WEN DG4500IX Dual Fuel Open Frame Generator Electric Start User Manual

4500W DUAL FUEL

INVERTER GENERATOR

Instruction Manual

MODEL DG4500iX

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

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

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

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

NEED HELP? CONTACT US!

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

TECHSUPPOR[email protected]1-800-232-1195 (M-F 8AM-5PM CST)

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

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

Assembly & Adjustments ............................................................................... 12

Generator Preparation .................................................................................... 12

BEFORE OPERATING

OPERATION & MAINTENANCE 19

Starting Your Generator ................................................................................. 19

Using Your Generator ..................................................................................... 22

Shutting Off Your Generator ........................................................................... 29

Maintenance ................................................................................................... 31

Transportation & Storage ............................................................................... 39

Troubleshooting Guide ................................................................................... 40

Wiring Diagram .............................................................................................. 41

Exploded View & Parts List ............................................................................ 42

Warranty Statement ....................................................................................... 49

To purchase accessories for your tool, visit WENPRODUCTS.COM

WEN Parallel Connection Kit

Weatherproof Generator Cover, Medium (Model 56406)

High-Altitude Kit (Part DG4500iX-HA36 and DG4500iX-HA69)

SPECIFICATIONS

Rated Wattage Gasoline: 3650 Watts; LPG: 3285 Watts

Surge Wattage Gasoline: 4500 Watts; LPG: 4500 Watts

Rated Voltage

AC: 120V

DC: 5V (USB)

Rated Amperage

AC: 30.4A Total (Total), 30A (TT-30R), 20A (5-20R), 30A (L5-30R)

DC: 2.1A / 2.1A (USB)

Phase Single

Frequency 60Hz

Decibel Rating 68 dBA (25% load from 22 feet away)

Product Dimensions

With Wheel Kit: 22-3/4 in. x 22-3/4 in. x 21-1/2 in.

Without Wheel Kit: 20-3/4 in. x 18 in. x 18-3/4 in.

Product Net Weight

With Wheel Kit: 90.8 Pounds

Without Wheel Kit: 83.8 Pounds

GENERATOR

ENGINE

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

Engine Displacement 224cc

Engine Speed 3600 RPM

Fuel Tank Capacity 4 gal (15.20 L), 87 Octane Minimum

Oil Capacity 20 ﬂ. oz. (0.60 L)

Half-Load Run Time 12 Hours (Gasoline), 12 Hours (20 lb LPG tank)

Lubrication System Splash Lubrication

Spark Plug Type F6RTC

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

Spark Plug Torque 1/2 - 3/4 turn after gasket contacts base or 15 ft-lbs

Battery 12V, 7Ah, Lead-Acid

INTRODUCTION

Thanks for purchasing the WEN 4500-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 1-800-232-1195, M-F

8-5 CST; you will be asked to provide the following generator information when calling.

Generator Model Number: DG4500iX

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 INTRODUCTION

Safety is a combination of common sense, staying alert, and knowing how your tool works. This manual contains

important information regarding the generator’s potential safety concerns, as well as preparation, operation, and

maintenance instructions. Before operating this generator, be sure to read and observe all warnings and instructions

both on the generator labels and in this instruction manual. Failure to follow all instructions listed below may result

in personal injury.

NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur.

WEN reserves the right to change this product and speciﬁcations at any time without prior notice.

At WEN, we are continuously improving our products. If you ﬁnd that your tool does not exactly match this manual,

please visit wenproducts.com for the most up-to-date manual or contact customer service at 1-800-232-1195, M-F

8-5 CST.

Keep this manual available to all users during the entire life of the tool and review it frequently to maximize

safety for both yourself and others.

SAVE THESE SAFETY INSTRUCTIONS.

SAFETY SYMBOLS

The purpose of following safety symbols is to attract your attention to possible dangers. The safety symbols, and

their explanations, deserve your careful attention and understanding. The safety warnings do not by themselves

eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention

measures.

NOTICE REGARDING EMISSIONS

Engines that are certiﬁed to comply with U.S. EPA emission regulations for SORE (Small Off Road Equipment), are

certiﬁed to operate on regular unleaded gasoline, and may include the following emission control systems: (EM)

Engine Modiﬁcations and (TWC) Three-Way Catalyst (if so equipped).

QUESTIONS? PROBLEMS?

In order to answer questions and solve problems in the most efﬁcient and speedy manner, contact customer

service at 1-800-232-1195, M-F 8-5 CST or email [email protected].

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

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

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

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

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 INFORMATION

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.

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals and produces exhaust known

to the State of California to cause cancer, birth defects and other reproductive harm.

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 and fuel selector knob 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.

Accessories

Handle Assembly

Foot Support Assembly Wheel Assembly

UNPACKING

With the help of a friend or trustworthy foe, such as one of your in-laws, carefully remove the generator from the

packaging and place it on a sturdy, ﬂat surface. Make sure to take out all contents and accessories. Do not discard

the packaging until everything is removed. Check the packing list below to make sure you have all of the parts and

accessories. If any part is missing or broken, please contact customer service at 1-800-232-1195 (M-F 8-5 CST),

or email [email protected].

