Wen DF1200X Instruction Manual
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Wen DF1200X Instruction Manual

12000-watt dual fuel portable generator
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MODEL DF1200X
12000-WATT DUAL FUEL
PORTABLE GENERATOR
Instruction Manual
NEED HELP? CONTACT US!
Have product questions? Need technical support? Please feel free to contact us:
1-800-232-1195 (M-F 8AM-5PM CST)
TECHSUPPORT@WENPRODUCTS.COM
IMPORTANT: Your new tool has been engineered and manufactured to WEN's highest standards for dependability,
ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged,
trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use
your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.
WENPRODUCTS.COM
For replacement parts and the most up-to-date instruction manuals, visit

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  • Page 1 1-800-232-1195 (M-F 8AM-5PM CST) TECHSUPPORT@WENPRODUCTS.COM IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest standards for dependability, ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged, trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.

  • Page 2: Table Of Contents

    CONTENTS WELCOME Specifications ....................3 Introduction ..................... 4 SAFETY General Safety Rules ..................5 Generator Safety Warnings ................7 BEFORE OPERATING Know Your Generator ..................10 Unpacking & Packing List ................12 Assembly & Adjustments ................12 Generator Preparation ..................14 OPERATION &...

  • Page 3: Welcome

    SPECIFICATIONS GENERATOR Model Number DF1200X Surge (Starting) Wattage 12000W (Gasoline) / 11000W (LPG) Rated (Running) Wattage 9500W (Gasoline) / 9000W (LPG) Rated Voltage 120V / 240V AC, 12V DC Rated Amperage 79.2A / 39.6A AC, 8.3A DC Phase Single Frequency...

  • Page 4: Introduction

    INTRODUCTION Thanks for purchasing the WEN 12000-Watt Portable Generator. Refer to the illustration below for the location of the serial number on the specifications label. Record the generator information in the spaces provided below. If as- sistance for information or service is required, please contact customer service by calling 1-800-232-1195, M-F 8-5 CST;...

  • Page 5: Safety

    GENERAL SAFETY RULES WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Safety is a combination of common sense, staying alert and knowing how your item works. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
  • Page 6 GENERAL SAFETY RULES WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Safety is a combination of common sense, staying alert and knowing how your item works. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

  • Page 7: 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 8 GENERATOR SAFETY WARNINGS WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury. OPERATING ENVIRONMENT 3. If any part of the generator, electrical device or pow- er cord is broken, damaged, or defective, make sure 1.
  • Page 9 GENERATOR SAFETY WARNINGS WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules. Failure to follow the safety instructions may result in serious personal injury. TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your generator at least once a month for 20 to 30 minutes.

  • Page 10: Before Operating

    KNOW YOUR GENERATOR TOOL PURPOSE Generators provide you with power when and where you need it most. Refer to the following diagrams to become familiarized with all the parts and controls of your Generator. The components will be referred to later in the manual for assembly and operation instructions.
  • Page 11 KNOW YOUR GENERATOR CONTROL PANEL 1. Oil Level LED 7. NEMA 14-50R Receptacle Illuminates if the oil level is too low. AC 120V / 240V. 2. Engine Key Switch 8. Main Circuit Breaker Start and shut down the engine. Flip the lever to reset the circuit. 3.

  • Page 12: Unpacking & Packing List

    UNPACKING & PACKING LIST UNPACKING Fig. 1 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.
  • Page 13 ASSEMBLY & ADJUSTMENTS ASSEMBLY Fig. 2 Refer to the packing list 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 FEET The feet are installed on the air filter side of the generator.

