WEN - Shop Generators, Woodworking Tools, and Power Tools — WEN Products
Instruction Manual for WEN models including: 56400iX, 4000W Inverter Generator
WEN 56400iX 044459056409 0044459056409 1007431125
WEN 56400iX Quiet 3200/4000W Inverter Generator: Spec Review & Deals
MODEL 56400iX
4000W INVERTER GENERATOR
Instruction Manual
EPA CERTIFIED CARB COMPLIANT
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.
For replacement parts and the most up-to-date instruction manuals, visit WENPRODUCTS.COM
CONTENTS
WELCOME
3
Specifications................................................................................................... 3 Introduction ..................................................................................................... 4
SAFETY
5
Safety Information ........................................................................................... 5 Generator Safety Warnings .............................................................................. 6
BEFORE OPERATING
9
Unpacking & Packing List ................................................................................ 9 Know Your Inverter Generator........................................................................ 10 Generator Preparation.................................................................................... 12
OPERATION & MAINTENANCE
19
Starting Your Generator ................................................................................. 19 Using Your Generator..................................................................................... 21 Stopping Your Generator ............................................................................... 28 Maintenance................................................................................................... 29 Transportation & Storage ............................................................................... 37 Troubleshooting Guide ................................................................................... 38 Wire Diagram ................................................................................................. 39 Exploded View & Parts List ............................................................................ 40 Warranty Statement ....................................................................................... 51
To purchase accessories for your tool, visit WENPRODUCTS.COM
Magnetic Oil Dipstick (Model No. 55201) Weatherproof Generator Cover (Model No. 56310iC)
WEN Parallel Connection Kit
High-Altitude Kit (Part No. 56380i-HA36 & 56380i-HA68)
2
GENERATOR
Surge Wattage Rated Wattage
Rated Voltage
Rated Amperage
Phase Frequency Decibel Rating
Product Dimensions
Product Net Weight
ENGINE
Engine Type Engine Displacement Engine Speed Fuel Tank Capacity Oil Capacity Half-Load Run Time Lubrication System Spark Plug Type Spark Plug Gap Spark Plug Torque Battery
SPECIFICATIONS
4000 Watts 3200 Watts AC: 120V DC: 12V (Cigarette Lighter), 5V (USB) AC: 26.7A (Total), 26.7A (TT-30R), 20A (5-20R) DC: 10A (Total), 8A (Cigarette Lighter), 1A/2.1A (USB) Single 60Hz 57 dB Length: 23.2 in. (590 mm) Width: 18 in. (456 mm) Height: 20.1 in. (511 mm) 99.2 lbs (45 kg)
4-Stroke, OHV, Single Cylinder with Forced Air Cooling System 212cc 3600 RPM 2.2 US Gallons (8.3 L), 87 Octane Minimum 18.6 fl. oz. (0.55 L) 8.5 Hours Splash Lubrication NGK BPR6ES / Torch F6RTC 0.7 - 0.8 mm (0.028 - 0.031 in.) 1/2 - 3/4 turn after gasket contacts base or 15 ft-lbs 12V, 1.6 Ah Lithium-Ion
3
INTRODUCTION
Thanks for purchasing the WEN 4000-Watt Inverter Generator. Refer to the illustration below for the location of the serial number on the side of the engine. 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.
Generator Model Number: 56400iX Date of Purchase: ______________________________________________ Purchased From: _______________________________________________ Serial Number: ________________________________________________
Serial Number
SERVICE RECORD
Record the service dates of your generator in the chart below. Please perform maintenance checks and operations according to the "Maintenance" section of the manual.
Service Record
Date
Date
Date
Date
Date
Date
Change Oil
Change Spark Plug
Clean Fuel Tank
Clean Air Cleaner
Clean Spark Arrestor
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.
4
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. Before operating this generator, be sure to read and observe all warnings and instructions both on the generator labels and in this instruction manual. Failure to follow all instructions listed below may result in personal injury.
NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur. 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.
Keep this manual available to all users during the entire life of the tool and review it frequently to maximize safety for both yourself and others.
SAVE THESE SAFETY INSTRUCTIONS.
SAFETY SYMBOLS
The purpose of following safety symbols is to attract your attention to possible dangers. The safety symbols, and their explanations, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures.
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.
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).
QUESTIONS? PROBLEMS?
In order to answer questions and solve problems in the most efficient and speedy manner, contact customer service at 1-800-232-1195, M-F 8-5 CST or email techsupport@wenproducts.com.
5
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. 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 batterybackup 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! 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. Allow generator to cool for at least 2 minutes before removing
fuel cap. Loosen cap slowly to relieve pressure in tank. · Do not overfill fuel tank. Gasoline may expand during operation. Do not fill to the top of the tank. Allow for
expansion. Always check for spilled fuel before operating. · If fuel spills, move the generator at least 30 feet away from the spill and wipe clean any spilled fuel before
starting the engine. · Empty fuel tank before storing or transporting the generator.
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 derived system in accordance with all applicable laws and electrical codes and 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.
CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals and produces exhaust known to the State of California to cause cancer, birth defects and other reproductive harm.
6
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. If any part of the generator, electrical device or power cord is broken, damaged, or defective, make sure it is repaired or replaced before operation. Service should only be performed by a qualified technician. Do not use receptacles or cords that show signs of damage, such as broken or cracked insulation.
3. Do not operate near open flame, heat, or flammable materials. 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 an explosion even if it isn't directly in contact with gasoline.
4. Do not expose the generator to rainy or wet conditions; doing so significantly increases the risk of electrical shock. Never handle the generator, electronic devices, or any cord while standing in water, while barefoot, or when hands or feet are wet.
5. Always operate the generator on a dry, firm, level surface.
6. The generator should have at least 5 feet of clearance from buildings or other equipment during operation.
7. Do not allow children or non-qualified persons to operate the generator.
4. Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as metal decking or steel work. Extension cords with in-line GFCIs are recommended for these operations to maximize safety.
5. If connecting the generator to a building's electrical system for standby power, you MUST consult a qualified electrician and install a transfer switch. Such connections 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.
6. Never modify the generator in any way. Modifying or using the machine for any other purpose for which it is not designed may result in serious injuries, machine damage and voiding of the warranty.
GENERATOR OPERATION
1. Only use the generator for its intended purposes. Modifying or using the generator for operations for which it was not designed may cause hazards and personal injury.
GENERATOR PREPARATION
1. Always ground the generator before using it to maximize safety (see "Ground the Generator" section).
2. Do not overfill fuel tank, as gasoline may expand during operation. Do not fill to the very top of the tank. Leave room for gasoline expansion. Always check for spilled fuel before operating.
2. Do not touch bare wires or receptacles (outlets).
3. Do not exceed the wattage capacity of the generator by plugging in more electrical devices than the unit can handle. This could damage the generator and/or connected electrical devices. Check the operating voltage and frequency requirements of all electrical devices prior to plugging them into the generator.
Generator safety warnings continue on the next 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.
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. If you do not run it often, it will greatly shorten the generator's lifespan and void the warranty.
