MODEL GN625i 6250-WATT INVERTER GENERATOR Instruction Manual 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 General Safety Rules......................................................................................... 5 Generator Safety Warnings...............................................................................
SPECIFICATIONS GENERATOR Model Number GN625i Surge (Starting) Wattage 6250W Rated (Running) Wattage 5000W Rated Voltage 120V / 240V AC Rated Amperage 41.6A / 20.8A Phase Single Frequency 60 Hz Product Weight With Wheel Kit 119.5 lbs Product Weight Without Wheel Kit 109.6 lbs Product Dimensions With Wheel Kit 27 in. x 25 in. x 24 in. Product Dimensions Without Wheel Kit 24 in. x 20 in. x 21 in.
INTRODUCTION Thanks for purchasing the WEN 6250-Watt Inverter Generator. Refer to the illustration below for the location of the serial number on the specifications label. 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.
GENERAL SAFETY RULES WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Safety is a combination of common sense, staying alert and knowing how your item works. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. SAVE THESE SAFETY INSTRUCTIONS. WORK AREA SAFETY 1. Keep work area clean and well lit.
GENERAL SAFETY RULES WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Safety is a combination of common sense, staying alert and knowing how your item works. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. SAVE THESE SAFETY INSTRUCTIONS. 7.
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. Do not operate near open flame, heat, or flammable materials.
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 TOOL PURPOSE Generators provide you with power when and where you need it most. 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.
KNOW YOUR GENERATOR CONTROL PANEL 1 2 3 4 AC BREAKER 12 11 10 5 6 AC BREAKER 9 1. Indicator Lights The output light (green) will turn on when the receptacles have power, the overload light (red) will turn on if the generator is overloaded, the oil light (yellow) will turn on if the oil is low. 2. Choke Button Adjusts the amount of air allowed into the engine during startup. 3. Eco-Mode Switch Flip this switch to ON to increase fuel economy and runtime when the load is below 3750W (75% load). 4.
ASSEMBLY & ADJUSTMENTS HIGH ALTITUDE OPERATION ABOVE 3000 FEET The fuel system on this generator may be affected by operation at high altitudes. Proper operation can be ensured by installing an altitude kit at altitudes higher than 3000 feet above sea level. At elevations above 8000 feet, the engine may experience a decrease in performance, even with the proper altitude kit.
ASSEMBLY & ADJUSTMENTS WARNING! Do not turn on the generator until it is fully assembled according to the instructions. Read through and become familiarized with the following procedures of handling and adjusting your tool. Failure to follow the safety instructions may result in serious personal injury. • Never use the handle as a lifting point to support the entire weight of the generator. Only use the handle to pull the generator with the help of the wheels. • Use caution when collapsing the handle.
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 generator is shipped without oil. User must add the proper amount of oil before operating the generator for the first time.
GENERATOR PREPARATION TO CHECK OIL LEVEL (before every subsequent start): Fig. 5 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. 6 Fuel Cap 2. Unscrew the fuel cap (Fig. 6) 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. Fuel Cap NOTE: Do not fill the fuel tank to the very top.
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 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 THE 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." 3. Check that there is a sufficient level of oil in the crankcase. Add oil if necessary. Refer to "Step 1 - Add/Check Oil." 4. Check that there is a sufficient level of fuel in the fuel tank. Add gas if necessary.
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. Turn the voltage selector switch to 120V or 240V, depending on the appliance(s) connected. NOTE: You cannot use the 120V and 240V outlets at the same time. 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.
USING YOUR GENERATOR LIGHT GREEN (POWER INDICATOR) MEANING RED (OVERLOAD) RESOLUTION ON OFF Generator output is normal. No action needed. OFF Flashes 1x, repeating every 3 sec Voltage at alternator is too low. No electrical output. Check for loose connections. Call 1-800-232-1195 for assistance. OFF Flashes 2x, repeating every 3 sec Engine speed is too low. No electrical output. Check carburetor and stepper motor. Ensure Eco-Mode is OFF.
SHUTTING OFF THE 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 generator in the future. Never store the generator for extended periods of time (over 2 months) with fuel in the fuel tank.
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. 12 Drain the carburetor after every use and before storing the generator (refer to 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. Close fuel valve. 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 Fig. 14 Inspect and clean the spark arrestor every 100 hours of operation (refer to 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 two bolts that secure the spark arrestor to the muffler. See Fig. 14. 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 switch to the STOP position. 3. Drain the fuel tank if possible. Refer to "Draining The Fuel Tank." 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.
