4050-WATT
PORTABLE GENERATOR
Instruction Manual
MODEL 56400M
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.
NEED HELP? CONTACT US!
Have product questions? Need technical support? Please feel free to contact us:
TECHSUPPOR[email protected]1-800-232-1195 (M-F 8AM-5PM CST)
For replacement parts and the most up-to-date instruction manuals, visit WENPRODUCTS.COM
EPA III CERTIFIED
2
CONTENTS
WELCOME 3
Specifications ................................................................................................... 3
Introduction ..................................................................................................... 4
SAFETY 5
Safety Information ........................................................................................... 5
Generator Safety Warnings .............................................................................. 6
BEFORE OPERATING 9
Unpacking & Packing List ................................................................................ 9
Assembly & Adjustments ............................................................................... 10
Know Your Generator ..................................................................................... 12
Generator Preparation .................................................................................... 14
OPERATION & MAINTENANCE 17
Starting Your Generator ................................................................................. 17
Using Your Generator ..................................................................................... 19
Shutting Off Your Generator ........................................................................... 22
Maintenance ................................................................................................... 23
Transportation & Storage ............................................................................... 28
Troubleshooting Guide ................................................................................... 29
Wiring Diagram .............................................................................................. 31
Exploded View & Parts List ............................................................................ 32
Warranty Statement ....................................................................................... 40
To purchase accessories for your tool, visit WENPRODUCTS.COM
Magnetic Oil Dipstick (Model No. 55201), and Generator Cover (Model No. 56406).
CONTENTSSPECIFICATIONS
3
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.
GENERATOR
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. (0.5 L)
Half-Load Run Time 11 hours
Lubrication System Splash
Spark Plug Type NGK BP7ES/Torch F7TC
Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.031 in.)
Spark Plug Torque ½ - ¾ turn after gasket contacts base or 15 ft-lbs
ENGINE
4
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; you will be asked to provide the following generator information when calling.
Generator Model Number: 56400M
Date of Purchase: ______________________________________________
Purchased From: _______________________________________________
Serial Number: ________________________________________________
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.
SERVICE RECORD
Record the service dates of your generator in the chart below. Please perform maintenance checks and operations
according to this manual. Refer to "Maintenance" on page 23.
Service Record Date Date Date Date Date Date
Change Oil
Change Spark Plug
Clean Fuel Tank
Clean Air Cleaner
Clean Spark Arrestor
Serial
Number
5
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.
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 [email protected].
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.
6
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 battery-
backup 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 accor-
dance 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 con-
ductor. 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.
7
GENERATOR SAFETY WARNINGS
OPERATING ENVIRONMENT
1. Using a generator indoors can kill you in minutes.
Only use a generator outside and far away from win-
dows, doors and vents.
2. Do not smoke near the generator.
3. Do not operate near open flame, heat, or flam-
mable materials. This generator may emit highly flam-
mable 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 con-
ditions; doing so significantly increases the risk of
electrical shock. Never handle the generator, electronic
devices, or any cord while standing in water, while bare-
foot, 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 clear-
ance from buildings or other equipment during opera-
tion.
7. Do not allow children or non-qualified persons to
operate the generator.
GENERATOR PREPARATION
1. Always ground the generator before using it to max-
imize 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.
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. Ser-
vice 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.
4. Use a ground fault circuit interrupter (GFCI) in high-
ly conductive areas such as metal decking or steel
work. Extension cords with in-line GFCIs are recom-
mended for these operations to maximize safety.
5. If connecting the generator to a building’s electrical
system for standby power, you MUST consult a quali-
fied 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 per-
sonal injury.
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 volt-
age and frequency requirements of all electrical devices
prior to plugging them into the generator.
Generator safety warnings continue on the next page.
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.
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.
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 recep-
tacles. 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.
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.
8. Turn off all connected electrical devices before
stopping the generator.
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 fur-
naces, water heaters, or any other appliances that pro-
duce heat or have automatic ignitions. Store the genera-
tor and fuel away from sparks, open flames, pilot lights,
heat and other sources of ignition.
12. Always wash hands after handling generator.
CAUTION: Misuse of this generator can damage it or
shorten its lifespan.
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.
Components
9
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 every-
thing 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
UNPACKING & PACKING LIST
Handle Assembly PartsLeg Assembly Parts
Spark Plug Tools
Generator
(1)
L14-30R Plug
(1)
5-20R Plug
(1)
Legs (2)
Hardware (4) Hardware (2)
Handles (2)
Wheel Assembly Parts
Wheels (2)
Wrench (1)Handle (1)Screwdriver (1)
Axles (2)
Assembly Tools
10/12mm
Wrench (2)
14/17mm
Wrench (2)
Your WEN generator comes with two high altitude kits. See page 11.
ASSEMBLY
All hardware comes pre-assembled with the nuts and
washers attached to the proper bolts for the wheels, legs,
and handles. See the packing list on page 9. For video
instructions, visit bit.ly/wheelkit.
INSTALLING THE WHEELS
Refer to the packing list on page 9 to gather the proper
parts and tools for installing the wheels.
