WEN DF475X 4750 Watt Dual Fuel Generator Instruction Manual
- June 15, 2024
- WEN
Table of Contents
- DF475X 4750 Watt Dual Fuel Generator
- Specifications
- Introduction
- Safety
- General Safety Rules
- Generator Safety Warnings
- Know Your Generator
- Unpacking & Packing List
- Assembly & Adjustments
- Generator Preparation
- Q: Where can I find replacement parts for the generator?
- Q: What is the run time of the generator?
- Q: What type of spark plug does the generator use?
DF475X 4750 Watt Dual Fuel Generator
Specifications
-
Model Number: DF475X
-
Rated Wattage: Gasoline: 3800 Watts, LPG: 3500
Watts -
Surge Wattage: Gasoline: 4750 Watts, LPG: 4350
Watts -
Phase: Single
-
Frequency: 60 Hz
-
Rated Voltage: AC: 120V/240V, DC: 12V
-
Rated Amperage: AC: 32A/16A, DC: 8A
-
Product Dimensions (With Wheel Kit): 25.00 in.
x 23.00 in. x 21.00 in. (L x W x H) -
Product Net Weight (With Wheel Kit): 125.40
Pounds (56.88 kg)
Introduction
Thanks for purchasing the WEN 4750-Watt Portable Generator.
Refer to the illustration below for the location of the serial
number on the specifications label. Record the generator
information in the spaces provided below. If 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
General Safety Rules
1. Read and understand all instructions in the manual before
operating the generator.
2. Keep bystanders, especially children and pets, away from the
generator during operation.
3. Do not operate the generator in a closed area or indoors.
4. Always wear appropriate safety gear such as gloves and safety
goggles when operating the generator.
Generator Safety Warnings
1. Do not connect the generator to a building’s electrical
system unless it has been properly installed by a qualified
electrician.
2. Do not operate the generator in wet conditions or expose it
to rain or snow.
3. Do not refuel the generator while it is running or hot. Allow
it to cool down before refueling.
4. Do not overload the generator by connecting too many devices
or appliances.
Before Operating
Know Your Generator
1. Familiarize yourself with the various components and controls
of the generator.
2. Locate the fuel tank, oil dipstick, spark plug, and other
important parts for easy access.
Unpacking & Packing List
1. Carefully unpack the generator and check for any damage or
missing parts.
2. Refer to the packing list to ensure that all components are
included.
Assembly & Adjustments
1. Follow the step-by-step instructions provided in the manual
to assemble the generator.
2. Make any necessary adjustments according to the
instructions.
Generator Preparation
1. Check the fuel level and ensure that there is enough fuel for
operation.
2. Check the oil level using the dipstick and add oil if
necessary.
3. Connect any required accessories or devices to the
generator.
Operation & Maintenance
To purchase accessories and replacement parts for your tool,
visit WENPRODUCTS.COM
- Magnetic Oil Dipstick (Model 55201)
- Universal Weatherproof Medium Generator Cover (Model
- 1800-Watt Generator to RV Adapter Cord (Model PC3012)
- 50 ft. Heavy-Duty Outdoor Extension Cord (Model PC5124)
- 100 ft. Heavy-Duty Outdoor Extension Cord (Model PC1123)
- 3 ft. Generator Extension Cord Splitter (Model PC3104-2)
FAQ
Q: Where can I find replacement parts for the generator?
A: You can find replacement parts for the generator on
WENPRODUCTS.COM.
Q: What is the run time of the generator?
A: The run time of the generator is 11 hours with gasoline and 7
hours with LPG (with a 20 lb tank).
Q: What type of spark plug does the generator use?
A: The generator uses a Torch F7TC/NGK BP7ES spark plug.
MODEL DF475X
4750-WATT DUAL FUEL GENERATOR
Instruction Manual
NEED HELP? CONTACT US!
Have product questions? Need technical support? Please feel free to contact us:
1-847-429-9263 (M-F 8AM-5PM CST)
TECHSUPPORT@WENPRODUCTS.COM
IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest
standards for dependability, ease of operation, and operator safety. When
properly cared for, this product will supply you years of rugged, trouble-free
performance. Pay close attention to the rules for safe operation, warnings,
and cautions. If you use your tool properly and for its intended purpose, you
will enjoy years of safe, reliable service.
For replacement parts and the most up-to-date instruction manuals, visit
WENPRODUCTS.COM
CONTENTS
WELCOME
3
Specifications……………………………………………………………………………………… 3 Introduction ……………………………………………………………………………………….. 4
SAFETY
5
General Safety Rules ……………………………………………………………………………. 5 Generator Safety Warnings …………………………………………………………………… 7
BEFORE OPERATING
10
Know Your Generator…………………………………………………………………………. 10 Unpacking & Packing List …………………………………………………………………… 12 Assembly & Adjustments……………………………………………………………………. 13 Generator Preparation………………………………………………………………………… 14
OPERATION & MAINTENANCE
20
Starting the Generator………………………………………………………………………… 20 Using the Generator …………………………………………………………………………… 22 Shutting Off the Generator ………………………………………………………………….. 26 Maintenance……………………………………………………………………………………… 27 Transportation & Storage ……………………………………………………………………. 34 Troubleshooting Guide ……………………………………………………………………….. 35 Wiring Diagram…………………………………………………………………………………. 36 Exploded View & Parts List …………………………………………………………………. 37 Warranty Statement …………………………………………………………………………… 43
To purchase accessories and replacement parts for your tool, visit
WENPRODUCTS.COM
Magnetic Oil Dipstick (Model 55201) Universal Weatherproof Medium Generator
Cover (Model 56406)
1800-Watt Generator to RV Adapter Cord (Model PC3012) 50 ft. Heavy-Duty
Outdoor Extension Cord (Model PC5124) 100 ft. Heavy-Duty Outdoor Extension
Cord (Model PC1123) 3 ft. Generator Extension Cord Splitter (Model PC3104-2)
2
SPECIFICATIONS
GENERATOR
Model Number
DF475X
Rated Wattage
Gasoline: 3800 Watts LPG: 3500 Watts
Surge Wattage
Gasoline: 4750 Watts LPG: 4350 Watts
Phase
Single
Frequency
60 Hz
Rated Voltage
AC: 120V/240V, DC: 12V
Rated Amperage
AC: 32A/16A, DC: 8A
Product Dimensions (With Wheel Kit) 25.00 in. x 23.00 in. x 21.00 in. (L x W x H)
Product Net Weight (With Wheel Kit) 125.40 Pounds (56.88 kg)
ENGINE
Engine Type Engine Displacement No-Load Speed Fuel Tank Capacity Oil Capacity
Half-Load Run Time
Spark Plug Type Spark Plug Gap Spark Plug Torque Length of LPG Hose Battery
4-stroke, OHV, Single Cylinder 224cc 3600 RPM 4 US Gallons (15 L), 87 octane minimum 20.3 fl. oz. (0.6 L) Gasoline: 11 hours LPG (with 20 lb tank): 7 hours Torch F7TC/NGK BP7ES 0.7 – 0.8 mm (0.028 – 0.031 in) 1/2 – 3/4 turn after gasket contacts base or 15 ft-lbs 47 inches (1200 mm) 12V 7Ah Lead-Acid
3
INTRODUCTION
Thanks for purchasing the WEN 4750-Watt Portable Generator. Refer to the
illustration below for the location of the serial number on the specifications
label. Record the generator information in the spaces provided below. If
assistance for information or service is required, please contact customer
service by calling 1-800-232-1195, M-F
8-5 CST; you will be asked to provide the following generator information when
calling.
Generator Model Number: DF475X Date of Purchase:
___ Purchased From:
____ Serial Number:
Serial Number
SERVICE RECORD
Record the service dates of your generator in the chart below. Please perform
maintenance checks and operations according to the “Maintenance” section of
the manual.
Service Record
Date
Date
Date
Date
Date
Date
Change Oil
Change Spark Plug
Clean Fuel Tank
Clean Air Cleaner
Clean Spark Arrestor
TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your
generator at least once a month for 20 to 30 minutes. Start the generator
according to the instructions and plug a small load in to make sure the outlet
is producing electricity.
4
GENERAL SAFETY RULES
WARNING! Read all safety warnings and all instructions. Failure to follow the
warnings and instructions may result in electric shock, fire and/or serious
injury.
Safety is a combination of common sense, staying alert and knowing how your
item works. The term “power tool” in the warnings refers to your mains-
operated (corded) power tool or battery-operated (cordless) power tool.
SAVE THESE SAFETY INSTRUCTIONS.
WORK AREA SAFETY
1. Keep work area clean and well lit. Cluttered or dark areas invite
accidents.
2. Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases or dust. Power tools create sparks which
may ignite the dust or fumes.
3. Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
ELECTRICAL SAFETY
1. Power tool plugs must match the outlet. Never modify the plug in any way.
Do not use any adapter plugs with earthed (grounded) power tools. Unmodified
plugs and matching outlets will reduce risk of electric shock.
2. Avoid body contact with earthed or grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk of electric
shock if your body is earthed or grounded.
3. Do not expose power tools to rain or wet conditions. Water entering a
power tool will increase the risk of electric shock.
4. Do not abuse the cord. Never use the cord for carrying, pulling or
unplugging the power tool. Keep cord away from heat, oil, sharp edges or
moving parts. Damaged or entangled cords increase the risk of electric shock.
5. When operating a power tool outdoors, use an extension cord suitable for
outdoor use. Use of a cord suitable for outdoor use reduces the risk of
electric shock.
6. If operating a power tool in a damp location is unavoidable, use a ground
fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the
risk of electric shock.
PERSONAL SAFETY
1. Stay alert, watch what you are doing and use common sense when operating a
power tool. Do not use a power tool while you are tired or under the influence
of drugs, alcohol or medication. A moment of inattention while operating power
tools may result in serious personal injury.
2. Use personal protective equipment. Always wear eye protection. Protective
equipment such as a respiratory mask, non-skid safety shoes and hearing
protection used for appropriate conditions will reduce the risk of personal
injury.
3. Prevent unintentional starting. Ensure the switch is in the off-position
before connecting to power source and/or battery pack, picking up or carrying
the tool. Carrying power tools with your finger on the switch or energizing
power tools that have the switch on invites accidents.
4. Remove any adjusting key or wrench before turning the power tool on. A
wrench or a key left attached to a rotating part of the power tool may result
in personal injury.
5. Do not overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations.
6. Dress properly. Do not wear loose clothing or jewelry. Keep your hair and
clothing away from moving parts. Loose clothes, jewelry or long hair can be
caught in moving parts.
5
GENERAL SAFETY RULES
WARNING! Read all safety warnings and all instructions. Failure to follow the
warnings and instructions may result in electric shock, fire and/or serious
injury.
Safety is a combination of common sense, staying alert and knowing how your
item works. The term “power tool” in the warnings refers to your mains-
operated (corded) power tool or battery-operated (cordless) power tool.
SAVE THESE SAFETY INSTRUCTIONS.
7. If devices are provided for the connection of dust extraction and
collection facilities, ensure these are connected and properly used. Use of
dust collection can reduce dust-related hazards.
POWER TOOL USE AND CARE
1. Do not force the power tool. Use the correct power tool for your
application. The correct power tool will do the job better and safer at the
rate for which it was designed.
7. Use the power tool, accessories and tool bits, etc. in accordance with
these instructions, taking into account the working conditions and the work to
be performed. Use of the power tool for operations different from those
intended could result in a hazardous situation.
8. Use clamps to secure your workpiece to a stable surface. Holding a
workpiece by hand or using your body to support it may lead to loss of
control.
2. Do not use the power tool if the switch does not turn it on and off. Any
power tool that cannot be controlled with the switch is dangerous and must be
repaired.
3. Disconnect the plug from the power source and/or the battery pack from the
power tool before making any adjustments, changing accessories, or storing
power tools. Such preventive safety measures reduce the risk of starting the
power tool accidentally.
4. Store idle power tools out of the reach of children and do not allow
persons unfamiliar with the power tool or these instructions to operate the
power tool. Power tools are dangerous in the hands of untrained users.
5. Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired before use. Many accidents
are caused by poorly maintained power tools.
6. Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
9. KEEP GUARDS IN PLACE and in working order.
SERVICE
1. Have your power tool serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the power
tool is maintained.
CALIFORNIA PROPOSITION 65 WARNING
Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities may contain chemicals, including lead, known to the
State of California to cause cancer, birth defects, or other reproductive
harm. Wash hands after handling. Some examples of these chemicals are:
· Lead from lead-based paints. · Crystalline silica from bricks, cement, and
other
masonry products. · Arsenic and chromium from chemically treated
lumber.
Your risk from these exposures varies depending on how often you do this type
of work. To reduce your exposure to these chemicals, work in a well-ventilated
area with approved safety equipment such as dust masks specially designed to
filter out microscopic particles.
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 batterybackup CO alarm in the home. If you start to feel
sick, dizzy, or weak after the generator has been running, move to fresh air
RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.
WARNING! RISK OF EXPLOSION. HIGHLY FLAMMABLE: This generator may emit highly
flammable and explosive gasoline vapors, which can cause severe burns or even
death, if ignited. A nearby open flame can lead to explosion even if not
directly in contact with gasoline.
· Do not operate near open flame, heat, or any other ignition source. Do not
smoke near the generator. · Always operate on a firm, level surface. · Always
turn generator off before refueling. Allow generator to cool for at least 2
minutes before removing
fuel cap. Loosen cap slowly to relieve pressure in tank. · Do not overfill
fuel tank. Gasoline may expand during operation. Do not fill to the top of the
tank. Allow for
expansion. Always check for spilled fuel before operating. · If fuel spills,
move the generator at least 30 feet away from the spill and wipe clean any
spilled fuel before
starting the engine. · Empty fuel tank before storing or transporting the
generator.
WARNING! If this generator is used as a supply for a building’s wiring system,
the generator must be installed by a qualified electrician and connected to a
transfer switch as a separately derived system in accordance with all
applicable laws and electrical codes and the National Electrical Code, NFPA
70. The generator shall be connected to a transfer switch that switches all
conductors excluding the equipment grounding conductor. The frame of the
generator shall be connected to an approved grounding electrode.
CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals and
produces exhaust known to the State of California to cause cancer, birth
defects and other reproductive harm. For more information, visit
www.P65Warnings.ca.gov
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
1. Using a generator indoors can kill you in minutes. Only use a generator
outside and far away from windows, doors and vents.
2. Do not smoke near the generator.
3. If any part of the generator, electrical device or power cord is broken, damaged, or defective, make sure it is repaired or replaced before operation. Service should only be performed by a qualified technician. Do not use receptacles or cords that show signs of damage, such as broken or cracked insulation.
3. Do not operate near open flame, heat, or flammable materials. This
generator may emit highly flammable and explosive gasoline vapors, which can
cause severe burns or even death if ignited. A nearby open flame can lead to
an explosion even if it isn’t directly in contact with gasoline.
4. Do not expose the generator to rainy or wet conditions; doing so
significantly increases the risk of electrical shock. Never handle the
generator, electronic devices, or any cord while standing in water, while
barefoot, or when hands or feet are wet.
5. Always operate the generator on a dry, firm, level surface.
6. The generator should have at least 5 feet of clearance from buildings or
other equipment during operation.
7. Do not allow children or non-qualified persons to operate the generator.
4. Use a ground fault circuit interrupter (GFCI) in highly conductive areas
such as metal decking or steel work. Extension cords with in-line GFCIs are
recommended for these operations to maximize safety.
5. If connecting the generator to a building’s electrical system for standby
power, you MUST consult a qualified electrician and install a transfer switch.
Such connections must comply with local electrical laws and codes. Failure to
comply can create a back-feed, which may result in serious injury or death to
utility workers.
6. Never modify the generator in any way. Modifying or using the machine for
any other purpose for which it is not designed may result in serious injuries,
machine damage and voiding of the warranty.
GENERATOR OPERATION
1. Only use the generator for its intended purposes. Modifying or using the
generator for operations for which it was not designed may cause hazards and
personal injury.
GENERATOR PREPARATION
1. Always ground the generator before using it to maximize safety (see
“Ground the Generator” section).
2. Do not overfill fuel tank, as gasoline may expand during operation. Do not
fill to the very top of the tank. Leave room for gasoline expansion. Always
check for spilled fuel before operating.
2. Do not touch bare wires or receptacles (outlets).
3. Do not exceed the wattage capacity of the generator by plugging in more
electrical devices than the unit can handle. This could damage the generator
and/or connected electrical devices. Check the operating voltage and frequency
requirements of all electrical devices prior to plugging them into the
generator.
Generator safety warnings continue on the next page.
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. Start the generator according to the instructions and plug a small load in to make sure the outlet is producing electricity. If you do not run it often, it will greatly shorten the generator’s lifespan and void the warranty.
4. Allow generator to run for several minutes before connecting electrical
devices. Do not start or stop engine with electrical devices plugged in to the
receptacles. Failure to do so could damage the generator and/or connected
electrical devices.
5. Do not turn on electrical devices until after they are connected to the
generator.
6. Generators vibrate in normal use. During and after the use of the
generator, inspect both the generator as well as extension and power supply
cords for damage resulting from vibration.
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 “STOP” position when the engine is not running.
11. Empty fuel tank before storing or transporting the generator. Do not
store generator or gasoline near furnaces, water heaters, or any other
appliances that produce heat or have automatic ignitions. Store the generator
and fuel away from sparks, open flames, pilot lights, heat and other sources
of ignition.
12. Always wash hands after handling generator.
CAUTION: Misuse of this generator can damage it or shorten its lifespan.
9
KNOW YOUR GENERATOR
TOOL PURPOSE
Generators provide you with power when and where you need it most. Refer to
the following diagrams to become familiarized with all the parts and controls
of your Generator. The components will be referred to later in the manual for
assembly and operation instructions.
GENERATOR
1. Fuel Tank Cap
2. Pressure Relief Valve 3. Fuel Gauge
4. Choke Lever
5. Recoil Starter 6. Air Filter 7. Engine 8. Handle
9. Fuel Tank
10. Control Panel 11. Fuel Valve
12. Battery 13. Oil Fill & Dip Stick
14. Wheels
15. LPG Hose Connector
1. Fuel Tank Cap Access to the fuel tank for adding gasoline.
2. Pressure Relief Valve Helps prevent pressure buildup in the fuel tank.
3. Fuel Gauge Indicates amount of fuel inside the fuel tank. E indicates
Empty, F indicates Full.
4. Choke Lever Adjusts the amount of air let into the engine during startup.
5. Recoil Starter Pull cord for manually starting the engine.
6. Air Filter A case with a sponge-like element that filters the air entering
the engine.
7. 224cc OHV Engine
8. Handle For easy transport of the generator.
9. Fuel Tank
10. Control Panel Refer to the next page for descriptions.
11. Fuel Valve Allows fuel to enter engine from the fuel tank.
12. Battery Connect the battery before starting the generator.
13. Oil Fill & Dipstick For filling and checking oil.
14. Wheels
15. LPG Hose Connector Connects to LPG hose and LPG cylinder.
10
CONTROL PANEL
1
KNOW YOUR GENERATOR
2
3
4
5
6
7
before s t ar ting
Maintenance Rules 1. Drain the carburetor after each use. 2. Run generator at
least once a month for 15 minutes. 3. Empty gas tank and disconnect LPG tank
before
storing for extended periods.
11
10
9
8
1. Fuel Selector Switch
7. AC 120/240V 30A NEMA L14-30R Receptacle
Turn the dial to easily switch between gasoline or LPG be- Connect electrical devices that run on 120V/240V, 60
fore operation.
Hz, single phase, AC current.
2. Engine Key Switch Start and shut down the engine.
8. Main Circuit Breakers Push the button to reset the circuit.
3. DC 12V Receptacle Cigarette lighter style receptacle, 12V DC, 8A.
4. NEMA 5-20R GFCI Duplex Receptacle Connect electrical devices that run on
120V, 60 Hz, single phase, AC current.
5. AC 20A Circuit Breaker Thermal protector that protects the 5-20R
receptacle from overload.
6. Voltage Selector Sets the generator’s output voltage to 120V or 240V.
· 120V (left): 5-20R outlet (4) is active. L14-30R outlet (14) puts out 120V.
9. Grounding Nut Connection point for grounding the generator to the earth.
See p. 19 for more information.
10. DC Circuit Breaker Thermal protector that protects the DC circuit from
overload.
11. CO WATCHDOG Carbon Monoxide Monitor Measures the accumulation of
poisonous CO gas while the generator is running. If the level of CO gas gets
too high, the CO Watchdog system will automatically shut down the generator.
See p. 25 for more details.
· 120V/240V (right): 5-20R outlet (4) is inactive. L1430R outlet (14) puts out 240V.
11
UNPACKING & PACKING LIST
UNPACKING
With the help of a friend or trustworthy foe, such as one of your in-laws,
carefully remove the generator from the packaging and place it on a sturdy,
flat surface. Make sure to take out all contents and accessories. Do not
discard the packaging until everything is removed. Check the packing list
below to make sure you have all of the parts and accessories. If any part is
missing or broken, please contact customer service at
1-800-232-1195 (M-F 8-5 CST), or email
techsupport@wenproducts.com.
IMPORTANT: Two red shipping brackets have been added to the bottom of your generator to protect the generator during shipping. Please make sure to remove BOTH shipping brackets before operation. Make sure there is no gasoline or oil in the generator, and carefully tip the generator on its end for easier access to the brackets.
IMPORTANT: The LPG hose is packed underneath the fuel tank, sitting above the engine. Remove the hose and set it aside before assembling or operating the generator.
PACKING LIST
No.
Accessory
Qty.
No.
43
Foot Support Assembly
2
49
44
Foot Support Isolator
2
31
32
M6x40 Bolt
4
64
45
M6 Nut
6
59
42
Wheel
2
30
48
Wheel Axle
2
15
16
Flat Washer
2
N/A
25
Cotter Pin
2
N/A
19
Handle
1
N/A
Accessory
Qty.
Handle Connector
1
M8x35 Bolt
2
M8 Hex Nut
8
Handle Bolt
1
Handle Fixing Clip
1
M6x55 Bolt
1
Spark Plug Wrench
1
First Stage Regulator
1
Oil Bottle
1
12
ASSEMBLY & ADJUSTMENTS
TO INSTALL THE FEET:
Slide two M6x40 bolts (32) through the foot support assembly (43) and the
generator frame. Tighten with M6 nuts (45). Repeat for the other foot.
TO INSTALL THE WHEELS:
NOTE: Connecting/disconnecting the battery’s negative terminal requires
removing the right wheel. Before installing the wheels, verify that the
negative terminal of the battery has been connected securely (see p. 18 for
more information). Slide the wheel axle (48) through the wheel (42), flat
washer (16), and wheel bracket on the frame. Insert a cotter pin (25) through
the hole on the end of the axle to keep the wheel in place. Repeat for the
other wheel.
TO INSTALL THE HANDLE:
Slide the M8x35 bolts (31) through the handle connector (49) and the frame.
Tighten with the M8 nuts (64). Slide the handle bolt (59) through the handle
connector (49) and the handle (19), and tighten with M8 nut (64). Next,
install the handle fixing clip (30). Insert the M6x55 bolt (15) through the
frame and handle fixing clip (30) and tighten with M6 nut (45).
Fig. 1
NOTE: Only the generator frame is shown to maximize clarity for assembly.
13
GENERATOR PREPARATION
The following section describes the necessary steps to prepare the generator for use. If you are unsure about how to perform any of the steps please call 1-800-232-1195 (M-F 8-5 CST) for customer service. Failure to perform these steps properly can damage the generator or shorten its life.
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’s crankcase is 20.3 fl. oz. (0.6 L).
ENGINE OIL RECOMMENDATIONS
Select good quality detergent oil bearing the American Petroleum Institute
(API) service classifications SJ, SL, or SM (synthetic oils may be used).
Select the SAE viscosity grade of oil that matches the expected operating
temperature.
Fig. 2
°F -20
30W
10W-30
Synthetic 5W-30
0
20 32 40
60
80
· 30W Engine Oil Temperatures above 40°F
· 10W-30 Engine Oil Temperatures between 0°F – 40°F
· Synthetic 5W-30 Engine Oil
100
All temperature ranges
°C -30
-20
-10
0
10
20
30
40
TO ADD OIL:
1. Place the generator on a level surface. Make sure the engine is OFF before
adding or checking oil.
CAUTION! Keep the generator level. Tilting the generator to assist in filling will cause oil to flow into the wrong areas of the engine and cause damage.
2. Unscrew the oil dipstick (Fig. 3) 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. 4.
4. Reinstall the oil dipstick and firmly tighten it. Wipe clean any spilled
oil.
NOTE: Extend the lifespan of your generator by catching the loose metal
filaments that naturally build up inside the crank case with the WEN Magnetic
Dipstick (Model 55201), available for purchase at wenproducts.com.
Upper Fill Line Lower Fill Line
Dipstick
Fig. 3 Fig. 4
14
GENERATOR PREPARATION
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.
Fig. 5
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.
Upper Limit
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 dipstick (or when you can see the oil coming halfway up the oil fill threads). See Fig. 5.
Lower Limit
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
FUEL OPTION A: GASOLINE
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 generator performs best with ethanol-free
gasoline. DO NOT use gasoline with over 10% ethanol.
The capacity of the fuel tank is 4 US gallons (15 L). 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.
15
GENERATOR PREPARATION
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. 6) 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.
Fuel Fuel Cap Gauge
Fig. 6
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. 6) to see if
there is sufficient fuel inside the tank: · E = Empty · F = Full
2. If the tank is empty, add gasoline to the fuel tank. See above section,
“To Add Gasoline”.
WARNING! If using gasoline, the LPG tank must be shut OFF. If using LPG, the fuel valve on the generator must be turned to the OFF position.
FUEL OPTION B: LIQUID PETROLEUM GAS (LPG)
DANGER! Explosion and fire. LP vapors are extremely flammable and explosive.
Do not use or store LP cylinder in a building, garage or enclosed area.
Failure to do so will result in death or serious injury.
WARNING! Explosion and fire. The cylinder valve should be turned OFF (closed)
when generator is not in use. Failure to do so could result in death or
serious injury.
· Always keep the LPG cylinder in an upright position. · When transporting and
storing, keep cylinder secured in an upright position with cylinder valve
turned off. Keep cylinders ventilated and away from heat when in a vehicle. ·
Liquid Petroleum Gas (LPG) is highly flammable and explosive. Flammable gas
under pressure can cause a fire or explosion if ignited. · In any petroleum
gas fire, flames should not be extinguished unless the fuel supply valve is
turned OFF. If a fire is extinguished and a supply of fuel is not turned OFF,
an explosion hazard could be created. · RISK OF BURNS. Contact with liquid
contents of cylinder will cause freeze burns to the skin. If liquid contents
contacts skin or eyes, seek immediate medical attention. · When exchanging LPG
cylinders, be sure the cylinder valve is of the same type.
16
GENERATOR PREPARATION
FUEL OPTION B: LIQUID PETROLEUM GAS (LPG) (CONT.)
NOTE: LPG regulator inlet pressure is approximately 30 PSI at 0 °F, and 218
PSI at 100 °F.
· You can use LPG tanks with Type 1, right hand Acme threads with this
generator. Verify that the qualification date on tank has not expired. Do not
use rusted or damaged cylinders.
· All new cylinders must be purged of air and moisture prior to filling. Used
cylinders that have not been plugged or kept closed must also be purged.
· The purging process should be done by the propane gas supplier. (Cylinders
from an exchange supplier should have been purged and properly filled by
supplier).
To connect your generator to an LPG cylinder: 1. Take off the safety caps from
the cylinder valve, generator-mounted regulator, and regulator connecting hose
ends.
2. With the LPG tank closed, attach the first-stage regulator to the valve.
Turn the regulator’s plastic coupling right (clockwise) to tighten the
assembly onto the LPG tank (Fig. 7).
3. Connect the other end of the hose to the generator’s onboard regulator
with a 3/4 in. (19mm) wrench (not supplied) (Fig. 8).
4. Turn the LPG tank valve ON (Fig. 9) and check for leaks by spraying soapy
water to check the connections. If bubbles appear, become larger in size, or
increase in number, a leak exists. This must be corrected before using the
generator. Contact your local Independent Authorized Service Dealer (IASD) for
assistance.
NOTE: You can use Teflon (or other tape) to help seal the connection between
the regulator hose and the generator.
Fig. 7 Fig. 8
CAUTION! Always position the LPG cylinder so the connection between the valve
and regulator won’t cause sharp bends or kinks in hose.
WARNING! Risk of burns. Contact with liquid contents of cylinder will cause
freeze burns to the skin. If liquid contents contacts skin or eyes, seek
immediate medical attention.
WARNING! When transporting and storing, keep cylinder secured in an upright
position with cylinder valve turned off. Keep cylinders ventilated and away
from heat when in a vehicle.
Fig. 9
17
GENERATOR PREPARATION
STEP 3 – CONNECT THE BATTERY
WARNING! BATTERY GIVES OFF EXPLOSIVE HYDROGEN GAS. · Keep battery away from
spark, flame, or cigarette. · Do not connect or disconnect battery while
generator is running. · Service or use battery only in well ventilated areas.
WARNING! Battery contains sulfuric acid. Battery acid is poisonous. Tilting
the generator with the battery installed can cause battery acid to spill. ·
Wear protective clothing and eye wear when servicing battery. · Keep out of
reach of children. · Do not tilt generator with battery installed. · If
battery acid gets on your skin, wash with water immediately. · If battery acid
gets in your eyes, flush with water for at least 15 minutes and call a doctor
immediately.
If battery acid is swallowed, call a doctor immediately. Drink a large amount
of water or milk. Then drink milk of magnesia or vegetable oil.
The generator comes with the battery disconnected for safety. When using
gasoline to run the generator, the battery must be connected whether using
electric or recoil start. The battery must also be connected for electric
start when using LPG, but the battery does not need to be connected for recoil
start on LPG. Connecting / disconnecting the battery’s negative terminal
requires removing the right wheel. To connect the battery: 1. Remove the black
cover from the negative (-) battery terminal. 2. Connect the black cable to
the negative (-) battery terminal with the suitable nuts and bolts. 3. Make
sure connections are secure and slide rubber boot over the negative (-)
battery terminal and connection hardware. 4. Connect the red cable to the
positive (+) terminal with the suitable nuts and bolts. (This has already been
done for the battery included with the generator.) 5. Make sure all
connections are secure and slide rubber boots over the battery terminals and
connection hardware. IMPORTANT: If you do not plan to use the generator for an
extended period of time, it is recommended to DISCONNECT the negative battery
cable from the battery to protect the battery from losing charge. After
disconnecting the cable, cover the free end with an insulator such as
electrical tape. If the battery is dead or disconnected, the generator will
not start when using gasoline, or when using LPG and electric start. The
battery receives charge when the generator is running. To help maximize your
battery’s lifespan, and ensure it’s ready when needed, run your generator once
a month, disconnect the negative battery cable as outlined above, or connect
the battery to a trickle charger.
18
GENERATOR PREPARATION
STEP 4 – GROUND THE GENERATOR
To reduce the risk of electric shock and to maximize safety, the generator
should be properly grounded.
Ground the generator by tightening the grounding nut on the front control panel (Fig. 10) against a grounding wire. A generally acceptable grounding wire is a No. 12 AWG (American Wire Gauge) stranded copper wire.
This grounding wire should be connected at the other end to a copper, brass, or steel-grounding rod that is driven into the earth. Wire and grounding rods are not included with the generator.
Grounding Nut
NOTE: Grounding codes can vary by location. Contact a local electrician to check the area codes.
WARNING! Failure to properly ground the generator increases your risk of electric shock.
Fig. 10
HIGH ALTITUDE OPERATION ABOVE 2000 FEET
The fuel system on this generator may be affected by operation at high
altitudes. Proper operation can be ensured by installing an altitude kit at
altitudes higher than 2000 feet above sea level. At elevations above 7000
feet, the engine may experience a decrease in performance, even with the
proper altitude kit. Operating this generator without said kit may increase
the engine’s emissions and decrease both fuel economy and performance.
This kit should be installed by a qualified mechanic. You can order the kit at
wenproducts.com by searching part number DF475-HA27. Refer to the instructions
included with your altitude kit for more information about installation.
WARNING! To prevent serious injury from fire, follow the kit installation
procedures in a well-ventilated area away from ignition sources. If the engine
is hot from use, shut the engine off and wait for it to cool before
proceeding. Do not smoke near the generator. Warranty will be void if
adjustments are not made for high altitude use.
CAUTION: Engines with the high-altitude kit installed operated at lower
altitudes could cause severe engine damage and affect emissions compliance. Be
sure to uninstall the high altitude kit when operating at altitudes below 2000
feet.
After completing the above preparation, the generator is ready to be started.
19
STARTING THE GENERATOR
Before starting the generator, make sure you have read and performed the steps
in the “Generator Preparation” section of this manual. If you are unsure about
how to perform any of the steps in this manual please call
1-800-232-1195 (M-F 8-5 CST) for
customer service.
DANGER: CARBON MONOXIDE Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison gas you
cannot see or smell. If you can smell the generator exhaust, you are breathing
CO. But even if you cannot smell the exhaust, you could be breathing CO.
NEVER use a generator inside homes, garages, crawl spaces, or other partially
enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Using a fan or opening windows and doors does NOT supply enough fresh air.
ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
Even if you use a generator correctly, CO may leak into the home. ALWAYS use a
battery-powered or batterybackup CO alarm in the home. If you start to feel
sick, dizzy, or weak after the generator has been running, move to fresh air
RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.
WARNING: The exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects, or other reproductive harm.
WARNING: Do not operate generator near open flame or flammable materials This
generator may emit highly flammable and explosive gasoline vapors, which can
cause severe burns or even death if ignited. A nearby open flame can lead to
explosion even if it isn’t directly in contact with gasoline. Do not smoke
near the generator.
WARNING: This generator produces powerful voltage, which can result in
electrocution.
WARNING: Do not use in rainy or wet conditions. Do not touch bare wires or
receptacles (outlets). Do not allow children or non-qualified persons to
operate.
WARNING: Generator should only be connected to electrical devices, either
directly or with an extension cord. NEVER connect to a building electrical
system unless a qualified electrician has connected the generator to a
transfer switch as a separately derived system. Such connections must comply
with local electrical laws and codes. Failure to comply can create a back-
feed, which may result in serious injury or death to utility workers.
To maximize safety, ALWAYS ground the generator before using it. Refer to
“Step 4 – Ground The Generator.” Use a ground fault circuit interrupter (GFCI)
in highly conductive areas such as metal decking or steel work. GFCIs are
available in-line with some extension cords.
CAUTION! Disconnect all electrical loads from the generator before attempting
to start it.
Follow the instructions on the next page to start your generator.
20
STARTING THE 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 (see “Ground the Generator”).
3. Check there is sufficient level of oil in the crankcase. Add oil if necessary (see “Add/check Oil”).
4. Verify the fuel selection dial is turned to the desired fuel. Turn the dial up to the 12 o’clock position for gasoline and down to the 6 o’clock position for LPG. Check that there is adequate supply of the selected fuel.
5. Make sure all electrical devices are unplugged from the
generator during ignition. Otherwise it will be difficult for
1
the engine to start.
Fig. 11 Fig. 12
WARNING! The LPG cylinder valve must be shut OFF when using gasoline. The generator’s fuel valve must be shut OFF when using LPG.
STARTING THE GENERATOR
1. To use gasoline, turn the fuel valve to the ON position (Fig. 11). To use
LPG, make sure all of the LPG connectors
and hoses are well connected and sealed. Close the fuel valve, then open the
LPG tank valve.
2. Move the choke lever (Fig. 12 – 1) to the CLOSE/START position.
3. Make sure the battery is connected. See p. 18 for more information.
a. To start the engine with electric starter:
4. Insert the key and turn the engine switch to the START position for 2-3
seconds. NOTE: If the engine does not start, release the switch and try again.
Keeping the switch in the START position too long can damage the starter.
5. When engine starts, release the switch to the ON.
6. Slowly move choke lever to the OPEN/RUN position. If engine fires, but
does not continue to run, move choke lever to CLOSE/START position and repeat
starting instructions.
b. To start the engine with recoil starter: 4. Turn the engine switch to the
ON position.
5. Pull on the recoil starter handle slowly until a slight resistance is
felt, then pull quickly to start the engine. Return cord gently into the
recoil starter. Never allow the cord to snap back.
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.
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.
21
USING YOUR GENERATOR
CALCULATING THE WATTAGE OF YOUR DEVICE(S)
Connect electrical devices running on AC current according to their wattage
requirements. Calculate the total running wattage and starting wattage of the
device(s) you wish to connect, and MAKE SURE that they are within the capacity
of your generator and the capacity of each individual outlet.
Generator Wattage Capacity
Generator Running (Rated) Watts
Generator Starting (Surge) Watts
Gasoline: 3800W
Gasoline: 4750W
LPG: 3500W
LPG: 4350W
What this means:
What this means:
The generator can produce a maximum of Some devices such as box fans require short
3800W/3500W on a continuous basis to sup- bursts of extra power in addition to the rated
ply ongoing power to your electronic devices. wattage listed by the device to start their
motors.
NOTE: Also check the rated amperage for
each outlet and make sure not to overload The generator can produce a maximum
the individual outlets.
wattage of 4750W/4350W for a short period
of time (seconds) to cover the extra starting
power required by your electronic devices.
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 Fig. 11.
The wattage can be calculated using this equation: Watts = Volts x Amperes
To calculate the total running watts of your To calculate the total starting watts of your
devices:
devices:
+ Add up the running wattages of all the device(s) you plan to connect
+ Add up the total running wattage of all the device(s) you plan to connect
Electronic Device Wattage
Calculation
= The total running wattage
This wattage should NOT exceed the running wattage of 3800W/3500W.
It is recommended to maintain a load at or below 3420W/3150W (90% of the rated
output) to ensure steady voltage output and to prolong the generator’s
lifespan.
+ Add the single highest ADDITIONAL starting wattage out of the device(s) you
plan to connect
= The total surge (starting) wattage
This wattage should NOT exceed the starting wattage of 4750W/4350W.
If any of either of the total calculated running watts or starting watts is higher than the capacity of your generator, adjust the load until both wattage requirements are met. Otherwise you will overload the generator, and cause damage to the engine and your electrical device(s).
22
Table 1 – How to Calculate Wattages
USING YOUR GENERATOR
CALCULATING THE WATTAGE OF YOUR DEVICE(S) – CONTINUED
The chart below serves as a reference for the estimated wattage requirements
of common electrical devices. However, do not solely rely on this chart – all
electronics and appliances are built differently. Always check the wattage
listed on the electrical device before consulting this chart.
Tool or Appliance Hot Plate
Saw – Radial Arm Electric Stove (Each Element)
Saw – Circular Air Compressor (1 HP) Window Air Conditioner
Saw – Miter Microwave Well Water Pump Sump Pump Refrigerator Freezer Furnace
Blower Computer Electric Drill Television Deep Freezer Garage Door Opener
Stereo Box Fan Clock Radio Security System DVD Player / VCR Common Light Bulb
Rated (Running) Watts
Surge (Starting) Watts
2500 2000 1500-2800 1500 1500 1200 1200 1000 1000 800 800 800 800 600 500 500 480 400 300 300 180 100 75
0 2000
0 1500 3000 1800 1200
0 1000 1200 1200 1300
0 900
0 500 0
0 600
0 0 0 0
Table 2 – Estimated Wattages of Common Electrical Appliances
NOTE: Become familiar with the functions and capacity of each component on the control panel before connecting electrical devices. See page 11 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.
23
USING YOUR GENERATOR
CONNECTING ELECTRICAL DEVICES
CAUTION: Become familiar with the functions and capacity of each component on
the control panel (page 11) before connecting electrical devices. Do not
overload generator or individual panel receptacles. Do not connect 50Hz or
3-phase loads to the generator.
Follow the steps below to properly connect your device(s) to the generator: 1.
Before connecting electrical devices, allow the generator to run for a few
minutes to stabilize the speed and voltage output.
2. 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.
IN CASE OF OVERLOAD
If your generator becomes overloaded from too much drawn wattage, the push-to-
reset circuit breaker(s) on your control panel will activate and cut off the
output. When an overload occurs, reduce the load by turning off and unplugging
your electronic device(s), then press the activated circuit breaker to reset
your generator. If the circuit breaker does not reset, wait several minutes
and try again. If no power is produced after resetting, restart your
generator.
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.
Amps
2.5 5 7.5 10 15 20 25 30 40
Device Requirements
Watts (120V)
Watts (240V)
300
600
600
1200
900
1800
1200
2400
1800
3600
2400
4800
3000
6000
3600
7200
4800
9600
*NR = Not Recommended
8 wire
NR NR NR NR NR 175 150 125 90
Max. Cord Length (ft) by Wire Gauge
10 wire #12 wire #14 wire #16 wire
NR
NR
375
250
NR
300
200
125
350
200
125
100
250
150
100
50
150
100
65
NR
125
75
50
NR
100
60
NR
NR
65
NR
NR
NR
NR
NR
NR
NR
Table 3 – Power Cord Requirement Guide
WARNING! Generator should only be connected to electrical devices, either directly or with an extension cord. NEVER CONNECT TO A BUILDING ELECTRICAL SYSTEM unless a qualified electrician has connected the generator 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.
24
USING YOUR GENERATOR
CO SENSOR INFORMATION
The CO Watchdog carbon monoxide monitoring system (Fig. 13) measures the
accumulation of poisonous CO gas while the generator is running. If the level
of CO gas gets too high, the CO Watchdog system will automatically shut down
the generator. This system is not a substitute for an indoor CO alarm.
Fig. 13
Whenever the CO Watchdog system shuts down the generator, one of the LED lights on the generator control panel (Fig. 13) will blink red for at least 5 minutes after the generator is shut down. If you notice that the LED is blinking red, vacate the area immediately. Go to an open, outdoor area. Ventilate the area around the generator thoroughly before returning. Let the generator stay shut down for a few minutes before restarting the engine. This should allow carbon monoxide to dissipate from the area. If you restart the generator and the CO Watchdog detects that CO levels are still too high, it will shut down the generator again. If CO levels are low enough, the generator will run normally.
NOTE: If the generator is oriented so that the engine exhaust is blown towards the CO sensor, the generator may shut down.
Ensure that the generator is located in an open outdoor area, with the exhaust pointing away from occupied structures, and pointing away from the prevailing winds, such that those winds do not blow engine exhaust towards the sensor module. If anyone experiences dizziness, headaches, nausea, fatigue, or other symptoms of CO poisoning, get to fresh air immediately and seek the attention of a qualified medical professional. Follow all other directions in this manual regarding the connection and disconnection of electrical devices when starting or shutting down the generator.
When starting the generator, the CO Watchdog LEDs on the panel may flash. This
indicates that the system is running a self-test procedure, and does not
indicate a problem.
If the CO Watchdog LED on the panel is yellow, a system error has occurred, or
the CO sensor has reached the end of its life. Contact WEN customer service
(1-800-232-1195, M F 8 5 CST, or
techsupport@wenproducts.com) for assistance.
When operating your generator, please note the following:
· The CO Watchdog does not discriminate in its input; any source of carbon monoxide in the area around the generator could cause it to activate. If the CO Watchdog LED is blinking red, safety measures should be taken immediately.
· Tampering with, disconnecting, or bypassing the CO sensor could cause hazardous conditions, including but not necessarily limited to injury or death, and will void your warranty. The generator will not run with the CO sensor disconnected or bypassed, or if the CO sensor indicates an error.
· The CO sensor has a lifetime of about 7 years, and is capable of monitoring its lifetime. If your generator shows an error light several years after purchase, it may be time to replace the CO sensor. Contact WEN customer service for assistance.
25
USING YOUR GENERATOR
CHANGING FUELS
1. Before changing the fuel source, make sure the generator is turned off or
running under half-load. Do not change fuel when generator is over half-load.
2. If switching from LPG to gasoline, turn off the LPG tank valve and
disconnect LPG fuel tank from generator. Then turn ON the fuel valve.
If switching from gasoline to LPG, turn off the fuel valve. Then follow the
LPG connecting procedure in section “FUEL OPTION B: Liquid petroleum gas
(LPG)”.
3. Check the fuel level of the selected fuel and make sure there is an
adequate amount.
4. Turn the fuel selection dial to the desired fuel; turn the dial up to the
12 o’clock position for gasoline and down to the 6 o’clock position for LPG.
SHUTTING OFF THE GENERATOR
TO STOP THE GENERATOR
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.
3a. If using LPG, make sure the fuel valve is off, turn the fuel selection
dial to gasoline position (12 o’clock) and turn the engine key to the OFF
position. This is the final step.
IMPORTANT: Always ensure that the fuel valve and the engine switch are in the
OFF position when the generator is not in use.
3b. If using gasoline, turn the fuel valve to the OFF (horizontal) position.
Let the generator run until the fuel is used up. Continue on to step 4.
4. Turn the engine key to the OFF position
5. Drain the carburetor (See “Draining the Carburetor”).
WARNING! Allow the generator to cool down before touching areas that become hot during use.
CAUTION: Allowing gasoline to sit in the fuel tank for long periods of time can make it difficult to start the generator in the future. Never store the generator for extended periods of time (over 2 months) with fuel in the fuel tank. Refer to “Storing the Generator”.
26
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.
Before maintaining or servicing the generator, turn OFF the generator,
disconnect all devices and allow the generator to cool down.
Recommended Maintenance Schedule
Every 8 Hours or
Daily
Every 25 Hours
Check Level
X
Engine Oil
Replace
X*
Air Filter Spark Plug
Check
Clean Check/Clean/
Regap Change
Check Level
X
Fuel
Drain
Carburetor
Drain
X
Spark Arrestor
Check/Clean
- Clean/change more often under dusty conditions or operating under heavy load.
Every 3 Every 6 Months or Months or 50 Hours 100 Hours
Before Storage
As Necessary
X X X
X
X
X
X
X
X
X
Table 4 – Recommended Maintenance Schedule
IMPORTANT GENERATOR MAINTENANCE TIPS: · Drain your carburetor after each use and before storage to prevent it from clogging. · Do not store the generator with fuel inside the tank for more than 2 months – the fuel will go bad. · Run the generator for 20 to 30 minutes every month to maximize its lifespan.
NOTE: Failure to properly maintain the generator will void the warranty.
27
MAINTENANCE
CLEANING THE GENERATOR
Keep the generator clean to prevent improper operation or machine damage from
dirt and debris. Inspect all ventilation openings on the generator. These
openings must be kept clean and unobstructed.
If the generator becomes dirty, use a damp cloth to wipe exterior surfaces. Use a soft bristle brush to loosen dirt and oil and use a vacuum to pick up loose dirt. Use low pressure air (not to exceed 25 PSI) to blow away dirt.
WARNING! Never clean the generator when it is running! Never clean with a bucket of water or a hose. Water can get inside the working parts of the generator and cause corrosion or a short circuit.
DRAINING THE CARBURETOR
We recommend draining the carburetor after every use and before storing the
generator. 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.
Fig. 14
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 Phillipshead screwdriver (not included) and drain out any gasoline that has built up inside.
Fuel Drain Screw
3. Once the fuel has drained, close the drain screw.
NOTE: Make sure to drain your carburetor before storing the generator for long periods of time.
28
MAINTENANCE
CHECKING/ADDING OIL
Check the oil level before each use and every 8 hours of operation. The oil
capacity of the generator engine is 20.3 fl. ounces. Add oil when the oil
level is low. For proper type and weight of oil refer to “add oil” portion of
the “Generator Preparation” section. This is a critical step for proper engine
starting. The generator is equipped with an automatic shutoff to protect it
from running on low oil.
To check the oil level and add oil: 1. Make sure the generator is on a level surface. Do not tilt the generator, as oil will flow into engine areas and cause damage. Keep generator level!
2. Clean around the oil fill. Remove the dipstick and wipe the it with a clean rag.
3. Insert the dipstick into the oil fill opening without screwing in. Remove the dipstick to check the oil mark (Fig. 15). Add oil if the oil mark covers less than one half of the dipstick.
Fig. 15
4. Using a funnel or appropriate dispenser, slowly add more oil. Repeat step 3 until the oil mark reaches the top of the dipstick (you can see oil coming up the threads of the oil fill). Do not over fill.
Upper Limit
5. Reinstall dipstick and wipe clean any spilled oil with a rag. Reinstall the oil access cover.
Lower Limit
DRAINING/CHANGING OIL
Change the oil according to the Recommended Maintenance Schedule.
Fig. 16
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.
To drain the oil from the generator: 1. Place generator on elevated platform.
Prepare an approved gasoline-storage container underneath the oil drain bolt
next to the oil dipstick to catch the oil as it drains.
2. Unscrew the oil drain bolt (Fig. 16) and allow oil to drain from the
engine completely.
Oil Drain Bolt
3. Reinstall the oil drain bolt and tighten it securely. Wipe clean any oil spillage.
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.
29
N
M
MAINTENANCE
AILR FILTER MAINTENANCE
Check every 50 hours of operation (refer to Recommended Maintenance Schedule).
Routine maintenance of the air filter helps maintain proper airflow to the
carburetor. Occasionally check that the air filtKer is free of excessive dirt.
Clean air filter more frequently in dirty or dusty conditions
To inspect and clean the air filter: 1. JRemove the air filter cover (Fig. 17)
by undoing the clasps at the top and bottom of the air filter cover.
2.HRemove the sponge-like air filter element from the casing. Wipe excessive
oil and any dirt from inside of the air filter casing.
3.GCheck and clean the foam air filter element. Good elements can be washed in
soapy water. Dry the element in clean cloth (do not twist it).F A small amount
of oil left in the element is normal and necessary for the engine to work
properly.
If tEhe air filter element has been damaged, replace it with a new one.
Replacement air filters can be ordered from wenproducts.com by searching part
no. DF475-166.1.
D
4. Reinstall the air filter element and air filter cover.
Air Filter Cover
Fig. 17
C 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.
B
SPARK ARRESTOR MAINTENANCE
The spark arrestor is located outside the muffler, which gets very hot
1
Fig. 18
duAring operation. Allow the engine to cool completely before servic-
ing the spark arrestor. To inspect and clean the spark arrestor:
1. Re24move23the scre22ws hol2d1 ing the20 cover p19 late wh18ich reta17ins the 16end 15
14
13
12
11
10
9
of the spark arrestor to the muffler (Fig. 18 – 1).
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.
4. Reinstall the spark arrestor in the muffler and secure it in place with the screws.
30
MAINTENANCE
SPARK PLUG MAINTENANCE
Refer to Recommended Maintenance Schedule for maintaining the spark plug. The
spark plug is important for proper engine operation. Check the spark plug
regularly to maintain proper engine operation. A good spark plug should be
intact, free of deposits, and properly gapped.
To inspect or replace the spark plug: 1. Pull on the spark plug boot to remove
it (Fig. 19). Be careful not to tear insulation or wire.
2. Remove the spark plug rubber boot and unscrew the spark plug from the
engine using the spark plug wrench provided (Fig. 20). TIP: There is limited
space for the wrench to turn. Use both rows of holes in the spark plug wrench
to gain leverage to loosen the plug.
Fig. 19
Spark Plug Boot
3. Visually inspect the spark plug. If it is cracked or chipped, or if the electrodes are worn or burned, discard it and replace with a new spark plug.
Cylinder Assembly
We recommend replacing with an NGK BP7ES/Torch F7TC spark plug (part no.
DF475-145), available for purchase at wenproducts.com.
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.
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.) (Fig. 21). Carefully adjust the gap if necessary.
Fig. 20
Plug Wrench Spark Plug Boot
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 spark plug
is ½ to ¾ of a turn (15 ft-lb torque/20.33 Nm) after spark plug gasket
contacts spark plug hole.
7. Reinstall the spark plug boot over the spark plug.
Fig. 21 0.7 – 0.8 mm
31
MAINTENANCE
BATTERY MAINTENANCE/STORAGE
The battery (part no. DF475-041) shipped with the generator has been fully
charged. The battery will receive charge when the engine is running. Remember
to run the generator once a month for 20-30 minutes to charge the battery. A
charged battery will allow you to start the generator using the electric start
switch during your next time of need.
If the battery is out of charge, you can still manually start the generator
using the recoil start with LPG as your fuel source.
IMPORTANT: If the generator is not used for a long period, it is recommended
to disconnect the negative battery cable from the battery to protect the
battery from losing charge. After disconnecting the cable, cover the free end
with an insulator such as electrical tape. You may can also connect the
battery to an automatic trickle charger to keep the battery charged.
To reinstall/replace the battery: 1. Disconnect the negative (-) battery
terminal first (black wire).
2. Disconnect the positive (+) battery terminal second (red wire).
3. To install a new battery, install the hold down bracket, insert the
threaded rod and tighten with M6 nuts.
4. Connect the positive (+) battery terminal (red wire) first. Slide rubber
boot over the connection hardware.
5. Connect the negative (-) battery terminal (black wire) second. Slide
rubber boot over connection hardware.
NOTE: Always recycle used batteries in accordance with local laws and
regulations. Contact your local solid waste collection site or recycling
facility to obtain information on local recycling processes.
DRAINING THE FUEL TANK
Drain and clean the fuel tank each year, or before storing the generator for
longer than two months.
To drain the fuel tank: 1. Prepare an approved gasoline-storage container to
collect 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 back of control panel.
Disconnect the fuel line from the fuel valve. 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. Turn the fuel valve to ON to start
draining the fuel from the fuel valve opening.
5. Once the fuel is drained, shut OFF the fuel valve.
6. Start and run the engine until the fuel runs out.
7. Drain the carburetor.
8. Store the emptied gasoline in a suitable place. DO NOT store flammable
materials near the gasoline. Do not store fuel for more than 3 months.
CAUTION: Store the emptied gasoline in a suitable place. Never store fuel for
more than 2 months.
NOTE: You can also drain the fuel tank through the carburetor. Follow the
procedures in “Draining the Carburetor”, and turn the fuel valve ON. It may
take a while for the fuel tank to drain, depending on the amount of fuel in
the tank.
32
MAINTENANCE
TESTING THE GFCI OUTLETS
Test the GFCI outlets monthly. The GFCI outlets have two buttons between the
receptacles (refer to Fig. 22): · RESET (upper) · TEST (lower)
To test: 1. Start the generator according to the instructions in this manual.
Wait a few minutes for the generator to stabilize its speed and voltage
output.
2. Press the RESET button on the GFCI outlet (Fig. 22).
3. Connect a device to the outlet and turn it ON.
4. With the device ON, press the TEST button on the GFCI outlet. The power to
the device should be cut off instantly, and the device should turn OFF.
5. Disconnect the device from the outlet and press the RESET button again.
Shut down the generator normally.
Fig. 22
CAUTION: If the device does not instantly turn OFF, you may have a faulty GFCI outlet. Call customer service 1-800-232-1195 M-F 8-5 CST or email techsupport@wenproducts.com for assistance in replacing the outlet.
33
TRANSPORTATION & STORAGE
TRANSPORTING THE GENERATOR
To prevent fuel spillage when transporting, be sure to perform the following
to your generator:
1. Tighten the fuel cap and make sure the fuel valve is turned OFF. 2. Make
sure the engine switch is in the OFF position. 3. Drain the fuel tank if
possible (see “Draining the Fuel Tank”). 4. Keep the generator upright. Never
place the generator on its side or upside down – doing so could damage the
internal components of the generator and make it difficult to start.
WARNING! Avoid direct sunlight inside a vehicle. If the generator is left in
an enclosed vehicle for many hours, the high temperature could cause the fuel
to vaporize and result in a possible explosion.
STORING THE GENERATOR
Shut off the generator and allow the unit to cool to room temperature before
storing it. Never place any type of storage cover on the generator while it is
still hot. Do not obstruct any ventilation openings.
Follow the procedures below for properly storing your generator. We highly
recommend running your generator once a month for 20 to 30 minutes. Plug in a
small load in to ensure there is proper power output.
For Short Periods (30 to 60 Days):
· Drain the carburetor (see page 26).
· Disconnect the negative terminal from the battery.
· Add fuel stabilizer: Follow the suggested portions and instructions of your
preferred stabilizer. Run the engine for 15 to 20 minutes, allowing the fuel
stabilizer to mix with the gasoline and circulate through the carburetor, and
then top off with fuel. Filling the fuel tank full reduces the amount of air
in the tank and helps fight deterioration of fuel.
For Extended Periods (Over 60 Days):
· Disconnect the negative terminal from the battery (see page 30) .
· Drain the fuel tank and carburetor (see “DRAINING THE FUEL TANK”). NEVER
store generator with fuel in the tank for more than two months.
· Change the engine oil (see “CHANGING OIL”).
WARNING! Store the generator upright in a cool and dry location, away from
sources of heat, open flames, sparks or pilot lights.
PRODUCT DISPOSAL
Do not dispose of used generator or parts with your household waste. This
product contains electrical or electronic components that should be recycled.
Please take this product to your local recycling facility for responsible
disposal to minimize its environmental impact.
Do not dispose of used oil or fuel in the trash or down a drain. Please
contact your local recycling center or auto garage to arrange proper oil/fuel
disposal.
34
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
Engine switch is set to OFF.
Set engine switch to ON.
Fuel valve is turned to OFF.
Turn fuel valve to ON.
Oil is low.
Add or replace oil.
Engine is out of fuel.
Add fuel.
Engine is filled with contaminated or old fuel.
Drain fuel in the tank. Fill with fresh fuel.
Spark plug is dirty or broken.
Clean or replace the spark plug.
Engine will not start. Carburetor is air locked.
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.
Propane tank is OFF.
Turn tank ON.
Regulator is stuck.
Turn OFF propane tank. Disconnect hose from onboard regulator. Spray a small amount of penetrating oil into regular inlet, then gently insert a pin into inlet to break valve free.
CO levels too high.
Refer to “CO Sensor Information” on p. 25.
CO sensor disconnected, removed, or faulty.
Connect or install the CO sensor. If an error is shown, contact WEN customer service for assistance. Also refer to “CO Sensor Information” on p. 25.
Engine runs but there is no electrical output from
the GFCI outlets.
GFCI has been tested but not reset.
Defective GFCI outlet.
Press RESET button on GFCI outlet. Contact customer service at 1-800-232-1195.
Circuit breaker has been tripped due to overload.
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.
Engine runs but there is no electrical output
whatsoever.
Bad connecting cords/wires.
Bad electrical device connected to the generator.
Check the power cords and extension cords. Do not use if any cord is damaged.
Replace damaged cords immediately.
Try connecting a different device.
Voltage regulator is bad
Check voltage regulator with a multimeter, replace if necessary.
Carbon brushes worn or need adjustment
Check carbon brushes, adjust so that both brushes extrude the same length, or replace if worn.
Generator runs but does not support all electrical
devices connected.
Generator is overloaded.
Short circuit in one of the devices.
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.
Try disconnecting any faulty or short-circuited electrical loads.
Air filter is dirty.
Clean or replace the air filter element.
1. The fuel isn’t running through Turn off the generator and wait for it to cool down.
the fuel valve.
Perform the following steps:
Engine is “hunting” during operation (engine
RPM is fluctuating).
2. The air filter is clogged. 3. The muffler or spark arrestor
is blocked 4. There is gunk in the carburetor
1. Check if the fuel is properly and consistently going through the fuel
valve 2. Check for any blockage in the air filter. Check and clean the air
filter as
necessary. 3. Check if the spark arrestor is blocked. Clean with metal brush
as neces-
preventing a consistent fuel/
sary.
air mixture.
4. Use “gunk remover” spray on the carburetor jets.
35
/FVUSBM
WIRING DIAGRAM
36
GENERATOR
EXPLODED VIEW & PARTS LIST
37
EXPLODED VIEW & PARTS LIST
GENERATOR
No.
Part No.
Description Qty. No.
Part No.
Description Qty.
1 1.1
DF475X-001 DF475-001.1
Alternator Assembly 1
Carbon Brush Assembly
1
29 DF475X-029ASM 29.1 DF475-029.1
Control Panel Assembly
Ignition Switch
1 1
2
DF475-002
Motor Stand
1
N.P.
P55340
Starter Key (set of 2) 1
3
DF475-003
Switch Dial Assembly 1
29.2
DF475-029.2
DC Receptacle, 12V 1
4
DF475-004
Hexagon Pattern Pan Head Screws M6x12
1
29.3
DF475-029.3
DC Breaker, 8A
1
NEMA 5-20R 120V
5
DF475-005
Nut M8
2
29.4 DF475X-029.4
20A GFCI Duplex
1
6
DF475-006
Wire Harness Clip 2
Outlet
7
DF475X-007
Frame
1
29.5
DF475-029.5
AC Breaker, 20A
1
8
DF475-008
Isolator A
2
29.6
DF475-029.9
Grounding Lug
1
9
DF475-009
Isolator B
2
29.7
DF475-029.6
Voltage Selector Switch
1
10
DF475-010
Fuel Filter
1 29.8 DF475-029.7
AC Breaker, 16A
2
11
DF475X-011
Fuel Tank Assembly 1
NEMA L14-30R
12
DF475-012
Fuel Cock
1
29.9
DF475-029.8
125V/250V 30A
1
13
DF475X-013
Regulator Assembly 1
Receptacle
14
DF475X-014
Regulator
1 29.10 DF475-029.10
Rectifier
1
15
DF475-015
Bolt M6x55
1 29.11 DF1100-029.11
Charger
16
DF475-016
Flat Washer
2 29.12 DF475X-029.12
CO Sensor LED
17
DF475-017
Bolt M8-1×220
1
30
DF475-030
Handle Clip
1
18
DF475-018
Rotor Bolt Gasket Ø8.5x24x3
1
31 32
DF475-031 DF475-032
Bolt M8x35
2
Bolt M6x40
4
19
DF475-019
Handle Assembly 1
33
DF475-033
Voltage Regulator 1
20
DF475-020
Bolt M6x175
4
34
DF475-034
Bolt M5x16
1
21
DF475-021
Bolt M6x12
13
35
DF475-035
Bolt M5x12
7
22 23
DF475-022 DF475-023
Nut M5
3
Air Cleaner Bracket 1
36
DF475X-036
CO Sensor Engine Controller
1
24
DF475-024
Exhaust Packing
1
37
DF475X-037
Bolt M6x25
4
25
DF475-025
Cotter Pin
2
38
DF475-038
End Cover
1
26
DF475-026
Muffler Comp
1
39
DF475-039
Positive Lead
1
27
DF475-027
Spring Washer Ø8 2
40
DF475-040
Negative Lead
1
28
DF475X-028 Vibration Isolation Pad 1
41
DF475-041
Battery 12V 7Ah
1
42
DF475-042
Wheel
2
38
EXPLODED VIEW & PARTS LIST
GENERATOR
No.
