Wen DF480iX Instruction Manual
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Wen DF480iX Instruction Manual

4800-watt dual fuel inverter generator
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MODEL DF480iX
4800-WATT DUAL FUEL
INVERTER 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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Summary of Contents for Wen DF480iX

  • 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

    Exploded View & Parts List ................36 Warranty Statement ..................42 WENPRODUCTS.COM To purchase accessories for your tool, visit Magnetic Oil Dipstick (Model No. 55201) Weatherproof Generator Cover (Model No. 56310iC) High-Altitude Kit (Part No. DF480iX-HA39) WEN Parallel Connection Kit...

  • Page 3: Welcome

    SPECIFICATIONS GENERATOR Model Number DF480iX Gasoline: 4800W Surge (Starting) Wattage LPG: 4320W Gasoline: 4000W Rated (Running) Wattage LPG: 3600W Rated Voltage AC: 120V; DC: 12V / 5V Rated Amperage AC 33.3A; DC 8.3A (12V), 2.1A / 1A (USB) Phase Single...

  • Page 4: Introduction

    INTRODUCTION Thanks for purchasing the WEN 4800-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 1-847-429-9263, 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 1-847-429-9263, 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 KNOW YOUR INVERTER GENERATOR CONTROL PANEL 1. Parallel Connection 8. CO WATCHDOG Carbon Monoxide Monitor Connect to share wattage between inverter generators. Measures the accumulation of poisonous CO gas while the generator is running. If the level of CO gas gets too 2.

  • Page 12: Preparation

    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 1-847-429-9263 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 13 See Fig. 3. 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 14 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 15 This MUST be corrected before using generator. Contact WEN customer service at 1-847-429-9263, M-F 8-5 CST, or email techsupport@wenproducts.com for assistance. NOTE: If you would like to purchase other accessories for your dual-fuel generator, consult your local dealer of pro- pane and propane accessories, I tell you what.
  • Page 16 (American Wire Gauge) stranded copper wire. order the kit at wenproducts.com by searching part number Grounding codes can vary by location. Contact a DF480iX-HA39. Refer to the instructions included with your local electrician to check the area codes. altitude kit for more information about installation.
  • Page 17 PREPARATION STEP 4 - CONNECT THE BATTERY WARNING! Use only genuine WEN batteries with your generator (part no. DF480iX-067). Use of other bat- teries may induce premature product failure and could pose a safety risk. ABOUT THE BATTERY 7. DO NOT SHORT CIRCUIT. Batteries will short circuit if a metal object makes a connection between the posi- 1.

  • Page 18: Operation & Maintenance

    STARTING YOUR GENERATOR Before starting the generator, make sure you have read and performed the steps in the “Preparation” section of this manual, pages 12 - 17. 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 19 STARTING YOUR GENERATOR BEFORE STARTING THE GENERATOR Fig. 9 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. See page 16, “GROUND THE GENERATOR.”...
  • Page 20 STARTING YOUR GENERATOR STARTING THE GENERATOR (LPG) 1. Place the generator outside on a dry, level surface. Allow at least two feet of clearance on all sides of the generator. 2. Check there is sufficient level of oil in the crankcase. Add oil if necessary (refer to “ADD / CHECK OIL” on page 12).
  • Page 21 PARALLEL OPERATION Fig. 13 The parallel connection feature (Fig. 14 - 1) allows you to connect two WEN generators to increase the total available electrical power. The “Parallel Connection Kit” can be purchased from wenproducts. com. Follow the instructions included with your WEN parallel connection kit for proper installation and operation.

  • 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 (4000W) 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 • 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 27: Stopping Your Generator

    STOPPING YOUR GENERATOR SHUTTING OFF THE GENERATOR 1. Turn off all electrical devices and then unplug the devices from the generator. CAUTION! Unplugging running devices can cause damage to the generator. Never stop the engine with elec- trical devices connected and running. 2.

  • Page 28: 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 29 MAINTENANCE WARNING! Make sure generator is shut off before performing any inspection or maintenance procedures. CHECKING / ADDING OIL Fig. 18 Check the oil level of the generator according to the Recommended Main- tenance Schedule in Table 4. The oil level should be checked before each use or every 8 hours of operation.
  • Page 30 MAINTENANCE SPARK PLUG MAINTENANCE Fig. 20 The spark plug is important for proper engine operation. A good spark plug should be intact, free of deposits, and properly gapped. Refer to Recommended Maintenance Schedule in Table 4 for in- structions on maintaining. To inspect the spark plug: 1.
  • Page 31 MAINTENANCE AIR FILTER MAINTENANCE Fig. 22 Routine maintenance of the air filter helps maintain proper airflow to the carburetor. Occasionally check that the air filter is free of ex- cessive dirt. The air filter should be checked every 50 hours of use. Refer to Recommended Maintenance Schedule in Table 4.
  • Page 32 MAINTENANCE SPARK ARRESTOR MAINTENANCE Fig. 25 It is recommended to inspect and clean the spark arrestor (Fig. 25 - 1) every 100 hours of operation. 1. The spark arrestor is located outside the muffler, which gets very hot dur- ing operation. Allow the engine to cool completely before servicing the spark arrestor.

  • Page 33: Transportation & Storage

    TRANSPORTATION & STORAGE TRANSPORTING THE GENERATOR To prevent fuel spillage when transporting, be sure to perform the following: 1. To extend or collapse the handle, press the handle release button, adjust the handle as desired, then release the button. The handle will automatically lock in the fully-extended and the locked positions. 2.

  • Page 34: Troubleshooting Guide

    TROUBLESHOOTING GUIDE WARNING! Stop using the generator immediately if any of the following problems occur or risk serious personal injury. If you have any questions, please contact customer service at 1-847-429-9263 (M-F 8-5 CST), or email techsupport@wenproducts.com. PROBLEM POSSIBLE CAUSE SOLUTION Engine switch is set to OFF.

  • Page 35: Wire Diagram

    WIRING DIAGRAM 20A,C.B 20A,C.B 5-20R 5-20R TT-30R Parallel Stepper Motor Terminal Yellow Blue Orange Black Black Pink Yellow/Green Yellow/Green Yellow/Green Yellow/Green Orange Inverter Unit Blue/White White Gray Yellow Main Violet Winding Blue Over Violet White Inverter Black/Red Unit Winding White ECO switch Black/Red Yellow/Green...

  • Page 36: Exploded View & Parts List

    EXPLODED VIEW & PARTS LIST GENERATOR NOTE: Not all parts may be available for purchase. Parts and accessories that wear down over the course of normal use are not covered under the warranty.
  • Page 37 EXPLODED VIEW & PARTS LIST GENERATOR PART NO. DESCRIPTION QTY. PART NO. DESCRIPTION QTY. DF480iX-001 Handle Assembly 56477i-035 Bolt, M6x22 DF480iX-002 Fuel Tank Cap 56202i-051 Bolt, M6x12 DF480iX-003 Fuel Tank Nut 56360iX-108 Wiring Sheath, 25mm DF480iX-004 Top Cover 56477i-038 Fuel Pump...
  • Page 38 QTY. PART NO. DESCRIPTION QTY. Remote Start & Solenoid Valve 56480iX-068 DF360iX-034 Electric Start Module Controller 56360iX-125 CO Alarm DF480iX-082 LPG Quick-connector CO Sensor Shield DF480iX-083 Nut, M12 56480iX-070 Housing DF480iX-084 LPG Hose 56480iX-071 Grounding Wire DF480iX-085 LPG Hose Jacket...
  • Page 39 Bolt, M5x12 56477i-116 Intake Manifold Gasket 56477i-117 Intake Manifold 56477i-105 Breather Hose 56360iX-029 Clamp 56477i-106 Air Filter Gasket 56477i-119 Fuel Hose DF480iX-107 Carburetor 56477i-120 Bolt, M8x30 56477i-108 Carburetor Gasket 56477i-121 Bushing, 12x16.8-8.5x6.5 56480iX-109 Screw, M4x8 56477i-122 Crankcase Cover 56480iX-110 Nut, M4...
  • Page 40 Bolt, M6x12 56477i-138 Ignition Coil 56360iX-055 Oil Seal, 25 x 41.25 x 6 56477i-139 Engine Cowling, Right 56480iX-179 Stator 56477i-140 Valve Cover Plate Gasket DF480iX-180 Bolt, M6x50 56477i-141 Rocker Arm Assembly 56480iX-181 Rotor 56477i-142 Rocker Arm Base 56477i-182 Cooling Fan 56477i-143...
  • Page 41 DESCRIPTION QTY. 56203i-005.4 Eco-Mode Switch NEMA 5-20R 120V DG4500iX-208 20A AC Duplex 56203i-005.14R Parallel Socket, Red Receptacle 56203i-005.14B Parallel Socket, Black DF480iX-214 Multi-meter 56360iX-205 Nut, M6 56477i-215 Reset Button 56203i-005.11 Lock Washer, 6mm USB Receptacle 56203i-005.12 Flat Washer, 6mm 56477i-216 (2.1A / 1A)

  • Page 42: 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 43 NOTES...
  • Page 44 THANKS FOR REMEMBERING V. 2023.12.14...

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