Durostar DS5500EH User manual

DS5500EH 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.DuroMaxpower.com

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

844-DuroMax

User Manual

*Gasoline & Propane Tank Not Included

REV:DS5500EH-05232018

CONTENTS

1.

Introduction .................................................................................................................... 6

General Safety Procedures ........................................................................................... 7

Quick Start Guide (Gasoline) ....................................................................................... 10

Quick Start Guide (Propane) ........................................................................................ 12

Generator Components ............................................................................................... 14

Package Contents ......................................................................................................... 16

Introduction

3.

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

Check the Gas Level ..................................................................................................... 25

Starting the Generator Using Gasoline ...................................................................... 26

Starting the Generator Using Propane....................................................................... 28

Starting the Generator

2.

Shipping Braces ............................................................................................................ 18

Wheel Kit Installation .................................................................................................... 19

Adding Oil ...................................................................................................................... 20

Adding Gasoline ............................................................................................................ 21

Grounding the Generator ........................................................................................... 22

High Altitude Operation .............................................................................................. 22

Generator Setup

4.

AC Usage ........................................................................................................................ 32

Connecting a Load to the Generator .......................................................................... 34

Voltage Selector Switch ................................................................................................ 35

DC Usage ........................................................................................................................ 36

Using the Generator

3

CONTENTS

4

5.

6.

7.

Maintenance Schedule .................................................................................................. 40

Maintenance Log ........................................................................................................... 41

Checking the Oil ............................................................................................................ 42

Changing the Oil ............................................................................................................. 43

Cleaning the Air Cleaner ............................................................................................... 44

Spark Plug Maintenance ............................................................................................... 46

Emptying the Gas Tank ................................................................................................. 48

Cleaning the Fuel Filter Cup .......................................................................................... 50

Storage and Transportation ......................................................................................... 51

Specications .................................................................................................................. 52

.......................................................................................................................... 62

Basic Troubleshooting .................................................................................................. 54

Changing / Inspecting the Carbon Brushes ............................................................... 55

Changing / Inspecting the AVR .................................................................................... 57

Wiring Diagram ............................................................................................................. 60

Maintenance and Care

Warranty

Troubleshooting

8.

.................................................................................................. 66

Contact Information

5

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 oerings to include Pressure

Washers, Water Pumps, Engines and now oering 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 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).

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-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

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 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 gas.

● 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 overll 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 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 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 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-qualied 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 (GASOLINE)

Remove shipping braces

The shipping braces prevent engine movement during

shipment. Flip the generator over and remove the brightly

colored brace between the motor and the frame, and the

wood brace under the generator.

1.

Add gasoline

The fuel cap is located on top of the fuel tank. Fill the tank

with fresh unleaded gasoline 87 octane or higher. The tank

is full when you see fuel in the bottom of the fuel lter cup.

DO NOT overll the tank.

3.

Turn gas valve on

The gas valve is located above the recoil start on the

bottom of the fuel tank. Rotate the valve clockwise to the

vertical position to turn on the gas supply.

5.

Add oil

The oil ll cap is located on the lower engine block to the

right of the recoil start housing. Remove the oil ll cap and

ll with 10w30 oil.

2.

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.

4.

10

Close choke

The choke lever is located above the air lter to the right

of the recoil start. Slide the lever to the left to cut the air

supply and allow more gas into the engine to start.

6.

Open choke

The choke lever is located above the air lter to the right

of the recoil start. Slide the lever to the right to open the

choke and increase air into the carburetor for normal

running.

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

QUICK START GUIDE (PROPANE)

Remove shipping braces

The shipping braces prevent engine movement during

shipment. Flip the generator over and remove the brightly

colored brace between the motor and the frame, and the

wood brace under the generator.

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.

Connect propane hose

The propane regulator / decompression valve is located

on the frame of the generator below the OHV valve cover.

Ensure the propane hose is securely connected to the

regulator/compression valve.

5.

Add oil

The oil ll cap is located on the lower engine block to the

right of the recoil start housing. Remove the oil ll cap and

ll with 10w30 oil.

2.

Turn gas valve o

The gas valve is located above the recoil start on the

bottom of the fuel tank. Rotate the valve counter clockwise

to the horizontal position to stop the ow of gasoline to

the carburetor.

4.

