MODEL 56400M 4050-WATT PORTABLE GENERATOR Instruction Manual EPA III CERTIFIED NEED HELP? CONTACT US! Have product questions? Need technical support? Please feel free to contact us: 1-800-232-1195 (M-F 8AM-5PM CST) TECHSUPPORT@WENPRODUCTS.COM IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest standards for dependability, ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged, trouble-free performance.
CONTENTS WELCOME 3 Specifications.................................................................................................... 3 Introduction...................................................................................................... 4 SAFETY 5 Safety Information............................................................................................ 5 Generator Safety Warnings...............................................................................
SPECIFICATIONS CONTENTS GENERATOR Model Number 56400M Surge (Starting) Wattage 4050 Watts Rated (Running) Wattage 3500 Watts Rated Voltage 120V/240V AC Rated Amperage 29A/14.5A Phase Single Frequency 60Hz Product Weight 111.2 lbs Product Dimensions 24.4 in. × 17.7 in. × 18.5 in. ENGINE Engine Type 4 stroke, OHV, single cylinder with forced air cooling system Engine Displacement 212cc Fuel Tank Capacity 4 US gallons (15 L), 87 octane minimum Oil Capacity 17.0 fl. oz. (0.
INTRODUCTION Thanks for purchasing the WEN 4050-Watt Portable 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.
SAFETY INFORMATION WARNING: Before operating the generator, make sure to read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire or serious injury. SAFETY INTRODUCTION Safety is a combination of common sense, staying alert, and knowing how your tool works. This manual contains important information regarding the generator’s potential safety concerns, as well as preparation, operation, and maintenance instructions.
GENERATOR SAFETY WARNINGS DANGER: CARBON MONOXIDE Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This is a poison gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO. NEVER use a generator inside homes, garages, crawl spaces, or other partially enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
GENERATOR SAFETY WARNINGS WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury. OPERATING ENVIRONMENT 1. Using a generator indoors can kill you in minutes. Only use a generator outside and far away from windows, doors and vents. 2. Do not smoke near the generator. 3.
GENERATOR SAFETY WARNINGS WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury. TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your generator at least once a month for 20 to 30 minutes. Start the generator according to the instructions and plug a small load in to make sure the outlet is producing electricity.
UNPACKING & PACKING LIST UNPACKING With the help of a friend or trustworthy foe, 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.
ASSEMBLY & ADJUSTMENTS WARNING! Do not plug in or turn on the tool until it is fully assembled according to the instructions. Read through and become familiarized with the following procedures of handling and adjusting your tool. Failure to follow the safety instructions may result in serious personal injury. Nut Fig. 1 Small Washer Axle Assembly (2) Large Washer ASSEMBLY All hardware comes pre-assembled with the nuts and washers attached to the proper bolts for the wheels, legs, and handles.
ASSEMBLY & ADJUSTMENTS INSTALLING THE HANDLES Fig. 5 Refer to the packing list on page 9 to gather the proper parts and tools for installing the handles. 1. Remove the nuts from the bolts. Slide the handles into place on the generator frame and align the holes on the legs with the holes on the frame (Fig. 5). Bolt Nut 2. Tighten the nuts onto the bolts using the 10/12mm wrenches (Fig. 5). Ensure the handles can rotate up and down.
KNOW YOUR GENERATOR KNOW YOUR GENERATOR 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 Fuel Cap Fuel Gauge Choke Lever Control Panel Fuel Valve Oil Fill & Dipstick Air Filter Recoil Starter Handles • FUEL GAUGE Indicates amount of fuel inside the fuel tank. E indicates empty, F indicates full.
