DuroStar DS4500DX, User Manual

Page 1: ...5 pm PST Mon Fri 844 DUROMAX DS4500DX U S E R M A N U A L 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 ...

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Page 3: ...the Generator Using Propane 32 Starting the Generator Using Recoil Start 36 Starting the Generator 3 Generator Components 16 Package Contents 18 Packing Braces 19 Wheel Kit Installation 20 Connect the Battery 22 Adding Oil 23 Adding Gasoline 24 Grounding the Generator 25 High Altitude Operation 25 Generator Setup 4 AC Usage 40 Connecting a Load to the Generator 42 Using the Digital Multimeter 44 U...

Page 4: ...l 51 Cleaning the Air Filter 52 Spark Plug Maintenance 54 Storage and Transportation 56 Specifications 57 68 Basic Troubleshooting 60 Changing Inspecting the Carbon Brushes 61 Changing Inspecting the AVR 63 Wiring Diagram 66 Maintenance and Care Warranty Troubleshooting 9 72 Contact Information ...

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Page 6: ...daily lives Inevitability when disaster strikes and we are left without power for a prolonged period of time our way of life is put at risk This is by far the most critical time for reliable portable power DUROSTAR FOR WORK On the job site portable power allows you the ability to get work done in remote locations when traditional power sources are usually unavailable Equipment like table saws sand...

Page 7: ... simple We are committed to Powering Everyone Anywhere STOP Please do not return to the store DuroMax representatives are ready to help you with any questions concerns or issues about your new product We can guide you through assembly start up and how to operate your new generator We want you to be able to put your new generator to use right away CALL US BEFORE YOU CONSIDER RETURNING THE PRODUCT 1...

Page 8: ...st 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 i...

Page 9: ...off position and 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 The generator should only be plugged into electrical devices either directly or with an extension cord NEVER connect to a building electrical system ...

Page 10: ...bove safety notices please familiarize yourself with the safety and hazard markings on the generator GENERAL SAFETY PROCEDURES DANGER DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE EXPLOSION OR DEATH 1 5 10 ...

Page 11: ...DON T TOUCH CAUTION HIGH TEMPERATURE DANGER HOT EXHAUST KEEP SAFE DISTANCE DON T TOUCH BURN RISK CARBON MONOXIDE SAFE DISTANCE GENERAL SAFETY PROCEDURES 11 ...

Page 12: ... detector for your home the CO Alert tests the air for to keep you safe and healthy CO Detected If dangerous carbon monoxide levels are detected Generators are convenient but they can also be dangerous All fuel burning appliances and equipment release a poisonous gas called carbon monoxide Carbon monoxide also known as CO can be dangerous for humans and pets even in small amounts because it blocks...

Page 13: ...utely mandatory to keep your family safe from carbon monoxide But there s even more you can do By educating yourself about all carbon monoxide risks you ll be better prepared to protect your family from this colorless odorless threat Visit takeyourgeneratoroutside com for more information ...

Page 14: ...ice in the future If you have a paper receipt staple it here for easy reference If you purchased the unit online save the email receipt where you can access it and record your details here for convenience in the future Purchase Date ____________________________________________ Order Number ____________________________________________ Retailer Name _____________________________________________ Seri...

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 15 ...

Page 16: ...itch 5 Fuel Tank All metal 4 Gallon gasoline fuel tank 6 Power Panel Contains the start switch plugs meters and circuit breakers 7 Handles Longest handles of any model allow easy movement across any surface 8 Battery 12V DC battery that powers the electric start system 9 Oil Fill and Dipstick Use to add or check the oil 10 Propane Inlet Provides a regulated LPG fuel supply to the engine Intended f...

Page 17: ...s 16 120v 3 Prong GFCI Receptacles Use to connect electrical devices that run 120 volt 60Hz single phase AC current NEMA 5 20 17 120 240v 4 Prong Twist Lock Use to connect electrical devices that run 120 or 240 volt 60Hz single phase AC current NEMA L14 30 18 CO Alert Shuts down the engine in the event of CO buildup 19 Charging Light Will light when the generator is charging the on board battery 1...

