DuroStar DS4000S - Manual

SAFETY ALERT SYMBOL 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...

QUICK START GUIDE Remove shipping braces The shipping braces prevent engine movement during shipment. Flip the generator over and remove the brightly colored brace between the motor and the frame, and the wood brace under the generator. 1. Add gasoline The fuel cap is located on top of the fuel tank...

17. Muffler GENERATOR COMPONENTS 12 2. Choke Lever 1. Air Cleaner 9. Volt Meter 5. Circuit Breaker 8. 120V 30A Twist Lock 6. 120V 3-Prong Recepticle 7. Ground Terminal 11. Oil Fill and Dipstick 12. Engine Switch 13. Recoil Start 1. Air Cleaner - a removable, cleanable, oiled, sponge-like element tha...

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. ● Note: Actual tools may differ in appearance or design from image shown. Double Sided Screw Driver Oil Funnel w/ hose Spanner Spark Plug Wrench Pl...

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.

GENERATOR SETUP Unpack a. Remove the generator from the box. b. Place the largest piece of packing foam on a flat surface. c. Flip the generator upside down on the pad. CAUTION: NEVER Attempt this if you have put fuel or oil in the generator. 1. Step 1 - Remove Shipping Braces Remove braces a. Compl...

GENERATOR SETUP Install lower handle lock Position the lower handle lock on the frame and secure with bolt. 1. Step 3 - Handle Installation (Optional) Install upper handle bracket Insert upper handle bracket and secure with provided bolts. 2. 18 Install retaining pin Insert and secure the retaining ...

19 Test handle pivot The handle should easily flip up and down after installation. 1.

-20 20 40 60 80 0 100 F -30 -40 -10 0 10 20 30 -20 40 C 30 10W-30 ENVIRONMENTAL TEMPERATURE 5W-30 SAE GENERATOR SETUP (CONTINUED) 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 amoun...

WARNING: Gasoline and gas fumes are highly flammable. ● Do not fill tank near an open flame. ● Do not overfill. Always check for fuel spills. 21 Step 4 - Adding Gasoline Add Gasoline a. Make sure the generator is on a level surface. b. Unscrew gas cap and set aside (NOTE: the gas cap may be tight an...

23 STARTING THE GENERATOR If this is not your first time using the generator there 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 ...

Step 1 - Check the oil 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: a. Make su...

25 Check Fuel Level Before starting the generator, check to see that there is sufficient gasoline in the fuel tank. The fuel gauge on top of the tank will give a rough estimate of the gasoline level. The gauge will appear white then fill red as the tank is filled. Note: Fuel gauge may not register w...

STARTING THE GENERATOR Shut 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. Starting the Generator Using Gasoline Turn gas valve on Close choke Flip engine switch to ON The gas valve is lo...

CAUTION: Disconnect all electrical loads from the generator before attempting to start! 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. 27 Pull recoil start Pul...

USING THE GENERATOR If this is not your first time using the generator there 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”...

USING THE GENERATOR AC Usage ● You may connect electrical devices running on AC current according to their wattage requirements. ● The chart below shows the rated and surge wattage of your generator according to its model number. ● The rated wattage corresponds to the maximum wattage the generator c...

33 Choosing the right power cord 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 cords based on the power requirement of t...

MAINTENANCE AND CARE Proper maintenance 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

MAINTENANCE AND CARE Proper routine maintenance of your generator is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. Maintenance Schedule Remember that this schedule is based on the assumption that your machine will be used for its designed purpose...

MAINTENANCE LOG Date Generator Hours Maintenance Performed 37

Routine maintenance of the air cleaner helps maintain proper airflow to the carburetor. Check that the air cleaner is free of excessive dirt after every use. Note: Improper maintenance may cause less air to enter the engine or dirty air to enter the engine causing overheating and engine wear. MAINTE...

Replace elements in casing Replace the sponge-like elements in the air cleaner casing 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 eleme...

Drain gas from generator 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. 4. Shut fuel valve off Replace fuel filter cup Store emptied gas Turn the fuel valve to the “OFF” position. Reinstall the fuel filter ...

MAINTENANCE AND CARE (CONTINUED) Shut fuel valve off Turn the fuel valve to the “OFF” position. 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 ...

CAUTION: Never place any type of storage cover on the generator while it is still hot. When transporting your generator: ● 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 i...

SPECIFICATIONS AC Rated Wattage (Gasoline) 3300W AC Surge Wattage (Gasoline) 4000W AC Rated Voltage 120V AC Rated Frequency 60 Hz AC Phase Single DC Voltage 12V DC Amperage 8.3A Dimensions LENGTH 23.2in. WIDTH 17in. HEIGHT 17in. Engine Type 4-Stroke OHV Forced-Air Ignition System Non-Contact Transis...

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

TROUBLESHOOTING Mode Description Engine will not start Engine Switch is “Off” Set engine switch to “run” Fuel Valve is “Closed” Turn fuel valve to “open” Choke is open Close the choke Engine is out of fuel Add fuel Fuel is old or contaminated Change fuel Spark Plug is dirty Clean spark plug Spark Pl...

Changing / Inspecting the Carbon Brushes (Cont.) Install new brush 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 b...

Reconnect the AVR wire clip Insert and connect the 2 wires from the AVR, be sure 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 wir...

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

WARRANTY 3-year Warranty All DuroMax/DuroStar Power Equipment warrant the original purchasers to a 3-year Parts Warranty (Residential Use ONLY: Unusually heavy or commercial use is covered for a period of 1-year) in the event of failure due to defects in electrical or mechanical components. Freight ...

60 CUSTOMER SERVICE Duromax Power Equipment is comitted to ensuring that our products perform when they need to. Our generators 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 Par...