Wen DF451i Instruction Manual
  1. Manuals
  2. Brands
  3. Wen Manuals
  4. Portable Generator
  5. DF451i
  6. Instruction manual

Wen DF451i Instruction Manual

4500w dual fuel inverter generator
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
MODEL DF451i
4500W 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

Advertisement

Table of Contents
loading

Related Manuals for Wen DF451i

Summary of Contents for Wen DF451i

  • 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

    Wiring Diagram ....................41 Exploded View & Parts List ................42 Warranty Statement ..................53 WENPRODUCTS.COM To purchase accessories for your tool, visit Magnetic Oil Dipstick (Model 55201) WEN Parallel Connection Kit Weatherproof Generator Cover (Model 56310iC) High-Altitude Kit (Part DF400i-HA36 & DF400i-HA68)

  • Page 3: Welcome

    SPECIFICATIONS GENERATOR Rated Wattage Gasoline: 3500 Watts; LPG: 3150 Watts Surge Wattage Gasoline: 4500 Watts; LPG: 4050 Watts AC: 120V Rated Voltage DC: 12V (Cigarette Lighter), 5V (USB) AC: 26.6A (Total), 26.6A (TT-30R), 20A (5-20R) Rated Amperage DC: 10A (Total), 8A (Cigarette Lighter), 1A/2.1A (USB) Phase Single Frequency...

  • Page 4: Introduction

    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 side of the engine. 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;...

  • 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 pow- er cord is broken, damaged, or defective, make sure 1.
  • 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. TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR: We recommend running your generator at least once a month for 20 to 30 minutes.

  • Page 9: Before Operating

    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 10: Know Your Inverter Generator

    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.
  • Page 11 If the overload light is ON, press this button to reset. 12. AC 120V NEMA 5-20R Receptacles 4. Parallel Connection Port Connect two WEN inverter generators through a parallel 13. Engine Switch connection kit for a higher output. Start and shut down the engine (see p. 21).

  • Page 12: Generator Preparation

    GENERATOR PREPARATION REMOVING THE MOUNTING PLATES Your generator is shipped with four mounting plates that secure the engine to the generator housing in order to prevent machine damage during shipping. Make sure to remove the four mounting plates before operating your generator.
  • Page 13 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 14 The oil level of the engine should be checked before each Upper Limit start to ensure that the engine crankcase contains suf- ficient lubricant. TIP: Your WEN generator is compatible with the WEN 55201 Magnetic Oil Dipstick (not included), available Lower Limit for purchase at wenproducts.com. The dipstick’s in- dustrial-strength magnetic tip will collect metal shav- ings from your generator’s oil compartment to help...
  • 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 "Switching Fuels" for more information. STEP 3 - CONNECT THE BATTERY WARNING! Use only genuine WEN batteries with your generator (part no. 56380i-1304). Use of other bat- teries may induce premature product failure and could pose a safety risk. ABOUT THE BATTERY 1.
  • Page 18 GENERATOR PREPARATION STEP 3 - CONNECT THE BATTERY (CONTINUED) WARNING! Use only genuine WEN batteries with your generator (part no. 56380i-1304). Use of other bat- teries may induce premature product failure and could pose a safety risk. To connect the battery: Fig.
  • Page 19 GENERATOR PREPARATION STEP 4 - GROUND THE GENERATOR Fig. 15 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. 15 - 1) on the front control panel against a grounding wire.

  • Page 20: 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. 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 YOUR GENERATOR BEFORE STARTING THE GENERATOR 1. Verify that the 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.
  • Page 22 STARTING YOUR GENERATOR STARTING THE GENERATOR (LPG) Fig. 19 1. Turn the ECO-MODE (Fig. 19) switch to “OFF” during starting. 2. Turn the 3-in-1 dial switch (Fig. 20) to the "CHOKE" position. 3. Push the engine switch (Fig. 19) to the ON (I) position. 4.