4. Allow generator to run for several minutes before connecting electrical devices. Do not start or stop engine with electrical devices plugged in to the receptacles. Failure to do so could damage the generator and/or connected electrical devices.
5. Do not turn on electrical devices until after they are connected to the generator.
6. 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.
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 transporting the generator. Do not store generator or gasoline near furnaces, water heaters, or any other appliances that produce heat or have automatic ignitions. Store the generator and fuel away from sparks, open flames, pilot lights, heat and other sources of ignition.
7. Do not touch hot parts. This generator produces heat when running. Temperatures near exhaust can exceed 150ºF (65ºC). Allow generator to cool down after use before touching engine or areas of the generator that become hot during use.
12. Always wash hands after handling generator.
CAUTION: Misuse of this generator can damage it or shorten its lifespan.
8. Turn off all connected electrical devices before stopping the generator.
8
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. 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
Components
Spark Arrestor Tools
Generator Assembly Tools
Accessories
Handle Wrench
8mm / 10mm Wrench
14mm / 17mm Wrench
Screwdriver
Funnel Cup Funnel Tube
9
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.
GENERATOR
Carrying Handle
Fuel Cap
Control Panel Battery Access Cover
Ventilation Slots Overload Indicator (Red)
Output Indicator (Green)
Recoil Start Oil Access Cover Transportation Handle
Low Oil Indicator (Yellow)
Load Indicator
Fuel Indicator
Digital Display (Voltage, Frequency, Run Time, Maintenance Alert at 50 hours)
10
CONTROL PANEL
KNOW YOUR INVERTER GENERATOR
1
2
3
4
5
VOLTAGE FREQUENCY TIME
16 6
15
7
14
13 12
11 10 9
8
1. Data Meter with Indicator Light
2. Overload Reset If the overload light is ON, press this button to reset.
3. CO WATCHDOG Carbon Monoxide Monitor 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. See p. 23 for more information.
4. Eco-Mode Switch Turn ON to increase fuel economy and runtime when the load is below 2550W (75% load).
5. Parallel Connection Port Connect two WEN inverter generators through a parallel connection kit for a higher output.
6. DC 12V Cigarette-Lighter Style Receptacle
7. DC 5V USB Outlet
8. Grounding Nut Ground generator to reduce risk of electric shock.
9. DC Circuit Breaker (10A) 10. AC 120V NEMA TT-30 Receptacle (28.3A) 11. AC Circuit Breaker for NEMA 5-20R (20A) 12. AC 120V NEMA 5-20 Duplex Receptacles (20A) 13. Manual Shutoff Button Push down for 10 sec. to shutoff generator manually. 14. 3-in-1 Switch Turn switch to start, run, and automatically shut off the generator. 15. Engine Start Button Turn switch to "Start" and press button to ignite the engine. 16. Auto OFF / Fuel Shutoff Automatically shuts off generator after fuel in the carburetor is consumed.
11
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. 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 following pages to prepare your generator for starting.
Fig. 1
1
2
2
2
2
3
3
3
3
12
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. The oil capacity of the engine crankcase is 18.6 fl. oz. (0.55 L).
ENGINE OIL RECOMMENDATIONS
Select good quality detergent oil bearing the American Petroleum Institute (API) service classifications SJ, SL, or SM (synthetic oils may be used). Select the SAE viscosity grade of oil that matches the expected operating temperature.
30W
· 30W Engine Oil
Temperatures above 40°F
°F -20
10W-30
Synthetic 5W-30
0
20 32 40
60
· 10W-30 Engine Oil Temperatures between 0°F - 40°F
· Synthetic 5W-30 Engine Oil
80
100
All temperature ranges
°C -30
-20
-10
0
10
20
30
40
To add oil, follow these steps:
1. Place the generator on a level surface. Make sure the engine is off before adding or checking oil.
CAUTION: Keep the generator level! Tilting the generator to assist in filling will cause oil to flow into the wrong areas of the engine and cause damage.
2. Turn the oil access cover knob to the unlocked position, and remove the access 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. Reinstall the oil access cover. Turn the oil access cover knob to the locked position to secure the cover in place.
Upper Level Fill Line
Lower Level Fill Line
Fig. 2 Fig. 3
13
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. Insert the dipstick into the oil fill without screwing it in. Remove the dipstick to check the oil mark (Fig. 4).
If the oil mark covers less than one half of the dipstick, slowly add oil until the oil mark reaches to the top of the dipstick (or when you can see 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 engine oil level is low and need to be refilled.
Fig. 4
The oil level of the engine should be checked before each start to ensure that the engine crankcase contains sufficient lubricant.
Upper Limit
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 your generator's oil compartment to help preserve the engine and extend your generator's lifespan.
Lower Limit Low Oil Indicator
Fig. 5
14
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. Allow generator to cool for at least 2 minutes before removing
fuel cap. Loosen cap slowly to relieve pressure in tank. · Do not overfill fuel tank. Gasoline may expand during operation. Do not fill to the top of the tank. Allow for
expansion. Always check for spilled fuel before operating. · If fuel spills, move the generator at least 30 feet away from the spill and wipe clean any spilled fuel before
starting the engine. · Empty fuel tank before storing or transporting the generator.
Use ONLY fresh (within 30 days from purchase), lead-free gasoline with a minimum of 87 octane rating. The generator 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 (8.3 L). Do not mix oil with gasoline.
To add gasoline:
1. Make sure the generator is shut OFF and on a level surface. Unscrew the fuel cap (Fig. 6) and set it aside. The fuel cap may be tight and hard to unscrew.
2. Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill.
NOTE: Do not fill the fuel tank to the very top. If you do so, gasoline will expand and spill during use, even with the fuel cap in place.
IMPORTANT:
· Avoid getting dirt or water into the fuel tank. · Keep gasoline away from sparks, open flames,
pilot lights, heat, and other sources of ignition. · Gasoline can age in the tank and make starting
difficult. Never store the generator for more than 2 months with fuel in the tank. · Never use an oil/gasoline mixture. · Never use old gasoline.
3. Reinstall fuel cap and wipe clean any spilled gasoline with
a dry cloth.
Fuel Cap
Fig. 6
To check fuel level: During operation, the fuel level will be displayed by the indicator lights on the right side of the multi-meter. If the fuel level is low, refill the fuel tank before starting your generator for the next time.
15
GENERATOR PREPARATION
STEP 4 - CONNECT THE BATTERY
WARNING! Use only genuine WEN batteries with your generator (part no. 56380i-1304). Use of other batteries may induce premature product failure and could pose a safety risk.
ABOUT THE BATTERY
1. The lithium-ion battery supplied with your generator is only partially charged, in order to maximize its service life. The battery may not have enough charge to start the engine during its first use. If this is the case, connect the battery according to the instructions below, and start the generator using the recoil starter, according to the instructions below. The battery will receive charge when the generator is running.
2. Lithium-ion batteries are subject to a natural aging process. The battery must be replaced at the latest when its capacity falls to just 80% of its capacity when new. Weakened cells in an aged battery are no longer capable of meeting the high power requirements needed for the proper operation of your generator, and therefore pose a safety risk.
