconnect all devices and allow the generator to cool down.

Recommended

Maintenance Schedule

Check Level X

Engine Oil

Replace X* X

Check X*

Air Filter

Clean X*

Check/Clean/

Spark Plug

Fuel

Carburetor Drain X X

Spark

Arrestor

Regap

Change X X

Check Level X

Drain X X

Check/Clean X

Every 8

Hours or

Daily

Every 25

Hours

Every 3

Months or

50 Hours

Every 6 Months or 100 Hours

Before

StorageAsNecessary

Table 4 - Recommended Maintenance Schedule* Clean/change more often under dusty conditions

or operating under heavy load.

IMPORTANT GENERATOR MAINTENANCE TIPS:

• Drain your carburetor after each use and before storage to prevent it from clogging.

• Do not store the generator with fuel inside the tank for more than 2 months - the fuel will go bad.

• Run the generator for 20 to 30 minutes every month to maximize its lifespan.

NOTE: Failure to properly maintain the generator will void the warranty.

MAINTENANCE

CLEANING YOUR GENERATOR

Keep the generator clean to prevent improper operation or machine damage from dirt and debris. Inspect all ventilation openings on the generator. These openings must be kept clean and unobstructed.

If the generator becomes dirty, use a damp cloth to wipe exterior surfaces. Use a soft bristle brush to loosen dirt and oil and use a vacuum to pick up loose dirt. Use low pressure air (not to exceed 25 PSI) to blow away dirt.

WARNING! 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 corrosion or a short circuit.

CHECKING/ADDING OIL

Check the oil level before each use and every 8 hours of operation (refer to page 20, Table 4). The oil capacity

of the generator engine is 20.3 fl. oz. (0.6 L). Add oil when the oil level is low. For the proper type and weight of oil refer to page 11, Fig. 1. This is a critical step for proper engine starting. The generator is equipped with a with low-oil shut down to protect it from running without oil.

To check the oil level and/or add oil refer to "Step 1 - Add/Check Oil" on page 11.

TIP: Your WEN generator is compatible with the WEN 55201 Magnetic Oil Dipstick (not included), available for

purchase at wenproducts.com. The dipstick’s industrial-strength magnetic tip will collect metal shavings from your generator’s oil tank to help preserve the engine and extend your generator’s lifespan.

DRAINING/CHANGING OIL

Change the oil according to the Recommended Maintenance Schedule (refer to page 20, Table 4). Change

the 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. Changing the oil when the engine is warm allows for complete drainage.

1. Place generator on a level, elevated platform. Prepare an approved oil-storage container underneath the oil drain bolt next to the oil dipstick to catch the oil as it drains. See Fig. 9. NOTE: To avoid possible fuel spills from the carburetor bowl, drain the carburetor (refer to "Draining The Carburetor" on page 22) before draining the oil.

2. Unscrew the oil drain bolt and allow oil to drain from the engine completely.

3. Reinstall the oil drain bolt and tighten it securely. Wipe clean any oil spillage.

4. To add new oil, refer to "Step 1 - Add/Check Oil" on page

11.

Fig. 9

Dipstick

Oil Drain

Bolt

NOTE: Never dispose of used engine oil in the trash or down a drain. Please call a local recycling center or auto garage to arrange proper oil disposal.

2120

MAINTENANCE

DRAINING THE CARBURETOR

Drain the carburetor after every use and before storing the generator (refer to page 20, Table 4). Draining the

carburetor can help prevent build-up and blockages caused by stagnant fuel inside of the carburetor.

1. Prepare an approved gasoline-storage container under the carburetor to collect the drained fuel.

2. The carburetor can be accessed from the backside of the generator between the engine and the air filter. To drain the carburetor, open up the carburetor drain screw with a Phillips-head screwdriver and drain out any gasoline that has built up inside. See Fig. 10.

3. Once the fuel has drained, close the drain screw.

Drain Screw

NOTE: Make sure to drain your carburetor before storing the generator for long periods of time.

Fig. 10

INSPECTING/CLEANING THE AIR FILTER

Inspect and clean the air filter every 50 hours of operation (refer to page 20, Table 4). Routine maintenance of

the air filter helps maintain proper airflow to the carburetor. Occasionally check that the air filter is free of excessive dirt. Clean air filter more frequently in dirty or dusty conditions.

WARNING! Running the engine with a dirty, damaged or missing air filter element can result in danger to

the operator and cause the engine to wear out prematurely.

