Wen DF402iX Instruction Manual
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Wen DF402iX Instruction Manual

4000-watt dual fuel inverter generator
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MODEL DF402iX
4000-WATT DUAL FUEL
INVERTER 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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Summary of Contents for Wen DF402iX

  • 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

    To purchase accessories for your tool, visit Magnetic Oil Dipstick (Model No. 55201) Generator Cover (Model 56310iC and GNC400) 30A 3600W Parallel Connection Kit (Model GNA36i) 50A 6000W Parallel Connection Kit (Model GNA50i) High Altitude Kit (Model DF402iX-HA36 and DF402iX-HA68) 2 2 2...

  • Page 3: Welcome

    SPECIFICATIONS CONTENTS GENERATOR Model Number DF402iX Surge (Starting) Wattage 4000W (Gas) 3600W (LPG) Rated (Running) Wattage 3500W (Gas) 3200W (LPG) Rated Voltage 120V AC Rated Amperage 29.2A Phase Single Frequency 60Hz Product Weight 66.1 lbs Product Dimensions 19.8 in. × 13.8 in. × 18.9 in.

  • Page 4: Introduction

    INTRODUCTION Thanks for purchasing the WEN 4000-Watt Dual Fuel Inverter Generator. Refer to the illustration below for the loca- tions of the serial number on the side of the engine or on the serial number label. Record the generator information in the spaces provided below.

  • Page 5: Safety

    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.

  • Page 6: 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 7 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 power cord is broken, damaged, or defective, make 1.

  • Page 8: Before Operating

    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 9 Fuel Cup Seal (1) Fuel Cup Seal (1) 3000 - 6000 ft High Altitude Kit (1) 6000 - 8000 ft High Altitude Kit (1) (Part DF402iX-HA36) (Part DF402iX-HA68) REMOVING THE SHIPPING BRACKETS Fig. 1 Your generator comes with two shipping brackets that pro- tect the generator during delivery.

  • Page 10: Assembly & Adjustments

    ASSEMBLY & ADJUSTMENTS HIGH ALTITUDE OPERATION ABOVE 3000 FEET WARNING! To prevent serious injury from The fuel system on this generator may be affected by op- fire, follow the kit installation procedures in a eration at high altitudes. Proper operation can be ensured well-ventilated area away from ignition sources.

  • Page 11: Know Your Generator

    KNOW YOUR GENERATOR KNOW YOUR GENERATOR Refer to the following diagrams to become familiarized with all the parts and controls of your generator. The com- ponents will be referred to later in the manual for assembly and operation instructions. GENERATOR Muffler Fuel Gauge Fuel Cap...
  • Page 12 KNOW YOUR GENERATOR CONTROL PANEL 1. AC 120V NEMA TT-30R RV Receptacle 7. Parallel Connection Standard RV connector. Connect your generator to another generator with a parallel kit to gain more power. 2. Engine Switch This switch makes the engine run or stop. 8.

  • Page 13: 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 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.
  • Page 14 (or when you can see the oil coming halfway up the oil fill threads). See Fig. 6. TIP: Your WEN generator is compatible with the OIL LEVEL SHUTDOWN WEN 55201 Magnetic Oil Dipstick (not included), To protect the unit from damage, the generator is equipped available for purchase at wenproducts.com.
  • Page 15 GENERATOR PREPARATION STEP 2 - ADD / CHECK FUEL FUEL OPTION A: GASOLINE WARNING! RISK OF EXPLOSION. HIGHLY FLAMMABLE: This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death, if ignited. A nearby open flame can lead to explosion even if not directly in contact with gasoline.
  • Page 16 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 techsupport@wenproducts.com for as- sistance.
  • Page 17 GENERATOR PREPARATION AUTO FUEL SELECTION Your generator is equipped with Auto Fuel Selection Technology. What this means is that the generator will auto- matically select the fuel source (LPG or gasoline) depending on availability. LPG is prioritized; this means that if a propane tank with enough LPG is connected, the generator will automatically use LPG.

  • Page 18: Operation & Maintenance

    STARTING YOUR GENERATOR Before starting the generator, make sure you have read and performed the steps in the “Generator Preparation” section of this manual, pages 14-16. 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 19 STARTING YOUR GENERATOR BEFORE STARTING THE GENERATOR 1. Verify that the generator is outside on a dry, level surface. Allow at least two feet of clearance on all sides of the generator. 2. To maximize safety, check that the generator is properly grounded. Refer to "Step 3 - Ground The Generator" on page 17.
  • Page 20 STARTING YOUR GENERATOR STARTING THE GENERATOR (LPG) Fig. 14 1. Turn the fuel valve (Fig. 14 - 1) to the OFF position. 2. Connect the LPG regulator hose assembly to the inlet on the generator. Turn the LPG tank valve ON. 3.

  • Page 21: Using Your 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 22 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 23 2400W. PARALLEL OPERATION The parallel connection ports (page 12) 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 instruc- tions included with your parallel connection kit for proper installation and operation.
  • Page 24 USING YOUR GENERATOR LIGHT MEANING RESOLUTION GREEN (POWER INDICATOR) (OVERLOAD) Generator output is normal. No action needed. Flashing continuously Generator is exceeding rated output. Reduce load on generator. Flashes 1x, repeating Voltage at alternator is too low. No Check for loose connections. Call every 3 sec electrical output.
  • 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 Your Generator

    SHUTTING OFF YOUR GENERATOR CAUTION! Unplugging running devices can cause damage to the generator. Never stop the engine with electrical devices connected and running. 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.

