Gasoline Powered Generator

Owner’s Manual

Product Support

(Product: information, application, service info & warranty questions)

[email protected]

or call 1-800-629-3325 (option 3) Monday -Thursday 6am to 6pm, Friday 6am to 5pm. 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 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 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

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 turn fuel valve to off and disconnect the spark plug.

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 uncovered 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 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 the generator only for its intended purposes.

• Operate only on dry, level surfaces.

• Allow generator to run for 3 - 5 minutes before connecting any 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, and turn off the breaker, 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 are included with your generator.

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/ 240 Volt AC Receptacle Use to connect electrical devices that run 120 and/or

240 Volt, 60Hz, single phase, AC current (NEMA L14-30R).

(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 × duplex NEMA L5-20R).

(9) 12V DC Battery.

(10) Volt Meter Provides reading of voltage output.

(11) 12V DC Receptacle Use for charging 12 Volt automotive-type batteries only.

(12) Oil Filler Cap Use to Add 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 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

DS4400 DS4400E

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:

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.

Model number

Gas tank capacity

DS4400 DS4400E

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 ).

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.

• Do not fill tank near an open flame.

• Always allow the 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 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.

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 J 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 earth.

Grounding codes can vary by location. Please contact a local 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. l. 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 basis.

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 Rated (Running) Wattage

DS4400

Surge Wattage

3500 4400

DS4400E 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 cannot find this wattage, you may calculate it by multiplying the Voltage requirement by the Amperage drawn:

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 .

Tool or Appliance

Electric water heater (40 gal)

Hot plate

Saw-radial arm

Electric stove

Rated (Running) Watts

4000

2500

2000

1500

Additional Surge Watts

0

0

2000

0

Air compressor (1HP)

Window air conditioner

1500

1200

3000

1800

Well water pump

Reciprocating saw

Sump pump

Refrigerator freezer

Furnace blower

Electric drill

Deep freezer

Garage door opener

1000

960

800

800

800

600

500

480

1500

1040

1200

1200

1300

900

800

600

Box fan

Clock radio

Security system

DVD player/VCD

Common light bulb

300

300

180

100

75

600

0

0

0

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 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.

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 a depiction 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.

Figure 11- Receptacles available on the generator

VOLTAGE SELECTOR SWITCH

The voltage selector switches the main power carrying windings of the generator to produce

"120V ONLY" or "120/240V". If a 240V appliance is connected to the 4-prong receptacle, the switch must be in the "120/240V" position. If only a 120V appliance is being connected select the "120V ONLY" position.

Change the Voltage Selector Switch after turning the AC circuit breaker to OFF. The generator may be damaged if the Voltage Selector Switch is changed with the breaker on.

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 for the electrical device. See Figure 12 for recommended cords based on the power requirement of the electrical device.

Device Requirements Max. Cord Length (ft) by Wire Gauge

Amps

Watts

(120V)

Watts

(240V)

#8 wire #10 wire #12 wire #14 wire #16 wire

2.5 300 600 NR 1000 600 375 250

5 600 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 of the 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 a battery.

•

Always wear protective goggles and rubber gloves when charging a battery.

☆ If battery acid gets on your skin, flush with water.

☆ If battery acid gets in your eyes, flush with water and call a physician immediately.

☆ If battery acid is swallowed, drink large quantities of milk and call a

Physician immediately.

If your generator is electric start model, once running, it will charge the battery on the generator automatically. While charging, you can see the indication light is on, after the battery is full, the light will turn off.

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

Replace

Air cleaner Check

×

×

Clean

Fuel filter Clean cup

Spark plug Check/clean

Gas tank Check gas level

Clean

×

Every month or

20 hrs

×

Every 3 months or

50 hrs

×

Every 6 months or

100 hrs

×

×

Every year or

300 hrs

× ×

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.

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

DS4400 DS4400E

20 fluid oz.

Figure 15- Engine Oil Capacity.

It is only necessary to drain the oil from the crankcase, other than for regular oil changes 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

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

).

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.

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 F6RTC spark plug such as NGK BPR5ES.

4. Measure the plug gap with a gauge (see figure 21 ). The gap should be 0.7-0.8 mm

(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.

