DUROMAX DUAL FUEL HYBRID ELITE XP11500EH User Manual Download Page 65

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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 AVR bolts

Disconnect AVR wire clip

Remove the 2 bolts of the generator cover then pull the cover

off the generator.

Remove the 2 bolts holding the AVR.

Disconnect the wire clip.

Summary of Contents for DUAL FUEL HYBRID ELITE XP11500EH

Page 1: ...ri 844 DUROMAX XP11500EH GENERATOR User Manual REV XP11500EH 02192020 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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Page 3: ...rator Using Recoil Start 36 Starting the Generator 3 Shipping Braces 20 Wheel Kit Installation 21 Connect the Battery 22 Adding Oil 23 Adding Gasoline 24 Grounding the Generator 25 High Altitude Operation 25 Generator Setup 5 AC Usage 40 Connecting a Load to the Generator 42 Using the Digital Multimeter 44 Using the Generator 2 Quick Start Guide Gasoline 12 Quick Start Guide Propane 14 Generator C...

Page 4: ...52 Spark Plug Maintenance 54 Emptying the Gas Tank 56 Cleaning the Fuel Filter Cup 58 Storage and Transportation 59 Specifications 60 70 Basic Troubleshooting 62 Changing Inspecting the Carbon Brushes 63 Changing Inspecting the AVR 65 Wiring Diagram 68 Maintenance and Care Warranty Troubleshooting 9 74 Contact Information ...

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Page 6: ...storm that knocks out power draining a flooded property or washing away a deck for the summer season Engines that are certified to comply with U S EPA emission regulations for SORE Small off Road Equipment are certified to operate on regular unleaded gasoline and may include the following emission control systems EM Engine Modifications and TWC Three Way Catalyst if so equipped 6 STOP Please do no...

Page 7: ... can exceed 150 F 65 C Do not touch hot surfaces Pay attention to warning labels on the generator denoting hot parts of the machine Allow generator to cool several minutes after use before touching engine or areas which heat during use 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 ...

Page 8: ...disconnect the spark plug WARNING This generator produces a powerful voltage which can result in electrocution ALWAYS ground the generator before using it see the Grounding the Generator portion of the PREPARlNG THE GENERATOR FOR USE section Generator should only be plugged into electrical devices either directly or with an extension cord NEVER connect to a building electrical system without a qua...

Page 9: ...In addition to the above safety notices please familiarize yourself with the safety and hazard markings on the generator GENERAL SAFETY PROCEDURES 9 ...

Page 10: ...ice in the future If you have a paper receipt staple it here for easy reference If you purchased the unit online save the email receipt where you can access it and record your details here for convenience in the future Purchase Date ____________________________________________ Order Number ____________________________________________ Retailer Name _____________________________________________ Seri...

Page 11: ...QUICK START Quick Start of your generator is the minimum necessary setup that will get you going as soon as possible Be sure to read the instructions starting on pg 20 for full setup instructions 11 ...

Page 12: ...ll when you see fuel in the bottom of the fuel filter cup DO NOT overfill the tank 3 Turn gas valve on The gas valve is located above the recoil start on the bottom of the fuel tank Rotate the valve counterclockwise to the vertical position to turn on the gas supply 5 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 ...

Page 13: ...rease air into the carburetor for normal running 8 Connect devices Connect your devices to the receptacles on the front panel Start with the largest loads first 10 Start generator The engine switch is located on the left side of the front power panel Press the top Start position on the rocker switch to start the generator Allow the switch to return to the run position once started 7 Turn breaker o...

Page 14: ...tarting the generator 3 Connect propane hose The propane regulator is located on the frame of the generator below the OHV valve cover on the rear of the generator Ensure the propane hose is securely connected to the regulator 5 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 2 Turn gas valve off ...

Page 15: ...the right side of the front power panel Flip the breaker up to allow power to flow to the receptacles Connect your devices to the receptacles on the front panel Start with the largest loads first 10 7 Open choke The choke lever is located above the air filter to the left of the recoil start Slide the lever to the right to open the choke and increase air into the carburetor for normal running 9 Sta...

