DS5000X - Generator DuroStar - Free user manual and instructions

Type of product	Portable Generator
Brand	DuroStar
Model	DS5000X
Manufacturer	DuroMax
Power Output (Peak)	5000 Watts
Power Output (Running)	4000 Watts
Engine Displacement	7.0 HP (196 cc)
Fuel Type	Gasoline
Fuel Tank Capacity	4 Gallons
Run Time at 50% Load	8 hours
Starting System	Recoil Start
Outlets	2x 120V AC 20A, 1x 120V AC 30A (NEMA L5-30R), 1x 12V DC
Dimensions (L x W x H)	23 x 18 x 18 inches
Weight	95 lbs
Noise Level	69 dB(A) @ 25 feet
Oil Type	SAE 10W-30 (recommended)
Oil Capacity	0.63 quarts (20 oz)
Spark Plug	F7RTC or equivalent
Safety Features	Low oil shutdown, overload protection, GFCI outlets
Maintenance	Check oil every use, change oil after 20 hrs, clean air filter regularly
Warranty	2-year warranty with free technical support

Frequently Asked Questions - DS5000X DuroStar

What type of oil should I use in my DuroStar DS5000X?

For optimal performance, use SAE 10W-30 oil. In colder climates, 5W-30 may be used. The oil capacity is 0.63 quarts (20 oz).

How do I break in the engine?

During the first 20 hours, avoid high load (under 50% capacity) and vary engine speed. Change oil after the first 20 hours of use.

Can I use the generator during rain?

No, never operate the generator in rain, snow, or wet conditions. Use only in a well-ventilated, dry area protected from moisture.

How often should I change the oil?

Change the oil after the first 20 hours of break-in, then every 100 hours or annually, whichever comes first.

What is the fuel type and capacity?

The DS5000X runs on unleaded gasoline (octane rating 87 or higher). The fuel tank holds 4 gallons.

How do I start the generator?

1. Check oil and fuel. 2. Turn fuel valve to ON. 3. Close choke (pull knob). 4. Set engine switch to ON. 5. Pull the recoil starter cord firmly. 6. After engine warms, open choke gradually.

What outlets are available?

It features two 120V 20A outlets, one 120V 30A twist-lock outlet (NEMA L5-30R), and a 12V DC outlet for battery charging.

Why does the generator shut off unexpectedly?

Common causes: low oil (triggers low oil shutoff), empty fuel tank, or overload. Check oil level, refuel, or reduce connected load.

How do I clean the air filter?

Remove the air filter cover, take out the foam filter, wash with soapy water, rinse and let dry completely. Re-oil lightly with engine oil and squeeze out excess. Reinstall.

Can I connect it directly to my house?

Only use a transfer switch installed by a licensed electrician. Never plug into a household outlet without proper equipment.

USER MANUAL DS5000X DuroStar

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.

5800 Ontario Mills Pkwy

Ontario, CA 91764 USA

www.DuroMaxPower.com

Call our Customer Care Team Toll Free 8-5 pm PST Mon-Fri

844-DUROMAX

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Pure black rectangle on white background with no text, numbers, or symbols

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CONTENTS

1. Introduction

Introduction 6

General Safety Procedures 8

Carbon Monoxide Safety 12

Unit and Purchase Information 14

2. Generator Components

Generator Components.... 16

Package Contents 18

3. Generator Setup

Remove Shipping Braces 21

Wheel Kit Installation.... 22

Connect the Battery.... 24

Adding Oil 25

Adding Gasoline 26

Grounding the Generator 27

High Altitude Operation 27

4. Starting the Generator

Checking the Oil 30

Check the Gas Level 31

Starting the Generator 32

Starting the Generator Using Recoil Start 34

5. Using the Generator

AC Usage 38

Connecting the Generator to a Home.... 41

Connecting a Load to the Generator.... 42

Choosing the Right Power Cord 43

Using the Digital Multimeter 44

Voltage Selector Switch 45

CONTENTS

6. Maintenance and Care

Maintenance Schedule 48

Break-In Period 49

Maintenance Log 49

Checking the Oil 50

Changing the Oil.... 51

Cleaning the Air Filter 52

Spark Plug Maintenance 54

Emptying the Gas Tank 56

Transporting the Generator 58

Storing the Generator for Same Day Use 59

Storing the Generator for Use Within 30 Days....61

Storing the Generator for Longer than 30 Days 62

Specifications.... 64

7. Troubleshooting

Basic Troubleshooting 66

Changing / Inspecting the Carbon Brushes 67

Changing / Inspecting the AVR 69

Wiring Diagram 72

8. Warranty 74

9. Contact Information 78

POWERING EVERYONE...

ANYWHERE!

Duro Star

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...

Family of four sitting on stone steps, smiling and engaged in conversation (no visible text or symbols)

DUROSTAR FOR HOME

Electricity in our home not only provides comfort but safety as well. From keeping the heat or A/C on to keeping our food cold, power is essential to our daily lives. Inevitability when disaster strikes and we are left without power for a prolonged period of time, our way of life is put at risk. This is by far the most critical time for reliable portable power.

