MODEL 56450iX 4500-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.
CONTENTS WELCOME 3 Specifications.................................................................................................... 3 Introduction...................................................................................................... 4 SAFETY 5 Safety Information............................................................................................ 5 Generator Safety Warnings...............................................................................
SPECIFICATIONS GENERATOR Surge Wattage 4500 Watts Rated Wattage 3500 Watts Rated Voltage AC: 120V DC: 12V (Cigarette Lighter), 5V (USB) Rated Amperage 29.16A Phase Single Frequency 60 Hz Decibel Rating 58 dB Length: 23.2 in. (590 mm) Product Dimensions Width: 18 in. (456 mm) Height: 20.1 in. (511 mm) Product Net Weight 99.
INTRODUCTION Thanks for purchasing the WEN 4500-Watt Inverter Generator. Refer to the illustration below for the location of the serial number on the side of the engine and on the main specifications label. Record the generator information in the spaces provided below. If assistance for information or service is required, please contact customer service by calling 1-800-232-1195, M-F 8-5 CST; you will be asked to provide the following generator information when calling.
SAFETY INFORMATION WARNING! Before operating the generator, make sure to read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire or serious injury. SAFETY INTRODUCTION Safety is a combination of common sense, staying alert, and knowing how your tool works. This manual contains important information regarding the generator’s potential safety concerns, as well as preparation, operation, and maintenance instructions.
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. 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.
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 1. Using a generator indoors can kill you in minutes. Only use a generator outside and far away from windows, doors and vents. 2. Do not smoke near the generator. 3. Do not operate near open flame, heat, or flammable materials.
GENERATOR SAFETY WARNINGS WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury. TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your generator at least once a month for 20 to 30 minutes. Start the generator according to the instructions and plug a small load in to make sure the outlet is producing electricity.
UNPACKING & PACKING LIST UNPACKING With the help of a friend or trustworthy foe, such as one of your in-laws, carefully remove the generator from the packaging and place it on a sturdy, flat surface. Make sure to take out all 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.
KNOW YOUR INVERTER GENERATOR TOOL PURPOSE Inverter Generators provide you with clean and quiet 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.
KNOW YOUR INVERTER GENERATOR CONTROL PANEL 1 2 3 4 5 VOLTAGE FREQUENCY TIME 6 7 14 13 12 11 10 9 8 1. Data Meter with Indicator Light 6. DC 12V Cigarette-Lighter Style Receptacle 2. Overload Reset If the overload light is ON, press this button to reset. 7. DC 5V USB Outlet 3. CO WATCHDOG Carbon Monoxide Monitor Measures the accumulation of poisonous CO gas while the generator is running.
GENERATOR PREPARATION REMOVING THE MOUNTING PLATES Your generator is shipped with four mounting plates that secure the engine to the generator housing in order to prevent machine damage during shipping. Make sure to remove the four mounting plates before operating your generator. 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.
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 (800) 232-1195 M-F 8-5 CST for customer service. Failure to perform these steps properly can damage the generator or shorten its life. STEP 1 - ADD / CHECK OIL The generator is shipped without oil. User must add the proper amount of oil before operating the generator for the first time.
GENERATOR PREPARATION STEP 1 - ADD / CHECK OIL (CONTINUED) For subsequent operation, the oil level should be checked before each use, or after every 8 hours of operation. The generator is equipped with a low-oil sensor and will not start without a sufficient amount of oil. To check oil level (before every subsequent start): 1. Place the generator on a level surface. Make sure the engine is off before adding or checking oil. 2. Open the oil access cover. Remove and wipe the dipstick with a clean rag. 3.
GENERATOR PREPARATION STEP 2 - ADD / CHECK FUEL WARNING! RISK OF EXPLOSION. HIGHLY FLAMMABLE: 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 not directly 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.
GENERATOR PREPARATION STEP 5 - GROUND THE GENERATOR Fig. 7 To reduce the risk of electric shock and to maximize safety, the generator should be properly grounded. Ground the generator by tightening the grounding nut (Fig. 7) on the front control panel against a grounding wire. 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.
STARTING YOUR GENERATOR 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 1-(800) 232-1195 M-F 8-5 CST for customer service. 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.
STARTING YOUR GENERATOR BEFORE STARTING THE GENERATOR 1. Verify that generator is outside on a dry, level surface with at least two feet of clearance on all sides. 2. To maximize safety, check that the generator is properly grounded (see “Ground the Generator”). 3. Check there is sufficient level of oil in the crankcase. Add oil if necessary (see “Add / check Oil”). 4. Make sure there is sufficient level of gasoline in the fuel tank. Add fuel if necessary (see “Add / check Fuel”). 5.
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 running 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.
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. However, 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.