1. Remove the air filter cover by unscrewing the cover lock knob at the bottom of the air filter cover. See Fig. 11.

2. Remove the foam, sponge-like air filter element from the casing. Wipe excessive oil and any dirt from inside of the air filter casing.

3. Check the foam, sponge-like air filter element. a) Good elements can be washed in soapy water. Dry

the element in clean cloth (do not twist it). Add a few drops of engine oil to the air filter element and spread it evenly. A small amount of oil left in the element is normal and necessary for the engine to work properly.

b) Damaged elements should be replaced with a new one. Replacement air filters can be purchased from

wenproducts.com by searching part number GN4500-167.1.

Cover Lock

Air Filter Cover

Fig. 11

4. Reinstall the air filter element and air filter cover.

MAINTENANCE

INSPECTING/CLEANING THE SPARK ARRESTOR

Inspect and clean the spark arrestor every 100 hours of operation (refer to page 20, Table 4). The spark arrestor

is located outside the muffler, which gets very hot during operation. Allow the engine to cool completely before servicing the spark arrestor.

1. Remove the screw/clamp that secures the spark arrestor

to the muffler. See Fig. 12.

2. Remove the spark arrestor screen.

3. Carefully clean and remove the carbon deposits from the

spark arrestor screen with a wire brush. Replace the spark arrestor if it is damaged. Replacement spark arrestors can be purchased from wenproducts.com by searching the part number GN4500-026.1.

4. Reinstall the spark arrestor in the muffler and secure it in

place with the screws.

SPARK PLUG MAINTENANCE

Inspect and change the spark plug every 100 hours of operation (refer to page 20, Table 4). The spark plug

is important for proper engine operation. Check the spark plug regularly to maintain proper engine operation. A good spark plug should be intact, free of deposits, and properly gapped.

Spark Arrestor

Spark Plug Boot

Cylinder Assembly

Fig. 12

Muffler

Fig. 13

1. Gently pull on the spark plug boot to remove it. Be care-

ful not to tear insulation or wire. See Fig. 13.

2. Use the included spark plug wrench (Fig. 14) to unscrew

the spark plug from the engine. Remove the spark plug from the engine. TIP: There is limited space for the wrench to turn. Use both rows of holes in the spark plug wrench to gain leverage to loosen the plug.

3. Visually inspect the spark plug. If it is cracked or chipped,

or if the electrodes are worn or burned, discard it and replace with a new spark plug. We recommend replacing it with an NGK BP7ES/Torch F7TC spark plug. These can be purchased from wenproducts.com by searching part number DF475-145.

4. If re-using the spark plug, use a wire brush to clean any

dirt from around the spark plug base, then re-gap the spark plug.

Instructions continue on the next page.

Fig. 14

Wrench (1)Handle (1)

2322

MAINTENANCE

5. Measure the plug gap with a spark plug gap gauge. The

gap should be 0.7 to 0.8 mm (0.028-0.031 in). Carefully adjust the gap if necessary. See Fig. 15.

6. Screw the spark plug back into the spark plug hole us-

ing the spark plug wrench. Do not over-tighten spark plug. Recommended tightening of the spark plug is ½ to ¾ of a turn (15 ft-lb torque/20.33 Nm) after the spark plug gasket contacts the spark plug hole.

7. Reinstall the spark plug boot over the spark plug.

DRAINING THE FUEL TANK

Drain and clean the fuel tank each year, or before storing the generator for longer than two months.

1. Prepare an approved gasoline-storage container to col-

lect the drained fuel. Place it near the fuel valve.

2. Turn the fuel valve to the OFF position.

3. Locate the fuel line between the fuel valve and the carbu-

retor. Disconnect the fuel line from the fuel valve. See Fig.

16. NOTE: A small amount of fuel may leak from the fuel

line during removal.

Fuel Valve

Fuel Line

Fig. 15

0.7 - 0.8mm

Fig. 16

4. Place a funnel below the fuel valve opening, and direct

the other end of the funnel over the prepared container.

5. Turn the fuel valve to the ON position to start draining

the fuel from the fuel valve opening. NOTE: The draining process may take a few hours, depending on the amount of fuel in your gas tank.

6. Once the fuel is completely drained, turn the fuel valve to

the OFF position.

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

8. Drain the carburetor. Refer to "Draining The Carburetor"

on page 22.

CAUTION! Store the emptied gasoline in a suitable place. Never store fuel for more than 2 months.