1. Prepare a set of blocks on level ground (a 4×4 block of
wood works well). Place the generator on the blocks.
2. Remove both nuts and both washers from each axle as-
sembly (Fig. 1). Set aside.
3. Insert the short side of the axle into the opening on the
generator frame. Tighten the nut onto the axle using the
14/17mm wrenches. See Fig. 2.
4. Slide the large washer onto the body of the axle, then
slide on the wheel and the small washer. Tighten the nut
onto the axle using the 14/17mm wrenches. See Fig. 3. En-
sure the wheel can spin. If it cannot, loosen the nut slightly
until it spins. Repeat steps 3-4 with the second wheel.
INSTALLING THE LEGS
Refer to the packing list on page 9 to gather the proper
parts and tools for installing the legs. NOTE: The hardware
for the legs are the four smaller pre-assemblies. The hard-
ware for the handles is slightly larger.
1. Remove the nuts from the bolts. Slide the legs into place
on the generator frame and align the holes on the legs with
the holes on the frame (Fig. 4).
2. Slide the bolts through the legs and generator frame.
Tighten the nuts onto the bolts using the 10/12mm wrench-
es (Fig. 4).
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.
10
Fig. 4
Leg
Nut
Frame
Axle Assembly
(2)
Fig. 1
Nut
Small Washer
Large Washer
Fig. 2
Nut
Axle - Short Side
Fig. 3
Large Washer
Small Washer Nut
INSTALLING THE HANDLES
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).
2. Tighten the nuts onto the bolts using the 10/12mm
wrenches (Fig. 5). Ensure the handles can rotate up and
down. If they cannot, loosen the nuts slightly until the han-
dles are able to rotate up and down.
HIGH ALTITUDE OPERATION ABOVE 3000 FEET
Refer to Fig. 6 to gather the proper parts and tools for in-
stalling the high altitude kit. Installation instructions are
included with the high altitude kits.
This kit should be installed by a qualified mechanic. Con-
tact customer service at 1-800-232-1195 (M-F 8-5 CST),
or email [email protected] for information
about service centers near you.
The fuel system on this generator may be affected by op-
eration at high altitudes. Proper operation can be ensured
by installing an altitude kit at altitudes higher than 3000
feet above sea level. At elevations above 7000 feet, the en-
gine may experience a decrease in performance, even with
the proper altitude kit. Operating this generator without the
high altitude kit at elevations above 3000 feet may increase
the engine’s emissions and decrease both fuel economy
and performance.
ASSEMBLY & ADJUSTMENTS
11
Fig. 5
Bolt
Nut
Handle
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! UNINSTALL the high altitude kit when
operating at altitudes below 3000 feet.
High Altitude Kit Packing List
Fig. 6
3000 - 6000 ft High Altitude Kit (1) 6000 - 8000 ft High Altitude Kit (1)
Fuel Cup Seal (1)
Bolt Seal (1)
Main Jet (1)
Fuel Cup Seal (1)
Bolt Seal (1)
Main Jet (1)
12
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
Fuel Valve
Choke Lever
Air Filter
Handles
Control
Panel
Oil Fill
& Dipstick
Engine ON/OFF Switch
Recoil
Starter
• FUEL GAUGE
Indicates amount of fuel inside the fuel tank.
E indicates empty, F indicates full.
• CHOKE LEVER
Adjusts the amount of air allowed into the
engine during startup.
• FUEL VALVE
Allows fuel to enter the engine from the fuel
tank.
• AIR FILTER
A case with a sponge-like element that filters
the air entering the engine.
• RECOIL STARTER
Pull the cord to start the engine.
• HANDLES
Lift the handles up and pull to transport the
generator. The wheels, handles, and legs
need to be installed.
• FUEL CAP
Access to the fuel tank to add gasoline.
• CONTROL PANEL
Refer to the next page for more information.
• OIL FILL AND DIPSTICK
Access to the oil tank to check oil levels and
add oil.
FLOATING NEUTRAL
VOLTAGE SELECTOR
CIRCUIT
BREAKER
POWER
INDICATOR
VOLTMETER
AC 120V
5-20R
GROUND
ON
OFF
AC 120V/240V
NEMA L14-30R
CIRCUIT
BREAKER
ON
OFF
POWER
INDICATOR
POWER INDICATOR
13
KNOW YOUR GENERATOR
CONTROL PANEL
2 3 4
8
1
75 6
1. AC 120V NEMA 5-20R Duplex Receptacles (20A)
Standard household outlets provide 120V 60Hz
power.
2. Circuit Breakers
Push the button to reset the circuit. Refer to "Cir-
cuit Breakers" on page 21.
3. 120V/240V Power Indicator
After starting the generator, these lights will
turn on if the voltage selector is to the right
(240V/120V) to indicate that both the 120V
5-20R 20A receptacles and the 120V/240V
NEMA L14-30R 30A receptacle has power. If
both of these lights are not on, it means your
generator cannot reach 240V.
4. AC 120V/240V NEMA L14-30R Receptacle
Provides 120V or 240V, 60Hz power, depending
on the position of the voltage selector switch.
5. Voltmeter
Indicates the voltage the generator is currently
putting out.
