DuroStar DS4000S User Manual
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DuroStar DS4000S User Manual

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DS4000S GENERATOR
User Manual
REV: DS4000S-08142019
5800 Ontario Mills Pkwy
Ontario, CA 91764 USA
This manual provides information regarding the operation
www.duromaxpower.com
and maintenance of these products. We have made every
effort to ensure the accuracy of the information in this
Call our Customer Care Team Toll Free 8-5pm PST Mon-Fri
manual. We reserve the right to change this product at
844-DUROMAX
any time without prior notice.

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  • Page 1 DS4000S GENERATOR User Manual REV: DS4000S-08142019 5800 Ontario Mills Pkwy Ontario, CA 91764 USA This manual provides information regarding the operation www.duromaxpower.com and maintenance of these products. We have made every effort to ensure the accuracy of the information in this Call our Customer Care Team Toll Free 8-5pm PST Mon-Fri manual.

  • Page 3: Table Of Contents

    CONTENTS Introduction Introduction ........................6 General Safety Procedures .................... 7 Quick Start Guide ......................10 Generator Components ....................12 Package Contents ......................14 Generator Setup Shipping Braces ......................16 Wheel Kit Installation ....................17 Handle Installation ......................18 Adding Oil ........................20 Adding Gasoline ......................
  • Page 4 CONTENTS Maintenance and Care Maintenance Schedule ....................36 Maintenance Log ......................37 Checking the Oil ......................38 Changing the Oil ......................39 Cleaning the Air Cleaner ....................40 Spark Plug Maintenance ....................42 Emptying the Gas Tank ....................44 Cleaning the Fuel Filter Cup ..................46 Storage and Transportation ..................

  • Page 6: Introduction

    INTRODUCTION DuroMax has cemented its reputation as one of the markets leading power equipment companies who are headquartered in the US. All of our products are manufactured to the strictest guidelines and go through countless testing in all phases of production. Evolving our strong engine line, DuroMax has complemented its offerings to include Pressure Washers, Water Pumps, Engines and now offering V-Twin engines.

  • Page 7: General Safety Procedures

    GENERAL SAFETY PROCEDURES SAFETY ALERT SYMBOL 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 this manual and on the generator. Please familiarize yourself with the following safety symbols and words: DANGER: Indicates a hazard that will result in serious injury or death if instructions are not ●...
  • Page 8 GENERAL SAFETY PROCEDURES WARNING: This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death. A nearby open flame can lead to an explosion even if not directly in contact with gas. Do not operate near an open flame. ●...
  • Page 9 GENERAL SAFETY PROCEDURES In addition to the above safety notices, please familiarize yourself with the safety and hazard markings on the generator.

  • Page 10: Quick Start Guide

    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. Add oil The oil fill cap is located on the lower engine block to the right of the recoil start housing.
  • Page 11 Close choke 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. Flip engine switch to ON The engine switch is located on the left side of the front power panel.

  • Page 12: Generator Components

    GENERATOR COMPONENTS 9. Volt Meter 5. Circuit Breaker 2. Choke Lever 6. 120V 3-Prong Recepticle 15. Fuel Valve 8. 120V 30A Twist Lock 7. Ground Terminal 1. Air Cleaner 11. Oil Fill and Dipstick 13. Recoil Start 12. Engine Switch 1.
  • Page 13 14. Fuel Filter Cup 3. Fuel Gauge 4. Fuel Cap 16. Spark Plug 17. Muffler 11. Oil Fill and Dipstick - Use to add or check the oil. 12. Engine Switch – 3 Position Switch to “Start”, “Run”, or turn “Off” the generator. 13.

  • Page 14: 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. Oil Funnel w/ hose Spark Plug Wrench Used to add oil to the generator without messy spills. Used in spark plug maintenance, inspection, and installation.

  • Page 15: Generator Setup

    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: Shipping Braces

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

  • Page 17: Wheel Kit Installation

    Step 2 - Wheel Kit Installation (Optional) Install support legs Secure the support legs to the frame with provided bolts and lock nuts. Install wheels Secure the axle bracket welded to axle to the frame with the provided bolts and lock nuts. Secure the loose axle bracket to the frame with the provided bolts and lock nuts.

