Gasoline Powered Generator

Owners Manual

Product Support (Product: information, application, service info & warranty questions)
product_ support@duromaxgenerators.com
or call 1-800-629-3325 (option 3) Monday -Friday 6am to 6pm 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 7.0 Hp, Air Cooled Overhead Valve Engine.
Heavy Duty Steel Frame with Four Point Fully Isolated Motor
Mounts for Smooth and Quiet Operation.
Full Power Panel with Engine Shutoff Switch, Volt Meter,
Circuit Breaker and Power Outlets.
(2) Fully Protected 120V Standard Household Outlets
& (1) High Amperage 120V Twist-Lock Outlet.
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

STARTING THE GENERATOR...................................................................................................................... 9

USING THE GENERATOR .......................................................................................................................... 10
AC Usage ............................................................................................................................................. 10
DC Usage ............................................................................................................................................. 13
STOPPING THE GENERATOR ................................................................................................................... 13
MAINTENANCE / CARE .............................................................................................................................. 13
Cleaning the Generator ........................................................................................................................ 14
Checking the Oil ................................................................................................................................... 14
Changing / Adding Oil........................................................................................................................... 15
Air Cleaner Maintenance...................................................................................................................... 15
Fuel Filter Cup Cleaning....................................................................................................................... 16
Spark Plug Maintenance ...................................................................................................................... 16
Emptying the Gas Tank ........................................................................................................................ 17
STORAGE / TRANSPORT PROCEDURE .................................................................................................. 17
SPECIFICATIONS........................................................................................................................................ 17
TROUBLESHOOTING ................................................................................................................................. 18
INSTALLING OPTIONAL WHEEL AND HANDLE KIT................................................................................. 19
CHANGE THE CARBON-BRUSH ............................................................................................................... 20
CHANGE THE AVR...................................................................................................................................... 20
WIRING DIAGRAM ...................................................................................................................................... 21
EXPLODED VIEW AND PARTS LIST.......................................................................................................... 22

GENERAL SAFETY PROCEDURES

Please familiarize yourself with the following safety symbols and words:
is used with one of the safety words (DANGER, CAUTION, or
The safety alert symbol
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 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 gasoline tank before storing or transporting the generator.
Before transporting, turn fuel valve to off and disconnect spark plug.
1

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
decking or steel work. GFCIS are available in-line with some extension cords.
Do not use in rainy or wet conditions.
Do 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 150F (65C).
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.
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 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.

In addition to the above safety notices, please familiarize yourself with the safety and hazard
markings on the generator.

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

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 Volt AC Receptacle - Use to connect electrical devices that run 120 Volt, 60 Hz,
single phase, AC current (NEMA L5-30).
(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 (NEMA 5-20R)
(9) Volt Meter - Provides reading of voltage output.
(10) Oil Filler Cap - Use to Add oil or checking the oil.
5

(11) Oil Drain Bolt - Location for used for draining the oil.
(12) Engine Switch - Used to start/stop engine.
(13) Recoil Starter - Pull-cord for starting engine.
(14) Fuel Filter Cup - Traps dirt and water from fuel before it enters the engine.
(15) Fuel valve - Allows fuel to enter engine.
(16) Spark plug - Provides proper engine ignition.
(17) 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.
Model number
Engine oil capacity

XP4000S
20 fluid oz.

Figure 1- Generator Oil Capacity

CAUTION:
Do not apply engine oil with additives or
2-stroke gasoline engine oil, as they
havent enough lubrication, which may
shorten the engines 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:

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
6

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.
Model number
Gas tank capacity

XP4000S
15L(3.96 us. gallons)

Figure 4 - Gas Tank Capacity

Step 3- Ground the Generator

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).
7

A generally acceptable grounding wire is a 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 arc highly flammable.

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
8

generator ). Always check for fuel spills.

IMPORTANT:

Use only UNLEADED 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.
STARTING THE GENERATOR
CAUTION: Disconnect all electrical loads from the generator before attempting
to start.
To start your generator, perform the following steps:
1. 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 a slight resistance is felt (see figure 8).
Then pull quickly to start the engine. Return cord gently 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 a minute, 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.

