WEN DF500IX Dual Fuel Portable Inverter Generator User Manual

5000-WATT DUAL FUEL

INVERTER GENERATOR

Instruction Manual

IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest standards for dependability,

ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged,

trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use

your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.

NEED HELP? CONTACT US!

Have product questions? Need technical support? Please feel free to contact us:

TECHSUPPOR[email protected]1-847-429-9263 (M-F 8AM-5PM CST)

For replacement parts and the most up-to-date instruction manuals, visit WENPRODUCTS.COM

MODEL DF500iX

CONTENTS

WELCOME 3

Speciﬁcations ....................................................................................................3

Introduction ......................................................................................................4

SAFETY 5

Safety Information ............................................................................................5

Generator Safety Warnings ...............................................................................6

Unpacking & Packing List .................................................................................9

Know Your Inverter Generator .........................................................................10

Preparation .....................................................................................................12

BEFORE OPERATING

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 ........................................................................................43

To purchase accessories for your tool, visit WENPRODUCTS.COM

Weatherproof Generator Cover (Model No. 56310iC)

High-Altitude Kit (Part No. DF500iX-HA39)

WEN Parallel Connection Kit

SPECIFICATIONS

Model Number DF500iX

Surge (Starting) Wattage

Gasoline: 5000W

LPG: 5000W

Rated (Running) Wattage

Gasoline: 4220W

LPG: 3800W

Rated Voltage AC: 120V / 240V; DC: 12V / 5V

Rated Amperage AC Gas: 35.1A LPG: 31.6A; DC 8A (12V), 2.1A / 1A (USB)

Phase Single

Frequency 60 Hz

Product Weight 93.7 Pounds

Product Dimensions 22.8 in. x 16.6 in. x 19.7 in.

GENERATOR

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

Engine Displacement 224cc

Engine Speed 3600 RPM

Fuel Tank Capacity 2.9 Gallons (11 L)

Oil Capacity 26.37 ﬂ. oz. (0.78 L)

Half-Load Run Time

Gasoline: 9 Hours

LPG: 11 Hours

Spark Plug Type LG F6RTC (NGK BPR6ES)

Spark Plug Gap 0.024 - 0.031 in. (0.6 - 0.8 mm)

Spark Plug Torque 14.75 - 18.44 ft-lbs (20 - 25 Nm)

Battery 12V, 7Ah, Lead-Acid

ENGINE

INTRODUCTION

Thanks for purchasing the WEN 5000-Watt Dual Fuel Inverter Generator. Refer to the illustration below for the loca-

tion 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: DF500iX

Date of Purchase: _______________________________________________

Purchased From: ________________________________________________

Serial Number: _________________________________________________

TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your generator at least once a

month for 20 to 30 minutes. Start the generator according to the instructions and plug a small load in to make

sure the outlet is producing electricity.

SERVICE RECORD

Record the service dates of your generator in the chart below. Please perform maintenance checks and operations

according to 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

Serial NumberSerial NumberSerial Number

SAFETY INFORMATION

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.

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 [email protected].

DANGER: indicates a hazard, which, if not avoided, will result in death or serious injury.

WARNING: indicates a hazard, which, if not avoided, could result in death or serious injury.

CAUTION: indicates a hazard, which, if not avoided, might result in minor or moderate injury.

CAUTION! when used without the alert symbol, indicates a situation that could result in damage to the machine.

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.

GENERATOR SAFETY WARNINGS

DANGER! CARBON MONOXIDE

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This

is a poison gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even

if you cannot smell the exhaust, you could be breathing CO.

NEVER use a generator inside homes, garages, crawl spaces, or other partially enclosed areas. Deadly levels

of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply

enough fresh air. ONLY use a generator outside and far away from windows, doors, and vents. These openings

can pull in generator exhaust.

Even if you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or battery-

backup CO alarm in the home. If you start to feel sick, dizzy, or weak after the generator has been running, move

to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

WARNING! RISK OF EXPLOSION. HIGHLY FLAMMABLE: This generator may emit highly ﬂammable and

explosive gasoline vapors, which can cause severe burns or even death, if ignited. A nearby open ﬂame can lead

to explosion even if not directly in contact with gasoline.

• Do not operate near open ﬂame, heat, or any other ignition source. Do not smoke near the generator.

• Always operate on a ﬁrm, level surface.

• Always turn generator off before refueling. Allow generator to cool for at least 2 minutes before removing

fuel cap. Loosen cap slowly to relieve pressure in tank.

• Do not overﬁll fuel tank. Gasoline may expand during operation. Do not ﬁll to the top of the tank. Allow for

expansion. Always check for spilled fuel before operating.

• If fuel spills, move the generator at least 30 feet away from the spill and wipe clean any spilled fuel before

starting the engine.

• Empty fuel tank before storing or transporting the generator.

WARNING! If this generator is used as a supply for a building’s wiring system, the generator must be in-

stalled 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.

GENERATOR SAFETY WARNINGS

OPERATING ENVIRONMENT

1. Using a generator indoors can kill you in minutes.

Only use a generator outside and far away from win-

dows, doors and vents.

2. Do not smoke near the generator.

3. Do not operate near open ﬂame, heat, or 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 con-

ditions; doing so signiﬁcantly increases the risk of

electrical shock. Never handle the generator, electronic

devices, or any cord while standing in water, while bare-

foot, or when hands or feet are wet.

5. Always operate the generator on a dry, ﬁrm, level

surface.

6. The generator should have at least 5 feet of clear-

ance from buildings or other equipment during opera-

tion.

7. Do not allow children or non-qualiﬁed persons to

operate the generator.

GENERATOR PREPARATION

1. Always ground the generator before using it to maxi-

mize safety (see “Ground the Generator” section).

2. Do not overﬁll fuel tank, as gasoline may expand

during operation. Do not ﬁll to the very top of the tank.