Two construction workers in hard hats and blue shirts working on scaffolding (no visible text or symbols)

DUROSTAR FOR WORK

On the job site, portable power allows you the ability to get work done in remote locations when traditional power sources are usually unavailable. Equipment like table saws, sanders, and work lights are a necessity and portable power can play a critical role in getting a job done successfully and efficiently.

Family of four gathered outdoors near a campfire, with a camouflaged vehicle in the background (no visible text or symbols)

DUROSTAR FOR PLAY

Camping outdoors in a remote location can get one in touch with nature and allow them to forget the stress of the day to day grind. Here portable power can provide comfort as well as safety. With portable power, you can keep your cell phone charged, light up your campsite, or even brew a cup of coffee, all while being miles from civilization.

The DuroStar Way is a commitment to excellence. This vision is focused on the quality, reliability, and durability of our products combined with outstanding customer service. We understand that having dependable power whenever and wherever you need it provides comfort, safety, and peace of mind. It is through this philosophy that DuroStar achieves our vision of...

POWERING EVERYONE... ANYWHERE!

INTRODUCTION

DuroStar Power Equipment is headquartered in Ontario, California and is the industry's leader in Dual Fuel portable generator technology. In addition to a full assortment of portable generators ranging from digital inverters to large 15,000-watt portable standby units, their product line includes pressure washers, engines, pumps, and accessories.

The foundation of our company is built on quality, reliability, durability, and customer service. At DuroStar our vision is simple, we are committed to Powering Everyone... Anywhere!

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. 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).

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:

• 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.

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.
• Do not smoke near the generator.
  • Always operate on a firm, level surface.
  • Always turn the generator off before refueling.
• Allow generator to cool for at least 2 minutes before removing the fuel cap. Loosen cap slowly to relieve pressure in the tank.
• Do not overfill the 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 the 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 "PREPARING THE GENERATOR FOR USE").
• The 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 steelwork. GFCIs 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.

GENERAL SAFETY PROCEDURES

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

DANGER

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and vents.

Avoid other generator hazards. READ MANUAL BEFORE USE

CARBON MONOXIDE SAFETY

Carbon Monoxide

Generators are convenient, but they can also be dangerous. All fuel-burning appliances and equipment release a poisonous gas called carbon monoxide.

Carbon monoxide (also known as CO) can be dangerous for humans and pets, even in small amounts, because it blocks oxygen from getting into your body. Carbon monoxide poisoning can lead to death in a very short time. It is odorless, tasteless and invisible, so you may be exposed without knowing it. That is why carbon monoxide is sometimes called "the silent killer."

CO-ALERT

Description

The DuroStar CO-ALERT system was created to protect our customers and their families from dangerous carbon monoxide. Just like the detector for your home the CO-ALERT tests the air for to keep you safe and healthy.

CO Detected

If dangerous carbon monoxide levels are detected:

• 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.

ALWAYS READ THE OWNER'S MANUAL FIRST

KNOW THE SYMPTOMS

• HEADACHE • DIZZINESS
• NAUSEA • FATIGUE
• SHORTNESS OF BREATH

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Abstract geometric pattern with diagonal lines and a circular element (no text or symbols)

POINT FUMES AWAY FROM NEARBY PEOPLE

KEEP IT OUTSIDE AND AWAY FROM DOORS AND WINDOWS

Illustration of a charging station with a lightning bolt and wheels (no text or symbols)

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. Visit takeyourgeneratoroutside.com for more information.

TAKE IT OUTSIDE™

CARBON MONOXIDE KILLS

■ UNIT AND PURCHASE INFORMATION

Serial Number

Close-up of a red and black utility gas generator with visible wheels and control panel (no text or symbols)

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.

Engine Model:

Serial Number: ____

STAPLE RECEIPT HERE

A purchase receipt may be necessary for warranty parts or service in the future. If you have a paper receipt, staple it here for easy reference.

If you purchased the unit online, save the email receipt where you can access it, and record your details here for convenience in the future.

Purchase Date: ____

Order Number: ____

Retailer Name: ____

Exterior view of a DuroStar Gas turbine with red fuel pump and control panel (no signage)

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.

■ GENERATOR COMPONENTS

1. Recoil Start – Easy pull recoil start to start the engine without the electric start.
2. Air Cleaner - A removable, cleanable, oiled, element that cleans the air going into the engine.
3. Choke Lever - Restricts the airflow into the carburetor to assist in starting the engine.
4. Fuel Valve - ON/OFF valve that allows gasoline to the fuel switch.
5. Fuel Tank - All metal 5.3 gallon gasoline fuel tank.
6. Power Panel - Contains the start switch, plugs, meters, and circuit breakers.
7. Handles - Longest handles of any DuroStar model allow easy movement across any surface.
8. Battery - 12V DC battery that powers the electric start system.
9. Oil Fill and Dipstick - Use to add or check the oil.
10. Engine Switch - 3 position switch to "START", "RUN", or turn "OFF" the generator.