  • Page 14: Generator Preparation

    4. Reinstall the oil dipstick and firmly tighten it. Wipe clean any spilled oil. NOTE: Extend the lifespan of your generator by catching the loose metal filaments that naturally build up inside the crank case with the WEN Magnetic Dipstick (Model GNA273), available for purchase at wenproducts.com. Lower Fill Line...
  • Page 15 GENERATOR PREPARATION TO CHECK OIL LEVEL (before every subsequent start): Fig. 7 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. Upper Limit 3.
  • Page 16 GENERATOR PREPARATION TO ADD GASOLINE: Fig. 8 Fuel 1. Place the generator on a level surface. Make sure the Gauge engine is OFF before adding or checking the fuel. Fuel Cap 2. Unscrew the fuel cap (Fig. 8) and set it aside. The fuel cap may be tight and hard to unscrew.
  • Page 17 GENERATOR PREPARATION FUEL OPTION B: LIQUID PETROLEUM GAS (LPG) (CONT.) NOTE: LPG regulator inlet pressure is approximately 30 PSI at 0 °F, and 218 PSI at 100 °F. • You can use LPG tanks with Type 1, right hand Acme threads with this generator. Verify that the qualification date on tank has not expired.
  • Page 18 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 19 This kit should be installed by a qualified mechanic. You can order the kit at wenproducts.com by searching part number DF1200X-HA36 & DF1200X-HA68. Refer to the instructions included with your altitude kit for more infor- mation about installation.

  • Page 20: Operation & Maintenance

    STARTING THE GENERATOR Before starting the generator, make sure you have read and performed the steps in the “Generator Preparation” sec- tion 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.
  • Page 21 STARTING THE GENERATOR BEFORE STARTING THE GENERATOR Fig. 13 1. Verify that the generator is outside on a dry, level sur- face. Allow at least two feet of clearance on all sides of the generator. 2. To maximize safety, check that the generator is properly FUEL VALVE grounded (see “Ground the Generator”).

  • Page 22: Using The Generator

    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.
  • Page 23 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.
  • Page 24 USING YOUR GENERATOR CONNECTING ELECTRICAL DEVICES CAUTION: Become familiar with the functions and capacity of each component on the control panel (page 11) before connecting electrical devices. Do not overload generator or individual panel receptacles. Do not connect 50Hz or 3-phase loads to the generator. Follow the steps below to properly connect your device(s) to the generator: 1.
  • Page 25 • 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...

  • Page 26: Shutting Off The Generator

    USING YOUR GENERATOR CHANGING FUELS 1. Before changing the fuel source, make sure the generator is turned off or running under half-load. Do not change fuel when generator is over half-load. 2. If switching from LPG to gasoline, turn off the LPG tank valve and disconnect LPG fuel tank from generator. Then turn ON the fuel valve.

  • Page 27: 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 below, Table 4. If there are any questions about the maintenance procedures listed in this manual, please contact customer service at 1-800-232-1195 (M-F 8-5 CST), or email techsupport@wenproducts.com.
  • Page 28 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.
  • Page 29 MAINTENANCE CHECKING/ADDING OIL Check the oil level before each use and every 8 hours of operation. The oil capacity of the generator engine is 32 fl. ounces. Add oil when the oil level is low. For proper type and weight of oil refer to “add oil”...
  • Page 30 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. DF1200X-1202.1. 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 31 MAINTENANCE SPARK PLUG MAINTENANCE Refer to Recommended Maintenance Schedule for maintaining the spark plug. The spark plug is important for proper engine operation. Check the spark plug regularly to maintain proper engine operation. A good spark plug should be intact, free of deposits, and properly gapped. To inspect or replace the spark plug: Fig.
  • Page 32 3 months. BATTERY MAINTENANCE/STORAGE The battery (part no. DF1200X-1526) 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 33: 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 OFF. 2. Make sure the engine switch is in the OFF position. 3.

  • Page 34: Troubleshooting Guide

    Refer to “CO Sensor Information” on p. 25. CO sensor disconnected, re- Connect or install the CO sensor. If an error is shown, contact WEN customer moved, or faulty. service for assistance. Also refer to “CO Sensor Information” on p. 25.

  • Page 35: Wiring Diagram

    WIRING DIAGRAM...

