Wen 56455i Instruction Manual
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Wen 56455i Instruction Manual

4500-watt inverter generator
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MODEL 56455i
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. Pay close attention to the rules for safe operation, warnings, and cautions. If you use
your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.
WENPRODUCTS.COM
For replacement parts and the most up-to-date instruction manuals, visit

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  • Page 1 1-800-232-1195 (M-F 8AM-5PM CST) TECHSUPPORT@WENPRODUCTS.COM IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest standards for dependability, ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged, trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.

  • Page 2: Table Of Contents

    Wire Diagram ....................38 Exploded View & Parts List ................39 Warranty Statement ..................50 WENPRODUCTS.COM To purchase accessories for your tool, visit Magnetic Oil Dipstick (Model 55201) WEN Parallel Connection Kit Weatherproof Generator Cover (Model 56310iC) High-Altitude Kit (Parts 56380i-HA36 & 56380i-HA68)

  • Page 3: Welcome

    SPECIFICATIONS GENERATOR Rated Wattage 3500 Watts Surge Wattage 4500 Watts AC: 120V Rated Voltage DC: 12V (Cigarette Lighter), 5V (USB) AC: 29.1A (Total), 29.1A (TT-30R), 20A (5-20R) Rated Amperage DC: 10A (Total), 8A (Cigarette Lighter), 1A/2.1A (USB) Phase Single Frequency 60 Hz Decibel Rating 57 dB...

  • Page 4: Introduction

    INTRODUCTION Thanks for purchasing the WEN 4500-Watt Inverter Generator. Refer to the illustration below for the location of the serial number on the specifications label. Record the generator information in the spaces provided below. If assis- tance for information or service is required, please contact customer service by calling 1-800-232-1195, M-F 8-5 CST;...

  • Page 5: Safety

    WEN reserves the right to change this product and specifications at any time without prior notice. At WEN, we are continuously improving our products. If you find that your tool does not exactly match this manual, please visit wenproducts.com for the most up-to-date manual or contact customer service at 1-800-232-1195, M-F 8-5 CST.

  • Page 6: Generator Safety Warnings

    GENERATOR SAFETY WARNINGS DANGER! CARBON MONOXIDE Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This is a poison gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.
  • Page 7 GENERATOR SAFETY WARNINGS WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury. OPERATING ENVIRONMENT 3. If any part of the generator, electrical device or pow- er cord is broken, damaged, or defective, make sure 1.
  • Page 8 GENERATOR SAFETY WARNINGS WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury. TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your generator at least once a month for 20 to 30 minutes.

  • Page 9: Before Operating

    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.

  • Page 10: Know Your Inverter Generator

    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 fol- lowing diagrams to become familiarized with all the parts and controls of your Generator. The components will be referred to later in the manual for assembly and operation instructions.
  • Page 11 Turn switch to start, run, and automatically shut off the 6. Parallel Connection Port generator Connect two WEN inverter generators through a parallel connection kit for a higher output. 14. Engine Start Button Turn switch to "Start" and press button to ignite the en- 7.

  • Page 12: Generator Preparation

    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.
  • Page 13 GENERATOR PREPARATION The following section describes the necessary steps to prepare the generator for use. If you are unsure about how to perform any of the steps, please call 1-(800) 232-1195 M-F 8-5 CST for customer service. Failure to perform these steps properly can damage the generator or shorten its life.
  • Page 14 The oil level of the engine should be checked before each Upper Limit start to ensure that the engine crankcase contains suf- ficient lubricant. TIP: Your WEN generator is compatible with the WEN 55201 Magnetic Oil Dipstick (not included), available Lower Limit for purchase at wenproducts.com. The dipstick’s in- dustrial-strength magnetic tip will collect metal shav- ings from your generator’s oil compartment to help...
  • Page 15 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.
  • Page 16 (e.g. pierced with a nail, hit with a hammer, stepped on, etc.). 6. DO NOT DISASSEMBLE. Incorrect reassembly may pose a serious risk of electric shock, fire or exposure to toxic battery chemicals. If the battery or charger are damaged, call WEN customer service at 1-800-232-1195 for as- sistance.
  • Page 17 GENERATOR PREPARATION To connect the battery: Fig. 7 1. Using a quarter coin or flat-head screwdriver (not includ- Battery ed), open and remove the battery access cover (Fig. 7). Access 2. Loosen the rubber belt and pull out the battery. Cover 3.
  • Page 18 GENERATOR PREPARATION STEP 5 - GROUND THE GENERATOR Fig. 9 To reduce the risk of electric shock and to maximize safety, the genera- tor should be properly grounded. Ground the generator by tightening the grounding nut on the front control panel (Fig. 9) against a grounding wire. A generally acceptable grounding wire is a No.