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 9 shows the rated and surge wattage of your generator according to its model
number.
The rated wattage corresponds to the maximum wattage the generator can output on a continuous
The surge wattage corresponds to the maximum amount of power the generator can output
for a short 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
XP4000S

Rated (Running) Wattage

3300

Surge Wattage
4000

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 cannot find this wattage, you may calculate it by multiplying the Voltage
requirement by the Amperage drawn:
basis.
Watts = Volts Amperes
If these specifications are not available you may estimate the Watts required by your device
by using the chart in figure 10.
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 a total 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 a rated (running) wattage equal to or less than the rated
wattage of the generator. Never connect devices requiring a rated 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.

10

Tool or Appliance
Electric water heater (40 gal)
Hot plate
Saw-radial arm
Electric stove
Saw-circular
Air compressor (1HP)
Window air conditioner
Saw-miter
Microwave
Well water pump
Reciprocating saw
Sump pump
Refrigerator freezer
Furnace blower
Computer
Electric drill
Television
Deep freezer
Garage door opener
Stereo
Box fan
Clock radio
Security system
DVD player/VCD
Common light bulb

Rated (Running) Watts

4000
2500
2000
1500
1500
1500
1200
1200
1000
1000
960
800
800
800
800
600
500
500
480
400
300
300
180
100
75

Additional Surge Watts

0
0
2000
0
1500
3000
1800
1200
0
1000
1040
1200
1200
1300
0
900
0
500
0
0
600
0
0
0
0

Figure 10- Estimated wattage requirements of common electrical devices.

11

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.
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.

Figure 11- Receptacles available on the generator

Change the Voltage Selector Switch only after turning the AC circuit breaker to OFF. The
generator may be damaged if you attempt to switch modes while drawing power.

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 a slightly higher rated wattage requirement by the electrical
device. See Figure 12 for recommended cords based on the power requirement of the
electrical device.
*NR= not recommended
Device Requirements
Amps
2.5
5
7.5
10
15
20
25
30
40

Watts
(120V)
300
600
900
1200
1800
2400
3000
3600
4800

Watts
(240V)
600
1200
1800
2400
3600
4800
6000
7200
9600

Max. Cord Length (ft) by Wire Gauge

#8 wire

#10 wire

#12 wire

#14 wire

#16 wire

NR
NR
NR
NR
NR
175
150
125
90

1000
500
350
250
150
125
100
65
NR

600
300
200
150
100
75
60
NR
NR

375
200
125
100
65
50
NR
NR
NR

250
125
100
50
NR
NR
NR
NR
NR

Figure 12-Maximum Extension Cord Lengths by Powe

Power Requirement
12

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 of the 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 /CARE
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
use
Engine oil

Check level

Every
month or
20 hrs

Check

Clean
Fuel filter
cup
Spark plug
Gas tank

Clean

Check/clean
Check
level
Clean

Every
year or
300 hrs

Replace
Air cleaner

Every 6
Every 3
months or months or
100 hrs
50 hrs

gas

Figure 13- Recommended maintenance schedule

Cleaning the Generator

Always try to use your generator in a cool dry place. However, in the event your generator
becomes dirty you may clean the exterior with one or more of the following:
- A damp cloth
- A soft brush
- A vacuum
- Pressurized air
Never clean your generator with a bucket of water or a hose. Water can get inside the working
pats of the generator and cause a short circuit or corrosion.
13

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 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 (see figure 14).
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 "Changing/
Adding Oil" in this section.
5. Be sure to replace cap when finished checking oil.

Figure 14- Checking the Oil

Changing/ 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
Model number
Engine oil capacity

XP4000S

20 fluid oz.

Figure 15- Engine Oil Capacity.

14

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 a bucket 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 a level surface.
2. Unscrew the oil filler/dipstick cap from the engine as shown in figure 14 above.
3. Using a funnel, add high detergent motor oil to the crankcase. We recommend SAE
10W-30 motor oil for general use. When full, the oil level should come close in the top
of the oil fill opening (see figure 17).

NOTE: Never dispose of used motor oil in the trash or down a drain. 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 of the 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.

Figure 18- Removing the air cleaner casing.

15

Fuel Filter Cup Cleaning

The fuel filter cup is a small 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 a wrench. Turn the valve toward you
to unscrew (see figure 19).
3. Clean the cup of all sediment. Using a rag or brush.
4. Reinstall the fuel filter cup.

Figure 19 Removing the Fuel Filter Cup

Spark Plug Maintenance
The spark plug is important for proper engine operation. A good 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 a new
spark plug. We recommend using a F7RTC spark plug
4. Measure the plug gap with a gauge (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 a wire 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.