PACKING LIST

UNPACKING & PACKING LIST

Components

Generator

Support Assembly (1)

M8x6 Bolts (2)

Wheels (2)

R-Clips (2)

Axle Pins (2)

M8x40 Bolts (2)

M8 Nuts (2)

Engine Oil (20 ﬂ. oz.) (1)

5mm Hex Wrench (1)

Funnel (1)

Spark Plug Socket (1)

LPG Regulator

Hose Assembly (1)

Wrenches (3)

(10-12mm, 13-15mm, 19mm)

Handle Assemblies (2)

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

Fuel Gauge

Fuel Tank Cap

Control Panel

Wheels

Fuel Selector Knob

Air Filter

Recoil Starter

Oil Drain Bolt

Oil Dipstick

Battery

LPG Inlet

Carrying Handle

KNOW YOUR INVERTER GENERATOR

CONTROL PANEL

1 4

1. Indicator Lights

The oil light (yellow) will turn on if the oil is low, the

overload light (red) will turn on if the generator is over-

loaded, and the output light (green) will turn on when

the receptacles have power.

2. 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. 28 for more information.

3. AC Circuit Breaker (20A)

4. Parallel Connection Port

Connect two WEN inverter generators through a parallel

connection kit for more output.

5. Data Meter

Displays voltage, frequency, total runtime (HHHH), and

session runtime (HH:MM). Press the MODE button to

switch between displays.

6. AC 120V NEMA TT-30R RV Receptacle (30A)

Standard RV connector.

2 3

7. Grounding Nut

Ground generator to reduce risk of electric shock.

8. AC 120V NEMA L5-30R Receptacle (30A)

Multipurpose outlet.

9. AC 120V NEMA 5-20R Duplex Receptacles (20A)

Standard household outlets provide 120V 60Hz power.

10. DC 5V USB Ports

The upper and lower USB ports each provide 2.1A.

11. Overload Reset

If the overload light is ON, press this button to reset your

generator.

12. Engine Switch

Start the engine using this switch.

13. Eco-Mode Switch

Flip this switch to ON to increase fuel economy and run-

time when the load is below 2730W (75% load).

710 89111213 6

GENERATOR PREPARATION

REMOVING THE SHIPPING POSTS

Your generator is shipped with three red shipping posts that

secure the engine to the generator housing in order to pre-

vent machine damage during shipping. Make sure to remove

the three mounting posts before operating your generator.

Failure to do so could lead to engine damage.

1. With the help of another person, place generator on an el-

evated platform such as table or workbench. Make sure the

generator is stable. Do not tilt the generator as there may be

remaining oil inside the crankcase from testing.

2. Use the included hex wrench to remove the three socket-

Fig. 1

head cap screws and red shipping posts (Fig. 1 - 1) from the generator's frame.

3. Follow the instructions in the following pages to prepare your generator for starting.

ASSEMBLY & ADJUSTMENTS

ASSEMBLY

Refer to the packing list on p. 9 to gather the proper parts and tools for installing the feet, wheels, and handles.

NOTE: There are different sizes of bolts/nuts; be sure to use the proper bolts/nuts for each assembly step.

INSTALLING THE FOOT ASSEMBLY

The foot assebly is installed on the base of the generator, towards the rear, opposite the control panel.

1. Prepare a set of blocks on level ground (a 4×4 block of wood works well). Place the generator on the blocks. Have

someone help you lift the generator.

2. Slide the foot assembly into place on the generator frame and align the holes.

3. Slide the M8x6 bolts through the foot assembly and generator frame. Tighten the bolts using the included wrench.

INSTALLING THE WHEELS

1. The wheels are installed on either side of the generator, towards the front, beside the control panel.

2. Align the wheels with the holes on the generator frame. Slide the axle pin through the wheel and the generator

frame. Repeat for the other wheel.

3. Lock the wheels in place by ﬁtting the R-clips through the holes in the axle pins.

INSTALLING THE HANDLES

1. The handles are installed on the rear of the generator, opposite the control panel.

2. Align the holes on the handle with the holes on the generator frame. Secure using an M8x40 bolt and an M8 nut.

Repeat for the other handle.

WARNING! Do not turn on the generator until it is fully assembled according to the instructions. Read

through and become familiarized with the following procedures of handling and adjusting your tool. Failure to

follow the safety instructions may result in serious personal injury.

• Never use the handle as a lifting point to support the entire weight of the generator. Only use the handle

to pull the generator with the help of the wheels.

• Use caution when collapsing the handle. Hands and ﬁngers could get caught and pinched.

Synthetic 5W-30

30W

10W-30

GENERATOR PREPARATION

The following section describes the necessary steps to prepare the generator for use. If you are unsure about how to

perform any of the steps, please call 1-(800) 232-1195 M-F 8-5 CST for customer service. Failure to perform these

steps properly can damage the generator or shorten its life.

STEP 1 - ADD / CHECK OIL

The generator is shipped without oil. User must add the proper amount of oil before operating the generator for the

ﬁrst time. The oil capacity of the engine crankcase is 20 ﬂ. oz. (0.60 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.

°F

°C

-20 0 20 32 40 60 80 100

40200

-20

-10

-30 30

To add oil, follow these steps:

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

gine is off before adding or checking oil.

CAUTION: Keep the generator level! Tilting the generator

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

areas of the engine and cause damage.

2. Turn the oil dipstick (Fig. 2 - 1) a quarter turn counter-

clockwise, then remove the dipstick.

3. Using an oil funnel or appropriate dispenser, slowly add

oil into the oil ﬁll, being careful not to overﬁll the unit. Fill the

crankcase until oil comes up the dipstick halfway between

the L and H marks (see next page).