  • Page 19: Operation & Maintenance

    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.
  • Page 20 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.

  • Page 21: Using Your Generator

    USING YOUR GENERATOR CALCULATING THE WATTAGE OF YOUR DEVICE(S) Connect electrical devices running on AC current according to their wattage requirements. Calculate the total run- ning wattage and starting wattage of the device(s) you wish to connect, and MAKE SURE that they are within the capacity of your generator and the capacity of each individual outlet.
  • Page 22 USING YOUR GENERATOR CALCULATING THE WATTAGE OF YOUR DEVICE(S) - CONTINUED The chart below serves as a reference for the estimated wattage requirements of common electrical devices. How- ever, do not solely rely on this chart - all electronics and appliances are built differently. Always check the wattage listed on the electrical device before consulting this chart.
  • Page 23 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.
  • Page 24 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 Max.
  • Page 25 PARALLEL OPERATION Fig. 14 The parallel connection ports (Fig. 14) allow you to connect two WEN generators to increase the total available electrical power. The WEN Parallel Connection Kit can be purchased from wenproducts.com. Follow the instructions included with your parallel connection kit for proper installation and operation.
  • Page 26 USING YOUR GENERATOR CIRCUIT BREAKERS Fig. 16 In addition to the reset button that protects the generator’s main circuit, the circuit breakers (Fig. 16) protect the individual AC and DC circuits. The 20-amp AC circuit breaker will activate when the NEMA 5-20 outlets exceed 20A.

  • Page 27: Shutting Off Your Generator

    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. This prolongs the lifespan of the generator by preventing build-up and blockages caused by stagnant fuel inside of a carburetor.

  • Page 28: Maintenance

    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.
  • Page 29 5. Reinstall dipstick and wipe clean any spilled oil with a rag. Reinstall the oil access cover. TIP: Your WEN generator is compatible with the WEN 55201 Magnetic Oil Dipstick (not included), available for purchase at wenproducts.com. The dipstick’s industrial-strength magnetic tip will collect metal shavings from...
  • Page 30 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 car- buretor can prevent the fuel from clogging up the carburetor;...
  • Page 31 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: Fig.
  • Page 32 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: Fig.
  • Page 33 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.
  • Page 34 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. 27 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.
  • Page 35 MAINTENANCE BATTERY MAINTENANCE/STORAGE The lithium-ion battery will receive charge when the engine is running. Remember to run the generator once a month for 20-30 minutes to charge the battery. A charged battery will allow you to start the generator us¬ing the electric start button during your next time of need.

  • Page 36: Transportation & Storage

    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.

  • Page 37: Troubleshooting Guide

    TROUBLESHOOTING GUIDE WARNING! Stop using the generator immediately if any of the following problems occur or risk serious personal injury. If you have any questions, please contact customer service at 1-800-232-1195 (M-F 8-5 CST), or email techsupport@wenproducts.com. PROBLEM POSSIBLE CAUSE SOLUTION 3-in-1 switch is set to OFF.

  • Page 38: Wire Diagram

    WIRE DIAGRAM...