  • Page 18: Handle Installation

    GENERATOR SETUP Step 3 - Handle Installation (Optional) Install lower handle lock Position the lower handle lock on the frame and secure with bolt. Install upper handle bracket Insert upper handle bracket and secure with provided bolts. Install handle Insert the handle into the upper bracket secure with pin. Install retaining pin Insert and secure the retaining pin.
  • Page 19 Test handle pivot The handle should easily flip up and down after installation.

  • Page 20: Adding Oil

    . You must add the proper amount of oil before operating the generator for the first time. This amount is equal to the oil capacity of the engine crankcase: Model Number DS4000S Engine Oil Capacity 20 fl. oz (0.6L) WARNING: Do not apply engine oils with additives or 2-stroke gasoline engine oils. They don’t have enough lubrication, and may shorten the engine’s service life.

  • Page 21: Adding 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 DS4000S Gas Tank Capacity 3.96 US Gallons (15L)

  • Page 22: Grounding The Generator

    GENERATOR SETUP (CONTINUED) Step 5 - Grounding the Generator Attach grounding wire Ground the generator by tightening the grounding nut against a grounding wire. Connect the other end to a copper or brass grounding rod that’s driven into the earth. A generally acceptable grounding wire is a No.
  • Page 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 SETUP”...

  • Page 24: Checking The Oil

    BEFORE YOU START YOUR 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.

  • Page 25: Check The Gas Level

    Step 2 - Check the gas level 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.

  • Page 26: Starting The Generator

    STARTING THE GENERATOR Starting the Generator Using Gasoline 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. Turn gas valve on The gas valve is located above the recoil start on the bottom of the fuel tank.
  • Page 27 Pull recoil start Pull the recoil start handle quickly the complete length of the rope and then let it retract slowly. The unit will generally start within 3 pulls. CAUTION: DO NOT let go of the handle while the rope is extended this may cause damage to yourself or your machine.

  • Page 29: Using The Generator

    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”...

  • Page 30: Ac Usage

    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 can output on a continuous basis.
  • Page 31 Tool or Appliance Rated (Running) Watts Additional Surge Watts Electric water heater (40 gal) 4000 Hot plate 2500 Radial arm saw 2000 2000 Electric Stove 1500 Circular Saw 1500 1500 Air compressor (1 HP) 1500 3000 Window air conditioner 1200 1800 Miter saw 1200...

  • Page 32: Connecting A Load To The Generator

    USING THE GENERATOR (CONTINUED) Connecting a load to the generator NOTE: Be sure to attach devices to the correct receptacle (outlet). 120v devices can be directly connected to the 120v ONLY receptacles. ● CAUTION: Do not connect 240V loads to the generator. CAUTION: Do not connect 50Hz or 3-phase loads to the generator.
  • Page 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 the electrical device. DEVICE REQUIREMENTS WIRE GAUGE BY LENGTH (ft.) AMPS...

  • Page 35: Maintenance And Care

    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.

  • Page 36: Maintenance Schedule

    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. WARNING: Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously injured or killed. Always follow the inspection and maintenance recommendations and schedules in this instruction manual.

  • Page 37: Maintenance Log

    MAINTENANCE LOG Date Generator Hours Maintenance Performed...

  • Page 38: Checking The Oil

    MAINTENANCE AND CARE (CONTINUED) Checking 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.

  • Page 39: Changing The Oil

    Changing the oil 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 contaminated with water or dirt.

  • Page 40: Cleaning The Air Cleaner

    MAINTENANCE AND CARE (CONTINUED) Cleaning the air cleaner 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.
  • Page 41 Wash cleaner element Wash the sponge-like elements in household dish detergent and warm water. Dry cleaner element Allow the elements to dry completely. Add engine oil to elements Soak the dry elements in a small amount of engine oil. Ring out any excess oil.

  • Page 42: Spark Plug Maintenance

    MAINTENANCE AND CARE (CONTINUED) 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. Improper maintenance may cause reduced fuel economy, misfires, trouble starting, or damage to the spark plug threads.
  • Page 43 Measure plug gap Measure the plug gap with a gauge. The gap should be 0.7-0.8 mm (0.028-0.031 in). Clean and re-gap 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.