16

Emptying the Gas Tank

Before storing your generator for extended periods of time, you should drain your generator of
gasoline. To drain the generator of gas:
1. Turn the fuel valve to the "OFF position.
2. Remove the fuel filter cup (see "Removing the Fuel Filter Cup" earlier in this section.
3. Empty the fuel filter cup of any fuel.
4. With a receptacle underneath the generator to catch the gas, turn the fuel valve to the
"ON" position. Drain all the gas from the generator.
5. Turn the fuel valve to the "OFF" position.
6. Replace the fuel filter cup.
7. Store the emptied gasoline in a suitable place.

CAUTION: Do not store fuel from one season to another.

STORAGE/TRANSPORT PROCEDURES
CAUTION: Never place any type of storage cover on the generator while it is still
hot.
When transporting or storing your generator for extended periods of time:

Empty the gas tank (see "Emptying the Gas Tank" in the "Maintenance" section).
Disconnect the spark plug.
Do not obstruct any ventilation openings.
Keep the generator in a cool dry area.

GENERATOR SPECIFICATIONS
AC Output
Rated Wattage
Surge Wattage
Rated Voltage
Rated Frequency
Phase

3300W
4000W
120V
60Hz
Single

Engine

Engine type
Ignition system
Displacement
Starting type
Fuel tank capacity:
Oil capacity
Run time on 50% load
Noise Level

XP4000S
4-stroke OHV single cylinder with forced air cooling
system
Non-contact transistor
208cc
Recoil
15L(3.96US gal.)
0.6L(20fl oz.)
12hrs
69 dB
17

TROUBLESHOOTING
Problem
Engine will
not start

Engine will
not start
(continued
from page
19)
Engine
runs but
there is no
electrical
output
Generator
runs but
does not
support all
electrical
devices
connected.

Cause
Engine switch is set to OFF.
Fuel valve is turned to
CLOSED.
Choke is open.
Engine is out of gas.
Engine is filled with
contaminated or old gas
Spark plug is dirty.
Spark plug is broken.
Generator is not on level
surface.
Oil is low
Circuit breaker is off.
Bad connecting wires/cables.
Bad electrical device
connected to generator.

Solution
Set engine switch to ON.
Turn fuel valve to OPEN position.
Close the choke
Add gas.
Change the gas on the engine.
Clean spark plug.
Replace spark plug.
Move generator to a level surface to
prevent low oil shutdown from
triggering.
Add or replace oil.
Set the circuit breaker to the ON
position.
If you are using an extension cord,
try a different one.
Try connecting a different device.

Shorten one of the connected

devices.

Try connecting fewer electrical loads

to the generator.
Try disconnecting any faulty or
short-circuited electrical loads.

Air cleaner is dirty.

Clean or replace air cleaner.

Generator is overloaded

18

INSTALLING THE OPTIONAL WHEEL AND HANDLE KIT

If you have purchased the optional wheel and handle kit for your unit, please follow the instructions
below. If you have not purchased the optional wheel and handle kit, skip this section.
1. Place the bottom of the generator cradle on a flat, even surface. Te mporarily place
unit on blocks to ease assembly.
2. Secure the support leg to the cradle with cap screws (M8 x 16) and lock nut s (M8)
(see figure 22 ).
3. Secure the axle to the cradle with cap screws (M8 x 16) and lock nuts (M8) (see fig u re
23 ).
4. Slide a wheel and a flat washer over the axle, then secure the wheel with a retaining pin
(see Figure 24, Figure 25 ).
5. Position the lower handle lock on the frame and secure with bolt. Insert upper handle
bracket and secure with provided bolts. Insert the handle into the upper bracket secure
with pin. Insert and secure the retaining pin. ( Figure 26 - Figure 30).
6. The unit comes with solid rubber tires which require no additional care.