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

DS4400 DS4400E

3500W 3500W

4400W 4400W

120/240V

60Hz

120/240V

60Hz

DC Output

DS4400 DS4400E

Amperage 8.3A 8.3A

Dimensions (in):

Length=23.2

Width=17

Height=17

Length=23.2

Width=17

Height=17

Engine

Engine type

DS4400 DS4400E

4-stroke OHV single cylinder with forced air cooling system

Ignition system Non-contact transistor

Displacement 210cc

Starting type

Fuel tank capacity:

Oil capacity

Run time on 50% load

Noise Level

Recoil Electric

15L(3.96US gal.)

0.6L(20fl oz.)

< 69dB

TROUBLESHOOTING

Problem Cause

Engine will not start

Engine switch is set to “OFF”. Set engine switch to “ON”.

Fuel valve is turned to

“CLOSED”.

Solution

Turn fuel valve to “OPEN” position.

Choke is open. Close the choke

Engine is out of gas. Add gas.

Engine will

Engine is filled with contaminated or old gas

Spark plug is dirty.

Change the gas on the engine.

Clean spark plug.

not start

(continued from page

19)

Spark plug is broken.

Generator is not on level surface.

Oil is low

Circuit breaker is off. Engine runs but there is no electrical output

Generator runs but does not support all electrical devices connected.

Bad connecting wires/cables.

Bad electrical device connected to generator.

Generator is overloaded

Shorten one of the connected devices.

Air cleaner is dirty.

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.

Try connecting fewer electrical loads to the generator.

Try disconnecting any faulty or short-circuited electrical loads.

Clean or replace air cleaner.

GENERATOR ASSEMBLY AND MOUNTING

Generator is supplied with a wheel kit. If you want to install the wheel kit on your unit, please follow the instructions below. If you will not be using the wheel kit, skip this section.

1. Place the bottom of the generator cradle on a flat, even surface. Temporarily place unit on blocks to ease assembly.

2. Secure the support leg to the cradle with cap screws (M8 x 16) and lock nuts (M8)

(see figure 22 ).

3. Secure the axle to the cradle with cap screws (M8 x 16) and lock nuts (M8) (see figure

23 ).

4. Slide a wheel over the axle, then secure the wheel with a retaining pin.

(see figure 24,Figure 25, Figure 26 ).

5. Position the handles on the cradle and attach, cap screws (M8 x 16) and lock nuts (M8)

( Figure 27,Figure 28 ).

6. Check that all fasteners are tight.

Figure 22 Figure 23 Figure 24

Figure 25 Figure 26 Figure 27

Figure 28

CHANGE THE CARBON-BRUSH

CHANGE THE AVR

WIRING DIAGRAM

(DS4400)

23

WIRING DIAGRAM

(DS4400E)

24

EXPLODED VIEW AND PARTS LIST

(DS4400)

84

25

Ite m

1

4

5

2

3

8

9

6

7

10

11

32

33

34

35

28

29

30

31

36

37

38

39

40

41

24

25

26

27

20

21

22

23

16

17

18

19

12

13

14

15

42

Part

DJ168F-16121-K

GBT5787-B6-8

DJ168F-16118

DJ170N-16121-A

GBT6177/10-N-14

DJ168F-16000-A

DJ168F-16002-A

DJ168F-16200-C

DJ168F-18300-A

DJ168F-11400-A

DJ168F-18100-C

1

1

4

1

Qt y

1

1

1

1

1

1

1

Description

Recoil Starter

Bolt Flange M6×8

Grommet drain hole

Fan case

Flange nut M14

Starting Cup

Flywheel Fan

Flywheel

Amplifier

Wind Shiel Assembly

Ignition Coil

GBT5787-B6-25

DJ168F-11004-A

DJ168F-11005-A

DJ168F-11014-A

DJ170F-11100-C

DJ170FD-14100-B

DJ168F-14119

GBT5787-B6-16

DJ168F-11012-A

DJ168F-14027-A

DF2500H-14205-A

GBT5787-B6-12

GBT5787-B5-14

DJ168F-14204

DJ170F-14201

DJ168F-14202

DJ168F-14206

GBT6177-N-6

DJ168F-14205-A

DJ168F-14014-A

DJ168FD-14001-A

DJ168F-14005-A

DJ168F-14004-A

DJ168F-14003-B

DJ170F-11200-B

DJ168FD-11013-A

DJ168F-11300-C

DJ168F-11011-A

GBT5787-B8-60

DJ168F-14002-A

2

2

2

2

Flange bolt M6×25

Drain Plug Washer

Washer, drain lug

Oil seal, 25×41×6

1

1

Crank case assy.

