DS7000Q GENERATOR
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.duromaxpowerequipment.com
Call our Customer Care Team Toll Free 8-5pm PST Mon-Fri
844-DUROMAX
User Manual
REV: DS7000Q-05252018
CONTENTS
1.
Introduction .................................................................................................................... 6
General Safety Procedures ........................................................................................... 7
Quick Start Guide .......................................................................................................... 10
Generator Components ............................................................................................... 12
Package Contents ......................................................................................................... 14
Introduction
3.
Checking the Oil ........................................................................................................... 20
Check the Fuel Level .................................................................................................... 21
Starting the Generator ................................................................................................. 22
Starting the Generator - Remote Start ...................................................................... 24
Starting the Generator
2.
Adding Oil ...................................................................................................................... 16
Adding Diesel ................................................................................................................. 17
Grounding the Generator ........................................................................................... 18
Generator Setup
4.
AC Usage ......................................................................................................................... 28
Connecting a Load to the Generator ........................................................................... 30
Voltage Selector Switch ................................................................................................ 31
DC Usage ........................................................................................................................ 32
Using the Generator
3
CONTENTS
4
5.
6.
7.
Maintenance Schedule .................................................................................................. 36
Maintenance Log ........................................................................................................... 37
Checking the Oil ............................................................................................................ 38
Changing the Oil ............................................................................................................. 39
Cleaning the Air cleaner ................................................................................................ 40
Specications .................................................................................................................. 42
.......................................................................................................................... 50
Basic Troubleshooting .................................................................................................. 44
Changing / Inspecting the AVR .................................................................................... 46
Maintenance and Care
Warranty
Troubleshooting
8.
.................................................................................................. 54
Contact Information
INTRODUCTION
Notice Regarding Emissions
DuroStar 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, DuroStar has complemented its oerings to include Pressure
Washers, Water Pumps, Engines and now oering 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 ooded property, or washing away a deck for the summer season
Engines that are certied to comply with U.S. EPA emission regulations for SORE (Small o Road
Equipment), are certied to operate on regular diesel, and may include the following emission
control systems: (EM) Engine Modications and (TWC) Three-Way Catalyst (if so equipped).
6
STOP
Please do not return
to store.
Durostar 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!
1-844-DUROMAX
TOLL FREE
SAFETY ALERT SYMBOL
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-conned 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.
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.
GENERAL SAFETY PROCEDURES
7
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.
WARNING: This generator may emit highly ammable and explosive diesel vapors, which
can cause severe burns or even death. A nearby open ame can lead to an explosion
even if not directly in contact with fuel.
● Do not operate near an open ame.
● Do not smoke near generator.
● Always operate on a rm, level surface.
● Always turn generator o 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 overll fuel tank. Fuel may expand during operation. Do not ll to the top of
the tank.
● Always check for spilled fuel before operating.
● Empty the diesel tank before storing or transporting the generator.
● Before transporting, turn fuel valve to the o 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 qualied
electrician. Such connections must comply with local electrical laws and codes. Failure
to comply can create a backow 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-qualied persons to operate.
GENERAL SAFETY PROCEDURES
8
In addition to the above safety notices, please familiarize yourself with the safety and
hazard markings on the generator.
GENERAL SAFETY PROCEDURES
9
QUICK START GUIDE
Add diesel
The fuel cap is located on top of the fuel tank. Fill the tank
with fresh diesel uel. The tank is full when you see fuel in
the bottom of the fuel lter cup. DO NOT overll the tank.
2.
Run/Stop Switch
The Run/Stop Switch is located inside the mainentance
door above the oil ll. Flip the switch to the right to allow
the unit to run.
Add oil
The oil ll cap is located on the lower engine block inside
the maintenance door. Remove the oil ll cap and ll with
15w40 diesel oil.
1.
Turn breaker o
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.
3.
10
4.
Check power indicator
The power indicator is located to the right of the keyswitch.
Ensure the power indicator is lit before powering
appliances.
8.
Connect devices
Connect your devices to the receptacles on the front panel.
Start with the largest loads rst.
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 breaker is located on the right side of the front power
panel. Flip the breaker up to allow power to ow to the
receptacles.
9.
11
GENERATOR COMPONENTS
12
8. Battery
5. Oil Fill
4. Air Filter
3. Lifting Ring
2. Fuel Cap
6. Oil Drain
7. Stop / Run
Switch
1. Muer - Reduces engine emissions and reduces noise
2. Fuel Cap - Allows access to ll the diesel tank.
3. Lifting Ring - Use to lift the generator with a truck crane or winch.
4. Air Filter - a removable element that cleans the air going into the engine.
5. Oil Fill and Dipstick - Use to add or check the engine oil.
6. Oil Drain - Use to remove the engine oil during regular oil changes.
7. Stop/Run Switch - To the right for Connect a ground wire here to properly ground the
generator.
