DF480iX 4800 Watt Dual Fuel Inverter Generator

Specifications

• GENERATOR

  • Model Number: DF480iX

  • Surge (Starting) Wattage: Gasoline: 4800W,
    LPG: 4320W

  • Rated (Running) Wattage: Gasoline: 4000W, LPG:
    3600W

  • Rated Voltage: AC: 120V; DC: 12V / 5V

  • Rated Amperage: AC 33.3A; DC 8.3A (12V), 2.1A
    / 1A (USB)

  • Phase: Single

  • Frequency: 60 Hz

  • Product Weight: 78.5 Pounds

  • Product Dimensions: 23.8 in. x 12.6 in. x 22.1
    in.

• ENGINE

  • Engine Type: 4 Stroke, OHV, Single Cylinder
    with Forced Air Cooling System

  • Engine Displacement: 224cc

  • Engine Speed: 3600 RPM

  • Fuel Tank Capacity: 1.9 gallons (7.20 L)

  • Oil Capacity: 20.3 fl. oz. (0.60 L)

  • Half-Load Run Time: Gasoline: 7 Hours, LPG: 12
    Hours on a 20lb-Tank

  • Spark Plug Type: LG F6RTC (NGK BPR6ES)

  • Spark Plug Gap: 0.024 – 0.031 in. (0.6 – 0.8
    mm)

  • Spark Plug Torque: 11 – 14.5 ft-lbs (15 – 20
    Nm)

  • Battery: 12V, 1.6Ah, Li-Ion

Product Usage Instructions

Introduction

Thank you for choosing the WEN 4800-Watt Dual Fuel Inverter
Generator. To get started, locate the serial number on the
specifications label and record the generator information for
future reference.

Safety Information

Before operating the generator, ensure to read and understand
the safety information provided in the manual. Safety should always
be a top priority when using any power equipment.

Before Operating

Unpacking & Packing List:

When unpacking the generator, check that all listed items are
included in the packaging to ensure you have all necessary
components for operation.

Know Your Inverter Generator:

Familiarize yourself with the different parts of the generator
and their functions as outlined in the manual to operate the unit
effectively.

Preparation:

Prior to starting the generator, make sure it is placed on a
stable and flat surface. Check the fuel and oil levels according to
the specifications provided.

Operation & Maintenance

For any accessories needed for your generator, visit
WENPRODUCTS.COM to purchase genuine parts that are compatible with
your model for optimal performance and longevity.

FAQ

Q: How do I switch between gasoline and LPG fuel sources?

A: To switch between gasoline and LPG fuel sources, refer to the
user manual for detailed instructions on the proper procedure to
ensure safe operation.

Q: What is the recommended maintenance schedule for this

generator?

A: The recommended maintenance schedule can be found in the user
manual provided with the generator. It is essential to follow these
guidelines to keep your generator running smoothly.

MODEL DF480iX
4800-WATT DUAL FUEL INVERTER 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

Safety Information ………………………………………………………………………………..5 Generator Safety Warnings …………………………………………………………………….6

BEFORE OPERATING

9

Unpacking & Packing List ………………………………………………………………………9 Know Your Inverter Generator……………………………………………………………….10 Preparation ………………………………………………………………………………………..12

OPERATION & MAINTENANCE

18

Starting Your Generator ……………………………………………………………………….18 Using Your Generator…………………………………………………………………………..22 Stopping Your Generator ……………………………………………………………………..27 Maintenance ……………………………………………………………………………………….28 Transportation & Storage ……………………………………………………………………..33 Troubleshooting Guide …………………………………………………………………………34 Wire Diagram ……………………………………………………………………………………..35 Exploded View & Parts List …………………………………………………………………..36 Warranty Statement …………………………………………………………………………….42

To purchase accessories for your tool, visit WENPRODUCTS.COM
Magnetic Oil Dipstick (Model No. 55201) Weatherproof Generator Cover (Model No. 56310iC)
High-Altitude Kit (Part No. DF480iX-HA39) WEN Parallel Connection Kit

2

SPECIFICATIONS

GENERATOR
Model Number
Surge (Starting) Wattage
Rated (Running) Wattage
Rated Voltage Rated Amperage Phase Frequency Product Weight Product Dimensions

DF480iX Gasoline: 4800W LPG: 4320W Gasoline: 4000W LPG: 3600W AC: 120V; DC: 12V / 5V AC 33.3A; DC 8.3A (12V), 2.1A / 1A (USB) Single 60 Hz 78.5 Pounds 23.8 in. x 12.6 in. x 22.1 in.

ENGINE
Engine Type Engine Displacement Engine Speed Fuel Tank Capacity Oil Capacity
Half-Load Run Time
Spark Plug Type Spark Plug Gap Spark Plug Torque Battery

4 Stroke, OHV, Single Cylinder with Forced Air Cooling System 224cc 3600 RPM 1.9 gallons (7.20 L) 20.3 fl. oz. (0.60 L) Gasoline: 7 Hours LPG: 12 Hours on a 20lb-Tank LG F6RTC (NGK BPR6ES) 0.024 – 0.031 in. (0.6 – 0.8 mm) 11 – 14.5 ft-lbs (15 – 20 Nm) 12V, 1.6Ah, Li-Ion

3

INTRODUCTION
Thanks for purchasing the WEN 4800-Watt Dual Fuel Inverter 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 1-847-429-9263, M-F 8-5 CST; you will be asked to provide the following generator information when calling.
Generator Model Number: DF480iX 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 Filter

Clean Spark Arrestor

TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your generator at least once a month for 20 to 30 minutes. Start the generator according to the instructions and plug a small load in to make sure the outlet is producing electricity.
4

SAFETY INFORMATION
WARNING! Before operating the generator, make sure to read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire or serious injury.
SAFETY INTRODUCTION
Safety is a combination of common sense, staying alert, and knowing how your tool works. This manual contains important information regarding the generator’s potential safety concerns, as well as preparation, operation, and maintenance instructions. Before operating this generator, be sure to read and observe all warnings and instructions both on the generator labels and in this instruction manual. Failure to follow all instructions listed below may result in personal injury.
NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur. WEN reserves the right to change this product and specifications at any time without prior notice.
At WEN, we are continuously improving our products. If you find that your tool does not exactly match this manual, please visit wenproducts.com for the most up-to-date manual or contact customer service at 1-847-429-9263, M-F 8-5 CST.
Keep this manual available to all users during the entire life of the tool and review it frequently to maximize safety for both yourself and others.
SAVE THESE SAFETY INSTRUCTIONS.
SAFETY SYMBOLS
The purpose of following safety symbols is to attract your attention to possible dangers. The safety symbols, and their explanations, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures.
DANGER: indicates a hazard, which, if not avoided, will result in death or serious injury.
WARNING: indicates a hazard, which, if not avoided, could result in death or serious injury.
CAUTION: indicates a hazard, which, if not avoided, might result in minor or moderate injury.
CAUTION! when used without the alert symbol, indicates a situation that could result in damage to the machine.
NOTICE REGARDING EMISSIONS
Engines that are certified to comply with U.S. EPA emission regulations for SORE (Small Off Road Equipment), are certified to operate on regular unleaded gasoline, and may include the following emission control systems: (EM) Engine Modifications and (TWC) Three-Way Catalyst (if so equipped).
QUESTIONS? PROBLEMS?
In order to answer questions and solve problems in the most efficient and speedy manner, contact customer service at 1-847-429-9263, M-F 8-5 CST or email techsupport@wenproducts.com.
5

GENERATOR SAFETY WARNINGS
DANGER! CARBON MONOXIDE Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This is a poison gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.
NEVER use a generator inside homes, garages, crawl spaces, or other partially enclosed areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh air. ONLY use a generator outside and far away from windows, doors, and vents. These openings can pull in generator exhaust.
Even if you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or batterybackup CO alarm in the home. If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.
WARNING! RISK OF EXPLOSION. HIGHLY FLAMMABLE: This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death, if ignited. A nearby open flame can lead to explosion even if not directly in contact with gasoline.
· Do not operate near open flame, heat, or any other ignition source. Do not smoke near the generator. · Always operate on a firm, level surface. · Always turn generator off before refueling. Allow generator to cool for at least 2 minutes before removing
fuel cap. Loosen cap slowly to relieve pressure in tank. · Do not overfill fuel tank. Gasoline may expand during operation. Do not fill to the top of the tank. Allow for
expansion. Always check for spilled fuel before operating. · If fuel spills, move the generator at least 30 feet away from the spill and wipe clean any spilled fuel before
starting the engine. · Empty fuel tank before storing or transporting the generator.
WARNING! If this generator is used as a supply for a building’s wiring system, the generator must be installed by a qualified electrician and connected to a transfer switch as a separately derived system in accordance with all applicable laws and electrical codes and the National Electrical Code, NFPA 70. The generator shall be connected to a transfer switch that switches all conductors excluding the equipment grounding conductor. The frame of the generator shall be connected to an approved grounding electrode.
WARNING! This product can expose you to chemicals including carbon monoxide and engine exhaust, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information, go to www.P65Warnings.ca.gov.
6

GENERATOR SAFETY WARNINGS

WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury.

