Wen 56400M Instruction Manual
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Wen 56400M Instruction Manual

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

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Summary of Contents for Wen 56400M

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

  • Page 2: Table Of Contents

    CONTENTS WELCOME Specifications ....................3 Introduction ..................... 4 SAFETY Safety Information ................... 5 Generator Safety Warnings ................6 BEFORE OPERATING Unpacking & Packing List ................9 Assembly & Adjustments ................10 Know Your Generator ..................12 Generator Preparation ..................14 OPERATION &...

  • Page 3: Welcome

    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.

  • Page 4: Introduction

    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 as- sistance for information or service is required, please contact customer service by calling 1-800-232-1195, M-F 8-5 CST;...

  • Page 5: Safety

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

  • Page 6: Generator Safety Warnings

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

  • Page 9: Before Operating

    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. Your WEN generator comes with two high altitude kits. See page 11. PACKING LIST Components...

  • Page 10: Assembly & Adjustments

    ASSEMBLY & ADJUSTMENTS Fig. 1 WARNING! Do not plug in or turn on the tool until it is fully assembled according to the instructions. Read Small Washer through and become familiarized with the following procedures of handling and adjusting your tool. Failure to follow the safety instructions may result in serious Axle Assembly personal injury.
  • Page 11 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 Bolt place on the generator frame and align the holes on the legs with the holes on the frame (Fig.

  • Page 12: Know Your Generator

    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...
  • Page 13 KNOW YOUR GENERATOR CONTROL PANEL CIRCUIT CIRCUIT BREAKER BREAKER AC 120V/240V NEMA L14-30R POWER INDICATOR POWER AC 120V 5-20R INDICATOR VOLTAGE SELECTOR POWER INDICATOR VOLTMETER GROUND FLOATING NEUTRAL 1. AC 120V NEMA 5-20R Duplex Receptacles (20A) 5. Voltmeter Standard household outlets provide 120V 60Hz Indicates the voltage the generator is currently power.

  • Page 14: Generator Preparation

    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.
  • Page 15 (or when you can see the oil coming halfway up the oil fill threads). See Fig. 10. TIP: Your WEN generator is compatible with the OIL LEVEL SHUTDOWN WEN 55201 Magnetic Oil Dipstick (not included), To protect the unit from damage, the generator is equipped available for purchase at wenproducts.com.
  • Page 16 GENERATOR PREPARATION TO ADD GASOLINE: Fuel Cap Fig. 11 1. Place the generator on a level surface. Make sure the engine is OFF before adding or checking the fuel. 2. Unscrew the fuel cap (Fig. 11) and set it aside. The fuel cap may be tight and hard to unscrew.

  • Page 17: Operation & Maintenance

    STARTING YOUR GENERATOR Before starting the generator, make sure you have read and performed the steps in the “Generator Preparation” section of this manual, 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.
  • Page 18 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.

  • Page 19: Using Your Generator

    USING YOUR GENERATOR CALCULATING THE WATTAGE OF YOUR DEVICE(S) Connect electrical devices running on AC current according to their wattage requirements. Calculate the total run- ning wattage and starting wattage of the device(s) you wish to connect, and MAKE SURE that they are within the capacity of your generator and the capacity of each individual outlet.
  • Page 20 USING YOUR GENERATOR CALCULATING THE WATTAGE OF YOUR DEVICE(S) - CONTINUED The chart below serves as a reference for the estimated wattage requirements of common electrical devices. How- ever, do not solely rely on this chart - all electronics and appliances are built differently. Always check the wattage listed on the electrical device before consulting this chart.
  • Page 21 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.

  • Page 22: Shutting Off Your Generator

    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 gen- erator in the future.

  • Page 23: Maintenance

    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.
  • Page 24 To check the oil level and/or add oil refer to "Step 1 - Add/Check Oil" on page 14. 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 tank to help preserve the engine and extend your generator’s lifespan.
  • Page 25 Damaged elements should be replaced with a new Cover one. Replacement air filters can be purchased from wen- Lock products.com by searching part number P54178-1. 4. Reinstall the air filter element and air filter cover.
  • Page 26 MAINTENANCE INSPECTING/CLEANING THE SPARK ARRESTOR Fig. 18 Inspect and clean the spark arrestor every 100 hours of operation (refer to page 23, Table 4). The spark arrestor Spark Arrestor Assembly is located outside the muffler, which gets very hot during operation.
  • Page 27 MAINTENANCE 5. Measure the plug gap with a spark plug gap gauge. The Fig. 21 gap should be 0.7 to 0.8 mm (0.028-0.031 in). Carefully adjust the gap if necessary. See Fig. 21. 0.7 - 0.8mm 6. Screw the spark plug back into the spark plug hole us- ing the spark plug wrench.

