DUROMAX DuroStar DS5000DX User Manual
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DUROMAX DuroStar DS5000DX User Manual

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DS5000DX
U S E R
U S E R
Call our Customer Care Team Toll Free 8-5 pm PST Mon-Fri
844-DUROMAX
M A N U A L
M A N U A L
5800 Ontario Mills Pkwy
Ontario, CA 91764 USA
www.DuroMaxPower.com

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Summary of Contents for DUROMAX DuroStar DS5000DX

  • Page 1 Ontario, CA 91764 USA this manual. We reserve the right to change www.DuroMaxPower.com this product at any time without prior notice. Call our Customer Care Team Toll Free 8-5 pm PST Mon-Fri 844-DUROMAX...

  • Page 3: Table Of Contents

    CONTENTS Introduction Introduction ........................6 General Safety Procedures ................... 8 Carbon Monoxide Safety ..................... 12 Unit and Purchase Information .................. 14 Generator Components Generator Components ....................16 Package Contents ......................18 Generator Setup Remove Shipping Braces ..................... 21 Wheel Kit Installation ....................22 Connect the Battery......................
  • Page 4 CONTENTS Maintenance and Care Maintenance Schedule ....................52 Break-In Period ......................53 Maintenance Log ......................53 Checking the Oil ......................54 Changing the Oil ......................55 Cleaning the Air Filter ....................56 Spark Plug Maintenance ....................58 Emptying the Gas Tank ....................60 Transporting the Generator ..................
  • Page 6 THE DUROSTAR WAY The DuroStar Way is more than just a brand, it is our understanding and appreciation of just how important power can be to someone without it… DUROSTAR FOR HOME DUROSTAR FOR WORK DUROSTAR FOR PLAY Electricity in our home not On the job site, portable Camping outdoors in a only provides comfort but...

  • Page 7: Introduction

    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.

  • Page 8: General Safety Procedures

    GENERAL SAFETY PROCEDURES SAFETY ALERT SYMBOL The safety alert symbol is used with one of the safety words (DANGER, WARNING, or CAUTION) to alert you of hazards. Please pay attention to these hazard notices both in this manual and on the engine. Please familiarize yourself with the following safety symbols and words: ●...
  • Page 9 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. DS13000DX DECAL SHEET REVISED 07-14-2021 PINK LINE IS TRIM LINE DO NOT PRINT DS13000DX...
  • Page 11 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 indicator will light red. ● The engine will shutdown. The engine will not restart for 5 minutes. ● Maintenance Required If an error in the CO-ALERT system is detected the indicator will light yellow. Please contact DuroMax service at 844-DUROMAX for assistance.
  • 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 COMPONENTS To help you get familiar with your new DuroMax generator, please see this component section for easy reference on all the generator’s individual features.

  • Page 16: Generator Components

    GENERATOR COMPONENTS 5. Fuel Tank 6. Power Panel 3. Choke Lever 7. Handles 4. Fuel Valve 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 13. Multimeter 12. Low Oil Alert 14. Power Boost 11. Engine Switch 10. Propane Inlet 19. Charging Light 16. GFCI 20A Receptacles 18. CO Alert 15. Circuit Breaker 17. 240V 30A Receptacle 12. Low Oil Alert – Will light only if the generator shuts down due to low oil. 13.

  • 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: 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 21: Remove Shipping Braces

    GENERATOR SETUP Step 1 - Remove Shipping Braces 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 22: 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 23 Install wheels Place the wheels onto either side of the axle. Install outside wheel washers Place the other large washers onto each side the axle in front of the wheel. Install cotter pins Place a cotter pin through the hole in each end of the axle and bend it out to secure the wheels.

  • Page 24: 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 25: Adding Oil

    Step 4 - Adding 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 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 DS5000DX Engine Oil Capacity...

  • Page 26: Adding Gasoline

    GENERATOR SETUP (CONTINUED) Step 5 - Adding Gasoline (Optional) Add gasoline Make sure the generator is on a level surface. Unscrew gas cap and set aside (NOTE: the gas cap may be tight and hard to unscrew). Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill.

  • Page 27: 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 29: 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 30: 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 31: 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 32: 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 33 Open choke Push the choke to the “OPEN” position as the engine warms Turn breaker ON/ 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 receptacles.

  • Page 34: Starting The Generator Using Propane

    STARTING THE GENERATOR (CONTINUED) Starting the Generator Using Propane 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. Turn the gas valve OFF The gas valve is located above the recoil start on the bottom of the fuel tank.
  • Page 35 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. Start the generator The engine switch is located on the left side of the front power panel.
  • Page 36 STARTING THE GENERATOR (CONTINUED) Starting the Generator Using Propane WARNING: WHEN USING THE GENERATOR WITH LPG, MAKE SURE THERE IS NO POSSIBLE IGNITION SOURCE CLOSE TO THE GENERATOR. 1. Before using, make sure all of the LPG connectors and hoses are well connected and sealed.

  • Page 38: Starting The Generator Using Recoil Start

    STARTING THE GENERATOR (CONTINUED) Starting the Generator Using Recoil Start 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.
  • Page 39 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 41: 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 42: 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 43 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 45: Connecting The Generator To A Home

    Connecting the Generator to a Home Extension cords ● The most straightforward and affordable option. ● Zero commitment, no installation needed: Simply plug in your appliances and go! ● Perfect for renters, RV/camping trips, and power on the job-site. Transfer switch ●...