8. Battery - 12V DC 7ah Battery that powers the Electric Start System.
9. Engine Switch – 3 Position Switch to “Start”, “Run”, or turn “O” the generator.
10. Low Oil Alert - Will light if the engine shuts down or will not start due to low oil.
11. Volt Meter - Provides reading of voltage output.
11. Power Indicator - Use to conrm the generator has power output before connecting devices.
1. Muer
14. Circuit Breaker
13. Power Boost
12. Voltmeter
11. Power Indicator
10. Low Oil Alert
12. Volt Meter - Provides reading of voltage output.
13. Power Boost – DuroStar exclusive Power Boost doubles the amperage available in “120v Only”
for heavy loads like RV air conditioners.
14. Circuit Breaker - Resettable switch that protects the generator from electrical overload.
15. 12v DC Charging Posts – DC Output for charging batteries or running small DC powered items.
16. Ground Terminal - Connect a ground wire here to properly ground the generator.
17. 120/240v 4-Prong Twist Lock - Use to connect electrical devices that run 120 or 240 Volt, 60Hz,
single phase, AC current (NEMA L14-30).
18. 120v 3-Prong Twist Lock - Use to connect electrical devices that run 120 Volt, 60 Hz, single
phase, AC current (NEMA 6-20).
19. 120v 3-Prong GFCI Receptacle - Use to connect electrical devices that run 120 Volt, 60 Hz,
single phase, AC current (NEMA 5-20).
13
9. Engine
Switch
19. 120V
3-Prong
Receptacle
18. 120V 3-Prong
Twist Lock
17. 120/240
4-Prong Twist
Lock
16. Ground
Terminal
15. 12V DC
Charging Posts
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.
● Note: Actual tools may dier in appearance or design from image shown.
Double Sided
Screw Driver
Oil Funnel w/ hose
Spanner
DC Charge Cables
Spark Plug 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.
Plug heads for the receptacles
found on the generator are
included to make or rewire
your own cords.
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.
-20 20 40 60 800 100 F
-30-40 -10 0 10 20
30
-20
40 C
30
10W-30
ENVIRONMENTAL TEMPERATURE
5W-30
SAE
GENERATOR SETUP
Add 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 rst time. This amount is equal to the oil capacity of the engine crankcase:
WARNING: Do not apply engine oils with additives or 2-stroke engine oils. They don’t have
enough lubrication, and may shorten the engine’s service life.
a. Make sure the generator is on a level surface.
b. Unscrew the oil ller/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 ller cap.
1.
Step 1 - Adding Oil
Engine oil recommended: SAE 15W-40. 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.
Model Number DS7000Q
Engine Oil Capacity 54 . oz (1.6L)
16
WARNING: DO NOT overll the crankcase. This
may damage the motor and shorting overall life
of your generator.
WARNING: Diesel and fuel fumes are highly ammable.
● Do not ll tank near an open ame.
● Do not overll. Always check for fuel spills.
17
Step 2 - Adding Diesel
Add Diesel
a. Make sure the generator is on a level surface.
b. Unscrew fuel cap and set aside (NOTE: the fuel cap
may be tight and hard to unscrew).
c. Slowly add diesel to the fuel tank. Be careful not
to overll.
d. The fuel gauge on the top of the fuel tank indicates
how much diesel is in the generator fuel tank.
e. Replace fuel cap and wipe up any spilled diesel
with a dry cloth.
NOTE: Fuel can expand. Do not ll the fuel tank
to the very top. Leave a minimum of 1.5 in of open
space.
IMPORTANT:
● Never use an oil/diesel mixture. Never use old fuel.
● Avoid getting dirt or water in the fuel tank.
● Fuel 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.
2.
Model Number DS7000Q
Fuel Tank Capacity 3.8 US Gallons (14.5L)
WARNING: DO NOT overll the crankcase. This
may damage the motor and shorting overall life
of your generator.
GENERATOR SETUP (CONTINUED)
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.
1.
Step 3 - Grounding the Generator
WARNING: Failure to properly ground the generator can result in electrocution.
18
19
STARTING THE GENERATOR
If this is not your rst 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 rst
portion of this section entitled “GENERATOR SETUP” If you have not yet read this section, go
back and read it now.
