DS4000S GENERATOR

User Manual

REV: DS4000S-01242018
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
any time without prior notice. 844-DUROMAX
CONTENTS

1. Introduction
Introduction...................................................................................................................... 6
General Safety Procedures............................................................................................. 7
Quick Start Guide........................................................................................................... 10
Generator Components................................................................................................ 12
Package Contents.......................................................................................................... 14

2. Generator Setup

Shipping Braces.............................................................................................................. 16
Wheel Kit Installation..................................................................................................... 17
Handle Installation......................................................................................................... 18
Adding Oil....................................................................................................................... 20
Adding Gasoline............................................................................................................. 21
Grounding the Generator............................................................................................. 22
High Altitude Operation................................................................................................ 22

3. Starting the Generator

Checking the Oil............................................................................................................. 24

Check the Gas Level....................................................................................................... 25
Starting the Generator.................................................................................................. 26

4. Using the Generator

AC Usage......................................................................................................................... 30
Connecting a Load to the Generator........................................................................... 32

3
CONTENTS

5. 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......................................................................................... 47
Specifications.................................................................................................................. 48

6. Troubleshooting
Basic Troubleshooting .................................................................................................. 50
Changing / Inspecting the Carbon Brushes ............................................................... 51
Changing / Inspecting the AVR .................................................................................... 53

7. Warranty .......................................................................................................................... 58

8. Contact Information................................................................................................... 62

4
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. Reliability is the highest
standard we hold ourselves to, whether its powering a heater during a winter storm that knocks
out power, dewatering a flooded property, or washing away a deck for the summer season

STOP
Please do not return
to 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.
We want you to be able to put your new generator
to use right away!
CALL US BEFORE YOU CONSIDER
RETURNING THE PRODUCT!

TOLL FREE
1-844-DUROMAX

Notice Regarding Emissions

Engines that are certified to comply with U.S. EPA emission regulations for SORE (Small off Road
Equipment), are certified to operate on regular unleaded gasoline, and may include the following
emission control systems: (EM) Engine Modifications and (TWC) Three-Way Catalyst (if so equipped).

6
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
followed.
●● WARNING: Indicates a strong possibility of causing serious injury or death if instructions are not
followed.
●● CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not
followed.

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.

●● Use outdoors ONLY in non-confined areas.

●● Keep several feet of clearance on all sides to allow proper ventilation of the generator.

WARNING: The exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.

WARNING: This generator produces heat when running. Temperatures near exhaust can
exceed 150°F (65°C).

●● Do not touch hot surfaces. Pay attention to warning labels on the generator denoting
hot parts of the machine.
●● Allow generator to cool several minutes after use before touching engine or areas
which heat during use.

7
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.

●● Do not smoke near generator.
●● Always operate on a firm, level surface.
●● Always turn generator off before refueling.
●● Allow generator to cool for at least 2 minutes before removing fuel cap. Loosen cap
slowly to relieve pressure in tank.
●● Do not overfill gas tank. Gas may expand during operation. Do not fill to the top of
the tank.
●● Always check for spilled gas before operating.
●● Empty the gasoline tank before storing or transporting the generator.
●● Before transporting, turn fuel valve to the off position and disconnect the spark plug.

WARNING: This generator produces a powerful voltage, which can result in electrocution.

●● ALWAYS ground the generator before using it (see the “Grounding the Generator”
portion of the “PREPARlNG THE GENERATOR FOR USE section).
●● Generator should only be plugged into electrical devices, either directly or with an
extension cord. NEVER connect to a building electrical system without a qualified
electrician. Such connections must comply with local electrical laws and codes. Failure
to comply can create a backflow of power, which may result in serious injury or death
to utility workers.
●● Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as metal
decking or steel work. GFCls are available in-line with some extension cords.
●● Do not use uncovered in rainy or wet conditions.
●● Do not touch bare wires or receptacles (outlets).
●● Do not allow children or non-qualified persons to operate.

8
GENERAL SAFETY PROCEDURES
In addition to the above safety notices, please familiarize yourself with the safety and
hazard markings on the generator.

9
QUICK START GUIDE

1. 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.

2. Add oil
The oil fill cap is located on the lower engine block to the
right of the recoil start housing. Remove the oil fill cap and
fill with 10w30 oil.