Leave room for gasoline expansion. Always check for

spilled fuel before operating.

3. If any part of the generator, electrical device or pow-

er 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.

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 electri-

cal 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 per-

sonal injury.

2. Do not touch bare wires or receptacles (outlets).

3. Do not exceed the wattage capacity of the generator

by plugging in more electrical devices than the unit

can handle. This could damage the generator and/or

connected electrical devices. Check the operating volt-

age and frequency requirements of all electrical devices

prior to plugging them into the generator.

Generator safety warnings continue on the next page.

WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety

rules. Failure to follow the safety instructions may result in serious personal injury.

GENERATOR SAFETY WARNINGS

WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules.

Failure to follow the safety instructions may result in serious personal injury.

4. Allow generator to run for several minutes before

connecting electrical devices. Do not start or stop en-

gine with electrical devices plugged in to the receptacles.

Failure to do so could damage the generator and/or con-

nected 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 be-

fore touching engine or areas of the generator that be-

come hot during use.

8. Turn off all connected electrical devices before stop-

ping the generator.

9. Always turn generator off before refueling. Allow

generator to cool for at least 2 minutes before removing

fuel cap. Loosen cap slowly to relieve pressure in tank.

10. Turn the engine switch to “OFF” position when the

engine is not running.

11. Empty fuel tank before storing or transporting the

generator. Do not store generator or gasoline near fur-

naces, water heaters, or any other appliances that pro-

duce heat or have automatic ignitions. Store the genera-

tor and fuel away from sparks, open ﬂames, pilot lights,

heat and other sources of ignition.

12. Always wash hands after handling generator.

CAUTION: Misuse of this generator can damage it or

shorten its lifespan.

TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your generator at least once a

month for 20 to 30 minutes. Start the generator according to the instructions and plug a small load in to make

sure the outlet is producing electricity. If you do not run it often, it will greatly shorten the generator’s lifespan

and void the warranty.

Components

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 [email protected].

PACKING LIST

UNPACKING & PACKING LIST

Tools & Accessories

Generator

Funnel

Screwdriver

LPG Regulator Hose

Engine Oil,

25.4 ﬂ. oz. (0.75 L)

Spark Plug Socket (1)

8/10mm Wrench

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 fol-

lowing 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

Control Panel

Fuel Cap

Spark Plug (Inside Panel)

Air Filter (Inside Panel)

4-in-1 Switch

Recoil Starter

Oil Dipstick (Inside Panel)

Battery (Inside Panel)

Handle Release Button

LPG Inlet

Panel Lock Knobs

Spark Arrestor

Panel Lock Knobs

KNOW YOUR INVERTER GENERATOR

CONTROL PANEL

1. Voltage Selector

Sets the generator’s output voltage to 120V or 240V. When

the switch is set to 120V, the 120V and parallel outlets are

active; when the switch is set to 240V, the L14-30R outlet is

active.

2. AC Circuit Breaker (20A)

Press to reset the NEMA 5-20R recepticles.

3. AC Circuit Breaker (30A)

Press to reset the NEMA TT-30R RV recepticle.

4. DC Circuit Breaker (8A)

Press to reset the USB and 12V recepticles.

5. 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 gen-

erator. See p. 26 for more information.

6. 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.

7. Reset Button

Press to reset the circuit in case of overload.

8. Engine Start Button

Press to start the generator.

9. Eco-Mode Switch

Maximizes fuel economy & run time.

10. 5V USB Port

1A & 2.1A for charging various electronic devices.

11. 12V DC Outlet

Cigarette-style outlet provides DC power.

12. Parallel Connection

Connect to share wattage between inverter generators. 120V

only.

13. AC 120V NEMA TT-30R RV Receptacle

Standard RV connector.

14. AC 120V NEMA 5-20R Duplex Receptacles

Standard household outlets provide 120V 60Hz power.

15. Grounding Nut

Ground the generator to reduce the risk of electric shock.

16. AC 120/240V 30A NEMA L14-30R Receptacle

Connect electrical devices that run on 120V/240V, 60 Hz,

single phase, AC current.

20A 30A

PARALLEL

CONNECT

2 3 4 5 76

910111213141516

PREPARATION

TO ADD OIL:

1. Place the generator on a level surface. Make sure the engine is

OFF before adding or checking oil.

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 26.37 ﬂ. oz. (0.78 L).

• 30W Engine Oil

Temperatures above 40°F

• 10W-30 Engine Oil

Temperatures between 0°F - 40°F

• Synthetic 5W-30 Engine Oil

All temperature ranges

ENGINE OIL RECOMMENDATIONS

Select good quality detergent oil bearing the American 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.

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.

1. Open the side panel (to the left of the control panel) by twisting

the panel lock knobs (Fig. 2 - 1) a quarter turn.

2. Remove and wipe the oil dipstick (Fig. 2 - 2) with a clean rag.

Insert the dipstick into the oil ﬁll opening without screwing it in.

3. Remove the dipstick 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.

CAUTION! For subsequent operation, the oil

level should be checked before each use, or

after every 8 hours of operation. The gen-

erator 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.

Fig. 1

Fig. 2

Synthetic 5W-30

30W

10W-30

°F

°C

-20 0 20 32 40 60 80 100

40200

-20

-10

-30 30

PREPARATION

TO CHECK OIL LEVEL (before every subsequent start):

1. Place the generator on a level surface. Make sure the en-

gine 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 up-

per limit mark and halfway mark of the dipstick. See Fig. 3.

Fig. 3

Lower Limit

Upper Limit

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 genera-

tor performs best with ethanol-free gasoline. DO NOT use

gasoline with over 10% ethanol.

The capacity of the fuel tank is 2.9 gallons (11L). Do not

mix oil with gasoline.

