DuroStar DS4500X User manual

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
DS4500X
USER MANUAL

CONTENTS
1.
Introduction .................................................................................................................... 6
General Safety Procedures ........................................................................................... 8
Carbon Monoxide Safety ............................................................................................. 12
Unit and Purchase Information .................................................................................. 14
Introduction
Checking the Oil ........................................................................................................... 28
Check the Gas Level ..................................................................................................... 29
Starting the Generator Using Gasoline ...................................................................... 30
Starting the Generator Using Recoil Start ................................................................. 32
Starting the Generator
3.
Generator Components............................................................................................... 16
Package Contents ......................................................................................................... 18
Packing Braces ............................................................................................................. 19
Wheel Kit Installation.................................................................................................... 20
Connect the Battery .................................................................................................... 22
Adding Oil ...................................................................................................................... 23
Adding Gasoline ............................................................................................................ 24
Grounding the Generator ........................................................................................... 25
High Altitude Operation .............................................................................................. 25
Generator Setup
4.
AC Usage ........................................................................................................................ 36
Connecting a Load to the Generator.......................................................................... 38
Using the Digital Multimeter ....................................................................................... 40
Using the Generator
2.

CONTENTS
6.
7.
8.
Maintenance Schedule.................................................................................................. 44
Maintenance Log ........................................................................................................... 45
Checking the Oil ............................................................................................................ 46
Changing the Oil............................................................................................................. 47
Cleaning the Air Filter .................................................................................................... 48
Spark Plug Maintenance ............................................................................................... 50
Storage and Transportation ......................................................................................... 52
Specications.................................................................................................................. 53
.......................................................................................................................... 64
Basic Troubleshooting .................................................................................................. 56
Changing / Inspecting the Carbon Brushes ............................................................... 57
Changing / Inspecting the AVR .................................................................................... 59
Wiring Diagram ............................................................................................................. 62
Maintenance and Care
Warranty
Troubleshooting
9. .................................................................................................. 68
Contact Information

6
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...
THE DUROSTAR WAY
The DuroMax Way is more than just a brand, it is our understanding and appreciation of just how
important power can be to someone without it…
DUROSTAR FOR HOME
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.
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 necessities
and portable power can
play a critical role in getting
a job done successfully and
eciently.
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 cellphone charged, light
up your campsite, or even
brew a cup of coee, all while
being miles from civilization.

7
INTRODUCTION
Notice Regarding Emissions
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, our 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!
1-844-DUROMAX
TOLL-FREE
Engines that are certied to comply with U.S. EPA emission regulations for SORE (Small O-Road
Equipment), are certied to operate on regular unleaded gasoline and may include the following
emission control systems: (EM) Engine Modications and (TWC) Three-Way Catalyst (if so equipped).

8
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-conned 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
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 gasoline 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 gasoline.
●Do not operate near an open ame.
●Do not smoke near the generator.
●Always operate on a rm, level surface.
●Always turn the generator o 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 overll the gas tank. Gas may expand during operation. Do not ll 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 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”).
●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 qualied
electrician. Such connections must comply with local electrical laws and codes. Failure
to comply can create a backow 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. 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-qualied persons to operate.
9
GENERAL SAFETY PROCEDURES

In addition to the above safety notices, please familiarize
yourself with the safety and hazard markings on the
generator.
GENERAL SAFETY PROCEDURES
DANGER
DO NOT OVERFILL
THE GAS TANK
OVERFILLING CAN RESULT
IN A FIRE, EXPLOSION,
OR DEATH.
1.5”
10

DON’T TOUCH
CAUTION HIGH TEMPERATURE
DANGER HOT EXHAUST
KEEP SAFE DISTANCE
DON’T TOUCH
BURN RISK CARBON MONOXIDE SAFE DISTANCE
GENERAL SAFETY PROCEDURES
11

CARBON MONOXIDE SAFETY
Carbon Monoxide
CO-ALERT
●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 DuroStar Service at
844-DUROMAX for assistance.
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:
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.”
12

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.

Serial Number
Serial number format
STAPLE RECEIPT HERE
The serial number will be shown in two parts. The engine
model, followed by the serial number.
Engine Model: _____________________________________________
Serial Number: _____________________________________________
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: _____________________________________________
Serial Number
The serial number is located on the engine block, above and
to the left of the oil ll.
UNIT AND PURCHASE INFORMATION
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.
15

GENERATOR COMPONENTS
5. Fuel Tank
16
2. Air Cleaner
7. Handles
8. Battery
9. Oil Fill and Dipstick
1. Recoil Start
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 airow into the carburetor to assist in starting the engine.
4. Fuel Valve - On/o valve that allows gasoline to the fuel switch.
5. Fuel Tank - All metal 4 Gallon gasoline fuel tank.
6. Power Panel - Contains the start switch, plugs, meters, and circuit breakers.
7. Handles - Longest handles of any 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 “O” the generator.
11. Low Oil Alert – Will light only if the generator shuts down due to low oil.
6. Power Panel
4. Fuel Valve
3. Choke Lever

16. 120/240V 4-Prong Twist Lock
10. Engine Switch
12. Multimeter – Displays voltage, hertz, and time running.
13. Power Boost – DuroMax exclusive Power Boost doubles the amperage available in “120V Only”
for heavy loads like RV air conditioners.
14. Circuit Breaker - Protects the panel from overload and short circuits.
15. 120v 3-Prong GFCI Receptacles - Use to connect electrical devices that run 120 volt, 60Hz,
single-phase, AC current (NEMA 5-20).
16. 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).
17. CO Alert - Shuts down the engine in the event of CO buildup.
18. Charging Light - Will light when the generator is charging the on-board battery.
17
18. Charging Light
13. Power Boost
14. Circuit Breaker
12. Multimeter
15. GFCI 20A Receptacles
17. CO Alert
11. Low Oil Alert

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 dier in appearance or design from the images shown.
Double-Sided
Screw Driver
Oil Funnel w/ hose
Spanner 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. 10mm/12mm and
13mm/15mm.
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.
18

GENERATOR SETUP
Unpack
a. Remove the generator from the box.
b. Place the largest piece of packing foam on a at surface.
c. Flip the generator upside down on the pad.
CAUTION: NEVER attempt this if you have put fuel or oil in
the generator.
1.
Step 1 - Remove Shipping Braces
Remove braces
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.
2.
19
Note: Shipping braces can be thrown away.
They will not be needed again.

Install support legs
a. Secure the support legs to the frame with the
provided lock nuts.
1.
Step 2 - Wheel Kit Installation (Optional)
Install inside wheel washers
a. Place one of the large washers onto both sides of
the axle behind the wheel.
4.
Install wheel axle
a. Insert wheel axle bolts through the frame and
secure with the provided nut and wrenches
2.
GENERATOR SETUP (CONTINUED)
Install wheel axle bracket
a. Insert wheel axle bracket bolts through the frame
and secure with the provided nut and wrenches
3.
20