Carburetor Assembly

1 Lever comp, choke

15 Bolt Flange M6×16

1

7

1

1

Air-leading Cover

Air Cleaner Gasket

Stay, air cleaner

Flange bolt M6×12

1

1

4 Flange bolt M5×14

1 Air Cleaner Cover

Element, air cleaner

Air Cleaner Housing

1

1

4

2

1

1

1

1

2

1

1

2

Packing Slip

Flange nut M6

1 Air Cleaner Base

1 Grommet

Bolt Stud, 6×90

Carbretor Gasket

Connecting Block,Carbretor

Inlet Gasket

Head comp, cylinder

Tube, Breather

Cylinder Head Cover Assembly

Cylinder Head Cover Gasket

Flange bolt M8×60

Bolt head, M8×35

DJ170F-11010-C 1 Casket, cylinder head

26

Ite m

43

44

45

46

47

48

49

50

51

52

53

Part

DJ168F-11009-A

GB276-89-6205

DJ168F-18500-A

DJ170F-13009-A

DJ170F-13008-B

DJ168F-13300-A

DJ168F-13202-A

DJ168F-13203-A

DJ168F-13204-A

DJ168F-13201-A

DJ170F-12002-A

74

75

76

77

70

71

72

73

78

79

80

81

82

83

66

67

68

69

62

63

64

65

58

59

60

61

54 DJ168F-12003-A

55 DJ170F-12200-B

56

57

DJ168F-13006-A

DJ168F-13004-A

DJ168F-13005-A

DJ168F-13003-A

DJ168F-13010-A

DJ168F-13002-A

DJ168F-13001-A

DJ168F-13100-B

DJ168F-12104

DJ168F-12100-BB

DJ168F-18200-A

DJ168F-15001-A

DJ168F-15006-A

DJ170F-15008-A

DJ168F-15004-A

DJ168F-15005-A

DJ170F-15007-A

DJ168F-15100-A

DJ168FD-15200-A

DJ170F-11003-B

DJ168F-11002-C

DJ168F-11007-A

DF1800H-33016-A

GBT5787-B8-35

DJ168FD-11001-C

DJ170F-12001-B

DJ170F-12300-A

DJ168F-11039-A

84 DJ168F-11002-B

2

2

2

1

Qt y

2

2

2

1

2

2

1

1

1

1

1

1

1

6

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

2

1

Description

Set Pin, 10×14

Radial ball bearing (6025)

Spark Plug F7TC

Tappet Litter Valve

Rod, push

Plate, push rod guide

Fastening Bolt

Adjusting Nut

Lock Nut

Arm, valve rocker

Pin, piston

Clip, piston pin

Tie-rod Assembly

Rotator, valve

Retainer, IN. Valve spring

Retainer, EX. Valve spring

Spring, valve

Returnrer, Exhaust Valve

Intake Valve

Exhaust Valve

Camshaft assy.

Woodruff Key

Crankshaft Assembly

Oil Sensor Assembly

Shaft, governor assy.

Pulling Rod

Fine Regulating Spring C

Speed Regulating Arm

Lock Bolt

Back Spring B centrifugal assy.

