DUROMAX XP4400E, XP4400 Owner's Manual

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Gasoline

XP4400
XP4400E

GENERATION

Owner's

D

D

IVISI~

POWER

Powered

Manual

SYSTEMS

Generator

[e-mail]
or call 1-800-629-3325 (option 3) Monday -Thursday 6am to 7pm, Friday - Saturday 6am to 3pm. PST

[e-mail]
or call 1-800-629-3325 (option 3) Monday -Thursday 6am to 7pm, Friday - Saturday 6am to 3pm. PST

This manual provides information regarding the operation and maintenance
We have made every effort to ensure the accuracy of the information
We reserve the right to change this product at any time without prior notice.

of

in

this manual.

these products.

FEATURES

• Durable 6.5 Hp,

Air

Cooled Overhead Valve Engine.

• Heavy Duty Steel Frame with Four PointFully Isolated Motor
Mounts for Smooth

and

Quiet Operation.

• Wheel and Handle Kit for Easy Transporting.

• Full PowerPanel with Engine ShutoffSwitch, Volt Meter,
Circuit Breaker

and

Power Outlets.

• (2) Fully Protected 120VOutlets & (1) 120VI240V Twist-Lock

Outlet.

• 8 HourRun Time.

•

All

Steel 4.0 Gal. Fuel Tank with EZ-Read Gauge.

•

Low

Oil Shut-OffProtects Engine.

• Super Quiet Muffler Reduces Engine Noise.

• Meets

EPA

and

CARB Emission Standards.

Notice Regarding Emissions

Engines that are certified

to

comply with California and U.S.

EPA

emission regulations for

SORE (Small Off Road Equipment), are certified to operate

on

regular unleaded gasoline,

and may include the following emission control systems: (EM) Engine Modifications and

(TWC) Three-Way Catalyst (if so equipped).

2

TABLE OF CONTENTS

GENERAL SAFETY PROCEDURES 1
PACKAGE

CONTENTS 4

GENERATOR COMPONENTS : : : 5
PREPARING THE GENERATOR FOR USE 6

Using

the

Generator

for

the

First

Time 6

Step

1-

Add

Oil 6

Step

2 -

Add

Gasoline

7

Step

3 -

Ground

the

Generator 8

Subsequent

Useofthe

Generator 8

Step

1-

Check

the

Oil

8

Step

2 -

Check

the

Gas

Level

8

Step

3 -

Ground

the

Generator 9

STARTING THE GENERATOR 9
USING THE GENERATOR 10

AC

Usage 10

,DC

Usage

13

STOPPING THE GENERATOR 14
MAINTENANCE / CARE 14

Cleaning

the

Generator

15

Checking

the

Oil

15

Changing/Adding

Oil

15

Air

Cleaner

Maintenance

17

Fuel

Filter

Cup

Cleaning

17

Spark

Plug

Maintenance

17

Emptying

the

Gas

Tank 18

STORAGE / TRANSPORT PROCEDURE

18

SPECiFiCATIONS 19

TROUBLESHOOTING 19
GENERATOR ASSEMBLY

AND

MOUNTING 20

CHANGE THE CARBON-BRUSH

21

CHANGE THE

AVR

22

WIRING DIAGRAM 23

EXPLODED VIEW

AND

PARTS

LIST : 25

3

GENERAL

SAFETY

PROCEDURES

Please familiarize yourself with the following safety symbols and words:

The safety alert symbol

& is used with one

of

the safety words (DANGER, CAUTION, or

WARNING) to alert you to hazards. Please pay attention to these hazard notices both

in

this

manual and

on

the generator.

DANGER: Indicates a hazard that will result

in

serious injury or death if instructions are not

followed.

WARNING: Indicates a strong possibility of causing serious injury or death if instructions are not

followed.

CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not

followed.

& DANGER:

This

generator

produces

poisonous

carbon

monoxide

gas when

running.

This gasisboth

odorless

and colorless. Evenifyou

do

not

seeorsmell

gas,

carbon

monoxide

may

still

be present. Breathing

this

poison

can lead

to

headaches, dizziness,

drowsiness,

and

eventually

death.

• Use outdoors ONLYinnon-confined areas.

• Keep several feet

of

clearance on all sides to allow proper ventilationofthe

generator.

& WARNING: The

exhaust

from

this

product

contains

chemicals

knowntothe State

of

Californiatocause cancer,

birth

defects,orother

reproductive

harm.

& WARNING: This

generator

may

emit

highly

flammable

and

explosive

gasoline

vapors,

which

can cause severe

burnsoreven death. A nearby open flame can lead

to

explosion

evenifnot

directlyincontact

with

gas.

• Do not operate near open flame.

• Do not smoke near generator.

• Always operate on a firm, level surface.

411

Always turn generator off before refueling. Allow generator to cool for at least 2

minutes before removing fuel cap. Loosen cap slowly to relieve pressure

in

tank.