USING YOUR GENERATOR CONNECTING ELECTRICAL DEVICES 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 (3500W) of the generator, DO NOT connect all these devices. Select a combination of electrical devices with a total rated wattage lower than or equal to the rated wattage of the generator.
USING YOUR GENERATOR 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. Device Requirements Amps 2.5 5 7.5 10 15 20 25 30 40 Watts (120V) 300 600 900 1200 1800 2400 3000 3600 4800 *NR = Not Recommended Max.
USING YOUR GENERATOR ECO-MODE SWITCH This generator is equipped with an Eco-Mode Idle Control Switch (Fig. 11). Engaging this switch allows the system to regulate the engine speed and automatically adjust its fuel consumption to match the required load. When the electrical load changes, the generator engine will automatically speed up and slow down as needed. This reduces fuel consumption and noise levels, while extending runtime and engine’s lifespan. Fig.
USING YOUR GENERATOR CO SENSOR INFORMATION The CO Watchdog carbon monoxide monitoring system (Fig. 15 - 1) measures the accumulation of poisonous CO gas while the generator is running. If the level of CO gas gets too high, the CO Watchdog system will automatically shut down the generator. This system is not a substitute for an indoor CO alarm. Whenever the CO Watchdog system shuts down the generator, the LED on the generator control panel (Fig.
USING YOUR GENERATOR MULTI-METER The multi-meter on your generator switches between voltage (e.g. 120.1), frequency (e.g. 60.0H), and runtime (e.g. 12.3) every 5 seconds. When you first use the generator, the meter will count runtime, but will not store runtime until the generator is run for longer than 2 hours at a time. Once the generator has been run for more than 2 hours at a time, the meter will track runtime normally. For an example, as well as more explanation, please refer to Table 4 below.
STOPPING YOUR GENERATOR CAUTION! Unplugging running devices can cause damage to the generator. Never stop the engine with electrical devices connected and running. OPTION 1: AUTOMATIC FUEL SHUTOFF (RECOMMENDED) The WEN 4500W Inverter Generator is equipped with automatic fuel shutoff. This feature turns off the flow of fuel, allowing for the generator to use up the remaining fuel from the carburetor before turning off.
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 Table 4. CAUTION! Never perform maintenance operations while the generator is running. Before maintaining or servicing the generator, turn OFF the generator, disconnect all devices and allow the generator to cool down.
MAINTENANCE CLEANING THE GENERATOR Keep the generator clean to prevent improper operation or machine damage from dirt and debris. Inspect all ventilation 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. Use low pressure air (not to exceed 25 PSI) to blow away dirt.
MAINTENANCE DRAINING THE CARBURETOR We recommend draining the carburetor after every use and before storing the generator. (If the generator is shut off using the AUTO OFF/FUEL OFF, it is only necessary to drain it before periods of long storage.) Draining the carburetor can prevent the fuel from clogging up the carburetor; a clogged carburetor can prevent the generator from starting. 1. With the help of another person, place the generator on an elevated platform such as a table or desk. Fig. 18 1 2.
MAINTENANCE AIR FILTER MAINTENANCE Check every 50 hours of operation (refer to Table 4 - Recommended Maintenance Schedule). Routine maintenance of the air filter helps maintain proper airflow to the carburetor. Occasionally check that the air cleaner is free of excessive dirt. To inspect and clean the air filter: 1. Using a Phillips-head screwdriver, unscrew the top two screws (Fig. 18 - 1) and remove the service panel on the opposite side of the recoil starter. Fig. 20 Air Cleaner Cover 2.
MAINTENANCE SPARK PLUG MAINTENANCE Refer to Recommended Maintenance Schedule in Table 4 for maintaining the spark plug. The spark plug is important for proper engine operation. Check the spark plug regularly to maintain proper engine operation. A good spark plug should be intact, free of deposits, and properly gapped. To inspect or replace the spark plug: 1. Using a Phillips-head screwdriver, unscrew the top two screws (Fig. 20 - 1) and remove the service panel on the opposite side of the recoil starter.
MAINTENANCE DRAINING / CHANGING OIL Change the oil according to the Recommended Maintenance Schedule in Table 4. Change the oil MORE OFTEN if operating 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 more-complete drainage. To change engine oil: Fig. 25 1.
MAINTENANCE DRAINING THE FUEL TANK Drain and clean the fuel tank each year, or before storing the generator for longer than two months. To drain the fuel tank and carburetor: Fig. 26 1. Using a Phillips-head screwdriver, remove the service panel on the opposite side of the recoil starter by unscrewing the top two screws (Fig. 20 - 1). 2. Locate the carburetor and the transparent drain tube that extends down through the base plate of the generator (Fig. 26). 3.