3. DO NOT INCINERATE BATTERY. Do not throw the battery into an open fire as this poses a risk of explosion. Do not ignite the battery or expose it to fire.
4. AVOID DAMAGE AND SHOCKS. Immediately replace batteries that have been dropped from a height of more than one meter (3 feet) or those that have been exposed to violent shocks, even if the housing of the battery appears 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 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 assistance.
7. DO NOT SHORT CIRCUIT. Batteries will short circuit if a metal object makes a connection between the positive and negative contacts on the battery. Do not place the battery near anything that may cause a short circuit, such as paper clips, coins, keys, screws, nails and other metallic objects. A short-circuited battery poses a risk of fire and severe personal injury.
NOTE: The safe temperature range for charging the battery is 25°F 104°F.
The generator is shipped with the lithium-ion battery's negative (-) terminal disconnected to maximize safety. To start the generator using electric start, the battery must be connected.
16
GENERATOR PREPARATION
To connect the battery:
1. Using a quarter coin or flat-head screwdriver (not included), open and remove the battery access cover (Fig. 7).
2. Loosen the rubber belt and pull out the battery.
3. Remove the cover from the battery's negative (-) terminal and connect the black cable to the battery's negative (-) terminal as shown in Fig. 8.
The generator's positive pole has already been connected. Double check to confirm that the connection is secure.
4. Return the battery into position and use the rubber belt to fasten the battery.
5. Reinstall and secure the battery access cover.
Rubber Belt
IMPORTANT: If you do not plan to use the generator for a long period of time, we recommend DISCONNECTING the negative battery cable from the battery to protect the battery from losing charge. After disconnecting 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 Battery Access Cover
Fig. 8
17
GENERATOR PREPARATION
STEP 5 - GROUND THE GENERATOR
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 on the front control panel (Fig. 9) 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. Wire and grounding rods are not included with the generator.
NOTE: Grounding codes can vary by location. Contact a local electrician to check the area codes.
Grounding Nut
Fig. 9
WARNING! Failure to properly ground the generator increases your risk of electric shock.
HIGH ALTITUDE OPERATION ABOVE 3000 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 engine may experience 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 between 3000 and 6000 feet (56380i-HA36), and the other for altitudes from 6000 to 8000 feet (56380i-HA68). This kit should be installed by a qualified mechanic. Refer to the instructions included with your altitude kit for more information about installation
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. Do not smoke near the generator. Warranty will be void if adjustments are not made for high altitude use.
CAUTION: 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.
After completing the above preparation, the generator is ready to be started.
18
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. 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 batterybackup 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, or other reproductive harm.
WARNING! Do not operate generator near open flame or flammable materials 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! This generator produces powerful voltage, which can result in electrocution.
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! Generator should only be connected to electrical devices, either directly or with an extension cord. NEVER connect to a building electrical system without a qualified electrician and connected to a transfer switch as a separately derived system. Such connections must comply with local electrical laws and codes. Failure to comply can create a back-feed, which may result in serious injury or death to utility workers.
To maximize safety, ALWAYS ground the generator before using it. See section "Ground the Generator".
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.
CAUTION! Disconnect all electrical loads from the generator before attempting to start.
Follow the instructions on the next page to start your generator.
19
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. Make sure all electrical devices are unplugged from the generator during ignition. Otherwise it will be difficult for the engine to start.
STARTING THE GENERATOR
1. Turn the ECO-MODE (Fig. 10) switch to "OFF" during starting. 2. Turn the 3-in-1 dial switch (Fig. 11) to the "START" position.
Fig. 10
NOTE: If starting the generator with a warm engine, turn the dial switch to the "RUN" position.
Option A: Electric Start
3. Push the start button inwards until the engine starts.
NOTE: If the engine does not start, release the button and try again. Keeping the switch in the START position too long can damage 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 the switch to the "RUN" position.
Fig. 11
Option B: Pull Start
3. Place one hand on the generator to hold it in place, and pull on the recoil starter handle slowly until a slight resistance is felt (Fig. 12). Then pull quickly to start the engine. Return cord gently into the machine. Never allow the cord to snap back.
4. If engine fails to start, repeat step 3B.
Fig. 12
NOTE: If you have repeated failed attempts to start the engine, please consult the troubleshooting guide (page 36). If problems persist, please call please call 1-(800) 232-1195 M-F 8-5 CST.
5. After the engine has started, turn the 3-in-1 switch to the "RUN" position. The output indicator light (green) will light up.
6. Allow the generator to run for several minutes before attempting to connect any electrical devices. This allows the generator to stabilize its speed and temperature. 20
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.
Generator Wattage Capacity
GENERATOR RUNNING (RATED) WATTS
GENERATOR STARTING (SURGE) WATTS
3200W
4000W
What this means: The generator can produce a maximum of 3200W on a continuous basis to supply ongoing power to your electronic devices.
What this means: Some devices such as box fans require short bursts of extra power in addition to the rated wattage listed by the device to start their motors.
NOTE: Also check the rated amperage for each outlet and make sure not to overload the individual outlets.
The generator can produce a maximum wattage of 4000W for a short period of time (seconds) to cover the extra starting power required by your electronic devices.
Electronic Device Wattage
Calculation
Find the wattage information of each device you plan to connect. The information should be listed on the device or in its instruction manual, or you may refer to page 22, Table 2.
The wattage can be calculated using this equation: Watts = Volts x Amperes
To calculate the total running watts of your To calculate the total starting watts of your
devices:
devices:
+ Add up the running wattages of all the + Add up the total running wattage of all the
device(s) you plan to connect.
device(s) you plan to connect.
= The total running (rated) wattage.
This wattage should NOT exceed the running wattage of 3200W.
It is recommended to maintain a load at or below 2880W (90% of the rated output) to ensure steady voltage output and to prolong the generator's lifespan.
+ Add the single highest ADDITIONAL starting wattage out of the device(s) you plan to connect.
= The total starting (surge) wattage.
This wattage should NOT exceed the starting wattage of 4000W.
If any of either of the total calculated running watts or starting watts is higher than the capacity of your generator, adjust the load until both wattage requirements are met. Otherwise you will overload the generator, and cause damage to the engine and your electrical device(s).
Table 1 - How to Calculated Wattages
21
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.
Tool or Appliance Electric Water Heater (40 Gal)
Hot Plate Saw - Radial Arm Electric Stove (Each Element)
Saw - Circular Air Compressor (1 HP) Window Air Conditioner
Saw - Miter Microwave Well Water Pump Sump Pump Refrigerator Freezer Furnace Blower Computer Electric Drill Television Deep Freezer Garage Door Opener
Stereo Box Fan Clock Radio Security System Dvd Player / VCR Common Light Bulb
Rated (Running) Watts
Surge (Starting) Watts
4000
0
2500
0
2000
2000
1500-2800
0
1500
1500
1500
3000
1200
1800
1200
1200
1000
0
1000
1000
800
1200
800
1200
800
1300
800
0
600
900
500
0
500
500
480
0
400
0
300
600
300
0
180
0
100
0
75
0
Table 2 - Estimated Wattages of Common Electrical Appliances
NOTE: Become familiar with the functions and capacity of each component on the control panel before connecting electrical devices. See page 23 for more information about the components of the control panel. Do not overload generator or individual panel receptacles. Do not connect 50Hz or 3-phase loads to the generator.