6. 120V Power Indicator
After starting the generator, this light will turn
on if the voltage selector is to the left (120V)
to indicate that the 120V 5-20R 20A receptacles
have power.
7. 120V/240V Voltage Selector Switch
Flip the switch to the left to run all receptacles
at 120V. Flip the switch to the right to run the
5-20R 20A receptacles at 120V and the NEMA
L14-30R receptacle at 240V.
8. Grounding Nut
Ground the generator to reduce the risk of elec-
tric shock. Refer to "Step 3 - Ground The Gen-
erator" on page 16.
1514
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. The oil capacity of the engine crankcase is 17.0 fl. oz. (0.5 L).
Fig. 7
• 30W Engine Oil
Temperatures above 40°F.
• 10W-30 Engine Oil
Temperatures between 0°F - 40°F.
• Synthetic 5W-30 Engine Oil
All temperature ranges.
ENGINE OIL RECOMMENDATIONS - Select good quality detergent oil bearing the American Petro-
leum 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. For general use (above 40° F), we
recommend using 30W engine oil.
Fig. 8
Fig. 9
Lower Fill Line
Upper Fill Line
CAUTION! Keep the generator level. Tilting the genera-
tor to assist in filling will cause oil to flow into the wrong
areas of the engine and cause damage.
TO ADD OIL:
1. Place the generator on a level surface. Make sure the
engine is OFF before adding or checking oil.
2. Unscrew the oil dipstick (Fig. 8) from the engine.
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. See Fig. 9.
4. Reinstall the oil dipstick and firmly tighten it. Wipe clean
any spilled oil.
CAUTION! For subsequent operation, the oil level should
be checked before each use, or after every 8 hours of op-
eration. The generator is equipped with a low-oil sensor
and will not start without a sufficient amount of oil. Follow
the instructions on the next page to check the oil level.
Dipstick
Dipstick
1514
GENERATOR PREPARATION
Lower Limit
Upper Limit
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. 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.
4. If the oil mark covers less than one half of the dipstick,
slowly add oil until the oil mark reaches the top of the dip-
stick (or when you can see the oil coming halfway up the
oil fill threads). See Fig. 10.
OIL LEVEL SHUTDOWN
To protect the unit from damage, the generator is equipped
with a low-oil-pressure shutoff that will automatically shut
down the engine when the oil level is too low. The oil level
of the engine should be checked before each start to ensure
that the engine crankcase contains sufficient lubricant.
STEP 2 - ADD/CHECK FUEL
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.
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.
ONLY use fresh (within 30 days from purchase), lead-free
gasoline with a minimum of 87 octane rating. The genera-
tor performs best with ethanol-free gasoline. DO NOT use
gasoline with over 10% ethanol.
The capacity of the fuel tank is 4 gallons. Do not mix oil
with gasoline.
Follow the instructions on the next page to add gasoline.
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.
Fig. 10
16
GENERATOR PREPARATION
FLOATING NEUTRAL
VOLTAGE SELECTOR
CIRCUIT
RESET
POWER
INDICATOR
VOLTMETER
AC 120V
5-20R
GROUND
ON
OFF
AC 120V/240V
NEMA L14-30R
CIRCUIT
RESET
ON
OFF
POWER
INDICATOR
POWER INDICATOR
Grounding Nut
Control Panel
Fig. 12
TO ADD GASOLINE:
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.
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. If you do
so, gasoline will expand and spill during use, even with
the fuel cap in place.
TO CHECK GAS LEVEL (before every subsequent start):
1. Before starting the generator, check the fuel gauge (Fig.
11) to see if there is sufficient fuel inside the tank:
• E = Empty
• F = Full
2. If the tank is empty add gasoline to the gas tank. See
above section, "To Add Gasoline".
STEP 3 - GROUND THE GENERATOR
To reduce the risk of electric shock and to maximize safety,
the generator should be properly grounded.
1. Attach one end of the grounding wire to the grounding
nut (Fig. 12). Tighten the nut to secure the grounding wire.
2. Connect the other end of the grounding wire to a copper,
brass, or steel-grounding rod that is driven into the earth.
Fuel Cap
Fig. 11
Fuel Gauge
WARNING! Failure to properly ground the
generator increases your risk of electric shock.
NOTE: Grounding wire and grounding rods
are not included with the generator. A general-
ly acceptable grounding wire is a No. 12 AWG
(American Wire Gauge) stranded copper wire.
Grounding codes can vary by location. Contact a
local electrician to check the area codes.
17
CAUTION!
Disconnect all electrical loads from the generator before attempting to start.
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.
To maximize safety, ALWAYS ground the generator before using it. Refer to "Step 3 - Ground The Generator" on
page 16.
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.
STARTING YOUR GENERATOR
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 battery-
backup 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.
Follow the instructions on the next page to start your generator.
1918
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. Check that there is a sufficient level of fuel in the fuel tank. Add gas if necessary. Refer to "Step 2 - Add/Check
Fuel" on page 15.
5. Make sure all electrical devices are unplugged from the generator during ignition. Otherwise it will be difficult
for the engine to start.