  • Page 36: Exploded View & Parts List

    Description Qty. Crankcase Cover Crankcase Crankcase Cover Oil Seal 1 Gasket GN625i-0207 Engine Oil Sensor Oil Dipstick Rubber Plug DF1200X-0203 Subassembly DF1200X-0105 Engine Oil Switch Bolt, M6x12 Bolt, M8x40 Flat Washer, 12mm Ball Bearing, Drain Plug Bolt, M12- 5613K-0207 6208P53 1.5x18...
  • Page 37 Position Pin, 12mm Cylinder Head Bolt, M10-1.25x85 Spark Plug, Torch F6TC 3-10 56475-F6TC (NGK BP6ES) Part No. Description Qty. Cylinder Head 3-11 Piston Pin Clip Subassembly Piston 3-12 Muffler Gasket Piston Pin 3-13 Nut, M8 Connecting Rod DF1200X-0505 Piston Ring Set...
  • Page 38 ASSEMBLY 7 - RECOIL STARTER CAMSHAFT SUBASSEMBLY Part No. Description Qty. Part No. Description Qty. Bolt, M6x20 Recoil Starter Camshaft Assembly DF1200X-0702 Assembly DF1200X-0602 Valve Set Retaining Ring Guide Seal Valve Spring ASSEMBLY 8 - SHROUD & Valve Spring Seat LOWER SHIELD Valve Tappet...
  • Page 39 Gasket Carburetor Insulator 10-2 Starter Pulley Plate 10-3 Impeller Carburetor Gasket 10-4 Flywheel Carburetor 10-5 Bolt, M6x28 DF1200X-0903 Assembly 10-6 DF1200X-1006 Ignition Coil Air Filter Gasket 10-7 Bolt, M6x10 Hose Clamp 1 10-8 Charger Coil Clamp Fuel Tube 10-9 Bolt, M6x32...
  • Page 40 Muffler Assembly 12-1 Flanged Hex Nut, M6 N.P. DF1200X-1303.1 Spark Arrestor 12-2 Air Filter Assembly 13-4 Bolt, M8x16 12-3 DF1200X-1202.1 Air Filter Element 13-6 Exhaust Pipe Gasket 13-7 Muffler Bracket Part No. Description Qty. ASSEMBLY 14 - FUEL TANK 14-1...
  • Page 41 15-26 DF1200X-1526 Battery, 12V, 14Ah 15-9 M10-1.25 Anode (Negative) 15-27 15-10 Flanged Hex Nut, M8 Wire 15-11 DF1200X-1511 Flanged Hex Nut, M8 Cathode (Positive) 15-28 Wire 15-12 DF1200X-1108 Flanged Hex Nut, M6 15-29 Bolt, M6x12 DF1200X- 15-13 Foot Assembly 1513ASM...
  • Page 42 16-16 Hex Bolt, M6x25 NEMA 14-50R Outlet Secondary LPG 16-3 16-17 Subassembly Regulator Bracket 16-4 30A AC Breaker Secondary LPG 16-18 DF1200X-1618 Regulator 16-5 20A AC Breaker 16-19 Hose Clamp 16-6 Multi-meter 16-20 GN625iX-1430 CO Sensor Module 16-7 CO Sensor LED...
  • Page 43 Flat Washer, 10mm Spring Washer, Rotor Bolt, M10- 17-2 17-13 1.25x285 17-3 Cover Stopper 17-14 Stator Bolt, M6x199 17-4 Rotor 17-15 DF1200X-1715 Voltage Regulator 17-5 Stator 17-16 Wire Loop 17-6 Terminal Block 17-17 Alternator Cover Carbon Brush 17-18 Bolt, M5x12...

  • Page 44: Warranty Statement

    Contact techsupport@wenproducts.com or 1-800-232-1195 with the following information to make arrangements: your shipping address, phone number, serial number, required part numbers, and proof of purchase. Damaged or defective parts and products may need to be sent to WEN before the replacements can be shipped out.

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