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. 30 POSSIBLE CAUSE SOLUTION 1. Engine switch is set to OFF. 1. Set engine switch to ON. 2. Fuel valve is turned to OFF. 2. Turn fuel valve to ON. 3.
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 Generator runs but does not support all electrical devices connected. POSSIBLE CAUSE 1. Generator is overloaded. 1. Turn off and unplug all electrical devices. Wait 5 minutes, then press the circuit breaker to reset.
Spark Plug V.F.
EXPLODED VIEW & PARTS LIST NOTE: Replacement parts can be purchased from wenproducts.com, or by calling our customer service at 1-(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 for purchase. ASSEMBLY 1 - CYLINDER HEAD, SPARK PLUG No. Part No. Description ASSEMBLY 2 - CRANKCASE Qty. No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 3 - CRANKCASE COVER 34 ASSEMBLY 4 - CRANKSHAFT No. Part No. Description Qty. 3-1 GN625i-0301 Crankcase Cover 1 3-2 GN625i-0302 Crankcase Cover Gasket 1 3-3 GN400i-0205 Pin 2 3-4 GN625i-0304 Oil Dipstick Subassembly 1 3-5 GN625i-0305 Bearing, 6206P53 1 3-6 GN400i-1310 Bolt, M8x35 7 No. Part No. Description Qty. 4-1 GN625i-0401 Crankshaft Assembly 1 ASSEMBLY 5 - PISTON RING SET, CONNECTING ROD No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 6 - VALVE TRAIN, CAMSHAFT No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 8 - SHROUD, LOWER SHIELD No. Part No. Description Qty. 8-1 56200-1202 Bolt, M6x12 5 8-2 GN625i-0802 Retaining Ring 1 8-3 GN625i-0803 Shroud 1 8-4 56200-1202 Bolt, M6x12 2 8-5 GN625i-0805 Cylinder Body Shroud 1 8-6 GN400i-0703 Clip 1 ASSEMBLY 10 - AIR FILTER No. Part No. 10-1 GN625i-1001 10-2 36 56200-0506 Description Qty. Air Filter Assembly 1 Nut, M6 2 ASSEMBLY 9 - CARBURETOR No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 11 - FLYWHEEL, IMPELLER, STARTER PULLEY No. Part No. Description ASSEMBLY 12 - MUFFLER ASSEMBLY Qty. 11-1 GN625i-1101 Flywheel Nut, M16-1.5 1 11-2 56200-1202 Bolt, M6x12 3 11-3 GN625i-1103 Starter Pulley 1 11-4 56200-1202 Bolt, M6x12 4 11-5 56380i-0705 Starter Pulley Seat 1 11-6 GN625i-1106 Impeller 1 11-7 56310i-1103 Screw, M6x60 3 11-8 GN625i-1108 Rotor 1 11-9 GN625i-1109 Stator 1 11-10 GN625i-1110 Flat Washer, 6mm 3 No.
EXPLODED VIEW & PARTS LIST ASSEMBLY 13 - FUEL TANK 38 No. Part No. Description Qty. 13-1 GN625i-1301 Fuel Tank 1 13-2 56380i-1207 Fuel Tank Damper 13-3 GN625i-1303 13-4 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 14 - FRAME No. Part No. Description Qty. No. Part No. Description Qty. 14-1 GN625i-1401 Frame Assembly 1 14-13 56200-0706 Bolt, M6x10 2 14-2 GN625i-1402 Nut, M10-1.25 8 14-14 GN400i-1311 Bolt, M6x8 1 14-3 56310i-1404 Nut, M8 4 14-15 GN625i-1415 Cllp 1 14-4 GN625i-1404 Engine Plate, Rear 1 14-16 GN400i-1313 Nut, M6 1 14-5 GN625i-1405 Engine Plate, Forward 1 14-22 GN625i-1422 Fuel Valve 1 14-6 GN625i-1406 Bolt, M10-1.
EXPLODED VIEW & PARTS LIST ASSEMBLY 15 - CONTROL PANEL 40 ASSEMBLY 16 - WHEEL AND HANDLE No. Part No. Description Qty. 15-1 GN625i-1501 Control Panel Subassembly 1 15-2 GN625i-1502 Bolt, M6x16 4 15-3 GN625i-1503 Bolt, M6x20 4 15-4 GN625i-1504 Flat Washer, 6mm 4 15-5 GN625i-1505 Inverter 15-6 GN625i-1506 15-7 No. Part No. Description Qty.
WARRANTY STATEMENT 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 fessional or commercial use.
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THANKS FOR REMEMBERING V. 2020.11.
