DUROMAX XP4400E User manual

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NEXT GENERATION
IVISI~
POWER SYSTEMS
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Gasoline Powered Generator
Owner's Manual
XP4400 D
XP4400E D
customer_[email protected]
or call 1-800-629-3325 (option 3) Monday -Thursday 6am to 7pm, Friday -Saturday 6am to 3pm. PST
[email protected]
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
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 6.5 Hp, Air Cooled Overhead Valve Engine.
•Heavy Duty Steel Frame with FourPoint Fully Isolated Motor
Mounts for Smooth
and Quiet Operation.
•Wheel andHandle Kit for Easy Transporting.
•Full Power Panel with Engine ShutoffSwitch, Volt Meter,
Circuit Breaker
and Power Outlets.
•(2) Fully Protected 120VOutlets &(1) 120VI240VTwist-Lock
Outlet.
•8Hour Run 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 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
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 ahazard that will result in serious injury or death if instructions are not
followed.
WARNING: Indicates astrong possibility ofcausing serious injury or death if instructions are not
followed.
CAUTION: Indicates apossibility of personal injury or equipment damage if instructions are not
followed.
&DANGER: This generator produces poisonous carbon 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. Anearby 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 afirm, 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 in
electrocution.
eALWAYS ground the generator before using it (see the "Grounding the Generator"
portion ofthe "PREPARING THE GENERATOR FOR USE" section).
eGenerator should only be plugged into electrical devices, either directly or with an
extension cord. NEVER connect to abuilding electrical system without a.qualified
electrician. Such connections must comply with local electrical laws and codes.
Failure to comply can create abackflow of power, which may result in serious injury
or death to utility workers.
eUse aground fault circuit interrupter (GFCI) in highly conductive areas such as metal
decking or steel work. GFCIS are available in-line with some extension cords.
eDo not use in rainy or wet conditions.
eDo not touch bare wires or receptacles (outlets).
•Do not allow children
or non-qualified persons to operate.
&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.
•Use generator only for its intended purposes.
eOperate 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 ofthe 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.
•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
Generatorexhaust contains
toxic
carbon monoxide gas. NEVER operate
indoors or in poorlyventilated areas.
IA] WARNINGl RISK OF EXPLOSION
-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 ofthe 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- aremovable, 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
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 Xduplex GFCI).
(9) 12V
DC of batteries.
(10) Volt Meter- Provides reading of voltage 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- 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 afew 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 ofthe
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.
Model
number
XP4400 IXP4400E
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 -20 020 40 60 80 100°F
I I , I I I I I
-30 -20 -10 010 20 30 40°C
Environment Temperature

all FillER CAP
1. Make sure the generator is on alevel surface.
2. Unscrew the oil filler/dipstick cap from the engine as shown in figure 2.
3. Using afunnel, 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 ofthe 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. To add gasoline:
1. Make sure the generator is on alevel 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 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 adry cloth.
IMPORTANT:
•Never use
an oil/gasoline mixture.
oNever 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 oftime with fuel in the tank.
Model
number XP4400 IXP4400E
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 agrounding wire (see figure 5).
Agenerally acceptable grounding wire is aNo. 12 AWG (American Wire Gauge) stranded
copper wire. This grounding wire should
be connected at the other end to acopper or
brass-grounding rod that is driven into the. end. Grounding codes can vary by location. Please
contact alocal electrician to check the grounding regulations for your area.
Grounding ----
Wing Nut
Figure 5 - Attaching the Grounding Wire to the Generator
Subsequent Use of the Generator
If this is not yourfirst time using the generator there are still steps you should take to prepare itfor
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 shutoffto 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 asufficient amount.
To check the oil level:
1. Make sure the generator is on alevel surface.
2. Unscrew the oil filler/dipstick cap.
3. With adry cloth, wipe the oil off ofthe 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
Ion the stick, or oil 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 can be found in the "Specifications" section ofthis
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 arc highly flammable.
11

