Wen GN4500 Instruction Manual
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Wen GN4500 Instruction Manual

4500-watt portable generator
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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. 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.
WENPRODUCTS.COM
For replacement parts and the most up-to-date instruction manuals, visit

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Summary of Contents for Wen GN4500

  • Page 1 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. 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.

  • Page 2: Table Of Contents

    CONTENTS WELCOME Specifications ....................3 Introduction ..................... 4 SAFETY Safety Information ................... 5 Generator Safety Warnings ................6 BEFORE OPERATING Unpacking & Packing List ................8 Know Your Generator ..................9 Generator Preparation ..................11 OPERATION & MAINTENANCE Starting Your Generator ................. 14 Using Your Generator ..................

  • Page 3: Welcome

    SPECIFICATIONS CONTENTS GENERATOR Model Number GN4500 Surge (Starting) Wattage 4500 Watts Rated (Running) Wattage 3600 Watts Rated Voltage 120V AC Rated Amperage Phase Single Frequency 60Hz Product Weight 97.9 lbs (without wheel kit), 104.5 lbs (with wheel kit) Product Dimensions 23-1/4 in.

  • Page 4: Introduction

    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 as- sistance for information or service is required, please contact customer service by calling 1-800-232-1195, M-F 8-5 CST;...

  • Page 5: Safety

    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.

  • Page 6: Generator Safety Warnings

    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.
  • Page 7 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 3. If any part of the generator, electrical device or power cord is broken, damaged, or defective, make 1.

  • Page 8: Before Operating

    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.

  • Page 9: Know Your Generator

    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 Cap Fuel Gauge Control Panel...
  • Page 10 KNOW YOUR GENERATOR CONTROL PANEL ENGINE AC 120V 20A AC 120V 20A AC 120V 30A AC 120V 30A MAIN BREAKER 5-20R 5-20R TT-30R L5-30R SWITCH BREAKER IMPORTANT BEFORE STARTING GROUNDING 1. Make sure the generator is properly grounded. BREAKER 2. Check that the crankcase is sufficiently filled with oil. 3.

  • Page 11: Generator Preparation

    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.
  • Page 12 (or when you can see the oil coming halfway up the oil fill threads). See Fig. 4. TIP: Your WEN generator is compatible with the OIL LEVEL SHUTDOWN WEN 55201 Magnetic Oil Dipstick (not included), To protect the unit from damage, the generator is equipped available for purchase at wenproducts.com.
  • Page 13 GENERATOR PREPARATION TO ADD GASOLINE: Fig. 5 Fuel Cap 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.

  • Page 14: Operation & Maintenance

    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.
  • Page 15 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.

  • Page 16: Using Your Generator

    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 run- ning 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.
  • Page 17 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. How- ever, 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.
  • Page 18 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.

  • Page 19: Shutting Off Your Generator

    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.

  • Page 20: Maintenance

    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.
  • Page 21 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.
  • Page 22 Damaged elements should be replaced with a new one. Replacement air filters can be purchased from wenproducts.com by searching part number Air Filter GN4500-167.1. Cover 4. Reinstall the air filter element and air filter cover.
  • Page 23 Replace the spark arrestor if it is damaged. Replacement spark arrestors can Muffler be purchased from wenproducts.com by searching the part number GN4500-026.1. Fig. 13 4. Reinstall the spark arrestor in the muffler and secure it in place with the screws.
  • Page 24 MAINTENANCE 5. Measure the plug gap with a spark plug gap gauge. The Fig. 15 gap should be 0.7 to 0.8 mm (0.028-0.031 in). Carefully adjust the gap if necessary. See Fig. 15. 0.7 - 0.8mm 6. Screw the spark plug back into the spark plug hole us- ing the spark plug wrench.

  • Page 25: Transportation & Storage

    Do not obstruct any ventilation openings. Follow the procedures below for properly storing your generator. TIP: Your WEN generator is compatible We highly recommend running your generator once a month for with the WEN 56406 Medium Generator 20 to 30 minutes.

  • Page 26: Troubleshooting Guide

    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.

  • Page 27: Wiring Diagram

    WIRING DIAGRAM...

  • Page 28: Exploded View & Parts List

    EXPLODED VIEW & PARTS LIST ENGINE EXPLODED VIEW...
  • Page 29 (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 Part No. Description Qty. Part No. Description Qty. GN4500-101 Crankcase DF475-126 Push Rod Guide Plate GN4500-102 Ball Bearing, 6205 DF475-127 Rocker Assembly DF475-103...
  • Page 30 (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 Part No. Description Qty. GN4500-152 Bolt, M6x28 GN4500-153 Flywheel Assembly GN4500-154 Recoil Starter Fan...
  • Page 31 EXPLODED VIEW & PARTS LIST 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 accesso- ries that wear down over the course of normal use are not covered by the two-year warranty.
  • Page 32 EXPLODED VIEW & PARTS LIST GENERATOR PARTS LIST Part No. Description Qty. Part No. Description Qty. GN4500-001 Alternator Assembly 29.1 GN4500-029.1 Engine Switch DF475-002 Motor Stand 29.2 GN4500-029.2 Multi-meter Clip, Fuel Line, NEMA 5-20R 120V 20A GN4500-003 29.3 GN4500-029.3 Ø11.5mm...

  • Page 33: Warranty Statement

    (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 pro- fessional or commercial use.
  • Page 34 NOTES NOTES...
  • Page 35 NOTES...
  • Page 36 THANKS FOR REMEMBERING v.2019.09.25...

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