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: 1-800-232-1195 (M-F 8AM-5PM CST) TECHSUPPORT@WENPRODUCTS.COM 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.
CONTENTS WELCOME 3 Specifications.................................................................................................... 3 Introduction...................................................................................................... 4 SAFETY 5 Safety Information............................................................................................ 5 Generator Safety Warnings...............................................................................
SPECIFICATIONS CONTENTS 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.
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.
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.
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.
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.
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. 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.
KNOW 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 Gauge Choke Lever Fuel Valve 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.
KNOW YOUR GENERATOR CONTROL PANEL 1 2 5 ENGINE SWITCH 3 AC 120V 20A AC 120V 20A 5-20R AC 120V 30A 5-20R BREAKER AC 120V 30A TT-30R MAIN BREAKER L5-30R ON ON ON OFF OFF IMPORTANT BEFORE STARTING 1. Make sure the generator is properly grounded. OFF GROUNDING NUT BREAKER 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.
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).
GENERATOR PREPARATION TO CHECK OIL LEVEL (before every subsequent start): Fig. 4 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. Upper Limit 3. Insert the dipstick into the oil fill without screwing it in. Remove the dipstick to check the oil mark. 4.
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. Fig. 5 Fuel Cap 2. Unscrew the fuel cap (Fig. 5) and set it aside. The fuel cap may be tight and hard to unscrew. Fuel Gauge 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.
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 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.
STARTING YOUR GENERATOR 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.
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.
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.
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.
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.
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.
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.
MAINTENANCE DRAINING THE CARBURETOR Fig. 10 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.
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. Fig. 12 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.
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. Fig. 15 0.7 - 0.8mm 6. Screw the spark plug back into the spark plug hole using 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.
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.
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 Engine will not start. Engine runs but there is no electrical output whatsoever. POSSIBLE CAUSE 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.
WIRING DIAGRAM Stator Coil ALTERNATOR KEY P Pink Br MultiMeter Breaker Brown Br/R Brown/Red G/Y Green/Yellow Bl/W Black/White Rotor Coil Sub-Field Coil LB Light Blue O Orange Bl Black R Red Bu Blue W White Gr Gray L5-30R AVR TT-30R 5-20R Breaker 20A 5-20R Ground Terminal Breaker 20A Oil Sensor Neutral Bonded CONTROL PANEL ENGINE Engine Switch Spark Ignition Plug Coil 27
36 67 48 65.
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. No. Part No. Description Qty.
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 - CONTINUED No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST 47 15 17 21 14 21 29.5 14 29.8 29.6 29.7 21 21 14 14 21 32 43 6 22 22 22 9 22 9 22 9 22 16 42 22 8 22 23 21 37 36 3 41 21 30 21 32 25 12 39 11.2 40 13 4 21 11.1 21 32 10 37 36 37 36 7 21 32 22 1 11 37 36 44 29.2 29.1 29.3 29.4 27 5 2 45 19 24 18 26 21 20 28 29 26.1 31 34 35 46 21 NOTE: Replacement parts can be purchased from wenproducts.com, or by calling our customer service at (800) 232-1195, M-F 8-5 CST.
EXPLODED VIEW & PARTS LIST GENERATOR PARTS LIST 32 No. Part No. Description Qty. No. Part No. Description Qty. 1 GN4500-001 Alternator Assembly 1 29.1 GN4500-029.1 Engine Switch 1 2 DF475-002 Motor Stand 1 29.2 GN4500-029.2 Multi-meter 1 3 GN4500-003 Clip, Fuel Line, Ø11.5mm 1 29.3 GN4500-029.3 NEMA 5-20R 120V 20A Duplex Receptacle 2 4 GN4500-004 Clip, Fuel Line, Ø12mm 1 29.4 GN4500-029.
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.
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THANKS FOR REMEMBERING v.2019.09.
