Wen DF623X Instruction Manual
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Wen DF623X Instruction Manual

6250-watt dual fuel generator
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MODEL DF623X
6250-WATT
DUAL FUEL GENERATOR
Instruction Manual
NEED HELP? CONTACT US!
Have product questions? Need technical support? Please feel free to contact us:
1-847-429-9263 (M-F 8AM-5PM CST)
TECHSUPPORT@WENPRODUCTS.COM
IMPORTANT: Your new tool has been engineered and manufactured to WEN's highest standards for dependability,
ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged,
trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use
your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.
WENPRODUCTS.COM
For replacement parts and the most up-to-date instruction manuals, visit

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  • Page 1 1-847-429-9263 (M-F 8AM-5PM CST) TECHSUPPORT@WENPRODUCTS.COM IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest standards for dependability, ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged, trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.

  • 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 ................13 Generator Preparation ..................14 OPERATION &...

  • Page 3: Specifications

    SPECIFICATIONS GENERATOR Model Number DF623X Gasoline: 5000 Watts Rated Wattage LPG: 4500 Watts Gasoline: 6250 Watts Surge Wattage LPG: 5625 Watts Phase Single Frequency 60 Hz Rated Voltage 120V / 240V Rated Amperage 41.7A / 20.8A Product Dimensions (With Wheel Kit) 26.1 in. x 23.4 in. x 22.1 in.

  • Page 4: Introduction

    INTRODUCTION Thanks for purchasing the WEN 6250-Watt Dual Fuel 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 1-847-429-9263, M-F 8-5 CST;...

  • Page 5: General Safety Rules

    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: Know Your Generator

    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. Fuel Selector Switch 7. Grounding Nut Turn the dial to easily switch between gasoline or LPG Connection point for grounding the generator to the earth. before operation. 8. AC 120V NEMA TT-30R RV Receptacle 2.

  • Page 12: Unpacking & Packing List

    UNPACKING & PACKING LIST UNPACKING With the help of a friend or trustworthy foe, such as one of your in-laws, carefully remove the generator from the packaging and place it on a sturdy, flat surface. Make sure to take out all contents and accessories. Do not discard the packaging until everything is removed.

  • Page 13: Assembly & Adjustments

    ASSEMBLY & ADJUSTMENTS TO INSTALL THE SUPPORT BRACKET: The support bracket (Fig. 1 - 1) comes with the two feet (Fig. 1 - 2) pre-installed with two hex nuts (Fig. 1 - 3) and two hex bolts (Fig. 1 - 4). Attach the support bracket (Fig. 1 - 1) to the frame of the generator using the two included M8x16 bolts (Fig.

  • Page 14: Generator Preparation

    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 55201), avail- able for purchase at wenproducts.com. Lower Fill Line...
  • Page 15 GENERATOR PREPARATION TO CHECK OIL LEVEL (before every subsequent start): Fig. 5 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. 6 Fuel Cap Fuel Gauge 1. Place the generator on a level surface. Make sure the engine is OFF before adding or checking the fuel. 2. Unscrew the fuel cap (Fig. 6) 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. Contact customer service at 1-847-429-9263 (M-F 8-5 CST), or email techsupport@wenproducts.com for information about service centers near you. You can order the kit at wenproducts.com by searching part number DF623X-HA36 or DF623X-HA68. Refer to the instructions included with your altitude kit for more information about installation.

  • Page 20: Starting The Generator

    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 1-847-429-9263 (M-F 8-5 CST) for customer service.
  • Page 21 STARTING THE GENERATOR BEFORE STARTING THE GENERATOR Fig. 11 Fig. 12 1. Verify that the generator is outside on a dry, level sur- face. Allow at least two feet of clearance on all sides. 2. To maximize safety, check that the generator is properly grounded (see “Ground the Generator”).

  • Page 22: 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 23 USING THE 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 THE 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 THE 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 1-847-429-9263 (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 33.8 fl. ounces (1.0 L). Add oil when the oil level is low. For proper type and weight of oil refer to “add oil”...
  • Page 30 MAINTENANCE AIR FILTER MAINTENANCE Check every 50 hours of operation (refer to Recommended Maintenance Schedule). Routine maintenance of the air filter helps maintain proper airflow to the carburetor. Occasionally check that the air filter is free of excessive dirt. Clean air filter more frequently in dirty or dusty conditions To inspect and clean the air filter: Fig.
  • 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 MAINTENANCE BATTERY MAINTENANCE/STORAGE The battery (part no. DF623X-075) 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 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: 1. Prepare an approved gasoline-storage container to collect the drained fuel. Place it near the fuel valve. 2.

  • Page 34: 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 35: Troubleshooting Guide

    CO levels too high. Refer to “CO Sensor Information”. CO sensor disconnected, re- Connect or install the CO sensor. If an error is shown, contact WEN cus- moved, or faulty. tomer service for assistance. Also refer to “CO Sensor Information”.

  • Page 36: Wiring Diagram

    WIRING DIAGRAM...

  • Page 37: Exploded View & Parts List

    EXPLODED VIEW & PARTS LIST GENERATOR...
  • Page 38 EXPLODED VIEW & PARTS LIST GENERATOR Part No. Description Qty. Part No. Description Qty. 56500-001 Handrail Jacket 56500-035 Rear Bracket DF623X-002 Push Handle 56500-036 Nut, M8 GN6000-003 Nut M8 56500-037 Earth Wire 56500-001 Handrail Plug GN6000-038 Damping Pad GN6000-005 Bolt, M8x40 56500-1038 Washer, ɸ6...
  • Page 39 EXPLODED VIEW & PARTS LIST GENERATOR Part No. Description Qty. Part No. Description Qty. GN9500X-071 CO Alarm Controler DF623X-074 Dust cover Self-tappling Screw, DF623X-075 Cathode Wire DF623X-065 ST4.2x16 DF623X-076 Battery DF623X-066 Across Bar GN9500-058 Binder Plate DF623X-067 Natural Gas Pipe...
  • Page 40 EXPLODED VIEW & PARTS LIST ENGINE...
  • Page 41 Part No. Description Qty. Part No. Description Qty. 56500-017 Bolt, M6x25 56500-137 Nut, M6 56500-1195ASM Valve Cover 56500-138 Stud, M8x60 DF623X-083 Breather Hose Gasket, Cylinder 56500-139 Head Gasket, Valve 56500-110 Cover Pin, ɸ10×14 56500-140 Rocker Arm 56500-142 Exhaust Valve 56500-111...
  • Page 42 EXPLODED VIEW & PARTS LIST ENGINE Part No. Description Qty. Part No. Description Qty. Oil Seal, DF623X-092 Ignition Module 56500-167 ɸ6xɸ11x4 56500-184 Wire Board 56500-168 Cotter Pin DF623X-093 Flywheel 56500-169 Governor Lever 56500-186 Cooling Fan Choke Linkage 56500-187 Starter Cup...
  • Page 43 EXPLODED VIEW & PARTS LIST CONTROL PANEL Part No. Description Qty. Part No. Description Qty. DF623X-301 Engine Switch 56500-204 DC 12V Outlet GN9500-313 Multi-Meter 56500-1205 AC Breaker, 30A AC 120V NEMA 56500-208 AC Breaker, 20A 56500-205 5-20R AC 120V NEMA...

  • Page 44: Warranty Statement

    Contact techsupport@wenproducts.com or 1-847-429-9263 with the following information to make arrangements: your shipping address, phone number, serial number, required part numbers, and proof of purchase. Damaged or defective parts and products may need to be sent to WEN before the replacements can be shipped out.

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