TRANSPORTATION & STORAGE

TRANSPORTING THE GENERATOR

To prevent fuel spillage when transporting, be sure to perform the following:

1. Tighten the fuel cap and turn the fuel valve to the OFF position.

2. Flip the engine ON/OFF switch to the OFF position.

3. Drain the fuel tank if possible. Refer to "Draining The Fuel Tank" on page 24.

4. Keep the generator upright. Never place the generator on its side or upside down - doing so could damage the

internal components of the generator and make it difficult to start.

WARNING! Avoid direct sunlight inside a vehicle. If the generator is left in an enclosed vehicle for many

hours, the high temperature could cause the fuel to vaporize and result in a possible explosion.

STORING THE GENERATOR

Shut off the generator and allow the unit to cool to room temperature before storing it. NEVER place any type of storage cover on the generator while it is still hot. Do not obstruct any ventilation openings.

Follow the procedures below for properly storing your generator. We highly recommend running your generator once a month for 20 to 30 minutes. Plug in a small load in to ensure there is proper power output.

For Short Periods (30 to 60 Days):

• Drain the carburetor. Refer to "Draining The Carburetor" on page 22.

• Add fuel stabilizer: Follow the suggested portions and instructions of your preferred stabilizer. Run the engine for 15 to 20 minutes, allowing the fuel stabilizer to mix with the gasoline and circulate through the carburetor, and then top off with fuel. Filling the fuel tank full reduces the amount of air in the tank and helps fight deterioration of fuel.

WARNING! Store the generator upright in a cool and dry location, away from sources of heat, open flames,

sparks or pilot lights.

TIP: Your WEN generator is compatible with the WEN 56406 Medium Generator cover (not included), available for purchase at wenproducts.com.

For Extended Periods (Over 60 Days):

• Drain the fuel tank and carburetor. Refer to "Draining The Fuel Tank" on page 24, and "Draining The Carburetor" on page 22.

• Never store generator with fuel in the tank for more than two months.

• Change the engine oil. Refer to "Checking/Adding Oil" on page 21.

PRODUCT DISPOSAL

Do not dispose of used generator or parts with your household waste. This product contains electrical or electronic components that should be recycled. Please take this product to your local recycling facility for responsible disposal to minimize its environmental impact.

Do not dispose of used oil or fuel in the trash or down a drain. Please contact your local recycling center or auto garage to arrange proper oil/fuel disposal.

Please recycle the packaging and electronic components where facilities exist. Please contact your local auto garage or recycling facility to properly dispose of oil/fuel.

2524

TROUBLESHOOTING GUIDE

WARNING! Stop using the generator immediately if any of the following problems occur or risk serious personal injury. If you have any questions, please contact customer service at 1-800-232-1195 (M-F 8-5 CST), or email techsupport@wenproducts.com.

PROBLEM POSSIBLE CAUSE SOLUTION

Engine switch is set to OFF. Set engine switch to ON.

Fuel valve is turned to OFF. Turn fuel valve to ON.

Oil is low. Add or replace oil.

Engine is out of fuel. Add fuel.

Engine will not

start.

Engine is filled with contaminated or old fuel.

Spark plug is dirty or broken. Clean or replace the spark plug.

Carburetor is air locked.

Drain fuel in the tank. Fill with fresh fuel.

Shut off the fuel valve. Remove the bolt from the bottom of the carburetor. Take off the carburetor bowl to allow it to reset. Replace carburetor bowl and reinstall the bolt.

Engine runs

but there is no

electrical output

whatsoever.

Generator runs but

does not support all

electrical devices

connected.

Turn off and unplug electrical device(s). Wait 5 minutes, then Circuit breaker has been tripped due to overload.

Bad connecting cords/wires.

Bad electrical device connected to the generator.

Voltage regulator is bad Check voltage regulator with a multimeter, replace if necessary.

Carbon brushes worn or need adjustment

Generator is overloaded.

Short circuit in one of the devices. Try disconnecting any faulty or short-circuited electrical loads.

Air filter is dirty. Clean or replace the air filter element.

The fuel isn’t running through the fuel valve.

press the circuit breaker to reset. Check the total wattage of the

devices and reduce the load if it exceeds the capacity of the gen-

erator. Then plug the loads back in one by one.

Check the power cords and extension cords. Do not use if any

cord is damaged. Replace damaged cords immediately.

Try connecting a different device.

Check carbon brushes, adjust so that both brushes extrude the

same length, or replace if worn.

Turn off and unplug all electrical devices. Wait 5 minutes, then

press the circuit breaker to reset. Reduce load as necessary, then

plug devices back in one by one.

Turn off the generator and wait for it to cool down. Check if the

fuel is properly and consistently going through the fuel valve.

