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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 

1-800-232-1195

 (M-F 8-5 CST), 

or email 

[email protected]

.

PROBLEM

POSSIBLE CAUSE

SOLUTION

Engine will not 

start.

1. 2-in-1 dial switch is in wrong position. 1. Set switch to CHOKE if engine is cold and RUN if engine is warm.

2. Engine switch is set to OFF (0).

2. Turn engine switch to ON (I) if using recoil start, or START (II) if 

using electric start.

3. Engine has not been primed (LPG 

only).

3. Prime engine.

4. Battery is out of power.

4. Electric start will not work if battery is out of power. Start generator

using the recoil start to charge the battery.

5. Battery is too cold.

5. Electric start may be difficult if the battery is too cold. Store the

generator or battery in a warmer location.

6. Oil is low.

6. Add oil.

7. Engine is out of fuel.

7. Add fuel.

8. Engine is filled with contaminated or 

old fuel.

8. Drain fuel in the tank and carburetor. Replace with fresh fuel.

9. Spark plug is dirty or broken.

9. Clean or replace spark plug.

10. Propane tank is turned OFF.

10. Dang it, Bobby, I told you to turn that thing on!

11. Carburetor is air locked.

11. Turn the 2-in-1 switch to OFF. Remove bolt from bottom of the

carburetor. Take off the carburetor bowl to allow it to reset. Replace 

carburetor bowl and reinstall the bolt.

12. Regulator is stuck.

12. Turn OFF propane tank. Disconnect hose from propane fitting. Contact 

WEN customer service for assistance.

13. Ghost in the generator.

13. Persuade ghost to leave. Consult Bill Murray if needed.

Engine runs, but 

there is no

electrical

output.

1. Reset button has activated due to watt-

age overload.

1. Turn off and unplug all electrical devices. Press reset button. Check 

the total wattage of the devices and reduce the load if it exceeds the 

capacity of the generator for your particular fuel (LPG or gasoline).

2. Breaker has tripped due to wattage 

overload.

2. Turn off and unplug all electrical devices. Wait 3 minutes, and press 

the activated breaker to reset. Check the total wattage of the devices 

and reduce the load if it exceeds the capacity of the generator for your 

particular fuel (LPG or gasoline).

3. Bad connecting cord or wire.

3. Check power cords & extension cords. Do not use if any cord is 

damaged. Replace damaged cords immediately.

4. Bad electrical device connected to the 

generator.

4. Try connecting a different device.

Generator runs, 

but does not

support all

electrical devices

connected.

1. AC or DC receptacles are overloaded; 

circuit breaker has tripped.

1. Turn off and unplug all electrical devices. Wait 3 minutes, then 

press the breaker to reset. Check the amperage of the devices to 

ensure they are within the receptacles’ rated capacities.

2. Short circuit in one of the devices.

2. Disconnect any faulty or short-circuited electrical devices.

3. Air filter is dirty.

3. Clean or replace the air filter element.

Engine is

“hunting”

during operation 

(engine RPM is 

fluctuating).

1. Gasoline is not running through fuel valve.

1. Make sure there is enough fuel. Make sure 2-in-1 switch is turned to RUN.

2. Propane level is getting low.

2. Switch to a new propane tank, or use gasoline.

3. Air filter is dirty.

3. Clean or replace the air filter element.

4. Spark arrestor is dirty.

4. Clean the spark arrestor.

5. There is gunk in the carburetor preventing 

a consistent fuel/air mixture.

5. Use carburetor cleaner spray on the carburetor bowl and jets.

IMPORTANT:

 Repairs and replacements should only be performed by an authorized technician. Parts and acces-

sories that wear down over the course of normal use are not covered by the three-year warranty.

40

Summary of Contents for DF400i

Page 1: ...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 NEED HELP CONTACT US Have product questions Nee...

Page 2: ...arting Your Generator 20 Using Your Generator 23 Shutting Off Your Generator 29 Maintenance 31 Transportation Storage 39 Troubleshooting Guide 40 Wiring Diagram 41 Exploded View Parts List 42 Warranty...

Page 3: ...idth 18 in 456 mm Height 20 1 in 511 mm Product Net Weight 100 0 lbs 45 5 kg GENERATOR ENGINE Engine Type 4 Stroke OHV Single Cylinder with Forced Air Cooling System Engine Displacement 212cc Engine S...

Page 4: ..._____________ Purchased From ________________________________________________ Serial Number _________________________________________________ TO MAXIMIZE THE LIFESPAN OF YOUR GENERATOR We recommend ru...

Page 5: ...ols is to attract your attention to possible dangers The safety symbols and their explanations deserve your careful attention and understanding The safety warnings do not by themselves eliminate any d...

Page 6: ...ctly in contact with gasoline Do not operate near open flame heat or any other ignition source Do not smoke near the generator Always operate on a firm level surface Always turn generator off before r...

Page 7: ...ld only be performed by a qualified technician Do not use receptacles or cords that show signs of damage such as broken or cracked insulation 4 Use a ground fault circuit interrupter GFCI in highly co...

