DUROMAX DUROSTAR DS11000DX User Manual Download Page 28 | Manualshive

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Summary of Contents for DUROSTAR DS11000DX

Page 1: ... pm PST Mon Fri 844 DUROMAX DS11000DX U S E R M A N U A L 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 ...

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Page 3: ...Recoil Start 38 Starting the Generator 3 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 Generator Setup 5 AC Usage 42 Connecting the Generator to a Home 45 Connecting a Load to the Generator 46 Choosing the Right Power Cord 47 Using the Digital Multimeter 48 Idle Control Usage 49 Usin...

Page 4: ...ng the Fuel Filter Cup 62 Transporting the Generator 63 Storing the Generator for Same Day Use 64 Storing the Generator for Use Within 30 Days 65 Storing the Generator for Longer than 30 Days 66 Specifications 68 78 Basic Troubleshooting 70 Changing Inspecting the Carbon Brushes 71 Changing Inspecting the AVR 73 Wiring Diagram 76 Maintenance and Care Warranty Troubleshooting 9 82 Contact Informati...

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Page 6: ...y 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 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 powe...

Page 7: ...o 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 Eng...

Page 8: ... 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 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 instructio...

Page 9: ...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 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 elect...

Page 10: ...WER SENSITIVE ELECTRONIC EQUIPMENT WITHOUT THE ADDITION OF AN APPROPRIATE LINE CONDITIONER SOLD SEPARATELY HIGH VOLTAGE ELECTRICAL DANGER DANGER DANGER Made in China DANGER Operating servicing and maintaining a generator or off road vehicle can expose you to chemicals including engine exhaust carbon monoxide phthalates and lead which are known to the State of California to cause cancer and birth d...

Page 11: ...DON T TOUCH CAUTION HIGH TEMPERATURE DANGER HOT EXHAUST KEEP SAFE DISTANCE DON T TOUCH BURN RISK CARBON MONOXIDE SAFE DISTANCE 11 ...

Page 12: ...he 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 bloc...

Page 13: ...utely 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 ...

Page 14: ...uture Purchase Date ____________________________________________ Order Number ____________________________________________ Retailer Name _____________________________________________ Serial Number 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 ser...

Page 15: ...15 GENERATOR COMPONENTS To help you get familiar with your new DuroStar generator please see this component section for easy reference on all the generator s individual features ...

Page 16: ... the start switch plugs meters and circuit breakers 6 Handles Longest handles of any DuroStar model allow easy movement across any surface 7 Battery 12V DC battery that powers the electric start system 8 Oil Fill and Dipstick Use to add or check the oil 9 Fuel Switch Fuel selection switch to choose Gas Propane or Storage mode 10 Propane Inlet Provides a regulated LPG fuel supply to the engine Inte...

Page 17: ... load 16 Circuit Breaker Protects the panel from overload and short circuits 17 Multimeter Displays voltage hertz and time running 18 CO ALERT Shuts down the engine in the event of CO buildup 19 50A Receptacle Use to connect electrical devices that run 120 or 240 Volt 60 Hz single phase AC current NEMA 14 50 20 240V 4 Prong Twist Lock Use to connect electrical devices that run 120 or 240 Volt 60 H...

Page 18: ... listed below Please check to see that all of the following items are included with your generator 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 13mm 15mm and 17mm 19mm Used ...

Page 19: ...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 19 ...

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Page 21: ...Remove Shipping Braces Remove braces a The shipping braces prevent engine movement 2 Note Shipping braces can be thrown away they will not be needed again CAUTION NEVER attempt this if you have put fuel or oil in the generator 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 ...

Page 22: ... legs to the frame with the provided lock nuts 1 Install wheels a Place the wheels onto the axles 4 Install wheel axles a Place the smallest washer onto the wheel axle bolts b Insert wheel axle bolts through the frame and secure with the provided nut and wrenches 2 Install inside wheel washers a Place one of the large washers onto the axles 3 22 ...

Page 23: ...ace the other large washers onto the axles 5 Install handles a Attach the handles to the brackets on the frame using the provided bolts and nuts 7 Install cotter pins a Place the cotter pin through the hole at the end of the axle and bend it out to secure the wheel 6 CAUTION Do not over tighten the handles it will prevent free movement ...

Page 24: ...ove 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 2 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 sc...

Page 25: ...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 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 ...

Page 26: ...moothly 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 Model Number DS11000DX Gas Tank Capacity 8 3 US gal 31 L DANGER DO NOT OVER...

Page 27: ...ication 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 car...

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Page 29: ...e are still steps you should take to prepare it for operation each time you use it IMPORTANT At this point you should be familiar with the procedures described in the first portion of this section entitled GENERATOR SETUP If you have not yet read this section go back and read it now ...

Page 30: ... 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 port...

Page 31: ...pear 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 11 2 space or more at the top of the tank ...