STARTING YOUR GENERATOR
CHOKE LEVER
CLOSE
START RUN
OPEN
FUEL VALVE
OFF
ON
Fig. 13
NOTE: In case you have had repeated failed attempts to start the engine, please consult the troubleshooting
guide before attempting to start the generator. If problems persist please call 1-800-232-1195, M-F 8-5 CST.
STARTING THE GENERATOR
1. Turn the fuel valve to the ON position (Fig. 13).
2. Move the choke lever to the CLOSE/START position (Fig.
13).
3. Flip the engine ON/OFF switch (page 12) to the ON
position.
4. Pull on the recoil starter handle (page 12) slowly until
a slight resistance is felt, then pull quickly to start the en-
gine. Return cord gently into the recoil starter. Never allow
the cord to snap back.
5. If engine fails to start, repeat this step.
6. Once the engine has started, slowly return the choke lever all the way to the OPEN/RUN position.
7. Allow the engine to run for several minutes before attempting to connect any electrical devices. This allows the
generator to stabilize its speed and temperature. Follow the instructions in the next section for properly connecting
your electrical devices.
1918
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.
Generator
Wattage
Capacity
GENERATOR RUNNING (RATED) WATTS GENERATOR STARTING (SURGE) WATTS
3500W 4050W
What this means:
The generator can produce a maximum of
3500W on a continuous basis to supply on-
going power to your electronic devices.
NOTE: Also check the rated amperage for
each outlet and make sure not to overload
the individual outlets.
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.
The generator can produce a maximum
wattage of 4050W 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 20, Table
2 - Estimated Wattages of Common Electrical Appliances.
The wattage can be calculated using this equation: Watts = Volts x Amperes
To calculate the total running watts of your
devices:
+ Add up the running wattages of all the
device(s) you plan to connect.
= The total running (rated) wattage.
This wattage should NOT exceed the run-
ning wattage of 3500W.
It is recommended to maintain a load at or
below 3150W (90% of the rated output) to
ensure steady voltage output and to prolong
the generator’s lifespan.
To calculate the total starting watts of your
devices:
+ Add up the total running wattage of all the
device(s) you plan to connect.
+ Add the single highest ADDITIONAL start-
ing wattage out of the device(s) you plan to
connect.
= The total starting (surge) wattage.
This wattage should NOT exceed the starting
wattage of 4050W.
If any of either of the total calculated running watts or starting watts is higher than the capac-
ity 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
2120
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.
Tool or Appliance Rated (Running) Watts Surge (Starting) Watts
Hot Plate 2500 0
Saw - Radial Arm 2000 2000
Electric Stove (Each Element) 1500-2800 0
Saw - Circular 1500 1500
Air Compressor (1 HP) 1500 3000
Window Air Conditioner 1200 1800
Saw - Miter 1200 1200
Microwave 1000 0
Well Water Pump 1000 1000
Sump Pump 800 1200
Refrigerator Freezer 800 1200
Furnace Blower 800 1300
Computer 800 0
Electric Drill 600 900
Television 500 0
Deep Freezer 500 500
Garage Door Opener 480 0
Stereo 400 0
Box Fan 300 600
Clock Radio 300 0
Security System 180 0
DVD Player / VCR 100 0
Common Light Bulb 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 con-
necting electrical devices. See page 13 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.
2120
USING YOUR GENERATOR
Table 3 - Power Cord Requirement Guide
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.
CIRCUIT BREAKERS
The circuit breakers protect the individual AC circuits. The 20A AC circuit breaker will activate when the NEMA
5-20R outlets exceed 20A. The 30-amp AC circuit breaker will activate when the NEMA L14-30R outlet exceeds
30A. When the circuit breaker activates, turn off and disconnect the device from its respective outlet, and press
the circuit breaker to reset.
SOME NOTES ABOUT POWER CORDS
Long or thin extension cords can drain the power provided to your electrical devices. Refer to the following chart
in determining the necessary gauge extension cord for each of your devices. Round up to the higher amperage in
the chart to maximize safety.
*NR = Not Recommended
Device Requirements Max. Cord Length (ft) by Wire Gauge
Amps Watts
(120V)
Watts (240V) #8 wire #10 wire #12 wire #14 wire #16 wire
2.5 300 600 NR NR NR 375 250
5 600 1200 NR NR 300 200 125
7.5 900 1800 NR 350 200 125 100
10 1200 2400 NR 250 150 100 50
15 1800 3600 NR 150 100 65 NR
20 2400 4800 175 125 75 50 NR
25 3000 6000 150 100 60 NR NR
30 3600 7200 125 65 NR NR NR
40 4800 9600 90 NR NR NR NR
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.
2322
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. Never store the generator for extended periods of time (over 2 months) with fuel in the fuel
tank. Refer to "Storing The Generator" on page 28.
IMPORTANT: Always ensure that the fuel valve
and the engine switch are in the OFF position
when the generator is not in use.
MANUAL SHUTOFF
1. Turn off all electrical devices prior to unplugging them
from the generator. Unplugging running devices can cause
damage to the generator. Never start or stop the generator
with electrical devices plugged in or turned on.