Engine is “hunting”

during operation

(engine RPM is

fluctuating).

The air filter is clogged.

The muffler or spark arrestor is blocked

There is gunk in the carburetor preventing a consistent fuel/air mixture.

Turn off the generator and wait for it to cool down. Check for any

blockage in the air filter. Check and clean the air filter as neces-

sary.

Turn off the generator and wait for it to cool down. Check if the

spark arrestor is blocked. Clean with metal brush as necessary.

Turn off the generator and wait for it to cool down. Use “gunk

remover” spray on the carburetor jets.

PinkP

Light BlueLB

White

Gray

Red

Blue

KEY

Orange

BlO

Black

ALTERNATOR

WIRING DIAGRAM

Stator

Coil

Bl/W

Black/White

BrownBr

Br/R

G/Y

Brown/Red

Green/Yellow

Coil

Rotor

Sub-Field

Coil

AVR

Multi-

Meter

Breaker

L5-30R TT-30R

Plug

Coil

Spark

Ignition

Oil Sensor

ENGINE

Engine Switch

Terminal

Ground

5-20R 5-20R

20A

Breaker 20A

Breaker

CONTROL PANEL

Neutral Bonded

2726

ENGINE EXPLODED VIEW

EXPLODED VIEW & PARTS LIST

65.1

EXPLODED VIEW & PARTS LIST

NOTE: Replacement parts can be purchased from wenproducts.com, or by calling our customer service at (800) 232-1195, M-F 8-5 CST. Parts and accessories that wear down over the course of normal use are not covered by the two-year warranty. Not all parts may be available.

ENGINE PARTS LIST

No. Part No. Description Qty.

2 GN4500-102 Ball Bearing, 6205 2 3 DF475-103 Oil Seal 2 4 GN4500-104 Governor Assembly 1 5 GN4500-105 Governor Arm Shaft 1

6 DF475-106

7 DF475-107 Lock Pin 1 8 DF475-108 Drain Screw 2 9 DF475-109 Drain Screw Washer 2

10 DF475-110

11 DF475-071 Bolt, M6x16 2

12 DF475-177

13 GN4500-113 Piston 1 14 GN4500-114 Piston Ring Set 1 15 GN4500-115 Connecting Rod 1 16 DF475-116 Piston Pin 1 17 DF475-117 Piston Clip 2

18 DF475-118

19 GN4500-119 Cylinder Head 1 20 DF475-120 Intake Valve 1

GN4500-101 Crankcase 1

Governor Arm Shaft

Washer

Oil Level Switch

Assembly

Crankcase Dowel Pin,

Ø8x12

Crankcase Cover

Assembly

No. Part No. Description Qty.

26 DF475-126 Push Rod Guide Plate 1 27 DF475-127 Rocker Assembly 2 28 DF475-128 Rotator 1 29 DF475-129 Stud Bolt (Carburetor) 2 30 DF475-130 Stud Bolt 2 31 GN4500-131 Carburetor Assembly 1 32 GN4500-132 Fuel Line 1

33 DF475-060

34 DF475-134 Governor Arm 1 35 DF475-168 Fuel Line Sleeve 1 36 DF475-136 Nut, M6 2 37 GN4500-137 Crankshaft Assembly 1 38 GN4500-138 Valve Lifter 2

39 DF475-139

40 GN4500-140 Camshaft Assembly 1 41 DF475-141 Dowel Pin 2 42 DF475-142 Bolt, M8x30 6

43 DF475-143 Cylinder Head Gasket 1

44 DF475-144 Bolt, M8x60 4

45 DF475-145

Clip, Fuel Line,

Ø7.5mm

Crankcase Cover

Gasket

Spark Plug, Torch

F7TC (NGK BP7ES)

21 GN4500-121 Exhaust Valve 1

22 DF475-122

23 DF475-123 Valve Spring 2

24 DF475-124

25 DF475-125

Intake Valve Spring

Seat, Lower

Intake Valve Spring

Seat, Upper

Exhaust Valve Spring

Seat

46 DF475-146 Push Rod 2

47 GN4500-147 Shroud 1 48 DF475-148 Bolt, M6x12 13

49 DF475-149

50 DF475-150 Cylinder Head Cover 1 51 GN4500-151 Airflow Cover 1

Cylinder Head Cover

Gasket

2928

EXPLODED VIEW & PARTS LIST

ENGINE PARTS LIST - CONTINUED

No. Part No. Description Qty.

