DuroStar DS1500 User Manual Download Page 45 | 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 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.

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Summary of Contents for DS1500

Page 1: ...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 REV DS1500 01242018 ...

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Page 3: ...Package Contents 14 Introduction 3 Checking the Oil 20 Check the Gas Level 21 Starting the Generator 22 Starting the Generator 2 Adding Oil 16 Adding Gasoline 17 Grounding the Generator 18 High Altitude Operation 18 Generator Setup 4 AC Usage 26 Connecting a Load to the Generator 26 Using the Generator ...

Page 4: ...ng the Oil 35 Cleaning the Air Cleaner 36 Spark Plug Maintenance 38 Storage and Transportation 40 Specifications 41 52 Basic Troubleshooting 44 Changing Inspecting the Carbon Brushes 45 Changing Inspecting the AVR 46 Maintenance and Care Warranty Troubleshooting 8 56 Contact Information ...

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Page 6: ...orm that knocks out power dewatering a flooded property or washing away a deck for the summer season Engines that are certified to comply with U S EPA emission regulations for SORE Small off Road Equipment are certified to operate on regular unleaded gasoline and may include the following emission control systems EM Engine Modifications and TWC Three Way Catalyst if so equipped 6 STOP Please do no...

Page 7: ... 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 ...

Page 8: ...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 qua...

Page 9: ...der wet conditions electric shock can occur Connect generator grounding terminal to a good earth ground Do not touch hot engine or muffler Do not connect this generator to any building s electrical system unless an isolation switch has been installed by a qualified electrician electrocution or property damage may occur DANGER TO REDUCE THE RISK OF INJURY OR DEATH Exhuast outlet and muffler will be...

Page 10: ...ousing Remove the oil fill cap and fill with 10w30 oil 1 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 3 Close choke The choke lever is located above the air filter to the right of the recoil start Slide the lever to the left to cut the air supply and allow more gas into...

Page 11: ...o of the handle while the rope is extended this may cause damage to yourself or your machine The choke lever is located above the air filter 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 6 7 Connect devices Connect your devices to the receptacles on the front panel Start with the largest loads first 8 11 ...

Page 12: ...that allows fuel into the engine 4 Air Cleaner a removable cleanable oiled sponge like element that cleans the air going into the engine 5 Recoil Start Easy Pull Recoil Start to start the engine without the electric start 6 Oil Fill and Dipstick Use to add or check the oil 7 Engine Switch 3 Position Switch to Start Run or turn Off the generator 8 Ground Terminal Connect a ground wire here to prope...

Page 13: ... Volt 60 Hz single phase AC current NEMA 5 20 11 Muffler Reduces engine emissions and reduces noise 12 Spark plug Provides ignition to the engine 13 Fuel Gauge Indicates the amount of fuel in the gasoline tank 14 Fuel Filter Cup Traps dirt and debris in gasoline before it enters the engine 15 Fuel Cap Allows access to fill the gasoline tank 13 ...

Page 14: ...e check to see that all of the following items are included with your generator Note Actual tools may differ in appearance or design from image shown Spark Plug Wrench DC Charging Cables Used in spark plug maintenance inspection and installation Used to charge batteries 14 ...

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 ...

Page 16: ...engine s service life a Make sure the generator is on a level surface b Unscrew the oil filler 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 filler cap 1 Step 1 Adding Oil Engine oil recommended SAE 10W ...

Page 17: ...pacity of your generator model d Replace fuel cap and wipe up any spilled gasoline with a dry cloth NOTE Gas can expand Do not fill the gas tank to the very top Leave a minimum of 1 5 in of open space IMPORTANT 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...

Page 18: ...altitude that 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 5 000 feet 1 500 meters have a dealer perform this carburetor modification This engine when operated at high altitude with the carburetor m...

Page 19: ...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 20: ...ck 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 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 Be sure to replace the c...

Page 21: ...e highly flammable Do not fill tank near an open flame Always allow engine to cool for several minutes before refueling DO NOT overfill fuel tank Fuel expands when shaken or heated ALWAY leave 11 2 space or more at the top of the tank ALWAYS use fresh fuel or stabilized fuel Old gasoline older than 30 days can cause permanent damage to the fuel system Always check for fuel spills ...

Page 22: ...air filter 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 The engine switch is located on the left side of the front power panel Flip the switch to on 1 2 3 Pull recoil start Pull the recoil start handle quickly the complete length of the rope and then let it retract slowly The unit will generally start within 3 pulls ...

Page 23: ...tempting 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 Open choke Push the choke to the OPEN position as the engine warms up 5 ...