speed adjuster

Crankcase Gasket

Pin, dowel, 9×12

Oil Filler Assembly

Plat bolt M8×35

Crankcase cover

Piston

Scraper Ring Set, Piston

O-Clip

Pin, dowel, 7×12

27

Item Part

Qt y

Description

85 DF2500H-31201-A 2 Bottom rubber A

86 DF2500H-31202-A 2 Bottom rubber B

87 GBT6177-N-8 4 Flange nut M8

Ite m

127 14306

Part

128 14303

129 GBT819-B-5

88 GBT889-N-8 10 Flange nut M8 130 14313

89 DF2500H-14304-A 1 Rubber Screws, Fuel Tank 131 14311

90 34107

91 34206-100

1 Earth terminal set

1 Circuit breaker

132 14305

133 14304

92 34204-003

93 34204-005

94 20140

95 34204-038

96 34208-004

97 34204-039

98 34203-004

99 XP4400-34101-A

100 34213-001

101 34205-001

1 4-holes Socket

1 3-holes Socket

4 Plain Washer

1 Output Set, DC A

1 Output Set, DC B

1 Engine switch

1 Control panel

1 Sub Wire Harness Assay

1 Voltmeter

134 DJ168FD-14007-C

135 DJ168F-14008-A

136 DF2500H-14302-A

137 DF2500H-14400-E

1 Over-current protector, DC 138 DJ188F-14010-A

139 DF2500H-14009

140 GB5787-B-8

141 DJ168F-14006-A

142 DF2500H-14018-B

143 DF2500H-31019-B

102 34210-001

103 34102-A

104 34109

105 34117

106 34212-001

107 GBT6170-N-8

108 GBT5789-B5-16

109 DF1800H-33006-B 1 Generator end cover

110 DF3500H-33015-A 4 Flange bolt M6×156

111 DF1800H-33005-A 1 GENERATOR STAY

112 DF3500H-33001

1 Rectifier bridge 30A

1 Control panel case

1 Boot, main wire harness

1 Boot, AC output wire

1 Boot, main wire harness

6 Flange nut M8

8 Flange bolt M5×16

1 BRUSH ASSEMBLY

113 DF3500H-33002 1 Conecting Plate

114 DF2500H-33011-A 1 Voltage regulator

115 DF3500H-33003-A 1 Bolt M8×220

116 GBT93-LW-8 1 Plain washer φ8

117 GBT97-W-8

118 GB276-89-6204

2 Plain Washer

1 Bearing 6204-2RS

119 DF3500H-33110-B 1 ROTOR ASSEMBLY

120

DF3000H33103-B-

23602

121 DF2500H-33023

1 Stator & Rotor Assy.

1 Generator fan

122 DF3500H-33129

123 DF3500H-33120

1 Stator cover

1 Stator Assy.

124 DF2500H-14322-D 1 rubber belt

125 DF2500H-14300-B 1 Fuel tank

126 14307 1 Fuel filter

Qty

1

1

2

1

4

4

4

1

2

1

1

1

1

2

Fuel filler cap comp

Fuel sensor

Screw M5×10

GASKET,FUEL SENSOR

Washer

Collar

Cushion

Outlet pipeφ4.5×165

Tube clip

Fuel cock

Muffler

Gasket , Exhaust Pipe

Exhaust Pipe

Flange bolt M8×25

Muffler Gasket

1 Outer Hood

2 φ3 Clip

Description

144 31017-F

145 DF3000H-31018-F

146 DF3000H-31070-E

147 GBT889-N-6

148 DF9000H-31204-A

149 DF6500H-31016-A

150 DF3800H-31058-C

2 Wheel comp

1 Well shaft

2 Support

2 Flange nut M6

2 Rubber feet

2 Rubber Coat, Handle

2 Handle

151 GBT889-N-8×20 10 Flange bolt M8×20

152 DFD3000H-31021-B 1 Axle

153 34202-006

154 DJ170N-B

155 XP4400-31100-B

1

1

1

Transfer Switch

Gasoline engine

Frame com

28

EXPLODED VIEW AND PARTS LIST

(DS4400E)