Page 8: ...e generator that be come hot during use 8 Turn off all connected electrical devices before stop ping the generator 9 Always turn generator off before refueling Allow generator to cool for at least 2 m...

Page 9: ...cessories Do not discard the packaging until everything is removed Check the packing list below to make sure you have all of the parts and accessories If any part is missing or broken please contact c...

Page 10: ...all the parts and controls of your Generator The components will be referred to later in the manual for assembly and operation instructions GENERATOR Fuel Cap Carrying Handle Control Panel Battery Acc...

Page 11: ...two WEN inverter generators through a parallel connection kit for a higher output 5 DC 5V USB Outlet 6 DC 12V Cigarette Lighter Style Receptacle 7 LPG Inlet 11 2 3 5 11 8 Grounding Nut Ground generat...

Page 12: ...could lead to engine damage To remove the mounting plates 1 With the help of another person place generator on an elevated platform such as table or workbench Make sure the generator is stable Do not...

Page 13: ...cosity grade of oil that matches the expected operating temperature F C 20 0 20 32 40 60 80 100 40 20 0 20 10 10 30 30 To add oil follow these steps 1 Place the generator on a level surface Make sure...

Page 14: ...tick or when you can see the oil coming halfway up the oil fill threads 4 Wipe clean any oil leaks and firmly tighten the dipstick Reinstall the oil access cover OIL LEVEL SHUTDOWN To protect the unit...

Page 15: ...ne rating The genera tor performs best with ethanol free gasoline DO NOT use gasoline with over 10 ethanol The capacity of the fuel tank is 2 2 US gallons 8 3 L Do not mix oil with gasoline To add gas...

Page 16: ...f 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...

Page 17: ...pacity falls to just 80 of its capacity when new Weakened cells in an aged battery are no longer capable of meet ing the high power requirements needed for the proper operation of your generator and t...

Page 18: ...rator s positive terminal has already been connected Double check that the positive terminal s connection is secure 4 Slide the battery back into the generator Pull downwards on the rub ber belt Fig 1...

Page 19: ...Operating this generator without said kit may increase the engine s emissions and decrease both fuel economy and performance You can order the kit at wenproducts com by searching part DF400i HA There...

Page 20: ...use a generator correctly CO may leak into the home ALWAYS use a battery powered or battery backup CO alarm in the home If you start to feel sick dizzy or weak after the generator has been running mo...

Page 21: ...an damage the starter NOTE The lithium ion battery is shipped partially charged in order to maximize its service life and may not have enough charge to start the engine during the first use of the gen...

Page 22: ...s the generator to stabilize its speed and temperature Fig 19 Fig 20 Fig 21 Option A Electric Start 6 Push engine switch to START II position for 2 3 seconds or until the engine starts Then release th...

Page 23: ...Wattage Calculation Find the wattage information of each device you plan to connect The information should be listed on the device or in its instruction manual or you may refer to page 22 Table 2 The...

Page 24: ...HP 1500 3000 Window Air Conditioner 1200 1800 Saw Miter 1200 1200 Microwave 1000 0 Well Water Pump 1000 1000 Sump Pump 800 1200 Refrigerator Freezer 800 1200 Furnace Blower 800 1300 Computer 800 0 El...

Page 25: ...vices are turned off Start plugging in each electric device from the highest wattage to the lowest Check the power indicator light green to ensure the generator is producing power 3 Do not overload th...

Page 26: ...TRICAL SYSTEM without a qualified electrician and connected to a transfer switch as a separately derived system Such connections must comply with local electrical laws and codes Failure to comply can...

Page 27: ...your generator When you ve overloaded the generator the overload light will stay on and the reset button Fig 24 will activate to cut off the output in 3 to 16 seconds depending on the load Reduce the...

Page 28: ...SSION DOES THE METER RESET COMMENTS 1 1 hr 30 min 1 5 Yes to 0 0 Meter will show 1 5 just before it is shut off but it has not been run for 2 hours at a time yet 2 30 min 0 5 Yes to 0 0 Meter will sho...

Page 29: ...ut off automatically This feature helps to prevent the car buretor from being clogged by stale fuel extending your genera tor s lifespan 6 Turn the engine switch to the OFF 0 position Fig 27 OPTION 1B...

Page 30: ...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 featur...

Page 31: ...ance Schedule Clean change more often under dusty conditions or operating under heavy load IMPORTANT GENERATOR MAINTENANCE TIPS Drain your carburetor after each use and before storage to prevent it fr...

Page 32: ...shut down to protect it from running without oil To check the oil level and add oil 1 Make sure the generator is on a level surface Do not tilt the generator as oil will flow into engine areas and cau...

Page 33: ...3 Using a Phillips head screwdriver unscrew the top two screws and remove the service panel on the opposite side of the recoil starter 4 The carburetor Fig 30 1 can be ac cessed between the engine and...

Page 34: ...r filters can be ordered from wenproducts com by searching part no 56380i 1001B 1 4 Reinstall the air filter element air filter cover and service panel WARNING Running the engine with a dirty damaged...

