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DuroStar DS4000WGE, User Manual

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DuroStar DS4000WGE User Manual Download Page 16

GENERATOR SETUP

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.

1.

Step 1 - Remove Shipping Braces

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.

2.

16

Note: Shipping braces can be thrown away. 
They will not be needed again.

Summary of Contents for DS4000WGE

Page 1: ... 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 5800 Ontario Mills Pkwy Ontario CA 91764 USA www duromaxpowerequipment com Call our Customer Care Team Toll Free 8 5pm PST Mon Fri 844 DUROMAX User Manual REV DS4000WGE 05292018 ...

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Page 3: ...the Oil 22 Check the Gas Level 23 Starting the Generator 24 Starting the Generator 2 Shipping Braces 16 Wheel Kit Installation 17 Adding Oil 18 Adding Gasoline 19 Grounding the Generator 20 High Altitude Operation 20 Generator Setup 4 AC Usage 28 Connecting a Load to the Generator 30 Voltage Selector Switch 31 DC Usage 34 Using the Generator 3 ...

Page 4: ...g the Oil 41 Cleaning the Air cleaner 42 Spark Plug Maintenance 44 Emptying the Gas Tank 46 Cleaning the Fuel Filter Cup 48 Storage and Transportation 49 Specifications 50 58 Basic Troubleshooting 52 Wiring Diagram 54 Maintenance and Care Warranty Troubleshooting 8 62 Contact Information ...

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Page 6: ...torm that knocks out power dewatering a flooded property or washing away a deck for the summer season 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 STOP Please do n...

Page 7: ... 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 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 ...

Page 8: ...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 qua...

Page 9: ...In addition to the above safety notices please familiarize yourself with the safety and hazard markings on the generator GENERAL SAFETY PROCEDURES 9 ...

Page 10: ... when you see fuel in the bottom of the fuel filter cup DO NOT overfill the tank 3 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 5 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...

Page 11: ...increase air into the carburetor for normal running 8 Connect devices Connect your devices to the receptacles on the front panel Start with the largest loads first 10 Start generator The key switch is located on the left side of the front power panel Insert the key and turn to the start position to start the generator Allow the key to return to the run position once started 7 Turn breaker on The b...

Page 12: ...leaner a removable cleanable oiled element that cleans the air going into the engine 7 Fuel Valve On Off Valve that allows fuel into the engine 8 Choke Allows the airflow into the carburetor to be restricted to assist in starting the engine 9 Engine Switch 3 Position Switch to Start Run or turn Off the generator 10 120v 3 Prong Receptacle Use to connect electrical devices that run 120 Volt 60 Hz s...

Page 13: ...protects the generator from electrical overload 14 Welding Terminals Easy use welding terminals males included 15 12v DC Charging Posts DC Output for charging batteries or running small DC powered items 13 11 Current Adjustment 15 12v DC Charging Posts 14 Welding Terminals 13 Circuit Breaker 12 120v 3 Prong Twist Lock 10 120v 3 Prong Receptacle 9 Engine Switch ...

Page 14: ... Wrench Plug Ends Phillips and slot blade screwdriver used for generator maintenance Used to add oil to the generator without messy spills Assorted wrenches used in generator maintenance and assembly Commonly 8mm 10mm 13mm and 15mm Used in conjunction with the charging posts to charge 12v automotive style batteries or small DC appliances Used in spark plug maintenance inspection and installation P...

Page 15: ...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: ...el or oil in the generator 1 Step 1 Remove Shipping Braces 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 2 16 Note Shipping braces can be thrown away They will not be nee...

Page 17: ...rackets on the frame using the provided bolts and nuts Do not over tighten the handles it will prevent free movement 3 Install wheels a Securetheaxlebracketweldedtoaxletotheframewith 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 2 ...

Page 18: ... the engine s service life 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 1 Step 3 Adding Oil Engine oil recommended SAE...

Page 19: ...e 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 ...

