DuroStar DS7000Q User manual

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OWNER’S MANUAL
Air –Cooled Diesel Engine Generator Set
Max Tool Customer Service
Email [e-mail] or Call 1-800-629-3325 (option 3)
Monday –Friday 7am to 5pm PST
Product Support (Product: information, application, service info & warranty questions)
Email [e-mail] or Call 1-800-629-3325 (option 3)
Monday –Friday 7am to 5pm PST
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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- - - - Diesel Series Generator Set - - - -
Thank you for purchasing a DuroStar Diesel Series Generator.
This manual explains how to operate and service your diesel generator. Please
take the time to read it before operating your generator. Everyone who
operates this generator must read and understand this manual. The time you
take reading this manual before operating will ensure your safety and will
prolong your generator life. Pay special attention to statements preceded by
the following words:
DANGER
Indicates an imminently hazardous situation which if not avoided will result in
death or serious injury. This signal word is to be limited to the most extreme
situations.
WARNING
Indicates a potentially hazardous situation which, if not avoided could result in
a death or serious injury.
CAUTION:
Indicates a potentially hazardous situation which if not avoided could result in
minor or moderate injury. It may also be used to alert against unsafe practices.
NOTE: Provides helpful information.
With the unceasing improvement and enhancement of products, we reserve
the right to make improvement in design and/or changes in specifications at
any time without prior notice or obligation. User should pay attention that there
may be some differences between the contents described in the operation
instruction and practical products.
WARNING
This generator is designed to give safe and dependable service provided
it is operated per the instructions. Read and understand the operation
manual before operating generator. Failure to do so could result in
personal injury or equipment damage.
CAUTION:
Should no manufacturing standard be specially defined in the contract of order,
all generator set will be manufactured per GB/T2820.3-1997 or ISO
8528-3:1993 standard.

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- - - - - - - - SAFETY TIPS - - - - - - - -
WARNING:
1. Preventing electrical shock:
The generator should be grounded to preventing electric shock. Never operate the
generator or handle any electrical equipment while standing in water, while barefoot,
while hands are wet, while in the rain or snow otherwise electric shock may result.
2. Preventing Fires:
Never add fuel to the fuel tank while the engine is running. Use a clean cloth to wipe
off the spilled fuel. Keep the diesel fuel, matches and other inflammable and explosive
matters away from the generator because the temperature around the muffler is very
high during operation. To prevent a fire hazard, it is necessary to provide sufficient
ventilation during the period of operation. At least 1m distance between the
generator, building and other equipment should be kept.
3. Preventing Burns:
Never touch hot muffler, hot exhaust manifold or engine cooling fans.
DANGER
4. This generator produces poisonous carbon monoxide gas that can kill you.
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.
•For outdoor use, ONLY, in non-confined areas. Never operate in an enclosed
area, indoors or near open windows or doors.
•Keep several feet of clearance on all sides to allow proper ventilation of the
generator.
5. Charging battery
Battery contains sulfuric acid which can cause blindness or severe burns. No
smoking, sparks or flames should exist when charging battery. In case of contact,
flush through with water and seek medical attention immediately, especially if your
eyes are affected
6. Other safety tips:
Know how to operate all the controls and how to stop the engine quickly. Keep
battery out of the reach of children. Operate on a level service. Keep vent caps tight
and level. The operator should wear safe shoes and working clothes.

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Table of Contents
Important Pre-Operation Information and Safety Tips......................................2
Series Appearance Diagram............................................................................5
1. Main Technical Specifications and Operation Circumstances..............6
1.1 Main Technical Specifications....................................................................6
1.2 Operation Circumstance ............................................................................7
2 Installation of Generator Set......................................................................8
3 Preparation for Starting..............................................................................9
3.1 Diesel Fuel, Air Cleaner Element, and Lube Oil.........................................9
3.2 Inspection for Diesel Generator Set.........................................................11
3.3 Bleed Air from the Fuel Line.....................................................................11
3.4 Before Starting, Operation must be done.................................................11
4 Start Generator Set...................................................................................11
4.1 Recoil Start ..............................................................................................11
4.2 Electric Start.............................................................................................14
4.3 Battery .....................................................................................................14
5 Operation for Generator Start..................................................................15
5.1 Operation of Diesel Engine......................................................................15
5.2 Generator Operating Speed.....................................................................15
5.3 Exercising the Generator Set...................................................................15
5.4 Open the Machine Case Door..................................................................16
6 Load Application.......................................................................................16
6.1 Determine Total Load Connected to the Generator Set...........................16
6.2 Start Electric Motors.................................................................................17
6.3 Extension Wire.........................................................................................18
6.5 AC Application .........................................................................................18
6.5 DC Application.........................................................................................18
6.6 Treat Machine with Double Voltage Output .............................................19
7 Stop the Generator Set.............................................................................19
8 Maintenance..............................................................................................20
8.1 Periodic Maintenance ..............................................................................20
8.2 Maintenance for Long Time Storage........................................................22
9 Inspection, Repair and Troubleshooting ................................................22
9.1 Doubtful Points and Problems..................................................................22
9.2 Inspection, Repair and Trouble Shooting.................................................22
Appendixes:
List for comments from users

