DUROMAX XP4400E User manual

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NEXT GENERATION
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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