KNOW YOUR GENERATOR CONTROL PANEL 1 2 CIRCUIT BREAKER 3 4 CIRCUIT BREAKER ON ON OFF OFF AC 120V/240V NEMA L14-30R POWER INDICATOR POWER INDICATOR AC 120V 5-20R VOLTAGE SELECTOR POWER INDICATOR VOLTMETER GROUND FLOATING NEUTRAL 5 6 7 8 1. AC 120V NEMA 5-20R Duplex Receptacles (20A) Standard household outlets provide 120V 60Hz power. 5. Voltmeter Indicates the voltage the generator is currently putting out. 2. Circuit Breakers Push the button to reset the circuit.
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. STEP 1 - ADD/CHECK OIL The generator is shipped without oil. User must add the proper amount of oil before operating the generator for the first time.
GENERATOR PREPARATION TO CHECK OIL LEVEL (before every subsequent start): Fig. 10 1. Place the generator on a level surface. Make sure the engine is OFF before adding or checking oil. 2. Remove and wipe the dipstick with a clean rag. Upper Limit 3. Insert the dipstick into the oil fill without screwing it in. Remove the dipstick to check the oil mark. 4.
GENERATOR PREPARATION TO ADD GASOLINE: Fuel Cap 1. Place the generator on a level surface. Make sure the engine is OFF before adding or checking the fuel. Fig. 11 2. Unscrew the fuel cap (Fig. 11) and set it aside. The fuel cap may be tight and hard to unscrew. 3. Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill. Reinstall fuel cap and wipe clean any spilled gasoline with a dry cloth. NOTE: Do not fill the fuel tank to the very top.
STARTING YOUR GENERATOR Before starting the generator, make sure you have read and performed the steps in the “Generator Preparation” section of this manual, pages 14-16. If you are unsure about how to perform any of the steps in this manual please call 1-800-232-1195 (M-F 8-5 CST) for customer service. DANGER: CARBON MONOXIDE Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This is a poison gas you cannot see or smell.
STARTING YOUR GENERATOR BEFORE STARTING THE GENERATOR 1. Verify that the generator is outside on a dry, level surface. Allow at least two feet of clearance on all sides of the generator. 2. To maximize safety, check that the generator is properly grounded. Refer to "Step 3 - Ground The Generator" on page 16. 3. Check that there is a sufficient level of oil in the crankcase. Add oil if necessary. Refer to "Step 1 - Add/Check Oil" on page 14. 4.
USING YOUR GENERATOR CALCULATING THE WATTAGE OF YOUR DEVICE(S) Connect electrical devices running on AC current according to their wattage requirements. Calculate the total running wattage and starting wattage of the device(s) you wish to connect, and MAKE SURE that they are within the capacity of your generator and the capacity of each individual outlet.
USING YOUR GENERATOR CALCULATING THE WATTAGE OF YOUR DEVICE(S) - CONTINUED The chart below serves as a reference for the estimated wattage requirements of common electrical devices. However, do not solely rely on this chart - all electronics and appliances are built differently. Always check the wattage listed on the electrical device before consulting this chart.
USING YOUR GENERATOR CONNECTING ELECTRICAL DEVICES 1. Before connecting electrical devices, allow the generator to run for a few minutes to stabilize the speed and voltage output. 2. Select the device with the highest wattage, and make sure it is turned off. Plug the device into the matching generator outlet and then turn the device on. Allow the engine to stabilize. 3. Repeat step 2 to plug in each additional device. Do not attempt to plug in or start multiple devices at the same time.
SHUTTING OFF YOUR GENERATOR CAUTION! Unplugging running devices can cause damage to the generator. Never stop the engine with electrical devices connected and running. 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.
MAINTENANCE RECOMMENDED MAINTENANCE SCHEDULE Proper routine maintenance of the generator will help prolong the life of the machine. Please perform maintenance checks and operations according to the maintenance schedule below, Table 4. If there are any questions about the maintenance procedures listed in this manual, please contact customer service at 1-800-232-1195 (M-F 8-5 CST), or email techsupport@wenproducts.com. WARNING! Never perform maintenance operations while the generator is running.