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. 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

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, genera-

tor 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 spray-

ing 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 [email protected] for assistance.

NOTE: If you would like to purchase other accessories for

your dual-fuel generator, consult your local dealer of pro-

pane and propane accessories, I tell you what.

Fig. 5

Fig. 6

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.

PREPARATION

AUTO FUEL SELECTION

Your generator is equipped with Auto Fuel Selection Technology. What this means is that the generator will auto-

matically 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 con-

nected, the generator will use gasoline (if there is gasoline in the fuel tank). The LPG regulator hose must be discon-

nected 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 Watt-

age 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.

PREPARATION

STEP 3 - GROUND THE GENERATOR

To reduce the risk of electric shock and to maximize safety,

the generator should be properly grounded.

1. Attach one end of the grounding wire to the grounding

nut (Fig. 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 opera-

tion 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

DF500iX-HA39. Refer to the instructions included with your

altitude kit for more information about installation.

WARNING! Failure to properly ground the generator

increases your risk of electric shock.

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.

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.

Fig. 7

STEP 4 - CONNECT THE BATTERY

WARNING! Battery gives off explosive hy-

drogen gas.

• Keep the battery away from sparks, ﬂames, and

cigarettes.

• Do not connect or disconnect the battery while

the generator is running.

• Service or use the 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 the battery.

• Keep out of the reach of children.

• Do not tilt the generator with the battery in-

stalled.

• If battery acid gets on your skin, wash with wa-

ter immediately.

• If battery acid gets in your eyes, ﬂush with wa-

ter for at least 15 minutes and call a doctor im-

mediately.

If battery acid is swallowed, call a doctor imme-

diately. Drink a large amount of water or milk.

Then drink the milk of magnesia or vegetable oil.

WARNING! Use only genuine WEN batteries

with your generator (part no. DG4500iX-074).

Use of other batteries may induce premature

product failure and could pose a safety risk.

PREPARATION

Fig. 8

1717

For more information on your

battery quick-connectors, scan the

QR code or visit the link below:

http://bit.ly/44sb6C2

STEP 4 - CONNECT THE BATTERY (CONT.)

To connect the battery:

1. Open the side panel (to the right of the control panel)

by twisting the panel lock knobs (Fig. 8 - 1) a quarter

turn.

2. Remove the rubber quick-connector covers.

3. Connect the two ends of the quick-connector on the

battery to the ends of the quick-connector on the starter

motor (Fig. 8 - 2).

IMPORTANT: If you do not plan to use the generator

for an extended period of time, we recommend DIS-

CONNECTING the quick connector. This will protect the

battery from losing its charge. Cover the ends with the

rubber covers, or an insulator such as electrical tape. Al-

ternatively, you can use a trickle charger (not included)

to maintain battery charge.

If the battery is dead or disconnected, the generator can only be started using the recoil starter; you may use gaso-

line or LPG. 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 quick connectors as outlined

above, or connect the battery to a trickle charger.

ABOUT THE BATTERY

1. 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.

2. 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 for proper battery disposal.

3. 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.).

4 DO NOT DISASSEMBLE. Incorrect reassembly may pose a serious risk of electric shock, ﬁre or exposure to toxic

battery chemicals. If battery or charger are damaged, call WEN customer service at 1-847-429-9263 for assistance.

5. 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.

CAUTION!

Disconnect all electrical loads from the generator before attempting to start.

Before starting the generator, make sure you have read and performed the steps in the “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 1-847-

429-9263 M-F 8-5 CST for customer service.

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.

STARTING YOUR GENERATOR

DANGER! CARBON MONOXIDE

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This

is a poison gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even

if you cannot smell the exhaust, you could be breathing CO.

NEVER use a generator inside homes, garages, crawl spaces, or other partially enclosed areas. Deadly levels

of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply

enough fresh air. ONLY use a generator outside and far away from windows, doors, and vents. These openings

can pull in generator exhaust.

Even if you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or battery-

backup CO alarm in the home. If you start to feel sick, dizzy, or weak after the generator has been running, move

to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

WARNING! The exhaust from this product contains chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

WARNING! Do not operate generator near open ﬂame or ﬂammable materials This generator may emit

highly ﬂammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A

nearby open ﬂame can lead to explosion even if it isn’t directly in contact with gasoline. Do not smoke near the

generator.

WARNING! This generator produces powerful voltage, which can result in electrocution.

WARNING! Do not use in rainy or wet conditions. Do not touch bare wires or receptacles (outlets). Do not

allow children or non-qualiﬁed persons to operate.

WARNING! Generator should only be connected to electrical devices, either directly or with an extension

cord. NEVER connect to a building electrical system without a qualiﬁed electrician and connected to a transfer

switch as a separately derived system. Such connections must comply with local electrical laws and codes.

Failure to comply can create a back-feed, which may result in serious injury or death to utility workers.

Follow the instructions on the next page to start your generator.

STARTING YOUR GENERATOR

BEFORE STARTING THE GENERATOR

1. Verify that the generator is outside on a dry, level surface. Allow at

least two feet of clearance on all sides of the generator.

2. To maximize safety, check that the generator is properly grounded.

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.

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.

Fig. 9

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 maxi-

mize 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-

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.

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.

Fig. 12

Fig. 10

Fig. 11

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 sec-

onds until the engine starts, then release.

NOTE: The battery is shipped partially charged, in order to maxi-

mize 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 steps 7, 8, 9, and 10.

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.

STARTING YOUR GENERATOR

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.

Follow the instructions included with your WEN parallel connection

kit for proper installation and operation.

NOTE: The parallel connection feature can be used at 120V only.

Make sure the voltage selector switch is set to 120V if using the

parallel connection feature.

ENGINE BREAK-IN PROCEDURE

The procedure below should be followed when you receive your gen-

erator 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-

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.