22
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 (3200W) 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.
CAUTION! Become familiar with the markings on the control panel before connecting electrical devices. Do not connect 50Hz loads to the generator. 1. Before connecting electrical devices, allow the generator to run for a few minutes to stabilize the speed and voltage output. 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 (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 generator will cut off power to protect itself. Unplug all electrical devices and then press the reset button to reset the entire circuit, or press the circuit breaker to reset the DC circuit. 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 reset button or circuit breaker does not reset, wait several minutes and try again. If problem still persists, please call 1-(800) 232-1195 M-F 8-5 CST.
VOLTAGE FREQUENCY TIME
23
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
Watts (240V)
600 1200 1800 2400 3600 4800 6000 7200 9600
*NR = Not Recommended
Max. Cord Length (ft) by Wire Gauge #8 wire #10 wire #12 wire #14 wire #16 wire
NR
NR
NR
375
250
NR
NR
300
200
125
NR
350
200
125
100
NR
250
150
100
50
NR
150
100
65
NR
175
125
75
50
NR
150
100
60
NR
NR
125
65
NR
NR
NR
90
NR
NR
NR
NR
Table 3 - Power Cord Requirement Guide
WARNING! Generator should only be connected to electrical devices, either directly or with an extension cord. NEVER CONNECT TO A BUILDING ELECTRICAL SYSTEM without a qualified electrician and connected to a transfer switch as a separately derived system. Such connections must comply with local electrical laws and codes. 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 machine's components, possibly leading to generator failure.
24
USING YOUR GENERATOR
ECO-MODE SWITCH
This generator is equipped with an Eco-Mode Idle Control Switch (Fig. 13). 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. 13
Keep this switch engaged ONLY when the power load requirement is less than 2550W (75% of the rated watts). Do not engage the Eco-Mode Switch when the total load is more than 2550W. The generator engine must run at full speed to supply power for anything over 2550W.
PARALLEL OPERATION
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.
Fig. 14
IN CASE OF OVERLOAD
If your generator becomes overloaded from too much drawn wattage, the overload indicator (red) on the control panel will light up. Follow the instructions below when an overload occurs:
Fig. 15
· When you're close to overloading the generator, the overload light will start to flash. Reduce the load by turning off and disconnecting your electronic device(s) until the overload light turns off. Then you may continue to operate your generator.
· When you've overloaded the generator, the overload light will stay on and the reset button (Fig. 15) will activate to cut off the output in 3 to 16 seconds, depending on the load. Reduce the load by turning off and disconnecting your electrical device(s) until the overload light turns off. Wait about five minutes 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.
CIRCUIT BREAKERS
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. The 10-amp DC circuit breaker will activate when the DC 12V and USB outlets exceed 10A. When the circuit breaker activates, turn off and disconnect the device from its respective outlet, and press the circuit breaker to reset.
Fig. 16
25
USING YOUR GENERATOR
CO SENSOR INFORMATION
The CO Watchdog carbon monoxide monitoring system (Fig.
1
17 - 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.
Fig. 17
Whenever the CO Watchdog system shuts down the generator, the LED on the generator control panel (Fig. 17 - 1) will blink red for at least 5 minutes after the generator is shut down. If you notice that the LED is blinking red, vacate the area immediately. Go to an open, outdoor area. Ventilate the area around the generator thoroughly before returning. Let the generator stay shut down for a few minutes before restarting the engine. This should allow carbon monoxide to dissipate from the area. If you restart the generator and the CO Watchdog detects that CO levels are still too high, it will shut down the generator again. If CO levels are low enough, the generator will run normally.
NOTE: if the generator is oriented so that the engine exhaust is blown towards the CO sensor, the generator may shut down.
Ensure that the generator is located in an open outdoor area, with the exhaust pointing away from occupied structures, and pointing away from the prevailing winds, such that those winds do not blow engine exhaust towards the sensor module. If anyone experiences dizziness, headaches, nausea, fatigue, or other symptoms of CO poisoning, get to fresh air immediately and seek the attention of a qualified medical professional. Follow all other directions in this manual regarding the connection and disconnection of electrical devices when starting or shutting down the generator.
When starting the generator, the CO Watchdog LED on the panel may flash. This indicates that the system is running a self-test procedure, and does not indicate a problem.
If the CO Watchdog LED on the panel is yellow, a system error has occurred, or the CO sensor has reached the end of its life. Contact WEN customer service (1-800-232-1195, M F 8 5 CST, or techsupport@wenproducts.com) for assistance.
When operating your generator, please note the following:
· The CO Watchdog does not discriminate in its input; any source of carbon monoxide in the area around the generator could cause it to activate. If the CO Watchdog LED is blinking red, safety measures should be taken immediately.
· Tampering with, disconnecting, or bypassing the CO sensor could cause hazardous conditions, including but not necessarily limited to injury or death, and will void your warranty. The generator will not run with the CO sensor disconnected or bypassed, or if the CO sensor indicates an error.
· The CO sensor has a lifetime of about 7 years, and is capable of monitoring its lifetime. If your generator shows an error light several years after purchase, it may be time to replace the CO sensor. Contact WEN customer service for assistance.
26
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.
SESSION NUMBER 1 2 3 4
5
SESSION LENGTH 1 hr 30 min 30 min 1 hr 3 hr
2 hr
HOUR METER AT END OF SESSION
1.5 0.5 1
3
5
DOES THE METER RESET?
COMMENTS
Yes, to 0.0 Yes, to 0.0 Yes, to 0.0
No No
Meter will show "1.5" just before it is shut off, but it has not been run for 2 hours at a time yet.
Meter will show "0.5" just before it is shut off, but it has not been run for 2 hours at a time yet.
Meter will show "1.0" just before it is shut off, but it has not been run for 2 hours at a time yet.
Meter will show "3.0" at the end, since it has been run for more than 2 hours. It will not include the 3 hours (1.5 + 0.5 + 1) the generator was run before.
Meter will show "5.0" at the end, since it has been run for 3 + 2 = 5 hours. The meter is counting normally, and will continue operating normally.
Every 50 hours, the meter will display "]--[", which is to remind you to perform 50-hour maintenance. Consult the maintenance chart for recommended procedures. The display code will appear every 15 seconds for 6 minutes. After 6 minutes, or after the generator is shut down and restarted, the code will clear and display voltage, frequency, and runtime, as before.
27
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 4000W 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.
1. Turn off all electrical devices prior to unplugging them from the generator. Unplugging running devices can cause damage to the generator.
Fig. 18
2. Allow generator to run at no load for a few minutes to stabilize internal temperatures.
3. Turn the engine switch to the "AUTO OFF" position (Fig. 18).
4. The engine will continue to run until the majority of the fuel in the carburetor is consumed. It will then shut off 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, and other maintenance issues. If this approach is frequently taken, make sure to drain your carburetor before any long storage periods.