  • 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 To check the oil level and/or add oil refer to "Step 1 - Add/Check Oil" on 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 29 MAINTENANCE DRAINING THE CARBURETOR Fig. 19 Drain the carburetor after every use and before storing the generator (refer to page 27, Table 4). Draining the carburetor can help prevent build-up and blockages caused by stagnant fuel inside of the carburetor. NOTE: We recommend draining the carburetor after every session in which gasoline was used.
  • Page 30 MAINTENANCE INSPECTING/CLEANING THE SPARK ARRESTOR Fig. 21 Inspect and clean the spark arrestor every 100 hours of operation (refer to page 27, Table 4). The spark arrestor is located outside the muffler, which gets very hot during Spark Arrestor Spark Arrestor operation.
  • Page 31 MAINTENANCE 5. Measure the plug gap with a spark plug gap gauge. The Fig. 22 gap should be 0.7 to 0.8 mm (0.028-0.031 in). Carefully adjust the gap if necessary. See Fig. 22. 0.7 - 0.8mm 6. Screw the spark plug back into the spark plug hole us- ing the spark plug wrench.

  • Page 32: Transportation & Storage

    Do not obstruct any ventilation openings. Follow the procedures below for properly storing your generator. TIP: Your WEN generator is compatible with We highly recommend running your generator once a month for the WEN 56310iC and GNC400 Generator 20 to 30 minutes.

  • Page 33: Troubleshooting Guide

    9. Turn OFF propane tank. Disconnect hose from propane fitting. Contact 9. Regulator is stuck. WEN customer service for assistance. 10. Ghost in the generator. 10. Persuade ghost to leave. Consult Bill Murray if needed.

  • Page 34: Wiring Diagram

    WIRING DIAGRAM...

  • Page 35: Exploded View & Parts List

    Qty. Part No. Description Qty. GN400i-0201 Crankcase Cover Crankcase GN400i-0101 56310i-0307 Bolt, M8x32 Subassembly Oil Dipstick Drain Plug Bolt, M10- DF402iX-0204 GN400i-0102 Subassembly 1.25 Deep Groove Ball Deep Groove Ball GN400i-0204 GN400i-0103 Bearing, 6205 Bearing, 6205 GN400i-0205 Positioning Pin 56310i-0306...
  • Page 36 Description Qty. GN400i-0401 Crankshaft Assembly GN400i-0301 Breather Tube 56200-1202 Bolt, M6x12 ASSEMBLY 5 - CONNECTING ROD, PISTON, PISTON RING SET Cylinder Head Cover DF402iX-0303 Subassembly Cylinder Head Cover GN400i-0304 Gasket Cylinder Head Bolt, 56310i-0106 M8x60 Cylinder Head GN400i-0306 Subassembly DF402iX-0307...
  • Page 37 Recoil Starter Part No. Description Qty. GN400i-0701 assembly GN400i-0601 Camshaft Assembly 56200-1202 Bolt, M6x12 GN400i-0602 Valve Lock Nut DF402iX-0703 Clip GN400i-0603 Valve Adjustment Nut GN400i-0604 Valve Rocker Arm ASSEMBLY 8 - CARBURETOR GN400i-0605 Rocker Shaft Bolt DF402iX-0606 Lifter Stopper Plate GN400i-0607...
  • Page 38 GN400i-1107 Muffler Gasket 11-8 GN400i-1108 Nut, M8 11-9 56380I-0313 Bolt, M6x12 ASSEMBLY 10 - AIR FILTER Part No. Description Qty. 10-1 DF402iX-1001 Air Filter Gasket 10-2 GN400i-1002 Air Filter Assembly 10-3 56200-0506 Flanged Hex Nut, M6 10-4 56310i-1420 Bolt, M6x25...
  • Page 39 EXPLODED VIEW & PARTS LIST ASSEMBLY 12 - FUEL TANK ASSEMBLY 13 - FRAME Part No. Description Qty. Part No. Description Qty. 13-1 DF402iX-1301 Frame Assembly 12-1 GN400i-1201 Fuel Tank 13-2 GN400i-1302 Foot 12-2 GN400i-1202 Fuel Tank Cap 13-3 GN400i-1303...
  • Page 40 GN625iX-1430 Module Regulator 14-6 GN400i-1406 Ignitor 15-4 DF402iX-1504 Hose Clamp 14-7 GN400i-1407 Choke Button and Cable 15-5 DF402iX-1505 LPG Hose 1 14-8 GN400i-1408 Rectifier Bridge 15-6 DF402iX-1506 LPG Hose 2 14-9 56380i-1423 Parallel Port, Negative 15-7 DF402iX-1507 Hose Clip 14-10...

  • Page 41: 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.
  • Page 42 NOTES...
  • Page 43 NOTES...
  • Page 44 THANKS FOR REMEMBERING V. 2022.05.27...

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