DuroStar DS7000Q Owner's 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.