2. Let engine run at no-load for several minutes to stabilize
internal temperatures of engine and generator.
3. Turn the fuel valve to the OFF position (Fig. 14). Let the
generator run until the fuel is used up.
4. Flip the engine ON/OFF switch (page 12) to the OFF
position.
5. Drain the carburetor. Refer to "Draining The Carburetor"
on page 25.
FUEL VALVE
OFF
ON
Fig. 14
NOTE: If for some reason (e.g. refueling, moving the generator, etc.) you need to shut down the generator
quickly, simply flip the engine switch to OFF. However, doing this will allow fuel to remain in the carburetor, and
will lead to problems if the carburetor is not drained after use.
2322
MAINTENANCE
WARNING! 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.
NOTE: Failure to properly maintain the generator will void the warranty.
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 [email protected].
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 20 to 30 minutes every month to maximize its lifespan.
Recommended
Maintenance Schedule
Every 8
Hours or
Daily
Every 25
Hours
Every 3
Months or
50 Hours
Every 6
Months or
100 Hours
Before
Storage
As
Necessary
Engine Oil
Check Level X
Replace X* X
Air Filter
Check X*
Clean X*
Spark Plug
Check/Clean/
Regap
X
Change X X
Fuel
Check Level X
Drain X X
Carburetor Drain X X
Spark
Arrestor
Check/Clean X
Table 4 - Recommended Maintenance Schedule* Clean/change more often under dusty conditions
or operating under heavy load.
2524
MAINTENANCE
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.
CLEANING YOUR GENERATOR
Keep the generator clean to prevent improper operation or machine damage from dirt and debris. Inspect all ven-
tilation 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.
CHECKING/ADDING OIL
Check the oil level before each use and every 8 hours of operation (refer to page 23, Table 4). The oil capacity
of the generator engine is 17.0 fl. oz. (0.5 L). Add oil when the oil level is low. For the proper type and weight of
oil refer to page 14, Fig. 7. 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/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.
DRAINING/CHANGING OIL
Change the oil according to the Recommended Maintenance Schedule (refer to page 23, 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 complete drainage.
Fig. 15
1. Place generator on a level, elevated platform. Prepare
an approved oil-storage container underneath the oil drain
bolt next to the oil dipstick to catch the oil as it drains. See
Fig. 15. NOTE: To avoid possible fuel spills from the car-
buretor bowl, drain the carburetor (refer to "Draining The
Carburetor" on page 25) before draining the oil.
2. Unscrew the oil drain bolt and allow oil to drain from the
engine completely.
3. Reinstall the oil drain bolt and tighten it securely. Wipe
clean any oil spillage.
4. To add new oil, refer to "Step 1 - Add/Check Oil" on page
14.
Dipstick
Oil Drain Bolt
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.
2524
MAINTENANCE
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.
Fig. 16
Fig. 17
NOTE: Make sure to drain your carburetor before
storing the generator for long periods of time.
DRAINING THE CARBURETOR
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. To drain
the carburetor, open up the carburetor drain screw with a
Phillips-head screwdriver and drain out any gasoline that
has built up inside. See Fig. 16.
3. Once the fuel has drained, close the drain screw.
INSPECTING/CLEANING THE AIR FILTER
Inspect and clean the air filter every 50 hours of operation (refer to page 23, Table 4). Routine maintenance of
the air filter helps maintain proper airflow to the carburetor. Occasionally check that the air filter is free of excessive
dirt. Clean air filter more frequently in dirty or dusty conditions.
1. Remove the air filter cover by unscrewing the cover lock
knob at the bottom of the air filter cover. See Fig. 17.
2. Remove the foam, sponge-like air filter element from the
casing. Wipe excessive oil and any dirt from inside of the
air filter casing.
3. Check the foam, sponge-like air filter element.
a) 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. A small amount of oil left in the element is normal
and necessary for the engine to work properly.
b) Damaged elements should be replaced with a new
one. Replacement air filters can be purchased from wen-
products.com by searching part number P54178-1.
4. Reinstall the air filter element and air filter cover.
Air Filter
Cover
Cover
Lock
Drain Screw
2726
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 ser-
vicing the spark arrestor.
1. Remove the two Phillips-head screws that secure the
spark arrestor to the muffler. See Fig. 18.
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 number P54403.
4. Reinstall the spark arrestor in the muffler and secure it in
place with the screws.
SPARK PLUG MAINTENANCE
Inspect and change the spark plug every 100 hours of
operation (refer to page 23, Table 4). 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.
1. Gently pull on the spark plug boot to remove it. Be care-
ful not to tear insulation or wire. See Fig. 19.
2. Use the included spark plug wrench (Fig. 20) to unscrew
the spark plug from the engine. Remove the spark plug
from the engine. 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.
3. Visually inspect the spark plug. If it is cracked or chipped,
or if the electrodes are worn or burned, discard it and re-
place with a new spark plug. We recommend replacing it
with an NGK BP7ES/Torch F7TC spark plug. These can be
purchased from wenproducts.com by searching part num-
ber P54060.
4. 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.