Step 1 - Check the oil
Check the oil
The generator is equipped with an automatic shuto 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 sucient amount.
To check the oil level:
a. Make sure the generator is on a level surface.
b. Unscrew the oil ller/dipstick cap.
c. With a dry cloth, wipe the oil o 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 lled (see “Adding
Oil” portion of the “Maintenance” section).
e. Be sure to replace the cap when nished checking
oil.
NOTE: The oil capacity for your generator can be found in
the “Specications” section of this manual.
1.
20
BEFORE YOU START YOUR GENERATOR
21
Check Fuel Level
Before starting the generator, check to see that there is
sucient diesel in the fuel tank. The fuel gauge on top of the
tank will give a rough estimate of the diesel level. The gauge
will appear white then ll red as the tank is lled.
Note: Fuel gauge may not register with less than 1/3 fuel
tank full.
1.
Step 2 - Check the fuel level
WARNING: Diesel and diesel fumes are highly ammable.
● Do not ll tank near an open ame.
● Always allow engine to cool for several minutes before refueling.
● DO NOT overll fuel tank. Fuel expands when shaken or heated. ALWAY leave 1
1
/
2
“
space or more at the top of the tank.
● ALWAYS use fresh fuel or stabilized fuel. Old diesel (older than 30 days) can cause
permanent damage to the fuel system.
● Always check for fuel spills.
Turn engine switch to START
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.
3.
STARTING THE GENERATOR
Shut breaker o
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.
1.
Starting the Generator
Run/Stop Switch
The Run/Stop Switch is located inside the mainentance
door above the oil ll. Flip the switch to the right to allow
the unit to run.
2.
22
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.
23
Check power indicator
The power indicator is located to the right of the keyswitch.
Ensure the power indicator is lit before powering appliances.
4.
Return engine switch to RUN
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.
6.
Turn engine switch to START
The key switch is located on the left side of the front power
panel. Insert the key and turn to the start position to OFF.
This will allow you to use the remote to start the generator.
3.
STARTING THE GENERATOR (CONTINUED)
Turn the breaker ON
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.
1.
Starting the Generator - Remote Start
Run/Stop Switch
The Run/Stop Switch is located inside the mainentance
door above the oil ll. Flip the switch to the right to allow
the unit to run.
2.
24
WARNING: Operating the starter motor for more than 5 seconds can damage the
motor. If the engine fails to start, press the stop button and wait 10 seconds before
operating the starter again.
25
Open the remote
Open the remote by sliding the cover down. Extend the
antenna
4.
Start the generator
Press the start button at the top with the lightening bolt to
start the generator.
5.
26
USING THE GENERATOR
If this is not your rst 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 rst
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.
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, nd 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 nd this wattage, you may calculate it by multiplying the Voltage requirement by the
Amperage drawn: Watts = Volts x Amps. If these specications 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 nd 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.
Fuel Source Rated (Running Wattage) Surge (Peak) Wattage
Diesel 5500 7000
28
29
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 gures are estimates only.
Try to check the wattage listed on your electrical devices before consulting this chart.
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 the 240v receptacle.
Plug in devices
Turn breaker on
Turn on connected 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
rst.
1.
2.
3.
CAUTION: Do not connect 50Hz or 3-phase loads to the generator.
30
31
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.
Voltage Selector Switch
Choosing the right power cord
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.
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.
TECHNOLOGY
POWER BOOST
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
CAUTION: The DC receptacle is for recharging 12 Volt automotive-type batteries
only. Do not connect any other device to this receptacle.
CAUTION: Never try to jump start a car with your generator.
USING THE GENERATOR (CONTINUED)
DC Usage
Connect the battery
Connect positive 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 free end of the positive wire to the positive
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 key to return to the run position
once started.
1.
2.
3.
32
DANGER - Stored batteries emit highly explosive hydrogen gas when charged.
Batteries also contain acid, which can cause severe chemical burns.
DANGER - Do not allow open ames or cigarettes nearby for several minutes after
charging a battery.
DANGER - Always wear protective goggles and rubber gloves when charging a
battery.
DANGER - If battery acid gets on your skin, ush with water. If battery acid gets in
your eyes, ush with water and call a physician immediately.
DANGER - If battery acid is swallowed, drink large quantities of milk and call a
Physician immediately.
33
Connect negative receptacle
Carefully connect the free end of the negative wire to the
negative receptacle on the generator.
4.
Disconnecting
When disconnecting, always disconnect the wires from the
generator rst to avoid a spark.
5.
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 ecient 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.
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.