MAINTENANCE CLEANING YOUR GENERATOR Keep the generator clean to prevent improper operation or machine damage from dirt and debris. Inspect all ventilation openings on the generator. These openings must be kept clean and unobstructed. If the generator becomes dirty, use a damp cloth to wipe exterior surfaces. Use a soft bristle brush to loosen dirt and oil and use a vacuum to pick up loose dirt. Use low pressure air (not to exceed 25 PSI) to blow away dirt.
MAINTENANCE DRAINING THE CARBURETOR Fig. 16 Drain the carburetor after every use and before storing the generator (refer to page 23, Table 4). Draining the carburetor can help prevent build-up and blockages caused by stagnant fuel inside of the carburetor. 1. Prepare an approved gasoline-storage container under the carburetor to collect the drained fuel. 2. The carburetor can be accessed from the backside of the generator between the engine and the air filter.
MAINTENANCE INSPECTING/CLEANING THE SPARK ARRESTOR Inspect and clean the spark arrestor every 100 hours of operation (refer to page 23, Table 4). The spark arrestor is located outside the muffler, which gets very hot during operation. Allow the engine to cool completely before servicing the spark arrestor. Fig. 18 Spark Arrestor Assembly 1. Remove the two Phillips-head screws that secure the spark arrestor to the muffler. See Fig. 18. 2. Remove the spark arrestor screen. Muffler 3.
MAINTENANCE 5. Measure the plug gap with a spark plug gap gauge. The gap should be 0.7 to 0.8 mm (0.028-0.031 in). Carefully adjust the gap if necessary. See Fig. 21. Fig. 21 0.7 - 0.8mm 6. Screw the spark plug back into the spark plug hole using the spark plug wrench. Do not over-tighten spark plug. Recommended tightening of the spark plug is ½ to ¾ of a turn (15 ft-lb torque/20.33 Nm) after the spark plug gasket contacts the spark plug hole. 7. Reinstall the spark plug boot over the spark plug.
TRANSPORTATION & STORAGE TRANSPORTING THE GENERATOR To prevent fuel spillage when transporting, be sure to perform the following: 1. Tighten the fuel cap and turn the fuel valve to the OFF position. 2. Flip the engine ON/OFF switch to the OFF position. 3. Drain the fuel tank if possible. Refer to "Draining The Fuel Tank" on page 27. 4. Keep the generator upright.
TROUBLESHOOTING GUIDE WARNING! Stop using the generator immediately if any of the following problems occur or risk serious personal injury. If you have any questions, please contact customer service at 1-800-232-1195 (M-F 8-5 CST), or email techsupport@wenproducts.com. PROBLEM Engine will not start. Engine runs but there is no electrical output. POSSIBLE CAUSE SOLUTION 1. Engine switch is set to OFF. 1. Set engine switch to ON. 2. Fuel valve is turned to OFF. 2. Turn fuel valve to ON. 3.
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 Generator runs but does not support all electrical devices connected. POSSIBLE CAUSE 1. Generator is overloaded. 1. Turn off and unplug all electrical devices. Wait 5 minutes, then press the circuit breaker to reset.
