OWNER’S MANUAL Air – Cooled Diesel Engine Generator Set Max Tool Customer Service Email support@maxtool.com or Call 1-800-629-3325 (option 3) Monday – Friday 7am to 5pm PST Product Support (Product: information, application, service info & warranty questions) Email support@maxtool.com 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.
- - - - 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.
- - - - - - - - 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.
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 ............................................................................
MAIN TECHNICAL SPECIFICATION 1.1 Main technical specification Type of set DS7000Q Item Kind Single phase Frequency (HZ) 60 Max power (kw) 5.0 Max output (kiva) 4.5 Voltage (AC) V 120/240 Self-excitation Brushless Generator Revolution (rpm) 3600 Voltage (DC) V 12 Current (DC) A 8.
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.
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.
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. Type Volume The effective volume of fuel Air Filter Element Don’t wash the air filter element because the component is a dry type.
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 Volume(L) British(gal) DS7000 Series DS7000Q 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.
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, 3.3 Bleed Air from the Fuel Line the system will automatically shut off the engine to avoid If the engine is having difficulty starting and the damaging while the ignition key is still in the ON position.
START GENERATOR 4.2 Electric Start (1) Disconnect all loads to generator. 4.3 Battery Application If your generator is used for the first time, you (2) Turn the main switch to “OFF” position. should fill electrolyte in the battery. For detailed (3) Turn the fuel cock to “ON” position. steps, please refer to your battery instructions. (4) Turn the ignition key to “ON” position. Wait a Check the level of electrolyte of the battery once few moments and then turn the key to “START” a month.
OPERATE YOUR GENERATOR 5 Operation for Generator Set If you find one of the above-mentioned issues, 5.1 Handle the Diesel Engine it is necessary to turn off machine. Please 5.1.1 Avoid overload contact the dealer. While your diesel engine is new, applications 5.3 Generator Operation Speed of heavy loading may shorten the engine’s life. The generator must be run at the correct It must run a light load within the first 20 hrs.
OPERATE YOUR GENERATOR SET The slight variation has no appreciable effect in 6.Load application the operation of motors, lights, and most 6.1 Determine total electrical load appliances. Electronic equipment may be It is important to determine the total electrical affected if correct speed is not maintained. load before connecting to the generator.
LOAD APPLICATION Use this chart to estimate the total load on your generator For determining generator load requirements Device Air Conditioner(12,000BTU) Battery Charger (20Amp) Belt Sander Chain Saw Circular Saw (6-12) Coffee Maker Compressor (3/4HP) Compressor(1/2HP) Curling Iron Dishwasher Edge Trimmer Electric Nail Gun Electric Range (1 Element) Electric Skillet Furnace Fan (1/3) Freezer Hair Dryer Hand Drill Hand Drill Hand Drill Hand Drill Hedge Trimmer Home Computer Impact Wrench Jet Pump Lawn Mower
LOAD APPLICATION To hard start load such as an air compressor or air conditioner, consult the dealer to determine the max power. Generator responds to severe overloading differently than the power line. When overloading, the engine is not able to supply enough power to bring the electric motor to operating speed. The generator responds to the high initial starting current but the engine speed drops dramatically. Overloading may stall the engine.
LOAD APPLICATION / STOPPING THE GENERATOR / GENERATOR MAINTENANCE NOTE: The DC output current should not 7 Stop the Generator Set be more than 8.3A, when charging the Disconnect all loads from the generator set. large capacity battery. The fuse from the Set the speed lever of the engine to the DC power supply may burn off and can “RUN” position. Operate the diesel engine for break easily for large charging current. about three minutes without load.
MAINTENANCE 8 Maintenance 8.1 Regular maintenance To keep the generator in a good state, the periodic inspections and maintenances are very important. The generator set consists of a diesel engine, generator, control panel, frame and so on. For details about the inspection or maintenance, please refer to the relative operation and maintenance instructions. CAUTION: Before maintenance, please turn off the diesel engine. Disconnect the battery from the generator.
MAINTENANCE 8.1.1 Change lube oil Screw out the dipstick and remove the drain plug. Drain old lube oil while the lube is still hot. The drain plug is located at the bottom of the cylinder block. Fasten the drain plug then fill with the recommended lube oil. Change the lube oil after 20hrs of initial operation or at the end of the first month, and then once every 50hrs for three times, once CAUTION: Never start the diesel every three months, or once every 100 hours engine without the filter element.
MAINTENANCE / INSPECTION / REPAIR / TROUBLESHOOTING 8.1.9 Check and replenish electrolytes of 8.2.6 Clean and store in dry area. battery and charge. 9 Inspection, repair, and trouble shooting. This generator set uses a 12V battery. The 9.1 Doubtful points and problems electrolyte of the accumulator will be lost If you have any questions or problems during through continuous charging and discharging. operation, please contact the dealer.
INSPECTION, REPAIRS, AND TROUBLESHOOTING Cause Not enough Fuel The diesel engine will not start Fuel cock is not in the “ON” position Remedy Add fuel (Diesel) Turn it to the “ON” position High pressure pump and fuel nozzle may Remove the fuel nozzle and clean or not be injecting enough fuel. repair it if necessary Speed control lever is not in the “RUN” Set the control lever to the “RUN” position position Check the level of engine lube oil.
Appendixes: list for comments from users Type Item Name of user Detailed address of user Detailed name of purchase place Condition of packing and unpacking Conditions of operation Conditions of parts wear Malfunction or problem Improvement opinion or request for generator set 23 Date of manufacturing Series number of manufacturing