12

Connect propane tank

The propane hose is located on the left side of the regulator,

below the OHV valve cover. Screw the open ACME nut

connection to your propane tank and turn the tank on.

6.

Adjust choke

The choke lever is located above the air lter to the right

of the recoil start. Slide the lever to the right to open the

choke and increase air into the carburetor for normal

running.

7.

Turn breaker on / connect

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. Connect your devices to the receptacles on

the front panel. Start with the largest loads rst.

9.

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.

8.

13

18. Muer

GENERATOR COMPONENTS

14

2. Choke Lever

1. Air Cleaner

10. Volt Meter

8. 120v 3-Prong

Receptacle

6. 120/240v 4-Prong

Receptacle

20. Power Boost

5. Circuit Breaker

7. Ground Terminal

9. Battery

12. Oil Fill and Dipstick

13. Engine Switch

14. Recoil Start

11. 12v DC Charging Posts

1. Air Cleaner - a removable, cleanable, oiled, sponge-like element that cleans the air going into

the engine.

2. Choke Lever - Allows the airow into the carburetor to be restricted to assist in starting the

engine.

3. Fuel Gauge - Indicates the amount of fuel in the gasoline tank.

4. Fuel Cap - Allows access to ll the gasoline tank.

5. Circuit Breaker - Resettable switch that protects the generator from electrical overload.

6. 120/240v 4-Prong Receptacle - Use to connect electrical devices that run 120 or 240 Volt,

60Hz, single phase, AC current (NEMA L14-30).

7. Ground Terminal - Connect a ground wire here to properly ground the generator.

8. 120v 3-Prong Receptacle - Use to connect electrical devices that run 120 Volt, 60 Hz, single

phase, AC current (NEMA 5-20).

9. Battery - 12V DC 7ah Battery that powers the Electric Start System.

10. Volt Meter - Provides reading of voltage output.

16. Fuel Valve

19. Propane Connector

4. Fuel Cap

15. Fuel Filter Cup

18. Muer

17. Spark Plug

3. Fuel Gauge

11. 12v DC Charging Posts – DC Output for charging batteries or running small DC powered items.

12. Oil Fill and Dipstick - Use to add or check the oil.

13. Engine Switch – 3 Position Switch to “Start”, “Run”, or turn “O” the generator.

14. Recoil Start – Easy Pull Recoil Start to start the engine without the electric start.

15. Fuel Filter Cup - Traps dirt and debris in gasoline before it enters the engine.

16. Fuel Valve - On/O Valve that allows fuel into the engine.

17. Spark plug – Provides ignition to the engine.

18. Muer – Reduces engine emissions and reduces noise.

19. Propane Tank Connector – Connects the LPG tank to the LPG Regulator.

20. Power Boost – DuroStar exclusive Power Boost doubles the amperage available in “120v Only”

for heavy loads like RV air conditioners.

15

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 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.

16

GENERATOR SETUP

Proper setup of your generator will get you going as soon as possible while making sure you and

your equipment are safe and cared for.

GENERATOR SETUP

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

a. Completely remove each of the 4 bolts holding the

orange metal brace in place.

b. Remove the brace.

c. Cut the nylon tie strap holding the wood brace in

place.

d. Grab the end of the second brace and pull it out.

e. This piece is no longer needed and can be discarded.

2.

18

Note: Shipping braces can be thrown away.

They will not be needed again.

19

Install support legs

Secure the support legs to the frame with provided bolts and

lock nuts.

1.

Step 2 - Wheel Kit Installation (Optional)

Install wheels

Install Handles

a. Secure the axle bracket welded to axle to the frame with

the provided bolts and lock nuts.

b. Secure the loose axle bracket to the frame with the

provided bolts and lock nuts.

c. Slide one wheel over each axle end and secure with

the provided retaining pins.

Attach the handles to the brackets on the frame using the

provided bolts and nuts.

Do not over tighten the handles, it will prevent

free movement.

2.

3.

-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 (CONTINUED)

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 gasoline 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 3 - Adding Oil

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.

Model Number DS5500EH

Engine Oil Capacity 20 . oz (0.6L)

20

WARNING: DO NOT overll the crankcase. This

may damage the motor and shorting overall life

of your generator.

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Durostar DS5500EH User manual

Durostar DS5500EH User manual

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