Page 32: ...ry switch ON The fuel switch is located on the left front panel Rotate the switch clockwise to the GAS position to turn on the gas supply The battery switch is located on the top center of the main power panel Turn the switch ON to allow power to the push button start 2 4 Turn idle control OFF The idle control is located on the top center of the main power panel Turn the switch OFF to prevent the ...

Page 33: ...ine switch is located on the left side of the front power panel Flip the switch up to the START Position When the engine starts allow the engine switch to return to the RUN position 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 5 Start the generator 6 Open cho...

Page 34: ...ator 1 Turn fuel switch to PROPANE Connectpropanehose Connectpropanetank The fuel switch is located on the left front panel Rotate the switch counter clockwise to the PROPANE position to turn on the fuel supply The propane inlet is located on the left hand front panel to the right of the fuel switch Securely connect the propane hose to the inlet Screw the open ACME nut connection to your propane t...

Page 35: ...uel valve OFF Turn the fuel valve to the OFF position 7 Turn battery switch ON The battery switch is located on the top center of the main power panel Turn the switch ON to allow power to the push button start 6 Turn idlecontrolOFF The idle control is located on the top center of the main power panel Turn the switch OFF to prevent the unit from trying to idle down before the engine is warmed up 5 ...

Page 36: ... 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 11 The engine switch is located on the left side of the front power panel Flip the switch up to the START Position When the engine starts allow the engine...

Page 37: ...ngine runs smoothly There may be remnant gasoline in the carburetor this can cause unsteady engine performance for several minutes 3 If the propane gas leaks shut off the LPG supply first and then quickly unplug or turn off any electrical devices powered by the unit 4 When stopping the engine unplug or turn off any electrical devices turn off the main circuit breaker and then turn off the LPG supp...

Page 38: ...e see step 2 on pg 32 If using propane see steps 2 4 on pg 34 2 Turn battery switch ON The battery switch is located on the top center of the main power panel Turn the switch ON to allow power to the push button start 4 Turn idle control OFF The idle control is located on the top center of the main power panel Turn the switch OFF to prevent the unit from trying to idle down before the engine is wa...

Page 39: ... yourself or your equipment 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 5 Open choke 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...

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Page 41: ...are still steps you should take to prepare it for operation each time you use it IMPORTANT At this point you should be familiar with the procedures described in the first portion of this section entitled GENERATOR SETUP If you have not yet read this section go back and read it now ...

Page 42: ...quirement 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 You may connect electrical devices running on AC curre...

Page 43: ...ectric drill 600 900 Television 500 0 Deep freezer 500 800 Garage door opener 480 600 Stereo 400 0 Box fan 300 600 Clock radio 300 0 Security system 180 0 DVD player 100 0 Common light bulb 75 0 CAUTION The generator can only run at its surge wattage capacity for a very short time Connect only electrical devices requiring a rated running wattage equal to or less than the rated wattage of the gener...

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Page 45: ...ly 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 i...

Page 46: ...ONLY be connected to the 240V receptacle CAUTION Do not connect 50Hz or 3 phase loads to the generator 3 Turn on connected devices Start or turn on appliances starting with the biggest loads first 1 2 Plug in devices Turn breaker ON 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...

Page 47: ...7200 10 10 10 8 NR 40 4800 9600 8 8 6 6 NR 50 6000 12000 6 6 6 NR NR NR NOT RECOMMENDED Gauge based on twisted copper wire 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 f...

Page 48: ...s run The number of hours the engine has currently been running When the generator is started the display will read the current voltage Press the MODE button to cycle through the multimeter functions Voltage The voltage currently produced by the generator in volts 1 Frequency The frequency currently produced by the generator in Hz 2 Hours run The number of hours the engine has currently been runni...

Page 49: ...to provide usable power Turn on the idle control when using intermittent loads like power tools and air compressors The idle control feature is designed for gasoline only use Idle Control Usage WARNING Power is unusable when idle control is engaged DO NOT use the idle control function when using the generator for backup house power Idle control function will cause massive fluctuations in voltage a...

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Page 51: ...enance and storage of your generator is essential to ensure trouble free use of your generator when you need it By following the maintenance and care requirements you can keep your generator running smooth and efficient for years to come ...

Page 52: ... 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 WARNING Improper maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously injured or killed Alw...

Page 53: ...n 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 necessar...

Page 54: ...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 ...

Page 55: ...n approved oil disposal container Contact your local auto parts store for information on oil disposal 2 Replace drain plug Replace the oil drain plug and tighten with a 12 mm hex wrench 3 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 becom...

Page 56: ...AUTION Improper maintenance may cause less air to enter the engine or dirty air to enter the engine causing overheating and engine wear Cleaning the Air Filter Remove the filter cover screw Remove filter cover Clean out filter casing Remove the filter cover screw Remove the filter cover and the sponge like element from the casing Wipe the dirt from inside the empty air cleaner casing 1 2 3 ...

Page 57: ...lace the cover 7 Washcleanerelement Wash the sponge like elements in household dish detergent and warm water 4 Drycleanerelement Pat dry on a dry cloth and allow the elements to dry completely 5 6 Addengineoiltoelements Soak the dry elements in a small amount of engine oil Ring out any excess oil ...