OPERATING ENVIRONMENT
1. Using a generator indoors can kill you in minutes. Only use a generator outside and far away from windows, doors and vents.
2. Do not smoke near the generator.

3. If any part of the generator, electrical device or power cord is broken, damaged, or defective, make sure it is repaired or replaced before operation. Service should only be performed by a qualified technician. Do not use receptacles or cords that show signs of damage, such as broken or cracked insulation.

3. Do not operate near open flame, heat, or flammable materials. This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A nearby open flame can lead to an explosion even if it isn’t directly in contact with gasoline.
4. Do not expose the generator to rainy or wet conditions; doing so significantly increases the risk of electrical shock. Never handle the generator, electronic devices, or any cord while standing in water, while barefoot, or when hands or feet are wet.
5. Always operate the generator on a dry, firm, level surface.
6. The generator should have at least 5 feet of clearance from buildings or other equipment during operation.
7. Do not allow children or non-qualified persons to operate the generator.

4. Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as metal decking or steel work. Extension cords with in-line GFCIs are recommended for these operations to maximize safety.
5. If connecting the generator to a building’s electrical system for standby power, you MUST consult a qualified electrician and install a transfer switch. Such connections must comply with local electrical laws and codes. Failure to comply can create a back-feed, which may result in serious injury or death to utility workers.
6. Never modify the generator in any way. Modifying or using the machine for any other purpose for which it is not designed may result in serious injuries, machine damage and voiding of the warranty.
GENERATOR OPERATION
1. Only use the generator for its intended purposes. Modifying or using the generator for operations for which it was not designed may cause hazards and personal injury.

GENERATOR PREPARATION
1. Always ground the generator before using it to maximize safety (see “Ground the Generator” section).
2. Do not overfill fuel tank, as gasoline may expand during operation. Do not fill to the very top of the tank. Leave room for gasoline expansion. Always check for spilled fuel before operating.

2. Do not touch bare wires or receptacles (outlets).
3. Do not exceed the wattage capacity of the generator by plugging in more electrical devices than the unit can handle. This could damage the generator and/or connected electrical devices. Check the operating voltage and frequency requirements of all electrical devices prior to plugging them into the generator.

Generator safety warnings continue on the next page.

7

GENERATOR SAFETY WARNINGS

WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury.

TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your generator at least once a month for 20 to 30 minutes. Start the generator according to the instructions and plug a small load in to make sure the outlet is producing electricity. If you do not run it often, it will greatly shorten the generator’s lifespan and void the warranty.

4. Allow generator to run for several minutes before connecting electrical devices. Do not start or stop engine with electrical devices plugged in to the receptacles. Failure to do so could damage the generator and/or connected electrical devices.
5. Do not turn on electrical devices until after they are connected to the generator.
6. Generators vibrate in normal use. During and after the use of the generator, inspect both the generator as well as extension and power supply cords for damage resulting from vibration.

9. Always turn generator off before refueling. Allow generator to cool for at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.
10. Turn the engine switch to “OFF” position when the engine is not running.
11. Empty fuel tank before storing or transporting the generator. Do not store generator or gasoline near furnaces, water heaters, or any other appliances that produce heat or have automatic ignitions. Store the generator and fuel away from sparks, open flames, pilot lights, heat and other sources of ignition.

7. Do not touch hot parts. This generator produces heat when running. Temperatures near exhaust can exceed 150ºF (65ºC). Allow generator to cool down after use before touching engine or areas of the generator that become hot during use.

12. Always wash hands after handling generator.
CAUTION: Misuse of this generator can damage it or shorten its lifespan.

8. Turn off all connected electrical devices before stopping the generator.

8

UNPACKING & PACKING LIST

UNPACKING
With the help of a friend or trustworthy foe, such as one of your in-laws, carefully remove the generator from the packaging and place it on a sturdy, flat surface. Make sure to take out all contents and accessories. Do not discard the packaging until everything is removed. Check the packing list below to make sure you have all of the parts and accessories. If any part is missing or broken, please contact customer service at 1-847-429-9263 (M-F 8-5 CST), or email techsupport@wenproducts.com.
PACKING LIST

Components

Tools & Accessories

Generator

Funnel

Spark Plug Socket (1)

Screwdriver

Engine Oil, 20.3 fl. oz. (0.60 L) LPG Regulator Hose

9

KNOW YOUR INVERTER GENERATOR
TOOL PURPOSE
Inverter Generators provide you with clean and quiet power, when and where you need it most. Refer to the following diagrams to become familiarized with all the parts and controls of your Generator. The components will be referred to later in the manual for assembly and operation instructions.
GENERATOR

Spark Plug Access Cover
Air Filter (Inside Panel) Recoil Starter Oil Dipstick (Inside Panel) 4-in-1 Switch

Fuel Cap Handle
Handle Release Button Control Panel
LPG Inlet

Battery Access Door 10

Spark Arrestor

KNOW YOUR INVERTER GENERATOR

CONTROL PANEL
1 234

56 7

8

9

13

12

11

10

1. Parallel Connection Connect to share wattage between inverter generators.
2. Eco-Mode Switch Maximizes fuel economy & run time.
3. Data Meter with Indicator Light Displays load level (left), fuel level (right), voltage (e.g. V120), frequency (e.g. F60.0), session runtime (e.g. A 0.0), and total runtime (e.g. 0.0). Press MODE to switch between displays.
4. Reset Button Press to reset the circuit in case of overload.
5. 5V USB Port 1A & 2.1A for charging various electronic devices.
6. DC Circuit Breaker (8A) Press to reset.
7. 12V DC Outlet Cigarette-style outlet provides DC power.

8. 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. 26 for more information. 9. Electric Start Button Press to start the generator. 10. AC 120V NEMA 5-20R Duplex Receptacles Standard household outlets provide 120V 60Hz power. 11. AC Circuit Breakers (20A) Press to reset. 12. AC 120V NEMA TT-30R RV Receptacle Standard RV connector. 13. Grounding Nut Ground the generator to reduce the risk of electric shock.
11

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 1-847-429-9263 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 20.3 fl. oz. (0.60 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. 1

30W

· 30W Engine Oil

Temperatures above 40°F

°F -20

10W-30

Synthetic 5W-30

0

20 32 40

60

· 10W-30 Engine Oil Temperatures between 0°F – 40°F

· Synthetic 5W-30 Engine Oil

80

100

All temperature ranges

°C -30

-20

-10

0

10

20

30

40

TO ADD OIL:

1. Place the generator on a level surface. Make sure the engine is OFF before adding or checking oil.

1

Fig. 2

CAUTION! Keep the generator level. Tilting the generator to

1

assist in filling will cause oil to flow into the wrong areas of the

engine and cause damage.

1. Open the side panel (to the right of the control panel) by removing the two screws (Fig. 2 – 1) at the top of the panel. Remove and wipe the oil dipstick with a clean rag. Insert the dipstick into the oil fill opening without screwing it in.
2. Remove the dipstick (Fig. 2 – 2) to check the oil mark on the dipstick (Fig. 3). Add oil if the oil mark covers less than one half of the dipstick.
3. Slowly add oil and repeat step 2 until the oil mark measures between the upper limit mark and halfway mark of the dipstick. Do not overfill the crankcase.
4. Wipe clean any oil leaks and firmly tighten the dipstick.
12

2
CAUTION! For subsequent operation, the oil level should be checked before each use, or after every 8 hours of operation. The generator is equipped with a low-oil sensor and will not start without a sufficient amount of oil. Follow the instructions on the next page to check the oil level.

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.
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 measures between the upper limit mark and halfway mark of the dipstick. See Fig. 3.

Upper Limit

Lower Limit

Fig. 3

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.

13

PREPARATION

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 1.9 gallons (7.20 L). Do not mix oil with gasoline.
TO ADD GASOLINE:
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 1.9 gallons. Do not mix oil with 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. 4 – 1) 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.
4. Reinstall fuel cap and wipe clean any spilled gasoline with a dry cloth.

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. 4
1

14

PREPARATION

FUEL OPTION B: LIQUID PETROLEUM GAS (LPG)

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 valve closed, attach the LPG regulator connecting hose (Fig. 5 – 1) to the valve. Turn the plastic coupling from the hose right (clockwise) to tighten hose assembly onto the LPG tank.
3. Remove the protective cover from the LPG inlet (Fig. 6 1) on the generator. Push the connector on the other end of the regulator hose into the LPG inlet until it clicks into place.
4. Turn the LPG tank valve ON and check for leaks by spraying soapy water to check connections. If bubbles appear, become larger in size, or increase in number, a leak exists. This MUST be corrected before using generator. Contact WEN customer service at 1-847-429-9263, M-F 8-5 CST, or email techsupport@wenproducts.com for assistance.
NOTE: If you would like to purchase other accessories for your dual-fuel generator, consult your local dealer of propane and propane accessories, I tell you what.