  • Page 28: Transportation & Storage

    Do not obstruct any ventilation openings. Follow the procedures below for properly storing your generator. TIP: Your WEN generator is compatible We highly recommend running your generator once a month for with the WEN 56406 Medium Generator 20 to 30 minutes.

  • Page 29: Troubleshooting Guide

    TROUBLESHOOTING GUIDE WARNING! Stop using the generator immediately if any of the following problems occur or risk serious personal injury. If you have any questions, please contact customer service at 1-800-232-1195 (M-F 8-5 CST), or email techsupport@wenproducts.com. PROBLEM POSSIBLE CAUSE SOLUTION 1.
  • Page 30 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 1.

  • Page 31: Wiring Diagram

    WIRING DIAGRAM...

  • Page 32: Exploded View & Parts List

    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 &...
  • Page 33 EXPLODED VIEW & PARTS LIST ASSEMBLY 3 - CRANKCASE COVER ASSEMBLY 5 - PISTON RING & CONNECTING ROD Part No. Description Qty. P54105 Piston Ring Assembly P54106 Piston Pin Clip P54109 Piston Part No. Description Qty. P54112 Piston Pin P54075 Crankcase Cover P54121 Connecting Rod...
  • Page 34 EXPLODED VIEW & PARTS LIST ASSEMBLY 7 - VALVE & CAMSHAFT ASSEMBLY 8 - CRANKCASE Part No. Description Qty. P54146 Camshaft Assembly P54150 Exhaust Valve P54152 Intake Valve Part No. Description Qty. P54156 Valve Spring Seat Exhaust Valve Spring P54011 Crankcase P54158 Seat...
  • Page 35 EXPLODED VIEW & PARTS LIST ASSEMBLY 9 - FUEL TANK ASSEMBLY 10 - AIR CLEANER Part No. Description Qty. P54178 Air Cleaner Assembly P54179 Part No. Description Qty. P54178-1 Air Cleaner Element 56400-141 Fuel Tank P56400-142 Cushion ASSEMBLY 11 - HANDLE KIT P56400-143 Fitting Bush P56400-144...
  • Page 36 EXPLODED VIEW & PARTS LIST ASSEMBLY 12 - CONTROL ASSEMBLY 13 - MUFFLER Part No. Description Qty. P54624 Regulating Arm Part No. Description Qty. P54176 Nut, M6 P54401 Muffler Assembly P54622 Lock Bolt P54402 Cover, Outer Muffler P54616 Back Spring P54412 Bracket, Muffler P54620...
  • Page 37 EXPLODED VIEW & PARTS LIST ASSEMBLY 14 - CARBURETOR ASSEMBLY 15 - SHROUD Part No. Description Qty. Part No. Description Qty. P54173 Carburetor Assembly P54668 Fan Hood Assembly P54168 Air Cleaner Gasket P54044 Wind Cover P54166 Carburetor Gasket P54596 Lower Shield Carburetor Insulator P54164 P54612...
  • Page 38 EXPLODED VIEW & PARTS LIST ASSEMBLY 16 - ENGINE FRAME ASSEMBLY 17 - CYLINDER HEAD Part No. Description Qty. P54051 Cylinder Head Gasket Cylinder Head Cover P54066 Assembly Cylinder Head Cover P54064 Gasket P54043 Air Duct P54040 Bolt, M6x12 P54047 Stud P54058 Stud...
  • Page 39 ASSEMBLY 19 - RECOIL STARTER Part No. Description Qty. Recoil Starter P54604 Part No. Description Qty. Assembly P54872-1 Wheel P54598 Bolt, M6x8 P54879 Wheel Shaft P54872-5 Nut, M12-1.25 P54872-3 Washer 56400-1805 Washer P54871 Rubber Foot Assembly P54874 Bolt P54875 56400M-1811 Nut, M10-1.25...

  • Page 40: Warranty Statement

    (2) 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 pro- fessional or commercial use.

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