ECO-MODE SWITCH

This generator is equipped with an Eco-Mode Idle Control Switch (Fig. 9 - 1). Engaging the switch automatically ad-

justs 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 needs 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.

Fig. 14

Fig. 13

USING YOUR GENERATOR

CALCULATING THE WATTAGE OF YOUR DEVICE(S)

Connect electrical devices running on AC current according to their wattage requirements. Calculate the total run-

ning wattage and starting wattage of the device(s) you wish to connect, and MAKE SURE that they are within the

capacity of your generator and the capacity of each individual outlet.

Generator

Wattage

Capacity

GENERATOR RUNNING (RATED) WATTS GENERATOR STARTING (SURGE) WATTS

Gasoline: 4220W Gasoline: 5000W

LPG: 3800W LPG: 5000W

What this means:

The generator can produce a maximum of

4220W / 3800W on a continuous basis to

supply ongoing power to your electronic de-

vices.

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 mo-

tors.

The generator can produce a maximum watt-

age of 5000W for a short period of time

(seconds) to cover the extra starting power

required by your electronic devices.

Electronic

Device

Wattage

Calculation

Find the wattage information of each device you plan to connect. The information should be

listed on the device or in its instruction manual, or you may refer to page 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 run-

ning wattage of 4220W / 3800W.

It is recommended to maintain a load at or

below 3800W / 3420W (90% of the rated

output) to ensure steady voltage output and

to prolong the generator’s lifespan.

To calculate the total starting watts of your

devices:

+ Add up the total running wattage of all the

device(s) you plan to connect.

+ Add the single highest ADDITIONAL start-

ing wattage out of the device(s) you plan to

connect.

= The total starting (surge) wattage.

This wattage should NOT exceed the starting

wattage of 5000W.

If any of either of the total calculated running watts or starting watts is higher than the capac-

ity of your generator, adjust the load until both wattage requirements are met. Otherwise you

will overload the generator, and cause damage to the engine and your electrical device(s).

Table 1 - How to 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. How-

ever, do not solely rely on this chart - all electronics and appliances are built differently. Always check the wattage

listed on the electrical device before consulting this chart.

Tool or Appliance Rated (Running) Watts Surge (Starting) Watts

Electric Water Heater (40 Gal) 4000 0

Hot Plate 2500 0

Saw - Radial Arm 2000 2000

Electric Stove (Each Element) 1500-2800 0

Saw - Circular 1500 1500

Air Compressor (1 HP) 1500 3000

Window Air Conditioner 1200 1800

Saw - Miter 1200 1200

Microwave 1000 0

Well Water Pump 1000 1000

Sump Pump 800 1200

Refrigerator Freezer 800 1200

Furnace Blower 800 1300

Computer 800 0

Electric Drill 600 900

Television 500 0

Deep Freezer 500 500

Garage Door Opener 480 0

Stereo 400 0

Box Fan 300 600

Clock Radio 300 0

Security System 180 0

Dvd Player / VCR 100 0

Common Light Bulb 75 0

Table 2 - Estimated Wattages of Common Electrical Appliances

NOTE: Become familiar with the functions and capacity of each component on the control panel before con-

necting electrical devices. See page 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.

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 (4220W) 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 volt-

age 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 per-

sists, please call 1-847-429-9263 M-F 8-5 CST.

Fig. 15

20A 30A

PARALLEL

CONNECT

USING YOUR GENERATOR

Table 3 - Power Cord Requirement Guide

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.

*NR = Not Recommended

Device Requirements Max. Cord Length (ft) by Wire Gauge

Amps Watts

(120V)

Watts (240V) #8 wire #10 wire #12 wire #14 wire #16 wire

2.5 300 600 NR NR NR 375 250

5 600 1200 NR NR 300 200 125

7.5 900 1800 NR 350 200 125 100

10 1200 2400 NR 250 150 100 50

15 1800 3600 NR 150 100 65 NR

20 2400 4800 175 125 75 50 NR

25 3000 6000 150 100 60 NR NR

30 3600 7200 125 65 NR NR NR

40 4800 9600 90 NR NR NR NR

WARNING! Generator should only be connected to electrical devices, either directly or with an extension

cord. NEVER CONNECT TO A BUILDING ELECTRICAL SYSTEM without a qualiﬁed electrician and connected to

a transfer switch as a separately derived system. Such connections must comply with local electrical laws and

codes. Failure to comply can create a back-feed, which may result in serious injury or death to utility workers.

NOTE: For power outages, permanently installed, stationary generators are better suited for providing backup

power to your home. Even a properly connected portable generator can become overloaded. This may result in

overheating or stressing the machine’s components, possibly leading to generator failure.

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

CO alarm.

Whenever the CO Watchdog system shuts down the genera-

tor, 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.

Ensure that the generator is located in an open outdoor area, with the exhaust pointing away from occupied struc-

tures, 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 [email protected])

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 genera-

tor 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.

NOTE: if the generator is oriented so that the

engine exhaust is blown towards the CO sensor,

the generator may shut down.

Fig. 16

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 elec-

trical 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

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 “EN-

GINE 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 caus-

ing 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.

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 fu-

ture. Never store the generator for extended periods of time (over

2 months) with fuel in the fuel tank. Refer to “Storing the Genera-

tor”.

Fig. 17

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 [email protected].

Recommended

Maintenance Schedule

Every 8

Hours or

Daily

Every 25

Hours

Every 3

Months or

50 Hours

Every 6

Months or

100 Hours

Before

Storage

Necessary

Engine Oil

Check Level x

Replace x** x** x* x

Air Filter

Check x*

Clean x*

Spark Plug

Check/Clean/

Regap

Change x x

Fuel

Check Level x

Drain x x

Carburetor Drain x x

Spark

Arrestor

Check/Clean x

Table 4 - Recommended Maintenance Schedule* Clean/change more often under dusty conditions or operating

under heavy load.