Instructions continue on the next page.
Fig. 18
Fig. 19
Fig. 20
Spark Plug Boot
Muffler
Spark Arrestor Assembly
Cylinder Assembly
Wrench (1)Handle (1)
2726
MAINTENANCE
Fig. 21
Fig. 22
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.
6. Screw the spark plug back into the spark plug hole us-
ing 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.
DRAINING THE FUEL TANK
Drain and clean the fuel tank each year, or before storing
the generator for longer than two months.
1. Prepare an approved gasoline-storage container to col-
lect the drained fuel. Place it near the fuel valve.
2. Turn the fuel valve to the OFF position.
3. Locate the fuel line between the fuel valve and the carbu-
retor. Disconnect the fuel line from the fuel valve. See Fig.
22. NOTE: A small amount of fuel may leak from the fuel
line during removal.
4. Place a funnel below the fuel valve opening, and direct
the other end of the funnel over the prepared container.
5. Turn the fuel valve to the ON position to start draining
the fuel from the fuel valve opening. NOTE: The draining
process may take a few hours, depending on the amount of
fuel in your gas tank.
6. Once the fuel is completely drained, turn the fuel valve to
the OFF position.
7. Start and run the engine until the fuel runs out.
8. Drain the carburetor. Refer to "Draining The Carburetor"
on page 25.
CAUTION! Store the emptied gasoline in a suitable
place. Never store fuel for more than 2 months.
0.7 - 0.8mm
Fuel Valve
Fuel Valve
2928
TRANSPORTATION & STORAGE
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.
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. 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.
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.
For Short Periods (30 to 60 Days):
• Drain the carburetor. Refer to "Draining The Carburetor" on
page 25.
• 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):
• Drain the fuel tank and carburetor.
Refer to "Draining The Fuel Tank"
on page 27, and "Draining The
Carburetor" on page 25.
• Never store generator with fuel in the
tank for more than two months.
• Change the engine oil. Refer to
"Checking/Adding Oil" on page 24.
WARNING! Store the generator upright in a cool and dry location, away from sources of heat, open flames,
sparks or pilot lights.
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.
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.
TIP: Your WEN generator is compatible
with the WEN 56406 Medium Generator
cover (not included), available for purchase
at wenproducts.com.
PRODUCT DISPOSAL
Do not dispose of 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 dis-
posal 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.
2928
TROUBLESHOOTING GUIDE
PROBLEM POSSIBLE CAUSE SOLUTION
Engine will not start.
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. Oil is low.
3. Add or replace oil. Refer to "Step 1 - Add/
Check Oil" on page 14.
4. Engine is out of fuel.
4. Add fuel. Refer to "Step 2 - Add/Check Fuel"
on page 15.
5. Engine is filled with
contaminated or old fuel.
5. Drain the fuel in the tank and fill with fresh
fuel. Refer to "Draining The Fuel Tank" on page
27.
6. Spark plug is dirty or
broken.
6. Clean or replace the spark plug. Refer to
"Spark Plug Maintenance" on page 26.
7. Carburetor is air locked.
7. Shut off the fuel valve. Remove the bolt
from the bottom of the carburetor. Take off the
carburetor bowl to allow it to reset. Replace
carburetor bowl and reinstall the bolt.
8. Ghost in the generator. 8. Persuade the ghost to leave.
Engine runs but there is
no electrical output.
1. Circuit breaker has been
tripped due to overload.
1. Turn off and unplug electrical device(s). Wait
5 minutes, then press the circuit breaker to
reset. 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.
2. Bad connecting cords/
wires.
2. Check the power cords and extension cords.
Do not use if any cord is damaged. Replace
damaged cords immediately.
3. Bad electrical device
connected to the generator.
3. Try connecting a different device.
4. Carbon brushes are worn or
need adjustment.
4. Check carbon brushes, adjust so that both
brushes extrude the same length, or replace if
worn. For instructions, visit bit.ly/wencarb.
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 [email protected].
3130
PROBLEM POSSIBLE CAUSE SOLUTION
Generator runs but does
not support all electrical
devices connected.
1. Generator is overloaded.
1. Turn off and unplug all electrical devices.
Wait 5 minutes, then press the circuit breaker
to reset. Reduce load as necessary, then plug
devices back in one by one.
2. Short circuit in one of the
devices.
2. Try disconnecting any faulty or short-
circuited electrical loads.
3. Air filter is dirty.
3. Clean or replace the air filter element. Refer
to "Inspecting/Cleaning The Air Filter" on page
25.
Engine is "hunting" during
operation (engine RPM is
fluctuating).
NOTE: Turn off the
generator and wait
for it to cool down
before preforming the
maintenance solutions.
1. The fuel isn’t running
through the fuel valve.
1. Check if the fuel is properly and consistently
going through the fuel valve
2. The air filter is clogged.
2. Check for any blockage in the air filter. Check
and clean the air filter as necessary.
3. The muffler or spark
arrester is blocked.
3. Check if the spark arrester is blocked. Clean
with metal brush as necessary.
4. There is gunk in the
carburetor preventing a
consistent fuel/air mixture.