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 o before you begin any maintenance or repairs.
● Let the engine and exhaust system cool before touching.
● To reduce the possibility of re or explosion, be careful when working around diesel.
Use only a nonammable solvent, not diesel, to clean parts. Keep cigarettes, sparks,
and ames away from all fuel related parts.
SERVICE
REGULAR SERVICE PERIOD
BEFORE
EACH USE
EVERY MO. OR
20 HRS
EVERY 3 MO. OR
50 HRS
EVERY 6 MO. OR
100 HRS
EVERY 12 MO.
OR 300 HRS
ENGINE OIL CHECK
CHANGE
AIR CLEANER CHECK
CHANGE
SEDIMENT CUP CLEAN
SPARK ARRESTOR CLEAN
IDLE SPEED CHECK /
ADJUST
VALVE CLEARANCE CHECK-
ADJUST
COMBUSTION
CHAMBER
CLEAN
500 HOURS
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
Check the oil
The generator is equipped with an automatic shuto 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 sucient amount.
To check the oil level:
a. Make sure the generator is on a level surface.
b. Unscrew the oil ller/dipstick cap.
c. With a dry cloth, wipe the oil o 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 lled (see “Adding
Oil” portion of the “Maintenance” section).
e. Be sure to replace the cap when nished checking
oil.
NOTE: The oil capacity for your generator can be found in
the “Specications” section of this manual.
1.
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.
Remove drain plug
Drain oil
Replace drain plug
Using a hex wrench, unscrew the oil drain plug, which is
located on the crankcase underneath the oil ller/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 with a 10 mm hex
wrench.
2.
2.
3.
39
Routine maintenance of the air cleaner helps maintain proper airow 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.
MAINTENANCE AND CARE (CONTINUED)
Cleaning the air cleaner
Open lter housing
Remove lter cover
Remove the element
Remove the 4 bolts on the right side of generator and remove
the cover to expose the air lter.
Unscrew the wingnut and remove the air cleaner cover.
Remove the retaining nut and inspect the air lter element.
If dirty dispose of the element and replace with OEM
replacement parts.
1.
2.
3.
40
41
Renstall the element
Reinstall the still clean, or new, element in the air cleaner base
and secure it with the retaining nut.
4.
Reinstall the lter cover
Place the air lter cover on the air lter base and tighten the
wingnut securely.
5.
6.
Reinstall lter housing
Reinstall the lter housing on the right side of the generator
and secure with the 4 bolts.
SPECIFICATIONS
AC Rated Wattage 5500W
AC Surge Wattage 7000W
AC Rated Voltage 120/240V
AC Rated Frequency 60 Hz
AC Phase Single
DC Voltage 12V
DC Amperage 8.3A
Dimensions LENGTH 38in.
WIDTH 22in.
HEIGHT 30in.
Engine Type 4-Stroke OHV Forced-Air
Ignition System Non-Contact Transistor
Displacement 418cc
Starting Type Electric
Fuel Tank Capacity 3.8 US Gal. (14.5L)
Oil Capacity 54 . oz. (1.1L)
Run Time @ 50% 10 hr.
Noise Level <74db
42
TROUBLESHOOTING
This section of the manual is to help you troubleshoot problems with your generator.
43
TROUBLESHOOTING
Mode Description
Engine will not start
Engine Switch is “O” Set engine switch to “run”
Engine is out of fuel Add fuel
Fuel is old or contaminated Change fuel
Generator is not level
Move generator to a level
surface
Oil is low Add / change oil
Engine runs, but there
is no electrical output.
Circ0uit Breaker is “O” 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 items to
reduce the load
Device connected to generator
is bad
Disconnect malfunctioning
device
Air Cleaner is dirty Clean / replace the air cleaner
44
45
Changing / Inspecting the AVR
The AVR regulates power from the generator. If the generator is overheated or overloaded, the
AVR may be damaged and require replacement.
Remove rear cover
Remove AVR bolts
Disconnect AVR wire clip
Remove the 4 bolts of the rear cover then pull the cover o
the generator.
Remove the 2 bolts holding the AVR.
Disconnect the wire clip.
1.
2.
3.
TROUBLESHOOTING (CONTINUED)
46
Install new AVR
Install the new AVR with the 2 bolts.
4.
Reconnect the AVR wire clips
Insert and connect the 2 wires clips from the AVR, be sure to
connect them securely.
5.
6.
Reinstall rear cover
Replace the rear cover and tighten the 4 bolts securely.
Changing / Inspecting the AVR (Continued)
47
WIRING DIAGRAM
48
49
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.