Fig. 5 1
Fig. 6
1

CAUTION! Always position the LPG cylinder so the connection between the tank and LPG inlet won’t cause sharp bends or kinks in the 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.

15

PREPARATION

AUTO FUEL SELECTION
Your generator is equipped with Auto Fuel Selection Technology. What this means is that the generator will automatically select the fuel source (LPG or gasoline) depending on availability. LPG is prioritized; this means that if a propane tank with enough LPG is connected, the generator will automatically use LPG. If no propane tank is connected, the generator will use gasoline (if there is gasoline in the fuel tank). The LPG regulator hose must be disconnected for the generator to switch to gasoline. If the LPG regulator hose is connected and you run out of LPG, the generator will not automatically switch to gasoline.

NOTE: Make sure the generator can handle the load(s) you plan to connect. The generator can provide more power when running on gasoline than on LPG. Consult the specifications table on p. 3, as well as the “Calculating the Wattage of Your Device(s)” chart to ensure that your load(s) will not exceed the rated wattage for a particular fuel. See also the “Switching Fuels” section for more information.

STEP 3 – GROUND THE GENERATOR
To reduce the risk of electric shock and to maximize safety, the generator should be properly grounded.

Fig. 7

1. Attach one end of the grounding wire to the grounding nut (Fig. 7 – 1). 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.

HIGH ALTITUDE OPERATION ABOVE 3000 FEET
The fuel system on this generator may be affected by operation at high altitudes. Proper operation can be ensured by installing an altitude kit at altitudes higher than 3000 feet above sea level. At elevations above 9800 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 DF480iX-HA39. Refer to the instructions included with your altitude kit for more information about installation.

1
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 generally 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.

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.
16

PREPARATION

STEP 4 – CONNECT THE BATTERY

WARNING! Use only genuine WEN batteries with your generator (part no. 56480iX-067). Use of other batteries may induce premature product failure and could pose a safety risk.

ABOUT THE BATTERY
1. The lithium-ion battery supplied with your generator is only partially charged, in order to maximize its service life. The battery may not have enough charge to start the engine during its first use. If this is the case, connect the battery according to the instructions below, and start the generator using the recoil starter, according to the instructions below. The battery will receive charge when the generator is running.
2. Lithium-ion batteries are subject to a natural aging process. The battery must be replaced at the latest when its capacity falls to just 80% of its capacity when new. Weakened cells in an aged battery are no longer capable of meeting the high power requirements needed for the proper operation of your generator, and therefore pose a safety risk.
3. DO NOT INCINERATE BATTERY. Do not throw the battery into an open fire as this poses a risk of explosion. Do not ignite the battery or expose it to fire.
4. AVOID DAMAGE AND SHOCKS. Immediately replace batteries that have been dropped from a height of more than one meter (3 feet) or those that have been exposed to violent shocks, even if the housing of the battery appears to be undamaged. The battery cells inside the battery may have suffered serious damage. In such instances, please read the waste disposal information on p. 30 for proper battery disposal.
5. DO NOT CRUSH, DROP OR DAMAGE BATTERY. Do not use the battery if it has sustained a sharp blow, been dropped, run over or has been damaged in any way (e.g. pierced with a nail, hit with a hammer, stepped on, etc.).
6. DO NOT DISASSEMBLE. Incorrect reassembly may pose a serious risk of electric shock, fire or exposure to toxic battery chemicals. If the battery or charger are damaged, call WEN customer service at 1-847-4299263 for assistance.
For more information on the battery quick-connectors, visit: http://bit.ly/44sb6C2

7. DO NOT SHORT CIRCUIT. Batteries will short circuit if a metal object makes a connection between the positive and negative contacts on the battery. Do not place the battery near anything that may cause a short circuit, such as paper clips, coins, keys, screws, nails and other metallic objects. A short- circuited battery poses a risk of fire and severe personal injury.
NOTE: The safe temperature range for charging the battery is 25°F ­ 104°F.
The generator is shipped with the lithium-ion battery disconnected to maximize safety. To start the generator using electric start, the battery must be connected.
To connect the battery: 1. Use the screwdriver to loosen the screw on the battery access door (Fig. 8 – 1). Open the battery access door. Connect the two ends of the quick connector on the battery (Fig. 8 – 2) to connect the battery to the generator’s system.
2. Close the door and tighten the screw.
NOTE: The generator can be run with the battery disconnected or with no charge using the recoil starter.
IMPORTANT: If you do not plan to use the generator for an extended period of time, we recommend DISCONNECTING the quick-connector. This will protect the battery from losing its charge. After disconnecting the quick-connector, cover the ends of the cable with an insulator such as electrical tape. Alternatively, you can use a trickle charger (not included) to maintain battery charge.
Fig. 8
1
2

17

STARTING YOUR GENERATOR
Before starting the generator, make sure you have read and performed the steps in the “Preparation” section of this manual, pages 12 – 17. If you are unsure about how to perform any of the steps in this manual please call 1-847429-9263 M-F 8-5 CST for customer service.
DANGER! CARBON MONOXIDE Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This is a poison gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.
NEVER use a generator inside homes, garages, crawl spaces, or other partially enclosed areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh air. ONLY use a generator outside and far away from windows, doors, and vents. These openings can pull in generator exhaust.
Even if you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or batterybackup CO alarm in the home. If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.
WARNING! The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
WARNING! Do not operate generator near open flame or flammable materials This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A nearby open flame can lead to explosion even if it isn’t directly in contact with gasoline. Do not smoke near the generator.
WARNING! This generator produces powerful voltage, which can result in electrocution.
WARNING! Do not use in rainy or wet conditions. Do not touch bare wires or receptacles (outlets). Do not allow children or non-qualified persons to operate.
WARNING! Generator should only be connected to electrical devices, either directly or with an extension cord. NEVER connect to a building electrical system without a qualified electrician and connected to a transfer switch as a separately derived system. Such connections must comply with local electrical laws and codes. Failure to comply can create a back-feed, which may result in serious injury or death to utility workers.
To maximize safety, ALWAYS ground the generator before using it. See page 16, “GROUND THE GENERATOR”.
Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as metal decking or steel work. GFCIs are available in-line with some extension cords.
CAUTION! Disconnect all electrical loads from the generator before attempting to start.
Follow the instructions on the next page to start your generator.
18

STARTING YOUR GENERATOR

BEFORE STARTING THE GENERATOR
1. Verify that the generator is outside on a dry, level surface. Allow at
least two feet of clearance on all sides of the generator. 1
2. To maximize safety, check that the generator is properly grounded.
See page 16, “GROUND THE GENERATOR.”

3. Check that there is a sufficient level of oil in the crankcase. Add oil if necessary. Refer to page 12, “STEP 1 – ADD / CHECK OIL.”

4. Check that there is a sufficient level of fuel in the fuel tank. Add gas if necessary. Refer to page 14, “FUEL OPTION A: GASOLINE”

5. Make sure all electrical devices are unplugged from the generator during ignition. Otherwise it will be difficult for the engine to start.

1

STARTING THE GENERATOR (GASOLINE)
1. Turn the ECO-MODE switch to “OFF” during starting (Fig. 9 – 1).

2. Turn the 4-in-1 switch (Fig. 10 – 1) to the “CHOKE” position.

Option A: Electric Start 3. Press the START button (Fig. 11 – 1) and hold for 2-3 seconds until the engine starts, then release.
NOTE: The battery is shipped partially charged, in order to maximize its service life, and may not have enough charge to start the engine during the first use of the generator. If you have trouble starting the generator the first time using electric start, use the pull start option and allow the generator to run for a few hours to charge the battery.

Option B: Pull Start.

3. Place one hand on the generator to hold it in place, and pull on the recoil starter handle (Fig. 12 – 1) slowly until a slight re-

1

sistance is felt. Then pull quickly to start the engine. Return cord

gently into the machine. Never allow the cord to snap back.

NOTE: If engine fails to start, repeat step 3.

Fig. 9
Fig. 10
Fig. 11 1
Fig. 12

4. Slowly turn the 4-in-1 switch (Fig. 10 – 1) to the “RUN” position.
5. Allow the generator to run for several minutes before attempting to connect any electrical devices. This allows the generator to stabilize its speed and temperature.
NOTE: If you have repeated failed attempts to start the engine, please consult the troubleshooting guide. If problems persist, please call please call 1-847-429-9263 M-F 8-5 CST.

19

STARTING YOUR GENERATOR
STARTING THE GENERATOR (LPG)
1. Place the generator outside on a dry, level surface. Allow at least two feet of clearance on all sides of the generator. 2. Check there is sufficient level of oil in the crankcase. Add oil if necessary (refer to “ADD / CHECK OIL” on page 12). 3. Make sure that the LPG regulator hose is properly connected to the LPG tank and the inlet on the generator (refer to “FUEL OPTION B: LIQUID PETROLEUM GAS (LPG)” on page 15). 4. To maximize safety, make sure the generator is properly grounded (refer to “GROUND THE GENERATOR” on page 16). 5. Make sure all electrical devices are unplugged from the generator during ignition. Otherwise it will be difficult for the engine to start. 6. Turn the ECO-MODE switch to “OFF” during starting (Fig. 9 – 1). 7. Turn the 4-in-1 switch (Fig. 10 – 1) to the “CHOKE” position. 8. Gently pull the recoil starter handle (Fig. 12 – 1) 3 – 5 times to prime the engine. 9. Slowly turn the 4-in-1 switch (Fig. 10 – 1) to the “RUN” position.
Option A: Electric Start 10. Press the START button (Fig. 11 – 1) and hold for 2-3 seconds until the engine starts, then release. NOTE: The battery is shipped partially charged, in order to maximize its service life, and may not have enough charge to start the engine during the first use of the generator. If you have trouble starting the generator the first time using electric start, use the pull start option and allow the generator to run for a few hours to charge the battery.
Option B: Pull Start. 10. Pull the recoil starter handle (Fig. 12 – 1) quickly to start the engine. Return the cord gently into the machine. Never allow the cord to snap back. NOTE: If engine fails to start, repeat step 7.
11. Allow the generator to run for several minutes before attempting to connect any electrical devices. This allows the generator to stabilize its speed and temperature. NOTE: If you have repeated failed attempts to start the engine, please consult the troubleshooting guide. If problems persist, please call please call 1-847-429-9263 M-F 8-5 CST.
20

STARTING YOUR GENERATOR

ECO-MODE SWITCH
This generator is equipped with an Eco-Mode Idle Control Switch (Fig. 9 – 1). Engaging the switch automatically adjusts the engine to match the load. When the electrical load changes, the generator engine will automatically speed up and slow down as needed. This reduces fuel consumption and noise levels.

Keep this switch engaged when the power load requirement is less than 3000W. Do not engage the Eco-Mode Switch when the total load is more than 3000W. The generator engine must run at full speed to supply power for anything over 3000W.

OIL LEVEL SHUTDOWN
The low oil indication light on the data meter (Fig. 13 – 1) will turn on to remind you that the engine oil level is low and need to be refilled. The generator is equipped with a low oil pressure shutoff that will automatically stop the engine when the oil level is too low to protect the unit from damage. The oil level of the engine should be checked before each start to ensure that the engine crankcase contains sufficient lubricant.

PARALLEL OPERATION

The parallel connection feature (Fig. 14 – 1) allows you to connect

two WEN generators to increase the total available electrical power.

The “Parallel Connection Kit” can be purchased from wenproducts.

com.

1

Fig. 13

Follow the instructions included with your WEN parallel connection kit for proper installation and operation.

ENGINE BREAK-IN PROCEDURE
The procedure below should be followed when you receive your generator in order to prolong the engine’s service life. This procedure helps to seat the piston rings properly in the cylinder, and will reduce overall wear on the engine.

For the first 8 hours of operation, vary the load, but keep it at or be-

1

low 50% of the generator’s rated wattage, if possible. If your genera-

tor is equipped with an Eco-mode switch (only applicable for certain

inverter generators), engage Eco-mode periodically during the first

8 hours. After the first 8 hours, change the oil, then change it again

after the first 25 hours. You may run the generator at full load af-

ter the 8-hour oil change. Refer to the Recommended Maintenance

Schedule in Table 4 for the full maintenance schedule.

Fig. 14

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
Electronic Device Wattage
Calculation

GENERATOR RUNNING (RATED) WATTS

GENERATOR STARTING (SURGE) WATTS

Gasoline: 4000W

Gasoline: 4800W

LPG: 3600W

LPG: 4320W

What this means: The generator can produce a maximum of 4000W / 3600W on a continuous basis to supply ongoing 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 4800W / 4320W 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 page 23, Table 2.
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 running wattage of 4000W / 3600W.
It is recommended to maintain a load at or below 3600W / 3240W (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 starting wattage out of the device(s) you plan to connect.
= The total starting (surge) wattage.
This wattage should NOT exceed the starting wattage of 4800W / 4320W.

If any of either of the total calculated running watts or starting watts is higher than the capacity of your generator, adjust the load until both wattage requirements are met. Otherwise you will overload the generator, and cause damage to the engine and your electrical device(s).

Table 1 – How to Calculate Wattages

22

USING YOUR GENERATOR

CALCULATING THE WATTAGE OF YOUR DEVICE(S) – CONTINUED
The chart below serves as a reference for the estimated wattage requirements of common electrical devices. However, do not solely rely on this chart – all electronics and appliances are built differently. Always check the wattage listed on the electrical device before consulting this chart.

Tool or Appliance Electric Water Heater (40 Gal)
Hot Plate Saw – Radial Arm Electric Stove (Each Element)
Saw – Circular Air Compressor (1 HP) Window Air Conditioner
Saw – Miter Microwave Well Water Pump Sump Pump Refrigerator Freezer Furnace Blower Computer Electric Drill Television Deep Freezer Garage Door Opener
Stereo Box Fan Clock Radio Security System Dvd Player / VCR Common Light Bulb

Rated (Running) Watts 4000 2500 2000
1500-2800 1500 1500 1200 1200 1000 1000 800 800 800 800 600 500 500 480 400 300 300 180 100 75

Surge (Starting) Watts 0 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
When the rated wattage requirement of each electrical device has been determined, add these numbers to find the total rated wattage needed. If this number exceeds the rated wattage (4000W) of the generator, DO NOT connect all these devices. Select a combination of electrical devices with a total rated wattage lower than or equal to the rated wattage of the generator.
CAUTION! Become familiar with the markings on the control panel (Fig. 15) before connecting electrical devices. Do not connect 50 Hz loads to the generator. 1. Before connecting electrical devices, allow the generator to run for a few minutes to stabilize the speed and voltage output. 2. Make sure that all devices are turned off. Start plugging in each electric device, from the highest wattage to the lowest. Check the power indicator light (green) to ensure the generator is producing power. 3. Do not overload the generator or individual panel receptacles. If an overload occurs, the overload indication light (red) will activate. If it is flashing, turn off and unplug one load. If it is solid (not flashing), the generator will cut off power to protect itself. Unplug all electrical devices and then press the reset button to reset the entire circuit, or press the circuit breaker to reset the DC circuit. Check the total wattage of the devices and reduce the load if it exceeds the capacity of the generator. Then, plug the loads back in one by one. NOTE: If the reset button or circuit breaker does not reset, wait several minutes and try again. If problem still persists, please call 1-847-429-9263 M-F 8-5 CST.
Fig. 15
24

USING YOUR GENERATOR

SOME NOTES ABOUT POWER CORDS
Long or thin cords can drain the power provided to an electrical device by the generator. When using such cords, allow for a slightly higher rated wattage requirement by the electrical device.

Device Requirements

Amps
2.5 5 7.5 10 15 20 25 30 40

Watts (120V)
300 600 900 1200 1800 2400 3000 3600 4800

Watts (240V)
600 1200 1800 2400 3600 4800 6000 7200 9600

8 wire

Max. Cord Length (ft) by Wire Gauge #10 wire #12 wire #14 wire #16 wire

NR

NR

NR

375

250

NR

NR

300

200

125

NR

350

200

125

100

NR

250

150

100

50

NR

150

100

65

NR

175

125

75

50

NR

150

100

60

NR

NR

125

65

NR

NR

NR

90

NR

NR

NR

NR

*NR = Not Recommended

Table 3 – Power Cord Requirement Guide

WARNING! Generator should only be connected to electrical devices, either directly or with an extension cord. NEVER CONNECT TO A BUILDING ELECTRICAL SYSTEM without a qualified electrician and connected to a transfer switch as a separately derived system. Such connections must comply with local electrical laws and codes. Failure to comply can create a back-feed, which may result in serious injury or death to utility workers.

NOTE: For power outages, permanently installed, stationary generators are better suited for providing backup power to your home. Even a properly connected portable generator can become overloaded. This may result in overheating or stressing the machine’s components, possibly leading to generator failure.

25

USING YOUR GENERATOR

CO SENSOR INFORMATION

The CO Watchdog carbon monoxide monitoring system (Fig.

16 – 1) measures the accumulation of poisonous CO gas

while the generator is running. If the level of CO gas gets too

high, the CO Watchdog system will automatically shut down

the generator. This system is not a substitute for an indoor

1

CO alarm.

Fig. 16

Whenever the CO Watchdog system shuts down the generator, the LED on the generator control panel (Fig. 16 – 1) will blink red for at least 5 minutes after the generator is shut down. If you notice that the LED is blinking red, vacate the area immediately. Go to an open, outdoor area. Ventilate the area around the generator thoroughly before returning. Let the generator stay shut down for a few minutes before restarting the engine. This should allow carbon monoxide to dissipate from the area. If you restart the generator and the CO Watchdog detects that CO levels are still too high, it will shut down the generator again. If CO levels are low enough, the generator will run normally.

NOTE: if the generator is oriented so that the engine exhaust is blown towards the CO sensor, the generator may shut down.

Ensure that the generator is located in an open outdoor area, with the exhaust pointing away from occupied structures, and pointing away from the prevailing winds, such that those winds do not blow engine exhaust towards the sensor module. If anyone experiences dizziness, headaches, nausea, fatigue, or other symptoms of CO poisoning, get to fresh air immediately and seek the attention of a qualified medical professional. Follow all other directions in this manual regarding the connection and disconnection of electrical devices when starting or shutting down the generator.

When starting the generator, the CO Watchdog LED on the panel may flash. This indicates that the system is running a self-test procedure, and does not indicate a problem.
If the CO Watchdog LED on the panel is yellow, a system error has occurred, or the CO sensor has reached the end of its life. Contact WEN customer service (1-847-429-9263, M ­ F 8 ­ 5 CST, or techsupport@wenproducts.com) for assistance.

When operating your generator, please note the following:

· The CO Watchdog does not discriminate in its input; any source of carbon monoxide in the area around the generator could cause it to activate. If the CO Watchdog LED is blinking red, safety measures should be taken immediately.

· Tampering with, disconnecting, or bypassing the CO sensor could cause hazardous conditions, including but not necessarily limited to injury or death, and will void your warranty. The generator will not run with the CO sensor disconnected or bypassed, or if the CO sensor indicates an error.

· The CO sensor has a lifetime of about 7 years, and is capable of monitoring its lifetime. If your generator shows an error light several years after purchase, it may be time to replace the CO sensor. Contact WEN customer service for assistance.

26

STOPPING YOUR GENERATOR

SHUTTING OFF THE GENERATOR
1. Turn off all electrical devices and then unplug the devices from the generator.

CAUTION! Unplugging running devices can cause damage to the generator. Never stop the engine with electrical devices connected and running.

2. Allow generator to run at no load for a few minutes to stabilize internal temperatures.

3. Turn the 4-in-1 switch (Fig. 17 – 1) to the “FUEL OFF” position.

4. If using LPG, turn the LPG tank valve OFF and remove the LPG

1

regulator hose from the tank and inlet on the generator. Push the

collar on the LPG quick-connector back to release the end of the LPG

regulator hose.

5. The engine will continue to run until the majority of the fuel in the carburetor is consumed, which takes a few minutes. It will then shut off automatically. This feature helps to prevent the carburetor from being clogged by stale fuel, extending your generator’s lifespan.

6. Once the engine switches OFF, turn the 4-in-1 switch to the “ENGINE OFF” position.

7. In case you are in a hurry and do not want to wait for the generator to automatically shut down, turn the 4-in-1 switch to the “ENGINE OFF” position and the generator will shut off right away. However, this method will leave stagnant fuel in the carburetor, possibly causing blockages, a shortened lifespan, and other maintenance issues. If this approach is frequently taken, make sure to drain your carburetor before any long storage periods.

Fig. 17

WARNING! Allow the generator to cool for several minutes 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”.

27

MAINTENANCE

Proper routine maintenance of the generator will help prolong the life of the machine. Please perform maintenance checks and operations according to the schedule in Table 4.

CAUTION! Never perform maintenance operations while the generator is running. Before maintaining or servicing the generator, turn OFF the generator, disconnect all devices and allow the generator to cool down.

If there are any questions about the maintenance procedures listed in this manual, please call 1-847-429-9263 M-F 8-5 CST or email techsupport@wenproducts.com.

Recommended Maintenance Schedule

Every 8 Hours or
Daily

Every 25 Hours

Every 3 Every 6 Months or Months or 50 Hours 100 Hours

Before Storage

As Necessary

Check Level

x

Engine Oil

Replace

x**

x**

x*

x

Check

x*

Air Filter

Clean

x*

Spark Plug

Check/Clean/ Regap
Change

x

x

x

Fuel

Check Level Drain

x

x

x

Carburetor

Drain

x

x

Spark Arrestor

Check/Clean

x

• Clean/change more often under dusty conditions or operating under heavy load.
  ** Change the oil after the first 8 hours of operation, after the first 25 hours of operation, and every 50 hours after that.

Table 4 – Recommended Maintenance Schedule

IMPORTANT GENERATOR MAINTENANCE TIPS: · Drain your carburetor after each use and before storage to prevent it from clogging. · Do not store the generator with fuel inside the tank for more than 2 months – the fuel will go bad. · Run the generator for at least 20 minutes every month to maximize lifespan.

CLEANING THE GENERATOR
Keep the generator clean to prevent improper operation or machine damage from dirt and debris. Inspect all ventilation openings on the generator. These openings must be kept clean and unobstructed. If the generator becomes dirty, use a damp cloth to wipe exterior surfaces. Use a soft bristle brush to loosen dirt and oil and use a vacuum to pick up loose dirt. Use low pressure air (not to exceed 25 PSI) to blow away dirt.

CAUTION! Never clean the generator when it is running! Never clean with a bucket of water or a hose. Water can get inside the working parts of the generator and cause corrosion or a short circuit.

NOTE: Failure to properly maintain the generator will void the warranty. 28

MAINTENANCE

WARNING! Make sure generator is shut off before performing any inspection or maintenance procedures.

CHECKING / ADDING OIL
Check the oil level of the generator according to the Recommended Maintenance Schedule in Table 4. The oil level should be checked before each use or every 8 hours of operation. The oil capacity of the generator engine is 20.3 fl. oz. (0.60 L). Add oil when the oil level is low.
For proper type and weight of oil refer to “ADD / CHECK OIL” section on page 12. The generator is equipped with an automatic shutoff to protect it from running on low oil. To check the oil level:
1. Make sure the generator is on a level surface. Do not tilt the generator to assist in filling, as oil will flow into engine areas and cause damage. Keep generator level!
2. Open the side panel (to the right of the control panel) by removing the side panel access screws (Fig. 18 – 1). Remove and wipe the oil dipstick (Fig. 19) with a clean rag. Insert the dipstick into the oil fill opening without screwing it in.
3. Insert the dipstick into the oil fill opening without screwing in. Remove the dipstick to check the oil mark. Add oil if the oil mark covers less than one half of the dipstick.
4. Using a funnel or appropriate dispenser, slowly add more oil. Repeat step 3 until the oil mark measures between the upper limit mark and halfway mark of the dipstick. Do not over fill the crankcase.
5. Reinstall dipstick and wipe clean any spilled oil with a rag.

1 1
Upper Limit Lower Limit

Fig. 18 Fig. 19

DRAINING / CHANGING THE OIL
Change the oil according to the Recommended Maintenance Schedule in Table 4. Change the oil more often if operating under heavy load or high ambient temperatures. It is also necessary to drain the oil from the crankcase if it has become contaminated with water or dirt. Changing the oil when the engine is warm allows for complete drainage. Drain the oil from the generator according to the following steps.
1. Place generator on an elevated platform such as table or desk. Prepare a container underneath the oil fill to catch the oil as it drains.
2. Open the side panel. Remove the dipstick and tilt the generator towards you to allow the oil to drain from the engine completely.
3. Reinstall the oil dipstick and tighten it securely. Wipe clean any oil spillage and close the side panel.
NOTE: Do not dispose of used motor oil in the trash or down a drain. Please call a local recycling center or auto garage to arrange proper oil disposal.

29

MAINTENANCE

SPARK PLUG MAINTENANCE

The spark plug is important for proper engine operation. A good spark plug should be intact, free of deposits, and properly gapped.

2

Refer to Recommended Maintenance Schedule in Table 4 for in-

structions on maintaining. To inspect the spark plug:

1

Fig. 20

1. Open the spark plug access cover (Fig. 20 – 1) by removing the four screws (Fig. 20 – 2).

2. Pull up to remove the black plastic spark plug boot. Be careful not to tear any insulation or wire.
3. Use a spark plug wrench to unscrew and remove the spark plug from the engine.
4. Visually inspect the spark plug for cracks or excessive electrode wear. If the electrodes are worn or burned, or porcelain is cracked, replace with an LG F6RTC (NGK BPR6ES) spark plug (Part No. 56477i-163), available at wenproducts.com.

0.024 in. – 0.031 in. (0.6mm – 0.8mm)

Fig. 21

5. If re-using the spark plug, use a wire brush to clean any dirt from around the spark plug base then re-gap the spark plug.

6. Measure the plug gap with a wire gauge (Fig. 21). The gap should be 0.024 in. – 0.031 in. (0.6mm – 0.8mm). Carefully adjust the gap if necessary.

7. Screw the spark plug back into the spark plug hole by hand. After the spark plug is properly seated, use the spark plug wrench to tighten it.

NOTE: The recommended tightening of the spark plug is 1/2 to 3/4 of a turn after the spark plug gasket contacts the spark plug hole, or 11 – 14.5 ft-lbs (15 – 20 Nm). Do not over-tighten the spark plug.

8. Reinstall the spark plug boot over the spark plug.

9. Reinstall the spark plug access cover.

30

MAINTENANCE

AIR FILTER MAINTENANCE

Routine maintenance of the air filter helps maintain proper airflow to the carburetor. Occasionally check that the air filter is free of ex-

1

cessive dirt. The air filter should be checked every 50 hours of use.

Refer to Recommended Maintenance Schedule in Table 4.

1

1. Open the side panel (to the right of the control panel) by unscrewing the side panel access screws (Fig. 22 – 1).

2. Unscrew the air filter cover knob (Fig. 23 – 1), remove the cover, and remove the foam air filter element from the casing.

3. Check and clean the foam air filter element. Wash the filter ele-

ment in warm soapy water. Squeeze it thoroughly dry in a clean

cloth. Saturate the element in clean engine oil and squeeze off ex-

cess oil in a clean absorbent cloth. A small amount of oil in the

element is normal and necessary for the engine to work properly.

If the element is damaged, replace it with a new one (part. no.

56477i-103, available at wenproducts.com).

1

4. Reinstall the air filter element and the air filter cover. Replace the side cover and secure it with the screws.

Fig. 22 Fig. 23

CAUTION! Running the engine with a dirty, damaged, or missing air filter element will result in possible danger and cause the engine to wear out prematurely.

DRAINING THE CARBURETOR
Drain the carburetor after every use and before storing the generator (refer to 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.
2. Open the side panel (to the right of the control panel) by unscrewing the mounting screws (Fig. 22 – 1).
3. Open up the carburetor drain screw (Fig. 24 – 1) with a Phillips screwdriver and drain out any gasoline that has built up inside the carburetor.
4. Once the fuel has drained, tighten the drain screw with the screwdriver.
NOTE: Make sure to drain your carburetor before storing the generator for long periods of time.
5. Close the side panel.

Fig. 24 1

31

MAINTENANCE

SPARK ARRESTOR MAINTENANCE
It is recommended to inspect and clean the spark arrestor (Fig. 25 – 1) every 100 hours of operation.

Fig. 25

1. The spark arrestor is located outside the muffler, which gets very hot dur-

ing operation. Allow the engine to cool completely before servicing the spark

1

arrestor.

2. Unscrew the six Phillips head screws and remove the muffler cover.

3. Remove the screw that holds the spark arrestor (Fig. 25 – 1) to the muffler.

4. Remove the spark arrestor screen.

5. Carefully clean and remove the carbon deposits from the spark arrestor screen with a wire brush. Replace the spark arrestor if it is damaged (part no. 56477i-115, available for purchase at wenproducts.com).

6. Reinstall the spark arrestor in the muffler and secure it in place with the screw.

7. Replace the muffler cover and secure it with the six screws.

DRAINING THE FUEL TANK
1. Prepare an approved gasoline-storage container. Make sure the engine switch is turned to OFF.

2. Open the right side panel to access the carburetor, as instructed on the previous page.

3. Open the carburetor drain screw and turn the 4-in-1 switch to “RUN”. This will allow gasoline to drain from the gas tank through the carburetor.

NOTE: It may take a few hours for your tank to drain completely, depending on the amount of gasoline in the tank.

4. Once drained fully, close the carburetor drain screw, turn the engine switch OFF, and close the side panel.

CAUTION! Running the engine with a dirty, damaged, or missing air filter will result in possible danger and cause the engine to wear out prematurely.

BATTERY MAINTENANCE & STORAGE
The lithium-ion battery will receive charge when the engine is running. Remember to run the generator once a month for 20-30 minutes to charge the battery. A charged battery will allow you to start the generator using the electric start button during your next time of need. If the battery is out of charge, you may start the generator using the recoil starter. If the generator is not used for a long period, it is recommended to disconnect the quick- connector to protect it from losing charge. TIP: You can also connect the battery to an automatic trickle charger to keep the battery charged. If using a trickle-charger, charge the battery at room temperature.
Lithium-ion batteries can be damaged or suffer a shortened lifespan if they are charged in very cold temperatures (below freezing). If you expect to store the generator in temperatures below 25°F (-5°C), we recommend removing the battery from the generator and storing it indoors. If using the generator in temperatures below 25°F (-5°C), we recommend running the generator for at least 15 minutes with the battery removed, or the quick-connector disconnected and covered with an insulator such as electrical tape, and then connecting the battery. This will allow the inside of the generator to warm up, and will greatly reduce the chance of damage to the battery.

WARNING! It is best to store the battery indoors at room temperature. Do not store your battery outside in the winter, where temperatures may go below 25°F (-5°C), or in any location where temperatures may exceed 104°F (40°C), such as in direct sunlight or inside a vehicle or metal building during the summer.
32

TRANSPORTATION & STORAGE
TRANSPORTING THE GENERATOR
To prevent fuel spillage when transporting, be sure to perform the following:

1. To extend or collapse the handle, press the handle release button, adjust the handle as desired, then release the button. The handle will automatically lock in the fully-extended and the locked positions. 2. Tighten the fuel cap.
2. Flip the 4-in-1 switch to the “ENGINE OFF” position. 4. Drain the fuel tank if possible. Refer to page 32, “DRAINING THE FUEL TANK.”
   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.
   5. 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 page 31, “DRAINING THE CARBURETOR.”
· Disconnect the battery quick-connectors.
· 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 (see “DRAINING THE FUEL TANK”). Never store generator with fuel in the tank for more than two months.
· Disconnect the battery quickconnectors.
· 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.
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.
PRODUCT DISPOSAL
Do not dispose of a used generator or parts with your household waste. This product contains electrical or electronic components that should be recycled. Please take this product to your local recycling facility for responsible disposal to minimize its environmental impact.
Do not dispose of used oil or fuel in the trash or down a drain. Please contact your local recycling center or auto garage to arrange proper oil/fuel disposal.
Please recycle the packaging and electronic components where facilities exist. Please contact your local auto garage or recycling facility to properly dispose of oil/fuel.
33

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 1-847-429-9263 (M-F 8-5 CST), or email techsupport@wenproducts.com.

PROBLEM
Engine will not start.
Engine runs but there is no electrical output.
Generator runs but does not support all electrical devices
connected.
Engine is “Hunting” during Operation (Engine RPM is fluctuating).

POSSIBLE CAUSE Engine switch is set to OFF. Choke is open. Engine is out of fuel.
Battery is out of power.
Battery is too cold. Engine is filled with contaminated or old fuel. Spark plug is dirty. Spark plug is broken.
Oil level is low.
Carburetor is air locked.
LPG cylinder is out of fuel, and LPG regulator hose is connected. Circuit breaker has been tripped due to overload.
Bad connecting cords/wires.
Bad electrical device connected to the generator.
Generator is overloaded.
Short circuit in one of the devices. The air filter is dirty.
1. The fuel isn’t running through the fuel valve. 2. The air filter is clogged. 3. The muffler or spark arrestor is blocked 4. There is gunk in the carburetor preventing a consistent fuel/air mixture.

SOLUTION Set engine switch to ON. Close the choke. Add fuel. Electric start will not work if battery is out of power. Start generator using the recoil start to charge the battery. Store the generator in a warmer location.
Drain the fuel in the tank. Fill with fresh fuel.
Clean the spark plug. Replace spark plug. Add or replace oil. This generator is equipped with a low oil sensor. The engine will not start unless the oil level is sufficient. Remove the nut from the bottom of the carburetor. Take off the carburetor to allow it to reset. Place the carburetor back and reinstall the nut.
Disconnect LPG regulator hose from generator. Make sure there is enough gasoline in the tank.
Disconnect all the loads. Wait for two minutes and push the circuit breaker to the ON position to reset it. Check the power cords and extension cords. Do not use if any cord is damaged. Replace damaged cords immediately.
Try connecting a different device.
Perform these steps: 1. Turn off all electrical devices. 2. Unplug all electrical devices. 3. Turn off generator. 4. Wait several minutes. 5. Restart generator. 6. Try connecting fewer electrical loads to the generator. Try disconnecting any faulty or short-circuited electrical loads. Clean or replace the air filter element (see page 31). Turn off the generator and wait for it to cool down. Perform the following steps: 1. Check if the fuel is properly and consistently going through the fuel valve 2. Check for any blockage in the air filter. Check and clean the air filter as necessary. 3. Check if the spark arrestor is blocked. Clean with metal brush as necessary. 4. Use “Gunk remover” spray on the carburetor jets.

34

WIRING DIAGRAM

Main Winding Inverter Unit Winding CO winding
DC Winding
Ignition Winding

Stepper Motor CW

Yellow Blue Orange Pink

Red

Red

Parallel Terminal

Black

Black

Yellow/Green

20A,C.B TT-30R

20A,C.B 5-20R

5-20R

Yellow/Green

Yellow/Green

Yellow/Green

Orange Black

Red Yellow Blue White White Yellow/Green

Inverter Unit

Fuel solenoid valve

Solenoid Valve Controller

Red

White

Black

Blue

Blue

Violet
Violet Violet Violet Brown

CO Alarm

Black

Blue Pink

Red

Black

Orange Blue/White
White Gray Violet Violet Black/Red Black/Red Blue Black Brown Orange
Violet Violet

ECO switch Gas switch

White

Run Over
Digital Meter

CO

Protector/8A

12VDC/8A

–

OIL Green Yellow

Black Red

Blue Blue Black/White Red Yellow/Red Black/Red

Red Orange

Remote Controller

Blue Red Yellow Pink Orange

Stepping Motor CW

Violet Brown Green Black/Red Red
Digital Igniter

USB
5VDC/1A/2.1A
6A 10MIC
Black/Red Black/Red
NO C NC ON OFF
NC C
NO
Microswitch

Blue/White Yellow Blue Black Brown
Black/White Pink Green Black/Red

Black

Starter Motor Battery 12V Temperature Sensor
t Pulser Coil Oil Switch Level Spark Plug Ignition Coil Fuel Level Indicator

Motor Section

-+
M
Power Section

Panel Section

35

EXPLODED VIEW & PARTS LIST

GENERATOR

43 41 25 7
43

2

55

3

24

61

25

4

56
61 25
10 1

25

58

8 25
50 90 12

25 9
51 39 23 68 60

88 89 39
74 54

38 91 23 39
57
40 45
45 32 86

21 73
65 27
59 64 27
53

26
45 33

31 62
49

37 60

39 23 48

35 29 50 30

52 42

28

14

22

25

66

25 13

18 19
5

72 71 69 70
78 77 82

76
75 81 80 85

84

92 92

87 83

64

79

87
63 35
35

11

46

36

46

36

47

20
44 18
62

46 36

25
25 17
6
25
67 25 34 15 16

NOTE: Not all parts may be available for purchase. Parts and accessories that wear down over the course of normal use are not covered under the warranty.
36

EXPLODED VIEW & PARTS LIST

GENERATOR

NO. PART NO.

DESCRIPTION QTY. NO. PART NO.

DESCRIPTION QTY.

1 DF480iX-001

Handle Assembly 1 35 56477i-035

Bolt, M6x22

6

2 DF480iX-002

Fuel Tank Cap

1 36 56202i-051

Bolt, M6x12

4

3 DF480iX-003

Fuel Tank Nut

1 37 56360iX-108 Wiring Sheath, 25mm 1

4 DF480iX-004

Top Cover

1 38 56477i-038

Fuel Pump

1

5 56480iX-005

Wiring Harness

1

39

56477i-039

6 DF480iX-006 Rear Cover Assembly 1

Self-tapping Screw, ST3.5×13

6

7 56477i-007 8 DF480iX-008

Left Front Service Panel
Left Rear Service Panel

1 40 56477i-040B

Combination Fuel Valve and Engine 1

Switch

1 41

56477i-041

Recoil Starter Shield 1

9 56477i-009

Left Housing

1 42 56477i-042 Muffler Panel Gasket 1

10 56477i-010 Cylinder Head Cover 1 43 56202i-001

Screw, M4x10

7

11 56477i-011

Base

1 44 56477i-044

Bottom Bracket 2 1

12 DF480iX-012

Control Panel Assembly

45 56202i-013 1 46 56477i-046B

Bolt, M6x12

4

Foot

4

13 DF480iX-013

Front Cover

1 47 56477i-047

Bottom Bracket 1 1

14 56477i-014B

Right Housing

1 48 56480iX-048

Igniter

1

15 56477i-015 Battery Cover Panel 1 49 56477i-049

Grounding Wire

1

16 56477i-016 Phillips Bolt, M4x10.7 1 50 56477i-050

Clip

4

17 56477i-017

Muffler Panel

1 51 DF480iX-051

Wiring Harness

1

18 56477i-018

Bolt, M8x12

2 52 DF480iX-052

Handle Cover

1

19 DF480iX-019

Wheel

2 53 DF480iX-053

Fuel Hose

1

20 56477i-020

Axle Assembly

1 54 56477i-054

Fuel Tank Bumper 2

21 DF480iX-021

Fuel Tank

1 55 DF480iX-055

Fuel Filter

1

22 56477i-022

Bolt, M8x25

2 56 56477i-056

Handle Plug

2

23 56477i-023

Washer, 4mm

5 57 DF480iX-057

Fuel Hose

1

24 DF480iX-024

Bushing

1 58 DF480iX-058

Rear Cover

1

25 56477i-025 Phillips Screw, M5x12 45 59 56477i-059B

Fuel Hose

1

26 DF480iX-026 27 56360iX-118 28 56477i-028 29 56477i-029 30 56477i-030 31 DF480iX-031
32 56477i-032

Clip Clamp

1 60 56477i-060 2

Wiring Sheath with Notch

2

Engine Mount 1

2 61 56477i-061 Phillips Bolt, M6x5.5 6

Engine Mount 2

1 62 56477i-062

Nut, M8

6

Engine Mount 3

1 63 DF480iX-063

Wiring Harness

1

Engine Assembly 1 64 DF480iX-064

Wiring Harness

1

Inverter Mounting Bracket

1

65 DF480iX-065 66 56477i-065

Fuel Hose Wiring Clamp

1 2

33 34

56477i-033 56477i-034

Inverter

1

Retaining Ring, 4mm 1

67 56480iX-067

Battery, 12V 1.6Ah, Li-ion

1

37

EXPLODED VIEW & PARTS LIST

GENERATOR
NO. PART NO.
68 56480iX-068
69 56360iX-125
70 56480iX-070
71 56480iX-071 72 56480iX-072 73 DF480iX-073 74 56477i-068 75 DF480iX-075
76 DF480iX-076
77 DF480iX-077 78 DF480iX-078 79 DF480iX-079 80 DF480iX-080

DESCRIPTION QTY. NO.

Remote Start & Electric Start Module

1

81

CO Alarm

1 82

CO Sensor Shield Housing
Grounding Wire Bolt, M4x12 Fuel Hose Fuel Hose

1 83 84
1 85 1 86 1 1 87

Mounting Plate

1 88

Self-tapping Screw, ST4.2×16

2

89

Mounting Base

1 90

Screw, M2.5×20

2 91

Nut, M2.5 Bolt, M6x16

2 92 1

N.P.

PART NO. DF360iX-034 DF480iX-082 DF480iX-083 DF480iX-084 DF480iX-085 DF480iX-086 DF480iX-087 DF480iX-088 DF480iX-089 DF480iX-090 56477i-069 DF480iX-093
DF480iX-092

DESCRIPTION QTY.

Solenoid Valve Controller

1

LPG Quick-connector 1

Nut, M12

1

LPG Hose

1

LPG Hose Jacket

1

Mounting Plate

1

Fuel Hose Clamp, 16mm

2

Clip

1

Washer, 4mm

1

LPG Quick-connector Cap

1

Clamp

1

Self-tapping Screw, ST4.2×20

2

LPG Regulator Hose Assembly

1

38

EXPLODED VIEW & PARTS LIST

ENGINE 29 30 31

20 21 64

22 23 24

33
49
35 50

40

36

37

51

52

41

53

46

42

54

55

43

47

56

44

45

57

58

59

24

60

27

61
28 25
26
25 72 34

67 64
63

66 65

89 15

62 59

71 48 70
68 69

96 71

97 95

9 10

5

8

7

3

6

18

19

92

34

16 17 73

69 75

68

76

77

78

79

80 81

4

2 99

4

100

82
83
71 84 85

87

73

86

90

14

73

91 32

12

11 38

39 74

94 13
93

12 98

13 66
88 1

NO. PART NO.

DESCRIPTION

QTY. NO. PART NO.