  • Page 23: 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 24 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 25 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 (3200 / 2900W) of the generator, DO NOT con- nect all these devices.
  • Page 26 USING YOUR GENERATOR 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. Device Requirements Max.
  • Page 27 PARALLEL OPERATION Fig. 23 The parallel connection ports (Fig. 23) 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.
  • Page 28 USING YOUR GENERATOR CIRCUIT BREAKERS Fig. 25 In addition to the reset button that protects the generator’s main circuit, the circuit breakers (Fig. 25) protect the individual AC and DC circuits. The 20-amp AC circuit breaker will activate when the NEMA 5-20 outlets exceed 20A.

  • Page 29: Shutting Off Your Generator

    SHUTTING OFF THE 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.
  • Page 30 SHUTTING OFF THE 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.

  • Page 31: Maintenance

    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.
  • Page 32 5. Reinstall dipstick and wipe clean any spilled oil with a rag. Reinstall the oil access cover. 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...
  • Page 33 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 AUTO 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;...
  • Page 34 MAINTENANCE AIR FILTER MAINTENANCE Check every 50 hours of operation (refer to Table 5 - 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: Fig.
  • Page 35 MAINTENANCE SPARK PLUG MAINTENANCE Refer to Recommended Maintenance Schedule in Table 5 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 36 MAINTENANCE DRAINING / CHANGING OIL Change the oil according to the Recommended Maintenance Schedule in Table 5. 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.
  • Page 37 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: Fig. 37 1. Using a Phillips-head screwdriver, remove the service panel on the opposite side of the recoil starter by unscrewing the top two screws.
  • Page 38 MAINTENANCE BATTERY MAINTENANCE/STORAGE The lithium-ion 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 us¬ing the electric start button during your next time of need.

  • Page 39: Transportation & Storage

    TRANSPORTATION & STORAGE TRANSPORTING THE GENERATOR To prevent fuel spillage when transporting, be sure to perform the following: 1. Tighten the fuel cap. 2. Flip the engine switch to the OFF position. 3. Drain the fuel tank if possible. Refer to section, “Draining the Fuel Tank.” 4.

  • Page 40: Troubleshooting Guide

    12. Turn OFF propane tank. Disconnect hose from propane fitting. Contact 12. Regulator is stuck. WEN customer service for assistance. 13. Ghost in the generator. 13. Persuade ghost to leave. Consult Bill Murray if needed.

  • Page 41: Wiring Diagram

    WIRING DIAGRAM...

