Wen 56455i 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

4500-WATT

INVERTER GENERATOR

Instruction Manual

MODEL 56455i

Summary of Contents for 56455i

Page 1: ... 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 CO...

Page 2: ...rator 19 Using Your Generator 21 Shutting Off Your Generator 27 Maintenance 28 Transportation Storage 36 Troubleshooting Guide 37 Wire Diagram 38 Exploded View Parts List 39 Warranty Statement 50 OPERATION MAINTENANCE To purchase accessories for your tool visit WENPRODUCTS COM Magnetic Oil Dipstick Model 55201 WEN Parallel Connection Kit Weatherproof Generator Cover Model 56310iC High Altitude Kit...

Page 3: ...Height 20 1 in 511 mm Product Net Weight 99 2 lbs 45 kg GENERATOR ENGINE Engine Type 4 Stroke OHV Single Cylinder with Forced Air Cooling System Engine Displacement 212cc Engine Speed 3600 RPM Fuel Tank Capacity 2 2 US Gallons 8 50 L 87 Octane Minimum Oil Capacity 18 6 fl oz 0 55 L Half Load Run Time 8 5 Hours Lubrication System Splash Lubrication Spark Plug Type NGK BPR6ES Torch F6RTC Spark Plug ...

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 RECORD Record...

Page 5: ...t 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 regulations for SORE Smal...

Page 6: ...irectly in contact with gasoline 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 ...

Page 7: ...hould 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 electri c...

Page 8: ... the 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 transport...

Page 9: ...l contents and accessories Do not discard the packaging 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 Components Generator 14mm 17mm Wrench Wrench Screwdriver Handle ...

Page 10: ... and controls of your Generator The components will be referred to later in the manual for assembly and operation instructions GENERATOR Fuel Cap Carrying Handle Control Panel Battery Access Cover Transportation Handle Recoil Start Oil Access Cover Ventilation Slots Overload Indicator Red Output Indicator Green Low Oil Indicator Yellow Fuel Indicator Load Indicator Digital Display Voltage Frequenc...

Page 11: ...rough a parallel connection kit for a higher output 7 DC 120V Cigarette Lighter Style Receptacle 8 DC 5V USB Outlet 9 Grounding Nut Ground generator to reduce risk of electric shock 10 DC Circuit Breaker 10A 11 AC Circuit Breaker for NEMA 5 20R 20A 12 Manual Shutoff Button Push down for 10 seconds to shutoff generator manu ally see page 27 13 3 in 1 Switch Turn switch to start run and automaticall...

Page 12: ...ator To remove the mounting plates 1 With the help of another person place generator on an elevated platform such as table or workbench Make sure the generator is stable Do not to tilt the generator as there may be remaining oil inside the crankcase from testing 2 Remove the four nuts Fig 1 3 and mounting plates Fig 1 2 from the generator s baseplate Fig 1 1 3 Follow the instructions in the follow...

Page 13: ... cover from the side panel Unscrew the oil dipstick from the engine Fig 2 3 Using an oil funnel or appropriate dispenser slowly add oil into the oil fill being careful not to overfill the unit Fill the crankcase to the upper fill line so you can visually see the oil coming halfway up the oil fill threads Fig 3 4 Reinstall the oil dipstick and firmly tighten it Wipe clean any spilled oil 5 Reinstal...

Page 14: ... the oil coming halfway up the oil fill threads 4 Wipe clean any oil leaks and firmly tighten the dipstick Reinstall the oil access cover OIL LEVEL SHUTDOWN To protect the unit from damage the generator is equipped with a low oil pressure shutoff that will automatically stop the engine when the oil level is too low The yellow low oil indication light Fig 5 will turn ON to remind you that the engin...

Page 15: ...m of 87 octane rating The genera tor performs best with ethanol free gasoline DO NOT use gasoline with over 10 ethanol The capacity of the fuel tank is 2 2 US gallons 8 50 L Do not mix oil with gasoline To add gasoline 1 Make sure the generator is shut OFF and on a level sur face Unscrew the fuel cap Fig 6 and set it aside The fuel cap may be tight and hard to unscrew 2 Slowly add unleaded gasolin...

Page 16: ...ars to be undamaged The battery cells inside the battery may have suffered serious damage In such instances please read the waste disposal information on p 34 for proper battery disposal 5 DO NOT CRUSH DROP OR DAMAGE BATTERY Do not use the battery if it has sustained a sharp blow been dropped run over or has been damaged in any way e g pierced with a nail hit with a hammer stepped on etc 6 DO NOT ...