Page 16: ...v 3 Prong Twist Lock Use to connect electrical devices that run 120 Volt 60 Hz single phase AC current L5 30 5 120v 3 Prong Receptacle Use to connect electrical devices that run 120 Volt 60 Hz single phase AC current NEMA 5 20 6 120 240v 4 Prong Twist Lock Use to connect electrical devices that run 120 or 240 Volt 60Hz single phase AC current NEMA L14 30 7 Multimeter Provides reading of voltage ou...

Page 17: ...t the electric start 15 Muffler Reduces engine emissions and reduces noise 16 Gasoline Quick Start Start up instructions using gasoline as the fuel source 17 Warnings Safety and regulatory warning panel 18 Gasoline Quick Start Start up instructions using propane as the fuel source 19 Spark plug Provides ignition to the engine 20 Carburetor Provides fuel air mixture to the engine 21 Propane Regulat...

Page 18: ...ew Driver Oil Funnel w hose Spanner Spark Plug Wrench Plug Ends Phillips and slot blade screwdriver used for generator maintenance Used to add oil to the generator without messy spills Assorted wrenches used in generator maintenance and assembly Commonly 8mm 10mm 13mm and 15mm Used in spark plug maintenance inspection and installation Plug heads for the receptacles found on the generator are inclu...

Page 19: ...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 19 ...

Page 20: ...ER Attempt this if you have put fuel or oil in the generator 1 Step 1 Remove Shipping Braces Remove braces The shipping braces prevent engine movement during shipment Flip the generator over and remove the brightly colored braces between the motor and the frame and the wood brace under the generator 2 20 Note Shipping braces can be thrown away They will not be needed again ...

Page 21: ...ptional Install Handles Attach the handles to the brackets on the frame using the provided bolts and nuts Do not over tighten the handles it will prevent free movement 3 Install wheels a Insert wheel bolt through frame and secure with provided nut b Slide one wheel over each axle end and secure with the provided retaining pins 2 ...

Page 22: ... battery One side is connected to ground and the other end needs to be connected to the battery Route the free end to the negative battery terminal c Push the black rubber boot up the wire to expose the connector d Securely connect the free end of the battery cable to the negative battery terminal using the screw and nut from the battery with the screwdriver and wrench from the toolkit e Cover the...

Page 23: ...e s service life a Make sure the generator is on a level surface b Unscrew the oil filler dipstick cap from the engine c Using a funnel add the appropriate amount of oil into the crankcase You will know the crankcase is full when the oil level has reached the lower lip of the opening you have just poured the oil into d Replace oil filler cap Step 4 Adding Oil Engine oil recommended SAE 10W 30 Visc...

Page 24: ...el gauge on the top of the gas tank indicates how much gasoline is in the generator gas tank d Replace fuel cap and wipe up any spilled gasoline with a dry cloth NOTE Gas can expand Do not fill the gas tank to the very top Leave a minimum of 1 5 in of open space IMPORTANT Never use an oil gasoline mixture Never use old gas Avoid getting dirt or water in the fuel tank Gas can age in the tank and ma...

Page 25: ...t differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by specific modifications to the carburetor If you always operate your generator at altitudes above 3 000 feet 900 meters have a dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications f...

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Page 27: ...e 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 If you have not yet read this section go back and read it now ...

Page 28: ...ick cap c With a dry cloth wipe the oil off of the stick on the inside of the cap d Insert the dipstick as if you were replacing the cap and then remove again There should now be oil on the stick If there is no oil on the stick or oil only at the very end of the stick you should add oil until the engine crankcase is filled see Adding Oil portion of the Maintenance section e Be sure to replace the ...

Page 29: ...Check the gas level Optional WARNING Gasoline and gasoline fumes are highly flammable Do not fill tank near an open flame Always allow engine to cool for several minutes before refueling DO NOT overfill fuel tank Fuel expands when shaken or heated ALWAY leave 11 2 space or more at the top of the tank ALWAYS use fresh fuel or stabilized fuel Old gasoline older than 30 days can cause permanent damag...

Page 30: ... located above the recoil start on the bottom of the fuel tank Rotate the valve counterclockwise to the vertical position to turn on the gas supply The engine switch is located on the left side of the front power panel Press the top Start position on the rocker switch to start the generator 2 Close choke The choke lever is located above the air filter to the left of the recoil start Slide the leve...

Page 31: ...g 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 31 Turn engine switch to RUN When the engine starts allow the engine switch to return to the RUN position 5 Open choke Push the choke to the OPEN position as the engine warms up 6 ...

Page 32: ...e fuel tank Rotate the valve counter clockwise to the horizontal position to stop the flow of gasoline to the carburetor 2 Connect propane hose The propane regulator is located on the frame of the generator below the OHV valve cover on the rear of the generator Ensure the propane hose is securely connected to the regulator 3 Connect propane tank There propane hose is located on the left side of th...

Page 33: ...t of the recoil start Slide the lever to the right to open the choke and increase air into the carburetor for normal running 5 6 Start The engine switch is located on the left side of the front power panel Insert the switch and turn to the start position to start the generator Allow the switch to return to the on position once started Close choke The choke lever is located above the air filter to ...

Page 34: ...ces to generator ONLY after the engine runs smoothly There may be remnant gasoline in the carburetor this can cause unsteady engine performance for several minutes 3 If the propane gas leaks shut off the LPG supply first and then quickly unplug or turn off any electrical devices powered by the unit 4 When stopping the engine unplug or turn off any electrical devices turn off the Main Circuit Break...

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Page 36: ...art Select your fuel Turn engine switch to RUN If using gasoline see step 2 on pg 30 If using propane see steps 2 4 on pg 32 The engine switch is located on the left side of the front power panel Press the engine switch to the RUN position 2 Close choke The choke lever is located above the air filter to the left of the recoil start Slide the lever to the left to cut the air supply and allow more g...

Page 37: ... left side panel next to the air filter Pull the recoil handle slowly until resistance is felt then quickly pull the recoil handle until fully extended 5 Open choke After the engine has started Push the choke to the OPEN position as the engine warms up 6 Turn breaker on connect The breaker is located on the right side of the front power panel Flip the breaker up to allow power to flow to the recep...

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Page 39: ... 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 If you have not yet read this section go back and read it now 39 ...

Page 40: ...ed wattage of the generator itself To calculate the total wattage requirement of the electrical devices you wish to connect find the rated or running wattage of each device This number should be listed somewhere on the device or in its instruction manual If you cannot find this wattage you may calculate it by multiplying the Voltage requirement by the Amperage drawn Watts Volts x Amps If these spe...

Page 41: ...ectric drill 600 900 Television 500 0 Deep freezer 500 800 Garage door opener 480 600 Stereo 400 0 Box fan 300 600 Clock radio 300 0 Security system 180 0 DVD Player 100 0 Common light bulb 75 0 CAUTION The generator can only run at its surge wattage capacity for a very short time Connect only electrical devices requiring a rated running wattage equal to or less than the rated wattage of the gener...

Page 42: ...LY be connected the 240v receptacle Plug in devices Turn breaker on Turn on connected devices Plug in devices to the appropriate receptacle When using the generator balance the load as closely as possible Placing more load on one side of the circuit will reduce the breaker trip period Flip the circuit breaker up to the on position to allow power to the receptacles Start or turn on appliances start...

Page 43: ...l device See table below for recommended cords based on the power requirement of the electrical device DEVICE REQUIREMENTS WIRE GAUGE BY LENGTH ft AMPS WATTS 120 240V 10 25 50 100 150 5 600 1200 18 16 14 12 10 10 1200 2400 16 14 12 12 10 15 1800 3600 14 14 12 12 10 20 2400 4800 12 12 12 10 10 25 3000 6000 12 10 10 10 8 30 3600 7200 10 10 10 8 NR 40 4800 9600 8 8 6 6 NR 50 6000 12000 6 6 6 NR NR NR...

Page 44: ...e Press the MODE button to cycle through the multimeter functions Using the digital multimeter Voltage The voltage currently produced by the generator in volts 1 Frequency The frequency currently produced by the generator in Hz 2 Hours Run The number of hours the engine has currently been running 3 44 ...

Page 45: ...45 Hours Total The number of hours the generator has been run in total 4 ...

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Page 47: ...nce 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 47 ...

Page 48: ... instruction manual Make sure the engine is off before you begin any maintenance or repairs Let the engine and exhaust system cool before touching To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts SERVICE REGULAR SERVICE PERIOD BEFORE E...

Page 49: ...MAINTENANCE LOG Date Generator Hours Maintenance Performed 49 ...

Page 50: ... Unscrew the oil filler dipstick cap c With a dry cloth wipe the oil off of the stick on the inside of the cap d Insert the dipstick as if you were replacing the cap and then remove again There should now be oil on the stick If there is no oil on the stick or oil only at the very end of the stick you should add oil until the engine crankcase is filled see Adding Oil portion of the Maintenance sect...

Page 51: ...nated with water or dirt Remove drain plug Drain oil Replace drain plug Using a 12 mm hex wrench unscrew the oil drain plug which is located on the crankcase underneath the oil filler dipstick cap Allow all the oil to drain from the generator Drain oil into an approved oil disposal container Contact your local auto parts store for information on oil disposal Replace the oil drain plug and tighten ...

Page 52: ...less air to enter the engine or dirty air to enter the engine causing overheating and engine wear MAINTENANCE AND CARE CONTINUED Cleaning the air filter Open filter cover Remove filter element Wipe out filter casing Unhinge the clasps at the top and bottom of the air cleaner cover Remove the sponge like elements from the casing Wipe the dirt from inside the empty air cleaner casing 1 2 3 52 ...

Page 53: ... and replace the cover 7 53 Wash filter element Wash the sponge like elements in household dish detergent and warm water 4 Dry filter element Allow the elements to dry completely 5 6 Add engine oil to elements Soak the dry elements in a small amount of engine oil Ring out any excess oil ...

Page 54: ...plug threads Spark Plug Maintenance Remove spark plug cap Remove spark plug Inspect spark plug Pull on the spark plug cap to remove it Unscrew the spark plug from the generator using the spark plug wrench included with this product Visually inspect the spark plug If it is cracked or chipped discard and replace with a new spark plug We recommend using a F6RTC spark plug such as NGK BPR5ES 1 2 3 MAI...

Page 55: ...nd re gap Replace spark plug Replace spark plug cap 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 Screw the spark plug back into its place on the generator using the spark plug wrench Replace the spark plug cap 5 6 7 55 ...

Page 56: ... Turn the fuel valve to the OFF position Remove the fuel filter cup see Removing the Fuel Filter Cup earlier in this section Empty the fuel filter cup of any fuel 1 2 3 CAUTION Do not store fuel from one season to another Gasoline sold at the pump today contains additives such as ethanol that even when stored properly may damage the fuel system components MAINTENANCE AND CARE CONTINUED 56 ...

Page 57: ...lve to the ON position Drain all the gas from the generator 4 Shut fuel valve off Replace fuel filter cup Store emptied gas Turn the fuel valve to the OFF position Reinstall the fuel filter cup Store the emptied gasoline in a suitable place and add fuel stabilizer to keep fuel fresh and usable 5 6 7 57 ...

Page 58: ...ion 1 Cleaning the fuel filter cup Remove fuel filter cup Clean filter cup Replace fuel filter cup Unscrew the fuel filter cup from the fuel valve using a wrench Turn the valve towards you to unscrew Clean the cup of all sediment using a rag or brush Reinstall the fuel filter cup 2 3 4 58 ...

Page 59: ...unit to run 3 5 minutes 3 Turn off the fuel valve 4 Allow the unit to stall out 5 Turn off the switch 6 Add fuel stabilizer to the gas remaining in the tank 7 Store If you do not plan to start the unit for longer than 30 days 1 Turn off the main breaker 2 Allow the unit to run 3 5 minutes 3 Turn off the fuel valve 4 Allow the unit to stall out 5 Turn off the switch 6 Drain the fuel tank See Emptyi...