** Change the oil after the ﬁrst 8 hours of operation, after the

ﬁrst 25 hours of operation, and every 50 hours after that.

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 venti-

lation 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.

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 Main-

tenance 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 26.37 ﬂ. oz. (0.78 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 left of the control panel) by twisting the

panel lock knobs (Fig. 18 - 1) a quarter turn.

3. Remove and wipe the oil dipstick (Fig. 19) with a clean rag. Insert the

dipstick into the oil ﬁll opening without screwing it in.

4. Remove the dipstick to check the oil mark. Add oil if the oil mark covers

less than one half of the dipstick.

5. Using a funnel or appropriate dispenser, slowly add more oil. Repeat

step 3 until the oil mark measures between the upper limit mark and half-

way mark of the dipstick. Do not over ﬁll the crankcase.

6. Reinstall dipstick and wipe clean any spilled oil with a rag.

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 drainage valve to catch the oil as it drains.

2. Open the side panel. Open the oil drainage valve (Fig. 20 - 1) by turn-

ing the cap a quarter turn counterclockwise. Allow oil to drain from the

engine completely.

3. Close the oil drainage valve after the oil has drained.

NOTE: Do not dispose of used motor oil in the trash or down a drain.

Please call a local recycling center to arrange proper oil disposal.

4. Remove the oil dipstick. Using a funnel or appropriate dispenser, slow-

ly 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. Reinstall dipstick and wipe clean any spilled oil with a rag.

Fig. 18

Fig. 19

Upper Limit

Lower Limit

Fig. 20

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.

Refer to Recommended Maintenance Schedule in Table 4 for in-

structions on maintaining. To inspect the spark plug:

1. Open the side panel (to the left of the control panel) by twisting

the panel lock knobs (Fig. 21 - 1) a quarter turn.

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.

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. 22). 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 14.75 - 18.44 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.

0.024 in. - 0.031 in.

(0.6mm - 0.8mm)

Fig. 21

Fig. 22

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-

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

Refer to Recommended Maintenance Schedule in Table 4.

1. Open the side panel (to the left of the control panel) by twisting

the panel lock knobs (Fig. 23 - 1) a quarter turn.

2. Unscrew the air ﬁlter cover knobs (Fig. 24 - 1), remove the cov-

er, 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.

DF500iX-138, available at wenproducts.com).

4. Reinstall the air ﬁlter element and the air ﬁlter cover. Replace the

side cover and secure it with the screws.

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 gen-

erator (refer to Table 4). Draining the carburetor can help prevent

build-up and blockages caused by stagnant fuel inside of the car-

buretor.

1. Prepare an approved gasoline storage container.

2. Open the side panel (to the left of the control panel) by twisting

the panel lock knobs (Fig. 23 - 1) a quarter turn.

3. Open up the carburetor drain screw (Fig. 25 - 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 gen-

erator for long periods of time.

5. Close the side panel.

Fig. 23

Fig. 24

Fig. 25

1 1

MAINTENANCE

SPARK ARRESTOR MAINTENANCE

It is recommended to inspect and clean the spark arres-

tor (Fig. 26 - 1) every 100 hours of operation.

1. The spark arrestor is located outside the mufﬂer,

which gets very hot during operation. Allow the engine

to cool completely before servicing the spark arrestor.

2. Unscrew the two Phillips-head screws that hold the

spark arrestor (Fig. 26 - 1) to the mufﬂer.

3. Remove the spark arrestor screen.

4. 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. DF500iX-150,

available for purchase at wenproducts.com).

5. Reinstall the spark arrestor in the mufﬂer and secure

it in place with the 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, dam-

aged, or missing air ﬁlter will result in possible dan-

ger and cause the engine to wear out prematurely.

Fig. 26

BATTERY MAINTENANCE & STORAGE

The battery (part no. DG4500iX-074) shipped with the

generator has been fully charged. The battery will re-

ceive 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 gen-

erator 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

gasoline as your fuel source.

WARNING! It is best to store the battery indoors

at room temperature. Do not store your battery out-

side 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 sum-

mer.

IMPORTANT: If the generator is not used for a long pe-

riod, it is recommended to disconnect the battery quick-

connectors to protect the battery from losing charge. Af-

ter disconnecting the quick-connectors, cover the ends

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. Open the side panel (to the right of the control panel)

by twisting the panel lock knobs a quarter turn counter-

clockwise.

2. Disconnect the battery quick-connectors.

3. Unhook the rubber strap from the bottom of the bat-

tery compartment. Gently remove the battery.

4. Replace with an identical new battery (part no. DG-

4500iX-074).

5. Use a Phillips-head screwdriver to remove the quick-

connector wires from the old battery. Install them on the

new battery in the same orientation, making sure the red

wire is installed on the positive (+) battery terminal, and

the black wire is installed on the negative (-) battery ter-

minal.

6. Place the battery in the battery compartment. Secure

it with the rubber strap.

7. Connect the battery quick-connectors. Replace the

side panel.

TRANSPORTATION & STORAGE

WARNING! Avoid direct sunlight inside a vehicle. If the generator is left in an enclosed vehicle for many

hours, the high temperature could cause the fuel to vaporize and result in a possible explosion.

WARNING! Store the generator upright in a cool and dry location, away from sources of heat, open ﬂames,

sparks or pilot lights.

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.

3. 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.”

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.

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 elec-

tronic 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.

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 quick-

connectors.

• Change the engine oil (see “CHANGING

OIL”).

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.

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 [email protected].

PROBLEM POSSIBLE CAUSE SOLUTION

Engine will not start.

Eco-mode switch is set to ON. Set Eco-mode switch to OFF.

Choke is open. Close the choke.

Engine is out of fuel. Add fuel.

Battery is out of power or discon-

nected.

