DUROMAX Duro Star DS4400E, User Manual

Page 1: ...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 5800 Ontario Mills Pkwy Ontario CA 91764 USA www duromaxpower com Call our Customer Care Team Toll Free 8 5pm PST Mon Fri 844 DUROMAX User Manual REV DS4400E 01152018 ...

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Page 3: ...the Oil 22 Check the Gas Level 23 Starting the Generator 24 Starting the Generator 2 Shipping Braces 16 Wheel Kit Installation 17 Adding Oil 18 Adding Gasoline 19 Grounding the Generator 20 High Altitude Operation 20 Generator Setup 4 AC Usage 28 Connecting a Load to the Generator 30 Voltage Selector Switch 31 DC Usage 32 Using the Generator 3 ...

Page 4: ... Cleaner 40 Spark Plug Maintenance 42 Emptying the Gas Tank 44 Cleaning the Fuel Filter Cup 46 Storage and Transportation 47 Specifications 48 58 Basic Troubleshooting 50 Changing Inspecting the Carbon Brushes 51 Changing Inspecting the AVR 53 Maintenance and Care Warranty Troubleshooting 4 8 62 Contact Information ...

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Page 6: ...orm that knocks out power dewatering a flooded property or washing away a deck for the summer season Engines that are certified to comply with U S EPA emission regulations for SORE Small off Road Equipment are certified to operate on regular unleaded gasoline and may include the following emission control systems EM Engine Modifications and TWC Three Way Catalyst if so equipped 6 STOP Please do no...

Page 7: ... 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 The safety alert symbol is used with one of the safety words DANGER CAUTION or WARNING to alert you of hazards Please pay attention to these hazard notices both in ...

Page 8: ...disconnect the spark plug WARNING This generator produces a powerful voltage which can result in electrocution ALWAYS ground the generator before using it see the Grounding the Generator portion of the PREPARlNG 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 qua...

Page 9: ...In addition to the above safety notices please familiarize yourself with the safety and hazard markings on the generator GENERAL SAFETY PROCEDURES 9 ...

Page 10: ... full when you see fuel in the bottom of the fuel filter cup DO NOT overfill the tank 3 Turn gas valve on The gas valve is located above the recoil start on the bottom of the fuel tank Rotate the valve clockwise to the vertical position to turn on the gas supply 5 Add oil The oil fill cap is located on the lower engine block to the right of the recoil start housing Remove the oil fill cap and fill...

Page 11: ...nd increase air into the carburetor for normal running 8 Connect devices Connect your devices to the receptacles on the front panel Start with the largest loads first 10 Start generator The key switch is located on the left side of the front power panel Insert the key and turn to the start position to start the generator Allow the key to return to the run position once started 7 Turn breaker on Th...

Page 12: ... engine 3 Fuel Gauge Indicates the amount of fuel in the gasoline tank 4 Fuel Cap Allows access to fill the gasoline tank 5 Circuit Breaker Resettable switch that protects the generator from electrical overload 6 120 240v 4 Prong Receptacle Use to connect electrical devices that run 120 or 240 Volt 60Hz single phase AC current NEMA L14 30 7 Ground Terminal Connect a ground wire here to properly gr...

Page 13: ... the generator 14 Recoil Start Easy Pull Recoil Start to start the engine without the electric start 15 Fuel Filter Cup Traps dirt and debris in gasoline before it enters the engine 16 Fuel Valve On Off Valve that allows fuel into the engine 17 Spark plug Provides ignition to the engine 18 Muffler Reduces engine emissions and reduces noise 19 Power Boost DuroMax exclusive Power Boost doubles the a...

Page 14: ... Wrench Plug Ends Phillips and slot blade screwdriver used for generator maintenance Used to add oil to the generator without messy spills Assorted wrenches used in generator maintenance and assembly Commonly 8mm 10mm 13mm and 15mm Used in conjunction with the charging posts to charge 12v automotive style batteries or small DC appliances Used in spark plug maintenance inspection and installation P...