•Do not fill tank near an open flame.
•Always allow engine to cool for several minutes before refueling.
•Do not overfill (check the "Specifications" section for the tank capacity of your
generator). Always check for fuel spills.
IMPORTANT:
•Use only UI\ILEADED gasoline with an octane rating of 87 or higher.
•Do not use old gas.
•Never use an oil/gasoline mixture.
•Avoid getting dirt or water in the fuel tank.
•Never store generator for extended periods of time with fuel in the tank.
Step 3- Ground the Generator
& WAR~IING: Failure to properly ground the generator can result in electrocution.
Ground the generator by tightening the grounding nut against agrounding wire (see J
figure 5). Agenerally acceptable grounding wire is aNo. 12 AWG (American Wire Gauge)
stranded copper wire. This grounding wire should
be connected at the other end to acopper
or brass-grounding
rod that is driven into the earth.
Grounding codes can vary by location. Please contact alocal electrician to check the
grounding regulations for your area.
STARTING THE GENERATOR
&CAUTION: Disconnect all electrical loads from the generator before attempting
to start.
To start your generator, perform the following steps:
1. I. Make sure no electrical devices are connected to the generator. Such devices
can make it difficult for the engine to start.
2. Check that the generator is properly grounded (see page 13, "Ground the
Generator").
3. Turn the fuel valve to the "ON" position (see figure 6).
4. Move the choke lever to the "CLOSED" position (see figure 7).
5. Set the engine switch to the "ON" position.
6. Pull on the recoil starter handle slowly until aslight resistance is felt (see figure 8).
Then pull quickly to start the engine. Return cord ge~tly into the machine. Never
allow the cord to snap back.
7. If engine fails to start, repeat step 4. NOTE: After repeated attempts to start the
engine, please consult the troubleshooting guide before attempting again.
8. Once the engine has started and run for about aminute, move the choke lever
about half way towards the "OPEN" position. Wait another 30 seconds and then
move the choke lever all the way to the "OPEN" position.
9. Allow the generator to run for several minutes before attempting to connect any
electrical devices.
12

Figure 6- Fuel Valve in the "on"position
STARTER GRIP
i
CHOKE LEVER
'f=z~~
Figure 7- Choke in the "closed" position (refer to
choke location)
\
Figure 8 .. Pulling the start cord
CLOSED
OPEN
USING THE GENERATOR
Once you have allowed the engine to run for several minutes, you may connect electrical
devices to the generator.
AC Usage
You may connect electrical devices running on AC current according to their wattage requirements.
The chart
in figure 9shows the rated and surge wattage ofyour generator according to its model
number.
The rated wattage corresponds to the maximum wattage the generator
can output on acontinuous
basis.
The surge wattage corresponds to the maximum amount of power the generator can output
for ashort period
of time. Many electrical devices such as refrigerators require short bursts of
extra power, in addition the rated wattage listed by the device, to stop and start their motors.
The surge wattage ability
of the generator covers this extra power requirement.
Model Number Rated (Running) Wattage Surge Wattage
XP4400 3500 4400
--
XP4400E 3500 4400
Figure 9-generator wattage by model number
The total running wattage requirement of the electrical devices connected to the generator
should not exceed the rated wattage
of the generator itself. To calculate the total wattage
requirement
of the electrical devices you wish to connect, find the rated (or running) wattage
of each device. This number should be listed somewhere on the device or in its instruction
manual. If you cannotfind this wattage, you may calculate it by multiplying the Voltage
requirement by the Amperage drawn:
Watts =Volts xAmperes
13

If these specifications are not available you may estimate the Watts required by your device
by using the chart
in figure 10.
Tool or Appliance
Rated (Running) Watts
Additional Surge Watts
Electric water heater (40 gal) 4000 0
Hot plate 2500 0
Saw-radial arm 2000 2000
Electric stove 1500 0
Saw-circular 1500 1500
Air compressor
(1 HP) 1500 3000
Window air conditioner 1200 1800
Saw-miter 1200 1200
Microwave 1000 0
Well water pump 1000 1000
Reciprocating saw 960 1040
Sump pump 800 1200
Refrigerator freezer 800 1200
Furnace blower 800 1300
Computer 800 0
Electric drill 600 900
Television 500 0
Deep freezer 500 500
Garage door opener 480 0
Stereo 400 0
Box fan 300 600
Clock radio 300 0
Security system 180 0
DVD
playerNCD
100 0
Common light bulb 75 0
Figure 10- Estimated wattage requirements of common electrical devices.
Once you have found the rated wattage requirement of each electrical device, add these
numbers to find the total rated wattage you wish to draw from the generator. If this number
exceeds the rated wattage
of the generator, DO NOT connect all these devices, Select a
combination
of electrical devices, which has atotal rated wattage lower than or equal to the
rated wattage
of the generator.
CAUTION·The generator can run at its surge wattage capacity for only a short time.
Connect electrical devices requiring arated (running) wattage equal
to or less than the rated
wattage
of the generator. Never connectdevices requiring arated wattage equal to the surge
wattage of the generator.
NOTE: The above wattage figures are estimates. Try to check the wattage listed on your
electrical device before consulting this chart.
14