KEY ENGINE SWITCH IG E OFF ON Y Bu Br Y Bu R R Bu W Br W GENERATOR BLOCK Sub-Field Coil Sub-Field Coil Main Coil 2 Main Coil 1 Br Brown Yellow Red AVR Volt-Selector W White LG Light Green Y/G Yellow/Green BL Black Br Bu Blue Y G Green R Y Bu Bu Br Y Y Circuit Breaker Circuit Breaker EL Fuel Sensor Receptacle BL Y Oil Sensor BL Y EL EL Spark Plug Receptacle Ignition Coil BL BL BL G IG E ENGINE BLOCK ENGINE SWITCH WIRING DIAGRAM 31
EXPLODED VIEW & PARTS LIST 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. ASSEMBLY 1 - CONTROL PANEL ASSEMBLY 2 - ROTOR & STRATOR 4 11 12 12 9 13 1 8 14 10 7 5 3 2 Part No. 1 32 11 16 4 13 9 5 13 6 No. 10 1 7 17 8 15 14 6 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 3 - CRANKCASE COVER ASSEMBLY 5 - PISTON RING & CONNECTING ROD 2 3 8 6 5 1 4 5 2 31 5 4 No. Part No. Description Qty. 1 P54075 Crankcase Cover 1 2 P54004 Bearing 1 3 P54088 Oil Seal 1 4 P54080 Crankcase Gasket 1 5 P54082 Pin 2 6 P54086 Oil Dipstick Assembly 1 8 P54092 Bolt, M8x32 6 2 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 7 - VALVE & CAMSHAFT 7 6 ASSEMBLY 8 - CRANKCASE 3 4 5 6 3 16 7 14 15 13 5 1 8 12 10 11 9 4 9 8 2 11 34 No. Part No. Description Qty. 1 P54146 Camshaft Assembly 1 3 P54150 Exhaust Valve 1 4 P54152 Intake Valve 1 5 P54156 Valve Spring Seat 1 6 P54158 Exhaust Valve Spring Seat 1 7 P54160 Cap 1 8 P54161 Seal Guide 1 9 P54142 Tappet 10 P54140 11 1 10 8 9 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 9 - FUEL TANK 12 9 5 4 3 2 5 ASSEMBLY 10 - AIR CLEANER 7 8 10 1 5 5 4 3 2 4 3 2 4 3 2 3 2 1 14 13 15 16 No. Part No. Description Qty. 1 P54178 Air Cleaner Assembly 1 2 P54179 Nut 2 3 P54178-1 Air Cleaner Element 1 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 12 - CONTROL ASSEMBLY 13 - MUFFLER 8 2 6 6 8 1 7 4 10 4 6 3 5 8 5 1 3 2 36 7 No. Part No. Description Qty. 1 P54624 Regulating Arm 1 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 14 - CARBURETOR 5 ASSEMBLY 15 - SHROUD 6 7 1 4 4 3 8 3 6 29 2 28 1 No. Part No. Description Qty. 1 P54173 Carburetor Assembly 1 2 P54168 Air Cleaner Gasket 1 3 P54166 Carburetor Gasket 1 4 P54164 Carburetor Insulator Plate 1 5 P54162 Carburetor Insulator Gasket 1 28 P54388 Fuel Tube 29 P54390 Hose Clamp 5 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 16 - ENGINE FRAME ASSEMBLY 17 - CYLINDER HEAD 13 1 10 14 12 8 11 4 3 56 4 2 4 3 5 4 4 2 5 4 4 4 38 5 5 No. Part No. Description Qty. 1 P54237 Frame 1 2 P54242 Bottom Rubber Damper A 2 3 P54244 Bottom Rubber Damper B 2 4 P54246 Nut, M8 8 5 P54871 Rubber Foot Assembly 4 4 9 7 No. Part No. Description Qty.
EXPLODED VIEW & PARTS LIST ASSEMBLY 18 - WHEEL KIT ASSEMBLY 19 - RECOIL STARTER 1 3 4 5 9 2 11 1 11 10 2 11 12 5 10 6 4 9 3 6 No. Part No. Description Qty. No. Part No. Description Qty. 11 P54604 Recoil Starter Assembly 1 1 P54872-1 Wheel 2 12 P54598 Bolt, M6x8 3 2 P54879 Wheel Shaft 2 3 P54872-5 Nut, M12-1.25 2 4 P54872-3 Washer 2 5 56400-1805 Washer 2 6 P54871 Rubber Foot Assembly 2 9 P54874 Bolt 4 10 P54875 Nut 4 11 56400M-1811 Nut, M10-1.
WARRANTY 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 all WEN consumer power tools will be free from defects in material or workmanship during personal use for a period of two (2) years from date of purchase or 500 hours of use; whichever comes first.