Page 60: ...edFrequency 60 Hz AC Phase Single DC Voltage 12V DC Amperage 8 3A Dimensions LENGTH 28in WIDTH 22in HEIGHT 23in Engine Type 4 Stroke OHV Forced Air Ignition System Non Contact Transistor Displacement 457cc Starting Type Electric Recoil Fuel Tank Capacity 7 9 US Gal 30L Oil Capacity 37 fl oz 1 1L Run Time 50 Gasoline 10 hr Run Time 50 Propane 10 hr 40 lb Noise Level 74db 60 ...

Page 61: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator 61 ...

Page 62: ...l Move generator to a level surface Oil is low Add change oil Engine runs but there is no electrical output Circuit breaker is Off Turn on circuit breaker Wiring connection is bad Replace extension cord s Device connected to generator is malfunctioning Disconnect malfunctioning device Generator runs but does not support all electrical devices connected Generator is overloaded Disconnect 1 or more ...

Page 63: ...bon brushes are wearable parts and should be inspected every 250 running hours Remove generator cover Remove bolt from brush Disconnect AVR wires Remove the 2 bolts of the generator cover then pull the cover off the generator Remove the bolt holding the carbon brush Remove the two wires from the AVR on the carbon brush 1 2 3 63 ...

Page 64: ...ush Install new carbon brush with bolt 4 Connect AVR wires Insert and connect the 2 wires from the AVR be sure to connect and correctly 5 6 Replace generator cover Replace the back cover of the generator and secure with the 2 bolts TROUBLESHOOTING CONTINUED 64 ...

Page 65: ...or If the generator is overheated or overloaded the AVR may be damaged and require replacement Remove generator cover Remove AVR bolts Disconnect AVR wire clip Remove the 2 bolts of the generator cover then pull the cover off the generator Remove the 2 bolts holding the AVR Disconnect the wire clip 1 2 3 65 ...

Page 66: ...to connect and correctly 7 Disconnect wires from brush Remove the 2 wires from the AVR on the carbon brush 4 Install new AVR Install the new AVR with the 2 bolts 5 6 Reconnect wires to brush Reconnect the wire clip Changing Inspecting the AVR Continued TROUBLESHOOTING CONTINUED 66 ...

Page 67: ...Replace generator cover Replace the back cover of the generator and secure with the 2 bolts 8 67 ...

Page 68: ...WIRING DIAGRAM 68 ...

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Page 70: ...PRESSED OR IMPLIED U S EPA AND CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board The United States Environmental Protection Agency US EPA and DuroMax Power Equipment are pleased to explain the emission control system warranty on your 2020 2021 year small off road engine In the United States and California new small off road engin...

Page 71: ...844 387 6629 WEBSITE www duromaxpower com ADDRESS 5800 Ontario Mills Pkwy Ontario CA 91764 This telephone number is only for the engines which the company name DuroMax Power Equipment on the emission label DEFECTS WARRANTY REQUIREMENTS a The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser b General Emissions Warranty Coverage DuroMax Power Equipment...

Page 72: ...isions of Subsection 4 above warranty services or repairs must be provided at all DuroMax Power Equipment distribution centers that are franchised to service the subject engines 6 The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective provided that such diagnostic work is performed at a warranty station 7 DuroMax Power Equipmen...

Page 73: ...tor spacer if applicable ii EGR rate feedback and control system 5 Air Injection System i Air pump or pulse valve ii Valves affecting the distribution of flow iii Distribution manifold 6 Catalyst or Thermal Reactor System i Catalytic converter ii Thermal reactor iii Exhaust manifold 7 Particulate Controls i Traps filters precipitators and any other device used to capture particulate emissions 8 Mi...

Page 74: ...ors 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 Customer Service Hours 8 5pm PST Website www duromaxpower com Email customerservice duromaxpower com ...

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Page 76: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX ...

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