Page 18: ...park Plug 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 10mm 12mm and 13mm 15mm Used in spark plug maintenance inspection and installation Plug heads for the receptacles found on the generator are included to make or rewire your own cords 18 Propa...

Page 19: ...ER attempt this if you have put fuel or oil in the generator 1 Step 1 Remove Shipping Braces Remove braces The shipping braces prevent engine movement during shipment Flip the generator over and remove the brightly colored braces between the motor and the frame and the wood brace under the generator 2 19 Note Shipping braces can be thrown away They will not be needed again ...

Page 20: ...ashers a Place one of the large washers onto both sides of the axle behind the wheel 4 Install wheel axle a Insert wheel axle bolts through the frame and secure with the provided nut and wrenches 2 GENERATOR SETUP CONTINUED Install wheel axle bracket a Insert wheel axle bracket bolts through the frame and secure with the provided nut and wrenches 3 20 ...

Page 21: ... secure the wheels 7 Install outside wheel washers a Place the other large washers onto each side of the axle in front of the wheel 6 Install handles a Attach the handles to the brackets on the frame using the provided bolts and nuts b Flip the assembled generator over onto its wheels and support brackets Do not over tighten the handles it will prevent free movement 8 ...

Page 22: ...ther end needs to be connected to the battery b Route the free end to the negative battery terminal 2 Connect the negative cable a Push the black rubber boot up the wire to eDSose the connector b Securely connect the free end of the battery cable to the negative battery terminal using the screw and nut from the battery with the screwdriver and wrench from the toolkit 3 The generator battery is dis...

Page 23: ... 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 the oil filler cap Step 4 Adding Oil Engine oil recommended SAE 10W 30 Vis...

Page 24: ...s smoothly use only FRESH UNLEADED GAS WITH AN OCTANE RATING OF 87 OR HIGHER Never use an oil gasoline mixture Never use old gas Avoid getting dirt or water in the fuel tank The 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 DS4500DX Gas Tank Capacity 4 US Gal 15L DANGER DO NOT O...

Page 25: ...at 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 3 000 feet 900 meters have a dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications ...

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Page 27: ...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 28: ...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 it 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 ...

Page 29: ...he Gas Level Optional DANGER DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE EXPLOSION OR DEATH 1 5 WARNING Gasoline and gasoline fumes are highly flammable Do not fill the tank near an open flame ALWAYS allow the engine to cool for several minutes before refueling DO NOT overfill the fuel tank Fuel expands when shaken or heated ALWAYS leave 11 2 space or more at the top of the tank ...

Page 30: ... generator The gas valve is located above the recoil start on the bottom of the fuel tank Rotate the valve counterclockwise to the vertical position to turn on the gas supply The choke lever is located above the air filter to the left 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 engine switch is located on the left side of th...

Page 31: ...g to start 31 WARNING Operating the starter motor for 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 Allow switch return 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 ...

Page 32: ...CME nut connection to your propane tank and turn the tank on 3 4 Turn breaker off The breaker is located on the right side of the front power panel Flip the breaker down to prevent accidental load when starting the generator 1 Turn the gas valve off The gas valve is located above the recoil start on the bottom of the fuel tank Rotate the valve clockwise to the horizontal position to stop the flow ...

Page 33: ...ngine switch is located on the left side of the front power panel Flip the switch up to the START position When the engine starts allow the engine switch to return to the RUN position Close choke The choke lever is located above the air filter to the left of the recoil start Slide the lever to the left to cut the air supply and allow more gas into the engine to start 5 Start the generator 6 Open c...

Page 34: ...eady engine performance for several minutes 3 If the propane gas leaks shut off the LPG supply first and then quickly unplug or turn off any electrical devices powered by the unit 4 When stopping the engine unplug or turn off any electrical devices turn off the main circuit breaker and then turn off the LPG supply After the engine has stopped turn the switch to the OFF position CAUTION Disconnect ...