• Do not overfill gas tank. Gas may expand during operation. Do not fill to the top

of

the tank.

• Always check for spilled gas before operating.

• Empty gasoline tank before storing or transporting the generator.

• Before transporting, turn fuel valve to off and disconnect spark plug.

4

& WARNING: This generator produces powerful voltage,

which

can

result

electrocution.

e ALWAYS ground the generator before using it (see the "Grounding the Generator"

portion of the "PREPARING THE GENERATOR FOR

e Generator should only be plugged into electrical devices, either directly or with

USE"

section).

extension cord. NEVER connect to a building electrical system without a.qualified
electrician. Such connections must comply with local electrical laws and codes.
Failure to comply can create a backflow of power, which may result in serious injury
or death to utility workers.

e Use a ground fault circuit interrupter (GFCI)

in

highly conductive areas such as metal

decking or steel work. GFCIS are available in-line with some extension cords.

e Do not use

e Do not touch bare wires

• Do not allow children

in

rainyorwet conditions.

or

receptacles (outlets).

or

non-qualified persons to operate.

in

an

& WARNING: This generator produces heat when running. Temperatures near

exhaust can exceed 150°F (65°C).

• Do not touch hot surfaces. Pay attention to warning labels on the generator denoting
hot parts

of

the machine.

• Allow generator to cool several minutes after use before touching engine or areas

which heat during use.

CAUTION: Misuseofthis

generator can damageitor

shorten its life.

• Use generator only for its intended purposes.

e Operate only on dry, level surfaces.

• Allow generator to run for several minutes before connecting electrical devices.

• Shut off and disconnect any malfunctioning devices from generator.

• Do not exceed the Wattage capacity of the generator by plugginginmore electrical

devices than the unit can handle (see

"PRECAUTIONS-OVERLOADING THE

GENERATOR").

• Do not turn on electrical devices until after they are connected to the generator.

• Turn off all connected electrical devices before stopping the generator.

5

In

addition to the above safety notices, please familiarize your self with the safety and hazard

markings on the generator.

IAJ

CAUTIONI POISONOUS GAS

Generatorexhaustcontains

toxic

carbon monoxide gas.

NEVER

operate

indoors or in poorly ventilated areas.

IA]

WARNINGl

RISKOFEXPLOSION

- Stop generator before refueling.

- Check for spilled fuel.

-

Do

not operate near open flame.

IAI

CAUTIONI HOT EXHAUST

DO

NOT

TOUCH

l

6

PACKAGE CONTENTS

Your generator comes with the items listed below. Please check to see that all of the following

items may

be

included with your generator, depending on your generator model.

Screw driver

Spanner

Spark plug wrench

7

GENERATOR COMPONENTS

Please familiarize yourself with the locations and functions of the various components and

controls of your generator.

17

3

14 13

5

7

18

(1)

Air

cleaner- a removable, cleanable, sponge-like element that limits the amountofdirt
pulled into the engine.
(2)

Choke

lever- Adjusts the amountofair let into the engine.

(3) Fuel Gauge- Indicates the amount of fuel

in

the tank.
(4) Fuel Cap- Access to the fuel tank for adding fuel.
(5)

Circuit

Breaker- Reset switch that protects the generator from electrical overload.

(6)

120/240

Volt AC Receptacle- Use to connect electrical devices that

run

120 and/or
240 Volt, 60Hz, single phase, AC current (NEMA L14-30).
(7)

Ground

Terminal- Connect grounding wires here to properly ground unit.

(8) 120 Volt AC Receptacle- Use

to

connect electrical devices that

run

120 Volt, 60

Hz,

single phase, AC current

(2

X duplex GFCI).

(9) 12V

DCofbatteries.

(10) Volt Meter- Provides reading ofvoltage output.

8

(11)

12V

DC

Receptacle- Use for charging

12

Volt automotive-type batteries only.

(12) Oil

Filler

Cap- Use to Add oil or checking the oil.

(13) Oil Fill and

Dipstick-

Location for checking and filling engine oil.

(14)

Engine

Switch-

Usedtostart/stop engine.

(15)

Recoil Starter- Pull-cord for starting engine.

(16) Fuel

Filter

Cup- Traps dirt and water from fuel before it enters the engine.

(17) Fuel

valve-Allows fuel to enter engine.

(18) Spark

plug-

Provides proper engine ignition.

(19)

Muffler-

Reduces engine noise.

PREPARING THE GENERATOR FOR USE

Using the Generator

for

the

First

Time

If you are using the generator for the first time, there are a few steps you must take to prepare

it for operation.

Step 1-

Add

oil

The generator requires engine oil to operate properly. The generator, when new from the

package, contains no oil

in

the crankcase.

You

must add the proper amount of oil before

operating the generator for the first time. This amount, which is equal to the oil capacity of the

engine crankcase, can

be

found

on

the chart

in

figure

1.

When filling the engine with oilinthe

future, please refer to this chart.

