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DuroStar PS500 User Manual

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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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  • Page 1 All manuals and user guides at all-guides.com 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.
  • Page 2 All manuals and user guides at all-guides.com...

  • Page 3: Table Of Contents

    All manuals and user guides at all-guides.com 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 ....................
  • Page 4 All manuals and user guides at all-guides.com 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 ..................
  • Page 5 All manuals and user guides at all-guides.com...

  • 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

    All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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.

  • Page 10: Quick Start Guide

    All manuals and user guides at all-guides.com 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.

  • Page 11: Connect Devices

    All manuals and user guides at all-guides.com 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.

  • Page 12: Generator Components

    All manuals and user guides at all-guides.com 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.
  • Page 13 All manuals and user guides at all-guides.com 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.

  • Page 14: Package Contents

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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: Step 1 - Adding Oil

    All manuals and user guides at all-guides.com GENERATOR SETUP Step 1 - Adding Oil The generator requires engine oil to operate properly. The generator, when new from the package contains no oil in the crankcase . You must add the proper amount of oil before operating the generator for the first time.

  • Page 17: Step 2 - Adding Gasoline

    All manuals and user guides at all-guides.com Step 2 - Adding Gasoline WARNING: Gasoline and gas fumes are highly flammable. Do not fill tank near an open flame. ● Do not overfill. Always check for fuel spills. ● To ensure that the generator runs smoothly use only FRESH, UNLEADED GAS WITH AN OCTANE RATING OF 87 OR HIGHER.

  • Page 18: Grounding The Generator

    All manuals and user guides at all-guides.com 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.

  • Page 19: Starting The Generator

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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.
  • Page 23 All manuals and user guides at all-guides.com 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.
  • Page 24 All manuals and user guides at all-guides.com...

  • Page 25: Using The Generator

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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 ●...
  • Page 27 All manuals and user guides at all-guides.com 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...

  • Page 28: Connecting A Load To The Generator

    All manuals and user guides at all-guides.com 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.
  • Page 29 All manuals and user guides at all-guides.com 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.
  • Page 30 All manuals and user guides at all-guides.com...

  • Page 31: Maintenance And Care

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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.

  • Page 33: Maintenance Log

    All manuals and user guides at all-guides.com MAINTENANCE LOG Date Generator Hours Maintenance Performed...

  • Page 34: Checking The Oil

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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.

  • Page 38: Spark Plug Maintenance

    All manuals and user guides at all-guides.com 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: Replace Spark Plug

    All manuals and user guides at all-guides.com 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.

  • Page 40: Storage And Transportation

    All manuals and user guides at all-guides.com 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). Disconnect the spark plug.

  • Page 41: Specifications

    All manuals and user guides at all-guides.com 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.
  • Page 42 All manuals and user guides at all-guides.com...

  • Page 43: Troubleshooting

    All manuals and user guides at all-guides.com TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator.

  • Page 44: Basic Troubleshooting

    All manuals and user guides at all-guides.com 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...

  • Page 45: Changing / Inspecting The Carbon Brushes

    All manuals and user guides at all-guides.com 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

    All manuals and user guides at all-guides.com 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 –...
  • Page 47 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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.
  • Page 49 All manuals and user guides at all-guides.com Replace generator cover Replace the back cover of the generator and secure with the 2 bolts.

  • Page 50: Wiring Diagram

    All manuals and user guides at all-guides.com WIRING DIAGRAM...
  • Page 51 All manuals and user guides at all-guides.com...

  • 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

    All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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”...
  • Page 55 All manuals and user guides at all-guides.com Hoses, belts, connectors, and assemblies. Exhaust Emission Warranty Parts List. Evaporative Emission Warranty Part List Fuel Metering System Fuel Tank* Carburetor and internal parts (and/or Fuel Cap pressure regulator or fuel injection system). iii.

  • Page 56: Customer Service

    All manuals and user guides at all-guides.com 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...
  • Page 57 All manuals and user guides at all-guides.com...
  • Page 58 All manuals and user guides at all-guides.com 5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX...

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