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DuroStar DS4000WGE Owner's Manual

Gasoline generator/welder
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Gasoline Generator/Welder
Max Tool Customer Service
customer_service@maxtool.com
or call 1-800-629-3325 (option 3) Monday -Thursday 6am to 7pm, Friday - Saturday 6am to 3pm. PST
Product Support
support@maxtool.com
or call 1-800-629-3325 (option 3) Monday -Thursday 6am to 7pm, Friday - Saturday 6am to 3pm. PST
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.
Please keep this manual available to all users during the entire life of the generator/welder.
DS4000WGE
Owner's Manual
(Product: information, application, service info & warranty questions)
1

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Summary of Contents for DuroStar DS4000WGE

  • Page 1 DS4000WGE Gasoline Generator/Welder Owner’s Manual Max Tool Customer Service customer_service@maxtool.com or call 1-800-629-3325 (option 3) Monday -Thursday 6am to 7pm, Friday - Saturday 6am to 3pm. PST Product Support (Product: information, application, service info & warranty questions) support@maxtool.com or call 1-800-629-3325 (option 3) Monday -Thursday 6am to 7pm, Friday - Saturday 6am to 3pm. PST This manual provides information regarding the operation and maintenance of these products.
  • Page 2 WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. WARNING: The generator is a potential source of electrical shock if misused. Do not expose the generator to moisture, rain or snow.
  • Page 3 A FEW WORDS ABOUT SAFETY Your safety and the safety of others is very important. And using this generator/Welder safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

  • Page 4: Table Of Contents

    CONTENTS SAFETY................................1 Safety Label Locations..........................1 Safety Information............................1 COMPONENT INDENTIFICATION ......................3 CONTROLS..............................4 Engine Switch.............................. 4 Recoil Starter............................... 4 Fuel Valve Lever ............................5 Choke Rod..............................5 Circuit Breaker ............................5 Oil Alert System............................6 DC Receptacle............................. 6 A/C (Weld) Selector Switch........................

  • Page 5: Safety

    SAFETY SAFETY LABEL LOCATIONS These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact your Generator dealer for a replacement. SAFETY INFORMATION Our generator/welders are designed to give safe and dependable service if operated according to instructions.
  • Page 6 — Keep flammable materials away from the generator/welder. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. • Be careful not to touch the muffler while it is hot. Let the engine cool before storing the generator/welder indoors.

  • Page 7: Component Indentification

    COMPONENT IDENTIFICATION Record the engine and frame serial numbers for your future reference. Refer to these serial numbers • when ordering parts, and when making technical or warranty inquiries.

  • Page 8: Controls

    CONTROLS Engine Switch To start and stop the engine. Switch position: OFF: To stop the engine. ON: To run the engine. Recoil Starter To start the engine, pull the starter grip lightly until resistance is felt, then pull briskly. NOTICE: Do not allow the starter grip to snap back against the engine.

  • Page 9: Fuel Valve Lever

    Fuel Valve Lever The fuel valve is located between the fuel tank and carburetor. When the fuel valve lever is in the ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sure to return the fuel lever to the OFF position after stopping the engine.

  • Page 10: Oil Alert System

    Oil Alert System The Oil Alert System is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the oil alert system will automatically stop the engine (the engine switch will remain in the ON position).

  • Page 11: Welding Cable Terminal

    Welding Cable Terminal A separate terminal is provided for connection to the welding cable. CAUTION: Failure to use the proper gauge cable may lead to painful burns and/or damage to equipment. Welding Current Adjusting System For best results, it is essential the current be adjusted properly according to the thickness of the materials to be welded and method of welding.

  • Page 12: Generator/Welder Use

    GENERATOR/WELDER USE Connections To A Building Electrical System Connections for standby power to a buildings electrical system must be made by a qualified electrician. The generator/welder power connection must be isolate from the utility power, and must comply with all applicable laws and electrical codes. A transfer switch, which isolates the generator/welder power from utility power, is available through authorized generator dealers.

  • Page 13: Welding

    For continuous operation, do not exceed the rated load capacity (W-190: 2.0 KVA). In either case, be • sure to consider the total power requirements of all connected appliances. Do not exceed the current limit specified for any one receptacle. Substantial overloading will switch off the circuit breaker. Marginal overloading may not switch off the circuit breaker, but it will shorten the service life of the generator/welder.

  • Page 14: Selecting The Correct Welding Current

    Selecting the Correct Welding Current Measure the thickness of the metal you are welding and then refer to the table below to select the proper electrode size and current setting PLATE THICKNESS IN ELECTRODE DIAMETER IN CURRENT INCHES INCHES SETTING UP TO 3/16"...

  • Page 15: Polarity Selection

    Polarity Selection The welding terminals are labeled "+" (positive) and "-" (negative). Changing the polarity of the cables will affect the weld. The correct polarity selection is dependent on the type of electrode you are using and the type of material you are welding; refer to the electrode manufacturer's recommendations for best results.