Page 17: ...cting the cable cover the free end with an insulator such as electrical tape You may also choose to use a trickle charger not included to maintain battery charge Fig 7 Fig 8 Rubber Belt Battery Access Cover 17 ENGINE BREAK IN PROCEDURE The procedure below should be followed when you receive your generator in order to prolong the engine s service life This procedure helps to seat the piston rings p...

Page 18: ...ience 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 56380i HA There are two kits one for altitudes be tween 3000 and 6000 feet 56380i HA36 and the other for altitudes from 6000 to 8000 feet 56380i HA68 ...

Page 19: ...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 20: ...ge the starter NOTE The lithium ion battery is shipped partially charged in order to maximize its service life and may not have enough charge to start the engine during the first use of the generator If you have trouble starting the generator the first time using electric start use the pull start option and allow the generator to run for a few hours to charge the battery 4 When engine starts turn ...

Page 21: ...culation 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 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 wattag...

Page 22: ...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 23: ...ices are turned off Start plugging in each electric device from the highest wattage to the lowest Check the power indicator light green to ensure the generator is producing power 3 Do not overload the generator or individual panel receptacles If an overload occurs the overload indication light red will activate If it is flashing turn off and unplug one load If it is solid not flashing the generato...

Page 24: ...s 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 NOTE For power outages permanently installed stationary generators are better suited for providing backup power to your home Even a properly connected portable generator can become overloaded This may result in overheating or stressing the machi...

Page 25: ...s and then press the activated reset button to reset the circuit If no power is produced after resetting turn off and disconnect all electrical devices and restart your generator Fig 14 Fig 15 25 LIGHT MEANING RESOLUTION GREEN POWER INDICA TOR RED OVERLOAD ON OFF Generator output is normal No action needed ON Flashing Continuously Generator is exceeding rated output Reduce load on generator OFF Fl...

Page 26: ...refer to the chart below SESSION NUMBER SESSION LENGTH HOUR METER AT END OF SESSION DOES THE METER RESET COMMENTS 1 1 hr 30 min 1 5 Yes to 0 0 Meter will show 1 5 just before it is shut off but it has not been run for 2 hours at a time yet 2 30 min 0 5 Yes to 0 0 Meter will show 0 5 just before it is shut off but it has not been run for 2 hours at a time yet 3 1 hr 1 Yes to 0 0 Meter will show 1 0...

Page 27: ...automatically This feature helps to prevent the carburetor from being clogged by stale fuel extending your generator s lifespan OPTION 2 MANUAL SHUTOFF In case you are in a hurry and do not want to wait for the generator to automatically shut down the manual shutoff feature is available However this method will leave stagnant fuel in the carburetor possibly causing blockages a shortened lifespan a...

Page 28: ...itions or operating under heavy load Change the oil after the first 8 hours of operation after the first 25 hours of operation and every 50 hours after that 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 ...

Page 29: ... shut down to protect it from running without oil To check the oil level and add oil 1 Make sure the generator is on a level surface Do not tilt the generator as oil will flow into engine areas and cause damage Keep generator level 2 Turn the oil access cover knob to the unlocked position and remove the ac cess cover from the front panel Clean around the oil fill Remove the dipstick and wipe it wi...

Page 30: ... unscrew the top two screws Fig 19 1 and remove the service panel on the opposite side of the recoil starter 4 The carburetor can be accessed between the engine and the air filter Fig 19 Locate the transparent tube from the carburetor Fig 20 that extends down through the base plate of the generator 5 Prepare an approved gasoline storage con tainer and direct the end of the drain tube into the cont...

Page 31: ...lters can be ordered from wenproducts com by searching part no 56380i 1001B 1 4 Reinstall the air cleaner element air cleaner cover and service panel 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 SPARK ARRESTOR MAINTENANCE Inspect and clean the spark arrestor every 100 hours of operati...

Page 32: ...n the plug 4 Visually inspect the spark plug If it is cracked or chipped or if the electrodes are worn or burned discard it and replace with a new spark plug We recommend replacing with a NGK BPR6ES Torch F6RTC spark plug part no 56310i 0104 available for purchase at wenproducts com 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 spar...

