DuroStar DS11000DX User Manual Download Page 63 | Manualshive

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Changing / Inspecting the Carbon Brushes

The carbon brushes in conjunction with the AVR regulates
power from the generator. The carbon brushes are wearable
parts and should be inspected every 250 running hours.

Remove generator cover

Remove bolt from brush

Disconnect AVR wires

Remove the 2 bolts of the generator cover. Pull off the cover.

Remove the bolt holding the carbon brush.

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

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Summary of Contents for 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: ...the Generator Using Propane 32 Starting the Generator Using Recoil Start 36 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 40 Connecting a Load to the Generator 42 Using the Digital Multimeter 44 U...

Page 4: ...52 Spark Plug Maintenance 54 Emptying the Gas Tank 56 Cleaning the Fuel Filter Cup 58 Storage and Transportation 59 Specifications 60 70 Basic Troubleshooting 62 Changing Inspecting the Carbon Brushes 63 Changing Inspecting the AVR 65 Wiring Diagram 68 Maintenance and Care Warranty Troubleshooting 9 74 Contact Information ...

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Page 6: ...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 sand...

Page 7: ... 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...

Page 8: ...st 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 i...

Page 9: ...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 electrical system ...

Page 10: ...bove 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 ...

Page 11: ...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 ...

Page 12: ... 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...

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: ...________ 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 ____________________________________...

Page 15: ...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 ...

Page 16: ...ank 5 Power Panel Contains the start switch plugs meters and circuit breakers 6 Handles Longest handles of any DuroMax 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 ...

Page 17: ...rcuit 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 19 120 240V 4 Prong Receptacle Use to connect electrical devices that run 120 or 240 volt 60Hz single phase AC current NEMA 14 50 20 120 240V 4 Prong Twist Lock Use to connect electrical devices that run 120 or 240 volt...

Page 18: ...ance or design from the image 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 13mm 15mm Used in spark plug maintenance inspection and installation Plug heads for the rece...

Page 19: ...ER 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 ...

Page 20: ...onal Install wheels a Place the wheels onto the axles 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 GENERATOR SETUP CONTINUED Install inside wheel washers a Place one of the large washers onto the axles 20 ...

Page 21: ... the brackets on the frame using the provided bolts and nuts Do not overtighten the handles it will prevent free movement 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 Flip Over a Flip the assembled generator over onto its wheels and support brackets 8 ...

Page 22: ...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 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 scre...

Page 23: ...om the engine c Using a funnel add the appropriate amount of oil into the crankcase You will know the crankcase is full when the oil level has reached the lower lip of the opening you have just poured the oil into d Replace the oil filler cap Step 4 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 sm...

Page 24: ...th a dry cloth IMPORTANT To ensure that the generator runs smoothly use only FRESH UNLEADED GAS WITH AN OCTANE RATING OF 87 OR HIGHER Never use an oil gasoline mixture Never use old gas Avoid getting dirt or water in the fuel tank Gas can age in the tank and make it hard to start up the generator in the future Never store generator for extended periods of time with fuel in the tank DANGER DO NOT O...

Page 25: ...at differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by specific modifications to the carburetor If you always operate your generator at altitudes above 3 000 feet 900 meters have a dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications ...

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Page 27: ...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 28: ... the oil filler dipstick cap c With a dry cloth wipe the oil off of the stick on the inside of the cap d Insert the dipstick as if you were replacing the cap and then remove it again There should now be oil on the stick If there is no oil on the stick or oil only at the very end of the stick you should add oil until the engine crankcase is filled see Adding Oil portion of the Maintenance section e...

Page 29: ...he Gas Level Optional DANGER DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE EXPLOSION OR DEATH 1 5 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 30: ...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 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...

Page 31: ... 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 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 Start the generator Open...

Page 32: ...fuel switch is located on the left front panel Rotate the switch counter clockwise to the Propane position to turn on the fuel supply 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 Turn idle control OFF The idle control is located on the top center of the main power panel Turn the switch OFF ...

Page 33: ... 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 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 Start the generator Open...

Page 34: ...eady 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 supply After the engine has stopped turn the switch to the OFF position CAUTION Disconnect ...

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Page 36: ...Start Select your fuel If using gasoline see step 2 on pg 30 If using propane see steps 2 4 on pg 32 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 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 t...

Page 37: ...m to yourself or your equipment Turn breaker ON and 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 Close choke The choke lever is located above the air filter to the left of the recoil start Slide the lever to the...

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Page 39: ... 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 39 ...

Page 40: ...rement 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 40 You may connect electrical devices running on AC curre...

Page 41: ...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...

Page 42: ...s can ONLY be connected to the 240V receptacle Plug in devices Turn breaker on Turn on connected devices Plug in devices to the appropriate receptacle When using the generator balance the load as closely as possible Placing more load on one side of the circuit will reduce the breaker trip period Flip the circuit breaker up to the ON position to allow power to the receptacles Start or turn on appli...