  • Page 46: 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 47: Choosing The Right Power Cord

    *Gauge based on twisted copper wire From home back up to just running your electric edger and everything in-between DuroMax has the power cord for you. All DuroMax cords are 100% twisted copper wire for maximum life and reliability. 120V 15A...

  • Page 48: 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 Voltage The voltage currently produced by the generator in volts. The voltage currently produced by the generator in volts.

  • Page 49: Voltage Selector Switch

    Hours total The number of hours the generator has been run in total. Voltage Selector Switch This generator features Power Boost Technology, which gives the user the ability to double the power in the generator for more heavy duty applications. The voltage selector switches the dual 120V AC windings of the generator to produce “120V ONLY”...

  • Page 51: Maintenance And Care

    MAINTENANCE AND CARE Proper maintenance and storage of your generator 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 52: 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 53: Break-In Period

    Break-In Period As the best practice for any new combustion motor it’s recommended to perform the break in procedure as follows: ● Run the generator for the first 6-8 hours on conventional oil, then change the oil. After the break-in period synthetic oil may be used. ●...

  • Page 54: 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 55: Changing The Oil

    Changing the Oil CAUTION: 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 56: 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. CAUTION: Improper maintenance may cause less air to enter the engine or dirty air to enter the engine causing overheating and engine wear.
  • Page 57 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 58: Spark Plug Maintenance

    MAINTENANCE AND CARE (CONTINUED) Spark Plug Maintenance The spark plug is important for proper engine operation. SPARK PLUG A good spark plug should be intact, free of deposits, and CONSULT MANUAL properly gapped. BEFORE REMOVING CAUTION: Improper maintenance may cause reduced fuel economy, misfires, trouble starting, or damage to the spark plug threads.
  • Page 59 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 60: Emptying The Gas Tank

    MAINTENANCE AND CARE (CONTINUED) Emptying the Gas Tank If you have been using gasoline in your generator, before storing your generator for extended periods of time you should drain your generator fuel tank of gasoline. CAUTION: Do not store fuel from one season to another.
  • Page 61 Turn fuel valve ON and drain Turn the fuel valve to “ON” and allow gasoline to drain into the container until the gas tank is empty. Shut fuel valve OFF Once the gasoline is fully drained, move the fuel valve back to the “OFF”...

  • Page 62: Transporting The Generator

    MAINTENANCE AND CARE (CONTINUED) Transporting the Generator Empty the gas tank Fully drain your gas tank as shown in “Emptying the Gas Tank” on page 60-61. Disconnect the spark plug Pull on spark plug cap to disconnect spark plug from ignition wire.

  • Page 63: Storing The Generator For Same Day Use

    Storing the Generator for Same Day Use Turn the main breaker OFF Move the main breaker to the “OFF” position. Run the generator Allow the generator to run for 3-5 minutes. Move rocker switch to STOP Move the rocker switch to the “STOP” position to turn the generator off.

  • Page 65: Storing The Generator For Use Within 30 Days

    MAINTENANCE AND CARE (CONTINUED) Storing the Generator for Use Within 30 Days Turn breaker OFF and run Follow steps 1 and 2 as shown on “Storing the Generator For Same Day Use” on page 63. Shut fuel valve OFF and run dry Shut the fuel valve “OFF”...

  • Page 66: Storing The Generator For Longer Than 30 Days

    MAINTENANCE AND CARE (CONTINUED) Storing the Generator for Longer Than 30 Days Turn breaker OFF and run Follow steps 1 and 2 as shown on “Storing the Generator For Same Day Use” on page 63. Shut fuel valve OFF and run dry Shut the fuel valve “OFF”...
  • Page 67 Remove spark plug Remove spark plug as shown in “Spark Plug Maintenance” on page 58. Add oil to cylinder Add 2 tablespoons of 10W-30 motor oil directly into the spark plug hole, and pull the recoil to lubricate cylinder. After lubricating cylinder reinstall the spark plug.

  • Page 68: Specifications

    SPECIFICATIONS Model Number DS5000DX AC Rated Wattage (Gasoline) 4,000 W AC Rated Wattage (Propane) 3,800 W AC Surge Wattage (Gasoline) 5,000 W AC Surge Wattage (Propane) 4,750 W AC Rated Voltage 120/240V Dimensions 25”L x 23”W x 22”H Weight 135 lbs Recommended Oil 10W-30 Engine Displacement...

  • Page 69: Troubleshooting

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

  • Page 70: 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 71: 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 72 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 73: 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 74 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, be sure to connect + and –...
  • Page 75 Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts.

  • Page 76: Wiring Diagram

    WIRING DIAGRAM...

  • Page 78: Warranty

    OEM parts. Warranty Limitations DuroMax Power Equipment does not claim or hold any obligation to loss of time, freight charges, use of the product, or any incidental damages from the use of this product. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED.
  • Page 79 Equipment cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the small off-road engine owner, you should, however, be aware that DuroMax Power Equipment may deny you warranty coverage if your small off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 80 If the part fails prior to the first scheduled replacement, the part must be repaired or replaced by DuroMax Power Equipment according to Subsection (4) below. Any such part repaired or replaced under warranty must be warranted for the remainder of the period prior to the first scheduled replacement point for the part.
  • Page 81 (iii) Distribution manifold. (6) Catalyst or Thermal Reactor System (i) Catalytic converter. (ii) Thermal reactor. (iii) Exhaust manifold. DuroMax Power Equipment will furnish with each new engine written instructions for the maintenance and use of the engine by the owner...

  • Page 82: 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...
  • Page 84 5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX REV: DS5000DX-02032023...

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