1. Turn off all electrical devices prior to unplugging them from the generator. Unplugging running devices can cause damage to the generator.
2. Press the "MANUAL SHUTOFF" switch and hold it down in the "OFF" position for about 6 seconds until the engine shuts off.
WARNING! Allow the generator to cool down before touching areas that become hot during use.
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."
28
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.
If there are any questions about the maintenance procedures listed in this manual, please call 1-(800) 232-1195 M-F 8-5 CST or email techsupport@wenproducts.com.
Recommended Maintenance Schedule
Every 8 Hours or
Daily
Every 25 Hours
Engine Oil
Check Level Replace
x
x*
Air Filter
Check Clean
Check/Clean/
Spark Plug
Regap
Change
Fuel
Check Level
x
Drain
Carburetor
Drain
x
Spark Arrestor
Check/Clean
* Clean/change more often under dusty conditions or operating under heavy load.
Every 3 Every 6 Months or Months or 50 Hours 100 Hours
Before Storage
As Necessary
x x* x*
x
x
x
x
x
x
x
Table 4 - Recommended Maintenance Schedule
IMPORTANT GENERATOR MAINTENANCE TIPS: · Drain your carburetor after each use and before storage to prevent it from clogging. · Do not store the generator with fuel inside the tank for more than 2 months - the fuel will go bad. · Run the generator for at least 20 minutes every month to charge the battery and maximize lifespan.
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.
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.
NOTE: Failure to properly maintain the generator will void the warranty. 29
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.
WARNING! 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.
CHECKING / ADDING OIL
Check the oil level before each use and every 8 hours of operation (refer to Table 4). The oil capacity of the generator engine is 18.6 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 a with low-oil 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 access cover from the front panel. Clean around the oil fill. Remove the dipstick and wipe it with a clean rag.
Fig. 19
3. Insert the dipstick into the oil fill opening without screwing in. Remove the dipstick to check the oil mark (Fig. 19). 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 the step above until the oil mark reaches the top of the dipstick (you can see oil coming up the threads of the oil fill). Do not over fill.
5. Reinstall dipstick and wipe clean any spilled oil with a rag. Reinstall the oil access cover.
Upper Limit Lower Limit
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 your generator's oil pan to help preserve the engine and extend your generator's lifespan.
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 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.
1
Fig. 20
2. Make sure that the 3-in-1 dial switch to turned to "AUTO OFF". At this position, the fuel valve is turned OFF so that only the fuel left inside the carburetor will be drained out.
3. 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.
4. The carburetor can be accessed between the engine and the air filter (Fig. 20). Locate the transparent tube from the carburetor (Fig. 21) that extends down through the base plate of the generator.
Carburetor
5. Prepare an approved gasoline-storage container and direct the end of the drain tube into the container.
6. Open up the carburetor drain screw (Fig. 21) with a flat-head screwdriver and drain out any gasoline that has built up inside the carburetor through the drain tube into the approved gasoline-storage container.
Fig. 21
7. Once the fuel has drained, tighten the drain screw with the screwdriver.
NOTE: Make sure to drain your carburetor before storing the generator for long periods of time.
Drain Tube
Carburetor Drain Screw
8. Reinstall the service panel.
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:
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.
2. Take the cover off of the air cleaner (Fig. 22). Remove the sponge-like air filter element from the casing. Wipe excessive oil and any dirt from inside of the air filter casing.
Air Cleaner Cover
Fig. 22
3. Check and clean the foam air filter element. Good elements can be washed in soapy water. Dry the element in clean cloth (do not twist it). Add a few drops of engine oil to the air filter element and spread it evenly.
If the air filter element has been damaged, replace it with a new one. Replacement air filters 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 operation. The spark arrester is located outside the muffler, which gets very hot during operation. Allow the engine to cool completely before servicing the spark arrester. To inspect and clean the spark arrester:
1. Remove the two Phillips-head screws that secure the spark arrestor to the muffler (Fig. 23).
Fig. 23
2. Remove the spark arrestor screen.
3. Carefully clean and remove the carbon deposits from the spark arrestor screen with a wire brush. Replace the spark arrestor if it is damaged (replacement spark arrestors can be purchased from wenproducts.com by searching the part no. 56380i-1115).
4. Reinstall the spark arrestor in the muffler and secure it in place with the screws.
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:
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.
Spark Plug Boot
Fig. 24
2. Gently pull on the spark plug boot (Fig. 24) to remove it. Be careful not to tear any insulation or wire.
Cylinder Assembly
3. Use the included spark plug wrench to unscrew and then carefully remove the spark plug from the engine (Fig. 25).
TIP: There is limited space for the wrench to turn. Use both rows of holes in the spark plug wrench to gain leverage to loosen the plug.
Fig. 25
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.
Spark Plug Handle
Spark Plug Wrench
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.
Fig. 26
6. Measure the plug gap with a spark plug gap gauge. The gap should be 0.7 - 0.8 mm (0.028 - 0.031 in) (Fig. 26). Carefully adjust the gap if necessary.
0.7 mm - 0.8 mm
7. Screw the spark plug back into the spark plug hole using the spark plug wrench. Do not over-tighten spark plug. Recommended tightening of spark plug is ½ to ¾ of a turn (15 ft-lb torque/20.33 Nm) after spark plug gasket contacts spark plug hole.
8. Reinstall the spark plug boot, spark plug rubber cover, and service panel.
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.
To change engine oil:
1. With the help of another person, place the generator on an elevated platform such as table or workbench.
Fig. 27
NOTE: To avoid possible gasoline spills from the carburetor bowl, drain the carburetor before draining oil.
2. Turn the oil access cover knob to the unlocked position, and remove the cover from the side panel.
3. Prepare an approved oil-storage container and place it below the oil drainage valve (Fig. 27) 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.
Oil Drainage Valve
Oil Fill
5. Close the oil drainage valve after the oil has drained.
NOTE: Never dispose of used engine oil in the trash or down a drain. Please call a local recycling center or auto garage to arrange proper oil disposal.
6. Unscrew the oil dipstick. Using a funnel or appropriate dispenser, add 18.6 oz. of clean engine oil into the oil fill until you can see oil coming up the threads of the oil fill. Do not over fill.
7. Reinstall the oil dipstick and tighten it securely. Wipe clean any oil spillage and reinstall the oil access cover.
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:
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).
Fig. 28
2. Locate the carburetor and the transparent drain tube that extends down through the base plate of the generator (Fig. 28).
3. Prepare an approved gasoline-storage container and direct the end of the transparent tube into the container.
Drain Tube
Carburetor Drain Screw
4. Remove the fuel cap. Turn the 3-in-1 dial switch to the "RUN" position (Fig. 29). This will open up the fuel valve.
5. Open up the carburetor drain screw (Fig. 28) with a flathead screwdriver. Fuel will start draining from the carburetor and fuel tank through the drain tube.