3. Add gasoline
The fuel cap is located on top of the fuel tank. Fill the tank
with fresh unleaded gasoline 87 octane or higher. The tank
is full when you see fuel in the bottom of the fuel filter cup.
DO NOT overfill the tank.

4. 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.

5. Turn gas valve on

The gas valve is located above the recoil start on the
bottom of the fuel tank. Rotate the valve clockwise to the
vertical position to turn on the gas supply.

10
6. 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.

7. Flip engine switch to ON

The engine switch is located on the left side of the front
power panel. Flip the switch to on.

8. 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.

8. Open choke
The choke lever is located above the air filter to the right
of the recoil start. Slide the lever to the right to open the
choke and increase air into the carburetor for normal
running.

10. Turn breaker on & connect

devices
Connect your devices to the receptacles on the front panel.
Start with the largest loads first.

11
 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. Air Cleaner - a removable, cleanable, oiled, sponge-like element that cleans the air going into
the engine.
2. Choke Lever - Allows the airflow into the carburetor to be restricted to assist in starting the
engine.
3. Fuel Gauge - Indicates the amount of fuel in the gasoline tank.
4. Fuel Cap - Allows access to fill the gasoline tank.
5. Circuit Breaker - Resettable switch that protects the generator from electrical overload.
6. 120v 3-Prong Receptacle - Use to connect electrical devices that run 120 Volt, 60 Hz, single
phase, AC current (NEMA 5-20).
7. Ground Terminal - Connect a ground wire here to properly ground the generator.
8. 120v 3-Prong Twist Lock - Use to connect electrical devices that run 120 Volt, 60 Hz, single
phase, AC current (L5-30).
9. Volt Meter - Provides reading of voltage output.

12
 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. Recoil Start – Easy Pull Recoil Start to start the engine without the electric start.
14. Fuel Filter Cup - Traps dirt and debris in gasoline before it enters the engine.
15. Fuel Valve - On/Off Valve that allows fuel into the engine.
16. Spark plug – Provides ignition to the engine.
17. Muffler – Reduces engine emissions and reduces noise.

13
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 maintenance, inspection, and
maintenance. assembly. Commonly 8mm, installation.
10mm, 13mm, and 15mm.

Oil Funnel w/ hose Plug Ends

Used to add oil to the Plug heads for the receptacles
generator without messy spills. found on the generator are
included to make or rewire
your own cords.

●● Note: Actual tools may differ in appearance or design from image shown.

14
 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

Step 1 - Remove Shipping Braces

1. 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.

2. Remove braces
a. Completely remove each of the 4 bolts holding the
orange metal brace in place.
b. Remove the brace.
c. Cut the nylon tie strap holding the wood brace in
place.
d. Grab the end of the second brace and pull it out.
e. This piece is no longer needed and can be discarded.

Note: Shipping braces can be thrown away.

They will not be needed again.

16
Step 2 - Wheel Kit Installation (Optional)

1. Install support legs

Secure the support legs to the frame with provided bolts and
lock nuts.

2. Install wheels
a. Secure the axle bracket welded to axle to the frame with
the provided bolts and lock nuts.
b. Secure the loose axle bracket to the frame with the
provided bolts and lock nuts.
c. Slide one wheel over each axle end and secure with
the provided retaining pins.

17
GENERATOR SETUP

Step 3 - Handle Installation (Optional)

1. Install lower handle lock

Position the lower handle lock on the frame and secure with
bolt.

2. Install upper handle bracket

Insert upper handle bracket and secure with provided bolts.

3. Install handle
Insert the handle into the upper bracket secure with pin.

4. Install retaining pin

Insert and secure the retaining pin.

18
1. Test handle pivot
The handle should easily flip up and down after installation.

19
GENERATOR SETUP (CONTINUED)

Step 3 - 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 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.

SAE Engine oil recommended: SAE 10W-30. Viscosity varies with

30 regions and temperatures. Choose your oil viscosity using the
chart to the left.
10W-30

* A small amount of oil from factory testing may be present on

5W-30
arrival.
-20 0 20 40 60 80 100 F

-40 -30 -20 -10 0 10 20 30 40 C

ENVIRONMENTAL TEMPERATURE

1. Add oil
a. Make sure the generator is on a level surface.
b. Unscrew the oil filler/dipstick cap from the engine .
c. Using a funnel, add the appropriate amount of oil
into the crankcase. You will know the crankcase is
full when the oil level has reached the lower lip of
the opening you have just poured the oil into.
d. Replace oil filler cap.

