Wen GN625i Instruction Manual
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Wen GN625i Instruction Manual

6250-watt inverter generator
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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. 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 GN625i

  • 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 General Safety Rules ..................5 Generator Safety Warnings ................7 BEFORE OPERATING Unpacking & Packing List ................9 Know Your Generator ..................10 Assembly & Adjustments ................12 Generator Preparation ..................14 OPERATION &...

  • Page 3: Welcome

    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...

  • Page 4: Introduction

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

  • Page 5: Safety

    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.
  • Page 6 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.

  • Page 7: 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 8 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 pow- er cord is broken, damaged, or defective, make sure 1.

  • Page 9: Before Operating

    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. Components Handle Assembly Tools & Accessories Generator .........1 Handle Bracket ......1 GN625i-HA36 High Altitude Kit ....1 Handle ........1 GN625i-HA68 High Altitude Kit ....1 Feet Assembly M6x30 Bolt ......4 Spark Plug Socket ........1 Feet ..........2 Screwdriver ..........1...

  • Page 10: Know Your Generator

    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.
  • Page 11 KNOW YOUR GENERATOR CONTROL PANEL AC BREAKER AC BREAKER 1. Indicator Lights 6. Voltage Selector Switch The output light (green) will turn on when the recep- Switch between 120V and 240V outlets. tacles have power, the overload light (red) will turn 7.

  • Page 12: Assembly & Adjustments

    Fig. 1 tact customer service at 1-800-232-1195 (M-F 8-5 CST), or email techsupport@wenproducts.com for information about service centers near you. Two high-altitude kits (part numbers GN625i-HA36 and GN625i-HA68) are included with your generator. Carburetor Assembly Gather the parts in the high altitude kit.
  • Page 13 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. •...

  • Page 14: 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.
  • Page 15 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.
  • Page 16 GENERATOR PREPARATION TO ADD GASOLINE: Fig. 6 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. 6) and set it aside. The fuel cap may be tight and hard to unscrew.

  • Page 17: Operation & Maintenance

    STARTING THE GENERATOR Before starting the generator, make sure you have read and performed the steps in the “Generator Preparation” sec- tion 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.
  • Page 18 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.

  • Page 19: Using The 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 20 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 21 3750W. PARALLEL OPERATION The parallel connection ports allow you to connect two WEN generators to increase the total available electrical power. The WEN Parallel Connection Kit can be purchased from wenproducts.com. Follow the instructions included with your parallel connection kit for proper installation and operation.
  • Page 22 USING YOUR GENERATOR LIGHT MEANING RESOLUTION GREEN (POWER INDICATOR) (OVERLOAD) Generator output is normal. No action needed. Flashing continuously Generator is exceeding rated output. Reduce load on generator. Flashes 1x, repeating Voltage at alternator is too low. No elec- Check for loose connections. Call every 3 sec trical output.

  • Page 23: Shutting Off The Generator

    SHUTTING OFF THE GENERATOR CAUTION! Unplugging running devices can cause damage to the generator. Never stop the engine with elec- trical 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.
  • Page 24 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 25 MAINTENANCE CLEANING YOUR GENERATOR Keep the generator clean to prevent improper operation or machine damage from dirt and debris. Inspect all ventila- tion 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.

  • Page 26: Maintenance

    MAINTENANCE DRAINING THE CARBURETOR Fig. 11 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.
  • Page 27 MAINTENANCE INSPECTING/CLEANING THE SPARK ARRESTOR Fig. 13 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.
  • Page 28 MAINTENANCE 5. Measure the plug gap with a spark plug gap gauge. The Fig. 14 gap should be 0.7 to 0.8 mm (0.028-0.031 in). Carefully adjust the gap if necessary. See Fig. 14. 0.7 - 0.8mm 6. Screw the spark plug back into the spark plug hole us- ing the spark plug wrench.

  • Page 29: Transportation & Storage

    TIP: Your WEN generator is compatible We highly recommend running your generator once a month for with the WEN 56409 Generator Cover (not 20 to 30 minutes. Plug in a small load in to ensure there is proper included). It is available for purchase at power output.