Fig. 29
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-1 switch to "OFF" position. Tighten the drain screw with the screwdriver and reinstall the service panel.
7. Start and run the generator until the fuel runs out.
8. Store the emptied gasoline in a suitable place. DO NOT store flammable materials near the gasoline.
CAUTION: Store the emptied gasoline in a suitable place. Never store fuel for more than 2 months.
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 using the electric start button during your next time of need. If the battery is out of charge, you may start the generator using the recoil starter. If the generator is not used for a long period, it is recommended to disconnect the negative (black) battery cable from the battery to protect it from losing charge. After disconnecting the cable, cover the free end with an insulator such as electrical tape.
TIP: You can also connect the battery to an automatic trickle charger to keep the battery charged. If using a tricklecharger, charge the battery at room temperature.
Lithium-ion batteries can be damaged or suffer a shortened lifespan if they are charged in very cold temperatures (below freezing). If you expect to store the generator in temperatures below 25°F (-5°C), we recommend removing the battery from the generator and storing it indoors. If using the generator in temperatures below 25°F (-5°C), we recommend running the generator for at least 15 minutes with the battery removed, or the negative (black) battery cable disconnected 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.
WARNING! It is best to store the battery indoors at room temperature. Do not store your battery outside in the winter, where temperatures may go below 25°F (-5°C), or in any location where temperatures may exceed 104°F (40°C), such as in direct sunlight or inside a vehicle or metal building during the summer.
To reinstall/replace the battery: 1. Using a quarter coin or flat-head screwdriver (not included), open and remove the battery access cover (Fig. 30).
2. Loosen the rubber belt and pull out the battery (Fig. 30).
3. Disconnect negative (-) battery terminal first (black cable).
4. Disconnect positive (+) battery terminal second (red cable).
5. Replace with an identical new battery (part no. 56380i1304).
6. Connect the positive (+) battery terminal (red cable) first. Slide rubber boot over the positive terminal (Fig. 31).
7. Connect the negative (-) battery terminal (black cable) second. Slide rubber boot over the negative terminal (Fig. 31).
8. Return the battery into position and use the rubber belt to fasten the battery.
9. Reinstall and secure the battery access cover.
NOTE: Always recycle used batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. 36
Rubber Belt
Fig. 30 Battery Access Cover
Fig. 31
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. If the generator is left in an enclosed vehicle for many hours, the high temperature could cause the fuel to vaporize and result in a possible explosion.
STORING THE GENERATOR
Shut off the generator and allow the unit to cool to room temperature before storing it. NEVER place any type of storage cover on the generator while it is still hot. Do not obstruct any ventilation openings.
Follow the procedures below for properly storing your generator. We highly recommend running your generator once a month for 20 to 30 minutes. Plug in a small load in to ensure there is proper power output.
For Short Periods (30 to 60 Days): · Drain the carburetor. Refer to page 29, "Draining the Carburetor."
· Disconnect the negative lead from the battery.
· Add fuel stabilizer: Follow the suggested portions and instructions of your preferred stabilizer. Run the engine for 15 to 20 minutes, allowing the fuel stabilizer to mix with the gasoline and circulate through the carburetor, and then top off with fuel. 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): · Disconnect the negative lead from the battery.
· Drain the fuel tank and carburetor (see "Draining the Fuel Tank"). Never store generator with fuel in the tank for more than two months.
· Change the engine oil (see "CHANGING OIL").
WARNING! Store the generator upright in a cool and dry location, away from sources of heat, open flames, sparks or pilot lights.
PRODUCT DISPOSAL
Do not dispose of a used generator or parts with your household waste. This product contains electrical or electronic components that should be recycled. Please take this product to your local recycling facility for responsible disposal to minimize its environmental impact.
Do not dispose of used oil or fuel in the trash or down a drain. Please contact your local recycling center or auto garage to arrange proper oil/fuel disposal.
Please recycle the packaging and electronic components where facilities exist. Please contact your local auto garage or recycling facility to properly dispose of oil/fuel.
37
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. Battery is out of power Oil is low.
Set 3-in-1 to ON. Electric start will not work if battery is out of power. Start generator using the recoil start to charge the battery. Add or replace oil.
Battery is too cold
Store the generator in a warmer location.
Engine will not start.
Engine is out of fuel. Engine is filled with contaminated or old fuel. Spark plug is dirty or broken.
Add fuel. Drain fuel in the tank. Fill with fresh fuel. Clean or replace the spark plug.
Carburetor is air locked.
Turn the 3-in-1 switch to OFF. Remove bolt from bottom of the carburetor. Take off the carburetor bowl to allow it to reset. Replace carburetor bowl and reinstall the bolt.
Ghost in the generator.
Persuade ghost to leave.
Engine runs but there is no
electrical output.
Reset button is tripped due to wattage overload.
Bad connecting cords/wires. Bad electrical device connected to the generator.
Turn off and all unplug electrical devices. Wait 3 minutes, then press the activated reset button to reset. Check the total wattage of the devices and reduce the load if it exceeds the capacity of the generator.
Check power cords & extension cords. Do not use if any cord is damaged. Replace damaged cords immediately.
Try connecting a different device.
AC or DC receptacles are overGenerator runs but loaded, circuit breaker tripped does not support all
electrical devices Short circuit in one of the de-
connected.
vices.
Air filter is dirty.
Turn off and unplug the electrical devices. Wait 3 minutes, then press the circuit breaker to reset. Check the amperage of the devices to make sure they are within the capacity of the receptacles.
Disconnect any faulty or short-circuited electrical loads.
Clean or replace the air filter element.
Engine is "Hunting" during
operation (Engine RPM is
fluctuating).
1. The fuel isn't running through the fuel valve. 2. The air filter is clogged. 3. The muffler or spark arrester is blocked 4. There is gunk in the carburetor preventing a consistent fuel/ air mixture.
Turn off the generator and wait for it to cool down. Perform the following steps: 1. Check if the fuel is properly and consistently going through the fuel valve 2. Check for any blockage in the air filter. Check and clean the air filter as necessary. 3. Check if the spark arrester is blocked. Clean with metal brush as necessary. 4. Use "gunk remover" spray on the carburetor jets.
38
WIRE DIAGRAM
39
EXPLODED VIEW & PARTS LIST
Fig. 1 - Crankcase Assembly
No.
Part No.
Description Qty.
1-1 56380i-0101
Crankcase Subassembly
1
1-2 56380i-0102
Flat Washer
1
1-3
56380i-0103
Connector, Oil Drain Hose
1
1-4 56380i-0104
Oil Drain Hose
1
1-5 56380i-0105
Trigger
1
1-6 56310i-1106
Bolt
2
1-7
56380i-0107
Crankcase Side Shield
1
1-8 56310i-1201
Bolt
3
1-9
56310i-0211 Engine 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 56400iX-0117
Bolt
2
1-18 56380i-0118
Oil Dipstick
1
1-21 56380i-0117
Bolt
3
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-0203
Ball Bearing
1
2-4 56380i-0204 Gasket, Crankcase 1
2-5 56310i-0306
Seal, Oil
1
2-6 56310i-0307
Bolt
6
40
EXPLODED VIEW & PARTS LIST
Fig. 3 - Cylinder Head Assembly
No. Part No.