WARNING: DO NOT overfill the crankcase. This

may damage the motor and shorting overall life
of your generator.

20
 Step 4 - Adding Gasoline
WARNING: Gasoline and gas fumes are highly flammable.

●● Do not fill tank near an open flame.

●● Do not overfill. Always check for fuel spills.

To ensure that the generator runs smoothly use only FRESH, UNLEADED GAS WITH AN OCTANE
RATING OF 87 OR HIGHER.

2. 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 and hard to unscrew).
c. Slowly add unleaded gasoline to the fuel tank. Be
careful not to overfill. Please refer to the chart below
to find the gas capacity of your generator model. The
fuel gauge on the top of the gas tank indicates how
much gasoline is in the generator gas tank.
d. Replace fuel cap and wipe up any spilled gasoline
with a dry cloth.
NOTE: Gas can expand. Do not fill the gas tank
to the very top. Leave a minimum of 1.5 in of open
space.
IMPORTANT:
●● Never use an oil/gasoline mixture. Never use old gas.
●● Avoid getting dirt or water in the fuel tank.
●● 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)

21
GENERATOR SETUP (CONTINUED)

Step 5 - Grounding the Generator

1. Attach grounding wire

a. Ground the generator by tightening the grounding
nut against a grounding wire.
b. 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.

Grounding codes can vary by location. Please contact a local

electrician to check the grounding regulations for your area.

WARNING: Failure to properly ground the generator can result in electrocution.

High Altitude Operation

At high altitude, the standard carburetor air/fuel mixture will be too rich. Performance will decrease, and
fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting.
Operation at an altitude that differs from that at which this engine was certified, for extended periods of
time, may increase emissions. High altitude performance can be improved by specific modifications to the
carburetor. If you always operate your generator at altitudes above 5,000 feet (1,500 meters), have a dealer
perform this carburetor modification. This engine, when operated at high altitude with the carburetor
modifications for high altitude use, will meet each emission standard throughout its useful life. Even with
carburetor modification, engine horsepower will decrease about 3.5% for each 1,000-foot (300-meter)
increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor
modification is made.

When the carburetor has been modified for high altitude operation, the air/fuel mixture will be too lean
for low altitude use. Operation at altitudes below 5,000 feet (1,500 meters) with a modified carburetor may
cause the engine to overheat and result in serious engine damage.

22
 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” If you have not yet read this section, go
back and read it now.

23
BEFORE YOU START YOUR GENERATOR

Step 1 - Check the oil

1. 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 sure the generator is on a level surface.

b. Unscrew the oil filler/dipstick cap.
c. With a dry cloth, wipe the oil off of the stick on the
inside of the cap.
d. Insert the dipstick as if you were replacing the
cap and then remove again. There should now be
oil on the stick. If there is no oil on the stick, or oil
only at the very end of the stick, you should add
oil until the engine crankcase is filled (see “Adding
Oil” portion of the “Maintenance” section).
e. Be sure to replace the cap when finished checking
oil.

NOTE: The oil capacity for your generator can be found in

the “Specifications” section of this manual.

24
Step 2 - Check the gas level

1. 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 with less than 1/3 fuel
tank full.

WARNING: Gasoline and gasoline fumes are highly flammable.

●● Do not fill tank near an open flame.

●● Always allow engine to cool for several minutes before refueling.
●● DO NOT overfill fuel tank. Fuel expands when shaken or heated. ALWAY leave 11/2“
space or more at the top of the tank.
●● ALWAYS use fresh fuel or stabilized fuel. Old gasoline (older than 30 days) can cause
permanent damage to the fuel system.
●● Always check for fuel spills.

25
STARTING THE GENERATOR

Starting the Generator Using Gasoline

1. 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.

2. Turn gas valve on

The gas valve is located above the recoil start on the bottom
of the fuel tank. Rotate the valve clockwise to the vertical
position to turn on the gas supply.