1. Low Oil Alert – Will light only if the generator shuts down due to low oil.
2. Multimeter - Displays voltage, hertz, and time running.
3. Power Boost – DuroStar exclusive Power Boost doubles the amperage available in "120V only" for heavy loads like RV air conditioners.
4. Circuit Breaker - Protects the panel from overload and short circuits.
5. GFCI 20A Receptacle - Use to connect electrical devices that run 120 volt, 60 Hz, single-phase, AC current (NEMA 5-20).
6. 240V 30A Receptacle - Use to connect electrical devices that run 120 or 240 volt, 60 Hz, single-phase, AC current (NEMA L14-30).
7. CO-ALERT - Shuts down the engine in the event of CO buildup.
8. Charging Light - Will light when the generator is charging the on-board battery.

■ 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.

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Double-Sided Screw Driver

Phillips and slot blade screwdriver used for generator maintenance.

Two metallic wrenches with decorative patterns, no text or symbols visible

Two metallic cylindrical objects with grooves, one upright and one straight, against a white background (no text or symbols)

Spanner Spark Plug Wrench

Assorted wrenches used in generator maintenance and assembly. 10mm/12mm and 13mm/15mm.

Used in spark plug maintenance, inspection, and installation.

Simple curved line drawing resembling a tool or tool (no text or symbols)

Oil Funnel w/ Hose

Used to add oil to the generator without messy spills.

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Plug Ends

Plug heads for the receptacles found on the generator are included to make or rewire your own cords.

Note: Actual tools may differ in appearance or design from the images shown.

Exterior view of a DuroStar Gas turbine with red fuel pump and control panel (no signage)

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.

POWERING EVERYONE... ANYWHERE!

■ GENERATOR SETUP

Step 1 - Remove Shipping Braces

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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.

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2. Remove braces

a. The shipping braces prevent engine movement during shipment. Flip the generator over and remove the brightly colored braces between the motor and the frame, and the wood brace under the generator.

Collection of red metal bracket components including bolts, nuts, and bolts (no text or symbols visible)

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

■ GENERATOR SETUP (CONTINUED)

Step 2 - Wheel Kit Installation (Optional)

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1. Install support legs

a. Secure the support legs to the frame with the provided lock nuts.

Close-up of hands installing or adjusting a mechanical component with a wrench (no visible text or symbols)

2. Install wheel axle

a. Insert wheel axle bolts through the frame and secure with the provided nut and wrenches.

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3. Install wheel axle bracket

a. Insert wheel axle bracket bolts through the frame and secure with the provided nut and wrenches.

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4. Install inside wheel washers

a. Place one of the large washers onto both sides of the axle behind the wheel.

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5. Install wheels

a. Place the wheels onto either side of the axle.

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6. Install outside wheel washers

a. Place the other large washers onto each side the axle in front of the wheel.

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7. Install cotter pins

a. Place a cotter pin through the hole in each end of the axle and bend it out to secure the wheels.

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8. Install handles

a. Attach the handles to the brackets on the frame using the provided bolts and nuts.
b. Flip the assembled generator over onto its wheels and support brackets.

Do not over tighten the handles, it will prevent free movement.

■ GENERATOR SETUP (CONTINUED)

Step 3 - Connect the Battery

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1. Disconnected on arrival

a. The generator battery is disconnected on arrival to prevent discharge or accidental starting in storage and transportation.

Close-up of a hand inserting a black battery into a device, with a white arrow pointing to the component (no visible text or symbols)

2. Locate the negative cable

a. Locate the negative battery cable above and behind the battery. One side is connected to ground and the other end needs to be connected to the battery. b. Route the free end to the negative battery terminal.

Close-up of a hand using a screwdriver to adjust or install a black battery component (no visible text or symbols)

3. Connect the negative cable

a. Push the black rubber boot up the wire to expose the connector. b. Securely connect the free end of the battery cable to the negative battery terminal using the screw and nut from the battery with the screwdriver and wrench from the toolkit.

Close-up of a mechanical device with a red clamp and black frame, no visible text or symbols

4. Cover the terminal

a. Cover the connected terminal with the black rubber boot.

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 DS50	00X
Engine Oil Capacity 20	fl. oz (0.6 L)

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.

Engine oil recommended: SAE 10W-30.

Viscosity varies with regions and temperatures. Choose your oil viscosity using the chart to the left.

* A small amount of oil from factory testing may be present on arrival.
* Synthetic oil may be used after the 8 hour initial break-in period. Using synthetic oil does not increase the recommended oil change interval. Full synthetic 5W-30 oil will aid in starting in cold temperatures < 5^ (41°F).

Close-up of a hand adjusting a mechanical component with orange tool (no visible text or symbols)

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 the oil filler cap.

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WARNING: Do not overfill the crankcase. This may damage the motor and shorten the overall life of your generator.

■ GENERATOR SETUP (CONTINUED)

Step 5 - Adding Gasoline

Person pouring liquid into a blue industrial container with a yellow valve (no visible text or symbols)

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. 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.

