1600W PORTABLE
GENERATOR
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 intended purpose, you will enjoy years of safe, reliable service.
IMPORTANT:
NEED HELP? CONTACT US!
Have product questions? Need technical support?
Please feel free to contact us at:
800-232-1195
WENPRODUCTS.COM
(M-F 8AM-5PM CST)
Model # 56160
bit.ly/wenvideo
For replacement parts visit
WENPRODUCTS.COM
NOTICE: Please refer to wenproducts.com for the most up-to-date instruction manual.
TABLE OF CONTENTS
2
Generator Identification
3
3
4
4
6
7
8
10
12
14
15
19
21
22
26
27
28
Service Record
Introduction
Safety Information
Generator Safety Rules
Know Your Generator
Starting the Generator
Using the Generator
Stopping the Generator
Maintenance
Storage & Transport
Specifications
Exploded View and Parts List
Wiring Diagram
Warranty Statement
Troubleshooting
Generator Preparation
If assistance for information or service is required, please contact the Customer Service Help Line by calling
800-232-1195; customer will be asked to provide generator information when calling.
Refer to the illustration below for the location of the serial number. Record generator information in the spaces
provided below.
DATE OF PURCHASE: ______________________________________________
PURCHASED FROM: ______________________________________________
ENGINE SERIAL NUMBER: _________________________________________
SERVICE RECORD
Record Service Dates:
Date Date Date Date Date Date
Change Oil
Change Spark Plug
Clean Fuel Tank
Clean Air Filter
3
GENERATOR IDENTIFICATION
Serial Number
4
NOTE: The following safety information is not meant to cover all possible conditions and situations that may oc-
cur. WEN reserves the right to change this product and specifications at any time without prior notice.
Before operating this generator read and observe all warnings, cautions, and instructions both on the generator and
in this owner’s manual.
The safety alert symbol is used to identify safety information about hazards that can result in personal injury.
DANGER indicates a hazard, which, if not avoided, will result in death or serious injury.
WARNING indicates a hazard, which, if not avoided, could result in death or serious injury.
CAUTION indicates a hazard, which, if not avoided, might result in minor or moderate injury.
CAUTION when used without the alert symbol, indicates a situation that could result in damage to the machine.
SAFETY INFORMATION
A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to
indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may
be used to represent the type of hazard.
Thank you for purchasing a WEN Generator. This manual provides important information regarding the safe op-
eration and maintenance of this product. Read all the information carefully before the assembly and operation of
your generator to avoid personal injury and damage to the machine.
Please keep this manual available to all users during the entire life of the generator.
QUESTIONS? PROBLEMS?
In order to answer questions and solve problems in the most efficient and speedy manner, contact Customer Service
at (800) 232-1195, M-F 8-5 CST.
NOTICE REGARDING EMISSIONS
Engines that are certified to comply with U.S. EPA emission regulations for SORE (Small Off Road Equipment),
are certified to operate on regular unleaded gasoline, and may include the following emission control systems: (EM)
Engine Modifications and (TWC) Three-Way Catalyst (if so equipped).
INTRODUCTION
IMPORTANT: This manual contains special messages to bring attention to potential
safety concerns and generator damage as well as helpful operating and servicing information.
Please read all the information carefully to avoid injury and machine damage.
DANGER: CARBON MONOXIDE
Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon mon-
oxide (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. Using a fan or opening windows and doors does
NOT supply enough fresh air. ONLY use a generator outside and far away from windows, doors, and
vents. These openings can pull in generator exhaust.
Even if you 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.
5
SAFETY INFORMATION
WARNING: The exhaust from this product contains chemicals known to the State of Califor-
nia to cause cancer, birth defects, or other reproductive harm.
WARNING: This generator may emit highly flammable and explosive gasoline vapors, which
can cause severe burns or even death if ignited. A nearby open flame can lead to explosion even
if it isn’t directly in contact with gasoline.
WARNING: If this generator is used as a supply for a building’s wiring system, the generator
must be installed by a qualified electrician and connected to a transfer switch as a separately de-
rived system in accordance with the National Electrical Code, NFPA 70. The generator shall be
connected to a transfer switch that switches all conductors excluding the equipment grounding
conductor. The frame of the generator shall be connected to an approved grounding electrode.
WARNING: This generator produces heat when running. Temperatures near exhaust can ex-
ceed 150
0
F (65
0
C). DO NOT TOUCH HOT SURFACE.
NOTE: For power outages, permanently installed stationary generators are better suited for providing backup
power to the home. Even a properly connected portable generator can become overloaded. This may result in
overheating or stressing of the components, possibly leading to a generator failure.
SAVE THESE INSTRUCTIONS – This manual contains important instructions for the WEN generator that
should be followed during installation and maintenance of the generator.
For any questions regarding the hazard and safety notices listed in this manual or on the product, please call (800)
232-1195 M-F 8-5 CST or email [email protected] before using the generator.
6
GENERATOR SAFETY RULES
1. ONLY use a generator outside and far away from
windows, doors and vents. Using a generator indoors
can kill you in minutes.
2. Do not operate near open flame. This generator may
emit highly flammable and explosive gasoline vapors,
which can cause severe burns or even death if ignited.
