Page 1: ...7pm Friday Saturday 6am to 3pm PST support maxtool com or call 1 800 629 3325 option 3 Monday Thursday 6am to 7pm Friday Saturday 6am to 3pm PST This manual provides information regarding the operation and maintenance of these products We have made every effort to ensure the accuracy of the information in this manual We reserve the right to change this product at any time without prior notice ...
Page 2: ...0VI240V 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 Meets EPA and CARB Emission Standards Notice Regarding Emissions Engines that are certified to comply with California and U S EPA emission regulations for SORE Small Off Road Equipment are certified to operate on regular unleaded gasolin...
Page 3: ...tep 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 ...
Page 4: ... 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 ca...
Page 5: ...s 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 CAUTIO...
Page 6: ... on the generator IAJCAUTIONI POISONOUS GAS Generator exhaust contains toxic carbon monoxide gas NEVER operate indoors or in poorly ventilated areas IA WARNINGl RISK OF EXPLOSION Stop generator before refueling Check for spilled fuel Do not operate near open flame IAI CAUTIONI HOT EXHAUST DO NOT TOUCH l 6 ...
Page 7: ...NTS 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 7 ...
Page 8: ...unt of fuel in the tank 4 Fuel Cap Access to the fuel tank for adding fuel 5 Circuit Breaker Reset switch that protects the generator from electrical overload 6 120 240 Volt AC Receptacle Use to connect electrical devices that run 120 and or 240 Volt 60Hz single phase AC current NEMA L14 30 7 Ground Terminal Connect grounding wires here to properly ground unit 8 120 Volt AC Receptacle Use to conne...
Page 9: ...e 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 XP4400 I XP4400E ...
Page 10: ...GHER 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 genera...
Page 11: ...pped 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...
Page 12: ...your area STARTING THE GENERATOR CAUTION Disconnect all electrical loads from the generator before attempting to start To start your generator perform the following steps 1 I Make sure no electrical devices are connected to the generator Such devices can make it difficult for the engine to start 2 Check that the generator is properly grounded see page 13 Ground the Generator 3 Turn the fuel valve ...
Page 13: ...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 Surge Wattage XP4400 3500 4400 XP4400E 3500 4400 Figure 9 generator wattage by model number The...
Page 14: ...rNCD 100 0 Common light bulb 75 0 Figure 10 Estimated wattage requirements of common electrical devices Once you have found the rated wattage requirement of each electrical device add these numbers to find the total rated wattage you wish to draw from the generator If this number exceeds the rated wattage of the generator DO NOT connect all these devices Select a combination of electrical devices ...
Page 15: ...acles available on the generator VOLTAGE SELECTOR SWITCH XP4400 XP4400E 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 to any of the 120V 3 prong receptacles select the 120V ONLY position...
Page 16: ...eptacle 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 th...
Page 17: ... long periods of time without use can make it difficult to start the generator in the future Never store generator for extended periods of time with fuel in the tank MAINTENANCE ICARE Proper routine maintenance of your generator will help prolong the life of your machine Please perform maintenance checks and operations according the schedule in figure 13 CAUTION Never perform maintenance operation...
Page 18: ...th 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 Oir in this section 5 Be sure to replace cap when finished checking...
Page 19: ...ing 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 Figure 16 Draining oil Figure 17 Adding oil 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 ...
Page 20: ... 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 disca...
Page 21: ...derneath 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 ...
Page 22: ... Ignition system Non contact transistor Displacement 200cc Starting type Recoil I Electric Fuel tank capacity 15L 3 96US gal Oil capacity O 6L 20floz Run time on 50 load 14hrs I 12 hrs Noise Level 69dB TROUBLESHOOTING Problem Cause Solution Engine will Engine switch is set to OFF Set engine switch to ON not start Fuel valve is turned to Turn fuel valve to OPEN position CLOSED Choke is open Close t...
Page 23: ...aner connected 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...
Page 24: ...lled bolts Take down the carbon brush of electric machine back cover M5X 16 of carbon brush from DC wire of excitation Install the new carbon brush Insert and connect the DC Install the electric machine back with bolts M5X16 wire of excitation according cover with 2bolts M5X12 to anode cathode CHANGE THE AVR 24 ...
Page 25: ...VR Disconnect the sample wire hindered Take down the AVR from Install the new AVR with 2 carbon brush bolts M5X16 Connect the sample wire hindered Insert and connect the DC wire of excitation according to anode cathode Install the electric machine back cover with 2 bolts M5 X12 WIRING DIAGRAM XP4400 25 ...