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MAIN TECHNICAL SPECIFICATION
1.1 Main technical specification
Type of set
Item
DS7000Q
Generator
Kind
Single phase
Frequency (HZ)
60
Max power (kw)
5.0
Max output (kiva)
4.5
Voltage (AC) V
120/240
Self-excitation
Brushless
Revolution (rpm)
3600
Voltage (DC) V
12
Current (DC) A
8.3
Optional generator
grade
G1
Power factor cos
1
Steady state voltage
adjust rate
+-7%
No-load waveform
distortion rate
·≤10%
Insulation grade
≤15%
Diesel engine
Mode of power
KD186FA
kind
4-stroke single–cylinder air cooled direct injection
Persistence power (KW)
6.6
Max power (kw)
7.3
Cylinder diameter*
stroke (mm)
86×72
Cylinder displacement
(ml)
418
Cooling system
Force air-cooled
Volume of lube oil (L)
1.65
Start system
Electric start
Fuel
Diesel fuel
Set
Fuel tank volume (L)
14.5
Working way
Continuous operating for 12hours
Total weight (kg/lb.)
172/379
Over dimensions (Inch)
37.8” x 22.0” x 30.3”
MAIN TECHNICAL SPECIFICATIONS AND OPERATION

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CIRCUMSTANCE
Meaning of type symbols
※6500 Q --G1
G 1: Default type, used for
lights and other common
usage
Q: Low noise type
Code of power
Please confirm the model and functions of the generator set you purchased. For more
detailed information, contact the dealer.
1.2 Operation Circumstance
Under the following conditions, the generator set should output the rated power and
work reliably.
Altitude height
Ambient temperature (0)
Relative humidity
＜1000(m)
-15~40 (0)
＜90%
Please affirm your type of machine and understand its functions to operate and
maintain it correctly.

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INSTALLATION
2 Installation of Generator Set
2.1 Outdoor Operation
Choose a location where the generator will not be exposed to rain, snow, or
direct sunlight. Position the generator on a secure and level ground so it will
not tip or slide down on a hill. Place the generator so that the exhaust fumes
will not be directed towards anyone.
The installation site must be free from water, moisture, or dust. All electrical
components should be protected from excessive moisture or the insulation
system will deteriorate and result in grounding or will short out the generating
system.
Foreign matter, such as dust, dirt, sand, lint, or abrasive materials can cause
damage to the generator and engine and are not allowed into its cooling
system.
2.2 Generator Set Grounding
The generator is equipped with grounding terminal
located on the rear of the opening type and at the low
position of back side of the silent type (refer to figure 2-1).
Ground the generator by tightening the grounding nut
against a grounding wire. A generally acceptable
grounding wire is a No. 12 AWG (American Wire Gauge)
stranded copper wire. This grounding wire should be
connected at the other end to a copper or
brass-grounding rod that is driven into the end.
Grounding codes can vary by location. Please contact a
local electrician to check the grounding regulations for your area.
WARNING:
Failure to properly ground the generator can result in electrocution.
WARNING
Always use electrical cords that are in good condition. Worn, bare, frayed or
other damaged cords can cause electric shock.
Before operation, the generator should be grounded to prevent electric shock.
Contact a licensed electrician to wire electrical plugs and/or cord sets.
Improper wiring could result in a fire or electrical shock.
DANGER
Never use your generator inside enclose areas or indoors. Engines consume
oxygen and give off deadly carbon monoxide poisonous gas. Improper
ventilation will cause damage to generator and injury to people.

