Table of Contents
Advertisement
Quick Links
DS4500X
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
5800 Ontario Mills Pkwy
this manual. We reserve the right to change
Ontario, CA 91764 USA
this product at any time without prior
www.DuroMaxPower.com
notice.
Call our Customer Care Team Toll Free 8-5 pm PST Mon-Fri
844-DUROMAX
Advertisement
Table of Contents
Troubleshooting
Related Manuals for DuroStar DS4500X
Summary of Contents for DuroStar DS4500X
- Page 1 DS4500X 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 5800 Ontario Mills Pkwy this manual.
-
Page 3: Table Of Contents
CONTENTS Introduction Introduction ........................6 General Safety Procedures ................... 8 Carbon Monoxide Safety ..................... 12 Unit and Purchase Information .................. 14 Generator Setup Generator Components ....................16 Package Contents ......................18 Packing Braces ......................19 Wheel Kit Installation ....................20 Connect the Battery .................... - Page 4 CONTENTS Maintenance and Care Maintenance Schedule ....................44 Maintenance Log ......................45 Checking the Oil ......................46 Changing the Oil ......................47 Cleaning the Air Filter ....................48 Spark Plug Maintenance ....................50 Storage and Transportation ..................52 Specifications ........................53 Troubleshooting Basic Troubleshooting ....................
- Page 6 We understand that having dependable power whenever and wherever you need it provides comfort, safety, and peace of mind. It is through this philosophy that DuroStar achieves our vision of...
-
Page 7: Introduction
INTRODUCTION DuroStar Power Equipment is headquartered in Ontario, California and is the industry’s leader in Dual Fuel portable generator technology. In addition to a full assortment of portable generators ranging from digital inverters to large 15,000-watt portable standby units, our product line includes pressure washers, engines, pumps, and accessories. -
Page 8: 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: ●... - Page 9 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 gasoline. ● Do not operate near an open flame.
- Page 10 GENERAL SAFETY PROCEDURES In addition to the above safety notices, please familiarize yourself with the safety and hazard markings on the generator. DANGER DO NOT OVERFILL 1.5” THE GAS TANK OVERFILLING CAN RESULT IN A FIRE, EXPLOSION, OR DEATH.
- Page 11 GENERAL SAFETY PROCEDURES CAUTION HIGH TEMPERATURE DON’T TOUCH HOT EXHAUST DANGER KEEP SAFE DISTANCE BURN RISK CARBON MONOXIDE SAFE DISTANCE DON’T TOUCH...
-
Page 12: Carbon Monoxide Safety
“the silent killer.” CO-ALERT Description The DuroStar CO Alert system was created to protect our customers and their families from dangerous carbon monoxide. Just like the detector for your home the CO Alert tests the air for to keep you safe and healthy. - Page 13 As the only safe way to use a portable generator, taking your generator outside is absolutely 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.
-
Page 14: Unit And Purchase Information
UNIT AND PURCHASE INFORMATION Serial Number Serial Number The serial number is located on the engine block, above and to the left of the oil fill. Serial number format The serial number will be shown in two parts. The engine model, followed by the serial number. -
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: Generator Components
GENERATOR COMPONENTS 5. Fuel Tank 6. Power Panel 4. Fuel Valve 3. Choke Lever 7. Handles 8. Battery 2. Air Cleaner 1. Recoil Start 9. Oil Fill and Dipstick 1. Recoil Start – Easy pull recoil start to start the engine without the electric start. 2. - Page 17 12. Multimeter 11. Low Oil Alert 13. Power Boost 10. Engine Switch 18. Charging Light 15. GFCI 20A Receptacles 17. CO Alert 14. Circuit Breaker 16. 120/240V 4-Prong Twist Lock 12. Multimeter – Displays voltage, hertz, and time running. 13. Power Boost – DuroMax exclusive Power Boost doubles the amperage available in “120V Only” for heavy loads like RV air conditioners.
-
Page 18: 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. Double-Sided Spanner Spark Plug Wrench Screw Driver Phillips and slot blade Assorted wrenches used in Used in spark plug screwdriver used for generator generator maintenance and... -
Page 19: Packing 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 20: Wheel Kit Installation
GENERATOR SETUP (CONTINUED) Step 2 - Wheel Kit Installation (Optional) Install support legs Secure the support legs to the frame with the provided lock nuts. Install wheel axle Insert wheel axle bolts through the frame and secure with the provided nut and wrenches Install wheel axle bracket Insert wheel axle bracket bolts through the frame and secure with the provided nut and wrenches... - Page 21 Install wheels Place the wheels onto either side of the axle. Install outside wheel washers Place the other large washers onto each side of the axle in front of the wheel. Install cotter pins Place a cotter pin through the hole on each end of the axle and bend it out to secure the wheels.