52 GN4500-152 Bolt, M6x28 1 53 GN4500-153 Flywheel Assembly 1 54 GN4500-154 Recoil Starter Fan 1 55 GN4500-155 Recoil Starter Cup 1 56 DF475-155 Nut, M14 1 57 GN4500-157 Ignition Coil Assembly 1 58 DF475-157 Bolt, M6x25 2

59 GN4500-159

60 DF475-159 Carburetor Insulator 1 61 DF475-160 Gasket, Carburetor 1 62 GN4500-162 Gasket, Air Filter 1 63 DF475-162 Governor Rod 1 64 DF475-163 Throttle Return Spring 1

65 GN4500-165

N.P. GN4500-165.1 Recoil Starter 1

66 GN4500-166

67 GN4500-167 Air Filter Assembly 1

N.P. GN4500-167.1 Air Filter Element 1

68 DF475-167 Breather Tube 1 69 GN4500-169 Clip 1 70 DF475-169 Governor Spring 1

Gasket, Carburetor

Insulator

Recoil Starter

Assembly

Upper Shroud

Assembly

71 GN4500-171

72 DF475-171 Dipstick Assembly 1

73 DF475-175

N.P. = Not Pictured

Oil Level Switch

Amplifier

Rocker Arm Adjuster

Assembly

EXPLODED VIEW & PARTS LIST

26.1

GENERATOR EXPLODED VIEW

NOTE: Replacement parts can be purchased from

wenproducts.com, or by calling our customer service at (800) 232-1195, M-F 8-5 CST. Parts and accessories that wear down over the course of normal use are

not covered by the two-year warranty. Not all parts may be available.

29.7

29.6

29.2

29.8

29.5

29.4

29.3

29.1

11.1

11.2

3130

GENERATOR PARTS LIST

EXPLODED VIEW & PARTS LIST

No. Part No. Description Qty.

1 GN4500-001 Alternator Assembly 1

2 DF475-002 Motor Stand 1

3 GN4500-003

4 GN4500-004 Clip, Fuel Line, Ø12mm 1

5 DF475-005 Nut, M8 2

6 DF475-076 Connecting Tube 1

7 GN4500-007 Frame 1

8 DF475-008 Isolator A 2

9 DF475-009 Isolator B 2

10 DF475-075 Carbon Tank Assembly 1

11 GN4500-011 Fuel Tank Assembly 1

11.1 DF475-079 Fuel Filter 1

11.2 DF475-078 Fuel Gauge 1

12 GN4500-012 Fuel Valve 1

13 DF475-073 Fuel Tank Cap Assembly 1

14 DF475-072 Paper Washer 4

15 DF475-069 Grounding Wire 1

16 GN4500-016 Engine Assembly 1

17 GN4500-017 Bolt, M8-1.0x220 1

18 DF475-018

19 DF475-065 Toothed Washer, 6mm 1

20 GN4500-020 Bolt, M6x165 4

21 DF475-021 Bolt, M6x12 14

22 DF475-064 Nut, M8 10

23 DF475-023 Air Filter Bracket 1

24 DF475-024 Muffler Gasket 1

25 DF475-063 Clip, Fuel Line, Ø10mm 1

26 GN4500-026 Muffler 1

26.1 GN4500-026.1 Spark Arrestor 1

27 DF475-027 Lock Washer, 8mm 2

28 DF475-062 Bolt, M6x40 1

29 GN4500-029 Control Panel Assembly 1

Clip, Fuel Line,

Ø11.5mm

Rotor Bolt Gasket,

Ø8.5x24x3

No. Part No. Description Qty.