Page 20: ...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 m...

Page 21: ...e 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 ...

Page 22: ...ck 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 c...

Page 23: ...ister with less than 1 3 fuel tank full 1 Step 2 Check the gas level 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 olde...

Page 24: ...e the recoil start on the bottom of the fuel tank Rotate the valve clockwise to the vertical position to turn on the gas supply The choke lever is located above the air cleaner to the right of the recoil start Pull the lever out to cut the air supply and allow more gas into the engine to start The key switch is located on the left side of the front power panel Insert the key and turn to the start ...

Page 25: ...or 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 25 Turn engine switch to ON When the engine starts allow the engine switch to return to the ON position 5 Open choke Push the choke to the OPEN position as the engine warms up 6 ...

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Page 27: ...re 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 ...

Page 28: ...ed 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...

Page 29: ...ectric 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 gener...

Page 30: ...cted 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 Flip the circuit breaker up to the on position to allow power to the receptacles Start or turn on appliances starting with the biggest loads first 1 2 3 CAUTION Do not connect 50...

Page 31: ...ctrical 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 R...

Page 32: ... terminal to the black output terminal on the front panel Use the current adjuster to adjust the welding current from 50A to 210A 1 2 3 32 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...

Page 33: ...will offer unacceptable high resistance to current flow This high resis tance will shorten the service life of the generator welder and can even make the welding cables become hot enough to cause painful burns CABLE GAUGE CABLE DIA LENGTH IN FEET 0 50 ft 50 100 ft 100 250 ft CURRENT CAPACITY AMPERES 1 644 250 200 170 2 604 200 195 NOTE The cable lengths given in the table above are the combined le...

Page 34: ...onnect DC receptacle Start Generator Connect one charging wire to the positive terminal on the battery and the other charging wire to the negative terminal on the battery Connect the plug of the charging cable to the receptacle outlet on the generator The key switch is located on the left side of the front power panel Insert the key and turn to the start position to start the generator Allow the k...

Page 35: ...ery DANGER Always wear protective goggles and rubber gloves when charging a battery DANGER If battery acid gets on your skin flush with water If battery acid gets in your eyes flush with water and call a physician immediately DANGER If battery acid is swallowed drink large quantities of milk and call a Physician immediately 35 Disconnecting When disconnecting always disconnect the wires from the g...

Page 36: ...36 ...

Page 37: ...nce 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 37 ...

Page 38: ... 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 SERVICE REGULAR SERVICE PERIOD BEFORE E...

Page 39: ...MAINTENANCE LOG Date Generator Hours Maintenance Performed 39 ...

Page 40: ...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 secti...

Page 41: ...nated with water or dirt Remove drain plug Drain oil Replace 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 Drain oil into an approved oil disposal container Contact your local auto parts store for information on oil disposal Replace the oil drain plug and tighten ...

Page 42: ...less air to enter the engine or dirty air to enter the engine causing overheating and engine wear MAINTENANCE AND CARE CONTINUED Cleaning the air cleaner Open filter cover Remove filter element Wipe out filter casing Unhinge the clasps at the top and bottom of the air cleaner cover Remove the sponge like elements from the casing Wipe the dirt from inside the empty air cleaner casing 1 2 3 42 ...

Page 43: ... and replace the cover 7 43 Wash filter element Wash the sponge like elements in household dish detergent and warm water 4 Dry filter element Allow the elements to dry completely 5 6 Add engine oil to elements Soak the dry elements in a small amount of engine oil Ring out any excess oil ...

Page 44: ...plug threads Spark Plug Maintenance Remove spark plug cap Remove spark plug Inspect spark plug Pull on the spark plug cap to remove it Unscrew the spark plug from the generator using the spark plug wrench included with this product 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 1 2 3 MAI...

Page 45: ...nd re gap Replace spark plug Replace spark plug cap 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 Screw the spark plug back into its place on the generator using the spark plug wrench Replace the spark plug cap 5 6 7 45 ...