4. Reinstall the oil dipstick and ﬁrmly tighten it. Wipe clean

any spilled oil.

Fig. 2

Upper Level

Fill Line

Lower LevelLower Level

Fill LineFill Line

Lower Level

Fill Line

Fig. 3

GENERATOR PREPARATION

STEP 1 - ADD / CHECK OIL (CONTINUED)

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.

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 (Fig. 4).

If the oil mark covers less than one half of the dipstick, slowly add oil until the oil mark reaches to the top of the

dipstick.

4. Wipe clean any oil leaks and ﬁrmly tighten the dipstick.

OIL LEVEL SHUTDOWN

To protect the unit from damage, the generator is equipped

with a low-oil-pressure shutoff that will automatically stop

the engine when the oil level is too low. The yellow low oil

indication light (Fig. 5) will turn ON to remind you that the

engine oil level is low and needs to be reﬁlled.

The oil level of the engine should be checked before each

start to ensure that the engine crankcase contains suf-

ﬁcient lubricant.

Lower Limit

Upper Limit

Low Oil Indicator

Fig. 4

Fig. 5

GENERATOR PREPARATION

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.

STEP 2 - ADD / CHECK FUEL

Use ONLY fresh (within 30 days from purchase), lead-free gasoline with a minimum of 87 octane rating. The genera-

tor performs best with ethanol-free gasoline. DO NOT use gasoline with over 10% ethanol. The capacity of the fuel

tank is 4 US Gallons (15.20 L). Do not mix oil with gasoline.

To add gasoline:

1. Make sure the generator is shut OFF and on a level surface.

Unscrew the fuel cap (Fig. 6 - 1) and set it aside. The fuel cap

may be tight and hard to unscrew.

2. Slowly add unleaded gasoline to the fuel tank. Be careful

not to overﬁll.

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.

3. Reinstall fuel cap and wipe clean any spilled gasoline with

a dry cloth.

To check fuel level:

Check the fuel gauge on top of the fuel tank. If the fuel level

is low, reﬁll the fuel tank before starting your generator for

the next time.

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. 6

FUEL OPTION A: GASOLINE

1 2

GENERATOR PREPARATION

STEP 2 - ADD / CHECK FUEL (CONTINUED)

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 to the valve. Turn the plastic coupling from the hose right (clock-

wise) to tighten hose assembly onto the LPG tank (Fig. 7).

3. Remove the protective rubber cover from the LPG inlet (Fig. 8 -

1) on the generator panel. Connect the nut on the other end of the

regulator connecting hose to the LPG inlet. Tighten the nut using the

included 19mm wrench. Turn the 2-in-1 dial switch to OFF.

4. Turn the LPG tank valve ON (Fig. 9) 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 1-800-232-

1195, M-F 8-5 CST, or email [email protected] for as-

sistance.

NOTE: You can use Teﬂon (or other tape) to secure the connection of

the LPG hose to your generator.

NOTE: If you would like to purchase other accessories for your dual-

fuel generator, consult your local dealer of propane and propane ac-

cessories, I tell you what.

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 cyl-

inder will cause freeze burns to the skin. If liquid contents contacts

skin or eyes, seek immediate medical attention.

WARNING! When transporting and storing, keep cylinder secured in an upright position with cylinder valve

turned off. Keep cylinders ventilated and away from heat when in a vehicle.

Fig. 7

Fig. 8

Fig. 9

GENERATOR PREPARATION

ABOUT THE BATTERY

1. DO NOT INCINERATE BATTERY. Do not throw the bat-

tery 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 ap-

pears to be undamaged. The battery cells inside the

battery may have suffered serious damage. In such in-

stances, 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 dam-

aged, call WEN customer service at 1-800-232-1195 for

assistance.

5. DO NOT SHORT CIRCUIT. Batteries will short circuit

if a metal object makes a connection between the posi-

tive 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 tem-

perature range for charging the battery is 25°F – 104°F.

STEP 3 - CONNECT THE BATTERY

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.

WARNING! Battery gives off explosive hydro-

gen 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. Bat-

tery acid is poisonous. Tilting the generator with the

battery installed can cause battery acid to spill.

• Wear protective clothing and eye wear when ser-

vicing the battery.

• Keep out of the reach of children.

• Do not tilt the generator with the battery installed.

• If battery acid gets on your skin, wash with water

immediately.

• If battery acid gets in your eyes, ﬂush with water

for at least 15 minutes and call a doctor immediately.

If battery acid is swallowed, call a doctor immedi-

ately. Drink a large amount of water or milk. Then

drink the milk of magnesia or vegetable oil.

Fig. 10

To connect the battery:

1. Connect the two ends of the quick connector on the

battery (Fig. 10 - 1) to give power to the battery.

NOTE: The generator can be run with the battery discon-

nected or with no charge using the recoil starter. This

can be done during either gasoline or LPG operation.

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. 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.

GENERATOR PREPARATION

STEP 4 - GROUND THE GENERATOR

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

tor should be properly grounded.

Ground the generator by tightening the grounding nut (Fig. 11 - 1) on

the front control panel against a grounding wire. A generally acceptable

grounding wire is a No. 12 AWG (American Wire Gauge) stranded cop-

per wire.

