Wen DF475 Manual
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Wen DF475 Manual

4750 watt dual fuel generator
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bit.ly/wenvideo
For replacement parts visit
WENPRODUCTS.COM
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.
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NOTICE: Please refer to wenproducts.com for the most up-to-date instruction manual.
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DUAL FUEL GENERATOR
NEED HELP? CONTACT US!
Have product questions? Need technical support?
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800-232-1195
techsupport@wenproducts.com
WENPRODUCTS.COM
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IMPORTANT:
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Please feel free to contact us at:
(M-F 8am-5pm CST)
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4750 WATT
CARB COMPLIANT
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EPA CERTIFIED
UNLESS OTHERWISE SPECIFIED:
FINISH:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
SIGNATURE
DATE
DRAWN
CHK'D
APPV'D
MFG
MATERIAL:
Q.A
WEIGHT:
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DEBURR AND
BREAK SHARP
EDGES
TITLE:
DWG NO.
G
SCALE:1:5
3

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Summary of Contents for Wen DF475

  • Page 1 WENPRODUCTS.COM IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest standards for dependability, ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged, trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.

  • Page 2: Table Of Contents

    LPG (with 20 lb tank): 7 hours Product Dimensions 23.2 x 17.5 x 18.5 in. (L x W x H) Product Net Weight 105.8 lbs (48 kg) Your generator is compatible with the WEN 55201 Magnetic Oil Dipstick, available at wenproducts.com...

  • Page 3: Introduction

    If assistance for information or service is required, please contact the Customer Service Help Line by calling 800-232-1195, M-F 8-5 CST; you will be asked to provide the following generator information when calling. GENERATOR MODEL NUMBER: WEN DF475, WEN DF475T DATE OF PURCHASE: __________________________________________ PURCHASED FROM: ___________________________________________...

  • Page 4: Safety Information

    NOTE: The following safety information is not meant to cover all possible conditions and situations that may oc- cur. WEN reserves the right to change this product and specifications at any time without prior notice. SAVE THESE INSTRUCTIONS - Please keep this manual available to all users during the entire life of the tool.

  • Page 5: Generator Safety Warnings

    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.
  • Page 6 GENERATOR SAFETY WARNINGS WARNING: Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury. OPERATING ENVIRONMENT 1. Using a generator indoors can KILL YOU IN MINUTES. Only use a generator outside and far away from windows, doors and vents.
  • Page 7 GENERATOR SAFETY WARNINGS GENERATOR OPERATION 1. Only use the generator for its intended purposes. Modifying or using the generator for operations for which it was not designed may cause hazards and personal injury. 2. Do not touch bare wires or receptacles (outlets). 3.

  • Page 8: Know Your Generator

    KNOW YOUR GENERATOR Use the illustration below to become familiar with all the components and controls of this generator. If any part is damaged or missing, please contact our customer service at (800) 232-1195, M-F 8-5 CST or email us at techsup- port@wenproducts.com.
  • Page 9 KNOW YOUR GENERATOR KNOW YOUR CONTROL PANEL MODEL DF475 1. Fuel Selector Dial 6. 20A Circuit Breaker (for 5-20R) Turn the dial to select between gasoline Thermal protector that protects the 5-20 receptacles or LPG before operation from overload 2. Electric Start Key 7.

  • Page 10: Unpacking & Assembly

    UNPACKING & ASSEMBLY UNPACKING THE GENERATOR AND ACCESSORIES Open the packaging and take out all loose parts from the box. With the help of a good friend or trustworthy foe, carefully lift the generator from the packaging and place it on a sturdy, level surface. Make sure all the accessories are accounted for and fully assemble the generator before discarding the packaging.
  • Page 11 UNPACKING & ASSEMBLY TO INSTALL THE FEET: Slide two M6X40 bolts (32) through the foot support assembly (43) and the generator frame. Tighten with M6 nuts (45). Repeat for the other foot. TO INSTALL THE WHEELS: NOTE: Connecting/disconnecting the battery’s negative terminal requires removing the right wheel. For your convenience of assembly, the battery’s negative terminal has been pre-connectecd from the manufacturer.