Model Number DS5000X

Gas Tank Capacity 4 US gal. (15 L)

WARNING: Gas can expand. Do not fill the gas tank to the very top. Leave a minimum of 1.5 in open space. Gasoline and gas fumes are highly flammable. Do not fill the tank near an open flame. Always check for fuel spills.

IMPORTANT:

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

Step 6 - Grounding the Generator

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.

Note: If the generator is connected to a home, then it won't be necessary to attach the separate grounding wire and you can opt to use your home ground instead. Please see a certified electrician for further options with grounding your generator.

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

High Altitude Operation

At high altitudes, the standard carburetor air/fuel mixture will be too rich. The 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 3,000 feet (900 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 by 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 3,000 feet (900 meters) with a modified carburetor may cause the engine to overheat and result in serious engine damage.

POWERING EVERYONE...

ANYWHERE!

Exterior view of a DuroStar Gas turbine with red fuel pump and control panel (no signage)

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.

BEFORE YOU START YOUR GENERATOR

Step 1 - Check the Oil

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Close-up of a metallic mechanical component with a central cylindrical opening and flanged side (no visible text or symbols)

Person pouring liquid from a bottle into a small cup on a desktop device (no visible text or symbols)

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 it 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.

Model Number DS50	00X
Engine Oil Capacity 20	fl. oz (0.6 L)

Step 2 - Check the Gas Level

Person operating a yellow fuel pump on a blue industrial machine (no visible text or symbols)

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.

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 the tank near an open flame.
  • Always allow the engine to cool for several minutes before refueling.
• DO NOT overfill the fuel tank. Fuel expands when shaken or heated. ALWAYS leave 1^1/2 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.

■ STARTING THE GENERATOR

Starting the Generator

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.

Close-up of a blue automotive engine hood with a mechanical switch and valve (no visible text or symbols)

2. Turn gas valve ON

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

Close-up of a black mechanical device with a white arrow pointing to a component (no visible text or symbols)

3. 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.

4. Start the generator

The engine switch is located on the left side of the front power panel. Press the switch up to the "START" Position. Once the engine starts allow the switch to return to the "RUN" position.

Close-up of a black plastic case with an arrow pointing to the side panel (no visible text or symbols)

5. Open choke

Push the choke to the "OPEN" position as the engine warms up.

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

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.

■ STARTING THE GENERATOR (CONTINUED)

Starting the Gen

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.

Close-up of a blue car hood with a metallic switch and attached pipe (no visible text or symbols)

2. Turn gas valve ON

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

Close-up of a black mechanical device with a white arrow pointing to a component (no visible text or symbols)

3. 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.

4. Turn engine switch to RUN

The engine switch is located on the left side of the front power panel. Press the engine switch to the "RUN" position.

Close-up of a blue DUR fuel pump in a warehouse, with a hand adjusting its component (no visible text or symbols)

5. 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.

Close-up of a black plastic case with an arrow pointing to the side panel, no visible text or symbols

6. Open choke

After the engine has started. Push the choke to the "OPEN" position as the engine warms up.

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

CAUTION: Disconnect all electrical loads from the generator before attempting to start!

CAUTION: Release the recoil handle only after the cord has retracted. Releasing the recoil handle while extended may cause harm to yourself or your equipment.

POWERING EVERYONE...

ANYWHERE!

Exterior view of a D85000 X powertrain with red engine and control panel (no visible text or symbols on main body)

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. In addition to the rated wattage listed by the device, many electrical devices such as refrigerators require short bursts of extra power 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 4000 5000

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.

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

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.

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.

Person operating a power supply unit with a box, no visible text or symbols on the equipment.

Transfer switch

• The safest, most effortless way to power your home.
- Automatically switches power over to your generator during an outage. Requires an electrician to install.
- Once you choose which circuits you want to power, you're locked into your configuration.

Interlock kit

• Choose what circuits you want to run.
• Requires an electrician to install, but you have the flexibility of switching up your circuits depending on your power needs.
• More hands-on, and some electrical knowledge is needed so you don't overload 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.
• 240V devices can ONLY be connected to the 240V receptacle.

CAUTION: Do not connect 50 Hz or 3-phase loads to the generator.

1. Plug in devices

Plug in devices to the appropriate receptacle. When using the generator 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.

Exterior night view of a two-story residential house with illuminated windows and a stone staircase (no signage or text visible)

3. Turn on connected devices

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

Choosing the Right Power Cord

Long or thin cords can drain the power provided to an electrical device by the generator. When using such cords, allow for a slightly higher rated wattage requirement for the electrical device. See the table below for recommended cords based on the power requirement of the electrical device.

DEVICE REQUIREMENTS WIRE GA		UGE BY LENGTH (ft.)
AMPS	WATTS (120/240V) 10 25 50 100 150
5 600	/1200 18 16 14 12 10
10 120	00/2400 16 14 12 12 10
15 180	00/3600 14 14 12 12 10
20 240	00/4800 12 12 12 10 10
25 300	00/6000 12 10 10 10 8
30 360	00/7200 10 10 10 8 NR
40 480	00/9600 8 8 6 6 NR
50 600	00/12000 6 6 6 NR NR
*NR = NOT RECOMMENDED *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.