3. Do not smoke near generator.
4. Do not use in rainy or wet conditions.
5. Always operate on a dry, firm, level surface.
6. Only use generator for its intended purposes.
7. Do not allow children or non-qualified persons to
operate the generator.
8. ALWAYS ground the generator before using it (see
the “Ground the Generator” portion of the “Generator
Preparation” section).
9. Do not overfill fuel tank. Gasoline may expand dur-
ing operation. Do not fill to the top of the tank. Allow
for expansion.
10. Always check for spilled fuel before operating.
11. Make sure to have damaged items repaired or re-
placed before operation.
12. Do not use plugs or cords that show signs of dam-
age such as broken or cracked insulation.
13. Use a ground fault circuit interrupter (GFCI) in
highly conductive areas such as metal decking or steel
work. GFCIs are available in-line with some extension
cords.
14. NEVER connect the generator to a building’s elec-
trical system without a qualified electrician. Such con-
nections must comply with local electrical laws and
codes. Failure to comply can create a back-feed, which
may result in serious injury or death to utility workers.
15. Do not touch bare wires or receptacles (outlets).
16. Do not touch hot surfaces. See warning labels on the
generator identifying hot parts of the machine.
17. Allow generator to run for several minutes before
connecting electrical devices.
18. Do not exceed the wattage capacity of the generator
by plugging in more electrical devices than the unit can
handle.
19. Do not turn on electrical devices until after they are
connected to the generator.
20. Generators vibrate in normal use. During and after
the use of the generator, inspect both the generator as
well as extension and power supply cords for damage
resulting from vibration.
21. Have damaged items repaired or replaced as neces-
sary. Do not use plugs or cords that show signs of dam-
age such as broken or cracked insulation.
22. Allow generator to cool down after use before touch-
ing engine or areas of the generator that become hot
during use.
23. Turn off all connected electrical devices before stop-
ping the generator.
24. Shut off and disconnect any malfunctioning devices
from generator.
25. 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.
26. Turn the engine switch to “OFF” position when the
engine is not running.
27. Empty fuel tank before storing or transporting the
generator.
CAUTION: Misuse of this generator can damage it
or shorten its life.
7
Carefully unpack and remove all contents from the box. Use the illustrations below to become familiar with the
locations and functions of the various components and controls of this generator. If any part is damaged or miss-
ing, please contact our customer service at (800) 232-1195, M-F 8-5 CST or email [email protected].
KNOW YOUR GENERATOR
Fuel Tank Cap
Fuel Gauge
Pressure Relief
Valve
Air Cleaner
Choke Lever
Recoil Starter
Engine Switch
Oil Fill with Dipstick
Muffler
Spark Arrestor
Fuel Valve
Fuel Tank
Grounding Terminal
Carburetor
Spark Plug
AC 120V Duplex Receptacle
AC 12A Circuit Breaker
DC 8A Circuit Breaker
DC 12V Receptacle
STEP 1 - ADD/CHECK OIL
The generator is shipped without oil. A proper amount of oil must be added before operating the generator for the
first time. For subsequent operation, the oil level should be checked before each use or after every 8 hours of opera-
tion. This is a critical step for proper engine starting to ensure that the engine crankcase contains sufficient lubricant.
The oil capacity of the engine crankcase is 11.8 fl. ounces.
88
GENERATOR PREPARATION
CAUTION: The following section describes the necessary steps to prepare the generator for use. If af-
ter reading this section, you are unsure about how to perform any of the steps please call (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.
Oil Dipstick
Oil
Dipstick
Lower Level
Fill Line
Upper Level
Fill Line
32
-30 -20 -10 0 10 20 30
-20 0 20 40 60 80 100
40
°F
°C
Synthetic 5W-30
30
10W-30
• 30W, 4-stroke engine oil for temperatures above 40°F.
• 10W-30 engine oil for temperatures between 0°F - 40°F.
• Synthetic 5W-30 engine oil for all temperature ranges.
Fig. 2
Fig. 1
Fig. 3
Select good quality detergent oil bearing
the American Petroleum Institute (API)
service classifications SJ, SL, or SM (syn-
thetic oils may be used). Select the SAE
viscosity grade of oil from “Engine Oil
Recommendations” (Fig. 1) that matches
the expected operating temperature.
To ll oil, follow these steps:
1. Make sure the generator is shut off.
Place the generator on a level surface.
NOTE: Tilting the generator to assist in
filling will cause oil to flow into the engine
areas and will cause damage. Keep the
generator level!
ENGINE OIL RECOMMENDATIONS
2. Remove the dipstick from the engine (Fig. 2).
3. Using an oil funnel or appropriate dispenser, slowly add oil into the
oil fill. Fill the crank case to the upper fill line so you can visually see the
oil coming up the oil fill threads (Fig. 3). The oil capacity of the engine
crankcase is 11.8 fl. ounces. Be careful not to overfill the unit.
4. Reinstall the oil dipstick and wipe clean any spilled oil with a dry rag.
To check/add oil, follow these steps:
1. Remove and wipe the dipstick with a clean rag. Insert the dipstick into
the oil fill opening without screwing it in.
2. Remove the dipstick to check the oil mark on the dipstick. Add oil if
the oil mark covers less than one half of the dipstick.
3. Slowly add oil and repeat step 2 until the oil mark reaches to the top of
dipstick (or when you can see the oil coming up the oil fill threads). Do
not over fill the crankcase.