Once you have determined what electrical devices you will be powering with the generator,
connect these devices according to the following procedure:
1. Plug in each electrical device with the device turned off.
a. NOTE: Be sure to attach appliances to the correct receptacle (outlet). Connect
standard 120 Volt, single phase,
60 Hz loads only to the 120 Volt receptacle.
b. Connect 120/240 Volt, single phase, 60Hz loads with NEMA L14-30 plug only
to the 120/240 Volt receptacle See Figure 11 for adepiction of each of these
receptacles.
2. Switch the circuit breaker to the "ON" position.
3. Turn on the connected electrical devices in the order of the amount of power they
require beginning with the device with the highest rated Wattage requirement.
CAUTION: Do not connect 50Hz or 3-phase loads to the generator.
120VAC Receptacles
12V DC Receptacles
Figure 11- Receptacles available on the generator
VOLTAGE SELECTOR SWITCH (XP4400/XP4400E)
The voltage selector switches the main power carrying windings ofthe generator to produce
"120V ONLY" or "120/240V". If a240V appliance is connected to the 4-prong receptacle, the
switch must be
in the "120/240V" position. If only a120V appliance is being connected to any
of the 120V 3-prong receptacles, select the "120V
ON LY" position.
•120/240V: The 120V and 120/240V receptacles can be used simultaneously.
•120V: ONLY the 120V receptacles can be used. Do not use the 120/240V receptacle
in this position. Rated power will be available at the 120V twist lock receptacle.
Change the Voltage Selector Switch after turning the AC circuit breaker to OFF. The
generator may
be damaged.
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 aslightly higher rated wattage requirement by the electrical
device. See Figure 12 for recommended cords based
on the power requirement of the
electrical device.
15

Device Requirements Max. Cord length (ft) by Wire Gauge
Amps Watts Watts #8 wire #10 wire #12 wire #14 wire #16 wire
(120V) (240V)
2.5 300 600 NR 1000 600 375 250
5600 1200 NR 500 300 200 125
7.5 900 1800 NR 350 200 125 100
10 1200 2400 NR 250 150 100
50
15 1800 3600 NR 150 100 65
NR
20 2400 4800 175 125
75 50 NR
25 3000 6000 150 100
60 NR NR
30
3600 7200 125 65 NR NR NR
40 4800 9600
90 NR NR NR NR
*NR= not recommended
Figure 12-Maximum Extension Cord
lengths by Power Requirement
DC Usage
CAUTION: The
DC receptacle is for recharging 12 Volt automotive-type batteries only.
Do
not connect any other device to this receptacle.
CAUTION: Use the generator only to recharge 12 Volt batteries. Never try to jumpstart
a car with your generator.
To connect 12 Volt batteries to the DC receptacle:
1. Connect one charging wire to the positive terminal on the battery and the other
charging wire to the negative terminal.
2. Connect the free end of the positive wire to the positive receptacle (outlet) on the
generator.
3. Start the generator.
4. Carefully connect the free end ofthe negative wire to the negative receptacle on the
generator.
5. When disconnecting, always disconnect the wires from the generator first to avoid a
spark.
&DANGER: Storage batteries emit highly explosive hydrogen gas when charged.
Batteries also contain acid,
which can cause severe chemical burns.
•Do
not allow open flames or cigarettes nearby for several minutes after
charging abattery.
•
Always wear protective goggles and rubber gloves when charging abattery.
*: If battery acid gets on your skin, flush with water.
*: If battery acid gets in your eyes, flush with water and call aphysician
immediately.
*: If battery acid is swallowed, drink large quantities of milk and call a
Physician immediately.
16

If the generator you buy is electric start one, once beginning to work, it will charge the battery
on the generator automatically. At this time, you can see the indication light is shining, after
the battery is full, the light will be extinct.
STOPPING THE GENERATOR
To stop the generator:
1. Turn off, then unplug all connected electrical devices.
2. Switch the circuit breaker to the "OFF" position.
3. Allow the generator to run for several more minutes with no electrical devices
connected. This helps stabilize the temperature ofthe generator.
4. Set the engine switch to the "OFF" position.
5. Turn the fuel valve to the "OFF" position.
&WARNING: Allow the generator to cool for several minutes before touching areas
that become hot during use.
CAUTION: Allowing gas to sit in the generator tank for long periods of time without
use can make it difficult to start the generator in the future. Never store generator for
extended periods of time with fuel in the tank.
MAINTENANCE ICARE
Proper routine maintenance of your generator will help prolong the life of your machine.
Please perform maintenance checks and operations according the schedule
in figure 13.
CAUTION: Never perform maintenance operations while the generator is running.
Recommended Maintenance schedule
Each Every Every 3Every 6Every
month or months or
months or year or
use
20 hrs 50 hrs 100 hrs 300 hrs
Engine oil Check level X
Replace X
Air cleaner Check X
Clean X
Fuel filter
Clean X
cup
Spark plug Check/clean X
Gas tank
Check gas X
level
Clean X X
Figure 13- Recommended maintenance schedule
Cleaning the Generator
Always try to use your generator in acool dry place. However, in the event your generator
becomes dirty you may clean the exterior with one or more ofthe following:
- A damp cloth
- A soft brush
17