  • Page 44: Emptying The Gas Tank

    MAINTENANCE AND CARE (CONTINUED) Emptying the Gas Tank Before storing your generator for extended periods of time, you should drain your generator of gasoline. 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.
  • Page 45 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. Shut fuel valve off Turn the fuel valve to the “OFF” position. Replace fuel filter cup Reinstall the fuel filter cup.

  • Page 46: Cleaning The Fuel Filter Cup

    MAINTENANCE AND CARE (CONTINUED) Cleaning the fuel filter cup Shut fuel valve off Turn the fuel valve to the “OFF” position. Remove fuel filter cup Unscrew the fuel filter cup from the fuel valve using a wrench. Turn the valve towards you to unscrew Clean filter cup Clean the cup of all sediment using a rag or brush.

  • Page 47: Storage And Transportation

    Storage and Transportation 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. ●...

  • Page 48: Specifications

    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 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...

  • Page 49: Troubleshooting

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

  • Page 50: Basic Troubleshooting

    TROUBLESHOOTING Mode Description 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 Engine will not start Fuel is old or contaminated Change fuel Spark Plug is dirty Clean spark plug...

  • Page 51: Changing / Inspecting The Carbon Brushes

    Changing / Inspecting the Carbon Brushes The carbon brushes in conjunction with the AVR regulates power from the generator. The carbon brushes are wearable parts and should be inspected every 250 running hours. Remove generator cover Remove the 2 bolts of the generator cover then pull the cover off the generator.
  • Page 52 TROUBLESHOOTING (CONTINUED) Changing / Inspecting the Carbon Brushes (Cont.) Install new brush Install new carbon brush with bolt. Connect AVR wires Insert and connect the 2 wires from the AVR, be sure to connect + and – correctly. Replace generator cover Replace the back cover of the generator and secure with the 2 bolts.

  • Page 53: Changing / Inspecting The Avr

    Changing / Inspecting the AVR The carbon brushes in conjunction with the AVR regulates power from the generator. If the generator is overheated or overloaded, the AVR may be damaged and require replacement. Remove generator cover Remove the 2 bolts of the generator cover then pull the cover off the generator.
  • Page 54 TROUBLESHOOTING (CONTINUED) Changing / Inspecting the AVR (Continued) Disconnect wires from brush Remove the 2 wires from the AVR on the carbon brush. Install new AVR Install the new AVR with the 2 bolts. Reconnect wires to brush Reconnect the wire clip. Reconnect the AVR wire clip Insert and connect the 2 wires from the AVR, be sure to connect + and –...
  • Page 55 Replace generator cover Replace the back cover of the generator and secure with the 2 bolts.
  • Page 56 WIRING DIAGRAM...

  • Page 58: Warranty

    Warranty Limitations DuroMax/DuroStar Power Equipment does not claim or hold any obligation to loss of time, freight charges, use of product, or any incidental damages from the use of this product. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED.
  • Page 59 OWNER’S WARRANTY RESPONSIBILITIES: As the small off-road engine owner, you are responsible for performance of the required ● maintenance listed in your owner’s manual. DuroMax Power Equipment recommends that you retain all receipts covering maintenance on your small off-road engine, but DuroMax Power Equipment cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.
  • Page 60 WARRANTY (CONTINUED) 1. Any warranted part that is scheduled only for regular inspection in the Owner’s Manual must be warranted for the warranty period stated above. A statement in such written instructions to the effect of “repair or replace as necessary” will not reduce the period of warranty coverage. Any such part repaired or replaced under warranty must be warranted for the remaining warranty period.
  • Page 61 *Note: The parts list for equipment less than or equal to 80 cc only includes the fuel tank. **Note: As they relate to the evaporative emission control system. DuroStar Power Equipment will furnish with each new engine written instructions for the maintenance and use of the engine by the owner.

  • Page 62: Contact Information

    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 Parkway Ontario, CA 91764 Customer Service: 844-DUROMAX...
  • Page 64 5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX...

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