29

Ite m

1

2

Part

5

6

3

4

DJ168F-16121-K

GBT5787-B6-8

DJ168F-16118

DJ170N-16121-A

7

8

GBT6177/10-N-14

DJ168F-16000-A

DJ168F-16002-A

DJ168F-16200-I

9 DJ168F-18300-A

10 DJ170S-11400-A

11 DJ168F-18100-C

Q ty

Description

1 Recoil Sarer

4 Bolt Flange M6×8

1 Grommet drain hole

1 Fan case

1 Flange nut M14

1 Starting Cup

1 Flywheel Fan

1 Flywheel

1 Amplifier

1 Wind Shiel Assembly

1 Ignition Coil

12 GBT5787-B6-25

13 DJ168F-11004-A

14 DJ168F-11005-A

15 DJ168F-11014-A

16 DJ170F-11100-C

17 DJ170FD-14100-B

18 DJ168F-14119

19 GBT5787-B6-16

20 DJ168F-11012-A

21 DJ168F-14027-A

22 DF2500H-14205-A

23 GBT5787-B6-12

24 GBT5787-B5-14

25 DJ168F-14204

26 DJ170F-14201

27 DJ168F-14202

28 DJ168F-14206

29 GBT6177-N-6

30 DJ168F-14205-A

31 DJ168F-14014-A

32 DJ168FD-14001-A

33 DJ168F-14005-A

34 DJ168F-14004-A

35 DJ168F-14003-B

36 DJ170F-11200-B

37 DJ168FD-11013-A

38 DJ168F-11300-C

39 DJ168F-11011-A

40 GBT5787-B8-60

41 DJ168F-14002-A

4 Flange bolt M6×25

2 Drain Plug Washer

2 Washer, drain lug

2 Oil seal, 25×41×6

1 Crank case assy.

1 Carburetor Assembly

1 Lever comp, choke

15 Bolt Flange M6×16

1 Air-leading Cover

1 Air Cleaner Gasket

1 Stay, air cleaner

7 Flange bolt M6×12

4 Flange bolt M5×14

1 Air Cleaner Cover

1 Element, air cleaner

1 Air Cleaner Housing

1 Packing Slip

2 Flange nut M6

1 Air Cleaner Base

1 Grommet

2 Bolt Stud, 6×90

1 Carbretor Gasket

1 Connecting Block,Carbretor

1 Inlet Gasket

1 Head comp, cylinder

1 Tube, Breather

1 Cylinder Head Cover Assembly

1 Cylinder Head Cover Gasket

4 Flange bolt M8×60

2 Bolt head, M8×35

42 DJ170F-11010-C 1 Casket, cylinder head

30

Ite m

Part

43 DJ168F-11009-A

44 GB276-89-6205

45 DJ168F-18500-A

46 DJ170F-13009-A

47 DJ170F-13008-B

48 DJ168F-13300-A

49 DJ168F-13202-A

50 DJ168F-13203-A

51 DJ168F-13204-A

52 DJ168F-13201-A

53 DJ170F-12002-A

54 DJ168F-12003-A

55 DJ170F-12200-B

56 DJ168F-13006-A

57 DJ168F-13004-A

58 DJ168F-13005-A

59 DJ168F-13003-A

60 DJ168F-13010-A

61 DJ168F-13002-A

62 DJ168F-13001-A

63 DJ168F-13100-B

64 DJ168F-12104

65 DJ168F-12100-BB

66 DJ168F-18200-A

67 DJ168F-15001-A

68 DJ168F-15006-A

69 DJ170F-15008-A

70 DJ168F-15004-A

71 DJ168F-15005-A

72 DJ170F-15007-A

73 DJ168F-15100-A

74 DJ168FD-15200-A

75 DJ170F-11003-B

76 DJ168F-11002-F

77 DJ168F-11007-A

78 DF1800H-33016-A

79 GBT5787-B8-35

80 DJ168FD-11001-C

81 DJ170F-12001-B

82 DJ170F-12300-A

83 DJ168F-18600-A

84 DJ168F-11002-B

Q ty

Description

2 Set Pin, 10×14

2 Radial ball bearing (6025)

1 Spark Plug F7TC

2 Tappet Litter Valve

2 Rod, push

1 Plate, push rod guide

2 Fastening Bolt

2 Adjusting Nut

2 Lock Nut

2 Arm, valve rocker

1 Pin, piston

2 Clip, piston pin

1 Tie-rod Assembly

1 Rotator, valve

1 Retainer, IN. Valve spring

1 Retainer, EX. Valve spring

2 Spring, valve

1 Returnrer, Exhaust Valve

1 Intake Valve

1 Exhaust Valve

1 Camshaft assy.

1 Woodruff Key

1 Crankshaft Assembly

1 Oil Sensor Assembly

1 Shaft, governor assy.

1 Pulling Rod

1 Fine Regulating Spring C

1 Speed Regulating Arm

1 Lock Bolt

1 Back Spring B

1 centrifugal assy.

