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DS1500 GENERATOR
User Manual
REV: DS1500-01242018
5800 Ontario Mills Pkwy
Ontario, CA 91764 USA
This manual provides information regarding the operation
www.duromaxpower.com
and maintenance of these products. We have made every
effort to ensure the accuracy of the information in this
Call our Customer Care Team Toll Free 8-5pm PST Mon-Fri
manual. We reserve the right to change this product at
844-DUROMAX
any time without prior notice.
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Table of Contents
Troubleshooting
Related Manuals for DuroStar DS1500
Summary of Contents for DuroStar DS1500
- Page 1 DS1500 GENERATOR User Manual REV: DS1500-01242018 5800 Ontario Mills Pkwy Ontario, CA 91764 USA This manual provides information regarding the operation www.duromaxpower.com and maintenance of these products. We have made every effort to ensure the accuracy of the information in this Call our Customer Care Team Toll Free 8-5pm PST Mon-Fri manual.
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Page 3: Table Of Contents
CONTENTS Introduction Introduction ........................6 General Safety Procedures .................... 7 Quick Start Guide ......................10 Generator Components ....................12 Package Contents ......................14 Generator Setup Adding Oil ........................16 Adding Gasoline ......................17 Grounding the Generator .................... 18 High Altitude Operation ....................18 Starting the Generator Checking the Oil ...................... - Page 4 CONTENTS Maintenance and Care Maintenance Schedule ....................32 Maintenance Log ......................33 Checking the Oil ......................34 Changing the Oil ......................35 Cleaning the Air Cleaner ....................36 Spark Plug Maintenance ....................38 Storage and Transportation ..................40 Specifications ......................... 41 Troubleshooting Basic Troubleshooting ....................
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Page 6: Introduction
STOP Please do not return to store. Durostar 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. -
Page 7: General Safety Procedures
GENERAL SAFETY PROCEDURES SAFETY ALERT SYMBOL 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 this manual and on the generator. Please familiarize yourself with the following safety symbols and words: DANGER: Indicates a hazard that will result in serious injury or death if instructions are not ●... - Page 8 GENERAL SAFETY PROCEDURES WARNING: This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death. A nearby open flame can lead to an explosion even if not directly in contact with gas. Do not operate near an open flame. ●...
- Page 9 GENERAL SAFETY PROCEDURES In addition to the above safety notices, please familiarize yourself with the safety and hazard markings on the generator. DANGER TO REDUCE THE RISK OF INJURY OR DEATH . Read owner/operator manual before operating generator. Do not operate generator under wet conditions. electric shock can occur.
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Page 10: Quick Start Guide
QUICK START GUIDE Add oil The oil fill cap is located on the lower engine block to the right of the recoil start housing. Remove the oil fill cap and fill with 10w30 oil. Add gasoline The fuel cap is located on top of the fuel tank. Fill the tank with fresh unleaded gasoline 87 octane or higher. - Page 11 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. CAUTION: DO NOT let go of the handle while the rope is extended this may cause damage to yourself or your machine.
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Page 12: Generator Components
GENERATOR COMPONENTS 1. Volt Meter 2. Choke Lever 10. 110V 3-Prong Receptacle 3. Fuel Valve 9. 5.3A T-Shaped 12v Outlet 4. Air Cleaner 8. Ground Terminal 7. Engine Switch 5. Recoil Start 6. Oil Fill and Dipstick 1. Volt Meter - Provides reading of voltage output. 2. - Page 13 14. Fuel Filter Cup 13. Fuel Gauge 15. Fuel Cap 12. Spark Plug 11. Muffler 10. 110v 3-Prong Receptacle - Use to connect electrical devices that run 110 Volt, 60 Hz, single phase, AC current (NEMA 5-20). 11. Muffler – Reduces engine emissions and reduces noise. 12.
