Wen DG4500iX Instruction Manual
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Wen DG4500iX Instruction Manual

4500w dual fuel inverter generator
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MODEL DG4500iX
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

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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

    Troubleshooting Guide ................... 40 Wiring Diagram ....................41 Exploded View & Parts List ................42 Warranty Statement ..................49 WENPRODUCTS.COM To purchase accessories for your tool, visit WEN Parallel Connection Kit Weatherproof Generator Cover, Medium (Model 56406) High-Altitude Kit (Part DG4500iX-HA36 and DG4500iX-HA69)

  • Page 3: Welcome

    SPECIFICATIONS GENERATOR Rated Wattage Gasoline: 3650 Watts; LPG: 3285 Watts Surge Wattage Gasoline: 4500 Watts; LPG: 4500 Watts AC: 120V Rated Voltage DC: 5V (USB) AC: 30.4A Total (Total), 30A (TT-30R), 20A (5-20R), 30A (L5-30R) Rated Amperage DC: 2.1A / 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 specifications label. 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 3. AC Circuit Breaker (20A) If the overload light is ON, press this button to reset your generator. 4. Parallel Connection Port Connect two WEN inverter generators through a parallel 12. Engine Switch connection kit for more output. Start the engine using this switch.

  • Page 12: Assembly & Adjustments

    ASSEMBLY & ADJUSTMENTS WARNING! Do not turn on the generator until it is fully assembled according to the instructions. Read through and become familiarized with the following procedures of handling and adjusting your tool. Failure to follow the safety instructions may result in serious personal injury. •...
  • 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 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.
  • Page 14 GENERATOR PREPARATION STEP 1 - ADD / CHECK OIL (CONTINUED) For subsequent operation, the oil level should be checked before each use, or after every 8 hours of operation. The generator is equipped with a low-oil sensor and will not start without a sufficient amount of oil. To check oil level (before every subsequent start): 1.
  • 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 Fig. 8 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 If battery or charger are dam- • If battery acid gets in your eyes, flush with water aged, call WEN customer service at 1-800-232-1195 for for at least 15 minutes and call a doctor immediately. assistance.
  • Page 18 You can order the kit at wenproducts.com by searching part DG4500iX-HA. There are two kits - one for altitudes between 3000 and 6000 feet (part no. DG4500iX-HA36), and the other for altitudes from 6000 to 9800 feet (part no.

  • Page 19: 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 20 STARTING YOUR GENERATOR BEFORE STARTING THE GENERATOR 1. Verify that 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 21 STARTING YOUR GENERATOR STARTING THE GENERATOR (LPG) Fig. 15 1. Turn the ECO-MODE (Fig. 15) switch to "ON". 2. Turn the choke lever (Fig. 16 - 1) to the "CLOSED" position. 3. Turn the FUEL SELECTOR knob (Fig. 17 - 1) to "LPG". 4.

  • Page 22: 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 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 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 (3650W / 3285W) of the generator, DO NOT connect all these devices.
  • Page 25 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 26 PARALLEL OPERATION Fig. 19 The parallel connection ports (Fig. 19) 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 27 USING YOUR GENERATOR CIRCUIT BREAKERS Fig. 21 In addition to the reset button that protects the generator’s main circuit, the circuit breaker (Fig. 21) protects the NEMA 5-20 out- lets. The 20-amp AC circuit breaker will activate when the NEMA 5-20 outlets exceed 20A.
  • Page 28 • 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 29: Shutting Off Your Generator

    SHUTTING OFF YOUR 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 YOUR 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 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 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 GAS 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 Damaged elements should be replaced with a new one. Replacement air filters can be purchased from wen- products.com by searching part number 56500-134.
  • Page 35 MAINTENANCE SPARK PLUG MAINTENANCE Refer to Recommended Maintenance Schedule in Table 4 for maintaining the spark plug. The spark plug is impor- tant 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.
  • Page 36 MAINTENANCE DRAINING / CHANGING OIL Change the oil according to the Recommended Maintenance Schedule in Table 4. 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.
  • 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. 33 1. Locate the carburetor (Fig. 33 - 1). It can be accessed on the back of the generator, right beside the air filter.
  • Page 38 (Fig. 35). 2. Replace with an identical new battery (part no. DG4500iX-074). 3. Connect the new battery by connecting the two ends of the quick connector together. 4. Replace the battery bracket and bolt.

  • 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. Turn the FUEL SELECTOR knob to the "ENGINE 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 DG4500iX-038 Fuel Line (4x8x310) Assembly DG4500iX-039 Fuel Tank Outlet CO Sensor Engine DG4500iX-006 Control Module DG4500iX-040 Fuel Tank Assembly 56500-017 Bolt, M6x25 N.P. DG4500iX-040.1 Fuel Gauge DG4500iX-008 Inverter 56500-016 Washer, Ø6.5x2xØ25 DG4500iX-009 Bolt, M6x30 DG4500iX-042 Breather Hose DG4500iX-010 Battery Charger...
  • Page 44 Battery Wiring DG4500iX-073 Harness DG4500iX-086 Spark Arrester DG4500iX-074 Battery DG4500iX-087 Bolt, M5x12 DG4500iX-075 Rubber Pad High-Altitude Kit, N.P. DG4500iX-HA36 3000 - 6000 ft DG4500iX-076 Battery Bracket High-Altitude Kit, Support Base N.P. DG4500iX-HA69 DF430X-057 6000 - 9800 ft Assembly N.P. DG4500iX-418...
  • Page 45 EXPLODED VIEW & PARTS LIST ENGINE...
  • Page 46 EXPLODED VIEW & PARTS LIST ENGINE PART NO. DESCRIPTION QTY. PART NO. DESCRIPTION QTY. GN9500-101 Bolt, M6x16 DG4500iX-132 Screw, M4x12 DG4500iX-133 Stepper Motor Base DG4500iX-102 Cylinder Head Cover DG4500iX-134 Guide Clamp DG4500iX-103 Breather Hose Cylinder Head Cover DG4500iX-135 Spring DF430X-076...
  • Page 47 EXPLODED VIEW & PARTS LIST ENGINE PART NO. DESCRIPTION QTY. PART NO. DESCRIPTION QTY. DG4500iX-165 Camshaft Assembly DG4500iX-183 Bolt, M6x50 DG4500iX-166 Crankcase Gasket DG4500iX-184 Rotor Assembly DG4500iX-167 Crankcase Cover DG4500iX-185 Cooling Fan DF430X-106 Bolt, M8x32 DG4500iX-186 Starter Cup DG4500iX-169 Dipstick 56500-188 Nut, M14-1.5...
  • Page 48 EXPLODED VIEW & PARTS LIST PANEL PART NO. DESCRIPTION QTY. PART NO. DESCRIPTION QTY. DG4500iX-201 Data Meter 56203i-005.5 Reset Button 56203i-005.4 Eco-mode Switch 56203i-005.14R Parallel Outlet (Red) DF623X-301 Engine Start Switch 56203i-005.14B Parallel Outlet (Black) DG4500iX-204 CO Sensor LED DG4500iX-213...

  • Page 49: 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 50 NOTES...
  • Page 51 NOTES...
  • Page 52 THANKS FOR REMEMBERING V. 2022.09.01...

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