4. Wipe clean any oil leaks and firmly tighten the dipstick.
After completing the above preparation, the generator is ready to be started.
Step 2 - ADD/CHECK GASOLINE
Use fresh (within 30 days from purchase), lead-free gasoline with a
minimum of 87 octane rating. The capacity of the fuel tank is 1.6
gallons. Do not mix oil with gasoline.
To add gasoline, follow these steps:
1. Make sure the generator is on a level surface and in a well ven-
tilated area.
2. Unscrew the fuel cap and set it aside (Fig. 4). NOTE: The fuel
cap may be tight and hard to unscrew.
3. Slowly add unleaded gasoline to the fuel tank. Be careful not to
WARNING: Failure to properly ground the gen-
erator increases your risk of electric shock.
overfill. The capacity of the fuel tank is 1.6 gallons. NOTE: Do
not fill the fuel tank to the very top. Leave sufficient room in the
tank for gasoline to expand.
4. Reinstall fuel cap and wipe clean any spilled gasoline with a dry
cloth.
To check the fuel level:
Check the fuel gauge on the top of the gas tank (Fig. 5). The red
arrow indicates the amount of fuel left in the gas tank. “E” indi-
cates Empty and “F” indicates Full. Add fuel when fuel level is
low.
STEP 3 - GROUND THE GENERATOR
9
Grounding Nut
IMPORTANT:
• Use only UNLEADED gasoline.
• Never use an oil/gasoline mixture.
• Never use old gasoline.
• Avoid getting dirt or water into the fuel
tank.
• Never store generator for extended
periods of time with fuel in the tank.
GENERATOR PREPARATION
WARNING: Keep generator away from open flame. This generator may emit highly flam-
mable and explosive gasoline vapors, which can cause severe burns or even death if ignited.
A nearby open flame can lead to explosion even if not directly in contact with gasoline.
Fig. 4
Fig. 5
Fig. 6
E F
Ground the generator by tightening the grounding nut on the
front control panel against a grounding wire (Fig. 3). A generally
acceptable grounding wire is a No. 12 AWG (American Wire
Gauge) stranded copper wire. This grounding wire should be
connected at the other end to a copper, brass, or steel-grounding
rod that is driven into the earth. Wire and grounding rods are
not included with the generator.
Grounding codes can vary by location. Contact a local electrician
to check the area codes.
Fig. 5 Choke Lever
STARTING THE GENERATOR
DANGER: CARBON MONOXIDE - USING A GENERATOR INDOORS CAN KILL
YOU IN MINUTES.
Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monox-
ide (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. Using a fan or opening windows and doors does
NOT supply enough fresh air. ONLY use a generator outside and far away from windows, doors, and
vents. These openings can pull in generator exhaust.
Even if you 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: This generator may emit highly flammable and explosive gasoline vapors, which
can cause severe burns or even death if ignited. A nearby open flame can lead to explosion even
if it isn’t directly in contact with gasoline. Do not smoke near the generator.
WARNING: Do not use in rainy or wet conditions. Do not touch bare wires or receptacles
(outlets). Do not allow children or non-qualified persons to operate.
WARNING: This generator produces heat when running. Temperatures near exhaust can
exceed 1500 F (650 C). Do not touch hot surface.
WARNING: This generator produces powerful voltage, which can result in electrocution.
HIGH ALTITUDE OPERATION ABOVE 2000 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 2000 feet above sea level. At elevations above 7000 feet, the en-
gine may experience a decrease in performance, even with the proper altitude kit. Operating this generator without
the high altitude kit may increase the engine’s emissions and decrease both fuel economy and performance.
The high altitude kit can be ordered from wenproducts.com by searching the model number 56160-HA27. The kit
should be installed by a qualified mechanic.
NOTE: engines with the high-altitude kit installed operated at lower altitudes could cause severe engine damage and
affect emissions compliance. Be sure to uninstall the high altitude kit when operating at altitudes below 2000 feet.
WARNING: To prevent serious injury from fire, follow the kit installation procedures
in a well-ventilated area away from ignition sources. If the engine is hot from use, shut the
engine off and wait for it to cool before proceeding. Warranty will be void if adjustments
are not made for high altitude use.
10
STARTING THE GENERATOR
To start the generator, perform the following steps:
1. Place the generator outside on a dry, level surface.
2. Check there is sufficient level of oil in the crankcase. Add oil if nec-
essary (refer to “Add/Check Oil” an page 8).
3. Check there is sufficient level of gasoline in the fuel tank. Add fuel
is necessary (refer to “Add/Check Gasoline” on page 9).
4. To maximize safety, make sure the generator is properly grounded
(Refer to “Ground the Generator” on page 9).
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 (800) 232-
1195 M-F 8-5 CST for customer service.
STARTING THE GENERATOR
5. Make sure all electrical devices are unplugged from the generator
during ignition. Otherwise it will be difficult for the engine to start.
6. Turn the fuel valve to the ON position (Fig. 7).
7. Move the choke lever to the CLOSE position (Fig. 7).
8. Set the engine switch on the control panel to the ON position.
9. Pull on the recoil starter handle (Fig. 10) slowly until a slight resis-
tance is felt, then pull quickly to start the engine. Return cord gently
into the recoil starter. Never allow the cord to snap back.