This grounding wire should be connected at the other end to a copper,

brass, or steel grounding rod that is driven into the earth. Wire and

grounding rods are not included with the generator.

NOTE: Grounding codes can vary by location. Contact a local electrician

to check the area codes.

WARNING! Failure to properly ground the generator increases your risk of electric shock.

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.

You can order the kit at wenproducts.com by searching part DG4500iX-HA. There are two kits - one for altitudes

between 3000 and 6000 feet (part no. DG4500iX-HA36), and the other for altitudes from 6000 to 9800 feet (part

no. DG4500iX-HA69). This kit should be installed by a qualiﬁed mechanic. Refer to the instructions included with

your altitude kit for more information about installation.

NOTE: The high altitude kit must be installed for operation above 3000 feet, regardless of the fuel source (LPG or

gasoline) used.

WARNING! To prevent serious injury from ﬁre, follow the kit installation procedures in a well-ventilated

area away from ignition sources. If the engine is hot from use, shut the engine off and wait for it to cool before

proceeding. Do not smoke near the generator. Warranty will be void if adjustments are not made for high altitude

use.

CAUTION: Engines with the high-altitude kit installed operated at lower altitudes could cause severe engine dam-

age and affect emissions compliance. Be sure to uninstall the high altitude kit when operating at altitudes below

3000 feet.

After completing the above preparation, the generator is ready to be started.

Fig. 11

CAUTION!

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

Before starting the generator, make sure you have read and performed the steps in the “Generator Preparation”

section of this manual. If you are unsure about how to perform any of the steps in this manual please call 1-(800)

232-1195 M-F 8-5 CST for customer service.

To maximize safety, ALWAYS ground the generator before using it. See section “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

Follow the instructions on the next page to start 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.

STARTING YOUR GENERATOR

BEFORE STARTING THE GENERATOR

1. Verify that generator is outside on a dry, level surface with at least two feet of clearance on all sides.

2. To maximize safety, check that the generator is properly grounded (see "GROUND THE GENERATOR").

3. Check there is sufﬁcient level of oil in the crankcase. Add oil if necessary (see "ADD / CHECK OIL").

4. If using gasoline, make sure there is enough gasoline in fuel tank. Add fuel if necessary (see "ADD / CHECK FUEL").

If using LPG, make sure there is enough propane in tank, and that tank and regulator hose are properly connected.

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 (Fig. 12) to "ON".

2. Turn the choke lever (Fig. 13 - 1) to the "CLOSED" position.

NOTE: If starting the generator with a warm engine, turn the

choke lever to the "HALF-CHOKE" position.

3. Turn the FUEL SELECTOR knob (Fig. 14 - 1) to the "GAS ON"

position.

Option A: Electric Start

3. Push the ENGINE SWITCH (Fig. 12) to "START" and hold for

2-3 seconds, until the engine starts, then release.

NOTE: If the engine does not start, release the switch and try

again. Keeping the switch in the "START" position too long can

damage the starter.

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. 13 - 2) slowly until a slight

resistance is felt. Then pull quickly to start the engine. Return

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

back.

4. If engine fails to start (with gas), repeat step 3; If engine

fails to start (with LPG), turn the choke lever to "RUN", then

pull on the recoil starter handle to get started.

Fig. 12

Fig. 13

Fig. 14

4. When the engine starts, turn the choke lever (Fig. 13 - 1) to the "OPEN" position.

5. After the engine has started, the output indicator light (green) will light up.

6. 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-(800) 232-1195 M-F 8-5 CST.

ON OFF

ECO-MODE

STARTING YOUR GENERATOR

STARTING THE GENERATOR (LPG)

1. Turn the ECO-MODE (Fig. 15) switch to "ON".

2. Turn the choke lever (Fig. 16 - 1) to the "CLOSED" position.

3. Turn the FUEL SELECTOR knob (Fig. 17 - 1) to "LPG".

4. Prime the engine.

To do this, do one of the following:

a. Manual Start: Pull the recoil starter 1 – 3 times.

b. Electric Start: Push the ENGINE SWITCH to the START position

for about 2 seconds, 1 – 3 times.

5. Turn the choke lever (Fig. 13 - 1) to the "OPEN" position.

7. After the engine has started, the output indicator light (green) will light up.

8. 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-(800) 232-1195 M-F 8-5 CST.

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 below 50% of the generator's rated wattage, if

possible. If your generator 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 af-

ter the ﬁrst 25 hours. You may run the generator at full load after the 8-hour oil change. Refer to the Recommended

Maintenance Schedule in Table 4 for the full maintenance schedule.

Option A: Electric Start

6. Push the ENGINE SWITCH to START and hold for 2-3 sec-

onds, until the engine starts, then release the switch (Fig. 15).

NOTE: If the engine does not start, release the switch and try

again. Keeping the switch in the START position too long can

damage the starter.

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

6. Place one hand on the generator to hold it in place, and pull

on the recoil starter handle (Fig. 16 - 2) slowly until a slight

resistance is felt. Pull quickly to start the engine. Return cord

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

Fig. 15

Fig. 16

Fig. 17

ON OFF

ECO-MODE

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: 3650W Gasoline: 4500W

LPG: 3285W LPG: 4500W

What this means:

The generator can produce a maximum of

3650W / 3285W 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 4500W 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 3650W / 3285W.

It is recommended to maintain a load at or

below 3285 / 2950W (90% of the rated out-

put) 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 4500W.