4. Use "gunk remover" spray on the carburetor
jets.
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 [email protected].
IMPORTANT: Repairs and replacements should only be performed by an authorized technician. Parts and ac-
cessories that wear down over the course of normal use are not covered by the two-year warranty.
3130
WIRING DIAGRAM
EL
EL
EL
YY
Y
Y
Y
Bu
Bu
AVR
Bu
BrBr
Br
W
R
Bu
Br
W
R
Bu
Receptacle
Receptacle
Volt-Selector
Circuit Breaker
Circuit Breaker
BL
G
E
IG
Y
Y
BL
BL
BL
BL
Fuel Sensor Oil Sensor Spark Plug Ignition Coil
ENGINE BLOCK
ENGINE SWITCH
Main Coil 1
Main Coil 2
Sub-Field
Coil
Sub-Field
Coil
GENERATOR BLOCK
BrBL
Bu
Black
Blue
Green
White
Y/G
W
Y
R
Brown
Yellow
Red
Light Green
Yellow/Green
LG
G
ENGINE SWITCH
IG
OFF
ON
E
KEY
32
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.
No. Part No. Description Qty.
1 Control Panel 1
2 P54296 Ignition Switch 1
3 56400-1603 Voltmeter 1
4 P54826 Switch 1
5 56400-1605 Indicator Light 3
6 P54454
NEMA 5-20R 120V
Duplex Receptacle
1
7 P54262 Grounding Terminal 1
8 P54838 Circuit Breaker, 30A 2
9 P54272
NEMA L14-30R
120/240V Receptacle
1
11 P56400-1611 Panel Rear Case 1
12 P56400-1612
Control Panel
Assembly
1
13 P54304 Bolt 4
14 56400-1614 Rectification Bridge 1
13
12
11
14
8
10
9
43
2
1
7
5
6
13
ASSEMBLY 1 - CONTROL PANEL
No. Part No. Description Qty.
1 P54329 Alternator Assembly 1
4 P54336 Motor Housing 1
5 P54350 Bolt 4
6 P54348 Washer 1
7 P54354 Rotor Bolt 1
8 P54342 Voltage Regulator 1
9 P54360 Bolt 2
10 P54332
Carbon Brush
Subassembly
1
11 P54360 Bolt 1
12 P54337 End Cover 1
13 P54340 Bolt 2
14 56400-1714 Band 1
15 P54340 Bolt 1
16 56400-1716 Stopper 1
17 P54340 Bolt 1
4
1
5
9
7
10
11
8
14
12
13
15
6
16
17
ASSEMBLY 2 - ROTOR & STRATOR
33
EXPLODED VIEW & PARTS LIST
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
8
6
31
2 5
4
5
ASSEMBLY 3 - CRANKCASE COVER
No. Part No. Description Qty.
1 P54123 Crankshaft Assembly 1
1
ASSEMBLY 4 - CRANKSHAFT
No. Part No. Description Qty.
1 P54105 Piston Ring Assembly 1
2 P54106 Piston Pin Clip 2
3 P54109 Piston 1
4 P54112 Piston Pin 1
5 P54121 Connecting Rod 1
2
5
4
1
2
3
ASSEMBLY 5 - PISTON RING &
CONNECTING ROD
No. Part No. Description Qty.
1 P54630 Nut, M14-1.5 1
2 P54362 Starting Flange 1
3 P54634 Flywheel Fan 1
4 P54636 Flywheel 1
5 P54638 Ignition Coil Assembly 1
6 P54628 Bolt 2
4
3 2 1
5
6
ASSEMBLY 6 - FLYWHEEL &
IGNITION COIL
3534
EXPLODED VIEW & PARTS LIST
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 2
10 P54140 Lifter 2
11 P54138 Push Guide 1
12 P54134 Valve Adjusting Bolt 2
13 P54132 Valve Rocker 2
14 P54130 Sleeve 2
15 P54128 Lock Nut 2
16 P54154 Valve Spring 2
3 46
5
8
7
11
1
910
16
12
1314
15
ASSEMBLY 7 - VALVE & CAMSHAFT
No. Part No. Description Qty.
1 P54011 Crankcase 1
2 P54020 Oil Sensor 1
3 P54031
Regulating Gear
Assembly
1
4 P54024 Bolt 2
5 P54018 Pin 1
6 P54016 Washer 1
7 P54014 Regulating Sway Bar 1
8 P54000 Oil Drain Plug 2
9 P54002 Washer 2
10 P54008 Oil Seal 1
11 P54004 Bearing 1
ASSEMBLY 8 - CRANKCASE
2
3
5
6
7
89
98
10
11
4
1
3534
EXPLODED VIEW & PARTS LIST
No. Part No. Description Qty.
1 P54178 Air Cleaner Assembly 1
2 P54179 Nut 2
3 P54178-1 Air Cleaner Element 1
12
5
4
3
2
5
4
3
2
5
4
3
2
5
4
3
2
14
13
15
1
16
9
10
7
8
No. Part No. Description Qty.