3. 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.

4. Flip engine switch to ON

The engine switch is located on the left side of the front
power panel. Flip the switch to on.

26
 5. 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.

6. Open choke
Push the choke to the OPEN position as the engine warms up.

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
28
 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” If you have not yet read this section, go
back and read it now.
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.
●● The surge wattage corresponds to the maximum amount of power the generator can output for
a short period of time. Many electrical devices such as refrigerators require short bursts of extra
power, in addition the rated wattage listed by the device, to stop and start their motors. The
surge wattage ability of the generator covers this extra power requirement.

Fuel Source Rated (Running Wattage) Surge (Peak) Wattage

Gasoline 3300 4000

The total running wattage requirement of the electrical devices connected to the generator should
not exceed the rated wattage of the generator itself. To calculate the total wattage requirement of
the electrical devices you wish to connect, find the rated (or running) wattage of each device. This
number should be listed somewhere on the device or in its instruction manual.

If you cannot find this wattage, you may calculate it by multiplying the Voltage requirement by the
Amperage drawn: Watts = Volts x Amps. If these specifications are not available you may estimate
the Watts required by your device by using the chart on the next page.

Once you have found the rated wattage requirement of each electrical device, add these numbers
to find the total rated wattage you wish to draw from the generator. If this number exceeds
the rated wattage of the generator, DO NOT connect all these devices. Select a combination of
electrical devices, which has a total rated wattage lower than or equal to the rated wattage of the
generator.

30
 Tool or Appliance Rated (Running) Watts Additional Surge Watts
Electric water heater (40 gal) 4000 0
Hot plate 2500 0
Radial arm saw 2000 2000
Electric Stove 1500 0
Circular Saw 1500 1500
Air compressor (1 HP) 1500 3000
Window air conditioner 1200 1800
Miter saw 1200 1800
Microwave 1000 2000
Well water pump 1000 1500
Reciprocating saw 960 1040
Sump pump 800 1200
Refrigerator freezer 800 1200
Furnace blower 800 1300
Computer 800 0
Electric drill 600 900
Television 500 0
Deep freezer 500 800
Garage door opener 480 600
Stereo 400 0
Box fan 300 600
Clock radio 300 0
Security system 180 0
DVD Player 100 0
Common light bulb 75 0

CAUTION - The generator can only run at its surge wattage capacity for a very short time.
Connect only electrical devices requiring a rated (running) wattage equal to or less than
the rated wattage of the generator. Never connect devices requiring a rated wattage
equal to the surge wattage of the generator.

NOTE: The above wattage figures are estimates only.

Try to check the wattage listed on your electrical devices before consulting this chart.

31
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.

1. Plug in devices
Plug in devices to the appropriate receptacle. When using
the generator in 120/240v mode, balance the load as closely
as possible. Placing more load on one side of the circuit will
reduce the breaker trip period.

2. Turn breaker on
Flip the circuit breaker up to the on position to allow power to
the receptacles.

3. Turn on connected devices

Start or turn on appliances starting with the biggest loads
first.

32
 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 WATTS (120/240V) 10 25 50 100 150
5 600/1200 18 16 14 12 10
10 1200/2400 16 14 12 10 8
15 1800/3600 14 12 10 8 6
20 2400/4800 12 10 8 6 4
25 3000/6000 10 8 6 4 4
30 3600/7200 8 6 4 4 NR
40 4800/9600 6 4 4 NR NR
50 6000/1200 4 4 2 NR NR
*NR = NOT RECOMMENDED

33
34
 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.

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.

●● Make sure the engine is off before you begin any maintenance or repairs.
●● Let the engine and exhaust system cool before touching.
●● 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.

Maintenance Schedule
Remember that this schedule is based on the assumption that your machine will be used for its
designed purpose. Sustained high-load, high temperature operation, or use in unusually wet or
dusty conditions, will require more frequent service.