Page 46: ... Turn the fuel valve to the OFF position Remove the fuel filter cup see Removing the Fuel Filter Cup earlier in this section Empty the fuel filter cup of any fuel 1 2 3 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 MAINTENANCE AND CARE CONTINUED 46 ...

Page 47: ...lve to the ON position Drain all the gas from the generator 4 Shut fuel valve off Replace fuel filter cup Store emptied gas Turn the fuel valve to the OFF position Reinstall the fuel filter cup Store the emptied gasoline in a suitable place and add fuel stabilizer to keep fuel fresh and usable 5 6 7 47 ...

Page 48: ...ion 1 Cleaning the fuel filter cup Remove fuel filter cup Clean filter cup Replace fuel filter cup Unscrew the fuel filter cup from the fuel valve using a wrench Turn the valve towards you to unscrew Clean the cup of all sediment using a rag or brush Reinstall the fuel filter cup 2 3 4 48 ...

Page 49: ... 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 Add fuel stabilizer to the gas remaining in the tank 7 Store If you do not plan to start the unit for longer than 30 days 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 th...

Page 50: ... 210A Duty Cycle 60 150A Electrode Diameter 3 32 1 8 5 32 in 2 6 4 0mm DC Voltage 12V DC Amperage 8 3A Dimensions LENGTH 28in WIDTH 22in HEIGHT 23in Engine Type 4 Stroke OHV Forced Air Ignition System Non Contact Transistor Displacement 420cc Starting Type Electric Fuel Tank Capacity 6 6 US Gal 25L Oil Capacity 37 fl oz 1 1L Run Time 50 10 hr Noise Level 72db 50 ...

Page 51: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator 51 ...

Page 52: ... Move generator to a level surface Oil is low Add change oil Engine runs but there is no electrical output Circuit Breaker is Off Turn on circuit breaker Wiring connection is bad Replace extension cord s Device connected to generator is Malfunctioning Disconnect malfunctioning device Generator runs but does not support all electrical devices con nected Generator is overloaded Disconnect 1 or more ...

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Page 54: ...WIRING DIAGRAM 54 ...

Page 55: ...55 ...

Page 56: ...NTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The U S Environmental Protection Agency EPA California Air Resources Board and Imperial Industrial Supply Co LTD DuroMax Power Equipment are pleased to explain the emissions control system s warranty on your 2018 small off road engine In California new equipment that use small off road engines must be designed built and equipped to meet the State ...

Page 57: ...questions regarding your warranty coverage contact us at 800 629 4329 or email support duromaxpowerequipment com DEFECTS WARRANTY REQUIREMENTS The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser and extends for a period of Two Years GENERAL EMISSIONS WARRANTY COVERAGE DuroMax Power Equipment warrants to the ultimate purchaser and each subsequent own...

Page 58: ... provided at all manufacturer distribution centers that are franchised to service the subject engines 6 The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective provided that such diagnostic work is performed at a warranty station 7 The manufacturer is liable for damages to other engine components proximately caused by a failure ...

Page 59: ...her device used to capture particulate emissions 8 Electronic controls 9 Vacuum temperature and time sensitive valves and switches 10 Hoses belts connectors and assemblies 11 Evaporative Emission Warranty Part List i Fuel Tank ii Fuel Cap iii Fuel Line iv Fuel Line Fittings v Clamps vi Pressure Relief Valves vii Control Valves viii Control Solenoids ix Electronic Controls x Vacuum Control Diaphrag...

Page 60: ...our lifeline in the event of an emergency Should you have any problems please contact our customer service department DUROSTAR POWER EQUIPMENT 5800 Ontario Mills Parkway Ontario CA 91764 Customer Service 844 DUROMAX Customer Service Hours 8 5pm PST Website www duromaxpowerequipment com Email customer_service duromaxpowerequipment com ...

Page 61: ......

Page 62: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX ...

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