Model

number

XP4400

I

XP4400E

Engine

oil

capacity

20

fluid

oz.

Figure 1- Generator Oil Capacity

CAUTION:

41»

Do

not

apply

engine

oil

with

additives

or

2-stroke

gasoline

engine

oil, as they

haven't enough lubrication, which may

shorten the engine's service life.

41»

Engine

oil

recommended: SAE 10W-30.
As viscosity varies with regions and
temperatures, so the lubricant has to be
selected

in

accordance with our

recommendation.

To

add oil, follow these steps:

9

SAE

Temperature

-20 0 20 40

60

80 100°F

I I , I I I I I

-30 -20 -10 0 10

20

30

40°C

Environment Temperature

all

FillER

CAP

1.

Make sure the generator is

on

a level surface.

2.

Unscrew the

oil

filler/dipstick cap from the engine as shown

in

figure

2.

3.

Using a funnel,

add

the appropriate amount of oil, as found

in

figure

1,

into the

crankcase.

You

will know the crankcaseisfull when the oil level has reached the lower

lip of the opening

you

have just poured the oil into (see figure

3).

4.

Replace oil filler cap.

all

FilLER

HOLE

/

-----_l

r---

_

Figure 2-

Unscrewing

the

oil

cap Figure 3 -

Adding

oil

Step 2-

Add

Gasoline

& WARNING: Gasoline and gas

fumes

are

highly

flammable.

• Do

not

fill

tank

near an

open

flame.

• Do

not

overfill.

Always

check

for

fuel spills.

To

ensure that the generator runs smoothly use only FRESH, UNLEADED GAS WITH

AN

OCTANE RATING OF

87

OR HIGHER.Toadd gasoline:

1.

Make sure the generatorison a level surface.

2.

Unscrew gas cap and set aside (NOTE: the gas cap may

be

tight and hard to

unscrew).

3.

Slowly add unleaded gasoline to the fuel tank.

Be

careful not to overfill. Please refer

to the chart

in

figure 4to find the gas capacity of your generator model. The fuel

gauge

on

the top of the generator indicates how much gasolineisin

the generator

gas tank. NOTE: Gas can expand.

Do

not fill the gas tank to the very top.

4.

Replace fuel cap

and

wipe

up

any spilled gasoline with a dry cloth.

IMPORTANT:

• Never use

an

oil/gasoline mixture.

o Never use old gas.

• Avoid getting dirt or water

in

the fuel tank.

• Gas can age

in

the tank and make it hard to start up the generatorinthe future.

• Never store generator for extended periods oftime with fuelinthe tank.
Model

number

XP4400

I

XP4400E

Gas

tank

capacity

15L(3.96

us.

gallons)

Figure 4

- Gas Tank Capacity

Step 3-

Ground

the

Generator

10

& WARNING: Failure

to

properly

ground

the generator can result in electrocution.

Ground the generator by tightening the grounding nut against a grounding wire (see figure 5).
A generally acceptable grounding wire is a No. 12 AWG (American Wire Gauge) stranded

copper wire. This grounding wire should

be

connected at the other end to a copper

or

brass-grounding rod that is driven into

the.

end. Grounding codes can vary by location. Please

contact a local electrician to check the grounding regulations for your area.

Grounding

----

Wing Nut

Figure 5 - Attaching the

Grounding

Wiretothe Generator

Subsequent

Use

of

the

Generator

If

thisisnot your first time using the generator

there

are

still

steps

you

should

taketoprepare itfor

operation.

IMPORTANT:

At

this

point

you

should

be

familiar

with

the procedures described in

the

first

portionofthis

section

entitled"

Using the Generator

for

the

First

Time."

If

you

have

not

yet

read

this

section,

go

back and readitnow.

Step 1-

Check

the

oil

The generator is equipped with an automatic shutoff to protect it from damage due to low oil.

Nonetheless, you should check the oil level of the engine before each use to ensure that the

engine crankcase has a sufficient amount.

To

check the oil level:

1.

Make sure the generator is on a level surface.

2.

Unscrew the oil filler/dipstick cap.

3.

With a dry cloth, wipe the oil off of the stick on the inside ofthe cap.

4.

Insert the dipstick as if you were replacing the cap and then remove again. There
should now be oil on the stick. Ifthere is no oil

Ion

the stick, oroil only at the very end

of

the stick, you should add oil until the engine crankcase is filled (see "Adding Oir'

portion

of

the "Maintenance" section).

5.

Be sure to replace cap when finished checking oil.

NOTE: The oil capacity for your generator

canbefoundinthe "Specifications" section of this

manual.

Step 2 -

Check

the Gas

Level

Before starting the generator, check to see that there is sufficient gasolineinthe gas tank. The fuel
gauge on topofthe generator will indicate the gas levelinthe tank. Add gas if necessary according to
the steps in the "Adding Gasoline" portionofthe "Maintenance" section.

& WARNING: Gasoline and gasoline fumes arc

highly

flammable.

11