  • Page 16: Pre-Operation Check

    PRE-OPERATION CHECK Engine oil NOTICE: Engine oil is the major components affecting engine performance and service life. Non-detergent and 2-stroke engine oils will damage the engine and is not recommended. Check the oil level BEFORE EACH USE. When checking the oil be sure the generator is on a level surface with the engine stopped.
  • Page 17 WARNING: Gasoline is extremely flammable and is explosive under certain conditions. • Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow • flames or sparks in the area where the engine is refueled or where gasoline is stored.
  • Page 18 Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.

  • Page 19: Starting The Engine/Stopping The Engine

    STARTING THE ENGINE/STOPPING THE ENGINE Starting the Engine 1. Make sure that the AC circuit breaker is in the OFF position, and that there are no welding cables attached to the DC terminals. The generator may be hard to start if a load is connected. 2.

  • Page 20: Maintenance

    MAINTENANCE The Importance of Maintenance Good maintenance 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 hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner's manual.

  • Page 21: Emission Control System Information

    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. Remember that your servicing dealer knows your generator best and is fully equipped to maintain and repair it.

  • Page 22: Air Index

    with EPA and California emission regulations. We recommend the use of genuine parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system.

  • Page 23: Maintenance Schedule

    Maintenance Schedule REGULAR SERVICE PERIOD (3) First Every Every Every Each month 3 month 6 month year ITEM Perform at every indicated month or operating hour interval, 12 Hrs 50 Hrs 100 Hrs 300 Hrs whichever comes first • Engine oil Check level Change Air filter...

  • Page 24: Air Cleaner Service

    Wash your hands with soap and water after handling used oil. Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station or recycling center for reclamation. Do not throw it in the trash or pour it on the ground, or down a drain.

  • Page 25: Fuel Sediment Cup Cleaning

    Fuel Sediment Cup Cleaning The sediment cup prevents dirt or water which may be in the fuel tank from entering the carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned. 1. Turn the fuel valve lever to the OFF position. Remove the sediment Cup, O-ring, and filter. 2.
  • Page 26 4. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped. Clean the spark plug with a wire brush if it is to be reused. 5. Measure the plug gap with a feeler gauge. Correct as necessary by carefully bending the side electrode. The gap should be: 0.028-0.031 in (0.70--0.80 mm) 7.

  • Page 27: Transporting/Storage

    TRANSPORTING STORAGE When transporting the generator/welder, turn the engine switch and the fuel valve OFF and keep the generator/welder level to prevent fuel spillage. Fuel vapor or spilled fuel may ignite. WARNING: Contact with a hot engine or exhaust system can cause serious burns or fires. Let the engine cool before transporting or storing the generator/welder.
  • Page 28 2. Change the engine oil. 3. Remove the spark plug, and pour about a tablespoon of clean engine oil into the cylinder. Crank the engine several revolutions to distribute the oil, and then reinstall the spark plug. 4. Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are closed.

  • Page 29: Wiring Diagram

    WIRING DIAGRAM...

  • Page 30: Specifications

    SPECIFICATION Dimensions Model DS4000WGE Length x Width x Height 29 x 22 x 22 in (712 x 540 x 540mm) Dry weight 217.8 lb (98kg) Engine Model DS190FE Engine type 4-stroke, overhead valve, single cylinder Displacement (Bore x Stroke) 25.6cu in (419cc) 3.54 x 2.6 in (90 x 66mm) Compression ratio 8.0:1...

  • Page 31: Wheel Lit

    WHEEL KIT Handle/Wheel support and wheel kit.
  • Page 32 EXPLODED VIEW AND PARTS LIST...
  • Page 33 Item Part Description Item Part Description Gasoline engine 14400 Fuel sensor 15100 Frame comp GB 819-95 Screw M5x10 15002 Bottom rubber A 14410 Casket fuel tank 15003 Bottom rubber B GB5787-86 Flange bolt M6x25 GB6177-86 Flange nut M8 14022 Washer GB802-88 Flange nut M6 14005...
  • Page 35 Item Part Description Item Part Description 21100 Starter comp, recoil 22000 Stay assembly choke GB5787-86 Flange bolt M6x8 12012 Grommet fender 12310 Fan, cover comp 23000 Carburetor assembly GB5787-86 Flange bolt M6x12 23002 Packing, carburetor 19003 Shroud comp 23001 Insulator, carburetor 12302 Clip.
  • Page 36 11206 Nut, pivot adjusting 13105 Clip, piston pin GB5789-86 Flange bolt M8x40 13101 Piston 12100 Crankcase cover 13104 Pin, piston GB5789-86 Flange bolt M5x10 13106 Connecting rod assembly 12301 Fan cover 17220 Control assembly 121102 Cap assembly oil filler 17001 Spring, governor 12230 Governor kit...

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