10. If engine fails to start, repeat step 9.
NOTE: After repeated failed attempts to start the engine, please con-
sult the troubleshooting guide before attempting again. If problems
persist please call (800) 232-1195 M-F 8-5 CST.
11. Once the engine has started, slowly return the choke lever all the
way to the OPEN position.
12. Allow the engine to run for several minutes before attempting to
connect any electrical devices. This allows the generator to stabilize its
speed and temperature.
Fig. 10
ON
OFF
FUEL VALVE
CHOKE LEVER
Fig. 7
Fig. 8
Fig. 9
ON
OFF
OIL LEVEL SHUTDOWN
The generator is equipped with a low oil pressure shutoff that shuts down the engine when the oil level is too low
to protect the unit from damage. The oil level of the engine should be checked before each start to ensure that the
engine crankcase contains sufficient lubricant.
11
Tool or Appliance Running Watts Surge Watts
Window air conditioner 1200 1800
Saw - miter 1200 1200
Microwave 1000 0
Well water pump 1000 1000
Saw - reciprocating 960 1040
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
Fig. 11 - Estimated wattage requirements of common electrical devices
USING THE GENERATOR
DETERMINING ELECTRICAL DEVICES
The chart below shows the rated and surge wattage of the generator.
Generator Rated (Running) Wattage Surge Wattage
56160 1400 1600
Rated (Running) Wattage: the wattage that the generator can produce on a continuous basis. The total running
wattage requirement of the electrical devices connected to the generator should not exceed the rated wattage of the
generator 1400W.
Surge Wattage: the maximum amount of power the generator can produce for an extremely short period of time
(seconds). Many electrical devices such as refrigerators require short bursts of extra power in addition to the rated
wattage listed by the device to start their motors. The surge wattage ability of the generator covers this extra power
requirement.
To calculate the total wattage requirement of the electrical devices you plan to connect, find the rated (or running)
wattage of each device. This number should be listed on the device or in its instruction manual. If this wattage can-
not be found, calculate it by multiplying the Voltage requirement by the Amperage drawn: Watts = Volts x Amperes
DETERMINING ELECTRIC DEVICES
12
DETERMINING ELECTRICAL DEVICES (CONTINUED)
If the electrical specifications are not available for your electronic devices, estimated wattages are available in Fig.
11 on page 12. Do not solely rely on this chart - all electronics and appliances are built differently. These are not
standard wattages across the board, only estimations. Check the wattage listed on the electrical device before con-
sulting this chart.
When the rated wattage requirement of each electrical device has been determined, add these numbers to find the
total rated wattage needed. If this number exceeds the rated wattage of the generator, DO NOT connect all these
devices. Select a combination of electrical devices, which have a total rated wattage lower than or equal to the rated
wattage of the generator.
CAUTION: The generator can run at its surge wattage capacity for only a short time. Connect electrical
devices requiring a rated (running) wattage equal to or less than the rated wattage of the generator. Never
connect devices requiring a rated wattage equal to the surge wattage of the generator. This can trip the
circuit protectors (circuit breakers).
CONNECTING ELECTRICAL DEVICES
1. Before connecting electrical devices, allow the generator to run for a few minutes to stabilize the speed and volt-
age output.
CAUTION: Become familiar with the markings on the panel (Fig. 12) before connecting electrical
devices. Do not connect 50Hz loads to the generator.
2. Make sure that all devices are turned off. Start plugging in each electric device, from the highest wattage to the
lowest. Check the power indicator light to ensure the generator is producing power.
3. Do not overload the generator or individual panel receptacles. If an overload occurs, the power indicator light
will turn off. Unplug all electrical devices and 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 back in one by one.
NOTE: If the circuit breaker does not reset, wait several minutes and try again. If the power light still does not come
on, call the customer service number for further instructions.
Power Indicator Light
DC 8A Breaker
DC 12V
Receptacle
AC 120V NEMA 5-20R
Duplex Receptacles
AC 12A BreakerEngine ON/OFF Switch
Grounding Plug
USING THE GENERATOR
Fig. 12
13
14
USING THE GENERATOR
STOPPING THE GENERATOR
TO SHUT OFF THE GENERATOR
1. Turn off all electrical devices and then unplug the devices from the generator. Unplugging running devices can
cause damage to the generator.
2. Turn the engine switch to the OFF position.
3. Turn the fuel valve to the OFF (horizontal) position.
4. Drain the carburetor (See “Draining the Carburetor” on Page 17).
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. Refer to “Storing the Generator” on page 19.
WARNING: Allow the generator to cool for several minutes before touching areas that
become hot during use.
SOME NOTES ABOUT POWER CORDS
Long or thin cords can drain the power provided to an electrical device by the generator. When using such cords,
allow for a slightly higher rated wattage requirement by the electrical device. See Fig. 13 for recommended cords
based on the power requirement of the electrical device.
Device Requirements
Max. Cord Length (ft) by Wire Gauge
Amps Watts (120V) #8 wire #10 wire #12 wire #14 wire #16 wire
2.5 300 NR NR NR 375 250
5 600 NR NR 300 200 125
7.5 900 NR 350 200 125 100
10 1200 NR 250 150 100 50
15 1800 NR 150 100 65 NR
*NR = Not Recommended Fig. 13 - Maximum Extension Cord Lengths by Power Requirement
CLEANING THE GENERATOR
Keep the generator clean to prevent improper operation or machine damage from dirt and debris. Inspect all cool-
ing air 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. Only use low pressure air (not to exceed 25 PSI) to blow away dirt.