Electric start will not work if battery is out of power or disconnected.

Connect battery and start generator using the recoil start to charge the

battery.

Battery is too cold. Store the generator in a warmer location.

Engine is ﬁlled with contaminated

or old fuel.

Drain the fuel in the tank. Fill with fresh fuel.

Spark plug is dirty. Clean the spark plug.

Spark plug is broken. Replace spark plug.

Oil level is low.

Add or replace oil. This generator is equipped with a low oil sensor. The

engine will not start unless the oil level is sufﬁcient.

Carburetor is air locked.

Remove the nut from the bottom of the carburetor. Take off the carbure-

tor to allow it to reset. Place the carburetor back and reinstall the nut.

LPG cylinder is out of fuel, and

LPG regulator hose is

connected.

Disconnect LPG regulator hose from generator. Make sure there is

enough gasoline in the tank.

Engine runs but there is

no electrical output.

Circuit breaker has been tripped

due to overload.

Disconnect all the loads. Wait for two minutes and push the circuit

breaker to the ON position to reset it.

Bad connecting cords/wires.

Check the power cords and extension cords. Do not use if any cord is

damaged. Replace damaged cords immediately.

Bad electrical device connected to

the generator.

Try connecting a different device.

Voltage selector switch is set to

wrong setting.

Make sure voltage selector switch is set correctly for desired outlet.

Generator runs but

does not support all

electrical devices

connected.

Generator is overloaded.

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.

Short circuit in one of the devices. Try disconnecting any faulty or short-circuited electrical loads.

The air ﬁlter is dirty. Clean or replace the air ﬁlter element (see page 31).

Engine is “Hunting”

during Operation

(Engine RPM is

ﬂuctuating).

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.

Turn off the generator and wait for it to cool down. Perform the follow-

ing 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 nec-

essary.

4. Use “Gunk remover” spray on the carburetor jets.

WIRING DIAGRAM

Red

Black

Main

Winding

Main

Winding

Inverter

Unit Winding

Power Section

Stepper Motor

Yellow

Blue

Orange

Pink

Red

Yellow

Blue

Red

Yellow

Blue

White

Yellow/Green

Fuel Solenoid

Valve

DC Winding

Ignition

Winding

Blue

Motor Section

CCW

Stepping Motor

Blue

Yellow

Orange

Pink

Red

White

Remote Control

Module

Blue

Black

Pink

Red

Black/White

Orange

Green/White

White

Red/White

Orange

Black

Antenna

Starter

Motor

Battery 12V

Pulser

Coil

Oil Level

Switch

Spark

Plug

Ignition

Coil

Fuel Level

Indicator

Panel Section

Orange

Black

Microswitch

Digital Igniter

Red

Blue/White

Black/White

Black

Blue

Brown

Black/Red

Gray

Pink

Reset

ECO Switch

Pink

Red/White

Black

Red

Black

Gas Switch

Brown

Black/Red

Orange

White

Black

Blue

Red

Black

Charger

Red

Black

Circuit Breaker, 8A

DC 12V 8A

Black/White

Green

Yellow

Black

Red

Run

Overload

Oil

Digital Meter

Orange

Blue/White

White

Red/White

Black/White

Black/Red

Green/White

Blue/Red

Yellow/Green

Black

WhiteWhite

Yellow/GreenYellow/Green

Red

Parallel Outlets

Yellow/Green

Circuit

Breaker, 20A

Circuit

Breaker, 30A

Gray

White

Gray Gray

White

Gray

Inverter Unit

RedRed

WhiteWhite

BlackBlack

GrayGray

White

EXPLODED VIEW & PARTS LIST

GENERATOR

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.

NO. PART NO. DESCRIPTION QTY.

1 DF500iX-001 Screw, M5x10 6

2 DF500iX-002

Control Panel

Assembly

3 DF500iX-003 Step Bolt, M6x15 24

4 DF500iX-004 Front Cover 1

5 56360iX-108 Wiring Sheath, 25mm 2

6 56202i-051 Bolt, M6x12 8

7 DF480iX-090

LPG Quick-connector

Cap

8 DF500iX-008 Front Cover Plug 3

9 DF500iX-009 Engine Assembly 1

10 DF500iX-010

Self-tapping Screw,

ST3.5x13

11 DF500iX-011 Washer, 4mm 1

12 DF500iX-012 Igniter 1

13 DF500iX-013

Handle Protection

Plate

14 DF500iX-014

Sound Insulation Pad

15 DF500iX-015

Battery, 12V 7Ah,

Lead-acid

16 DF500iX-016 Left Housing 1

17 DF500iX-017 Left Panel Assembly 1

18 DF500iX-018 Nut, M6 6

19 DF500iX-019 Fuel Tank Cap 1

20 DF500iX-020 Fuel Tank Seal 1

21 DF500iX-021 Adjustable Handle 1

22 DF500iX-022 Drawbar Pin 2

23 DF500iX-023

Upper Housing

Assembly

24 DF500iX-024

Upper Handle Assem-

bly

25 DF500iX-025

Handle Connecting

Bolt

26 DF500iX-026 Bolt, M6x25 4

27 DF500iX-027

Washer,

6.5x1.5x25mm

28 DF500iX-028 Clamp 1

29 DF500iX-029 Fuel Hose 1

NO. PART NO. DESCRIPTION QTY.

