Wen GN9500 Instruction Manual Download

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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.

NEED HELP? CONTACT US!

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

[email protected]

1-800-232-1195 (M-F 8AM-5PM CST)

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

WENPRODUCTS.COM

9500W PORTABLE

GENERATOR

Instruction Manual

MODEL GN9500

Summary of Contents for GN9500

Page 1: ...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 NEED HELP CONTACT US Have product questions Need technical support Please feel free to contact us TECHSUPPORT WENPRODUCTS COM 1 800 232 1195 M F 8AM 5PM CST For replacement parts and the most up to date instruction manuals visit WENPRODUCTS ...

Page 2: ...erator Preparation 13 OPERATION MAINTENANCE 18 Starting Your Generator 18 Using Your Generator 22 Shutting Off Your Generator 26 Maintenance 27 Transportation Storage 33 Troubleshooting Guide 34 Wiring Diagram 36 Exploded View Parts List 37 Warranty Statement 43 To purchase accessories for your tool visit WENPRODUCTS COM Generator Cover Model 56409 and High Altitude Kit Model GN9500 HA36 GN9500 HA...

Page 3: ...t Net Weight 194 lbs 88 KG GENERATOR ENGINE Engine Type 4 Stroke OHV Single Cylinder with Forced Air Cooling System Engine Displacement 420cc Engine Speed 3600 RPM Fuel Tank Capacity 6 gallons 23 L Oil Capacity 37 2 fl oz 1 1 L Half Load Run Time 7 5 Hours Lubrication System Splash Lubrication Spark Plug Type Torch F6TC NGK BP6ES Spark Plug Gap 0 6 0 8mm 0 024 0 031 in Spark Plug Torque 15 20 Nm 1...

Page 4: ...________________ Purchased From ________________________________________________ Serial Number _________________________________________________ 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 SERVICE R...

Page 5: ...bols 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 NOTICE REGARDING EMISSIONS Engines that are certified to comply with U S EPA emission regulati...

Page 6: ...oline 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...

Page 7: ...uld 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 highly conductive areas such as metal decking or steel work Extension cords with in line GFCIs are recommended for these operations to maximize safety 5 If connecting the generator to a building s electrical ...

Page 8: ...he generator that be come hot during use 8 Turn off all connected electrical devices before stop ping 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 transportin...

Page 9: ...ng 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 PACKING LIST UNPACKING PACKING LIST Wheel Assembly Parts Generator 1 9 Handle Assembly Parts Spark Plug Tools Wheel 2 Wheel Axle Pin 2 R Clip 2 R Clip 2 ...

Page 10: ...amiliarized 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 10 Fuel Cap Fuel Gauge Fuel Tank Muffler End Cover Cylinder Head Wheel Key Start Control Panel Push Handle Battery Fuel Valve Choke Lever Recoil Start Support Bracket Air Filter ...

Page 11: ...M Press the MODE button to switch between displays 6 AC 120V 240V NEMA L14 30R Outlet 7 Grounding Nut Ground generator to reduce risk of electric shock 8 AC Circuit Breaker 30A 9 AC 120V NEMA TT 30R RV Outlet 10 AC 120V NEMA 5 20V Duplex Outlet 11 DC Circuit Breaker 10A 12 Remote Pairing Button Press to pair the remote to your generator See USING REMOTE START FUNCTION on page 20 13 Remote Power Bu...

Page 12: ... Place the wheel axle pin Fig 1 1 and washer Fig 1 2 through the wheel Fig 1 3 and mounting lug hole Fig 1 4 Secure it with the R clip Fig 1 5 INSTALLING THE SUPPORT BRACKET 1 Line up the support bracket with the corresponding holes on the bottom of the generator 2 Secure the support bracket Fig 2 1 to the generator using two M8x16 bolts Fig 2 2 and two M8 nuts Fig 2 3 INSTALLING THE HANDLES 1 Pla...

Page 13: ...e of oil that matches the ex pected operating temperature To add oil follow these steps 1 Place the generator on a level surface Make sure the en gine 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 2 Unscrew the oil dipstick Fig 5 1 from the engine 3 Using an...

Page 14: ...lean 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 OIL LEVEL SHUTDOWN To protect the unit from damage the generator is equipped with a low oil p...

Page 15: ...th ethanol free gasoline DO NOT use gasoline with over 10 ethanol The capacity of the fuel tank is 6 US gallons 23 L Do not mix oil with gasoline To add gasoline 1 Place the generator on a level surface Make sure the en gine is OFF before adding or checking the fuel 2 Unscrew the fuel cap Fig 8 1 and set it aside The fuel cap may be tight and hard to unscrew 3 Slowly add unleaded gasoline to the f...