1 56400-141 Fuel Tank 1
2 P56400-142 Cushion 4
3 P56400-143 Fitting Bush 4
4 P56400-144 Washer 4
5 P56400-145 Bolt 4
6 P56400-146 Valve 1
7 P56400-147 Clip 1
8 P56400-148 Chain 1
9 P56400-149 Fuel Cap 1
10 P56400-150 Fuel Filter 1
12 P56400-151 Fuel Gauge Assembly 2
13 P56400-152 Clamp 1
14 P56400-153 Rubber Hose 1
15 P56400-154 Fuel Cock 1
16 P56400-155 Fuel Tube 1
ASSEMBLY 9 - FUEL TANK
1
2
3
ASSEMBLY 10 - AIR CLEANER
No. Part No. Description Qty.
1 56475-2001 Rubber Seat 2
2 56475-2002 Bolt 2
3 56475-2003 Nut 4
4 56475-2004 Tube 2
5 56475-2005 Rubber Sleeve 2
4
1
2
3 3
5
ASSEMBLY 11 - HANDLE KIT
3736
EXPLODED VIEW & PARTS LIST
No. Part No. Description Qty.
1 P54624 Regulating Arm 1
2 P54176 Nut, M6 1
3 P54622 Lock Bolt 1
4 P54616 Back Spring 1
5 P54620 Pulling Rod 1
6 P54618 Regulating Spring 1
7 P54617 Regulating Assembly 1
8 P54619 Bolt 2
8
8
7
6
5
4
3
1
2
ASSEMBLY 12 - CONTROL
No. Part No. Description Qty.
1 P54401 Muffler Assembly 1
2 P54402 Cover, Outer Muffler 1
3 P54412 Bracket, Muffler 1
4 P54422 Bolt 1
5 P54404 Bolt 2
6 P54422 Bolt 5
7 P54426 Gasket, Exhaust Outlet 1
8 P54403
Spark Arrestor
Assembly
1
10 P54246 Nut 2
ASSEMBLY 13 - MUFFLER
62
3
4
6
1
8
10
5
7
3736
EXPLODED VIEW & PARTS LIST
No. Part No. Description Qty.
1 P54668 Fan Hood Assembly 1
2 P54044 Wind Cover 1
3 P54596 Lower Shield 1
4 P54612 Diode 1
5 P54040 Bolt, M6x12 4
6 P54040 Bolt, M6x12 3
7 P54596-1 Collar 1
8 P54186 Bolt, M6x24 1
5
1
3
7
6
8
4
2
6
ASSEMBLY 15 - SHROUD
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 1
29 P54390 Hose Clamp 2
3
4
5
28
29
1
ASSEMBLY 14 - CARBURETOR
3938
EXPLODED VIEW & PARTS LIST
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
5
5
5
5
4
4
4
4
1
4
4
4
4
2
2
3
3
ASSEMBLY 16 - ENGINE FRAME
No. Part No. Description Qty.
4 P54051 Cylinder Head Gasket 1
5 P54066
Cylinder Head Cover
Assembly
1
6 P54064
Cylinder Head Cover
Gasket
1
7 P54043 Air Duct 1
8 P54040 Bolt, M6x12 4
9 P54047 Stud 2
10 P54058 Stud 2
11 P54048 Pin 2
12 P54062 Bolt 4
13 P54060
Spark Plug, Torch
F7TC (NGK BP7ES)
1
14 P54054
Cylinder Head
Assembly
1
ASSEMBLY 17 - CYLINDER HEAD
8
56
13
4
7
12
14
10
9
11
3938
EXPLODED VIEW & PARTS LIST
No. Part No. Description Qty.
1 P54872-1 Wheel 2
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, M10-1.25 2
1
2
6
1
10
9
6
10
9
5
4
4
5
2
3
3
ASSEMBLY 18 - WHEEL KIT
No. Part No. Description Qty.
11 P54604
Recoil Starter
Assembly
1
12 P54598 Bolt, M6x8 3
ASSEMBLY 19 - RECOIL STARTER
11
12
11
11
WARRANTY
40
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. Ninety days for all WEN products if the tool is used for pro-
fessional or commercial use. Purchaser has 30 days from the date of purchase to report missing or damaged parts.
SELLER’S SOLE OBLIGATION AND YOUR EXCLUSIVE REMEDY under this Limited Warranty and, to the extent per-
mitted 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 inten-
tionally, 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 [email protected] 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 replace-
ments can be shipped out.
Upon the confirmation of a WEN representative, your product may qualify for repairs and service work. When re-
turning 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.
THIS 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, BAT-
TERIES, RECOIL STARTERS, HIGH PRESSURE HOSES, SPRAY GUNS, ETC. ANY IMPLIED WARRANTIES SHALL BE
LIMITED IN DURATION TO TWO (2) 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 IN-
CIDENTAL 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, CON-
TACT THE WEN CUSTOMER SUPPORT LINE. FOR WARRANTY PARTS OR PRODUCTS REPAIRED UNDER WARRAN-
TY SHIPPING TO ADDRESSES OUTSIDE OF THE CONTIGUOUS UNITED STATES, ADDITIONAL SHIPPING CHARGES
MAY APPLY.
v.2019.06.25