Description Qty.
No. Part No.
Description Qty.
3-1
56200-1202
Bolt
4
3-2
56380i-0302
Cylinder Head Cover Subassembly
1
3-3
56380i-0303
Cylinder Head Cover Gasket
1
3-4 56310i-0104
Spark Plug
1
3-5 56310i-0106 Cylinder Head Bolt 4
3-6 56380i-0306
Breather Tube
1
3-7 56380i-0307
Cylinder Head Subassembly
1
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
3-16 56400iX-0316
Pipe Clamp
1
Fig. 4 - Crankshaft Assembly
No. Part No.
Description Qty.
4-1 56380i-0401 Crankshaft Assembly 1
41
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
Fig. 7 - Recoil Starter
No. Part No.
Description Qty.
7-1
56380i-0701
Recoil Starter and Shroud Assembly
1
7-2 56200-1202
Bolt
4
7-3 56200-0706
Bolt
4
7-4 56400iX-0704
Starter Pulley
1
7-5 56200-0420
Handle
1
7-6 56400iX-0702
Clamp
1
7-7 56380i-0707
Shroud
1
7-8 56380i-0708
Recoil Starter Assembly
1
7-9 56400iX-0702
Pipe Clamp
1
42
Fig. 6 - Valve Train & Camshaft Subassembly
No.
Part No.
Description Qty.
6-1 56380i-0601B
Camshaft Assembly
1
6-2
56380i-0602
Valve Set
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 Assembly
2
6-9
56380i-0609 Valve Rocker Arm 2
6-10 56380i-0610
Rocker Shaft
2
6-12 56380i-0602.1 Exhaust Valve
1
6-11 56380i-0602.2
Intake Valve
1
EXPLODED VIEW & PARTS LIST
Fig. 8 - Carburetor Assembly
No.
Part No.
Description Qty.
8-1
56380i-0801
Carburetor Insulator Gasket
1
8-2
56380i-0802
Carburetor Insulator Plate
1
8-3 56380i-0803 Carburetor Gasket 1
8-4 56380i-0804
Carburetor Assembly
1
8-5 56200-1305
Fuel Strainer
1
8-6 56380i-0805
Clamp
1
8-7 56380i-0806
Fuel Tube
1
8-8 56380i-0805
Clamp
1
8-9 56400iX-0809 Rubber Jacket 1
Fig. 9 - Rotor/Stator Assembly
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 56400iX-0905
Stator
1
9-6
56380i-0906
Flat Washer
3
9-7
56380i-0907
Wiring Clamp
1
9-8
56310i-0207
Bolt
2
9-9 56400iX-0909
Tension Disc
1
9-10 56400iX-0910
Nut
2
Fig. 10 - Air Filter Assembly
No.
Part No.
Description Qty.
10-1 56380i-1001B Air Filter Assembly 1
10-2 56380i-1002
Intake Tube
1
10-3 56380i-1003 Intake Tube Clamp 2
10-4 56310i-1420
Bolt
2
10-5 56400iX-1005 Secondary Air Filter 1
10-6
56200-0506
Nut
2
10-7
56310i-0901
Air Filter Gasket
1
43
EXPLODED VIEW & PARTS LIST
No. 11-1 11-2 11-3 11-4 11-5 11-6 11-7 11-8 11-9 11-10 11-11 11-12
Fig. 11 - Muffler Assembly
Part No.
Description
Qty.
56380i-1101
Shroud
1
56380i-1102B
Muffler Outer Cover Support
1
56380i-1103
Impeller
1
56380i-1105
Muffler Assembly
1
56380i-1106
Muffler Gasket
1
56310i-1010
Nut
2
56380i-1108
Muffler Bracket
1
56310i-1009
Bolt
5
56310i-1004
Bolt
1
56380i-1112
Bolt
1
56200-0508
Bolt
3
56380i-1114
Bolt
1
44
EXPLODED VIEW & PARTS LIST
Fig. 12 - Fuel Tank Assembly
No. Part No.
Description Qty.
12-1 56380i-1201 Fuel Tank Assembly 1
12-2 56380i-1202
Fuel Gauge
1
12-3 56380i-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
12-14 56400iX-1214 Rubber Jacket
1
45
EXPLODED VIEW & PARTS LIST
No.
13-1 13-2 13-3 13-4 13-5 13-6
13-7 13-8 13-9 13-10 13-11 13-12 13-13
13-14
13-15
13-16
Fig. 13 - Frame
Part No.
Description Qty.
56400iX-1301
Engine Frame Assembly
1
56380i-1302 Battery Case
1
56380i-1303
Bolt
3
56380i-1304
Battery
1
56380i-1305 Battery Bracket 1
56380i-1306B
Anode Wire (Negative)
1
56380i-1307
Cathode Wire (Positive)
1
56310i-1420
Bolt
3
56310i-1421 Rubber Jacket 3
56310i-1419
Bushing
3
56380i-1311
Inverter
1
56310i-1425
Bolt
1
56380i-1313 Rubber Sleeve 1
56380i-1314
Carbon Tank Mounting Bracket
1
No.
13-17
13-18
13-19 13-20 13-21 13-22 13-23 13-24 13-25
13-26
13-27 13-28 13-29 13-30 13-31 13-32
56380i-1315 Carbon Tank
1
56380i-1316
Carbon Tank Hose, Primary
1
Part No.
Description Qty.
56380i-1317B Air Filter Hose 1
56380i-1318
Carbon Tank Hose, Secondary
1
56380i-1319
Clamp
2
56380i-1320
Clamp
1
56380i-1321
Clamp
1
56310i-1009
Bolt
2
56380i-1323 Front Handle 1
56380i-1324
Handle
1
56380i-1325
Bolt
2
56310i-1415
Screw
1
56380i-1327 Grounding Wire 1
GN625iX-1430 CO Sensor
1
56400iX-1329 Pan Head Screw 2
56400iX-1330 Mounting Bracket 1
56400iX-1331
Bolt
1
56400iX-1332 Flat Washer
1
46
EXPLODED VIEW & PARTS LIST
No. 14-1 14-2 14-3 14-4 14-5 14-6 14-7
14-8
14-9 14-10 14-11
14-12
14-13 14-14 14-15 14-16 14-17 14-18 14-19
Fig. 14 - Control Panel Assembly
Part No.
Description Qty.