Page 33: ... knob to the unlocked position and remove the cover from the side panel 3 Prepare an approved oil storage container and place it be low the oil drainage valve Fig 26 to catch oil as it drains 4 Open the oil drainage valve by turning the lever and allow oil to drain from the engine completely 5 Close the oil drainage valve after the oil has drained Fig 26 Oil Fill Oil Drainage Valve NOTE Never disp...

Page 34: ...to the RUN position Fig 28 This will open up the fuel valve 5 Open up the carburetor drain screw Fig 27 with a flat head screwdriver Fuel will start draining from the carburetor and fuel tank through the drain tube NOTE The draining process may take a few hours depending on the amount of fuel in your gas tank 6 Once fuel is completely drained from the tube reinstall the fuel cap and turn the 3 in ...

Page 35: ...nnected and covered with an insulator such as electrical tape and then connecting the battery This will allow the inside of the generator to warm up and will greatly reduce the chance of damage to the battery To reinstall replace the battery 1 Using a quarter coin or flat head screwdriver not includ ed open and remove the battery access cover Fig 33 2 Loosen the rubber belt and pull out the batter...

Page 36: ...roper power output PRODUCT DISPOSAL Do not dispose of a used generator or parts with your household waste This product contains electrical or elec tronic 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 r...

Page 37: ...heck the total wattage of the devices and reduce the load if it exceeds the capacity of the generator Bad connecting cords wires Check power cords extension cords Do not use if any cord is damaged Replace damaged cords immediately Bad electrical device connected to the generator Try connecting a different device Generator runs but does not support all electrical devices connected AC or DC receptac...

Page 38: ...WIRE DIAGRAM 38 ...

Page 39: ...ne Oil Sensor 1 1 10 56310i 0210 Nut 1 1 11 56380i 0111 Bearing 1 1 12 56310i 0306 Oil Seal 1 1 13 56380i 0113 Starter Motor 1 1 14 56380i 0114 Bolt 2 1 15 56380i 0115 Protective Cover 1 1 16 56380i 0116 Ignition Coil 1 1 17 56380i 0117 Bolt 2 1 18 56380i 0118 Oil Dipstick 1 Fig 2 Crankcase Cover Assembly No Part No Description Qty 2 1 56380i 0201 Cover Crankcase 1 2 2 56200 0803 Pin 2 2 3 56380i ...

Page 40: ...i 0306 Breather Tube 1 3 7 56380i 0307 Cylinder Head Subas sembly 1 No Part No Description Qty 3 8 56310i 0109 Bolt 2 3 9 56380i 0309 Bolt 2 3 10 56380i 0310 Cylinder Head Gasket 1 3 11 56380i 0311 Pin 2 3 12 56380i 0312 Limiter 1 3 13 56380i 0313 Bolt 1 3 14 56380i 0314 Breather Gasket 1 3 15 56380i 0315 Breather Plate 1 Fig 3 Cylinder Head Assembly Fig 4 Crankshaft Assembly No Part No Descriptio...

Page 41: ...602 2 Exhaust Valve 1 6 3 56310i 0603 Seal Guide 1 6 4 56310i 0604 Valve Spring 2 6 5 56380i 0605 Valve Spring Seat 2 6 6 56310i 0606 Valve Lock Clamp 4 6 7 56310i 0607 Valve Tappet 2 6 8 56380i 0608 Valve Lifter Subassembly 2 6 9 56380i 0609 Valve Rocker Arm 2 6 10 56380i 0610 Rocker Shaft 2 Fig 7 Recoil Starter No Part No Description Qty 7 1 56380i 0701 Recoil Starter Assembly 1 7 2 56200 1202 B...

Page 42: ...sembly No Part No Description Qty 9 1 56310i 1101 Flywheel Nut 1 9 2 56380i 0902 Impeller 1 9 3 56310i 1103 Bolt 3 9 4 56380i 0904 Rotor 1 9 5 56380i 0905 Stator 1 9 6 56380i 0906 Flat Washer 3 9 7 56380i 0907 Wiring Clamp 1 9 8 56310i 0207 Bolt 2 Fig 10 Air Filter Assembly No Part No Description Qty 10 1 56380i 1001B Air Filter Assembly 1 56380i 1001 1 Air Filter Element 1 10 2 56380i 1002 Intake...