29.1 GN4500-029.1 Engine Switch 1

29.2 GN4500-029.2 Multi-meter 1

29.3 GN4500-029.3

29.4 GN4500-029.4 AC Breaker, 20A 2

29.5 GN4500-029.5

29.6 GN4500-029.6

29.7 GN4500-029.7 Main Breaker 1

29.8 GN4500-029.8 Grounding Nut 1

30 DF475-061 Clip, Fuel Line, Ø9.5mm 1

31 DF475-050 Muffler Bracket 1

32 GN4500-032 Foot 4

33 DF475-033

34 DF475-034 Bolt, M5x16 1

35 DF475-035 Bolt, M5x12 7

36 DF475-036 Fuel Tank Washer 4

37 DF475-037 Bolt, M6x25 4

38 DF475-038 Generator End Cover 1

39 DF475-060 Clip, Fuel Line, Ø7.5mm 1

40 DF475-058

41 DF475-057

42 DF475-077 Dustproof Cover 1

43 GN4500-043 Damper, Fuel Tank 1

44 DF475-052 Damper 1

45 DF475-045 Nut, M6 1

46 DF475-046 Bolt, M8x16 2

47 DF1100-006 Lock Washer, 5mm 1

45 DF475-045 Nut, M6 1

46 DF475-046 Bolt, M8x16 2

47 DF1100-006 Lock Washer, 5mm 1

NEMA 5-20R 120V 20A

Duplex Receptacle

NEMA TT-30R 120V

30A RV Receptacle

NEMA L5-30R 120V

30A Receptacle

Automatic Voltage

Regulator

Breather Valve

Assembly

Connecting Tube (Fuel

Tank)

WARRANTY

WEN Products is committed to building tools that are dependable for years. Our warranties are consistent with this commitment and our dedication to quality.

LIMITED WARRANTY OF WEN PRODUCTS FOR HOME USE

GREAT LAKES TECHNOLOGIES, LLC (“Seller”) warrants to the original purchaser only, that all WEN consumer power tools will be free from defects in material or workmanship during personal use for a period of two (2) years from date of purchase or 500 hours of use; whichever comes first. Ninety days for all WEN products if the tool is used for professional or commercial use. Purchaser has 30 days from the date of purchase to report missing or damaged parts.

SELLER’S SOLE OBLIGATION AND YOUR EXCLUSIVE REMEDY under this Limited Warranty and, to the extent permitted by law, any warranty or condition implied by law, shall be the replacement of parts, without charge, which are defective in material or workmanship and which have not been subjected to misuse, alteration, careless handling, misrepair, abuse, neglect, normal wear and tear, improper maintenance, improper storage, incorrect lubricants/fuels, or other conditions adversely affecting the Product or the component of the Product, whether by accident or intentionally, by persons other than Seller. To make a claim under this Limited Warranty, you must make sure to keep a copy of your proof of purchase that clearly defines the Date of Purchase (month and year) and the Place of Purchase. Place of Purchase must be a direct vendor of Great Lakes Technologies, LLC. Purchasing through third party vendors, including but not limited to garage sales, pawn shops, resale shops, or any other secondhand merchant, voids the warranty included with this product. Contact techsupport@wenproducts.com or 1-800-232-1195 with the following information to make arrangements: your shipping address, phone number, serial number, required part numbers, and proof of purchase. Damaged or defective parts and products may need to be sent to WEN before the replacements can be shipped out.

Upon the confirmation of a WEN representative, your product may qualify for repairs and service work. When returning a product for warranty service, the shipping charges must be prepaid by the purchaser. The product must be shipped in its original container (or an equivalent), properly packed to withstand the hazards of shipment. The product must be fully insured with a copy of the proof of purchase enclosed. There must also be a description of the problem in order to help our repairs department diagnose and fix the issue. Repairs will be made and the product will be returned and shipped back to the purchaser at no charge for addresses within the contiguous United States.

THIS LIMITED WARRANTY DOES NOT APPLY TO ITEMS THAT WEAR OUT FROM REGULAR USAGE OVER TIME, INCLUDING FILTERS, SPARK PLUGS, VOLTAGE REGULATORS, BRUSHES, GASKETS, O-RINGS, WHEEL KITS, BATTERIES, RECOIL STARTERS, HIGH PRESSURE HOSES, SPRAY GUNS, ETC. ANY IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO TWO (2) YEARS FROM DATE OF PURCHASE. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING BUT NOT LIMITED TO LIABILITY FOR LOSS OF PROFITS) ARISING FROM THE SALE OR USE OF THIS PRODUCT. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE IN THE U.S., PROVINCE TO PROVINCE IN CANADA AND FROM COUNTRY TO COUNTRY.

THIS LIMITED WARRANTY APPLIES ONLY TO ITEMS SOLD WITHIN THE UNITED STATES OF AMERICA, CANADA AND THE COMMONWEALTH OF PUERTO RICO. FOR WARRANTY COVERAGE WITHIN OTHER COUNTRIES, CONTACT THE WEN CUSTOMER SUPPORT LINE. FOR WARRANTY PARTS OR PRODUCTS REPAIRED UNDER WARRANTY SHIPPING TO ADDRESSES OUTSIDE OF THE CONTIGUOUS UNITED STATES, ADDITIONAL SHIPPING CHARGES MAY APPLY.

3332

NOTESNOTES

NOTES

THANKS FOR

REMEMBERING

v.2019.09.25

Wen GN4500 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual