OWNER’S MANUAL

Air – Cooled Diesel Engine Generator Set

Max Tool Customer Service

Email [email protected] or Call 1-800-629-3325 (option 3)
Monday – Friday 7am to 5pm PST

Product Support (Product: information, application, service info & warranty questions)
Email [email protected] 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 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
Revolution (rpm) 3600
Voltage (DC) V 12
Current (DC) A 8.3
Optional generator G1
grade
Generator

Power factor cos 1

Steady state voltage +-7%
adjust rate
No-load waveform ·≤10%
distortion rate
Insulation grade ≤15%
Mode of power KD186FA

kind 4-stroke single–cylinder air cooled direct injection

Persistence power (KW) 6.6
Max power (kw) 7.3
Diesel engine

Cylinder diameter* 86×72

stroke (mm)
Cylinder displacement 418
(ml)
Cooling system Force air-cooled
Volume of lube oil (L) 1.65
Start system Electric start
Fuel Diesel fuel
Fuel tank volume (L) 14.5
Working way Continuous operating for 12hours
Set

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 Air Filter Element
3.1 Diesel Fuel, Air Filter Element, and Lube
Oil Don’t wash the air filter element because the
Diesel Fuel component is a dry type. If the output of the
Use clean light diesel fuel only. If the fuel is diesel engine drops or the color of the
dirty, it should be filtered cleanly. exhausted gas changes adversely, change the
Caution: Don’t let any dust or water air filter element immediately. Never start the
mix with the fuel and enter the fuel tank. diesel engine without using the filter element.
Otherwise the high-pressure pump and
the injector nozzle get clogged.

Type DS7000
Volume Series
The effective 14.6
volume of fuel 3.21
tank;(L) British
gal)
Type DS7000Q
Volume
The effective 12.8
volume of fuel 2.82
tank;(L) British
gal)

Caution: Do not let fuel level rise

above Red Mark To check air filter element on silent model,
loosen the four screws from the outside body
Caution: No Smoking near oil or when fixed cover.
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.

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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 DS7000
Series
Volume DS7000Q
Volume(L) 1.65
British(gal) 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, 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. fuel and oil level are acceptable, the problem can
The engine will not start until the oil is refilled to proper usually be traced to air bubbles trapped in the
level. If the diesel engine is running with insufficient lube fuel line. The air should be discharged.
oil, the oil temperature will raise. It is dangerous if there is The correct method is:
too much oil. This may cause lube oil to burn. It can then Turn the fuel cock beneath the fuel tank to the
cause the revolution speed of the diesel engine to OFF position. Disconnect the fuel distributing
increase suddenly and result in abnormal running. For pipe from high pressure pump. Turn the valve to
this purpose, it is necessary to check the lube oil level the ON position and allow fuel to drip from the
and the level should maintain between the low and high fuel line to a small container. Reattach the fuel
level. line to the fuel pump when no air bubbles appear.
3.2.2 Turn off main switch and disconnect all load (For ex: 3.4 Before starting the generator, make sure
lamp and switch of motor). Check for damaged parts, you have done the following:
loose or missing nuts and bolts. If problems occur, please a. The generator is positioned on a firm level
do not start the engine, and consult our dealer. 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.

Before starting the generator set, be sure to turn the main NOTE: On a cold day when it is difficult to
switch to the OFF position. If the switch is not at the OFF start the diesel engine, screw out the screw
position, it can cause damage to the generator and seize plug on the cover of the diesel engine and fill
up the start motor with load to start. in 2 ml of lube oil.

WARNING: The generator should be started

without load. 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.

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 11

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 12

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 START GENERATOR
4.2 Electric Start 4.3 Battery Application
(1) Disconnect all loads to generator. 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. Charging the battery consumes
position. electrolyte. When the liquid level goes down to
(5) After the diesel engine starts, remove your the lower mark, add distilled water to top mark.
hand from the ignition key. Let the switch restore If the electrolyte in the battery is low, the diesel
to “ON” position. engine may not start because the electric power
is insufficient.
CAUTION: When the diesel engine is If the electrolyte in the batter is overfilled, the
running, never draw out the start handle; liquid may spill and it may corrode its
otherwise it will damage the diesel engine. surrounding components.
Charge the battery once a month. For electric
start type generators, it can charge the battery
automatically during the period of operation If
your generator is used for spare power supply,
pay attention to charge time.
NOTE: Keep battery out of reach of children.
Do not allow battery to be un level or tip
DANGER: Charging a battery produces over. Keep vent caps tight and level.
colorless explosive gases which can cause CAUTION: Keep the liquid level of battery
blindness or injury. No smoking, sparks, or between the upper limit and the lower limit.
flames should exist when charging battery. Battery electrolyte contains sulfuric acid
Never charge a visibly damaged or frozen which can cause blindness or burns.
battery.
Note: Some models my come with a
sealed type battery, the above electrolyte
service is not required.

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 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. speed to produce the proper electrical voltage
(1) Avoid overload: Avoid applying any heavy and frequency. The speed of the engine was
load during the initial 20 hrs. carefully adjusted at the factory so the
(2) Change the lube oil regularly: Change the generator produces the proper voltage and
lube oil after 20 hours of initial operation or at frequency.
the end of the first month and then once every WARNING: Do not adjust the speed or fuel
50 hours for 3 times, every 3 months, or every limit bolt of the diesel engine. (They were
1000 hours thereafter. properly adjusted when delivered from
factory) If changed, the engine’s
performance will be affected.

NOTE: The lube oil should be drained while

the diesel engine is hot. If cooled, it is very
difficult to drain the engine oil completely.
5.1.2 Warm up the diesel engine for 5 minutes
without any load.
5.1.3 Check the indicator lamp
Though equipped with low oil pressure Before connecting a load to the generator, the
protection system, it is necessary to check pointer of the voltmeter should be in the green
whether the indicator lamp of oil pressure area to ensure the generator is working
signal lights up. The lube oil alarm indicator properly. Failure to do so could result in
will light when the oil pressure is low or the damage to the equipment plugged into the unit
lube oil is insufficient and the diesel engine will and possible injury.
shut off automatically. The engine will not be All engines tend to slow down when a load is
started until refilling oil to safe level. applied. When the electrical load is connected
5.2 Inspection during the engine running. to the generator, the engine is more heavily
(1) Abnormal sound or vibration; loaded and thus the speed drops slightly. This
(2) Color of exhausted gas, black or white; slight decrease in speed together with the
(3) Excessive change in engine speed; voltage drop results in a slightly lower voltage
(4) Sparking or arcs from generator; when the generator is loaded to its full
(5) Loss of electrical output; capacity than when it is running with no load.
(6) Engine has Fire.
(7) Flame or Smoke.

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 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. The
Output voltage should be checked periodically two major factors in determining the life of a
to ensure continued proper operation of the generator head are: Heat buildup caused by
generating plant and appliances. It can be over loading the generator and corrosive
checked by using an electric clock with a sweep contaminants that attack the wiring insulation. If
second hand timed against a watch or stop the generator is overloaded, the wires become
watch. The clock should be correct within + -2 excessively hot and cause the insulation to
seconds per minute. A qualified technician break down, reducing its ability to resist
should do all speed setting adjustments. corrosive contaminants. Over time the
5.4 Exercising the Generator effectiveness of the insulation is eliminated and
The generator should be operated every four a dead short can result.
weeks. Warm the unit up by starting the engine Always compare the generator nameplate data
and letting it run for 10-15 minutes. This will dry with that of the equipment to be used to ensure
out any moisture that has accumulated in the that watts, volts, amperage, and frequency
windings. This moisture can cause corrosion in requirements are suitable for operating
the winding. Frequent operation of the engine equipment. May require three to ten times more
generator will also ensure that set is operating wattage if influenced by the equipment
properly should it be needed in an emergency. efficiency and power factor.
5.5 How to open the machine case door (Q NOTE: If wattage is not given on equipment
series set) nameplate, approximate wattage may be
Rotate the know switch counter clock wise to determined by multiplying nameplate voltage by
open the door the of mechanical case and carry nameplate amperage
out the daily check. Example: VOLTS × AMPS= WATTS
120V × 5A= 600W
When connecting a resistive load as in
candescent lights, heaters or common electric
power tools, a capacity of up to the generator
full rated wattage output can be used.
When connecting a resistive-inductive load
such as a fluorescent or mercury light,
transformer or inductive coils, a capacity of up
to 0.6 times of the generator full rated output
can be used.

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 LOAD APPLICATION
Use this chart to estimate the total load on your generator
For determining generator load requirements (b) These loads may require up to 15 minutes
Device Running Watts to restart due to its normal build up of
Air 1700(a) compressor.
Conditioner(12,000BTU)
Battery Charger (20Amp) 500 CAUTION: Always allow the generator
Belt Sander 1000 to reach operating speed before a load is
Chain Saw 1200
applied.
Circular Saw (6-12) 900
Coffee Maker 1000 6.2 Starting electric motors
Compressor (3/4HP) 2000a Electric motors require much more current
Compressor(1/2HP) 1800a
Curling Iron 1400a
(amps) to start than to run. Some motors,
Dishwasher 700 particularly low cost split-phase motors, are
Edge Trimmer 500 very hard to start and require 5 to 7 times
Electric Nail Gun 1200
Electric Range (1 1500 more current to start than to run, Capacitor
Element) motors are easier to start and usually require
Electric Skillet 1250 2 to 4 times as much current to start than to
Furnace Fan (1/3) 1200a
Freezer 800b run. Repulsion induction motors are the
Hair Dryer 1200 easiest to start and require 1.5 to 2.5 times as
Hand Drill 1100
Hand Drill 875
much to start than to run.
Hand Drill 500 Most fractional motors take about the same
Hand Drill 250 amount of current to run them whether they
Hedge Trimmer 450
Home Computer 150 are of repulsion-induction (RI). Capacitor
Impact Wrench 500 (CAP) or split –phase (SP) type. The following
Jet Pump 800a chart shows the approximate current required
Lawn Mower 1200
Light Bulb 100 to start and run Cap type and size of 220 volt
Microwave Oven 700 50cycle electric motors under various
Milk Cooler 1100a
conditions.
Oil Burner on Furnace 300
Oil Fired Space 400 220v,50HZ Motors Starting Amps
Htr(14,000Btu) Hp motor Running amps Cap type
Oil Fired Space 225
Htr(85,000Btu) 10.5 2.3 12-16
Oil Fired Space 150 0.75 3.5 17-24
Htr(30,000Btu)
1.1 5 25-35
Oven 4500
Paint Sprayer(1/3HP) 600(a) 1.5 7 34-49
Paint Sprayer Airless 150 2.2 10 50-70
Radio 200
3 15 68-95
Refrigerator 600(b)
Slow Cooker 200 The figures given above are for an average
Submersible 2800(a) load such as a blower of fan. If the electric
Pump(1-1/2HP)
Submersible Pump(1HP) 2000(a) motor is connected to a hard-starting load
Submersible 1500(a) such as an air compressor, it will require more
Pump(1/2HP)
starting current. If it is connected to a light
Sump Pump 600(a)
Table Saw(10i) 2000(a) load or no load such as a power saw. It will
Television 500 require less starting current. The exact
Toaster 1000
Vacuum Cleaner 250
requirement will also vary with the brand or
VCR 70 design of the motor.
Water Heater 3000 CAUTION: To start the motor above
1.5kw power. The G2, G3 grade
(a) Hard-starting motors require 3 to 5 times
generator should be selected and
the rated running watts. method of drop voltage starting must be
carried out. For detailed step, consult
with our dealer or with us directly.

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 LOAD APPLICATION
To hard start load such as an air compressor or (2) When connecting load to the generator,
air conditioner, consult the dealer to determine equipment should be connected in order.
the max power. First connect heavy to light load to
Generator responds to severe overloading generator, then connect restive inductive
differently than the power line. When load, then re-restive load. If operation order
is improper, the engine speed may drop
overloading, the engine is not able to supply
sharply and the load should then be
enough power to bring the electric motor to
disconnected immediately and checked for
operating speed. The generator responds to the
causes.
high initial starting current but the engine speed (3) Balance of three phase generators for
drops dramatically. Overloading may stall the load: When connecting single phase load,
engine. If operated at very low speeds, the each phase cannot exceed 1/3 of generator
electric motor winding will burn out quickly. The rated power and difference between each
generator head winding may get damaged. phase amps’ value should not exceed 20%
Running the generator under these conditions rated current.
may result in damage to the generator stator as CAUTION: Serious misbalanced load
well as the rotor windings because the heavy connected to each phase can cause
surge of current is required for only an instant. burn out of generator set.
The generator will not be damaged if it can If the circuit overload makes the overload
protection switch (main switch) of AC circuit
bring the motor up to speed in a few seconds.
trip, it is necessary to reduce the circuit
Turn off all other electrical loads. If possible,
load. Wait several minutes before restoring
reduce the load on the electric motor.
the operation. If the indication on the
6.3 Extension cords voltmeter is too high or too low. It is
When electric power is provided to various necessary to stop the generator.
loads at some distance, extension cords can be 6.5 DC application
used. These cords should be sized to allow for Both DC terminals provided output: DC12V,
distance in length and amperage so that the 8.3A, the red terminal is I =i(positive)pole of
voltage drop between the set and point of use is power supply. It can be used as load for
held to a minimum. rated voltage DC12V and used for charging
Current/power Cord cuts 12V battery.
Amps Load) Cord Cord Cord Cord
(1) To charge the battery with two leads
connected to the start circuit, the negative
at watts Length length length Length
lead should be disconnected from the
240V 80m 50m 30m 20m
generator.
10 2400 8 4 4 2.5
(2) Connect the positive and negative
15 3600 10 8 6 4
poles of the battery with the positive and
20 4800 10 8 6 6
25 6000 12 10 8 6
negative poles of DC terminal.
30 7200 12 10 10 8 CAUTION: Be careful not to connect
CAUTION: Equipment damage can result positive and negative leads adversely,
from the voltage caused by using an otherwise the generator and the
extension cord with a small wire size. storage battery will be damaged
6.4 AC Application severely. Do not let positive and
(1) Observe the indicating voltmeter on the
negative leads touch each other, or the
control panel. The pointer should be in the
green area for load conditions. storage battery will short circuit.

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 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. Do not stop
DANGER: Charging battery produce the diesel engine dramatically. Doing so can
colorless explosive gases which can cause the engine temperature to rise and
cause blindness or injury. Do not let any result in a blocked injector nozzle damaging
spark, flame or smoking near generator. the engine.
To avoid producing sparks near the Follow steps below to stop engine:
battery, first connect the lead with the (1) Disconnect all loads from generator set.
battery, then connect the lead with the (2) After 3 minutes of running without load,
generator. When disconnecting, battery turn the ignition key to “OFF” position.
disconnect the ground motor cable first. (3) Set the fuel cock lever to “S Position”
Charging the battery should be in a place (4) Turn the fuel cock too “OFF” position.
with good ventilation. Before charging,
open vent caps of battery. If the
temperature of electrolyte is over 45 C,
terminate charging.
6.6 Treat machine with duplex voltages
output.
Before the generator applies AC, power
supply make sure it is the correct rated
voltage of load. Then choose the output
voltage through the transformer switch on the
output panel. Voltage can be measured
through the voltmeter or indicating lamp of CAUTION: When speed lever is set to
power supply at output panel. “STOP” position and the diesel engine is
CAUTION: Before using the voltage still in operation. It is possible to stop the
transformer switch, be sure to disconnect diesel engine by setting the fuel switch
all loads from the generator. “OFF” position or by unfastening the
high-pressure fuel pump nut. Do not break
the diesel engine with the decompression
lever.

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 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. First disconnect the negative cable then the positive.
After using the generator, it is necessary to wipe off the dirt on it with clean cloth to prevent
corrosion and remove the precipitate.
Generator maintenance: The single-phase generator is brushless and maintenance free for
three phase generators, consult with the dealer. Any major generator services including the
installation or replacement of parts should be performed only by a qualified electrical service
technician. Use only factory approved parts.

Service period regular Daily The first month or The third The sixth month or after Every
after 20 hours month or 500 hours year or
after 100 after
hours 1000
Item hours
Check and replenish fuel ○
Drain fuel ○
Check and replenish lube oil ○

Check for fuel leakage ○

Check and fasten every ○ ●
fastening parts Fasten head bolts
Change lube oil (the 1st time) (the ○ (the 5th
next three times time)
change interval
are 50 hours)
Clean the filter of lube oil ○ (change it if necessary)
Chang air filter (service more frequently
when used at dusty areas) (change)
Clean fuel filter ○ change
Check fuel injection pump ●
Check fuel injection nozzle ●
Check fuel pipe (change it if necessary)
Adjust valve clearance for intake ●
and exhaust valves
Mill intake and exhaust valves ●
Replace piston ring ●

Check electrolyte of battery Every month

Note: ● symbol means you need a special wrench, please contact dealer.

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 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. Change
thereafter. any damaged or old filter element when
needed.
8.1.4 Clean and replace the fuel filter
The fuel filter should be cleaned regularly to
insure maximum output power.
Time to be cleaned Every 6 months or
every 500 hours
Time to be replaced Every year or every
1000 hours
(1) Drain the fuel oil from the fuel tank
(2) Loosen the small screw of the fuel cock
and pull out the filter from fuel filling mouth.
Wash it thoroughly with diesel oil.
8.1.2 Clean the lube oil filter (3) Fuel filter on silent type generator is
Loosen the fasten bolt and pull out oil filter to locate beneath the fuel tank, open the case
clean door so you can see it and disassemble.
Time to be cleaned Every 6 months or Clean or replace as necessary.
every 500 hours Time to be cleaned Every 3 months or
Replace it if necessary every 1000 hours
8.1.3 Change the air filter 8.1.5 Fasten cylinder head bolts (refer to
Don’t clean the air filter or air element with operation instructions of diesel engine)
detergent, use a soft brush clean dust 8.1.6 Check the injection nozzle and
accumulated on the external surface of injection pump.
element. 8.1.7 Adjust the valve clearance for the
Time to be cleaned Every 3 months or intake and exhaust valves.
every 100hours 8.1.8 Replace piston ring.
The operations from 8.1.5 to 8.1.8 require
specific tools and skills. Do not try it yourself.
CAUTION: When operating, do not
expose bare skin to fuel spray. The fuel
can penetrate the skin and cause injury.

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 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. You will
Before starting, check the battery for any need to provide the following information.
damage and that its electrolyte level is (1) The type, model and serial number of the
normal. If necessary, replenish distilled water diesel generator set.
in it. If damaged, replace the battery. The cylinder block oil draining bolt locates the
Check electrolyte of battery: Once a month serial number and type. Type and
Voltage of battery: 12V-14V manufacturing date is located on the name
8.2 Maintenance for long time storage. plate.
If your generator should be stored for a long The model number of the diesel generator set
period, the following preparation should be is located on the chassis of the framework for
done: opening type. For the silent type, it is located
8.2.1 Operate the generator set for about on the foundation beside the battery.
15 minutes. (2) Status
8.2.2 Stop the diesel engine. When the What problem occurred when you operated
diesel engine is still hot, drain the old lube the generator set and at what speed?
oil out and fill new oil. (3) How long was your unit operated?
8.2.3 Pull out the screw plug on the cover (4) Operation conditions and time?
of the cylinder head and fill 2 ml of lube For more detailed information, please fill out
oil. Screw the plug tightly on its original an opinion form and mail it to your dealer.
position. 9.2 Inspection, repair and troubleshooting
8.2.4 Maintenance of starting position. If electricity cannot be generated after the
(1) Recoil starting: generator has been serviced following the
Set the fuel cock to “OFF” position. Press the chart of troubleshooting (next page), please
decompression lever down and pull the recoil contact your dealer directly.
handle 2 or 3 times. (Do not start the diesel
engine).
(2) Electric starting:
Set the fuel cock to “OFF” position. Start the
diesel engine about 2-3 seconds. Do not start
the diesel engine.
8.2.5 Pull the decompression lever out and
pull the recoil starter slowly. When you feel, it
fastening, stop? (The intake and drain valve is
closed. It helps prevent rust.)

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 INSPECTION, REPAIRS, AND TROUBLESHOOTING
Cause Remedy
Not enough Fuel Add fuel (Diesel)
Fuel cock is not in the “ON” position Turn it to the “ON” position
High pressure pump and fuel nozzle may Remove the fuel nozzle and clean or
The diesel engine will not start

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. Standard level of lube oil should be
between upper line “H” and lower line
“L”
Speed and force to pull the recoil starter Start the diesel engine as per
is not enough requirements of start procedures of
operation
Fuel nozzle is dirty Clean fuel nozzle
Storage battery exhausted Charge or replace storage battery
Main switch (breaker) is not turned on Turn the switch to the “ON” position
does not produce
The generator

Bad plug or socket contact Adjust the legs of plug

power

The rated speed of generator cannot Adjust to rated speed as per

have reached requirements
Fuse broken Replace fuse
Main breaker may be defective Replace breaker
Rated speed of generator can not Slightly adjust speed lever to rated
Too low of voltage

be reached speed (Confirm that voltage meter is

not defective, replace if necessary)
Voltage meter is broken and pointer Confirm that voltage meter is not
indicates too low defective, replace if necessary
AVR broken or wire disconnected Replace AVR or check wire
(Voltage shows approximately 80V) connections
low oil pressure protection system is Add engine lube oil. Oil level should
Stopped automatically
after running for a

activated be between upper line “H” and lower

line “L”
period

Speed regulating lever of generator Repair and adjust hook surface

switched off or cable/spring came lose.

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 Appendixes: list for comments from users

Type Date of
manufacturing
Series number
Item of
manufacturing
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

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