Page 24: ...24 ...

Page 25: ...re 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 26: ...ed the rated wattage of the generator itself To calculate the total wattage requirement of the electrical devices you wish to connect find 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 find this wattage you may calculate it by multiplying the Voltage requirement by the Amperage drawn Watts Volts x Amps If...

Page 27: ...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 28: ...devices can be directly connected to the 110v ONLY receptacles Plug in devices Plug in devices to the appropriate receptacle 1 CAUTION Do not connect 50Hz or 3 phase loads to the generator CAUTION Do not connect 240V loads to the generator 28 Turn on connected devices Start or turn on appliances starting with the biggest loads first 2 ...

Page 29: ...ctrical device See table 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 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 R...

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Page 31: ...nce 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 31 ...

Page 32: ... instruction manual Make sure the engine is off before you begin any maintenance or repairs Let the engine and exhaust system cool before touching To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts SERVICE REGULAR SERVICE PERIOD BEFORE E...

Page 33: ...MAINTENANCE LOG Date Generator Hours Maintenance Performed 33 ...

Page 34: ...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 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 secti...

Page 35: ...nated with water or dirt Remove drain plug Drain oil Replace drain plug Using a 10 mm 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 into an approved oil disposal container Contact your local auto parts store for information on oil disposal Replace the oil drain plug and tighten ...

Page 36: ...ss 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 cleaner cover Remove cleaner element Wipe out cleaner casing Unhinge the clasps at the top and bottom of the air cleaner cover Remove the sponge like elements from the casing Wipe the dirt from inside the empty air cleaner casing 1 2 3 36 ...

Page 37: ...and replace the cover 7 37 Wash cleaner element Wash the sponge like elements in household dish detergent and warm water 4 Dry cleaner element Allow the elements to dry completely 5 6 Add engine oil to elements Soak the dry elements in a small amount of engine oil Ring out any excess oil ...

Page 38: ...plug threads Spark Plug Maintenance Remove spark plug cap Remove spark plug Inspect spark plug 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 If it is cracked or chipped discard and replace with a new spark plug We recommend using a F6RTC spark plug such as NGK BPR5ES 1 2 3 MAI...

Page 39: ...nd re gap Replace spark plug Replace spark plug cap 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 Screw the spark plug back into its place on the generator using the spark plug wrench Replace the spark plug cap 5 6 7 39 ...

Page 40: ...5 minutes 3 Turn off the fuel valve 4 Allow the unit to stall out 5 Turn off the key 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 key 6 Drain the fuel tank See Emptying the Gas Tank in t...

Page 41: ...C Phase Single DC Voltage 12V DC Amperage 5 3A Dimensions LENGTH 18 25in WIDTH 14 75in HEIGHT 15 75in Engine Type 4 Stroke OHV Forced Air Ignition System Non Contact Transistor Displacement 87cc Starting Type Electric Fuel Tank Capacity 1 59 US Gal 6L Oil Capacity 13 5 fl oz 0 4L Run Time 50 Gasoline 8 hr Noise Level 93db 41 ...

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Page 43: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator 43 ...

Page 44: ...generator to a level surface Oil is low Add change oil Engine runs but there is no electrical output Circuit Breaker has popped Push in circuit breaker to reset 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 connected Generator is overloaded Disconnect 1 or...

Page 45: ...bon 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 45 ...

Page 46: ...ush 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 with the 2 bolts TROUBLESHOOTING CONTINUED 46 ...

Page 47: ...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 47 ...

Page 48: ...to connect and correctly 7 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 Reconnect the wire clip Changing Inspecting the AVR Continued TROUBLESHOOTING CONTINUED 48 ...

Page 49: ...Replace generator cover Replace the back cover of the generator and secure with the 2 bolts 8 49 ...

Page 50: ...WIRING DIAGRAM 50 ...

Page 51: ...51 ...

Page 52: ...RRANTY 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 off road engine In California new equipment that use small off road engines must be designed built and equipped to meet the Sta...

Page 53: ...any questions regarding your warranty coverage contact us at 844 DUROMAX or email support duromaxpowerequipment com 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 ...

Page 54: ...manufacturer distribution centers that are franchised to service the subject engines 5 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 6 The manufacturer is liable for damages to other engine components proximately caused by a failure under warranty of...

Page 55: ...hermal Reactor System i Catalytic converter i Thermal reactor ii Exhaust manifold 6 Particulate Controls 7 Traps filters 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...

Page 56: ...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 5pm PST Website www duromaxpower com Email customerservice duromaxpower com ...

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Page 58: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX ...

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