REGULAR SERVICE PERIOD

SERVICE BEFORE EVERY MO. OR EVERY 3 MO. OR EVERY 6 MO. OR EVERY 12 MO.
EACH USE 20 HRS 50 HRS 100 HRS OR 300 HRS
ENGINE OIL CHECK
CHANGE
AIR CLEANER CHECK
CHANGE
SEDIMENT CUP CLEAN
SPARK PLUG CLEAN-
ADJUST
REPLACE
SPARK ARRESTOR CLEAN
IDLE SPEED CHECK /
ADJUST
VALVE CLEARANCE CHECK-
ADJUST
COMBUSTION CLEAN
500 HOURS
CHAMBER
FUEL TANK / FILTER CLEAN
FUEL TUBE CHECK EVERY 24 MO. (REPLACE IF NECESSARY)
TO BE PERFORMED AT EVERY MONTH INDICATED OR HOUR INTERVAL WHICH EVER COMES FIRST

36
MAINTENANCE LOG

Date Generator Hours Maintenance Performed

37
MAINTENANCE AND CARE (CONTINUED)
Checking the oil

1. 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 sure the generator is on a level surface.

b. Unscrew the oil filler/dipstick cap.
c. With a dry cloth, wipe the oil off of the stick on the
inside of the cap.
d. Insert the dipstick as if you were replacing the
cap and then remove again. There should now be
oil on the stick. If there is no oil on the stick, or oil
only at the very end of the stick, you should add
oil until the engine crankcase is filled (see “Adding
Oil” portion of the “Maintenance” section).
e. Be sure to replace the cap when finished checking
oil.

NOTE: The oil capacity for your generator can be found in

the “Specifications” section of this manual.

38
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.

2. Remove drain plug

Using a 10 mm hex wrench, unscrew the oil drain plug, which
is located on the crankcase underneath the oil filler/dipstick
cap.

Allow all the oil to drain from the generator.

2. Drain oil
Drain oil into an approved oil disposal container. Contact
your local auto parts store for information on oil disposal.

3. Replace drain plug

Replace the oil drain plug and tighten with a 10 mm hex
wrench.

39
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.

1. Open cleaner cover

Unhinge the clasps at the top and bottom of the air cleaner
cover.

2. Remove cleaner element

Remove the sponge-like elements from the casing.

3. Wipe out cleaner casing

Wipe the dirt from inside the empty air cleaner casing.

40
4. Wash cleaner element
Wash the sponge-like elements in household dish detergent
and warm water.

5. Dry cleaner element

Allow the elements to dry completely.

6. Add engine oil to elements

Soak the dry elements in a small amount of engine oil. Ring
out any excess oil.

7. Replace elements in casing

Replace the sponge-like elements in the air cleaner casing and
replace the cover.

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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.

1. Remove spark plug cap

Pull on the spark plug cap to remove it.

2. Remove spark plug

Unscrew the spark plug from the generator using the spark
plug wrench included with this product.

3. Inspect spark plug

Visually inspect the spark plug. If it is cracked or chipped,
discard and replace with a new spark plug. We recommend
using a F6RTC spark plug such as NGK BPR5ES.

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4. Measure plug gap
Measure the plug gap with a gauge. The gap should be 0.7-0.8
mm (0.028-0.031 in).

5. 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.

6. Replace spark plug

Screw the spark plug back into its place on the generator
using the spark plug wrench.

7. Replace spark plug cap

Replace the spark plug cap.

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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.

1. Shut fuel valve off

Turn the fuel valve to the “OFF” position.

2. Remove fuel filter cup

Remove the fuel filter cup (see “Removing the Fuel Filter Cup”
earlier in this section.

3. Empty fuel filter cup

Empty the fuel filter cup of any fuel.

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4. 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.

5. Shut fuel valve off

Turn the fuel valve to the “OFF” position.

6. Replace fuel filter cup

Reinstall the fuel filter cup.

7. Store emptied gas

Store the emptied gasoline in a suitable place and add fuel
stabilizer to keep fuel fresh and usable.

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MAINTENANCE AND CARE (CONTINUED)

Cleaning the fuel filter cup

1. Shut fuel valve off

Turn the fuel valve to the “OFF” position.

2. Remove fuel filter cup

Unscrew the fuel filter cup from the fuel valve using a wrench.
Turn the valve towards you to unscrew

3. Clean filter cup

Clean the cup of all sediment using a rag or brush.

4. Replace fuel filter cup

Reinstall the fuel filter cup.

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 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.
●● Do not obstruct any ventilation openings & keep the generator in a cool dry area.