Page 43: ... Muffler Insulation Plate 1 11 5 56380i 1105 Muffler Assembly 1 11 6 56380i 1106 Muffler Gasket 1 11 7 56310i 1010 Nut 2 11 8 56380i 1108 Muffler Bracket 1 11 9 56310i 1009 Bolt 5 11 10 56380i 1110 Bolt 2 11 11 56310i 1004 Bolt 1 11 12 56380i 1112 Bolt 1 11 13 56200 0508 Bolt 3 11 14 56380i 1114 Bolt 1 N A 56380i 1115 Spark Arrestor 1 EXPLODED VIEW PARTS LIST 43 ...

Page 44: ...80i 1203 Fuel Tank Outlet 1 12 4 56310i 1701 Bolt 4 12 5 56380i 1205 Flat Washer 4 12 6 56380i 1206 Bushing 4 12 7 56380i 1207 Fuel Tank Damper 4 12 8 56380i 1208 Fuel Tank Cap 1 12 9 56380i 1209 Fuel Strainer 1 12 10 56380i 1210 Fuel Tank Sleeve 1 12 11 56200 0413 Fuel Level Sight Glass 1 12 12 56380i 1212 Upper Cover 1 12 13 56380i 1213 Cover Plug 1 44 ...

Page 45: ...13 12 56310i 1425 Bolt 1 13 13 56380i 1313 Rubber Sleeve 1 Fig No Part No Description Qty 13 14 56380i 1314 Carbon Tank Mounting Bracket 1 13 15 56380i 1315 Carbon Tank 1 13 16 56380i 1316 Carbon Tank Hose Primary 1 13 17 56380i 1317B Air Filter Hose 1 13 18 56380i 1318 Carbon Tank Hose Secondary 1 13 19 56380i 1319 Clamp 2 13 20 56380i 1320 Clamp 1 13 21 56380i 1321 Clamp 1 13 22 56310i 1009 Bolt...

Page 46: ...r 1 14 16 56200 0427B Nylon Nut 1 14 17 56380i 1417 Blocker 1 14 18 56380i 1418 Battery Cover 1 No Part No Description Qty 14 19 56380i 1419 Multimeter 1 14 20 56380i 1420 Reset Button 1 14 21 56380i 1421 NEMA 5 20R Duplex Outlet 1 14 22 56380i 1422 Switch Subassembly 1 14 23 56380i 1423 Parallel Port Nega tive 1 14 24 56380i 1424 Parallel Port Positive 1 14 25 56380i 1425 12V DC Outlet 1 14 26 56...

Page 47: ...at 1 15 7 56380i 1507B Right Handle Connector Seat 1 15 8 56200 0517 Bolt 2 No Part No Description Qty 15 9 56380i 1509 Bolt 4 15 10 56310i 0209 Bolt 4 15 11 56310i 1807 Nylon Nut 2 15 12 56380i 1512 Flat Washer 2 15 13 56380i 1513 Connector Fastener 2 15 14 56380i 1514 Flat Washer 6 15 15 56380i 1515 Positioning Block 2 15 16 56380i 1516 Washer 4 15 17 56380i 1517 Flat Washer 2 N A 56380i 1500ASM...

Page 48: ...00 0515 Fuel Tank Rubber Sleeve 4 16 9 56200 0508 Bolt 8 16 10 56380i 1610 Recoil Starter Guide Subassembly 1 No Part No Description Qty 16 11 56200 0612 Screw And Washer 2 16 12 56200 0420 Recoil Starter Handle 1 16 13 56380i 1613 Right Maintenance Door 1 16 14 56400iX 1614 Bolt 1 16 15 56380i 1615 Maintenance Door Lock 1 16 16 56200 0427B Nut 1 16 17 56380i 1617 Wheel 2 16 18 56380i 1618 Wheel A...

Page 49: ...0 0508 Bolt 2 17 7 56310i 1407 Cover Plug 1 17 8 56380i 1708 Nut 4 17 9 56380i 1709 Cushion 1 17 10 56380i 1710 Left Support 1 17 11 56380i 1711 Right Support 1 17 12 56310i 1409 Left Engine Frame Damper 2 17 13 56310i 1411 Right Engine Frame Damper 2 17 14 56310i 1412 Bolt 4 17 15 56310i 1404 Nut 10 17 16 56380i 1716 Crankcase Airflow Manifold 1 17 17 56380i 1717 Air Filter Support 1 17 18 56200 ...

Page 50: ...be sent to WEN before the replacements can be shipped out 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 insured with a copy of the proof of purchase enclosed There must also be a description of the will ...

Page 51: ...NOTES 51 ...

Page 52: ...THANKS FOR REMEMBERING V 2022 08 01 ...

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