-A vacuum
-Pressurized air
Never clean your generator with abucket
of water or ahose. Water can get inside the working
pats
of the generator and cause ashort circuit or corrosion.
Checking the Oil
The generator is equipped with an automatic shutoff to protect it from running on low oil.
Nonetheless, you should check the oil level
of the generator before each use to ensure that
the generator crankcase has asufficient amount.
To check the oil level:
1. Make sure the generator is on alevel surface.
2. Unscrew the oil filler/dipstick cap (see figure 14).
3. With adry 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. If there is no oil on the stick, or oil only at the very end
ofthe stick, you should add oil until the engine crankcase
is filled. See "Changing!
Adding
Oir in this section.
5. Be sure to replace cap when finished checking oil.
OIL FILLER HOLE
OIL FILLER CAP /
/
----.--i---
/ ---
Figure 14- Checking the Oil
Changingl Adding Oil
You should check the oil level of your generator according to the maintenance schedule in
figure 13. When the oil level is low you will need to add oil until the level is sufficient to run the
generator.
The oil capacity of your generator engine is listed
in figure 15
18

Model number XP4400 IXP4400E
Engine
oil capacity
20 fluid oz.
Figure 15- Engine Oil Capacity.
It is only necessary to drain the oil from the crankcase if it has become contaminated with
water or dirt.
In this case, you can drain the oil from the generator according to the following
steps:
1. Place abucket underneath the generator to catch oil as it drains.
2. Using a 10 mm hex wrench, unscrew the oil drain plug, which is located on the
crankcase underneath the oil filler/dipstick cap (see figure
16). Allow all the oil to drain
from the generator.
3. Replace the oil drain plug and tighten with a 10 mm hex wrench.
To add oil to the crankcase, follow these steps:
1. Make sure the generator is on alevel surface.
2. Unscrew the oil filler/dipstick cap from the engine as shown in figure 14 above.
3. Using afunnel, add high detergent motor oil to the crankcase. We recommend SAE
10W30 motor oil for general use. When full, the oil level should come close
in the top
of the oil fill opening (see figure 17).
Figure 16- Draining oil Figure 17- Adding oil
NOTE: Never dispose of used motor oil in the trash or down adrain. Please call your
local recycling center or auto garage to arrange oil disposal.
Air Cleaner Maintenance
Routine maintenance of the air cleaner helps maintain proper airflow to the carburetor.
Occasionally check that the air cleaner is free of excessive dirt.
1. Unhinge the clasps at the top and bottom ofthe air cleaner cover (see figure 18).
2. Remove the sponge-like elements from the casing.
3. Wipe the dirt from inside the empty air cleaner casing
4. Wash the sponge-like elements in household detergent and warm water. Allow to dry.
5. Soak the dry elements in engine oil. Squeeze out any excess oil.
6. Replace the sponge-like elements in the air cleaner casing and replace the cover.
19

\ -------
1.,--....==--_.-
~_.--
1----
\\
ELEMENT
/\
-----I-------_J
/
---L
COVER AIR CLEANER
SPRING COVER
I /
I ~/
--+--- /::.J ~
\~" 7 (~
'-y--
//
/
/
COVER
SPRING
Figure 18- Removing the air cleaner casing.
Fuel Filter Cup Cleaning
The fuel filter cup is asmall well underneath the fuel valve. It helps to trap dirt and water that
may be in your fuel tank before it can enter the engine. To clean the fuel filter cup:
1. Turn the fuel valve to the "OFF" position.
2. Unscrew the fuel filter cup from the fuel valve using awrench. Turn the valve toward you
to unscrew (see figure 19).
3. Clean the cup of all sediment. Using arag or brush.
4. Reinstall the fuel filter cup.
FUEL VALVE
-------,7'-\:--------~-
FUEL FILTER CUP
Figure 19 -Removing the Fuel Filter Cup
Spark Plug Maintenance
The spark plug is important for proper engine operation. Agood spark plug should be intact,
free
of deposits, and properly gapped. To inspect you spark plug:
1. Pull on the spark plug cap to remove it.
2. Unscrew the spark plug from the generator using the spark plug wrench included with
this product (see figure 20).
3. Visually inspect the spark plug. If it is cracked or chipped, discard and replace with anew
spark plug. We recommend using aF6RTC spark plug such as NGKBPR5ES.
4. Measure the plug gap with agauge (see figure 21). The gap should be 0.7-0.8 nun
(0.028-0.031 in).
5. If you are re-using the spark plug, use awire brush to clean any dirt from around the
spark plug base and then re-gap the spark plug.
6. Screw the spark plug back into its place on the generator using the spark plug wrench.
Replace the spark plug cap. 20