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 24 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 (3650W / 3285W) 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 before connecting electrical devices. Do

not connect 3-phase or 50Hz 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-(800) 232-1195 M-F 8-5 CST, or email [email protected].

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

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.

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.

SWITCHING FUELS

To switch fuels, turn the fuel selector knob to "GAS ON" or "LPG". To maximize your generator's lifespan, we recom-

mend removing all loads from the generator before switching between gasoline and LPG. If this is not possible,

reduce loads as much as possible in order to ensure a smooth switch. Your generator is rated to handle a higher

load when running on gasoline than on LPG, so keep this in mind when planning your fuel usage.

USING YOUR GENERATOR

ECO-MODE SWITCH

This generator is equipped with an Eco-Mode Idle Control Switch

(Fig. 18). Engaging this switch allows the system to regulate the

engine speed and automatically adjust its fuel consumption to

match the required 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, while

extending runtime and engine’s lifespan.

Keep this switch engaged ONLY when the power load requirement is less than 2730W. Do not engage the Eco-Mode

Switch when the total load is more than 2730W. The generator engine must run at full speed to supply power for

anything over 2730W.

PARALLEL OPERATION

The parallel connection ports (Fig. 19) allow you to connect two

WEN generators to increase the total available electrical power.

The WEN Parallel Connection Kit can be purchased from

wenproducts.com. Follow the instructions included with your

parallel connection kit for proper installation and operation.

IN CASE OF OVERLOAD

If your generator becomes overloaded from too much drawn

wattage, the overload indicator (red) on the control panel will

light up. Follow the instructions below when an overload occurs:

• When you’re close to overloading the generator, the overload

light will start to ﬂash. Reduce the load by turning off and dis-

connecting your electronic device(s) until the overload light turns

off. Then you may continue to operate your generator.

• When you’ve overloaded the generator, the overload light will stay on and the reset button (Fig. 20) will activate

to cut off the output in 3 to 16 seconds, depending on the load. Reduce the load by turning off and disconnecting

your electrical device(s) until the overload light turns off. Wait about ﬁve minutes and then press the activated reset

button to reset the circuit. If no power is produced after resetting, turn off and disconnect all electrical devices and

restart your generator.

Fig. 18

Fig. 19

Fig. 20

ON OFF

ECO-MODE

LIGHT

MEANING RESOLUTION

GREEN (POWER INDICATOR) RED (OVERLOAD)

ON OFF Generator output is normal. No action needed.

ON Flashing Continuously Generator is exceeding rated output. Reduce load on generator.

OFF

Flashes 1x

Repeating every 3 seconds

Voltage at alternator is too low.

No electrical output.

Check for loose connections.

Call 1-800-232-1195 for assistance.

OFF

Flashes 2x

Repeating every 3 seconds

Engine speed is too low.

No electrical output.

Check carburetor and stepper motor.

Ensure Eco-Mode is OFF. Have genera-

tor serviced; call 1-800-232-1195 for

assistance.

OFF

Flashes 3x

Repeating every 3 seconds

Inverter temperature is too high. No

electrical output.

Turn generator off and let cool down fully

(1-2 hours) before restarting.

OFF

Flashes 5x

Repeating every 3 seconds

Voltage at alternator is too high.

No electrical output.

Have generator serviced; call

1-800-232-1195 for assistance.

OFF

Flashes 6x

Repeating every 3 seconds

Generator has exceeded rated output

and cut off power to protect itself. No

electrical output.

Turn OFF and disconnect loads. Press

RESET button on panel. Reduce load on

generator.

USING YOUR GENERATOR

CIRCUIT BREAKERS

In addition to the reset button that protects the generator’s main

circuit, the circuit breaker (Fig. 21) protects the NEMA 5-20 out-

lets. The 20-amp AC circuit breaker will activate when the NEMA

5-20 outlets exceed 20A. When the circuit breaker activates,

turn off and disconnect the device from its respective outlet, and

press the circuit breaker to reset.

Fig. 21

USING YOUR GENERATOR

CO SENSOR INFORMATION

The CO Watchdog carbon monoxide monitoring system (Fig.

22 - 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. 22 - 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 (1-800-232-1195, 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. 22

SHUTTING OFF YOUR GENERATOR

CAUTION! Unplugging running devices can cause damage to the generator. Never stop the engine with elec-

trical devices connected and running.

OPTION 1A: AUTOMATIC FUEL SHUTOFF (RECOMMENDED – GASOLINE ONLY)

Your generator is equipped with automatic fuel shutoff. This feature turns off the ﬂow of fuel, allowing for the gen-

erator to use up the remaining fuel from the carburetor before turning off. This prolongs the lifespan of the generator

by preventing build-up and blockages caused by stagnant fuel inside of a carburetor.

1. Turn off all electrical devices prior to unplugging them from

the generator. Unplugging running devices can cause damage to

the generator.

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

internal temperatures.

3. Turn the propane tank valve to the OFF position (if the propane

regulator hose is connected to the generator).

4. Turn the FUEL SELECTOR knob to the "GAS OFF" position (Fig.

23 - 1).

Fig. 23

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. Turn the FUEL SELECTOR knob to the "ENGINE OFF" position.

OPTION 1B: AUTOMATIC FUEL SHUTOFF

(RECOMMENDED – LPG ONLY)

Although LPG is not prone to degradation the way gasoline is, it is still a good idea to turn the LPG tank OFF before

disconnecting the regulator hose from the generator, so that LPG does not leak from the hose.