Page 16: ... ventilated areas WARNING Battery contains sulfuric acid Battery acid is poisonous Tilting the generator with the battery installed can cause battery acid to spill Wear protective clothing and eye wear when servicing battery Keep out of reach of children Do not tilt generator with battery installed If battery acid gets on your skin wash with water immediately If battery acid gets in your eyes flus...

Page 17: ... a decrease in performance even with the proper altitude kit Operating this generator without said kit may increase the engine s emissions and decrease both fuel economy and performance You can order the kit at wenproducts com by searching part GN9500 HA36 or GN9500 HA68 There are two kits one for altitudes between 3000 and 6000 feet GN9500 HA36 and the other for altitudes from 6000 to 8000 feet G...

Page 18: ...u 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 The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects ...

Page 19: ...peated 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 a To start the engine with electric starter 3 Insert the key and turn the engine switch to the START position for 2 3 seconds NOTE If the engine does not start release the switch and try again Keeping the switch in t...

Page 20: ...STOPPING THE GENERATOR REMOTE START 1 Turn OFF and disconnect electrical devices 2 Press the STOP button Fig 14 2 on the remote control once DO NOT hold the button down The generator will immediately cut off power to the panel then shut down the engine about 5 seconds later For more about this feature see Panel Protection below NOTE during remote start and remote start you may see the data meter d...

Page 21: ...and will not happen if another method is used to start or stop the generator ALWAYS make sure loads are turned off and disconnected from the generator when starting or stopping the generator PAIRING MULTIPLE REMOTES You can pair up to 2 remotes at a time with your generator Remotes part no GN9500 303 2 can be purchased from wenproducts com To pair a new remote with your generator follow instructio...

Page 22: ...tion 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 23 Table 2 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 wa...

Page 23: ...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 Ta...

Page 24: ...peat step 2 to plug in each additional device Do not attempt to plug in or start multiple devices at the same time CONNECTING ELECTRICAL DEVICES IN CASE OF OVERLOAD If your generator becomes overloaded from too much drawn wattage the push to reset circuit breaker s on your control panel will activate and cut off the output When an overload occurs reduce the load by turning off and unplugging your ...

Page 25: ...0 6000 150 100 60 NR NR 30 3600 7200 125 65 NR NR NR 40 4800 9600 90 NR NR NR NR 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 Fa...

Page 26: ...e 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 inter nal temperatures of engine and generator 3 Turn the fuel valve Fig 16 to the OFF position Let the genera tor run until the fuel is used up 4 Turn the engine key start Fig 17 1 to the OFF position 5 Drain the carburetor Refer ...

Page 27: ...nance 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 at least 20 minutes every month to charge the battery and maximize l...

Page 28: ...oad 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 Prepare an approved oil storage container underneath the oil drain bolt next to the oil dipstick to catch the oil as it drains NOTE To avoid possible fuel spills from the carburetor bowl dr...

Page 29: ...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 loosening the clasps at the top and bottom of the air filter cover Fig 21 1 2 Remove the foam sponge like ai...

Page 30: ... Gently pull on the spark plug boot to remove it Be careful not to tear insulation or wire 2 Use included spark plug wrench to unscrew spark plug from the engine Remove the spark plug from the engine Fig 23 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 chipp...

Page 31: ...rom the fuel line during removal 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 t...

Page 32: ...e After disconnecting the cable cover the free end with an insulator such as electrical tape You may can also connect the battery to an automatic trickle charger to keep the battery charged To reinstall replace the battery 1 Disconnect the negative battery terminal first black wire 2 Disconnect the positive battery terminal second red wire 3 To install a new battery install the hold down bracket i...

Page 33: ...proper power output 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 rec...

Page 34: ... bowl and reinstall the bolt 8 Ghost in the generator 8 Persuade ghost to leave Engine runs but there is no electrical output 1 Circuit breaker has been tripped due to overload 1 Turn off and unplug electrical device s Wait 5 minutes then press the circuit breaker to reset Check the total wattage of the devices and reduce the load if it exceeds the capacity of the generator Then plug the loads bac...

Page 35: ...nting a consistent fuel air mixture 4 Use gunk remover spray on the carburetor jets Remote start does not work 1 Battery is disconnected 1 Connect battery See section CONNECT THE BAT TERY on p 16 2 Remote batteries drained 2 Replace batteries The remote takes 2 CR2016 batteries 3 Remote has not been paired with the generator 3 Pair the remote with the generator See section USING THE REMOTE START F...

Page 36: ...ck Bl Y Black Yellow Y Yellow W Bl White Black Bu Blue Y G Yellow Green G Green Bl R Black Red R Red Bl W Black White W White Bu W Blue White Or Orange Y W Yellow White P Pink G W Green White Br Brown R Y Red Yellow Gr Gray R G Red Green ...

Page 37: ...before the replacements can be shipped out Upon the confirmation of a WEN representative your product may qualify for repairs and service work When re turning 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 insure...

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