Storage Period Storage Preparation

1. Turn off the main breaker.

If you plan on starting 2. Allow the unit to run 3 - 5 minutes.
the same day. 3. Turn off the key.
4. Store.

1. Turn off the main breaker.

2. Allow the unit to run 3 - 5 minutes.
If you plan on starting 3. Turn off the fuel valve.
the unit again within 4. Allow the unit to stall out.
30 days. 5. Turn off the key.
6. Add fuel stabilizer to the gas remaining in the tank.
7. Store.

1. Turn off the main breaker.

2. Allow the unit to run 3 - 5 minutes.
3. Turn off the fuel valve.
4. Allow the unit to stall out.
5. Turn off the key.
6. Drain the fuel tank (See “Emptying the Gas Tank” in the “Maintenance” section)
If you do not plan to 7. Drain the carburetor
start the unit for a. Remove the drain bolt from the carburetor.
longer than 30 days. b. Drain the small amount of remaining fuel from the carburetor bowl.
8. Oil the cylinder
a. Remove the spark plug.
b. Put 2 tbsp. of 10w30 motor oil directly into the spark plug hole
c. Pull the recoil start one time.
d. Replace the plug.
9. Remove the battery and place on tender indoors.

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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 Transistor

Displacement 208cc

Starting Type Electric

Fuel Tank Capacity 3.96 US Gal. (15L)

Oil Capacity 20 fl. oz. (0.6L)

Run Time @ 50% (Gasoline) 12 hr.

Noise Level <69db

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

49
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

Spark Plug is broken Replace spark plug

Move generator to a level

Generator is not level
surface

Oil is low Add / change oil

Circuit Breaker is “Off” Turn “on” circuit breaker

Engine runs, but there

Wiring connection is bad Replace extension cord(s)
is no electrical output
Device connected to generator Disconnect malfunctioning
is malfunctioning device
Disconnect 1 or more items to
Generator is overloaded
Generator runs, but reduce the load
does not support all Device connected to generator Disconnect malfunctioning
electrical devices is bad device
connected
Air cleaner is dirty Clean / replace the air filter

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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.

1. Remove generator cover

Remove the 2 bolts of the generator cover then pull the cover
off the generator.

2. Remove bolt from brush

Remove the bolt holding the carbon brush.

3. Disconnect AVR wires

Remove the two wires from the AVR on the carbon brush

51
TROUBLESHOOTING (CONTINUED)

Changing / Inspecting the Carbon Brushes (Cont.)

4. Install new brush

Install new carbon brush with bolt.

5. Connect AVR wires

Insert and connect the 2 wires from the AVR, be sure to connect
+ and – correctly.

6. Replace generator cover

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

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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.

1. Remove generator cover

Remove the 2 bolts of the generator cover then pull the cover
off the generator.

2. Remove AVR bolts

Remove the 2 bolts holding the AVR.

3. Disconnect AVR wire clip

Disconnect the wire clip.

53
TROUBLESHOOTING (CONTINUED)

Changing / Inspecting the AVR (Continued)

4. Disconnect wires from brush

Remove the 2 wires from the AVR on the carbon brush.

5. Install new AVR

Install the new AVR with the 2 bolts.

6. Reconnect wires to brush

Reconnect the wire clip.

7. Reconnect the AVR wire clip

Insert and connect the 2 wires from the AVR, be sure to
connect + and – correctly.

54
8. Replace generator cover
Replace the back cover of the generator and secure with the
2 bolts.

55
WIRING DIAGRAM

56
57
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 on any items
submitted for replacement or repair under the Warranty are the responsibility of the equipment
owner. This warranty is non-transferable and only valid to the original purchaser.

Warranty Exclusions
The DuroMax/DuroStar Power Equipment warranty does not cover repairs or returns when
the fault is: Normal Wear and Tear, Installation Use or Maintenance Services, Cosmetic defects,
Accessories, Failures due to acts of God or Natural Disasters, or problems related to/from
aftermarket or non-OEM parts.

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.

58
59
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

Customer Service Hours: 8-5pm PST

Website: www.duromaxpower.com
Email: [email protected]

60
5800 Ontario Mills Parkway
Ontario, CA 91764
United States

844-DUROMAX