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Page 36: ...ator 1 Select your fuel Turn engine switch to Run If using gasoline see step 2 on pg 30 If using propane see steps 2 4 on pg 32 The engine switch is located on the left side of the front power panel Press the engine switch to the RUN position 2 Close choke The choke lever is located above the air filter to the left of the recoil start Slide the lever to the left to cut the air supply and allow mor...

Page 37: ...t side panel next to the air filter Pull the recoil handle slowly until resistance is felt then quickly pull the recoil handle until fully extended 5 Open choke After the engine has started push the choke to the OPEN position as the engine warms up 6 Turn breaker on and connect The breaker is located on the right side of the front power panel Flip the breaker up to allow the power to flow to the r...

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Page 39: ... 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 39 ...

Page 40: ... 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 Fuel Source Rated Running Wattage Surge Peak Wattage Gasoline 3500 4500 Propane 3212 4275 40 You may connect electrical devices running on AC curren...

Page 41: ...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 42: ...Y be connected to the 240V receptacle Plug in devices Turn breaker on Turn on connected devices Plug in devices to the appropriate receptacle When using the generator 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 appliances sta...

Page 43: ...ble below for recommended cords based on the power requirement of the electrical device DEVICE REQUIREMENTS WIRE GAUGE BY LENGTH ft AMPS WATTS 120 240V 10 25 50 100 150 5 600 1200 18 16 14 12 10 10 1200 2400 16 14 12 12 10 15 1800 3600 14 14 12 12 10 20 2400 4800 12 12 12 10 10 25 3000 6000 12 10 10 10 8 30 3600 7200 10 10 10 8 NR 40 4800 9600 8 8 6 6 NR 50 6000 12000 6 6 6 NR NR NR NOT RECOMMENDE...

Page 44: ... the generator in volts 1 Frequency The frequency currently produced by the generator in Hz 2 Hours Run The number of hours the engine has currently been running 3 44 When the generator is started the display will read the current voltage Press the MODE button to cycle through the multimeter functions ...

Page 45: ...45 Hours Total The number of hours the generator has been run in total 4 ...

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Page 47: ...aintenance and storage are 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 smoothly and efficiently for years to come 47 ...

Page 48: ...LACE SPARK ARRESTOR CLEAN IDLE SPEED CHECK ADJUST VALVE CLEARANCE CHECK ADJUST COMBUSTION CHAMBER CLEAN 500 HOURS FUEL TANK FILTER CLEAN FUEL TUBE CHECK EVERY 24 MO REPLACE IF NECESSARY TO BE PERFORMED AT MONTHS INDICATED OR HOUR INTERVAL WHICHEVER COMES FIRST 48 WARNING Improper maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously inju...

Page 49: ...MAINTENANCE LOG Date Generator Hours Maintenance Performed 49 ...

Page 50: ...ew 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 it 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...

Page 51: ...to an approved oil disposal container Contact your local auto parts store for information on oil disposal 2 Replace drain plug Replace the oil drain plug and tighten with a 12 mm hex wrench 3 51 Worn out or dirty oil does not cool the generator properly and can lead to catastrophic engine damage In addition to regular oil changes it is necessary to drain the oil from the crankcase if it has become...

Page 52: ...se less air to enter the engine or dirty air to enter the engine causing overheating and engine wear MAINTENANCE AND CARE CONTINUED Cleaning the Air Filter 52 Remove the filter cover screw Remove filter cover Clean out filter casing Remove the filter cover screw Remove the filter cover and the sponge like element from the casing Wipe the dirt from inside the empty air cleaner casing 1 2 3 ...

Page 53: ...ach the cover 7 Washcleanerelement Wash the sponge like elements in household dish detergent and warm water 4 Drycleanerelement Pat on a dry cloth and allow the elements to dry completely 5 6 Addengineoiltoelements Soak the dry elements in a small amount of engine oil Wring out any excess oil ...