30 DF500iX-030 Spacer 2

31 56477i-026 Clip 3

32 DF500iX-032 Fuel Tank 1

33 DF500iX-033 Inverter 1

34 DF500iX-034 Fuel Hose 1

35 DF500iX-035 Clamp 2

36 DF500iX-078

Display Multimeter

Wiring Harness

37 DF500iX-037 Clip 4

38 DF500iX-038 Fuel Hose Jacket 1

39 DF500iX-039 LPG Quick-connector 1

40 DF500iX-040 Rear Cover 1

41 56202i-121 Nut, M6 2

42 DF500iX-042 Rear Cover Gasket 1

43 DF500iX-080

Remote Start Engine

Control Module

44 DF480iX-076

Self-tapping Screw,

ST4.2x16

45 DF500iX-045 Bolt, M8x16 2

46 DF500iX-046 Stepped Bolt, M6x17 6

47 DF480iX-087

Fuel Hose Clamp,

16mm

48 DF500iX-048

Fuel Valve and

Selector Switch

49 DF500iX-049 Right Housing 1

50 DF500iX-050

Battery Wiring

Harness

51 DF500iX-051 Tape 1

52 DF500iX-052

Sound Insulation Pad

53 56477i-025 Bolt, M5x12 3

54 DF500iX-054 Right Panel Assembly 1

55 56202i-001 Phillips Screw, M4x10 1

56 DF500iX-056 Engine Mount 1 1

57 DF500iX-057 Engine Mount 2 1

58 DF500iX-058 Engine Mount 3 2

59 DF500iX-059 Nut, M8 10

60 DF500iX-060 Rectiﬁer 1

EXPLODED VIEW & PARTS LIST

GENERATOR

EXPLODED VIEW & PARTS LIST

GENERATOR

NO. PART NO. DESCRIPTION QTY.

61 DF500iX-061 Bottom Bracket 2

62 DF480iX-080 Bolt, M6x16 2

63 DF500iX-063 Charger 1

64 DF500iX-064 Support Frame 1

65 DF500iX-065 Switch Box Base 1

66 56360iX-125 CO Alarm 1

67 DF500iX-067 CO Sensor Cover 1

68 DF500iX-068 Bolt, M4x16 2

69 DF500iX-069 Wheel Shaft Assembly 1

70 56477i-019B Wheel 2

NO. PART NO. DESCRIPTION QTY.

71 56477i-018 Bolt, M8x12 2

72 56477i-046B Foot 4

73 DF500iX-073 Bolt, M6x12 3

74 DF480iX-078 Screw, M2.5x20 2

75 DF480iX-064

LPG Switch Wiring

Harness

76 DF480iX-079 Nut, M2.5 2

N.P. DF500iX-079

LPG Regulator and

Hose Assembly

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.

EXPLODED VIEW & PARTS LIST

ENGINE

102

103

105

106

104

101

108

107

109

100

EXPLODED VIEW & PARTS LIST

ENGINE

NO. PART NO. DESCRIPTION QTY.

1 56477i-134 Bolt, M6x16 13

2 DF500iX-102

Cylinder Head Cover,

Plastic

3 DF500iX-103 Cylinder Head Cover 1

4 DF500iX-104 Breather Hose 1

5 DF500iX-105

Cylinder Head Cover

Gasket

6 DF500iX-106 Bolt, M5x12 2

7 DF500iX-107 Rocker Arm Assembly 2

8 DF500iX-108 Rocker Arm Core Shaft 2

9 DF500iX-109 Valve Spring 2

10 56477i-146 Valve Adjustment Cap 2

11 56477i-143 Valve Spring Seat 2

12 56477i-147 Valve Locker 4

13 DF500iX-113 Intake Valve Seal 2

14 56360iX-015 Bolt, M8x60 4

15 DF500iX-115 Cylinder Head 1

16 56477i-163

Spark Plug, LG F6RTC

(NGK BPR6ES)

17 DF500iX-117 Cylinder Head Gasket 1

18 56360iX-085 Pin, Ø10x16 2

19 DF500iX-119 Intake Valve 1

20 DF500iX-120 Exhaust Valve 1

21 DF500iX-121 Push Rod 2

22 56360iX-038 Valve Tappet 2

23 56477i-158 Piston Ring Set 1

24 56477i-160 Piston 1

25 DF500iX-125

Carburetor Insulator

Gasket

26 DF500iX-126 Carburetor Insulator 1

27 DF500iX-127 Carburetor Gasket 1

28 DF500iX-128 Stud, M6x95 2

29 DF500iX-129 Carburetor 1

30 DF500iX-130 Fuel Hose 1

31 DF500iX-131 Carburetor Gasket 1

32 DF500iX-132 Intake Manifold 1

33 DF500iX-133 Nut, M6 2

34 DF500iX-134 Fuel Hose Clamp 1

NO. PART NO. DESCRIPTION QTY.

35 DF500iX-135 Clamp 1

DF500iX-

136ASM

Air Filter Assembly 1

37 DF500iX-137 Air Filter Cover 1

38 DF500iX-138 Air Filter Element 1

39 DF500iX-139 Air Filter Bafﬂe 1

40 DF500iX-140 Air Filter Base 1

41 DF500iX-141 Bolt, M6x18 2

42 DF500iX-142

Self-tapping Screw,

ST4.2x16

43 56477i-159 Piston Pin Circlip 2

44 DF500iX-144 Piston Pin 1

45 DF500iX-145

Connecting Rod

Assembly

46 DF500iX-146 Mufﬂer Exhaust Manifold 1

47 56202i-051 Bolt, M6x12 10

48 DF500iX-148 Mufﬂer Gasket 1

49 DF500iX-149 Mufﬂer Assembly 1

50 DF500iX-150 Spark Arrester 1

51 DF500iX-151 Bolt, M5x12 2

52 DF500iX-152 Bolt, M6x20 2

53 DF500iX-153 Stud, M6x98 1

54 DF500iX-154 Nut, M6 1

55 DF500iX-155 Crankcase 1

56 DF500iX-156

Crankcase Cover

Insulation Panel

57 DF500iX-157 Bolt, M8x25 7

58 DF500iX-158 Crankcase Cover 1

59 DF500iX-159 Crankcase Gasket 1

60 56477i-124 Pin, 8x14 2

61 56360iX-070 Bearing, TM6205 2

62 DF500iX-162 Crankshaft 1

63 56477i-128 Woodruff Key 1

64 DF500iX-164 Camshaft 1

65 DF500iX-165 Bolt, M6x18 2

66 DF500iX-166 Oil Sensor 1

67 56480iX-195 Pin, 8x8 2

NO. PART NO. DESCRIPTION QTY.