Figure 2 2

Figure 2 3

Figure 2 4

Figure 2 5

Figure 2 6

Fig ur8
e 27

Figure 2 8

Figure 2 9

Fig ur8
e 30

19

CHANGE THE CARBON-BRUSH

CHANGE THE AVR

20

20

WIRING DIAGRAM (XP4000S)

Main coil

Sub-fied coil

Field coil

Generator wiring diagram

W
R
Bu
Bu
R

W
R
Bu
Bu

W
Y/G

V
~
W

Bl

Bl

W
Y/G

Socket
NEMA L5-30R

Spark Ignition coil

plug

Oil alert unit

Bl

Breaker
30-18A-1P

Control panel block

Bl/W

fuel
protector

Socket
NEMA 5-20R

Y/G

Y/G

Engine block

21

EXPLODED VIEW AND PARTS LIST (XP4000S)

84

22

Ite
m

Part

Qt
y

Description

Ite
m

Part

Qt
y

Description
Set Pin, 1014

DJ168F-16121-K

Recoil Starter

43

DJ168F-11009-A

GBT5787-B6-8

Bolt Flange M68

44

GB276-89-6205

DJ168F-16118

Grommet drain hole

45

DJ168F-18500-A

Spark Plug F7TC

DJ168F-16100-F.
052

Fan case

46

DJ170F-13009-A

Tappet Litter Valve

GBT6177/10-N-14

Flange nut M14

47

DJ170F-13008-B

Rod, push

DJ168F-16000-A

Starting Cup

48

DJ 168F-13300-A

Plate, push rod guide

DJ168F-16002-A

Flywheel Fan

49

DJ168F-13202-A

Fastening Bolt

DJ168F-16200-C

Flywheel

50

DJ168F-13203-A

Adjusting Nut

DJ168F-18300-A

Amplifier

51

DJ168F-13204-A

Lock Nut

10

DJ168F-11400-A

Wind Shield Assembly

52

DJ168F-13201-A

Arm, valve rocker

11

DJ168F-18100-C

Ignition Coil

53

DJ170F-12002-A

Pin, piston

12

GBT5787-B6-25

Flange bolt M625

54

DJ168F-12003-A

Clip, piston pin

13

DJ168F-11004-A

Drain Plug

55

DJ170F-12200-B

Tie-rod Assembly

14

DJ168F-11005-A

Washer, drain plug

56

DJ168F-13006-A

Rotator, valve

15

DJ168F-11014-A

Oil seal, 25416

57

DJ168F-13004-A

Retainer, IN. Valve spring

16

DJ170F-11100-C

Crank case assy.

58

DJ168F-13005-A

Retainer, EX. Valve spring

17

DJ170FD-14100-B

Carburetor Assembly

59

DJ168F-13003-A

Spring, valve

18

DJ168F-14119

Lever comp, choke

60

DJ168F-13010-A

Returner, Exhaust Valve

19

GBT5787-B6-16

15

Bolt Flange M616

61

DJ168F-13002-A

Intake Valve

20

DJ168F-11012-A

Air-leading Cover

62

DJ168F-13001-A

Exhaust Valve

21

DJ168F-14027-A

Air Cleaner Gasket

63

DJ168F-13100-B

Camshaft assy.

22

DF2500H-14205-A

Stay, air cleaner

64

DJ168F-12104

Woodruff Key

23

GBT5787-B6-12

Flange bolt M612

65

DJ168F-12100-BB

Crankshaft Assembly

24

GBT5787-B5-14

Flange bolt M514

66

DJ168F-18200-A

Oil Sensor Assembly

25

DJ168F-14204

Air Cleaner Cover

67

DJ168F-15001-A

Shaft, governor assy.

26

DJ170F-14201

Element, air cleaner

68

DJ168F-15006-A

Pulling Rod

27

DJ168F-14202

Air Cleaner Housing

69

DJ170F-15008-A

Fine Regulating Spring C

28

DJ168F-14206

Packing Slip

70

DJ168F-15004-A

Speed Regulating Arm

29

GBT6177-N-6

Flange nut M6

71

DJ168F-15005-A

Lock Bolt

30

DJ168F-14205-A

Air Cleaner Base

72

DJ170F-15007-A

Back Spring B

31

DJ168F-14014-A

Grommet

73

DJ168F-15100-A

centrifugal assy.