Length	120V 15A					240V 30A	240V 50A
	14 Gauge	12 Gauge 10 Gauge		6 Gauge
	Single Outlet	Single Outlet	Triple Outlet	Single Outlet	Triple Outlet	L14-30P/L14-30R	14-50P/CS6364
10 ft						XP3010GC
15 ft							XP5015GC
25 ft	XPC14025A	XPC12025A	XPC12025C	XPC10025A	XPC10025C	XP3025GC	XP5025GC
50 ft			XPC12050C	XPC10050A	XPC10050C	XP3050GC	XP5050GC
100 ft		XPC12100A	XPC12100C	XPC10100A	XPC10100C

■ 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.

1. Voltage

The voltage currently produced by the generator in volts.

2. Frequency

The frequency currently produced by the generator in Hz.

3. Hours run

The number of hours the engine has currently been running.

4. 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" or "120/240V". If a 240V appliance is connected to the 4-prong receptacle, the switch must be in the "120/240V" position. If only 120V appliances are being connected to the generator select the "120V ONLY" position to double the 120V amperage and automatically balance the load.

WARNING: Only change the voltage selector switch with the main AC circuit breaker OFF. The generator can be seriously damaged if the voltage selector switch is changed with the breaker ON.

POWERING EVERYONE...

ANYWHERE!

Exterior view of a DuroStar Gas turbine with red fuel pump and control panel (no signage)

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.

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.

• 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.

SERVICE	EVERY USE	1ST MO. OR 8 HRS. (BREAK IN)	EVERY 3 MO. OR 50 HRS. OF HEAVY USE	EVERY 6 MO. OR 100 HRS. OF NORMAL USE	EVERY 12 MO. OR 300 HRS.	EVERY 3 YRS. OR 500 HRS.
ENGINE OIL CHECK CHANGE CHANGE
AIR CLEANER CHECK CHECK CHANGE CHANGE
SEDIMENT CUP			CLEAN CLEAN
SPARK PLUG CLEAN /			ADJUST	CLEAN / ADJUST
SPARK ARRESTOR	CHECK CLEAN
IDLE SPEED CHECK /					ADJUST
VALVE CLEARANCE					CHECK / ADJUST
FUEL TUBE CHECK CHECK /					REPLACE
FUEL TANK / FILTER					CLEAN
COMBUSTION CHAMBER						CLEAN

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.
• During the break in period of the first 6-8 hours keep the generator load under 50% for optimal results.
• Check and clean the air filter if necessary after the break-in period.

Maintenance Log

As a best practice it's recommended to keep a log of the generator hours and maintenance to ensure your generator is always operating to its full potential.

Date Generator Hours Maintenance Performed

■ MAINTENANCE AND CARE (CONTINUED)

Checking the Oil

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Close-up of a metallic mechanical component with a central hole and visible internal structure (no text or symbols)

Close-up of a hand pouring liquid into a white cup, with a bottle pouring from above (no visible text or symbols)

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 it 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. The oil will be visible in the oil fill spout when full.
f. Be sure to replace the cap when finished checking oil.

Model Number DS50	00X
Engine Oil Capacity 20	fl. oz (0.6 L)

Changing the Oil

Gray plastic container with red lid and handle, no visible text or symbols

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.

Close-up of a hand holding a wrench tool, adjusting a metal component inside a metal enclosure (no visible text or symbols)

1. Remove drain plug

Using a 12 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.

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2. Drain oil

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

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3. Replace drain plug

Replace the oil drain plug and tighten with a 12 mm hex wrench.

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.

1. Remove the filter cover screw

Remove the filter cover screw.

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2. Remove filter cover

Remove the filter cover and the sponge-like element from the casing.

Close-up of a hand cleaning a blue and black industrial device with a white cloth (no visible text or symbols)

3. Clean out filter casing

Wipe the dirt from inside the empty air cleaner casing.

Close-up of a hand pouring liquid from a bottle into a clear container, with another black plastic bottle in the background (no text or symbols visible)

4. Wash cleaner element

Wash the sponge-like elements in household dish detergent and warm water.

Hand holding a black rectangular object on a white surface, with another container and orange bottle in the background (no visible text or symbols)

5. Dry cleaner element

Pat on a dry cloth and allow the elements to dry completely.

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6. Add engine oil to elements

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

Close-up of a hand holding a black rectangular device with a circular vent on the back panel, next to a blue industrial machine (no visible text or symbols)

7. Replace elements in casing

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

■ 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.

CAUTION: Improper maintenance may cause reduced fuel economy, misfires, trouble starting, or damage to the spark plug threads.

Close-up of a hand holding a tool interacting with a mechanical component (no visible text or symbols)

1. Remove spark plug cap

Pull on the spark plug cap to remove it.

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2. Remove spark plug

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

Close-up of a hand holding a metallic connector next to a mechanical component (no visible text or symbols)

3. Inspect spark plug

Visually inspect the spark plug. If it is cracked or chipped, discard and replace it with a new spark plug. We recommend using an F6RTC spark plug such as NGK BPR6ES.

Close-up of hands holding a metallic measuring dial with a hole, no visible text or symbols

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).

Close-up of a hand using a red tool to apply a textured material onto a threaded pipe (no visible text or symbols)

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.

Close-up of a motorcycle's front bumper with visible engine and dashboard (no text or symbols)

6. Install spark plug

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

Close-up of a hand holding a tool interacting with mechanical components (no visible text or symbols)

7. Replace spark plug cap

Replace the spark plug cap.

■ MAINTENANCE AND CARE (CONTINUED)

Emptying the Gas Tank

Person pouring liquid into a red gas canister on a tray (no visible text or symbols)

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. Gasoline sold at the pump today contains additives such as ethanol that even when stored properly may damage the fuel system components.

Close-up of a blue car engine compartment showing internal components like a valve and screwdriver (no visible text or symbols)

1. Shut fuel valve OFF

Turn the fuel valve to the "OFF" position.

Close-up of a mechanical component with a white arrow pointing to a small component, no visible text or symbols.

2. Remove carburetor drain bolt

Remove the outward angled bolt that is located on the bottom of the carburetor.

Close-up of a hand using a funnel to press or inspect a mechanical component (no visible text or symbols)

3. Place funnel below drain port

Place funnel with container to catch the gasoline under the drain port location.

Close-up of a blue car hood with mechanical components and a metallic tool (no visible text or symbols)

4. 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.

Close-up of a blue car engine compartment showing a mechanical clamp and mesh fixture (no visible text or symbols)

5. Shut fuel valve OFF

Once the gasoline is fully drained, move the fuel valve back to the "OFF" position.

Close-up of a mechanical component with a white arrow pointing to a bolt, no visible text or symbols.

6. Replace carburetor drain bolt

Reinstall the carburetor drain bolt.

Red safety jujet with yellow handle and label (no visible text or symbols on body)

7. Store emptied gasoline

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

MAINTENANCE AND CARE (CONTINUED)

Transporting the Generator

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1. Empty the gas tank

Fully drain your gas tank as shown in "Emptying the Gas Tank" on page 56-57.

Close-up of a hand using a tool to adjust or install a mechanical component (no visible text or symbols)

2. Disconnect the spark plug

Pull on spark plug cap to disconnect spark plug from ignition wire.

CAUTION: Do not obstruct any ventilation openings and keep the generator in a cool dry area.

CAUTION: Never place any type of storage cover on the generator while it is still hot.

Storing the Generator for Same Day Use

1. Turn the main breaker OFF

Move the main breaker to the "OFF" position.

Exterior view of a portable electricity generator with red and black casing (no visible text or symbols)

2. Run the generator

Allow the generator to run for 3-5 minutes.

3. Move rocker switch to STOP

Move the rocker switch to the "STOP" position to turn the generator off.

Close-up of a blue car engine compartment with mechanical components and wiring (no visible text or symbols)

4. Turn fuel valve OFF/ Store

Turn the fuel valve clockwise to the horizontal position to shut off the flow of gasoline to the carburetor, then store the generator.

CAUTION: Do not obstruct any ventilation openings and keep the generator in a cool dry area.

POWERING EVERYONE... ANYWHERE!

MAINTENANCE AND CARE (CONTINUED)

Storing the Generator for Use Within 30 Days

1. Turn breaker OFF and run

Follow steps 1 and 2 as shown on "Storing the Generator For Same Day Use" on page 59.

Close-up of a blue automotive engine compartment showing valve and mesh components (no visible text or symbols)

2. Shut fuel valve OFF and run dry

Shut the fuel valve "OFF" and allow generator to run until it stalls out.

3. Move rocker switch to STOP

Move the rocker switch to the "STOP" position to turn the generator off.

4. Add fuel stabilizer and store

Add fuel stabilizer to gas remaining in tank, and store generator.

MAINTENANCE AND CARE (CONTINUED)

Storing the Generator for Longer Than 30 Days

1. Turn breaker OFF and run

Follow steps 1 and 2 as shown on "Storing the Generator For Same Day Use" on page 59.

Close-up of a blue car engine compartment with a mounted sensor and mesh fixture (no visible text or symbols)

2. Shut fuel valve OFF and run dry

Shut the fuel valve "OFF" and allow generator to run until it stalls out.

3. Move rocker switch to STOP

Move the rocker switch to the "STOP" position to turn the generator off.

Close-up of a hand using a funnel to add liquid into a container (no visible text or symbols)

4. Empty the gas tank

Fully drain your gas tank as shown in "Emptying the Gas Tank" on page 56-57.

Close-up of a hand using a tool to adjust or install a mechanical component, no visible text or symbols

5. Remove spark plug

Remove spark plug as shown in "Spark Plug Maintenance" on page 54.

