DuroStar DS4400, DS4000S, XP4000S, DS4400E Owner's Manual
Gasoline Powered Generator
Owner’s Manual
Product Support (Product: information, application, service info & warranty questions)
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This manual provides information regarding the operation and maintenance of these products.
We have made every effort to ensure the accuracy of the information in this manual.
We reserve the right to change this product at any time without prior notice.
FEATURES
• Durable 7 Hp, Air Cooled Overhead Valve Engine.
• Heavy Duty Steel Frame with Four Point Fully Isolated Motor
Mounts for Smooth and Quiet Operation.
• Wheel and Handle Kit for Easy Transporting.
• Full Power Panel with Engine Shutoff Switch, Volt Meter,
Circuit Breaker and Power Outlets.
• (2) Fully Protected 120V Outlets & (1) 120V/240V Twist-Lock
Outlets.
• 8 Hour Run Time.
• All Steel 4.0 Gal. Fuel Tank with EZ-Read Gauge.
• Low Oil Shut-Off Protects Engine.
• Super Quiet Muffler Reduces Engine Noise.
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 Use of the 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
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 ca rbon monoxide gas when
running. This gas is both odorless and colorless. Even if you do not see or smell
gas, carbon monoxide may still be present. Breathing this poison can lead to
headaches, dizziness, drowsiness, and eventually death.
• Use outdoors ONLY in non-confined areas.
• Keep several feet of clearance on all sides to allow proper ventilation of the
generator.
WARNING: The exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects, or other reproductive harm.
WARNING: This generator may emit highly flammable and explosive gasoline
vapors, which can cause severe burns or even death. A nearby open flame can lead
to explosion even if not directly in contact with gas.
• Do not operate near open flame.
• Do not smoke near generator.
• Always operate on a firm, level surface.
• 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 the gasoline tank before storing or transporting the generator.
• Before transporting, turn fuel valve to off and disconnect the spark plug.
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: Misuse of this generator can damage it or shorten its life.
• Operate only on dry, level surfaces.
• Shut off and disconnect any malfunctioning devices from generator.
• Do not exceed the Wattage capacity of the generator by plugging in more 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.
WARNING: This generator produces powerful voltage, which can result in
electrocution.
• ALWAYS ground the generator before using it (see the "Grounding the Generator"
portion of the "PREPARING THE GENERATOR FOR USE" section).
• Generator should only be plugged into electrical devices, either directly or with an
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.
• Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as metal
• Do not touch bare wires or receptacles (outlets).
• Do not allow children or non-qualified persons to operate.
decking or steel work. GFCIs are available in-line with some extension cords.
• Do not use uncovered in rainy or wet conditions.
• Use the generator only for its intended purposes.
• Allow generator to run for 3 - 5 minutes before connecting any electrical devices.
• Turn off all connected electrical devices, and turn off the breaker, before stopping
the generator.
markings on the generator.
In addition to the above safety notices, please familiarize yourself with the safety and hazard
PACKAGE CONTENTS
Screw driver
Spanner
Spark plug wrench
Your generator comes with the items listed below. Please check to see that all of the following
items are included with your generator.
GENERATOR COMPONENTS
Please familiarize yourself with the locations and functions of the various components and
controls of your generator.
(1) Air cleaner- a removable, cleanable, sponge-like element that limits the amount of dirt
pulled into the engine.
(2) Choke lever- Adjusts the amount of air 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
(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,
(10) Volt Meter- Provides reading of voltage output.
240 Volt, 60Hz, single phase, AC current (NEMA L14-30R).
single phase, AC current (2×duplex NEMA L5-20R).
(9) 12V DC Battery.
(13) Oil Fill and Dipstick- Location for checking and filling engine oil.
(14) Engine Switch- Used to start/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 oil in the
future, please refer to this chart.
Engine oil capacity
20 fluid oz.
Figure 1- Generator Oil Capacity
CAUTION:
• 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.
• 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:
(11) 12V DC Receptacle- Use for charging 12 Volt automotive-type batteries only.
(12) Oil Filler Cap- Use to Add oil.
Model number DS4400 DS4400E
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 crankcase is full 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.
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. To add gasoline:
1. Make sure the generator is on 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 4 to find the gas capacity of your generator model. The fuel
gauge on the top of the generator indicates how much gasoline is in 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.
• 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 generator in the future.
• Never store generator for extended periods of time with fuel in the tank.
Gas tank capacity
15L(3.96 us. gallons)
Figure 4 - Gas Tank Capacity
Step 3- Ground the Generator
Model number DS4400 DS4400E
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.
Figure 5 – Attaching the Grounding Wire to the Generator
Subsequent Use of the Generator
If this is not your first time using the generator there are still steps you should take to prepare it for
operation.
IMPORTANT: At this point you should be familiar with the procedures described in
the first portion of this section entitled "Using the Generator for the First Time." If you
have not yet read this section, go back and read it now.
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 of the cap.
4. Insert the dipstick as if you were replacing the cap and then remove again. There
should now be oil on the stick. If there is no oil on the stick, or oil only at the very end
of the stick, you should add oil until the engine crankcase is filled (see "Adding Oil"
portion of the "Maintenance" section).
5. Be sure to replace cap when finished checking oil.
NOTE: The oil capacity for your generator can be found in the "Specifications" section of this
manual.
Step 2 - Check the Gas Level
Before starting the generator, check to see that there is sufficient gasoline in the gas tank. The fuel
gauge on top of the generator will indicate the gas level in the tank. Add gas if necessary according to
the steps in the "Adding Gasoline" portion of the "Maintenance" section.
WARNING: Gasoline and gasoline fumes are highly flammable.
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