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PREPARE FOR STARTING
3 Prepare for Starting
3.1 Diesel Fuel,Air Filter Element, and Lube
Oil
Diesel Fuel
Use clean light diesel fuel only. If the fuel is
dirty, it should be filtered cleanly.
Caution: Don’t let any dust or water
mix with the fuel and enter the fuel tank.
Otherwise the high-pressure pump and
the injector nozzle get clogged.
Caution: Do not let fuel level rise
above Red Mark
Caution: No Smoking near oil or when
adding oil. Any sparks created can cause
fire or other damage. When filling oil,
don’t let oil overflow. After refueling,
make sure to fasten the cover nut on the
fuel inlet.
Type
Volume
DS7000
Series
The effective
volume of fuel
tank;(L) British
gal)
14.6
3.21
Type
Volume
DS7000Q
The effective
volume of fuel
tank;(L) British
gal)
12.8
2.82
Air Filter Element
Don’t wash the air filter element because the
component is a dry type. If the output of the
diesel engine drops or the color of the
exhausted gas changes adversely, change the
air filter element immediately. Never start the
diesel engine without using the filter element.
To check air filter element on silent model,
loosen the four screws from the outside body
fixed cover.

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PREPARE FOR STARTING
Lube oil
Put the generator set at level state.
Fill lube oil into the inlet. Check the oil
level with dipstick by inserting the dipstick.
Don’t screw in the dipstick. Keep oil level
between high (H) and low (L) levels.
type
Volume
DS7000
Series
DS7000Q
Volume(L)
British(gal)
1.65
0.36
A. P.I Engine Service Classification
We recommend A.P.I CD grade
NOTE: Nothing affects the performance and durability of your diesel engine more
than the lube oil you use. If inferior oil is used, you may risk piston seizure, piston ring
sticking, accelerated wear of the cylinder liner and other moving components
significantly. Your engine life may be seriously shortened. We recommend CD grade oil
of API engine service classification. Always use oil with the right viscosity for the
ambient temperature. Use the above chart when choosing your engine oil.

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PREPARE FOR STARTING
Caution: The machine has drained lube oil when it is delivered
from factory. Fill the crankcase with oil before starting.
3.2 Inspection for the Diesel Generator
3.2.1 When the oil pressure goes down below safe level,
the system will automatically shut off the engine to avoid
damaging while the ignition key is still in the ON position.
The engine will not start until the oil is refilled to proper
level. If the diesel engine is running with insufficient lube
oil, the oil temperature will raise. It is dangerous if there is
too much oil. This may cause lube oil to burn. It can then
cause the revolution speed of the diesel engine to
increase suddenly and result in abnormal running. For
this purpose, it is necessary to check the lube oil level
and the level should maintain between the low and high
level.
3.2.2 Turn off main switch and disconnect all load (For ex:
lamp and switch of motor). Check for damaged parts,
loose or missing nuts and bolts. If problems occur, please
do not start the engine, and consult our dealer.
Before starting the generator set, be sure to turn the main
switch to the OFF position. If the switch is not at the OFF
position, it can cause damage to the generator and seize
up the start motor with load to start.
WARNING: The generator should be started
without load.
3.3 Bleed Air from the Fuel Line
If the engine is having difficulty starting and the
fuel and oil level are acceptable, the problem can
usually be traced to air bubbles trapped in the
fuel line. The air should be discharged.
The correct method is:
Turn the fuel cock beneath the fuel tank to the
OFF position. Disconnect the fuel distributing
pipe from high pressure pump. Turn the valve to
the ON position and allow fuel to drip from the
fuel line to a small container. Reattach the fuel
line to the fuel pump when no air bubbles appear.
3.4 Before starting the generator, make sure
you have done the following:
a. The generator is positioned on a firm level
surface.
b. The generator has been grounded.
c. Check the lube oil level.
d. Any spilled fuel has been wiped off.
e. The ventilation is good.
4 Start Generator Set
4.1 Recoil Start
For the detailed start steps, please refer to
the operation diagram on the next page.
NOTE: On a cold day when it is difficult to
start the diesel engine, screw out the screw
plug on the cover of the diesel engine and fill
in 2 ml of lube oil.
CAUTION: When filling oil, the plug
screw should be screwed tightly on the
cover to prevent dust and moisture
sucked into the cylinder and can cause
accelerated wear of internal parts.