Close-up of a hand pouring orange liquid into a car engine compartment labeled 'OHV' (no other text or symbols visible)

6. 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.

Close-up of hands using a screwdriver to adjust or install a mechanical component (no visible text or symbols)

7. Remove battery and charge

Remove the generator battery and place it on a 12V battery tender indoors.

SPECIFICATIONS

Model Number DS5000X
AC Rated Wattage 4,000 W
AC Surge Wattage 5,000 W
AC Rated Voltage 120/240V
Dimensions 25"L x 23"W x 22"H
Weight 130 lbs
Recommended Oil 10W-30
Engine Displacement 224 cc
Gasoline Capacity 4 gal
Oil Capacity 20.3 fl. oz. (0.6 L)
Bore 70 mm
Stroke 58 mm
Engine Speed 3600 rpm
Oil Cooling Type Splash
Bearing Type Stainless steel ball bearing
Cylinder Sleeve Cast iron sleeve
Fuel Delivery System Carburetor
Valve Type OHV
Engine Type	4-Stroke
Engine Cooling Type Forced air
Run Time @ 50%	9 hr.
Starting Type Electric/ Recoil
Noise Level	<69 dB
Neutral System	Floating
AC Rated Frequency 60 Hz
AC Phase	Single
Winding Material	100% copper windings
Emissions Compliance	EPA/CARB

Exterior view of a DuroStar Gas turbine with red engine and control panel (no visible text or symbols on body)

TROUBLESHOOTING

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

■ TROUBLESHOOTING

Problem Description	Solution
The engine will not start	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
	Fuel is old or contaminated Change fuel
	Spark plug is dirty Clean spark plug
	Spark plug is broken Replace spark plug
	The generator is not level	Move the generator to a level surface
	Oil is low Add/change the oil
Engine runs, but there is no electrical output	The 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
The generator runs but does not support all electrical devices connected	Generator is overloaded	Disconnect 1 or more items to reduce the load
	Device connected to the generator is bad	Disconnect malfunctioning device
	The air filter is dirty Clean/ replace the air filter

Changing/ Inspecting the Carbon Brushes

Close-up of a blue circular device with internal wiring and a hand holding it, no visible text or symbols

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.

Close-up of a hand holding a blue circular device with ventilation grilles, mounted on a mechanical component (no visible text or symbols)

1. Remove generator cover

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

Close-up of a hand holding a small electrical connector with multicolored wires (no visible text or symbols)

2. Remove bolt from brush

Remove the bolt holding the carbon brush.

Close-up of a mechanical component with visible metal fasteners and wiring (no text or symbols)

3. Disconnect AVR wires

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

■ TROUBLESHOOTING (CONTINUED)

Changing / Inspecting the Carbon Brushes (Cont.)

Close-up of a hand adjusting a car engine component (no visible text or symbols)

4. Install new brush

Install new carbon brush with bolt.

Close-up of a car engine battery pack with red and white wires connected to a terminal block (no visible text or symbols)

5. Connect AVR wires

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

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6. Replace generator cover

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

Changing / Inspecting the AVR

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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.

Close-up of a hand holding a blue circular mechanical component with a black handle (no visible text or symbols)

1. Remove generator cover

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

Close-up of a mechanical assembly with visible components and wiring (no text or symbols)

2. Remove AVR bolts

Remove the 2 bolts holding the AVR.

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3. Disconnect AVR wire clip

Disconnect the wire clip.

■ TROUBLESHOOTING (CONTINUED)

Changing / Inspecting the AVR (Continued)

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4. Disconnect wires from brush

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

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5. Install new AVR

Install the new AVR with the 2 bolts.

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6. Reconnect wires to brush

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

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7. Reconnect the AVR wire clip

Reconnect the wire clip.

Hand holding a blue circular component with a small black clip, mounted on a mechanical engine (no visible text or symbols)

8. Replace generator cover

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

POWERING EVERYONE...

ANYWHERE!

WARRANTY

5-Year Warranty

All DuroMax Power Equipment warrant the original purchasers to a 5-Year Parts Warranty (Residential Use ONLY: Unusually heavy or commercial use is covered for a period of 1 year) in the event of failure due to defects in electrical or mechanical components. Freight on any items submitted for replacement or repair under the warranty is the responsibility of the equipment owner. This warranty is non-transferable and only valid to the original purchaser.

Warranty Exclusions

The DuroMax 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 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.

U.S EPA AND CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board, The United States Environmental Protection Agency (US EPA) and DuroMax Power Equipment are pleased to explain the emission control system warranty on your 2022-2023 year small off-road engine. In the United States and California, new small off-road engines must be designed built and equipped to meet the State's stringent anti-smog standards. DuroMax Power Equipment must warrant the emission control system on your small off-road engine for the periods of time listed below, provided there has been no abuse neglect or improper maintenance of your small off-road engine.

Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and a catalytic converter. Also included may be hoses, belts, connectors, and other emission-related assemblies.

Where a warrantable condition exists, DuroMax Power Equipment will repair your small off-road engine at no cost to you including diagnosis, parts, and labor.