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Page 14: Package Contents
PACKAGE CONTENTS Your generator comes with the items listed below. Please check to see that all of the following items are included with your generator. DC Charging Cables Used to charge batteries. Spark Plug Wrench Used in spark plug maintenance, inspection, and installation. -
Page 15: Generator Setup
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: Adding Oil
. You must add the proper amount of oil before operating the generator for the first time. This amount is equal to the oil capacity of the engine crankcase: Model Number DS1500 Engine Oil Capacity 13.5 fl. oz (0.4L) WARNING: Do not apply engine oils with additives or 2-stroke gasoline engine oils. They don’t have enough lubrication, and may shorten the engine’s service life. -
Page 17: Adding Gasoline
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. Model Number DS1500 Gas Tank Capacity 1.59 US Gallons (6L) -
Page 18: Grounding The Generator
GENERATOR SETUP (CONTINUED) Step 3 - Grounding the Generator Attach grounding wire Ground the generator by tightening the grounding nut against a grounding wire. Connect the other end to a copper or brass grounding rod that’s driven into the earth. A generally acceptable grounding wire is a No. -
Page 19: Starting The Generator
STARTING THE GENERATOR If this is not your first time using the generator there 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”... -
Page 20: Checking The Oil
BEFORE YOU START YOUR GENERATOR Step 1 - Check the oil Check the oil The generator is equipped with an automatic shutoff to protect it from damage due to low oil. Nonetheless, you should check the oil level of the engine before each use to ensure that the engine crankcase has a sufficient amount. -
Page 21: Check The Gas Level
Step 2 - Check the gas level Check Fuel Level Before starting the generator, check to see that there is sufficient gasoline in the fuel tank. WARNING: Gasoline and gasoline fumes are highly flammable. Do not fill tank near an open flame. ●... -
Page 22: Starting The Generator
STARTING THE GENERATOR Starting the Generator Using Gasoline 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. Close choke The choke lever is located above the air filter to the right of the recoil start. - Page 23 Open choke Push the choke to the OPEN position as the engine warms up. CAUTION: Disconnect all electrical loads from the generator before attempting 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.
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Page 25: Using The Generator
USING THE GENERATOR If this is not your first time using the generator there 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”... -
Page 26: Ac Usage
USING THE GENERATOR AC Usage ● You may connect electrical devices running on AC current according to their wattage requirements. The chart below shows the rated and surge wattage of your generator according to its model ● number. ● The rated wattage corresponds to the maximum wattage the generator can output on a continuous basis. - Page 27 Tool or Appliance Rated (Running) Watts Additional Surge Watts Electric water heater (40 gal) 4000 Hot plate 2500 Radial arm saw 2000 2000 Electric Stove 1500 Circular Saw 1500 1500 Air compressor (1 HP) 1500 3000 Window air conditioner 1200 1800 Miter saw 1200...
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Page 28: Connecting A Load To The Generator
USING THE GENERATOR (CONTINUED) Connecting a load to the generator NOTE: Be sure to attach devices to the correct receptacle (outlet). 110v devices can be directly connected to the 110v ONLY receptacles. ● CAUTION: Do not connect 240V loads to the generator. CAUTION: Do not connect 50Hz or 3-phase loads to the generator. - Page 29 Choosing the right power cord Long or thin cords can drain the power provided to an electrical device by the generator. When using such cords, allow for a slightly higher rated wattage requirement for the electrical device. See table below for recommended cords based on the power requirement of the electrical device. DEVICE REQUIREMENTS WIRE GAUGE BY LENGTH (ft.) AMPS...
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Page 31: Maintenance And Care
MAINTENANCE AND CARE Proper maintenance 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. -
Page 32: Maintenance Schedule
MAINTENANCE AND CARE Proper routine maintenance of your generator is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. WARNING: Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously injured or killed. Always follow the inspection and maintenance recommendations and schedules in this instruction manual. -
Page 33: Maintenance Log
MAINTENANCE LOG Date Generator Hours Maintenance Performed... -
Page 34: Checking The Oil
MAINTENANCE AND CARE (CONTINUED) Checking the oil Check the oil The generator is equipped with an automatic shutoff to protect it from damage due to low oil. Nonetheless, you should check the oil level of the engine before each use to ensure that the engine crankcase has a sufficient amount. -
Page 35: Changing The Oil
Changing the oil Worn out or dirty oil does not cool the generator properly and can lead to catastrophic engine damage. In addition to regular oil changes, it is necessary to drain the oil from the crankcase if it has become contaminated with water or dirt. -
Page 36: Cleaning The Air Cleaner
MAINTENANCE AND CARE (CONTINUED) Cleaning the air cleaner Routine maintenance of the air cleaner helps maintain proper airflow to the carburetor. Check that the air cleaner is free of excessive dirt after every use. Note: Improper maintenance may cause less air to enter the engine or dirty air to enter the engine causing overheating and engine wear. - Page 37 Wash cleaner element Wash the sponge-like elements in household dish detergent and warm water. Dry cleaner element Allow the elements to dry completely. Add engine oil to elements Soak the dry elements in a small amount of engine oil. Ring out any excess oil.