1

56477i-101

Bolt, M6x14

3

13 56360iX-084

2

56477i-102

Bolt, M6x85

2

14 56360iX-082

3

56477i-103

Air Filter Assembly

1

15 56477i-115

4

56477i-104

Bolt, M5x12

5

16 56477i-116

5

56477i-105

Breather Hose

1

17 56477i-117

6

56477i-106

Air Filter Gasket

1

18 56360iX-029

7 DF480iX-107

Carburetor

1

8

56477i-108

Carburetor Gasket

1

9 56480iX-109

Screw, M4x8

1

10 56480iX-110

Nut, M4

1

11 56477i-111 Self-tapping Screw, ST4.8×20 2

12 56360iX-087 Self-tapping Screw, ST4.2×25 6

19 56477i-119 20 56477i-120 21 56477i-121 22 56477i-122 23 56477i-123 24 56477i-124

DESCRIPTION
Clip Clip Spark Arrester Intake Manifold Gasket Intake Manifold Clamp Fuel Hose Bolt, M8x30 Bushing, 12×16.8-8.5×6.5 Crankcase Cover Crankcase Gasket Pin, 8×14

QTY.
2 3 1 1 1 1 1 8 1 1 1 2
39

EXPLODED VIEW & PARTS LIST

ENGINE

NO.
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
61
62
63
64
40

PART NO.
56360iX-070 56477i-126 56477i-127 56477i-128 56477i-129 56477i-130 56477i-131 56477i-132 56477i-133 56477i-134 56477i-135 56477i-136 56477i-137 56477i-138 56477i-139 56477i-140 56477i-141 56477i-142 56477i-143 56477i-144 56477i-145 56477i-146 56477i-147 56477i-148 56477i-149 56360iX-015 DF480iX-151 56477i-152 56360iX-085 56477i-154 56477i-155 56477i-156 56360iX-038 56477i-158 56477i-159 56477i-160
56477i-161
56477i-162
56477i-163
56477i-164

DESCRIPTION
Bearing, TM6205 Crankshaft Camshaft
Woodruff Key Valve Cover Cushion
Bolt, M6x10 Cylinder Head Plastic Cover
Dipstick Drip Guard Bolt, M6x25 Bolt, M6x16
Cylinder Head Cover Valve Cover Plate Bolt, M5x10 Ignition Coil
Engine Cowling, Right Valve Cover Plate Gasket Rocker Arm Assembly
Rocker Arm Base Valve Spring Seat
Valve Spring Intake Valve Seal Valve Adjustment Cap
Valve Locker Clip Base
Cylinder Head Cover Gasket Bolt, M8x60 Cylinder Head
Cylinder Head Gasket Pin, Ø10×16 Exhaust Valve Intake Valve Push Rod Valve Tappet
Piston Ring Set Circlip Piston
Connecting Rod Assembly Piston Pin
Spark Plug, LG F6RTC (NGK BPR6ES) Stud

QTY.
2 1 1 1 1 2 1 1 4 3 1 1 1 1 1 1 2 1 2 2 1 2 4 1 1 4 1 1 2 1 1 2 2 1 2 1
1
1
1
3

NO. PART NO.

DESCRIPTION

QTY.

65 56477i-165

Muffler Assembly

1

66 56477i-166

Nut, M6

5

67 56477i-167

Muffler Gasket

1

68 56477i-168

Grounding Bolt, M10-1.25×15)

2

69 56477i-169

Washer, 10 x 1.5 x 16

2

70 56477i-170

Grounding Wire

1

71 56477i-171

Bolt, M6x16

6

72 56477i-172

Oil Sensor

1

73 56477i-173

Bolt, M6x22

4

74 56477i-174

Gasket, Wire

1

75 56477i-175

Crankcase

1

76 56477i-176

Trigger

1

77 56360iX-093

Bolt, M6x12

2

78 56360iX-055

Oil Seal, 25 x 41.25 x 6

1

79 56480iX-179

Stator

1

80 DF480iX-180

Bolt, M6x50

3

81 56480iX-181

Rotor

1

82 56477i-182

Cooling Fan

1

83 56477i-183

Starter Cup

1

84 56477i-184

Nut, M14-1.5

1

85 56477i-185

Stud

2

86 56477i-186

Blower Housing

1

87 56477i-187

Stud

2

88 DF480iX-189

Recoil Starter

1

89 56477i-189 Self-tapping Screw, ST4.2×9.5 1

90 56477i-190

Engine Cowling, Left

1

91 56477i-191

Dipstick

1

92 56477i-192

Dipstick Seat Assembly

1

93 56477i-109

Rectifier

1

94 56202i-167

Bolt, M6x14

1

95 DF480iX-196

Starter Motor

1

96 56480iX-195

Pin, 8×8

2

97 56480iX-196

Bolt, M6x30

2

98 56480iX-197

Temperature Sensor

1

99 56477i-193

Fuel Hose

1

100 56477i-194

Fuel T-Pipe

1

N.P. DF480iX-HA39

High-Altitude Kit, 3000 – 9000 ft

1

EXPLODED VIEW & PARTS LIST

CONTROL PANEL
1 2 3 4,5,6,7,8,9,10,11

141156117819 20

12

21

13

13

NO. PART NO.

DESCRIPTION QTY.

1 56203i-005.4

Eco-Mode Switch

1

2 56203i-005.14R Parallel Socket, Red 1

3 56203i-005.14B Parallel Socket, Black 1

4 56360iX-205

Nut, M6

1

5 56203i-005.11 Lock Washer, 6mm 1

6 56203i-005.12 Flat Washer, 6mm 1

7 56360iX-208

Grounding Stud

1

8

56360iX-209

Toothed Lock Washer, 6mm

1

9 56360iX-210 Flat Washer, 5mm 1

10 56360iX-211 Lock Washer, 5mm 1

11 56360iX-212

Nut, M5

1

12 DG4500iX-207

NEMA TT-30R 120V 30A AC Receptacle

1

NO. PART NO.

DESCRIPTION QTY.

NEMA 5-20R 120V

13 DG4500iX-208

20A AC Duplex

2

Receptacle

14 DF480iX-214

Multi-meter

1

15 56477i-215

Reset Button

1

16 56477i-216

USB Receptacle (2.1A / 1A)

1

17 56477i-217

DC Breaker, 8A

1

18 56477i-218

12V DC Automotive Outlet

1

19 56235iX-005.19 CO Sensor LED

1

20 56480iX-220

Start Button

1

21 DF480iX-221

AC Breaker, 20A

2

NOTE: Not all parts may be available for purchase. Parts and accessories that wear down over the course of normal use are not covered under the warranty. 41

WARRANTY STATEMENT
WEN Products is committed to building tools that are dependable for years. Our warranties are consistent with this commitment and our dedication to quality.
LIMITED WARRANTY OF WEN PRODUCTS FOR HOME USE
GREAT LAKES TECHNOLOGIES, LLC (“Seller”) warrants to the original purchaser only, that this WEN consumer product will be free from defects in material or workmanship during personal use for a period of three (3) years from date of purchase or 500 hours of use; whichever comes first. Ninety days for all WEN products if the tool is used for professional or commercial use. Purchaser has 30 days from the date of purchase to report missing or damaged parts. Parts and labor are covered for one (1) year under this limited warranty; parts only are covered for three (3) years under this limited warranty.
SELLER’S SOLE OBLIGATION AND YOUR EXCLUSIVE REMEDY under this Limited Warranty and, to the extent permitted by law, any warranty or condition implied by law, shall be the replacement of parts, without charge, which are defective in material or workmanship and which have not been subjected to misuse, alteration, careless handling, misrepair, abuse, neglect, normal wear and tear, improper maintenance, improper storage, incorrect lubricants / fuels, or other conditions adversely affecting the Product or the component of the Product, whether by accident or intentionally, by persons other than Seller. To make a claim under this Limited Warranty, you must make sure to keep a copy of your proof of purchase that clearly defines the Date of Purchase (month and year) and the Place of Purchase. Place of Purchase must be a direct vendor of Great Lakes Technologies, LLC. Purchasing through third party vendors, including but not limited to garage sales, pawn shops, resale shops, or any other secondhand merchant, voids the warranty included with this product. Contact techsupport@wenproducts.com or 1-847-429-9263 with the following information to make arrangements: your shipping address, phone number, serial number, required part numbers, and proof of purchase. Damaged or defective parts and products may need to be sent to WEN before the replacements can be shipped out.
Upon the confirmation of a WEN representative, your product may qualify for repairs and service work. When returning a product for warranty service, the shipping charges must be prepaid by the purchaser. The product must be shipped in its original container (or an equivalent), properly packed to withstand the hazards of shipment. The product must be fully insured with a copy of the proof of purchase enclosed. There must also be a description of the problem in order to help our repairs department diagnose and fix the issue. Repairs will be made and the product will be returned and shipped back to the purchaser at no charge for addresses within the contiguous United States.
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 THREE (3) YEARS FROM DATE OF PURCHASE. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING BUT NOT LIMITED TO LIABILITY FOR LOSS OF PROFITS) ARISING FROM THE SALE OR USE OF THIS PRODUCT. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE IN THE U.S., PROVINCE TO PROVINCE IN CANADA AND FROM COUNTRY TO COUNTRY.
THIS LIMITED WARRANTY APPLIES ONLY TO ITEMS SOLD WITHIN THE UNITED STATES OF AMERICA, CANADA AND THE COMMONWEALTH OF PUERTO RICO. FOR WARRANTY COVERAGE WITHIN OTHER COUNTRIES, CONTACT THE WEN CUSTOMER SUPPORT LINE. FOR WARRANTY PARTS OR PRODUCTS REPAIRED UNDER WARRANTY SHIPPING TO ADDRESSES OUTSIDE OF THE CONTIGUOUS UNITED STATES, ADDITIONAL SHIPPING CHARGES MAY APPLY. 42

NOTES
43

THANKS FOR REMEMBERING
V. 2024.08.26

References

• How to Connect a WEN Generator Battery with Quick-Connectors — WEN Products
• WEN - Shop Generators, Woodworking Tools, and Power Tools — WEN Products
• P65Warnings.ca.gov

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