TRANSPORTATION & STORAGE TRANSPORTING THE GENERATOR To prevent fuel spillage when transporting, be sure to perform the following: 1. Tighten the fuel cap. 2. Flip the engine switch to the OFF position. 3. Drain the fuel tank if possible. Refer to section, “Draining the Fuel Tank.” 4. Keep the generator upright. Never place the generator on its side or upside down - doing so could damage the internal components of the generator and make it difficult to start. WARNING! Avoid direct sunlight inside a vehicle.
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 Engine will not start. Engine runs but there is no electrical output. POSSIBLE CAUSE 3-in-1 switch is set to OFF. Set 3-in-1 to ON. Oil is low. Add or replace oil. Engine is out of fuel. Add fuel.
WIRE DIAGRAM 36
EXPLODED VIEW & PARTS LIST Fig. 1 - Crankcase Assembly Description Fig. 2 - Crankcase Cover Assembly No. Part No. Qty.
EXPLODED VIEW & PARTS LIST Fig. 3 - Cylinder Head Assembly No. Part No. Description Qty. 3-1 56200-1202 4 3-2 56380i-0302 3-3 56380i-0303 Bolt, M6x20 Cylinder Head Cover Subassembly Cylinder Head Cover Gasket Spark Plug (Torch F6RTC, NGK BPR6ES) Cylinder Head Bolt, M8x60 Breather Tube 3-4 56310i-0104 3-5 56310i-0106 3-6 56380i-0306 1 1 1 4 1 Fig. 4 - Crankshaft Assembly 38 No. Part No. Description Qty. 4-1 56380i-0401 Crankshaft Assembly 1 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST Fig. 5 - Piston Ring Set & Connecting Rod No. Part No. Description Qty. 5-1 56310i-0501 Piston Ring Assembly 1 5-2 56310i-0505 Piston Pin Clip 2 5-3 56380i-0503 Piston 1 5-4 56310i-0504 Piston Pin 1 5-5 56380i-0505 Connecting Rod 1 No. Fig. 7 - Recoil Starter Part No. Description Fig. 6 - Valve Train & Camshaft Subassembly No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST No. 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 8-9 N.P. N.P. Fig. 8 - Carburetor Assembly Part No. Description Carburetor 56380i-0801 Insulator Gasket Carburetor 56380i-0802 Insulator Plate 56380i-0803 Carburetor Gasket Carburetor 56450i-0804 Assembly 56200-1305 Fuel Strainer 56380i-0805 Clamp 56380i-0806 Fuel Tube 56200-0103 Clamp 56400iX-0809 Rubber Jacket High-Altitude Kit, 56450i-HA36 3000 - 6000 ft High-Altitude Kit, 56450i-HA68 6000 - 8000 ft No. Fig.
EXPLODED VIEW & PARTS LIST Fig. 11 - Muffler Assembly No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST Fig. 12 - Fuel Tank Assembly 42 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST Fig. 13 - Frame No. Part No. 13-1 56380i-1301 Description Qty. No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST Fig. 14 - Control Panel Assembly No. Part No. 14-1 56200-0615 14-2 14-3 14-4 14-5 14-6 14-7 56380i-1402 56200-0621B 56200-0624B 56200-0623 56200-0502 56200-0628 14-8 56310i-1628 14-9 14-10 14-11 14-13 14-14 14-15 14-16 14-17 56380i-1409 56380i-1410 56200-0302 56450iX1412ASM 56200-0514 DF400i-1428 56200-0425C 56200-0427B 56380i-1417 14-18 56380i-1418 14-19 56380i-1419 14-12 44 Description Self-Tapping Screw, ST4.
EXPLODED VIEW & PARTS LIST Fig. 15 - Handle No. Part No. Description Qty. No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST Fig. 16 - Side Covers 46 No. Part No. Description Qty. 16-1 16-2 16-3 16-4 16-5 16-6 16-7 56380i-1601 56200-0406 56380i-1603 56380i-1604 56380i-1605 56200-0408 56380i-1607 1 4 1 1 1 8 8 16-8 56200-0515 16-9 56380i-0313 Left Cover Bolt, M5x12 Left Shell Right Shell Right Cover Nut, M6 Bolt, M6x20 Fuel Tank Rubber Sleeve Bolt, M6x12 4 8 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST No. Fig. 17 - Baseplate Part No.
WARRANTY STATEMENT WEN Products is committed to building tools that are dependable for years. Our warranties are consistent with this commitment and our dedication to quality. LIMITED WARRANTY OF WEN PRODUCTS FOR HOME USE GREAT LAKES TECHNOLOGIES, LLC (“Seller”) warrants to the original purchaser only, that this WEN consumer product will be free from defects in material or workmanship during personal use for a period of three (3) years from date of purchase or 500 hours of use; whichever comes first.