Page 35: ...ge to loosen the plug 4 Visually inspect the spark plug If it is cracked or chipped or if the electrodes are worn or burned discard it and replace with a new spark plug We recommend replacing with a N...

Page 36: ...o the unlocked position and remove the cover from the side panel 3 Prepare an approved oil storage container and place it be low the oil drainage valve Fig 36 to catch oil as it drains 4 Open the oil...

Page 37: ...g 38 This will open up the fuel valve 5 Open up the carburetor drain screw Fig 37 with a Phillips screwdriver Fuel will start draining from the carburetor and fuel tank through the drain tube NOTE The...

Page 38: ...negative black battery cable disconnected and covered with an insulator such as electrical tape and then connecting the battery This will allow the inside of the generator to warm up and will greatly...

Page 39: ...oper power output PRODUCT DISPOSAL Do not dispose of a used generator or parts with your household waste This product contains electrical or elec tronic components that should be recycled Please take...

Page 40: ...f and unplug all electrical devices Press reset button Check the total wattage of the devices and reduce the load if it exceeds the capacity of the generator for your particular fuel LPG or gasoline 2...

Page 41: ...WIRING DIAGRAM 41...

Page 42: ...10i 0307 Bolt M8x32 6 EXPLODED VIEW PARTS LIST No Part No Description Qty 1 12 56310i 0306 Oil Seal 1 1 13 56380i 0113 Starter Motor 1 1 14 56380i 0114 Bolt M6x28 2 1 15 56380i 0115 Protective Cover 1...

Page 43: ...56380i 0306 Breather Tube 1 3 7 56380i 0307 Cylinder Head Subassembly 1 No Part No Description Qty 3 8 56310i 0109 Bolt M8x34 2 3 9 56380i 0309 Stud Bolt M6x105 2 3 10 56380i 0310 Gasket Cylinder Hea...

Page 44: ...e Tappet 2 6 8 56380i 0608 Valve Lifter Subassembly 2 6 9 56380i 0609 Valve Rocker Arm 2 6 10 56380i 0610 Rocker Shaft 2 6 9 56380i 0609 Valve Rocker Arm 2 6 10 56380i 0610 Rocker Shaft 2 No Part No D...

Page 45: ...Clamp 1 8 12 DF400i 0812 Rubber Jacket 1 No Part No Description Qty 10 1 56310i 1101 Flywheel Nut M14 1 5 1 10 2 56380i 0902 Impeller 1 10 3 56310i 1103 Bolt M6x60 3 10 4 56380i 0904 Rotor 1 10 5 563...

Page 46: ...1105 Muffler Insulation Plate 1 11 6 56380i 1106 Muffler Assembly 1 11 7 56310i 1010 Gasket Muffler 2 11 8 56380i 1108 Nut M8 1 11 9 56310i 1009 Bolt M8x16 5 11 11 56310i 1004 Bolt M8x20 1 11 12 56380...

Page 47: ...olt M6x20 4 12 5 56380i 1205 Flat Washer 4 12 6 56380i 1206 Bushing 4 12 7 56380i 1207 Fuel Tank Damper 4 12 8 56380i 1208 Fuel Tank Cap 1 12 9 56380i 1209 Fuel Strainer 1 12 10 56380i 1210 Fuel Tank...

Page 48: ...56380i 1314 Carbon Tank Mounting Bracket 1 13 15 DF400i 1315 Carbon Tank 1 Fig No Part No Description Qty 13 16 56380i 1316 Carbon Tank Hose Primary 1 13 17 56380i 1317B Air Filter Hose 1 13 18 56380...

Page 49: ...crew ST4 2x16 3 14 17 56380i 1402 Switch Subassembly 1 14 18 56200 0621B Cover Plate 1 No Part No Description Qty 14 19 56200 0624B Adjustment Spring 1 14 20 56200 0623 Steel Ball 1 14 21 56200 0502 B...

Page 50: ...Seat 1 15 7 56380i 1507 Right Handle Connector Seat 1 15 8 56380i 0313 Bolt M6x12 2 No Part No Description Qty 15 9 56380i 1509 Bolt M6x10 4 15 10 56310i 1201 Bolt M6x16 4 15 11 56310i 1807 Nylon Nut...

Page 51: ...0515 Fuel Tank Rubber Sleeve 4 16 9 56200 1202 Bolt M6x12 8 16 10 56380i 1610 Recoil Starter Guide Subassembly 1 No Part No Description Qty 16 11 56200 0302 Screw M5x12 2 16 12 56200 0420 Recoil Star...

Page 52: ...er Plug 1 17 8 56380i 1619 Nut M5 4 17 9 56380i 1709 Cushion 1 17 10 56380I 1710 Left Support 1 17 11 56380I 1711 Right Support 1 17 12 56310i 1409 Left Engine Frame Damper 2 17 13 56310i 1411 Right E...

Page 53: ...nd proof of purchase Damaged or defective parts and products may need to be sent to WEN before the replacements can be shipped out Upon the confirmation of a WEN representative your product may qualif...

Page 54: ...54 NOTES...

Page 55: ...55 NOTES...

Page 56: ...THANKS FOR REMEMBERING V 2021 03 03...

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