Page 43: ...ble below for recommended cords based on the power requirement of the electrical device 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 12 10 15 1800 3600 14 14 12 12 10 20 2400 4800 12 12 12 10 10 25 3000 6000 12 10 10 10 8 30 3600 7200 10 10 10 8 NR 40 4800 9600 8 8 6 6 NR 50 6000 12000 6 6 6 NR NR NR NOT RECOMMENDE...

Page 44: ...oduced by the generator in volts Frequency The frequency currently produced by the generator in Hz Hours 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 ...

Page 45: ...45 4 Hours Total The number of hours the generator has been run in total ...

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Page 47: ...r maintenance and storage are essential to ensure trouble free use of your generator when you need it By following the maintenance and care requirements you can keep your generator running smoothly and efficiently for years to come ...

Page 48: ...LACE 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 MONTHS INDICATED OR HOUR INTERVAL WHICHEVER COMES FIRST 48 WARNING Improper maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously inju...

Page 49: ...MAINTENANCE LOG Date Generator Hours Maintenance Performed 49 ...

Page 50: ...el a Make sure the generator is on a level surface b Unscrew the oil filler dipstick cap c With a dry cloth wipe the oil off of the stick on the inside of the cap d Insert the dipstick as if you were replacing the cap and then remove it again There should now be oil on the stick If there is no oil on the stick or oil only at the very end of the stick you should add oil until the engine crankcase i...

Page 51: ...ome contaminated with water or dirt Using a 12mm hex wrench unscrew the oil drain plug which is located on the crankcase underneath the oil filler dipstick cap Allow all the oil to drain from the generator Drain oil Drain oil into an approved oil disposal container Contact your local auto parts store for information on oil disposal Replace drain plug Replace the oil drain plug and tighten with a 1...

Page 52: ...r to enter the engine or dirty air to enter the engine causing overheating and engine wear MAINTENANCE AND CARE CONTINUED Cleaning the air filter 52 Remove the filter cover Remove filter Clean out filter casing Release the clips on the top and bottom of the cover and remove the filter cover Remove the sponge like elements from the casing Wipe the dirt from inside the empty air cleaner casing 1 2 3...

Page 53: ...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 54: ...ires trouble starting or damage to the spark plug threads Spark Plug Maintenance Remove spark plug cap Removesparkplug Inspectsparkplug Pull on the spark 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 1 2 3 SPARK PLUG CONSULTMANUAL BEFORE REMOVING MAINTENANCE AND CARE CONTINUED 54 ...

Page 55: ...rd and replace it with a new spark plug We recommend using an F7RTC spark plug such as NGK BP6ES 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 5 6 55 ...

Page 56: ...e 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 fuel tank of gasoline MAINTENANCE ...

Page 57: ...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 57 ...

Page 58: ...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 58 ...

Page 59: ...run 3 5 minutes 3 Turn off the fuel valve 4 Allow the unit to stall out 5 Turn off the engine switch 6 Add fuel stabilizer to the gas remaining in the tank 7 Store If you do not plan to start the unit for longer than 30 days 1 Turn off the main breaker 2 Allow the unit to run 3 5 minutes 3 Turn off the fuel valve 4 Allow the unit to stall out 5 Turn off the engine switch 6 Drain the fuel tank See ...

Page 60: ...e 120 240V ACRatedFrequency 60 Hz AC Phase Single Dimensions LENGTH 28in WIDTH 22in HEIGHT 23in Engine Type 4 Stroke OHV Forced Air Ignition System Non Contact Transistor Displacement 457cc Starting Type Electric Recoil Fuel Tank Capacity 8 3 US Gal 31L Oil Capacity 40 5 fl oz 1 2L Run Time 50 Gasoline 9 hr Run Time 50 Propane 8 hr 40 lb Noise Level 74db 60 ...

Page 61: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator 61 ...

Page 62: ...vel 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 Dis...

Page 63: ...or The 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 Pull off the cover Remove the bolt holding the carbon brush Remove the two wires from the AVR on the carbon brush 1 2 3 63 ...

Page 64: ...h 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 TROUBLESHOOTING CONTINUED 64 ...

Page 65: ...he generator 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 Pull off the cover Remove the 2 bolts holding the AVR Disconnect the wire clip 1 2 3 65 ...

Page 66: ... 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 Make sure to connect and correctly Changing Inspecting the AVR Continued TROUBLESHOOTING CONTINUED 66 ...

Page 67: ...Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts 8 67 ...

Page 68: ...WIRING DIAGRAM 68 ...

Page 69: ...69 ...

Page 70: ...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 2021 2022 year small off road engine In the United States and California new small off road eng...

Page 71: ...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 72: ...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 73: ...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 74: ...ors 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 Website www duromaxpower com Email customerservice duromaxpower com ...

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Page 76: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX REV DS11000DX 09102021 ...

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