Part No.
Description Qty. No.
Part No.
Description Qty.
43
DF475-043
Frame Support
2
62
DF475-062
Frame Wire
1
44
DF475-044 Vibration Isolation Pad 2
63
DF475-063
Fuel Line Clip Ø10 1
45
DF475-045
Nut M6
9
64
DF475-064
Nut M8
12
46
DF475-046
Bolt M8X16
2
65
DF475-065 Tooth Type Gasket Ø6 1
47
DF475-047
Clip Ø12
2
66
DF475X-066
CO Sensor Module 1
48
DF475-048
Wheel Axle
2
67
DF475-067
Handle Rubber
1
49
DF475-049
Handle Connector 1
68 DF475X-068ASM Engine Assembly
1
50
DF475-050
Muffler Bracket
1
69
DF475-069
Grounding Wire
1
51
DF475X-051
Battery Bracket
1
70
DF475X-070 Fuel Selector Switch 1
52
DF475X-052
Battery Bolt
1
71
DF475X-071
Fuel Line Clip Ø11.5 1
53
DF475-077
Dustproof Sheet
1
72
DF475-072
Paper Washer
5
54
DF475X-054
Low Pressure Hose 1
73
DF475X-073
55
DF475X-055
Fuel Line 1
1
Fuel Tank Cap Assembly
1
56
DF475X-056
Fuel Line 2
1
74
DF475-074
LPG Regulator Cover 1
57
DF475-057
Connecting Pipe (Gas Tank)
1
75 76
DF475X-075 DF475-076
Carbon Tank Assembly 1
Connecting Pipe
1
58
DF475-058
59
DF475-059
Manual Choke Assembly
Handle Bolt
1
77
1
78
DF475X-077 DF475X-078
Fuel Line Clip Ø12 1
Phillips Head Screw, M4x28
2
60
DF475-060
Fuel Line Clip Ø7.5 1
N.P.
DF475-078
Fuel Gauge
1
61
DF475X-061
Fuel Line Clip Ø9.5 5
N.P.
DF475-079
Fuel Tank Filter
1
39
ENGINE
EXPLODED VIEW & PARTS LIST
40
EXPLODED VIEW & PARTS LIST
ENGINE
No.
Part No.
Description Qty.
No.
Part No.
Description Qty.
1
DF475-101
Crankcase
1
28
DF475-128
Rotator
1
2
DF475-102
Ball Bearing
2
29
DF475-129
Carburetor Stud Bolt 2
3
DF475-103
Oil Seal
2
30
DF475-130
Stud Bolt
2
4
DF475-104
Governor Assembly 1
31
DF475-131 Carburetor Assembly 1
5
DF475-105
Governor Arm Shaft 1
32
DF475X-132
Fuel Line
1
6
DF475-106
Governor Arm Shaft Washer
1
7
DF475-107
Lock Pin
1
8
DF475-108
Drain Plug Bolt
2
9
DF475-109
Drain Plug Washer 2
10
DF475-110
Oil Level Switch Assembly
1
11
DF475-111
Bolt M6x16
2
12
DF475-112
Crankcase Cover Dowel Pin, Ø8×12
4
33
DF475-133
Fuel Line Clip Ø7.5 1
34
DF475-134
Governor Arm
1
35
DF475X-135 Low Pressure Hose 1
36
DF475-136
Nut M6
2
37
DF475-137 Crankshaft Assembly 1
38
DF475-138
Valve Lifter
2
39
DF475-139
Casecover Packing 1
40
DF475-140
Camshaft Assembly 1
41
DF475-141
Dowel Pin
2
13
DF475-113
Piston
1
42
DF475-142
Bolt M8x30
6
14
DF475-114
Piston Scraper Ring Set
1
15
DF475-115
Connecting Rod Assembly
1
16
DF475-116
Piston Pin
1
17
DF475-117
Piston Clip
2
18
DF475-118
Crankcase Cover Assembly
1
19
DF475-119
Cylinder Head
1
20
DF475-120
In-Valve
1
21
DF475-121
Valve Exhaust
1
22
DF475-122 Intake Valve Returner 1
23
DF475-123
Valve Spring
2
24
DF475-124 In-Valve Spring Seat 1
25
DF475-125 Ex-Valve Spring Seat 1
26
DF475-126 Push Rod Guide Plate 1
27
DF475-127
Rocker Assembly
2
43
DF475-143 Cylinder Head Gasket 1
44
DF475-144
Bolt M8x60
4
45
DF475-145
Spark Plug, Torch F7TC (NGK BP7ES)
1
46
DF475-146
Push Rod
2
47
DF475-147
Shroud
1
48
DF475-148
Bolt M6x12
12
49
DF475-149
Headcover Packing 1
50
DF475-150
Cylinder Head Cover 1
51
DF475-151 Wind Shield Assembly 1
52
DF475-152
Bolt M6x28
1
53
DF475X-153
Recoil Starter Fan 1
54
DF475-154
Starter Pulley
1
55
DF475-155
Nut M14
1
56
DF475-156 Ignition Coil Assembly 1
57 DF475-157
Bolt M6x25
2
58
DF475-158
Carburetor Insulator Gasket
1
41
EXPLODED VIEW & PARTS LIST
ENGINE
No.
Part No.
Description Qty.
59 DF475-159 Carburetor Insulator 1
60 DF475-160 Carburetor Gasket 1
61 DF475-161
Air Filter Gasket 1
62 DF475-162
Governor Rod
1
63
DF475-163
Throttle Return Spring
1
64 DF475X-164
Recoil Starter Assembly
1
65
DF475-165
Upper Shroud Assembly
1
66
DF475-166 Air Filter Assembly 1
N.P. DF475-166.1 Air Filter Element 1
67
DF475-167
Breather Tube
1
No.
Part No.
Description Qty.
68
DF475-168
Fuel Rubber
1
69
DF475-169
Governor Spring 1
70
DF475-170
Clip
1
71
DF475-171
Dipstick
1
72
DF475-172
Bolt M6x30
2
73
DF475-173 Flywheel Assembly 1
74
DF475-174
Starting Motor Assembly
1
75
DF475-175 Adjuster Rocker Arm 2
76
DF475-176
Dustproof Sheet 1
77
DF475X-177
Low Pressure Hose Clip
1
42
WARRANTY STATEMENT
WEN Products is committed to building tools that are dependable for years. Our
warranties are consistent with this commitment and our dedication to quality.
LIMITED WARRANTY OF WEN PRODUCTS FOR HOME USE
GREAT LAKES TECHNOLOGIES, LLC (“Seller”) warrants to the original purchaser
only, that 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
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 permitted by law, any warranty or condition implied by law,
shall be the replacement of parts, without charge, which are defective in
material or workmanship and which have not been subjected to misuse,
alteration, careless handling, misrepair, abuse, neglect, normal wear and
tear, improper maintenance, improper storage, incorrect lubricants/ fuels, or
other conditions adversely affecting the Product or the component of the
Product, whether by accident or intentionally, by persons other than Seller.
To make a claim under this Limited Warranty, you must make sure to keep
chase. Place of Purchase must be a direct vendor of Great Lakes Technologies,
LLC. Purchasing through third party vendors, including but not limited to
garage sales, pawn shops, resale shops, or any other secondhand merchant,
voids the warranty included with this product. Contact
techsupport@wenproducts.com or
1-800-232-1195 with the following
information to make arrangements: your shipping address, phone number, serial
number, required part numbers, and proof of purchase. Damaged or defective
parts and products may need to be sent to WEN before the replacements can be
shipped out.
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
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, BATTERIES, 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 INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO
YOU.
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS WHICH VARY FROM STATE TO STATE IN THE U.S., PROVINCE TO PROVINCE
IN CANADA AND FROM COUNTRY TO COUNTRY.
THIS LIMITED WARRANTY APPLIES ONLY TO ITEMS SOLD WITHIN THE UNITED STATES OF
AMERICA, CANADA AND THE COMMONWEALTH OF PUERTO RICO. FOR WARRANTY COVERAGE
WITHIN OTHER COUNTRIES, CONTACT THE WEN CUSTOMER SUPPORT LINE. FOR WARRANTY
PARTS OR PRODUCTS REPAIRED UNDER WARRANTY SHIPPING TO ADDRESSES OUTSIDE OF THE
CONTIGUOUS UNITED STATES, ADDITIONAL SHIPPING CHARGES MAY APPLY.
43
THANKS FOR REMEMBERING
V. 2023.09.06
References
Read User Manual Online (PDF format)
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