68 DF500iX-168 Grounding Wire 1

69 56360iX-093 Bolt, M6x12 3

70 DF500iX-170 Washer, 12x2x20mm 1

71 DF500iX-171 Oil Drain Tube Assembly 1

72 DF500iX-172 Trigger 1

73 56360iX-055 Oil Seal, 25 x 41.25 x 6 1

74 DF500iX-174 Stator 1

75 DF500iX-175 Bolt, M6x60 4

76 DF500iX-176 Rotor 1

77 56477i-182 Cooling Fan 1

78 DF500iX-178 Starter Cup 1

79 56477i-184 Nut, M14-1.5 1

80 DF500iX-180 Fan Housing 1

81 56360iX-082 Clip 1

82 DF500iX-182 Bolt, M6x55 2

DG-

4500iX-193

Bolt, M6x100 1

84 DF500iX-184 Stud, M8x120 2

85 DF500iX-185 Resonant Cavity 1

86 DF500iX-186 Recoil Starter 1

87 DF500iX-187 Bumper Pad 1

88 DF500iX-188

Recoil Starter Shroud,

Lower

89 DF500iX-189 Dipstick Assembly 1

90 56477i-133 Bolt, M6x25 1

NO. PART NO. DESCRIPTION QTY.

91 DF500iX-191 Fuel Hose Bracket 1

92 DF500iX-192 Clip Housing 1

93 DF500iX-193

Recoil Starter Shroud,

Upper

94 56360iX-087

Self-tapping Screw,

ST4.2x25

95 56480iX-196 Bolt, M6x30 2

96 DF500iX-196 Ignition Coil 1

97 DF500iX-197

Self-tapping Screw,

ST4.8x25

98 DF500iX-198 Clip Base 1

99 DF500iX-199 Starter Motor 1

100 DF500iX-200 Clamp 1

101 DF500iX-201 Choke Lever Bracket 1

102 DF500iX-202 Fuel Hose Clamp 1

103 DF500iX-203 LPG Hose 1

104 DF500iX-204 Clamp 1

105 DF500iX-205 Washer, φ5 1

106 DF500iX-206 Bumper Pad 1

107 56480iX-109 Screw, M4x8 1

108 56480iX-110 Nut, M4 1

109 DF500iX-209

Self-tapping Screw,

ST4.2x13

N.P.

DF500iX-

HA39

High-altitude Kit,

3000 - 9000 ft

EXPLODED VIEW & PARTS LIST

ENGINE

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.

EXPLODED VIEW & PARTS LIST

CONTROL PANEL

NO. PART NO. DESCRIPTION QTY.

1 56500-207

Voltage Selector

Switch

2 DF500iX-302

NEMA L14-30R

120V/240V 30A AC

Receptacle

3 DF500iX-303 Nut, M6 1

4 56203i-005.11 Lock Washer, 6mm 1

5 56203i-005.12 Flat Washer, 6mm 1

6 56360iX-208 Grounding Stud 1

7 56360iX-209

Toothed Lock Washer,

6mm

8 56360iX-210 Flat Washer, 5mm 1

9 56360iX-211 Lock Washer, 5mm 1

10 56360iX-212 Nut, M5 1

11 DG4500iX-208

NEMA 5-20R 120V

20A AC Duplex

Receptacle

NO. PART NO. DESCRIPTION QTY.

12 56203i-005.14R Parallel Socket, Red 1

13 56203i-005.14B Parallel Socket, Black 1

14 DG4500iX-207

NEMA TT-30R 120V

30A AC Receptacle

15 56477i-218

12V DC Automotive

Outlet

16 56203i-005.4 Eco-Mode Switch 1

17 DF500iX-317 Start Button 1

18 56500-208 Breaker, AC 20A 1

19 GN9500-309 AC Breaker, 30A 1

20 56477i-217 DC Breaker, 8A 1

21 56477i-216

USB Receptacle

(2.1A / 1A)

22 DF500iX-322 Display Meter 1

23 56235iX-005.19 CO Sensor LED 1

24 56477i-215 Reset Button 1

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.

3,4,5,6,7,8,9,10

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 USELIMITED WARRANTY OF WEN PRODUCTS FOR HOME USE

GREAT LAKES TECHNOLOGIES, LLC (“Seller”) warrants to the original purchaser only, that this WEN consumer prod

uct 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 profes

sional 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 per

mitted by law, any warranty or condition implied by law, shall be the replacement of parts, without charge, which are

defective in material or workmanship and which have not been subjected to misuse, alteration, careless handling, mis

repair, 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 Pur-

chase must be a direct vendor of Great Lakes Technologies, LLC. Purchasing through third party vendors, including but

not limited to garage sales, pawn shops, resale shops, or any other secondhand merchant, voids the warranty included

with this product. Contact [email protected] or 1-847-429-9263 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, BAT

TERIES, 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 IN

CIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH

VARY FROM STATE TO STATE IN THE U.S., PROVINCE TO PROVINCE IN CANADA AND FROM COUNTRY TO COUNTRY.

THIS LIMITED WARRANTY APPLIES ONLY TO ITEMS SOLD WITHIN THE UNITED STATES OF AMERICA, CANADA

AND THE COMMONWEALTH OF PUERTO RICO. FOR WARRANTY COVERAGE WITHIN OTHER COUNTRIES, 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.

V. 2024.08.26

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WEN DF500IX Dual Fuel Portable Inverter Generator

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