1. Turn off all electrical devices prior to unplugging them. Unplugging running devices can cause damage to genera-

tor.

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

3. Turn the FUEL SELECTOR knob (Fig. 23 - 1) to the "GAS OFF" position. The engine will continue to run until pro-

pane in the carburetor is consumed, which will be nearly immediately. It will then shut down automatically.

4. Turn propane tank valve to OFF position.

NOTE: If there is gasoline in the fuel tank, and any gasoline has made it into the carburetor for some reason, the

generator may continue to run for a few minutes until the gasoline has been consumed.

5. Turn the FUEL SELECTOR knob to the "ENGINE OFF" position.

WARNING! Allow the generator to cool down before touching areas that become hot during use.

CAUTION: Allowing gasoline to sit in the fuel tank for long periods of time can make it difﬁcult to start the gen-

erator in the future. Never store the generator for extended periods of time (over 2 months) with fuel in the fuel

tank. Refer to “Storing the Generator.”

SHUTTING OFF YOUR GENERATOR

CAUTION! Unplugging running devices can cause damage to the generator. Never stop the engine with elec-

trical devices connected and running.

OPTION 2: MANUAL SHUTOFF

In case you are in a hurry and do not want to wait for the generator to automatically shut down, the manual shutoff

feature is available. 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.

1. Turn off all electrical devices prior to unplugging them from

the generator. Unplugging running devices can cause damage to

the generator.

2. Turn the FUEL SELECTOR knob to the "ENGINE OFF" position

(Fig. 24).

Fig. 24

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-(800) 232-1195 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 charge the battery and 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

CLEANING THE GENERATOR

Keep the generator clean to prevent improper operation or machine damage from dirt and debris. Inspect all ventila-

tion openings on the generator. These openings must be kept clean and unobstructed.

If the generator becomes dirty, use a damp cloth to wipe exterior surfaces. Use a soft bristle brush to loosen dirt and

oil and use a vacuum to pick up loose dirt. Use low pressure air (not to exceed 25 PSI) to blow away dirt.

WARNING! Never clean the generator when it is running! Never clean with a bucket of water or a hose. Water

can get inside the working parts of the generator and cause corrosion or a short circuit.

CHECKING / ADDING OIL

Check the oil level before each use and every 8 hours of operation (refer to Table 4).

The oil capacity of the generator engine is 18.6 ﬂ. ounces. Add oil when the oil level is low. For proper type and

weight of oil refer to “add oil” portion of the “Generator Preparation” section. This is a critical step for proper engine

starting. The generator is equipped with a with low-oil shut down to protect it from running without oil.

To check the oil level and add oil:

1. Make sure the generator is on a level surface. Do not tilt the generator, as oil will ﬂow into engine areas and cause

damage. Keep generator level!

2. Remove the dipstick and wipe it with a clean rag.

3. Insert the dipstick into the oil ﬁll opening without screwing in. Remove the

dipstick to check the oil mark (Fig. 25). 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 the

step above until the oil mark reaches the top of the dipstick. Do not over ﬁll.

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

Fig. 25

Upper Limit

Lower Limit

MAINTENANCE

DRAINING THE CARBURETOR

We recommend draining the carburetor after every use and before storing the generator. (If the generator is shut off

using the GAS OFF feature, it is only necessary to drain it before periods of long storage.) Draining the carburetor

can prevent the fuel from clogging up the carburetor; a clogged carburetor can prevent the generator from starting.

1. With the help of another person, place the

generator on an elevated platform such as a

table or desk.

2. Make sure that the FUEL SELECTOR knob

is turned to "ENGINE OFF". At this position,

the fuel valve is turned OFF so that only the

fuel left inside the carburetor will be drained

out.

3. The carburetor (Fig. 26 - 1) can be accessed

on the back of the generator, right beside the

air ﬁlter.

4. Prepare an approved gasoline-storage con-

tainer and a funnel.

5. Open up the carburetor drain screw (Fig.

26 - 2) with a Phillips-head screwdriver and

drain out any gasoline that has built up inside

the carburetor through the funnel into the ap-

proved gasoline-storage container.

6. Once the fuel has drained, tighten the drain

screw with the screwdriver.

NOTE: Make sure to drain your carburetor be-

fore storing the generator for long periods of

time.

Fig. 26

MAINTENANCE

AIR FILTER MAINTENANCE

Check every 50 hours of operation (refer to Table 4 - Recommended Maintenance Schedule).

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

cleaner is free of excessive dirt.

To inspect and clean the air ﬁlter:

1. Remove the air ﬁlter cover (Fig. 27 - 1) by unscrewing the

cover lock knob (Fig. 27 - 2) at the bottom of the air ﬁlter

cover.

2. Remove the foam, sponge-like air ﬁlter element from the

casing. Wipe excessive oil and any dirt from inside of the air

ﬁlter casing.

3. Check the foam, sponge-like air ﬁlter element.

a) Good elements can be washed in soapy water. Dry the

element in clean cloth (do not twist it). Add a few drops of

engine oil to the air ﬁlter element and spread it evenly. A

small amount of oil left in the element is normal and neces-

sary for the engine to work properly.

WARNING! Running the engine with a dirty, damaged or missing air ﬁlter element can result in danger to the

operator and cause the engine to wear out prematurely.