-
Page 22: Connect The Battery
GENERATOR SETUP (CONTINUED) Step 3 - Connect the Battery Disconnected on arrival The generator battery is disconnected on arrival to prevent discharge or accidental starting in storage and transportation. Locate the negative cable Locate the negative battery cable above and behind the battery. -
Page 23: 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 DS4500X 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 24: Adding Gasoline
Replace fuel cap and wipe up any spilled gasoline with a dry cloth. Model Number DS4500X Gas Tank Capacity 4 US Gal. (15L) DANGER DO NOT OVERFILL 1.5”... -
Page 25: Grounding The Generator
Step 6 - 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. 12 AWG (American Wire Gauge) stranded copper wire. -
Page 27: Starting The Generator
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 28: Checking The Oil
(see “Adding Oil” portion of the “Maintenance” section). Be sure to replace the cap when finished checking oil. Model Number DS4500X Engine Oil Capacity 20 fl. oz (0.6L) -
Page 29: Check The Gas Level
Step 2 - Check the Gas Level (Optional) Check fuel level If running the engine on gasoline, 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 30: Starting The Generator Using Gasoline
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 31 Allow switch return to RUN When the engine starts, allow the engine switch to return to the “RUN” position. Open choke Push the choke to the OPEN position as the engine warms up. CAUTION: LPG must be shut off when using gasoline! CAUTION: Gasoline must be shut off when using LPG! CAUTION:...
-
Page 32: Starting The Generator Using Recoil Start
STARTING THE GENERATOR (CONTINUED) Starting the Generator Using Recoil Start 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. Select your fuel. If using gasoline, see step 2 on pg. - Page 33 Pull the recoil start The recoil start is located on the left 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. Open choke After the engine has started, push the choke to the OPEN position as the engine warms up.
-
Page 35: 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 36: 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 37 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 38: 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. ● ● 120V devices can be connected to the 120/240V receptacle using an appropriate adapter. ●... - Page 39 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 the table below for recommended cords based on the power requirement of the electrical device. DEVICE REQUIREMENTS WIRE GAUGE BY LENGTH (ft.) AMPS...
-
Page 40: Using The Digital Multimeter
USING THE GENERATOR (CONTINUED) Using the Digital Multimeter When the generator is started, the display will read the current voltage. Press the MODE button to cycle through the multimeter functions. Voltage The voltage currently produced by the generator in volts. Frequency The frequency currently produced by the generator in Hz. - Page 41 Hours Total The number of hours the generator has been run in total.
-
Page 43: Maintenance And Care
MAINTENANCE AND CARE Proper maintenance 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. -
Page 44: 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, maintenance recommendations, and schedules in this instruction manual. -
Page 45: Maintenance Log
MAINTENANCE LOG Date Generator Hours Maintenance Performed... -
Page 46: Checking The Oil
(see “Adding Oil” portion of the “Maintenance” section). The oil will be visible in the oil fill spout when full. Be sure to replace the cap when finished checking oil. Model Number DS4500X Engine Oil Capacity 20 fl. oz (0.6L) -
Page 47: 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 48: Cleaning The Air Filter
MAINTENANCE AND CARE (CONTINUED) Cleaning the Air Filter 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 49 Wash cleaner element Wash the sponge-like elements in household dish detergent and warm water. Dry cleaner element Pat on a dry cloth and allow the elements to dry completely. Add engine oil to elements Soak the dry elements in a small amount of engine oil. Wring out any excess oil.
-
Page 50: 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. SPARK PLUG CONSULT MANUAL Improper maintenance may cause reduced fuel economy, BEFORE REMOVING misfires, trouble starting, or damage to the spark plug threads. - Page 51 Replace if necessary If it is cracked or chipped, discard and replace it with a new spark plug. We recommend using an F7RTC spark plug such as NGK BP6ES. Install spark plug Screw the spark plug back into its place on the generator using the spark plug wrench.
-
Page 52: Storage And Transportation
MAINTENANCE AND CARE (CONTINUED) 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 53: Specifications
SPECIFICATIONS AC Rated Wattage (Gasoline) 3500W AC Surge Wattage (Gasoline) 4500W AC Rated Voltage 120/240V AC Rated Frequency 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... -
Page 55: Troubleshooting
TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator. -
Page 56: Basic Troubleshooting
TROUBLESHOOTING Problem Description Solution Engine switch is “OFF” Set engine switch to “RUN” Fuel Valve is “CLOSED” Turn the fuel valve to “OPEN” Choke is open Close the choke The engine is out of fuel Add fuel The engine will not Fuel is old or contaminated Change fuel start... -
Page 57: 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. Pull off the cover. Remove bolt from brush Remove the bolt holding the carbon brush. - Page 58 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 it with the 2 bolts.
-
Page 59: 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. Pull off the cover. Remove AVR bolts Remove the 2 bolts holding the AVR. - Page 60 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 Insert and connect the 2 wires from the AVR. Make sure to connect + and –...
- Page 61 Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts.
-
Page 62: Wiring Diagram
WIRING DIAGRAM... -
Page 64: Warranty
WARRANTY 5-Year Warranty All DuroMax Power Equipment warrant the original purchasers to a 5-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 on any items submitted for replacement or repair under the warranty is the responsibility of the equipment owner. - Page 65 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 for your failure to ensure the performance of all scheduled maintenance.
- Page 66 WARRANTY (CONTINUED) Subsection (4) below. Any such part repaired or replaced under the warranty must be warranted for the remaining warranty period. (2) Any warranted part that is scheduled only for regular inspection in the written instructions required by subsection (d) must be warranted for the warranty period defined in Subsection (b) (2).
- Page 67 Exhaust Emission Warranty Parts List. (1) Fuel Metering System (7) Particulate Controls (i) Carburetor and internal parts (and/or (i) Traps, filters, precipitators, and any pressure regulator or fuel injection other device used to capture particulate emissions. system). (ii) Air/fuel ratio feedback and control (8) Miscellaneous Items Used in Above Systems system.
-
Page 68: Contact Information
CUSTOMER SERVICE DuroMax Power Equipment is committed 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 70 5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX REV: DS4500X-08242021...