CAUTION: Never clean the generator when it is running! Never clean with a bucket of water or a hose.
Water can get inside the working parts of the generator and cause corrosion or a short circuit.
15
MAINTENANCE
Proper routine maintenance of the generator will help prolong the life of the machine. Please perform maintenance
checks and operations according to the schedule in Figure 8. If there are any questions about the maintenance pro-
cedures listed in this manual, please call (800) 232-1195 M-F 8-5 CST.
IMPORTANT: Drain your carburetor after every use. Do not store the generator with fuel inside the tank for
more than 2 months. Run the generator for 15 minutes a month to maximize its lifespan.
CAUTION: Never perform maintenance operations while the generator is running.
Recommended
Maintenance Schedule
Each 8
hours or
daily
Every 25
hours
Every 3
months or
50 hours
Every 6
months or
100 hours
Every
year
As neces-
sary
Engine oil
Check
level
x
Replace x* x* x
Air cleaner
cartridge
Check x* x
Clean x*
Spark plug
Check/
clean/
regap
x x
Change x x
Fuel tank
Check
level
x
Clean x
Carburetor Drain x
Fig. 14 - Recommended Maintenance Schedule
* Clean/change more often under dusty conditions or operating under heavy load.
16
MAINTENANCE
CHECKING/ADDING THE OIL
Check the oil level of the generator according to the Recommended
Maintenance Schedule in Fig. 14. The oil level should be checked
before each use or every 8 hours of operation. The oil capacity of
the generator engine is 11.8 fl. ounces. Add oil when the oil level is
low. For proper type and weight of oil refer to “add oil” portion of
the “Generator Preparation” section. This is a critical step for proper
engine starting. The generator is equipped with an automatic shutoff to
protect it from running on low oil. To check the oil level:
1. Make sure the generator is on a level surface. Do not tilt the generator to assist in filling as oil will flow into engine
areas and cause damage. Keep generator level!
2. Remove the dipstick (Fig. 15) and wipe it with a clean rag.
3. Insert the dipstick into the oil fill opening without screwing in. Remove the dipstick to check the oil mark. Add
oil if the oil mark covers less than one half of the dipstick.
4. Using a funnel or appropriate dispenser, slowly add more oil. Repeat step 2 until the oil mark reaches the top of
the dipstick (and you can see oil coming up the threads of the oil fill). Do not over fill the crankcase.
5. Reinstall dipstick and wipe clean any spill oil with a rag.
DRAINING THE OIL
Change the oil according to the Recommended Maintenance Schedule in Fig. 14. Change the oil more often if oper-
ating under heavy load 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.
Drain the oil from the generator according to the following steps.
Fig. 15
Fig. 16
Oil Drain
Plug
WARNING: Make sure the generator is shut off before performing any inspection or
maintenance procedures.
1. Place generator on elevated platform such as table or desk. Prepare
a container underneath the oil drain plug next to the oil dipstick to
catch the oil as it drains.
2. Unscrew oil drain plug on the size of the crankcase (Fig. 16) and
allow the oil to drain from the engine completely.
3. Reinstall the oil drain plug and tighten it securely. Wipe clean any
oil spillage.
NOTE: Never dispose of used motor oil in the trash or down a drain.
Please call a local recycling center or auto garage to arrange proper oil
disposal.
17
MAINTENANCE
Carburetor
Drain Plug
Spark Plug
Boot
DRAINING THE CARBURETOR
Draining the carburetor is recommended after every use to prevent
the fuel from clogging up the carburetor. The carburetor can be ac-
cessed from the backside of the generator between the engine and
the air filter (Fig. 17).
1. Turn the fuel valve to OFF position to prevent gasoline from
draining from the fuel tank.
2. Open up the carburetor drain plug (Fig. 17) with a screwdriver
and drain out any gasoline that has built up inside.
3. Once the fuel has drained, close the drain plug with the screw-
driver. NOTE: Make sure to drain your carburetor before storing
the generator for long periods of time.
Fig. 17
SPARK PLUG MAINTENANCE
The spark plug is important for proper engine operation. A good
spark plug should be intact, free of deposits, and properly gapped.
Refer to Recommended Maintenance Schedule in Figure 14 for
maintaining the spark plug. To inspect the spark plug:
1. Remove the spark plug boot (Fig. 18). Be careful not to tear any
insulation or wire.
2. Unscrew the spark plug from the engine using the spark plug
wrench provided.
3. Visually inspect the spark plug for cracks or excessive electrode
wear. NOTE: Replace the plug if electrodes are worn, burned or
porcelain is cracked. Replace with NGK BPR6HS/BP6HS spark
plug.
4. Measure the plug gap with a wire gauge (Fig. 19). The gap should
be 0.7 to 0.8 mm (0.028-0.031 in).
5. If re-using the spark plug, use a wire brush to clean any dirt from
around the spark plug base then re-gap the spark plug.
6. Screw the spark plug back into the spark plug hole using the
spark plug wrench. Recommended tightening of spark plug is ½ to
¾ of a turn after spark plug gasket contacts spark plug hole. Do not
over-tighten the spark plug. Reinstall the spark plug boot.