Page 15: ...GENERATOR SETUP Proper setup of your generator will get you going as soon as possible while making sure you and your equipment are safe and cared for ...

Page 16: ...el or oil in the generator 1 Step 1 Remove Shipping Braces Remove braces a Completely remove each of the 4 bolts holding the orange metal brace in place b Remove the brace c Cut the nylon tie strap holding the wood brace in place d Grab the end of the second brace and pull it out e This piece is no longer needed and can be discarded 2 16 Note Shipping braces can be thrown away They will not be nee...

Page 17: ...xlebracketweldedtoaxletotheframewith the provided bolts and lock nuts b Secure the loose axle bracket to the frame with the provided bolts and lock nuts c Slide one wheel over each axle end and secure with the provided retaining pins Attach the handles to the brackets on the frame using the provided bolts and nuts Do not over tighten the handles it will prevent free movement 2 3 ...

Page 18: ...n the engine s service life a Make sure the generator is on a level surface b Unscrew the oil filler dipstick cap from the engine c Using a funnel add the appropriate amount of oil 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 d Replace oil filler cap 1 Step 3 Adding Oil Engine oil recommended SA...

Page 19: ...e top of the gas tank indicates how much gasoline is in the generator gas tank d Replace fuel cap and wipe up any spilled gasoline with a dry cloth NOTE Gas can expand Do not fill the gas tank to the very top Leave a minimum of 1 5 in of open space 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 ...

Page 20: ...altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by specific modifications to the carburetor If you always operate your generator at altitudes above 5 000 feet 1 500 meters have a dealer perform this carburetor modification This engine when operated at high altitude with the carburetor m...

Page 21: ...e are still steps you should take to prepare it for operation each time you use it IMPORTANT At this point you should be familiar with the procedures described in the first portion of this section entitled GENERATOR SETUP If you have not yet read this section go back and read it now ...

Page 22: ...ck cap c With a dry cloth wipe the oil off of the stick on the inside of the cap d 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 e Be sure to replace the c...

Page 23: ...ister with less than 1 3 fuel tank full 1 Step 2 Check the gas level WARNING Gasoline and gasoline fumes are highly flammable Do not fill tank near an open flame Always allow engine to cool for several minutes before refueling DO NOT overfill fuel tank Fuel expands when shaken or heated ALWAY leave 11 2 space or more at the top of the tank ALWAYS use fresh fuel or stabilized fuel Old gasoline olde...

Page 24: ...bove the recoil start on the bottom of the fuel tank Rotate the valve clockwise to the vertical position to turn on the gas supply The choke lever is located above the air filter to the right of the recoil start Slide the lever to the left to cut the air supply and allow more gas into the engine to start The key switch is located on the left side of the front power panel Insert the key and turn to...

Page 25: ...r more than 5 seconds can damage the motor If the engine fails to start release the switch and wait 10 seconds before operating the starter again 25 Turn engine switch to RUN When the engine starts allow the engine switch to return to the RUN position 5 Open choke Push the choke to the OPEN position as the engine warms up 6 ...

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Page 27: ...re still steps you should take to prepare it for operation each time you use it IMPORTANT At this point you should be familiar with the procedures described in the first portion of this section entitled GENERATOR SETUP If you have not yet read this section go back and read it now ...

Page 28: ...ed 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 x Amps If...

Page 29: ...ectric drill 600 900 Television 500 0 Deep freezer 500 800 Garage door opener 480 600 Stereo 400 0 Box fan 300 600 Clock radio 300 0 Security system 180 0 DVD Player 100 0 Common light bulb 75 0 CAUTION The generator can only run at its surge wattage capacity for a very short time Connect only electrical devices requiring a rated running wattage equal to or less than the rated wattage of the gener...

Page 30: ...nnected the 240v receptacle Plug in devices Turn breaker on Turn on connected devices Plug in devices to the appropriate receptacle When using the generator in 120 240v mode balance the load as closely as possible Placing more load on one side of the circuit will reduce the breaker trip period Flip the circuit breaker up to the on position to allow power to the receptacles Start or turn on applian...

Page 31: ...e 120 240V position If only 120V appliances are being connected to the generator select the 120V ONLY position to double the 120v amperage and automatically balance the load 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 table below for recommended cor...

Page 32: ...sitive receptacle Start Generator Connect one charging wire to the positive terminal on the battery and the other charging wire to the negative terminal on the battery Connect the free end of the positive wire to the positive receptacle outlet on the generator The key switch is located on the left side of the front power panel Insert the key and turn to the start position to start the generator Al...

Page 33: ...n charging a battery DANGER 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 DANGER If battery acid is swallowed drink large quantities of milk and call a Physician immediately 33 Connect negative receptacle Carefully connect the free end of the negative wire to the negative receptacle on the generator 4 Disconne...

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Page 35: ...nce and storage of your generator is essential to ensure trouble free use of your generator when you need it By following the maintenance and care requirements you can keep your generator running smooth and efficient for years to come 35 ...

Page 36: ... instruction manual Make sure the engine is off before you begin any maintenance or repairs Let the engine and exhaust system cool before touching To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts SERVICE REGULAR SERVICE PERIOD BEFORE E...

Page 37: ...MAINTENANCE LOG Date Generator Hours Maintenance Performed 37 ...

Page 38: ...Unscrew the oil filler dipstick cap c With a dry cloth wipe the oil off of the stick on the inside of the cap d 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 secti...

Page 39: ...nated with water or dirt Remove drain plug Drain oil Replace drain plug Using a 10 mm hex wrench unscrew the oil drain plug which is located on the crankcase underneath the oil filler dipstick cap Allow all the oil to drain from the generator Drain oil into an approved oil disposal container Contact your local auto parts store for information on oil disposal Replace the oil drain plug and tighten ...

Page 40: ...ss air to enter the engine or dirty air to enter the engine causing overheating and engine wear MAINTENANCE AND CARE CONTINUED Cleaning the air cleaner Open cleaner cover Remove cleaner element Wipe out cleaner casing Unhinge the clasps at the top and bottom of the air cleaner cover Remove the sponge like elements from the casing Wipe the dirt from inside the empty air cleaner casing 1 2 3 40 ...

Page 41: ...and replace the cover 7 41 Wash cleaner element Wash the sponge like elements in household dish detergent and warm water 4 Dry cleaner element Allow the elements to dry completely 5 6 Add engine oil to elements Soak the dry elements in a small amount of engine oil Ring out any excess oil ...

Page 42: ...plug threads Spark Plug Maintenance Remove spark plug cap Remove spark plug Inspect spark plug Pull on the spark plug cap to remove it Unscrew the spark plug from the generator using the spark plug wrench included with this product 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 such as NGK BPR6ES 1 2 3 MAI...

Page 43: ...nd re gap Replace spark plug Replace spark plug cap 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 Screw the spark plug back into its place on the generator using the spark plug wrench Replace the spark plug cap 5 6 7 43 ...

Page 44: ... Turn the fuel valve to the OFF position Remove the fuel filter cup see Removing the Fuel Filter Cup earlier in this section Empty the fuel filter cup of any fuel 1 2 3 CAUTION Do not store fuel from one season to another Gasoline sold at the pump today contains additives such as ethanol that even when stored properly may damage the fuel system components MAINTENANCE AND CARE CONTINUED 44 ...

Page 45: ...lve to the ON position Drain all the gas from the generator 4 Shut fuel valve off Replace fuel filter cup Store emptied gas Turn the fuel valve to the OFF position Reinstall the fuel filter cup Store the emptied gasoline in a suitable place and add fuel stabilizer to keep fuel fresh and usable 5 6 7 45 ...