U.S. EPA AND CALIFORNIA EMISSIONS CONTROL WARRANTY 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 o-road engine. In California, new equipment that
use small o-road engines must be designed, built, and equipped to meet the State’s stringent anti-
smog standards. DuroMax Power Equipment must warrant the emissions control system on your
small o-road engine for the period listed below provided there has been no abuse, neglect, or
improper maintenance of your equipment.
Your emissions control system may include parts such as: carburetors or the fuel injection system,
ignition system, catalytic converters, fuel tanks, valves, lters, clamps, connectors, and other
associated components. Also, included may be hoses, belts, connectors, sensors, and other
emission-related assemblies.
Where a warrantable condition exists, DuroMax Power Equipment will repair your small o-road
engine at no cost to you including diagnosis, parts, and labor.
MANUFACTURER’S WARRANTY COVERAGE:
This emissions control system is warranted for two years. If any emissions-related part on your
equipment is defective, the part will be repaired or replaced by DuroMax Power Equipment.
50
OWNER’S WARRANTY RESPONSIBILITIES:
● As the small o-road engine owner, you are responsible for 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 o-road engine, but DuroMax Power
Equipment cannot deny warranty solely for the lack of receipts or your failure to ensure the
performance of all scheduled maintenance.
● As the small o-road engine owner, you should however be aware that the DuroMax Power
Equipment may deny you warranty coverage if your small o-road engine or a part has failed
due to abuse, neglect, or improper maintenance or unapproved modications.
● You are responsible for presenting your small o-road engine to a DuroMax Power Equipment
distribution center or service center as soon as the 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 coverage, contact us at 800-629-4329 or
email [email protected].
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 owner that
the engine or equipment is:
1. Designed, built, and equipped to conform with all applicable regulations adopted by the 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.
The warranty on emissions-related parts will be interpreted as follows:
1. Any warranted part that is not scheduled for replacement as required maintenance in the
Owner’s Manual must be warranted for the warranty period stated above. If any such part fails
during the period of warranty coverage, it must be repaired or replaced by the manufacturer
according to Subsection (4) below. Any such part repaired or replaced under the warranty must
be warranted for the remaining warranty period.
51
WARRANTY (CONTINUED)
2. Any warranted part that is scheduled only for regular inspection in the Owner’s Manual must be
warranted for the warranty period stated above. A statement in such written instructions to the
eect 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 Owner’s
Manual must be warranted for the period prior to the rst scheduled replacement point for
that part. If the part fails prior to the rst scheduled replacement, the part must be repaired or
replaced by the engine manufacturer 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 rst
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 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 under warranty of any warranted part.
8. Throughout the emissions warranty period stated above, the manufacturer must maintain a
supply of warranted parts sucient 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.
a. Such use will not reduce the warranty obligations of the manufacturer.
10. Add-on or modied parts that are not exempted by the Air Resources Board may not be used.
The use of any nonexempt add-on or modied parts will be grounds for disallowing a warranty
claim. The manufacturer will not be liable to warrant failures of warranted parts caused using a
nonexempt add-on or modied part.
11. The manufacturer issuing the warranty shall provide any documents that describe that
manufacturer’s warranty procedures or policies within ve working days of request by the Air
Resources Board.
52
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.
2. Air Induction System
i. Controlled hot air intake system.
ii. Intake manifold.
3. Ignition System
i. Spark Plugs.
ii. Magneto or electronic ignition system.
iii. Spark advance/retard system.
4. Air Injection System
i. Air pump or pulse valve.
ii. Valves aecting distribution of ow.
iii. Distribution manifold.
5. Catalyst or Thermal Reactor System (i)
Catalytic converter.
i. Thermal reactor.
ii. Exhaust manifold.
6. Particulate Controls
7. Traps, lters, precipitators, and any other
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 Diaphragms**
xi. Control Cables**
xii. Control Linkages**
xiii. Purge Valves
xiv. Vapor Hoses
xv. Liquid/Vapor Separator
xvi. Carbon Canister
xvii. Canister Mounting Brackets
xviii. Carburetor Purge Port Connector
53
*Note: The parts list for equipment less than or equal to 80 cc only includes the fuel tank.
**Note: As they relate to the evaporative emission control system.
DuroStar Power Equipment will furnish with each new engine written instructions for the
maintenance and use of the engine by the owner.
54
CUSTOMER SERVICE
DuroStar 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:
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: [email protected]
5800 Ontario Mills Parkway
Ontario, CA 91764
United States
844-DUROMAX