SPARK ARRESTOR MAINTENANCE

Inspect and clean the spark arrestor every 100 hours of operation. The spark arrester is located outside the mufﬂer,

which gets very hot during operation. Allow the engine to cool completely before servicing the spark arrester. To

inspect and clean the spark arrester:

1. Remove the two Phillips-head screws that secure the spark

arrestor to the mufﬂer (Fig. 28 - 1).

2. Remove the spark arrestor screen.

3. Carefully clean and remove the carbon deposits from the

spark arrestor screen with a wire brush. Replace the spark

arrestor if it is damaged (replacement spark arrestors can be

purchased from wenproducts.com by searching the part no.

DG4500iX-086).

4. Reinstall the spark arrestor in the mufﬂer and secure it in

place with the screws.

Fig. 27

Fig. 28

b) Damaged elements should be replaced with a new one. Replacement air ﬁlters can be purchased from wen-

products.com by searching part number 56500-134.

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

MAINTENANCE

SPARK PLUG MAINTENANCE

Refer to Recommended Maintenance Schedule in Table 4 for maintaining the spark plug. The spark plug is impor-

tant for proper engine operation. Check the spark plug regularly to maintain proper engine operation. A good spark

plug should be intact, free of deposits, and properly gapped.

To inspect or replace the spark plug:

1. Gently pull on the spark plug boot (Fig. 29 - 1) to remove it.

Be careful not to tear any insulation or wire.

2. Use the included spark plug socket (Fig. 30) to unscrew and

then carefully remove the spark plug from the engine.

TIP: There is limited space for the wrench to turn. Use both

rows of holes in the spark plug wrench to gain leverage to

loosen the plug.

3. Visually inspect the spark plug. If it is cracked or chipped,

or if the electrodes are worn or burned, discard it and replace

with a new spark plug.

We recommend replacing with a F6RTC spark plug (part no.

56310i-0104), available for purchase at wenproducts.com.

4. If re-using the spark plug, use a wire brush to clean any dirt

from around the spark plug base, then re-gap the spark plug.

5. Measure the plug gap with a spark plug gap gauge. The gap

should be 0.6 - 0.8 mm (0.024 - 0.031 in) (Fig. 31). Carefully

adjust the gap if necessary.

6. Screw the spark plug back into the spark plug hole using

the spark plug wrench. Do not over-tighten spark plug. Rec-

ommended tightening of spark plug is ½ to ¾ of a turn (15

ft-lb torque/20.33 Nm) after spark plug gasket contacts spark

plug hole.

7. Reinstall the spark plug boot, spark plug rubber cover, and

service panel.

0.6 mm - 0.8 mm

Fig. 29

Fig. 30

Fig. 31

Spark Plug Socket

MAINTENANCE

DRAINING / CHANGING 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 more-complete

drainage.

To change engine oil:

1. With the help of another person, place the generator on an

elevated platform such as table or workbench.

NOTE: To avoid possible gasoline spills from the carburetor

bowl, drain the carburetor before draining oil.

2. Prepare an approved oil-storage container and place it be-

low the oil drainage bolt (Fig. 32 - 1) to catch oil as it drains.

4. Use a 10mm socket to loosen and remove the oil drainage

bolt, and allow oil to drain from the engine completely.

5. Replace and tighten the oil drainage bolt after the oil has

drained.

NOTE: Never dispose of used engine oil in the trash or down

a drain. Please call a local recycling center or auto garage to

arrange proper oil disposal.

6. Unscrew the oil dipstick. Using a funnel or appropriate dis-

penser, add 20 ﬂ. oz. (0.60 L) of clean engine oil into the oil

ﬁll. Check the oil level periodically using the dipstick. Do not

over ﬁll.

Fig. 32

MAINTENANCE

DRAINING THE FUEL TANK

Drain and clean the fuel tank each year, or before storing the generator for longer than two months.

To drain the fuel tank and carburetor:

1. Locate the carburetor (Fig. 33 - 1). It can

be accessed on the back of the generator,

right beside the air ﬁlter.

2. Prepare an approved gasoline-storage

container and a funnel.

3. Remove the fuel cap (Fig. 34 - 1). Turn the

FUEL SELECTOR knob (Fig. 34 - 2) to "GAS

ON".

4. Open up the carburetor drain screw (Fig.

33 - 2) with a Phillips screwdriver. Fuel will

start draining from the carburetor and fuel

tank through the funnel.

NOTE: The draining process may take a few

hours, depending on the amount of fuel in

your gas tank.

5. Once fuel is completely drained from the

tube, reinstall the fuel cap and turn the FUEL

SELECTOR knob to "ENGINE OFF". Tighten

the drain screw with the screwdriver.

6. Start and run the generator until the fuel

runs out.

7. Store the emptied gasoline in a suitable

place. DO NOT store ﬂammable materials

near the gasoline.

CAUTION: Store the emptied gasoline in a suitable place. Never store fuel for more than 2 months.

Fig. 33

Fig. 34

MAINTENANCE

BATTERY MAINTENANCE/STORAGE

The battery will receive charge when the engine is running. Remember to run the generator once a month for 20-30

minutes to charge the battery. A charged battery will allow you to start the generator using the electric start switch

during your next time of need. If the battery is out of charge, you 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 from the battery

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.