32

DJ168FD-14001-A

Bolt Stud, 690

74

DJ168FD-15200-A

speed adjuster

33

DJ168F-14005-A

Carburetor Gasket

75

DJ170F-11003-B

Crankcase Gasket

34

DJ168F-14004-A

Connecting Block,Carbretor

76

DJ168F-11002-C

Pin, dowel, 912

35

DJ168F-14003-B

Inlet Gasket

77

DJ168F-11007-A

Oil Filler Assembly

36

DJ170F-11200-B

Head comp, cylinder

78

DF1800H-33016-A

Plat

37

DJ168FD-11013-A

Tube, Breather

79

GBT5787-B8-35

bolt M835

38

DJ168F-11300-B

Cylinder Head Cover Assembly

80

DJ168FD-11001-C

Crankcase cover

39

DJ168F-11011-A

Cylinder Head Cover Gasket

81

DJ170F-12001-B

Piston

40

GBT5787-B8-60

Flange bolt M860

82

DJ 170F-12300-A

Scraper Ring Set, Piston

41
42

DJ168F-14002-A
DJ170F-11010-C

2
1

Bolt head, M835

83
84

DJ168F-11039-A
DJ168F-11002-B

1
1

O-Clip
Pin, dowel, 712

Casket, cylinder head

23

Radial ball bearing (6025)

24

Ite
Part
m
85 DF2500H-31201-A

Qt
Description
y
2 Bottom rubber A

Ite
Part
m
127 14306

86 DF2500H-31202-A

2 Bottom rubber B

87 GBT6177-N-8

Qty

Description

Fuel filler cap comp

128 14303

Fuel sensor

4 Flange nut M8

129 GBT819-B-5

Screw M510

88 GBT889-N-8

10 Flange nut M8

130 14313

GASKET,FUEL SENSOR

89 DF2500H-14304-A

1 Rubber Screws, Fuel Tank 131 14311

Washer

90 34107

1 Earth terminal set

132 14305

Collar

91 34206-008

1 Circuit breaker

133 14304

Cushion

92 34204-001

1 4-holes Socket

134 DJ168FD-14007-C

Outlet pipe4.5165

93 34204-005

1 3-holes Socket

135 DJ168F-14008-A

Tube clip

94 20140

4 Plain Washer

136 DF2500H-14302-A

Fuel cock

95 DF3000H-31058-A

1 Single curved handle

137 DF2500H-14400-E

Muffler

96 DF6500H-31016-A

1 Rubber Coat, Handle

138 DJ188F-14010-A

Gasket , Exhaust Pipe

97 DF3000H-31014-A

1 Handle Bracket

139 DF2500H-14009

Exhaust Pipe

98 34203-004
DS4000S-34100-ML0
99
1
100 34213-001

1 Engine switch

140 GB5787-B-8

Flange bolt M825

1 Control panel

141 DJ168F-14006-A

1 Sub Wire Harness Assay

142 DF2500H-14018-B

101 34205-001

1 Voltmeter

143 DF2500H-31019-B

3 Clip

102 DF6500H-31072-A

1 Rubber Clamp, Handle

144

Wheel comp

103 34102-A

1 Control panel case

145 DF3000H-31018-F

Well shaft

104 34109

1 Boot, main wire harness

146 DF3000H-31070-E

Support

105 34117

1 Boot, AC output wire

147 GBT889-N-6

Flange nut M6

106 34212-001

1 Boot, main wire harness

148 DF9000H-31204-A

Rubber feet

107 GBT6170-N-8

6 Flange nut M8

149 DJ170N-B

108 GBT5789-B5-16

8 Flange bolt M516

150 GBT889-N-635

Flange bolt M635

109 DF1800H-33006-B

1 Generator end cover

151 GBT889-N-820

Flange bolt M820

110 DF2500H-33015-A

4 Flange bolt M6120

152 DFD3000H-31021-B

Axle

111 DF1800H-33005-A

1 GENERATOR STAY

153 GBT889-N-655

Flange bolt M655

112 DF3500H-33001

1 BRUSH ASSEMBLY

154 DF3000H-31014-B

Flange bolt M8640

113 DF3500H-33002

1 Connecting Plate

155 DS4000S-31100-A.
010

Frame comp

114 DF2500H-33011-A

1 Voltage regulator

115 DF2500H-33003-A

1 Bolt M8195

116 GBT93-LW-8

1 Plain washer 8

117 GBT97-W-8

2 Plain Washer

118 GB276-89-6204

1 Bearing 6204-2RS

119 DF2500H-33110-B

1 ROTOR ASSEMBLY

120 DF2500H-33100D-10302 1 Stator & Rotor Assy.

121 DF2500H-33023
1 Generator fan
122 DF2500H-33129

1 Stator cover

123 DF2500H-33120
1 Stator Assy.
124 DF2500H-14322-D
1 rubber belt
125 DF2500H-14300-B001 1 Fuel tank
126 14307

1 Fuel filter
25

31017-F

Muffler Gasket

Outer Hood

Gasoline engine