Fig. 18
Fig. 19
18
MAINTENANCE
SPARK ARRESTER MAINTENANCE
It is recommended to inspect and clean the spark arrester after ev-
ery 200 hours of operation.
1. The spark arrester is located outside the muffler. Allow the en-
gine to cool completely before servicing the spark arrester.
2. Remove the screw holding the cover plate which attaches the end
of the spark arrester to the muffler (Fig. 21 - 1).
3. Remove the spark arrester screen.
4. Carefully clean and remove the carbon deposits from the spark
arrester screen with a wire brush.
5. Replace the spark arrester if it is damaged.
6. Position the spark arrester in the muffler and attach with the screw.
1
Cover Bolt
AIR CLEANER MAINTENANCE
Routine maintenance of the air cleaner helps maintain proper air-
flow to the carburetor. Occasionally check that the air cleaner is free
of excessive dirt. The air cleaner should be checked every 50 hours
of use. Refer to Recommended Maintenance Schedule in Fig. 14.
1. Unscrew the cover bolt (Fig. 20) and remove the air cleaner cover.
Remove the air cleaner element from the casing.
2. Check and clean the foam air cleaner element. Good elements
can be washed in soapy water, dried and reused. Wipe off excessive
oil from the air cleaner case. Small amount of oil in the element is
normal and necessary for the engine to work properly. Replace with
Fig. 20
Fig. 21
a new one if the element is damaged.
3. Reinstall the air cleaner element and cover. Secure with the cover bolt.
CAUTION: Running the engine with dirty, damaged or missing air cleaner element will cause the
engine to wear out prematurely.
19
STORAGE & TRANSPORT
DRAINING THE FUEL TANK
Clean the fuel tank every year and before storing the generator for
longer than one to two months. Refer to Recommended Mainte-
nance Schedule in Figure 14. To drain the fuel tank:
1. Turn the fuel valve to the OFF position (Fig. 22).
2. Prepare a suitable container under the carburetor for catching the
drained fuel.
3. Open up the carburetor drain plug (Fig. 23) with a screwdriver.
Gasoline will start to drain from the carburetor.
4. Open the fuel valve by turning it to the ON position to let the fuel
drain completely from the fuel tank.
5. Once the fuel has drained, shut off the fuel valve and close the
carburetor drain plug with the screwdriver.
6. Store the emptied gasoline in a suitable place.
CAUTION: Do not store the emptied fuel for more than 3 months.
ON
OFF
FUEL VALVE
Fig. 22
Fig. 23
Carburetor
Drain Plug
TRANSPORTING THE GENERATOR
• Tighten the fuel cap and turn the fuel valve to OFF position.
• Drain the fuel tank if possible (see Draining the Fuel Tank).
• Keep the generator upright. Never place the generator on its side or upside down. Doing so will make it difficult
to start.
STORAGE & TRANSPORT
STORING THE GENERATOR
Shut off the generator and allow the unit to cool to room temperature before storage. Never place any type of stor-
age cover on the generator while it is still hot. Do not obstruct any ventilation openings.
Store the generator and fuel in a cool and dry location, away from sources of heat, open flames, sparks or pilot lights.
Follow the procedures below for properly storing your generator.
For Short Periods (30 to 60 Days):
• Drain the carburetor.
• Gasoline stored over 30 days can go bad and damage fuel system components. Add fuel stabilizer, following
the suggested portions and instructions of your preferred stabilizer. Run the engine for 2 to 3 minutes, allow-
ing the fuel stabilizer to mix with the gasoline and circulate through the carburetor, and then top off with fuel.
NOTE: Filling the fuel tank full reduces the amount of air in the tank and helps fight deterioration of fuel.
For Extended Periods (Over 60 Days):
• Drain the carburetor.
• Drain the fuel tank (see Draining the Fuel Tank). Never store with fuel in the tank for more than two months.
• Change engine oil (see Draining the Oil).
IMPORTANT: Run the generator ONCE A MONTH for 15 minutes. This is necessary for prolonging the life-
time of your generator and ensure that the generator can function properly for your next operation. Afterwards, shut
off and drain the carburetor. Store the generator with a dry carburetor.
20
Rated Wattage 1400 Watts
Surge Wattage 1600 Watts
Phase Single
Frequency 60Hz
Rated Voltage AC: 120V, DC: 12V
Rated Amperage AC: 12A, DC: 8A
Dimensions
Length: 18.3 in.
Width: 14.2 in.
Height: 15.9 in.
Weight 56 lbs
ENGINE
Engine Type 4 stroke, OHV, single cylinder with forced air cooling system
Engine Displacement 98cc OHV
Engine Speed 3600 RPM
Fuel Tank Capacity 1.6 gallons (87 octane minimum)
Oil Capacity 11.8 fl.oz.