1 speed adjuster

1 Crankcase Gasket

1 Pin, dowel, 9×12

1 Oil Filler Assembly

1 Plat

6 bolt M8×35

1 Crankcase cover

1 Piston

1 Scraper Ring Set, Piston

1 Starting Motor Assembly

1 Pin, dowel, 7×12

31

Ite m

Part

84 XP4400E-31100-B

85 DF2500H-31201-A

86 DF2500H-31202-A

87 GBT6177-N-8

88 GBT889-N-8

89 DF2500H-14304-A

90 34107

91 34206-100

92 34204-003

93 34204-005

94 20140

95 34204-038

96 34208-004

97 34204-039

98 34203-002

99 XP4400E-34101-A

100 34213-002

101 34205-001

102 34210-001

103 34102-A

104 34109

105 34117

106 34212-001

107 GBT6170-N-8

108 GBT5789-B5-16

109 DF1800H-33006-B

110 DF3500H-33015-A

111 DF1800H-33005-A

112 DF3500H-33001

113 DF3500H-33002

114 DF2500H-33011-A

115 DF3500H-33003-A

116 GBT93-LW-8

117 GBT97-W-8

118 GB276-89-6204

119 DF3500H-33110-B

120

DF3000H33103-B-23

602

121 DF2500H-33023

122 DF3500H-33129

123 DF3500H-33120

124 DF2500H-14322-D

Qt y

Description

1 Frame comp

2 Bottom rubber A

2 Bottom rubber B

4 Flange nut M8

10 Flange nut M8

1 Rubber Screws, Fuel Tank

1 Earth terminal set

1 Circuit breaker

1 4-holes Socket

1 3-holes Socket

4 Plain Washer

1 Output Set, DC A

1 Over-current protector, DC

1 Output Set, DC B

1 Engine switch

1 Control panel

1 Sub Wire Harness Assay

1 Voltmeter

1 Rectifier bridge 30A

1 Control panel case

1 Boot, main wire harness

1 Boot, AC output wire

1 Boot, main wire harness

6 Flange nut M8

8 Flange bolt M5×16

1 Generator end cover

4 Flange bolt M6×156

1 GENERATOR STAY

1 BRUSH ASSEMBLY

1 Conecting Plate

1 Voltage regulator

1 Bolt M8×220

1 Plain washer φ8

2 Plain Washer

1 Bearing 6204-2RS

1 ROTOR ASSEMBLY

1 Stator & Rotor Assy.

1 Generator fan

1 Stator cover

1 Stator Assy.

1 rubber belt

32

Item Part

Qt y

Description

125 DF2500H-14300-B 1 Fuel tank

126 14307

127 14306

1 Fuel filter

1 Fuel filler cap comp

128 14303

129 GBT819-B-5

130 14313

1 Fuel sensor

2 Screw M5×10

1

GASKET,FUEL

SENSOR

4 Washer 131 14311

132 14305

133 14304

4 Collar

4 Cushion

134 DJ168FD-14007-C 1 Outlet pipeφ4.5×165

135 DJ168F-14008-A 2 Tube clip

136 DF2500H-14302-A 1 Fuel cock

137 DF2500H-14400-E 1 Muffler

138 DJ188F-14010-A

139 DF2500H-14009

1 Gasket , Exhaust Pipe

1 Exhaust Pipe

140 GB5787-B-8

141 DJ168F-14006-A

2 Flange bolt M8×25

Muffler Gasket

142 DF2500H-14018-B 1 Outer Hood

143 DF2500H-31019-B 2 φ3 Clip

144 31017-F 2 Wheel comp

145 DF3000H-31018-F 1 Well shaft

146 DF3000H-31070-E 2 Support

147 GBT889-N-6 2 Flange nut M6

148 DF9000H-31204-A 2 Rubber feet

149 DF6500H-31016-A 2 Rubber Coat, Handle

150 DF3800H-31058-C 2 Handle

151 GBT889-N-8×20

152

DFD3000H-31021-

B

153 34202-006

10 Flange bolt M8×20

1 Axle

1 Transfer Switch

154 DJ170N-BD

155 34224-001

1 Gasoline engine

1 Charger

156 DF1800H-31033-A 1 Foot

157 31040-001 1 Negative Wire of battery

158 31300-001

159 31038-001

1 7Ah battery

1 Positive wire of battery