  • Page 12: Generator Preparation

    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 (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.
  • Page 13 TIP: Your WEN generator is compatible with the WEN 55201 Magnetic Oil Dipstick (not included), available for purchase at wenproducts.com. The dipstick’s industrial-strength magnetic tip will collect metal shavings from your generator’s oil tank to help preserve the engine and extend your generator’s lifespan.
  • Page 14 GENERATOR PREPARATION STEP 2 - ADD/CHECK FUEL FUEL OPTION A: GASOLINE GASOLINE WARNING: Keep generator away from open flame. 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.
  • Page 15 GENERATOR PREPARATION WARNING: If using gasoline, the LPG tank must be shut OFF. If using LPG, the fuel valve on the genera- tor must be turned to OFF position. FUEL OPTION B: LIQUID PETROLEUM GAS (LPG) DANGER: EXPLOSION AND FIRE. LP vapors are extremely flammable and explosive. Do not use or store LP cylinder in a building, garage or enclosed area.
  • Page 16 GENERATOR PREPARATION FUEL OPTION B: LIQUID PETROLEUM GAS (LPG) - CONTINUED To connect your generator to an LPG cylinder: 1. Take off the safety caps from the cylinder valve, generator mounted regulator, and regulator connecting hose ends. 2. With the LPG tank closed, attach the LPG regulator connecting hose into the valve.
  • Page 17 GENERATOR PREPARATION STEP 3: CONNECT THE BATTERY WARNING: BATTERY GIVES OFF EXPLOSIVE HYDROGEN GAS. • Keep battery away from spark, flame, or cigarette. • Do not connect or disconnect battery while generator is running. • Service or use battery only in well ventilated areas. WARNING: Battery contains sulfuric acid.
  • Page 18 This kit should be installed by a qualified mechanic. You can order the kit at wenproducts.com by searching part number DF475-HA27. Refer to the instructions included with your altitude kit for more information about installa- tion.

  • Page 19: Starting The Generator

    STARTING THE GENERATOR Before starting the generator, make sure you have read and performed the steps in the “GENERATOR PREPARA- TION” section of this manual. If you are unsure about how to perform any of the steps in this manual please call (800) 232-1195 M-F 8-5 CST for customer service.
  • Page 20 STARTING THE GENERATOR BEFORE STARTING THE GENERATOR 1. Verify that the generator is outside on a dry, level surface. Allow at least two feet of clearance on all sides of the generator. 2. To maximize safety, check that the generator is properly grounded (see “GROUND THE GENERATOR”). 3.

  • Page 21: Using The Generator

    USING THE 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.
  • Page 22 Computer Electric drill Television Deep freezer Garage door opener Stereo Box fan Clock radio Security system DVD player / VCR Common light bulb Fig. 10 - Estimated wattage requirements of common electrical devices MODEL DF475 Fig. 11 - Control Panel...
  • Page 23 USING THE GENERATOR CONNECTING ELECTRICAL DEVICES CAUTION: Become familiar with the functions and capacity of each component on the control panel (page 9) before connecting electrical devices. Do not overload generator or individual panel receptacles. DO NOT con- nect 50Hz or 3-phase loads to the generator. Follow the steps below to properly connect your device(s) to the generator: 1.

  • Page 24: Shutting Off The Generator

    USING THE GENERATOR CHANGING FUELS 1. Before changing the fuel source, make sure the generator is turn OFF or running UNDER half-load. DO NOT change fuel when generator is over half-load. 2. If switching from LPG to gasoline, turn OFF the LPG tank valve and disconnect LPG fuel tank from generator. Then turn ON the fuel valve.

  • Page 25: Maintenance

    MAINTENANCE RECOMMENDED MAINTENANCE SCHEDULE Proper routine maintenance of the generator will help prolong the life of the machine. Please perform maintenance checks and operations according to the Maintenance Schedule in Fig. 14. If there are any questions about the maintenance procedures listed in this manual, please call (800) 232-1195 M-F 8-5 CST or email techsupport@ wenproducts.com.
  • Page 26 MAINTENANCE 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.
  • Page 27 MAINTENANCE CHECKING/ADDING OIL Check the oil level before each use and every 8 hours of operation (refer to Fig. 14). The oil capacity of the generator engine is 20.3 fl. ounces. Add oil when the oil level is low. For proper type and weight of oil refer to “ADD OIL”...
  • Page 28 Fig. 17 If the air filter element has been damaged, replace it with a new one. Replacement air filters can be ordered from wenproducts.com by searching part no. DF475-166.1. 4. Reinstall the air filter element and air filter cover. 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.
  • Page 29 We recommend replacing with an NGK BP7ES/Torch F7TC spark plug Plug Wrench (part no. DF475-145), available for purchase at wenproducts.com. Spark Plug Boot 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.
  • Page 30 BATTERY REPLACEMENT The battery (part no. DF475-041) shipped with the generator has been fully charged. The battery will receive charge when the engine is running. Remember to run the generator once a month for 20-30 minutes to charge the battery.
  • Page 31 MAINTENANCE 7. Drain the carburetor according to the instructions on page 26. 8. Store the emptied gasoline in a suitable place. DO NOT store flammable materials near the gasoline. Do not store fuel for more than 3 months. CAUTION: Store the emptied gasoline in a suitable place. Never store fuel for more than 2 months. TESTING THE GFCI OUTLET Test the GFCI outlet monthly.

  • Page 32: Transportation & Storage

    TRANSPORTATION & STORAGE TRANSPORTING THE GENERATOR To prevent fuel spillage when transporting, be sure to perform the following to your generator: 1. Tighten the fuel cap and make sure the fuel valve is turned to OFF. 2. Make sure the engine switch is in the OFF position. 3.

  • Page 33: Specifications

    SPECIFICATIONS GENERATOR Gasoline: 3800 Watts Rated Wattage LPG: 3500 Watts Gasoline: 4750 Watts Surge Wattage LPG: 4350 Watts Phase Single Frequency 60Hz Rated Voltage AC: 120V/240V, DC: 12V Rated Amperage AC: 32A/16A, DC: 8A Product Dimensions 23.2 x 17.5 x 18.5 in. (L x W x H) Product Net Weight 105.8 lbs (48 kg) ENGINE...

  • Page 34: Exploded View & Parts List

    EXPLODED VIEW & PARTS LIST GENERATOR EXPLODED VIEW...
  • Page 35 EXPLODED VIEW & PARTS LIST Part No. Description Qty. Part No. Description Qty. DF475-001 Rotor Stator Assembly DF475-033 Automatic Voltage Regulator DF475-001.1 Carbon Brush Assembly DF475-034 Bolt M5X16 DF475-035 Bolt M5X12 DF475-001.2 Grounding Post Assembly DF475-001.3 Rotor DF475-036 Fuel Tank Washer DF475-001.4...
  • Page 36 EXPLODED VIEW & PARTS LIST ENGINE EXPLODED VIEW...
  • Page 37 DF475-123 Valve Spring DF475-163 Throttle Return Spring DF475-124 In-Valve Spring Seat DF475-164 Recoil Starter Assembly DF475-125 Ex-Valve Spring Seat 64.1 DF475-164.1 Recoil Starter DF475-126 Push Rod Guide Plate DF475-165 Upper Shroud Assembly DF475-127 Rocker Assembly DF475-166 Air Cleaner Assembly DF475-128 Rotator 66.1 DF475-166.1...

  • Page 38: Wiring Diagram

    WIRING DIAGRAM...

  • Page 39: Troubleshooting Guide

    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 our customer service at (800) 232-1195, M-F 8-5 CST or email us at techsup- port@wenproducts.com.

  • Page 40: Warranty Statement

    (2) years from date of purchase or 500 hours of use; whichever comes first. Ninety days for all WEN products if the tool is used for pro- fessional or commercial use.

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Df475t

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