  • Page 42: Exploded View & Parts List

    EXPLODED VIEW & PARTS LIST NOTE: Replacement parts can be purchased from wenproducts.com, or by calling our customer service at 1-(800) 232-1195, M-F 8-5 CST. Parts and accessories that wear down over the course of normal use are not covered by the three-year warranty.
  • Page 43 EXPLODED VIEW & PARTS LIST FIG. 3. CYLINDER HEAD ASSEMBLY Part No. Description Qty. Part No. Description Qty. 56310i-1701 Bolt, M6x20 56310i-0109 Bolt, M8x34 Cylinder Head Cover 56380i-0309 Stud Bolt, M6x105 56380i-0302 Subassembly Gasket, Cylinder Gasket, Cylinder 3-10 56380i-0310 56380i-0303 Head Head Cover 3-11...
  • Page 44 EXPLODED VIEW & PARTS LIST FIG. 5. PISTON RING SET FIG. 6. VALVE TRAIN & & CONNECTING ROD CAMSHAFT SUBASSEMBLY Part No. Description Qty. Piston Ring 56310i-0501 Assembly Part No. Description Qty. 56310i-0505 Piston Pin Clip Camshaft 56380i-0601B 56380i-0503 Piston Assembly 56310i-0504 Piston Pin...
  • Page 45 EXPLODED VIEW & PARTS LIST FIG. 8. CARBURETOR ASSEMBLY FIG. 9. FLYWHEEL, IMPELLER, STARTER PULLEY, IGNITION COIL Part No. Description Qty. Part No. Description Qty. Gasket, Carburetor Flywheel Nut, M14- 56380i-0801 10-1 56310i-1101 Insulator 10-2 56380i-0902 Impeller Carburetor Insulator 56380i-0802 Plate 10-3 56310i-1103...
  • Page 46 EXPLODED VIEW & PARTS LIST FIG. 11. MUFFLER ASSEMBLY Part No. Description Qty. 11-1 DF400i-1101 Shroud 11-2 56380i-1102B Muffler Cover Support 11-3 56380i-1103 Impeller 11-5 56380i-1105 Muffler Insulation Plate 11-6 56380i-1106 Muffler Assembly 11-7 56310i-1010 Gasket, Muffler 11-8 56380i-1108 Nut, M8 11-9 56310i-1009 Bolt, M8x16...
  • Page 47 EXPLODED VIEW & PARTS LIST Part No. Description Qty. FIG. 12. FUEL TANK ASSEMBLY 12-1 56380i-1201 Fuel Tank Assembly 12-2 56380i-1202 Fuel Gauge 12-3 56380i-1203 Fuel Tank Outlet 12-4 56310i-1701 Bolt, M6x20 12-5 56380i-1205 Flat Washer 12-6 56380i-1206 Bushing 12-7 56380i-1207 Fuel Tank Damper 12-8...
  • Page 48 EXPLODED VIEW & PARTS LIST FIG. 13. FRAME Part No. Description Qty. Fig. No. Part No. Description Qty. Engine Frame As- Carbon Tank Hose, 13-1 56380i-1301B 13-16 56380i-1316 sembly Primary 13-2 56380i-1302 Battery Case 13-17 56380i-1317B Air Filter Hose Carbon Tank Hose, 13-3 56200-1202 Bolt, M6x12...
  • Page 49 EXPLODED VIEW & PARTS LIST FIG. 14. CONTROL PANEL Part No. Description Qty. Part No. Description Qty. 14-1 56380i-1419 Multi-meter 14-19 56200-0624B Adjustment Spring 14-2 56380i-1432 Rectifier Bridge 14-20 56200-0623 Steel Ball Eco-Mode Switch 14-21 56200-0502 Bolt, M6x14 14-3 56380i-1422 Subassembly 14-22 56200-0628...
  • Page 50 EXPLODED VIEW & PARTS LIST FIG. 15. WHEEL ASSEMBLY Part No. Description Qty. Part No. Description Qty. 15-1 56380i-1501 Handle Tube 15-9 56380i-1509 Bolt, M6x10 15-10 56310i-1201 Bolt, M6x16 15-2 56380i-1502 Left Rotation Arm 15-11 56310i-1807 Nylon Nut, M6 15-3 56380i-1503 Right Rotation Arm 15-12...
  • Page 51 EXPLODED VIEW & PARTS LIST FIG. 16. SHELL, OUTER COVERS Part No. Description Qty. Part No. Description Qty. 16-1 56380i-1601 Left Cover 16-11 56200-0302 Screw, M5x12 16-2 56200-0406 Bolt, M5x12 16-12 56200-0420 Recoil Starter Handle 16-3 56380i-1603 Left Shell Right Maintenance 16-13 56380i-1613 Door...
  • Page 52 EXPLODED VIEW & PARTS LIST Part No. Description Qty. FIG. 17. BASE PLATE 17-1 56380i-1701 Baseplate Engine Frame Damper 17-2 56380i-1702 Seat 17-3 56310i-1201 Bolt, M6x16 17-4 56200-0408 Nut, M6 17-5 56380i-1705 Reinforcement Plate 17-6 56200-1202 Bolt, M6x12 17-7 56310i-1407 Cover Plug 17-8 56380i-1619...

  • Page 53: Warranty Statement

    (3) 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 profes- sional or commercial use.
  • Page 54 NOTES...
  • Page 55 NOTES...
  • Page 56 THANKS FOR REMEMBERING V. 2022.07.14...

Table of Contents