Page 46: ...ion 1 Cleaning the fuel filter cup Remove fuel filter cup Clean filter cup Replace fuel filter cup Unscrew the fuel filter cup from the fuel valve using a wrench Turn the valve towards you to unscrew Clean the cup of all sediment using a rag or brush Reinstall the fuel filter cup 2 3 4 46 ...

Page 47: ... unit to run 3 5 minutes 3 Turn off the fuel valve 4 Allow the unit to stall out 5 Turn off the key 6 Add fuel stabilizer to the gas remaining in the tank 7 Store If you do not plan to start the unit for longer than 30 days 1 Turn off the main breaker 2 Allow the unit to run 3 5 minutes 3 Turn off the fuel valve 4 Allow the unit to stall out 5 Turn off the key 6 Drain the fuel tank See Emptying th...

Page 48: ...tage 12V DC Amperage 8 3A Dimensions LENGTH 23 2in WIDTH 17in HEIGHT 17in Engine Type 4 Stroke OHV Forced Air Ignition System Non Contact Transistor Displacement 212cc Starting Type Electric Fuel Tank Capacity 3 96 US Gal 15L Oil Capacity 20 fl oz 0 6L Run Time 50 Gasoline 12 hr Run Time 50 Propane 16 hr 5 Gallon Noise Level 69db 48 ...

Page 49: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator 49 ...

Page 50: ...l Move generator to a level surface Oil is low Add change oil Engine runs but there is no electrical output Circuit Breaker is Off Turn on circuit breaker Wiring connection is bad Replace extension cord s Device connected to generator is malfunctioning Disconnect malfunctioning device Generator runs but does not support all electrical devices connected Generator is overloaded Disconnect 1 or more ...

Page 51: ...bon brushes are wearable parts and should be inspected every 250 running hours Remove generator cover Remove bolt from brush Disconnect AVR wires Remove the 2 bolts of the generator cover then pull the cover off the generator Remove the bolt holding the carbon brush Remove the two wires from the AVR on the carbon brush 1 2 3 51 ...

Page 52: ...ush Install new carbon brush with bolt 4 Connect AVR wires Insert and connect the 2 wires from the AVR be sure to connect and correctly 5 6 Replace generator cover Replace the back cover of the generator and secure with the 2 bolts TROUBLESHOOTING CONTINUED 52 ...

Page 53: ...or If the generator is overheated or overloaded the AVR may be damaged and require replacement Remove generator cover Remove AVR bolts Disconnect AVR wire clip Remove the 2 bolts of the generator cover then pull the cover off the generator Remove the 2 bolts holding the AVR Disconnect the wire clip 1 2 3 53 ...

Page 54: ...to connect and correctly 7 Disconnect wires from brush Remove the 2 wires from the AVR on the carbon brush 4 Install new AVR Install the new AVR with the 2 bolts 5 6 Reconnect wires to brush Reconnect the wire clip Changing Inspecting the AVR Continued TROUBLESHOOTING CONTINUED 54 ...

Page 55: ...Replace generator cover Replace the back cover of the generator and secure with the 2 bolts 8 55 ...

Page 56: ...WIRING DIAGRAM 56 ...

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Page 58: ...ransferable and only valid to the original purchaser Warranty Exclusions The DuroMax DuroStar Power Equipment warranty does not cover repairs or returns when the fault is Normal Wear and Tear Installation Use or Maintenance Services Cosmetic defects Accessories Failures due to acts of God or Natural Disasters or problems related to from aftermarket or non OEM parts Warranty Limitations DuroMax Dur...

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Page 60: ...ors are your lifeline in the event of an emergency Should you have any problems please contact our customer service department DUROSTAR POWER EQUIPMENT 5800 Ontario Mills Parkway Ontario CA 91764 Customer Service 844 DUROMAX Customer Service Hours 8 5pm PST Website www duromaxpower com Email customerservice duromaxpower com ...

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Page 62: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX duromaxpower com ...