  • Page 39: Exploded View & Parts List

    EXPLODED VIEW & PARTS LIST Fig. 1 - Crankcase Assembly Fig. 2 - Crankcase Cover Assembly Part No. Description Qty. Part No. Description Qty. Crankcase 56380i-0201 Cover, Crankcase 56380i-0101 Subassembly 56200-0803 56380i-0102 Flat Washer 56380i-0203 Ball Bearing Connector, 56380i-0103 Oil Drain Hose 56380i-0204 Gasket, Crankcase 56380i-0104...
  • Page 40 EXPLODED VIEW & PARTS LIST Fig. 3 - Cylinder Head Assembly Part No. Description Qty. Part No. Description Qty. 56200-1202 Bolt 56310i-0109 Bolt Cylinder Head Cover 56380i-0309 Bolt 56380i-0302 Subassembly Cylinder Head Cover 3-10 56380i-0310 Cylinder Head Gasket 56380i-0303 Gasket 3-11 56380i-0311 56310i-0104...
  • Page 41 EXPLODED VIEW & PARTS LIST Fig. 5 - Piston Ring Set & Connecting Rod Part No. Description Qty. Piston Ring Fig. 6 - Valve Train & Camshaft Subassembly 56310i-0501 Assembly Part No. Description Qty. 56310i-0505 Piston Pin Clip Camshaft 56380i-0601B 56380i-0503 Piston Assembly...
  • Page 42 EXPLODED VIEW & PARTS LIST Fig. 8 - Carburetor Assembly Fig. 9 - Rotor/Stator Assembly Part No. Description Qty. Part No. Description Qty. Carburetor 56310i-1101 Flywheel Nut 56380i-0801 Insulator Gasket 56380i-0902 Impeller Carburetor 56310i-1103 Bolt 56380i-0802 Insulator Plate 56380i-0904 Rotor Carburetor 56380i-0803 56380i-0905...
  • Page 43 EXPLODED VIEW & PARTS LIST Fig. 11 - Muffler Assembly Part No. Description Qty. 11-1 56380i-1101 Shroud 11-2 56380i-1102B Muffler Cover Support 11-3 56380i-1103 Impeller 11-4 56380i-1104 Muffler Insulation Plate 11-5 56380i-1105 Muffler Assembly 11-6 56380i-1106 Muffler Gasket 11-7 56310i-1010 11-8 56380i-1108 Muffler Bracket...
  • Page 44 EXPLODED VIEW & PARTS LIST Fig. 12 - Fuel Tank Assembly Part No. Description Qty. Fuel Tank 12-1 56380i-1201 Assembly 12-2 56380i-1202 Fuel Gauge 12-3 56380i-1203 Fuel Tank Outlet 12-4 56310i-1701 Bolt 12-5 56380i-1205 Flat Washer 12-6 56380i-1206 Bushing 12-7 56380i-1207 Fuel Tank Damper 12-8...
  • Page 45 EXPLODED VIEW & PARTS LIST Fig. 13 - Frame Fig. No. Part No. Description Qty. Fig. No. Part No. Description Qty. Engine Frame Carbon Tank 13-1 56380i-1301B 13-14 56380i-1314 Assembly Mounting Bracket 13-2 56380i-1302 Battery Case 13-15 56380i-1315 Carbon Tank Carbon Tank Hose, 13-3 56380i-1303...
  • Page 46 EXPLODED VIEW & PARTS LIST Fig. 14 - Control Panel Assembly Part No. Description Qty. Part No. Description Qty. 14-1 56200-0615 Screw 14-19 56380i-1419 Multimeter Switch 14-20 56380i-1420 Reset Button 14-2 56380i-1402 Subassembly NEMA 5-20R 14-21 56380i-1421 14-3 56200-0621B Cover Plate Duplex Outlet 14-4 56200-0624B...
  • Page 47 EXPLODED VIEW & PARTS LIST Fig. 15 - Handle Part No. Description Qty. Part No. Description Qty. 15-1 56380i-1501 Handle Tube 15-9 56380i-1509 Bolt 15-10 56310i-0209 Bolt 15-2 56380i-1502 Left Rotation Arm 15-11 56310i-1807 Nylon Nut 15-3 56380i-1503 Right Rotation Arm 15-12 56380i-1512 Flat Washer...
  • Page 48 EXPLODED VIEW & PARTS LIST Fig. 16 - Side Covers Part No. Description Qty. Part No. Description Qty. 16-1 56380i-1601 Left Cover 16-11 56200-0612 Screw And Washer 16-2 56200-0406 Bolt 16-12 56200-0420 Recoil Starter Handle 16-3 56380i-1603 Left Shell 16-4 56380i-1604 Right Shell Right Maintenance...
  • Page 49 EXPLODED VIEW & PARTS LIST Fig. 17 - Baseplate Part No. Description Qty. 17-1 56380i-1701 Baseplate Engine Frame Damper 17-2 56380i-1702 Seat 17-3 56310i-0209 Bolt 17-4 56200-0505 17-5 56380i-1705 Reinforcement Plate 17-6 56200-0508 Bolt 17-7 56310i-1407 Cover Plug 17-8 56380i-1708 17-9 56380i-1709 Cushion...

  • Page 50: Warranty Statement

    Contact techsupport@wenproducts.com or 1-800-232-1195 with the following information to make arrangements: your shipping address, phone number, serial number, required part numbers, and proof of purchase. Damaged or defective parts and products may need to be sent to WEN before the replacements can be shipped out.
  • Page 51 NOTES...
  • Page 52 THANKS FOR REMEMBERING V. 2022.08.01...

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