Page 54: ...ires trouble starting or damage to the spark plug threads Spark Plug Maintenance Remove spark plug cap Removesparkplug Inspectsparkplug 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 1 2 3 SPARK PLUG CONSULTMANUAL BEFORE REMOVING MAINTENANCE AND CARE CONTINUED 54 ...

Page 55: ... and replace it with a new spark plug We recommend using an F7RTC spark plug such as NGK BP6ES 4 Install spark plug Replace spark plug cap Screw the spark plug back into its place on the generator using the spark plug wrench Replace the spark plug cap 5 6 55 ...

Page 56: ...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 engine switch 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 engine switch 6 Drain ...

Page 57: ...ge 120 240V ACRatedFrequency 60 Hz AC Phase Single Dimensions LENGTH 25in WIDTH 23in HEIGHT 22in Engine Type 4 Stroke OHV Forced Air Ignition System Non Contact Transistor Displacement 212cc Starting Type Electric Recoil Fuel Tank Capacity 4 US Gal 15L Oil Capacity 20 fl oz 0 6L Run Time 50 Gasoline 10 42 hr Run Time 50 Propane 8 92 hr 20 lb Noise Level 69db ...

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Page 59: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator 59 ...

Page 60: ...vel Move the generator to a level surface Oil is low Add change the oil Engine runs but there is no electrical output The 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 The generator runs but does not support all electrical devices connected Generator is overloaded Dis...

Page 61: ...or The carbon 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 Pull off the cover Remove the bolt holding the carbon brush Remove the two wires from the AVR on the carbon brush 1 2 3 61 ...

Page 62: ...h 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 it with the 2 bolts TROUBLESHOOTING CONTINUED 62 ...

Page 63: ...he generator 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 Pull off the cover Remove the 2 bolts holding the AVR Disconnect the wire clip 1 2 3 63 ...

Page 64: ... 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 Insert and connect the 2 wires from the AVR Make sure to connect and correctly Changing Inspecting the AVR Continued TROUBLESHOOTING CONTINUED 64 ...

Page 65: ...Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts 8 65 ...

Page 66: ...WIRING DIAGRAM 66 ...

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Page 68: ...EXPRESSED OR IMPLIED U S EPA AND CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board The United States Environmental Protection Agency US EPA and DuroMax Power Equipment are pleased to explain the emission control system warranty on your 2021 2022 year small off road engine In the United States and California new small off road eng...

Page 69: ...E www DuroMaxPower com ADDRESS 5800 Ontario Mills Pkwy Ontario CA 91764 This telephone number is only for the engines which the company name DuroMax Power Equipment on the emission label DEFECTS WARRANTY REQUIREMENTS a The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser b General Emissions Warranty Coverage DuroMax Power Equipment warrants to the ul...

Page 70: ...sions of Subsection 4 above warranty services or repairs must be provided at all DuroMax Power Equipment distribution centers that are franchised to service the subject engines 6 The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective provided that such diagnostic work is performed at a warranty station 7 DuroMax Power Equipment...

Page 71: ...or spacer if applicable ii EGR rate feedback and control system 5 Air Injection System i An air pump or pulse valve ii Valves affecting the distribution of flow iii Distribution manifold 6 Catalyst or Thermal Reactor System i Catalytic converter ii Thermal reactor iii Exhaust manifold 7 Particulate Controls i Traps filters precipitators and any other device used to capture particulate emissions 8 ...

Page 72: ...ors are your lifeline in the event of an emergency Should you have any problems please contact our customer service department DUROMAX POWER EQUIPMENT 5800 Ontario Mills Parkway Ontario CA 91764 Customer Service 844 DUROMAX Customer Service Hours 8 5 pm PST Website www DuroMaxPower com Email customerservice DuroMaxPower com ...

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Page 74: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX REV DS4500DX 08242021 ...