MANUFACTURER'S WARRANTY COVERAGE:

As the small off-road engine owner, you are responsible for the performance of the required

maintenance listed in your owner's manual. DuroMax Power Equipment recommends that you retain all receipts covering maintenance on your small off-road engine, but DuroMax Power Equipment cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

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.

You are responsible for presenting your small off-road engine to a DuroMax Power Equipment distribution center as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, contact DuroMax Power Equipment:

TEL: [phone]

WEBSITE: www.DuroMaxPower.com

ADDRESS: 5800 Ontario Mills Pkwy, Ontario CA 91764

This telephone number is only for the engines which the company name "DuroMax Power Equipment" on the emission label.

DEFECTS WARRANTY REQUIREMENTS:

(a) The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser.
(b) General Emissions Warranty Coverage. DuroMax Power Equipment warrants to the ultimate purchaser and each subsequent owner that the engine or equipment is:

(1) Designed, built, and equipped so as to conform with all applicable regulations adopted by US EPA & Air Resources Board; and

(2) Free from defects in materials and workmanship that causes the failure of a warranted part for a period of two years.

(c) The warranty on emissions-related parts will be interpreted as below:

(1) Any warranted part that is not scheduled for replacement as required maintenance in the written instructions required by subsection (d) must be warranted for the warranty period defined in Subsection(b)(2). If any such part fails during the period of warranty coverage, it must be repaired or replaced by DuroMax Power Equipment according to

■ WARRANTY (CONTINUED)

Subsection (4) below. Any such part repaired or replaced under the warranty must be warranted for the remaining warranty period.

(2) Any warranted part that is scheduled only for regular inspection in the written instructions required by subsection (d) must be warranted for the warranty period defined in Subsection (b) (2). A statement in such written instructions to the effect of “repair or replace as necessary” will not reduce the period of warranty coverage. Any such part repaired or replaced under warranty must be warranted for the remaining warranty period.
(3) Any warranted part that is scheduled for replacement as required maintenance in the written instructions required by Subsection (d) must be warranted for the period of time prior to the first scheduled replacement point for that part. 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.
(4) Repair or replacement of any warranted part under the warranty must be performed at no charge to the owner at a warranty station. (5) Notwithstanding the provisions of Subsection (4) above, warranty services or repairs must be provided at all DuroMax Power Equipment 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) DuroMax Power Equipment is liable for damages to other engine components proximately caused by a failure under warranty of any warranted part.
(8) Throughout the emissions warranty period defined in Subsection (b)(2), DuroMax Power Equipment must maintain a supply of warranted parts sufficient to meet the expected demand for such parts.
(9) Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner such use will not reduce the warranty obligations of DuroMax Power Equipment
(10) Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use of any non-exempted add-on or modified parts will be grounds for disallowing a warranty claim. DuroMax Power Equipment will not be liable to warrant failures of warranted parts caused by the use of a non-exempted add-on or modified part.
(11) DuroMax Power Equipment issuing the warranty shall provide any documents that describe that manufacturer's warranty procedures or policies within five working days of a request by the US EPA & Air Resources Board.

Exhaust Emission Warranty Parts List.

(1) Fuel Metering System
(i) Carburetor and internal parts (and/or pressure regulator or fuel injection system).
(ii) Air/fuel ratio feedback and control system.
(iii) Cold start enrichment system.
(iv) Fuel tank.
(2) Air induction system
(i) Controlled hot air intake system.
(ii) Intake manifolds.
(iii) Air filter.
(3) Ignition System
(i) Spark Plugs.
(ii) Magneto or electronic ignition system.
(iii) Spark advance/retard system.
(4) Exhaust Gas Recirculation (EGR) System
(i) EGR valve body, and carburetor spacer if applicable.
(ii) EGR rate feedback and control system.
(5) Air Injection System
(i) An air pump or pulse valve.
(ii) Valves affecting the distribution of flow.
(iii) Distribution manifold.
(6) Catalyst or Thermal Reactor System
(i) Catalytic converter.
(ii) Thermal reactor.
(iii) Exhaust manifold.

(7) Particulate Controls

(i) Traps, filters, precipitators, and any other device used to capture particulate emissions.

(8) Miscellaneous Items Used in Above Systems

(i) Electronic controls

(ii) Vacuum, temperature, and time-sensitive valves and switches.

(iii) Hoses, belts, connectors, and assemblies.

DuroMax Power Equipment will furnish with each new engine written instructions for the maintenance and use of the engine by the owner

CUSTOMER SERVICE

DuroMax Power Equipment is committed to ensuring that our products perform when they need to. Our generators are your lifeline in the event of an emergency. Should you have any problems, please contact our customer service department:

DUROMAX POWER EQUIPMENT 5800 Ontario Mills Parkway Ontario, CA 91764

Customer Service: 844-DUROMAX Customer Service Hours: 8-5 pm PST Mon-Fri

Website: www.duromaxpower.com Email: [e-mail]

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5800 Ontario Mills Parkway

Ontario, CA 91764

United States

844-DUROMAX