Page 26: ...k I Engine block Ignition switch connecting Main cod R j I IILB t LB Gr Y G I Y G B1 til I I y 10 _ l _ c o lli L B I WIRING DIAGRMI OF 120V 240V GENERATOR SET L _ I M nelic field CR I R cOlI I W II R II I I I I I I I DC coil 1 I L L _ _ I LL rl r goitiOO itch_ I t tiO R gBU A Bl Black Br Brown 0 Orange Ilr R Brown Red Bu Blue LB Light blue Gr Gray Y G Yellow Green R Red W White ...
Page 27: ... r 1 Main cui 1 DC coi I 1 WIRING DIAGRAM OF 120V 240V GENERATOR SET r I t I LB r LB ECS3 I I 1 I I LB LB 1 i R ta r R R9J 1 t A I J oo v I Ign ioo itoh _ _ _ RI L _ I Magnetic fieldeR cO 1 I W L Generator block I Engine block il Y Motor fu oj Spark Ignition coil _ _ _ _ _ _ _ _ _ _ protector plug Ignition sw itch c nnectin g Bl Black Br Brown 0 Orange Ilr R Brown Red Bu Blue LB Light blue Gr Gray...
Page 28: ...N 00 19 19 ...
Page 29: ...er 62 DJ168F 13001 A 1 Exhaust Valve 21 DJ168F 14027 A 1 Air Cleaner Gasket 63 DJ168F 13100 B 1 Camshaft assy 22 DF2500H 14205 A 1 Stay air cleaner 64 DJ168F 12104 1 Woodruff Key 23 GBT5787 B6 12 7 Flange bolt M6x12 65 DJ168F 12100 BB 1 Crankshaft Assembly 24 GI3T5787 B5 14 4 Flange bolt M5x14 66 DJ168F 18200 A 1 Oil Sensor Assembly 25 DJ168F 14204 1 Air Cleaner Cover 67 OJ168F 15001 A 1 Shaft gov...
Page 30: ...r L 12 94 12 1 122 __ 119 1 1 8 123 _ iA1 1 143 I 27 8 m i 2 1 151 143 l 145 151 T 144as 152 h 88 146 88 l X 47 14 148 88 7 14 10 6 137 23 I O VI I 23 142 i I 140 141 1Q7 w o ...
Page 31: ...43 DF2500H 31019 B 2 1 3 Clip 102 34210 001 1 Rectifier bridge 30A 144 31017 F 2 Wheelcomp 103 34102 A 1 Control panel case 145 DF3000H 31018 F 1 Well shaft 104 34109 1 Boot main wire harness 146 DF3000H 31070 E 2 Support 105 34117 1 Boot AC output wire 147 GBT889 N 6 2 Flange nut M6 106 34212 001 1 Boot main wire harness 148 DF9000H 31204 A 2 Rubber feet 107 GBT6170 N a 6 Flange nut Ma 149 DF6500...
Page 32: ...w IV 51 Of 50 m 0 r o c m c m z c g 0 f en r en f X 0 o o m ...
Page 33: ...68F 13001 A 1 Exhaust Valve 21 DJ168F 14027 A 1 Air Cleaner Gasket 63 DJ168F 13100 B 1 Camshaft assy 22 DF2500H 14205 A 1 Stay air cleaner 64 DJ168F 12104 1 Woodruff Key 23 GBT5787 B6 12 7 Flange bolt M6x12 65 DJ168F 12100 BB 1 Crankshaft Assembly 24 GBT5787 B5 14 4 Flange bolt M5x14 66 DJ168F 18200 A 1 OiLSensor Assembly 25 DJ168F 14204 1 Air Cleaner Cover 67 DJ168F 15001 A 1 Shaft governor assy ...
Page 34: ...w j 23 137 J 23 142 I 141 I 140 107 154 27 11 26 143 I I I I I ...
Page 35: ...Hood 102 34210 001 1 Rectifier bridge 30A 143 DF2500H 31019 B 2 cP 3 Clip 103 34102 A 1 Control panel case 144 31017 F 2 Wheel camp 104 34109 1 Boot main wire harness 145 DF3000H 31018 F 1 Well shaft 105 34117 1 Boot AC output wire 146 DF3000H 31070 E 2 Support 106 34212 001 1 Boot main wire harness 147 GBT889 N 6 2 Flange nut M6 107 GBT6170 N 8 6 Flange nut M8 148 DF9000H 31204 A 2 Rubber feet 10...
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