56200-0615
Screw
3
56380i-1402 Switch Subassembly 1
56200-0621B
Cover Plate
1
56200-0624B Adjustment Spring 1
56200-0623
Steel Ball
1
56200-0502
Bolt
1
56200-0628 Fuel Cock Assembly 1
56310i-1628B
Choke Handle Subassembly
1
56380i-1409
Bolt
6
56380i-1410
Panel Seat
1
90255-0512-53 Screw and Washer 6
56400iX-1412
Control Panel Subassembly
1
56200-0514
Screw
1
56380i-1414
Knob
1
56200-0425C
Bolt
1
56200-0427B
Nylon Nut
1
56380i-1417
Blocker
1
56380i-1418
Battery Cover
1
56380i-1419
Multimeter
1
No. 14-20 14-21 14-22 14-23
Part No. 56380i-1420 56380i-1421 56380i-1422 56380i-1423
14-24 56380i-1424
14-25 14-26 14-27 14-28 14-29 14-30 14-31 14-32 14-33 14-34 14-35 14-36 14-37
56380i-1425 56380i-1426 56380i-1427 56380i-1428 56380i-1429 56380i-1430 56380i-1431 56380i-1432 56380i-1433 56380i-1434 56380i-1435 56400iX-1436 GN625iX-1528
14-42 56400iX-1442
Description Qty.
Reset Button
1
NEMA 5-20R Duplex Outlet
1
Switch Subassembly 1
Parallel Port, Negative
1
Parallel Port, Positive
1
12V DC Outlet
1
USB Outlet
1
Grounding Nut
1
NEMA TT-30R Outlet 1
DC Breaker, 10A
1
AC Breaker, 20A
1
Switch Subassembly 1
Rectifier Bridge
1
Clamp
1
Fuel Tube
1
Clamp
1
Indicator
1
CO Sensor Module 1
Control Panel Harness
1
47
EXPLODED VIEW & PARTS LIST
Fig. 15 - Handle
No. Part No.
Description Qty.
No. Part No.
Description Qty.
15-1 56380i-1501
Handle Tube
1
15-2 56380i-1502 Left Rotation Arm 1
15-3 56380i-1503 Right Rotation Arm 1
15-4 56380i-1504
Left Handle Connector
1
15-5 56380i-1505
Right Handle Connector
1
15-6 56380i-1506B
Left Handle Connector Seat
1
15-7 56380i-1507B
Right Handle Connector Seat
1
15-8 56200-0517
Bolt
2
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
48
EXPLODED VIEW & PARTS LIST
Fig. 16 - Side Covers
No. Part No.
Description Qty.
No. Part No.
Description Qty.
16-1 56380i-1601
Left Cover
1
16-2 56200-0406
Bolt
4
16-3 56380i-1603
Left Shell
1
16-4 56380i-1604
Right Shell
1
16-5 56380i-1605
Right Cover
1
16-6 56200-0408
Nut
8
16-7 56380i-1607
Bolt
8
16-8
56200-0515
Fuel Tank Rubber Sleeve
4
16-9 56200-0508
Bolt
8
16-10
56380i-1610
Recoil Starter Guide Subassembly
1
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
Spark Plug Access Door Knob
1
16-15
56380i-1615
Maintenance Door Lock
1
16-16 56400iX-1616
Spring Clamp
1
16-17 56380i-1617
Wheel
2
16-18 56380i-1618
Wheel Axel
2
16-19 56380i-1619
Nut
16
49
EXPLODED VIEW & PARTS LIST
No. 17-1
17-2
17-3 17-4 17-5 17-6 17-7 17-8 17-9 17-10 17-11
17-12
17-13
17-14 17-15
17-16
17-17 17-18
Fig. 17 - Baseplate
Part No.
Description Qty.
56380i-1701
Baseplate
1
56380i-1702
Engine Frame Damper Seat
4
56310i-0209
Bolt
4
56200-0505
Nut
4
56380i-1705 Reinforcement Plate 1
56200-0508
Bolt
2
56310i-1407
Cover Plug
1
56380i-1708
Nut
4
56380i-1709
Cushion
1
56380i-1710
Left Support
1
56380i-1711
Right Support
1
56310i-1409
Left Engine Frame Damper
2
56310i-1411
Right Engine Frame Damper
2
56310i-1412
Bolt
4
56310i-1404
Nut
10
56380i-1716
Crankcase Airflow Manifold
1
56380i-1717 Air Filter Support
1
56200-0508
Bolt
2
Fig. 18 - Muffler Cover
No. Part No.
Description Qty.
18-1 56380i-1801 Outer Muffler Cover 1
18-2 56380i-1802
Bolt
6
18-3 56380i-1803
Heat Insulator
1
18-4 56380i-1804 Inner Muffler Cover 1
18-5 56200-0406
Bolt
6
NOTE: Replacement parts can be purchased from wenproducts.com, or by calling our customer service at (800) 232-1195, M-F 8-5 CST. Parts and accessories that wear down over the course of normal use are not covered by the two-year warranty.
50
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. Ninety days for all WEN products if the tool is used for professional or commercial use. Purchaser has 30 days from the date of purchase to report missing or damaged parts. Parts and labor are covered for one (1) year under this limited warranty; parts only are covered for three (3) years under this limited warranty.
SELLER'S SOLE OBLIGATION AND YOUR EXCLUSIVE REMEDY under this Limited Warranty and, to the extent permitted by law, any warranty or condition implied by law, shall be the replacement of parts, without charge, which are defective in material or workmanship and which have not been subjected to misuse, alteration, careless handling, misrepair, abuse, neglect, normal wear and tear, improper maintenance, improper storage, incorrect lubricants / fuels, or other conditions adversely affecting the Product or the component of the Product, whether by accident or intentionally, by persons other than Seller. 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 Purchase must be a direct vendor of Great Lakes Technologies, LLC. Purchasing through third party vendors, including but not limited to garage sales, pawn shops, resale shops, or any other secondhand merchant, voids the warranty included with this product. 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.
Upon the confirmation of a WEN representative, your product may qualify for repairs and service work. When returning 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 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 for addresses within the contiguous United States.
HIS LIMITED WARRANTY DOES NOT APPLY TO ITEMS THAT WEAR OUT FROM REGULAR USAGE OVER TIME, INCLUDING FILTERS, SPARK PLUGS, VOLTAGE REGULATORS, BRUSHES, GASKETS, O-RINGS, WHEEL KITS, BATTERIES, RECOIL STARTERS, HIGH PRESSURE HOSES, SPRAY GUNS, ETC. ANY IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO THREE (3) YEARS FROM DATE OF PURCHASE. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING BUT NOT LIMITED TO LIABILITY FOR LOSS OF PROFITS) ARISING FROM THE SALE OR USE OF THIS PRODUCT. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE IN THE U.S., PROVINCE TO PROVINCE IN CANADA AND FROM COUNTRY TO COUNTRY.
THIS LIMITED WARRANTY APPLIES ONLY TO ITEMS SOLD WITHIN THE UNITED STATES OF AMERICA, CANADA AND THE COMMONWEALTH OF PUERTO RICO. FOR WARRANTY COVERAGE WITHIN OTHER COUNTRIES, CONTACT THE WEN CUSTOMER SUPPORT LINE. FOR WARRANTY PARTS OR PRODUCTS REPAIRED UNDER WARRANTY SHIPPING TO ADDRESSES OUTSIDE OF THE CONTIGUOUS UNITED STATES, ADDITIONAL SHIPPING CHARGES MAY APPLY.
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THANKS FOR REMEMBERING
V. 2021.07.27