Lubrication System Splash lubrication
Half-Load Run Time 9 hours
Noise Rating 72 dB at 22 feet
Spark Plug Type NGK BPR6HS/BP6HS
Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.031 in)
Spark Plug Torque 1/2 - 3/4 turn after gasket contacts base or 15 ft.lb
SPECIFICATIONS
21
22
EXPLODED VIEW AND PARTS LIST
11.3
6.2
6.3
11.4
23
EXPLODED VIEW AND PARTS LIST
No. Part No. Description Qty
1 56160-001 Frame 1
2 56160-002 Isolator A 1
3 56160-003 Nut M8 4
4 56160-004 Rubber Damping Bracket 4
5 56160-005 Bolt M6X12 5
6 56160-006 Fuel Tank Assembly 1
6.1 56160-006.1 Fuel Tank Cap Assembly 1
6.2 56160-006.2 Fuel Tank Filter 1
6.3 56160-006.3 Fuel Gauge Assembly 1
7 56160-007 Fuel Cock 1
8 56160-008 Engine Assembly 1
9 56160-009 Carbon Tank Assembly 1
10 56160-010 Bolt M8X16 2
11 56160-011 Motor Assembly 1
11.1 56160-011.1 Carbon Brush Assembly 1
11.2 56160-011.2 Grounding Post Assembly 1
11.3 56160-011.3 Rotor 1
11.4 56160-011.4 Stator 1
12 56160-012 Motor Stand 1
13 56160-013 Bolt 1
14 56160-014
Gasket, Rotor Bolt
Ф8.5Xф24X3
1
15 56160-015 Bolt M6X12 4
16 56160-016 Bolt 4
17 56160-017 Isolator B 2
18 56160-018 Isolator B 1
19 56160-019 Nut M8 2
No. Part No. Description Qty
20 56160-020 Nut M6 1
21 56160-021 Tooth Type Gasket Φ6 1
22 56160-022 Clip Ф12 2
23 56160-023 Panel Assembly 1
23.1 56160-023.1 Switch Assembly 1
23.2 56160-023.2
NEMA 5-20R 120V
Duplex Receptacle
1
23.3 56160-023.3 Thermal Protector 12A 1
23.4 56160-023.4 Thermal Protector 8A 1
23.5 56160-023.5 12V DC Receptacle 1
24 56160-024 Washer 4
25 56160-025
Automatic Voltage
Regulator
1
26 56160-026 Bolt M5X12 6
27 56160-027 Bolt M5X16 1
28 56160-028 Washer, Fuel Tank 4
29 56160-029 Bolt M6X20 4
30 56160-030 Generator End Cover 1
31 56160-031 Fuel Line Clip Ф7.5 1
32 56160-032 Spring Washer Ф5 1
33 56160-033 Manual Choke Assembly 1
34 56160-034 Breather Tube 1
35 56160-035
Connecting Pipe
Ф4*Ф10*280Mm
1
36 56160-036 Clip, Fuel Line Ф10.5 1
37 56160-037 Clip, Fuel Line Ф9.5 1
38 56160-038 Clip 1
39 56160-039 Ground Wire 1
24
EXPLODED VIEW AND PARTS LIST
52.1
64.1
25
EXPLODED VIEW AND PARTS LIST
No. Part No. Description Qty
1 56160-101 Crankcase 1
2 56160-102 Ball Bearing 1
3 56160-103 Oil Seal 2
4 56160-104 Governor Assembly 1
5 56160-105 Governor Arm Shaft 1
6 56160-106 Intake Valve Returner 1
7 56160-107 Lock Pin 1
8 56160-108 Drain Plug Bolt 1
9 56160-109 Drain Plug Washer 1
10 56160-110
Oil Level Switch
Assembly
1
11 56160-111 Bolt M6X12 2
12 56160-112 Casecover Dowel Pin 2
13 56160-113 Piston 1
14 56160-114 Piston Scraper Ring Set 1
15 56160-115
Connecting Rod
Assembly
1
16 56160-116 Piston Pin 1
17 56160-117 Piston Clip 2
18 56160-118
Crankcase Cover As-
sembly
1
19 56160-119 Ball Bearing 1
20 56160-120 Cylinder Head 1
21 56160-121 In Valve 1
22 56160-122 Valve Exhaust 1
23 56160-123 Valve Spring 2
24 56160-124 Seat, Valve Spring, In 2
25 56160-125 Push Rod Guide Plate 1
26 56160-126 Rocker Assembly 2
27 56160-127 Stud Bolt 2
28 56160-128 Stud Bolt 2
29 56160-129 Carburetor Assembly 1
30 56160-130
Fuelv Line
Φ4Xφ8X120Mm
1
31 56160-131 Clip, Fuel Line Ф8 1
32 56160-132 Crankshaft Assembly 1
33 56160-133 Valve Lifter 2
34 56160-134 Casecover Packing 1
35 56160-135 Camshaft Assembly 1
36 56160-136 Dowel Pin 2
37 56160-137 Bolt M6X28 6
No. Part No. Description Qty
38 56160-138 Cylinder Head Gasket 1
39 56160-139 Bolt M8X50 4
40 56160-140 Spark Plug 1
41 56160-141 Rod, Push 2
42 56160-142 Shroud 1
43 56160-143 Bolt M6X12 13
44 56160-144 Headcover Packing 1
45 56160-145
Cylinder Head Cover
Assembly
1
46 56160-146 Wind Shield, LH 1
47 56160-147 Wind Shield, RH 1
48 56160-148 Flywheel Assembly 1
49 56160-149 Recoil Starter Fan 1
50 56160-150 Starter Pulley 1
51 56160-151 Nut M12 1
52 56160-152 Ignition Coil Assembly 1
52.1 56160-152.1 Spark Plug Boot 1
53 56160-153 Bolt M6X20 2
54 56160-154 Intake Packing 2
55 56160-155 Carburetor Insulator 1
56 56160-156 Governor Rod 1
57 56160-157 Throttle Return Spring 1
58 56160-158 Nut M6 4
59 56160-159 Governor Arm 1
60 56160-160 Recoil Starter Assembly 1
61 56160-161 Upper Shroud Assembly 1
62 56160-162 Air Cleaner Gasket 1
63 56160-163 Breather Tube 1
64 56160-164 Air Cleaner Assembly 1
64.1 56160-164.1 Air Cleaner Element 1
65 56160-165 Governor Spring 1
66 56160-166 Amplier 1
67 56160-167 Dipstick 1
68 56160-168
Secondary Gas
Injection Filter
1
69 56160-169 Flameout Wire 1
70 56160-170 Bolt M6X12 2
71 56160-171
Governor Arm Shaft
Washer
1
72 56160-172 Split Lock Washer 2
26
WIRING DIAGRAM
27
TROUBLESHOOTING
IMPORTANT: If trouble persists, please call our customer help line at (800) 232-1195 M-F 8-5 Central Time.