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Page 38: Spark Plug Maintenance
MAINTENANCE AND CARE (CONTINUED) Spark Plug Maintenance The spark plug is important for proper engine operation. A good spark plug should be intact, free of deposits, and properly gapped. Improper maintenance may cause reduced fuel economy, misfires, trouble starting, or damage to the spark plug threads. - Page 39 Measure plug gap Measure the plug gap with a gauge. The gap should be 0.7-0.8 mm (0.028-0.031 in). Clean and re-gap 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.
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Page 40: Storage And Transportation
MAINTENANCE AND CARE (CONTINUED) Storage and Transportation CAUTION: Never place any type of storage cover on the generator while it is still hot. When transporting your generator: Empty the gas tank (see “Emptying the Gas Tank” in the “Maintenance” section). ●... -
Page 41: Specifications
SPECIFICATIONS AC Rated Wattage (Gasoline) 1200W AC Surge Wattage (Gasoline) 1500W AC Rated Voltage 110V AC Rated Frequency 60 Hz AC Phase Single DC Voltage 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... -
Page 43: Troubleshooting
TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator. -
Page 44: Basic Troubleshooting
TROUBLESHOOTING Mode Description Engine Switch is “Off” Set engine switch to “run” Fuel Valve is “Closed” Turn fuel valve to “open” Choke is open Close the choke Engine is out of fuel Add fuel Engine will not start Fuel is old or contaminated Change fuel Spark Plug is dirty Clean spark plug... -
Page 45: Changing / Inspecting The Carbon Brushes
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 the 2 bolts of the generator cover then pull the cover off the generator. -
Page 46: Changing / Inspecting The Avr
TROUBLESHOOTING (CONTINUED) Changing / Inspecting the Carbon Brushes (Cont.) Install new brush Install new carbon brush with bolt. Connect AVR wires Insert and connect the 2 wires from the AVR, be sure to connect + and – correctly. Replace generator cover Replace the back cover of the generator and secure with the 2 bolts. - Page 47 Changing / Inspecting the AVR The carbon brushes in conjunction with the AVR regulates power from the generator. If the generator is overheated or overloaded, the AVR may be damaged and require replacement. Remove generator cover Remove the 2 bolts of the generator cover then pull the cover off the generator.
- Page 48 TROUBLESHOOTING (CONTINUED) Changing / Inspecting the AVR (Continued) Disconnect wires from brush Remove the 2 wires from the AVR on the carbon brush. Install new AVR Install the new AVR with the 2 bolts. Reconnect wires to brush Reconnect the wire clip. Reconnect the AVR wire clip Insert and connect the 2 wires from the AVR, be sure to connect + and –...
- Page 49 Replace generator cover Replace the back cover of the generator and secure with the 2 bolts.
- Page 50 WIRING DIAGRAM...
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Page 52: Warranty
Warranty Limitations DuroMax/DuroStar Power Equipment does not claim or hold any obligation to loss of time, freight charges, use of product, or any incidental damages from the use of this product. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. - Page 53 OWNER’S WARRANTY RESPONSIBILITIES: As the small off-road engine owner, you are responsible for performance of the required ● maintenance listed in your owner’s manual. DuroMax Power Equipment recommends that you retain all receipts covering maintenance on your small off-road engine, but DuroMax Power Equipment cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.
- Page 54 WARRANTY (CONTINUED) 1. Any warranted part that is scheduled only for regular inspection in the Owner’s Manual must be warranted for the warranty period stated above. A statement in such written instructions to the effect of “repair or replace as necessary” will not reduce the period of warranty coverage. Any such part repaired or replaced under warranty must be warranted for the remaining warranty period.
- Page 55 Exhaust Emission Warranty Parts List. Hoses, belts, connectors, and assemblies. Fuel Metering System Evaporative Emission Warranty Part List Carburetor and internal parts (and/or Fuel Tank* pressure regulator or fuel injection Fuel Cap system). iii. Fuel Line Fuel Line Fittings Air/fuel ratio feedback and control Clamps** system.
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Page 56: Contact Information
CUSTOMER SERVICE Duromax Power Equipment is comitted to ensuring that our products perform when they need to. Our generators 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... - Page 58 5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX...