Wen DF500iX Instruction Manual
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Wen DF500iX Instruction Manual

5000-watt dual fuel inverter generator
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MODEL DF500iX
5000-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 DF500iX

  • 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

    Transportation & Storage ................33 Troubleshooting Guide ..................34 Wire Diagram ....................35 Exploded View & Parts List ................36 Warranty Statement ..................43 WENPRODUCTS.COM To purchase accessories for your tool, visit Weatherproof Generator Cover (Model No. 56310iC) High-Altitude Kit (Part No. DF500iX-HA39) WEN Parallel Connection Kit...

  • Page 3: Welcome

    SPECIFICATIONS GENERATOR Model Number DF500iX Gasoline: 5000W Surge (Starting) Wattage LPG: 5000W Gasoline: 4220W Rated (Running) Wattage LPG: 3800W Rated Voltage AC: 120V / 240V; DC: 12V / 5V Rated Amperage AC Gas: 35.1A LPG: 31.6A; DC 8A (12V), 2.1A / 1A (USB)

  • Page 4: Introduction

    INTRODUCTION Thanks for purchasing the WEN 5000-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 PARALLEL CONNECT 1. Voltage Selector 8. Engine Start Button Sets the generator’s output voltage to 120V or 240V. When Press to start the generator. the switch is set to 120V, the 120V and parallel outlets are 9.

  • 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 PREPARATION TO CHECK OIL LEVEL (before every subsequent start): Fig. 3 1. Place the generator on a level surface. Make sure the en- gine is OFF before adding or checking oil. 2. Remove and wipe the dipstick with a clean rag. 3.
  • 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 This kit should be installed by a qualified mechanic. You can order the kit at wenproducts.com by searching part number WARNING! Battery contains sulfuric acid. DF500iX-HA39. Refer to the instructions included with your Battery acid is poisonous. Tilting the generator altitude kit for more information about installation.
  • Page 17 4 DO NOT DISASSEMBLE. Incorrect reassembly may pose a serious risk of electric shock, fire or exposure to toxic battery chemicals. If battery or charger are damaged, call WEN customer service at 1-847-429-9263 for assistance. 5. DO NOT SHORT CIRCUIT. Batteries will short circuit if a metal object makes a connection between the positive and negative contacts on the battery.

  • 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 (4220W) 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. 21 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 If the element is damaged, replace it with a new one (part. no. DF500iX-138, available at wenproducts.com). 4. Reinstall the air filter element and the air filter cover. Replace the side cover and secure it with the screws.
  • Page 32 Replace the ter disconnecting the quick-connectors, cover the ends spark arrestor if it is damaged (part no. DF500iX-150, with an insulator such as electrical tape. You may can available for purchase at wenproducts.com).

  • 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 Eco-mode switch is set to ON.

  • Page 35: Wire Diagram

    WIRING DIAGRAM Gray Yellow/Green Circuit Circuit Breaker, 20A Breaker, 30A Stepper Motor Yellow Blue Orange Gray Gray Gray White White White White Pink Gray Gray Parallel Outlets White White Black Black Yellow/Green Yellow/Green Main Yellow White Winding Blue Black Yellow/Green Inverter Unit Main Yellow...

  • Page 36: Exploded View & Parts List

    EXPLODED VIEW & PARTS LIST GENERATOR 35 29 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. DF500iX-001 Screw, M5x10 DF500iX-030 Spacer Control Panel 56477i-026 Clip DF500iX-002 Assembly DF500iX-032 Fuel Tank DF500iX-003 Step Bolt, M6x15 DF500iX-033 Inverter DF500iX-004 Front Cover DF500iX-034 Fuel Hose...
  • Page 38 EXPLODED VIEW & PARTS LIST GENERATOR PART NO. DESCRIPTION QTY. PART NO. DESCRIPTION QTY. DF500iX-061 Bottom Bracket 56477i-018 Bolt, M8x12 DF480iX-080 Bolt, M6x16 56477i-046B Foot DF500iX-063 Charger DF500iX-073 Bolt, M6x12 DF500iX-064 Support Frame DF480iX-078 Screw, M2.5x20 DF500iX-065 Switch Box Base...
  • Page 39 EXPLODED VIEW & PARTS LIST ENGINE...
  • Page 40 Piston Pin Circlip 56477i-146 Valve Adjustment Cap DF500iX-144 Piston Pin 56477i-143 Valve Spring Seat Connecting Rod DF500iX-145 Assembly 56477i-147 Valve Locker DF500iX-146 Muffler Exhaust Manifold DF500iX-113 Intake Valve Seal 56202i-051 Bolt, M6x12 56360iX-015 Bolt, M8x60 DF500iX-148 Muffler Gasket DF500iX-115 Cylinder Head DF500iX-149...
  • Page 41 Fuel Hose Bracket 56360iX-093 Bolt, M6x12 DF500iX-192 Clip Housing DF500iX-170 Washer, 12x2x20mm Recoil Starter Shroud, DF500iX-193 Upper DF500iX-171 Oil Drain Tube Assembly Self-tapping Screw, DF500iX-172 Trigger 56360iX-087 ST4.2x25 56360iX-055 Oil Seal, 25 x 41.25 x 6 56480iX-196 Bolt, M6x30 DF500iX-174...
  • Page 42 Voltage Selector 12 56203i-005.14R Parallel Socket, Red 56500-207 Switch 13 56203i-005.14B Parallel Socket, Black NEMA L14-30R NEMA TT-30R 120V DG4500iX-207 DF500iX-302 120V/240V 30A AC 30A AC Receptacle Receptacle 12V DC Automotive 56477i-218 DF500iX-303 Nut, M6 Outlet 56203i-005.11 Lock Washer, 6mm 56203i-005.4...

  • Page 43: 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 44 THANKS FOR REMEMBERING V. 2024.08.26...

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