PROBLEM CAUSE SOLUTION
Engine will not start. Engine switch is set to OFF. Set engine switch to ON.
Fuel valve is turned to OFF. Turn fuel valve to ON position.
Choke is open. Close the choke.
Engine is out of gas. Add gas.
Engine is filled with contaminated
or old gas.
Change the gas in the tank.
Spark plug is dirty. Clean the spark plug.
Spark plug is broken. Replace spark plug.
Generator is not on a level surface. Move the generator to a level surface to pre-
vent low oil shutdown from triggering.
Oil is low. Add or replace oil.
Carburetor is air locked. Shut off the gas valve and remove the screw
from the bottom of the carburetor to allow it
to reset.
Engine runs but there is
no electrical output.
Circuit reset button is off. Wait for two minutes and push the circuit
reset button to the ON position.
Bad connecting wires/cables. If you are using an extension cord, use a dif-
ferent one.
Bad electrical device connected to
the generator.
Try connecting a different device.
Generator runs but does
not support all electrical
devices connected.
Generator is overloaded. Perform these steps:
1. Turn off all electrical devices.
2. Unplug all electrical devices.
3. Turn off generator.
4. Wait several minutes.
5. Restart generator.
6. Try connecting few electrical loads to the
generator.
Short circuit in one of the devices. Try disconnecting any faulty or short-circuited
electrical loads.
Air cleaner is dirty. Clean or replace air cleaner.
28
WARRANTY STATEMENT
Remember to save the receipt and to accurately fill out and mail the product registration card. Proof of purchase
is required for all warranty work.
WEN® Generators are under warranty to be free from defects in materials and workmanship for a period of two
(2) years from date of original purchase. Generators used for Commercial or Rental use have a warranty period of
90 days from date of original purchase. Keep purchase receipt and mail in the product registration card for proof
of purchase.
WEN® will repair or replace, at its discretion, any part that is proven to be defective in materials or workman-
ship under normal use during the two (2) years warranty period. Warranty repairs or replacements will be made
without charge for parts or labor. Parts replaced during warranty repairs will be considered as part of the original
product and will have the same warranty period as the original product.
To exercise the warranty, DO NOT RETURN TO RETAILER. Instead, call the toll free Customer Service
number at (800) 232-1195 and you will be instructed on where to take the generator for warranty service. Take
the generator and proof of purchase (the receipt) to the repair facility recommended by the Customer Service
Representative. To make a claim under this Limited Warranty, you must make sure to keep a copy of your proof
of purchase that clearly defines the Date of Purchase (month and year) and the Place of Purchase. Place of pur-
chase must be a direct vendor of Great Lakes Technologies, LLC. Third party vendors such as garage sales, pawn
shops, resale shops, or any other secondhand merchant void the warranty included with this product. Contact
[email protected] or 1-800-232-1195 to make arrangements for repairs and transportation.
When returning a product for warranty service, the shipping charges must be prepaid by the purchaser. The prod-
uct must be shipped in its original container (or an equivalent), properly packed to withstand the hazards of ship-
ment. The product must be fully insured with a copy of the warranty card and/or the proof of purchase enclosed.
There must also be a description of the problem in order to help our repairs department diagnose and fix the
issue. Repairs will be made and the product will be returned and shipped back to the purchaser at no charge.
THIS LIMITED WARRANTY DOES NOT APPLY TO ACCESSORY ITEMS THAT WEAR OUT FROM
REGULAR USAGE OVER TIME INCLUDING BELTS, BRUSHES, BLADES, ETC.
The warranty does not extend to generators damaged or affected by fuel contamination, accidents, neglect, mis-
use, unauthorized alterations, use in an application for which the product was not designed and any other modifi-
cations or abuse. Labor for warranty parts is only covered for the contiguous United States (48 states).
WEN® is not liable for any indirect, incidental or consequential damages from the sale or use of this product.
Any implied warranties are limited to two (2) years as stated in this written limited warranty. Some states do not al-
low the exclusion or limitation of incidental or consequential damages. Some states do not allow limitation on the
length of an implied warranty. This warranty gives you specific legal rights, and you may have other rights that vary
from state to state.