  • Page 30: 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 1.
  • Page 31 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 1.

  • Page 32: Wiring Diagram

    WIRING DIAGRAM...

  • Page 33: Exploded View & Parts List

    ASSEMBLY 1 - CYLINDER HEAD, ASSEMBLY 2 - CRANKCASE SPARK PLUG Part No. Description Qty. Part No. Description Qty. Crankcase GN625i-0101 Cylinder Head Cover Bolt GN625i-0201 Subassembly Cylinder Head Cover Bolt GN625i-0102 GN625i-0202 Oil Seal Gaskets GN625i-0203 Oil Drain Valve...
  • Page 34 EXPLODED VIEW & PARTS LIST ASSEMBLY 3 - CRANKCASE COVER ASSEMBLY 4 - CRANKSHAFT Part No. Description Qty. Part No. Description Qty. GN625i-0401 Crankshaft Assembly GN625i-0301 Crankcase Cover GN625i-0302 Crankcase Cover Gasket ASSEMBLY 5 - PISTON RING SET, GN400i-0205 CONNECTING ROD...
  • Page 35 Rocker Shaft Bolt GN625i-0606 Lifter Stopper Plate GN625i-0607 Valve Lifter GN625i-0608 Valve Tappet Valve Set (Intake & GN625i-0609 Exhaust) 6-10 GN625i-0610 Seal Guide 6-11 GN625i-0611 Valve Spring Retainer 6-12 GN625i-0612 Valve Spring 6-13 GN625i-0613 Valve Spring Seat 6-14 GN625i-0614 Valve Lock Clamp...
  • Page 36 Bolt, M6x12 Plate GN625i-0805 Cylinder Body Shroud Carburetor Insulator GN625i-0905 GN400i-0703 Clip Gasket 56200-0103 GN625i-0907 Hose Clamp ASSEMBLY 10 - AIR FILTER GN625i-0908 Fuel Tube GN625i-0909 Rubber Cover Part No. Description Qty. 10-1 GN625i-1001 Air Filter Assembly 10-2 56200-0506 Nut, M6...
  • Page 37 ASSEMBLY 12 - MUFFLER ASSEMBLY STARTER PULLEY Part No. Description Qty. Part No. Description Qty. 12-1 GN625i-1201 Muffler Assembly 11-1 GN625i-1101 Flywheel Nut, M16-1.5 N.P. GN625i-1201.1 Spark Arrestor 11-2 56200-1202 Bolt, M6x12 12-2 GN625i-1202 Muffler Gasket 11-3 GN625i-1103 Starter Pulley...
  • Page 38 EXPLODED VIEW & PARTS LIST ASSEMBLY 13 - FUEL TANK Part No. Description Qty. Part No. Description Qty. 13-1 GN625i-1301 Fuel Tank 13-10 GN625i-1310 Fuel Tank Chain Clip 13-2 56380i-1207 Fuel Tank Damper 13-11 GN400i-1205 Breather Valve 13-3 GN625i-1303 Bushing 13-12 GN625i-1312...
  • Page 39 EXPLODED VIEW & PARTS LIST ASSEMBLY 14 - FRAME Part No. Description Qty. Part No. Description Qty. 14-1 GN625i-1401 Frame Assembly 14-13 56200-0706 Bolt, M6x10 14-2 GN625i-1402 Nut, M10-1.25 14-14 GN400i-1311 Bolt, M6x8 14-3 56310i-1404 Nut, M8 14-15 GN625i-1415 Cllp...
  • Page 40 EXPLODED VIEW & PARTS LIST ASSEMBLY 15 - CONTROL PANEL ASSEMBLY 16 - WHEEL AND HANDLE Part No. Description Qty. Control Panel 15-1 GN625i-1501 Subassembly Part No. Description Qty. 15-2 GN625i-1502 Bolt, M6x16 15-3 GN625i-1503 Bolt, M6x20 Handle Tube 16-1...

  • Page 41: Warranty Statement

    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.
  • Page 42 NOTES...
  • Page 43 NOTES...
  • Page 44 THANKS FOR REMEMBERING V. 2020.07.06...

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