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Gasoline Powered Generator
Product Support
product_support@durostarusa.com
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.
Owner's Manual
(Product: information, application, service info & warranty questions)
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Table of Contents
Related Manuals for DuroStar DS4400
Summary of Contents for DuroStar DS4400
- Page 1 Gasoline Powered Generator Owner’s Manual Product Support (Product: information, application, service info & warranty questions) product_support@durostarusa.com 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.
- Page 2 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.
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Page 3: Table Of Contents
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 –... -
Page 4: General Safety Procedures
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. - Page 5 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.
- Page 6 In addition to the above safety notices, please familiarize yourself with the safety and hazard markings on the generator.
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Page 7: Package Contents
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... -
Page 8: Generator Components
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. -
Page 9: Preparing The Generator For Use
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 DS4400 DS4400E 20 fluid oz. Engine oil capacity... -
Page 10: Step 2- Add Gasoline
• 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 DS4400 DS4400E 15L(3.96 us. gallons) -
Page 11: 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. -
Page 12: Step 3- Ground The Generator
• 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: •... -
Page 13: Using The Generator
The surge wattage ability of the generator covers this extra power requirement. Model Number Rated (Running) Wattage Surge Wattage 3500 4400 DS4400 3500 4400 DS4400E 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. - Page 14 If these specifications are not available you may estimate the Watts required by your device by using the chart in figure 10. Tool or Appliance Rated (Running) Watts Additional Surge Watts Electric water heater (40 gal) 4000 Hot plate 2500 Saw-radial arm 2000 2000...
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Page 15: Voltage Selector Switch
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. -
Page 16: Dc Usage
Device Requirements Max. Cord Length (ft) by Wire Gauge Watts Watts Amps #8 wire #10 wire #12 wire #14 wire #16 wire (120V) (240V) 1000 1200 1800 1200 2400 1800 3600 2400 4800 3000 6000 3600 7200 4800 9600 *NR= not recommended Figure 12-Maximum Extension Cord Lengths by Power Requirement DC Usage CAUTION:... -
Page 17: Stopping The Generator
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. -
Page 18: Checking The Oil
- 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. - Page 19 Model number DS4400 DS4400E Engine oil capacity 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.
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Page 20: Air Cleaner Maintenance
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. -
Page 21: Emptying The Gas Tank
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. -
Page 22: Specifications
GENERATOR SPECIFICATIONS AC Output DS4400 DS4400E Rated Wattage 3500W 3500W Surge Wattage 4400W 4400W Rated Voltage 120/240V 120/240V Rated Frequency 60Hz 60Hz Phase Single Single DC Output DS4400 DS4400E Voltage Amperage 8.3A 8.3A Length=23.2 Length=23.2 Dimensions (in): Width=17 Width=17 Height=17... -
Page 23: Generator Assembly And Mounting
not start Spark plug is broken. Replace spark plug. (continued Move generator to a level surface to Generator is not on level from page prevent low oil shutdown from surface. triggering. Oil is low Add or replace oil. Set the circuit breaker to the “ON” Circuit breaker is off. -
Page 24: Change The Carbon-Brush
Figure 25 Figure 26 Figure 27 Figure 28 CHANGE THE CARBON-BRUSH... -
Page 25: Change The Avr
CHANGE THE AVR... -
Page 26: Wiring Diagram
WIRING DIAGRAM (DS4400) - Page 27 WIRING DIAGRAM (DS4400E)
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Page 28: Exploded View And Parts List
EXPLODED VIEW AND PARTS LIST (DS4400) - Page 29 Part Description Part Description DJ168F-16121-K Recoil Starter DJ168F-11009-A Set Pin, 10×14 GBT5787-B6-8 Bolt Flange M6×8 GB276-89-6205 Radial ball bearing (6025) DJ168F-16118 Grommet drain hole DJ168F-18500-A Spark Plug F7TC DJ170N-16121-A Fan case DJ170F-13009-A Tappet Litter Valve GBT6177/10-N-14 Flange nut M14 DJ170F-13008-B Rod, push DJ168F-16000-A Starting Cup...
- Page 31 Item Part Description Part Description 85 DF2500H-31201-A 2 Bottom rubber A 127 14306 Fuel filler cap comp 86 DF2500H-31202-A 2 Bottom rubber B 128 14303 Fuel sensor 87 GBT6177-N-8 4 Flange nut M8 129 GBT819-B-5 Screw M5×10 88 GBT889-N-8 10 Flange nut M8 130 14313 GASKET,FUEL SENSOR 89 DF2500H-14304-A...
- Page 32 EXPLODED VIEW AND PARTS LIST (DS4400E)
- Page 33 Part Description Part Description DJ168F-16121-K Recoil Sarer DJ168F-11009-A Set Pin, 10×14 GBT5787-B6-8 Bolt Flange M6×8 GB276-89-6205 Radial ball bearing (6025) DJ168F-16118 Grommet drain hole DJ168F-18500-A Spark Plug F7TC DJ170N-16121-A Fan case DJ170F-13009-A Tappet Litter Valve GBT6177/10-N-14 Flange nut M14 DJ170F-13008-B Rod, push DJ168F-16000-A Starting Cup...
- Page 35 Part Description Item Part Description 84 XP4400E-31100-B 1 Frame comp 125 DF2500H-14300-B 1 Fuel tank 85 DF2500H-31201-A 2 Bottom rubber A 126 14307 1 Fuel filter 86 DF2500H-31202-A 2 Bottom rubber B 127 14306 1 Fuel filler cap comp 87 GBT6177-N-8 4 Flange nut M8 128 14303 1 Fuel sensor...