Page 58: ... plug cap to remove it Unscrew the spark plug from the generator using the spark plug wrench included with this product Visually inspect the spark plug If it is cracked or chipped discard and replace it with a new spark plug We recommend using an F6RTC spark plug such as NGK BPR6ES 1 2 3 CAUTION Improper maintenance may cause reduced fuel economy misfires trouble starting or damage to the spark pl...

Page 59: ...nd 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 5 Install spark plug Replace spark plug cap Screw the spark plug back into its place on the generator using the spark plug wrench Replace the spark plug cap 6 7 59 ...

Page 60: ...arlier in this section Empty the fuel filter cup of any fuel 1 2 3 CAUTION Do not store fuel from one season to another Gasoline sold at the pump today contains additives such as ethanol that even when stored properly may damage the fuel system components If you have been using gasoline in your generator before storing your generator for extended periods of time you should drain your generator fue...

Page 61: ...lve to the ON position Drain all the gas from the generator 4 Shut fuel valve OFF Replace fuel filter cup Store emptied gas Turn the fuel valve to the OFF position Reinstall the fuel filter cup Store the emptied gasoline in a suitable place and add fuel stabilizer to keep fuel fresh and usable 5 6 7 61 ...

Page 62: ...ve to the OFF position 1 Cleaning the Fuel Filter Cup Remove fuel filter cup Clean filter cup Replace fuel filter cup Unscrew the fuel filter cup from the fuel valve using a wrench Clean the cup of all sediment using a rag or brush Reinstall the fuel filter cup 2 3 4 62 ...

Page 63: ...as Tank on page 60 61 Pull on spark plug cap to disconnect spark plug from ignition wire 1 2 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 Transporting the Generator 63 ...

Page 64: ... store the generator CAUTION Do not obstruct any ventilation openings and keep the generator in a cool dry area 4 64 Turn the main breaker OFF Run the generator Move the main breaker to the OFF position Allow the generator to run for 3 5 minutes 1 2 Move rocker switch to STOP Move the rocker switch to the STOP position to turn the generator off 3 ...

Page 65: ...enerator For Same Day Use on page 64 1 Shut fuel valve OFF and run dry Turn the battery switch OFF Add fuel stabilizer and store Shut the fuel valve OFF and allow generator to run until it stalls out Turn the battery switch to the OFF position Add fuel stabilizer to gas remaining in tank and store generator 2 3 4 65 ...

Page 66: ...ame Day Use on page 64 1 Shut fuel valve OFF and run dry Turn the battery switch OFF Empty the gas tank Shut the fuel valve OFF and allow generator to run until it stalls out Turn the battery switch to the OFF position Fully drain your gas tank as shown in Emptying the Gas Tank on page 60 61 2 3 4 66 MAINTENANCE AND CARE CONTINUED ...

Page 67: ...der Remove battery and charge Remove spark plug as shown in Spark Plug Maintenance on page 58 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 Remove the generator battery and place it on a 12V battery tender indoors 6 7 8 67 ...

Page 68: ...0 5 fl oz 1 2 L Bore 92 mm Stroke 69 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 Gasoline 9 hr Run Time 50 Propane 7 hr 40 lb Starting Type Electric Recoil Noise Level 74 dB Neutral System Floating AC Rated Fr...

Page 69: ...69 TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator ...

Page 70: ...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 D...

Page 71: ...carbon brushes are wearable parts and should be inspected every 250 running hours Remove generator cover Remove bolt from brush Disconnect AVR wires Remove the 2 bolts of the generator cover then pull the cover off the generator Remove the bolt holding the carbon brush Remove the two wires from the AVR on the carbon brush 1 2 3 ...

Page 72: ...shes Cont Install new brush Install new carbon brush with bolt 4 Connect AVR wires Insert and connect the 2 wires from the AVR be sure to connect and correctly 5 6 Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts 72 ...

Page 73: ...or If the generator is overheated or overloaded the AVR may be damaged and require replacement Remove generator cover Remove AVR bolts Disconnect AVR wire clip Remove the 2 bolts of the generator cover then pull the cover off the generator Remove the 2 bolts holding the AVR Disconnect the wire clip 1 2 3 73 ...

Page 74: ...Disconnect wires from brush Remove the 2 wires from the AVR on the carbon brush 4 Install new AVR Install the new AVR with the 2 bolts 5 6 Reconnect wires to brush Insert and connect the 2 wires from the AVR be sure to connect and correctly Changing Inspecting the AVR Continued 74 ...

Page 75: ...Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts 8 75 ...

Page 76: ...WIRING DIAGRAM 76 ...

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Page 78: ...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 eng...

Page 79: ...844 387 6629 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...

Page 80: ...sions 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...

Page 81: ...or 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 ...

Page 82: ...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 customerservice duromaxpower com ...

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Page 84: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX REV DS11000DX 07182022 ...

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