To reinstall/replace the battery:

1. Using a 10mm socket, remove the bolt on the bottom of

the battery bracket and remove the bracket and battery (Fig.

35).

2. Replace with an identical new battery

(part no. DG4500iX-074).

3. Connect the new battery by connecting the two ends of

the quick connector together.

4. Replace the battery bracket and bolt.

Fig. 35

NOTE: Always recycle used batteries in accordance with local laws and regulations. Contact your local solid waste

collection site or recycling facility to obtain information on local recycling processes.

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. Tighten the fuel cap.

2. Turn the FUEL SELECTOR knob to the "ENGINE OFF" position.

3. Drain the fuel tank if possible. Refer to section "DRAINING THE FUEL TANK."

4. Keep the generator upright. Never place the generator on its side or upside down - doing so could damage the

internal components of the generator and make it difﬁcult to start.

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 33, “Draining the

Carburetor.”

• Disconnect the quick-connector from the battery.

• Add fuel stabilizer: Follow the suggested portions and

instructions of your preferred stabilizer. Run the engine for

15 to 20 minutes, allowing the fuel stabilizer to mix with the

gasoline and circulate through the carburetor, and then top

off with fuel. Filling the fuel tank full reduces the amount of

air in the tank and helps ﬁght deterioration of fuel.

For Extended Periods (Over 60 Days):

• Disconnect the quick-connector from

the battery.

• Drain the fuel tank and carburetor (see

“Draining the Fuel Tank”). Never store

generator with fuel in the tank for more

than two months.

• Change the engine oil (see “CHANGING

OIL”).

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 1-800-232-1195 (M-F 8-5 CST),

or email [email protected].

PROBLEM POSSIBLE CAUSE SOLUTION

Engine will not

start.

1. CHOKE lever is in wrong position. 1. Set switch to CHOKE if engine is cold and RUN if engine is warm.

2. Engine switch is set to OFF. 2. Turn engine switch to START.

3. Engine has not been primed (LPG only). 3. Prime the engine.

4. Battery is out of power.

4. Electric start will not work if battery is out of power. Start generator

using the recoil start to charge the battery.

5. Battery is too cold.

5. Electric start may be difﬁcult if the battery is too cold. Store the

generator or battery in a warmer location.

6. Oil is low. 6. Add oil.

7. Engine is out of fuel. 7. Add fuel.

8. Engine is ﬁlled with contaminated or old

fuel.

8. Drain fuel in the tank and carburetor. Replace with fresh fuel.

9. Spark plug is dirty or broken. 9. Clean or replace spark plug.

10. Propane tank is turned OFF. 10. Dang it, Bobby, I told you to turn that thing on!

11. Carburetor is air locked.

11. Turn the FUEL SELECTOR SWITCH to OFF. Remove bolt from bottom

of the carburetor. Take off the carburetor bowl to allow it to reset. Replace

carburetor bowl and reinstall the bolt.

12. Regulator is stuck.

12. Turn OFF propane tank. Disconnect hose from propane ﬁtting. Contact

WEN customer service for assistance.

13. Ghost in the generator. 13. Persuade ghost to leave. Consult Bill Murray if needed.

Engine runs, but

there is no

electrical

output.

1. Reset button has activated due to wattage

overload.

1. Turn off and unplug all electrical devices. Press reset button. Check the

total wattage of the devices and reduce the load if it exceeds the capacity of

the generator for your particular fuel (LPG or gasoline).

2. Breaker has tripped due to wattage over-

load.

2. Turn off and unplug all electrical devices. Wait 3 minutes, and press the

activated breaker to reset. Check the total wattage of the devices and reduce

the load if it exceeds the capacity of the generator for your particular fuel

(LPG or gasoline).

3. Bad connecting cord or wire.

3. Check power cords & extension cords. Do not use if any cord is damaged.

Replace damaged cords immediately.

4. Bad electrical device connected to the

generator.

4. Try connecting a different device.

Generator runs,

but does not

support all

electrical devices

connected.

1. AC or DC receptacles are overloaded;

circuit breaker has tripped.

1. Turn off and unplug all electrical devices. Wait 3 minutes, then press the

breaker to reset. Check the amperage of the devices to ensure they are within

the receptacles’ rated capacities.

2. Short circuit in one of the devices. 2. Disconnect any faulty or short-circuited electrical devices.

3. Air ﬁlter is dirty. 3. Clean or replace the air ﬁlter element.

Engine is

“hunting”

during operation

(engine RPM is

ﬂuctuating).

1. Gasoline is not running through fuel valve.

1. Make sure there is enough fuel. Make sure the CHOKE lever is turned to

RUN.

2. Propane level is getting low. 2. Switch to a new propane tank, or use gasoline.

3. Air ﬁlter is dirty. 3. Clean or replace the air ﬁlter element.

4. Spark arrestor is dirty. 4. Clean the spark arrestor.

5. There is gunk in the carburetor preventing

a consistent fuel/air mixture.

5. Use carburetor cleaner spray on the carburetor bowl and jets.

IMPORTANT: Repairs and replacements should only be performed by an authorized technician. Parts and acces-

sories that wear down over the course of normal use are not covered by the three-year warranty.

WEN DG4500IX Dual Fuel Open Frame Generator Electric Start and CO Watchdog for RV Use and Transfer Switch Ready

Product's Documents

Product manual

Specifications

WEN DG4500IX Questions and Answers