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DUROMAX XP12000E User Manual Download Page 63

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 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

Summary of Contents for XP12000E

Page 1: ...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 5800 Ontario Mills Pkwy Ontario CA 91764 USA www duromaxpower com Call our Customer Care Team Toll Free 8 5pm PST Mon Fri 844 DUROMAX User Manual REV XP12000E 07072020 ...

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Page 3: ...heck the Gas Level 25 Starting the Generator Using Gasoline 26 Starting the Generator 2 Shipping Braces 18 Wheel Kit Installation 19 Adding Oil 20 Adding Gasoline 21 Grounding the Generator 22 High Altitude Operation 22 Generator Setup 4 AC Usage 32 Connecting a Load to the Generator 34 Voltage Selector Switch 35 DC Usage 36 Using the Generator 3 CONTENTS ...

Page 4: ...4 Spark Plug Maintenance 46 Emptying the Gas Tank 48 Cleaning the Fuel Filter Cup 50 Storage and Transportation 51 Specifications 52 62 Basic Troubleshooting 54 Changing Inspecting the Carbon Brushes 55 Changing Inspecting the AVR 57 Maintenance and Care Warranty Troubleshooting 4 8 66 Contact Information CONTENTS ...

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Page 6: ...daily lives Inevitability when disaster strikes and we are left without power for a prolonged period of time our way of life is put at risk This is by far the most critical time for reliable portable power DUROMAX FOR WORK On the job site portable power allows you the ability to get work done in remote locations when traditional power sources are usually unavailable Equipment like table saws sande...

Page 7: ... simple we are committed to Powering Everyone Anywhere STOP Please do not return to the store DuroMax 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 We want you to be able to put your new generator to use right away CALL US BEFORE YOU CONSIDER RETURNING THE PRODUCT 1...

Page 8: ...st 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 i...

Page 9: ...lve to the off position and 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 The generator should only be plugged into electrical devices either directly or with an extension cord NEVER connect to a building...

Page 10: ...bove safety notices please familiarize yourself with the safety and hazard markings on the generator GENERAL SAFETY PROCEDURES DANGER DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE EXPLOSION OR DEATH 1 5 10 ...

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Page 12: ...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 13: ...utely mandatory to keep your family safe from carbon monoxide But there s even more you can do By educating yourself about all carbon monoxide risks you ll be better prepared to protect your family from this colorless odorless threat Visit takeyourgeneratoroutside com for more information ...

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Page 15: ...QUICK START The 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 25 for full setup instructions ...

Page 16: ...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 Turn breaker off The breaker is located on the right side of the front power panel Flip the breaker down to prevent accidental load when starting the generator 4 QUICK START GUIDE Remove shipping braces The shipping ...

Page 17: ...e switch is located on the left side of the front power panel Press the switch up to the start position to start the generator Allow the switch to return to the run position once started 7 Turn breaker on The breaker is located on the right side of the front power panel Flip the breaker up to allow the power to flow to the receptacles 9 Close choke The choke lever is located above the air filter t...

Page 18: ...erminal Connect a ground wire here to properly ground the generator 8 120v 3 Prong Receptacle Use to connect electrical devices that run 120 Volt 60 Hz single phase AC current NEMA 5 20 9 Battery 12V DC 7ah Battery that powers the Electric Start System 10 Volt Meter Provides reading of voltage output 11 12v DC Charging Posts DC Output for charging batteries or running small DC powered items GENERA...

Page 19: ...enters the engine 16 Fuel Valve On Off Valve that allows fuel into the engine 17 Spark plug Provides ignition to the engine 18 Muffler Reduces engine emissions and reduces noise 120v 3 Prong Twist Lock Use to connect electrical devices that run 120 Volt 60 Hz single phase AC current L5 30 19 120 240v 4 Prong Receptacle Use to connect electrical devices that run 120 or 240 Volt 60Hz single phase AC...

Page 20: ... 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 conjunction with the charging posts to charge 12v automotive style batteries or small DC appliances Used in spark plug maintenance inspection and installation P...

Page 21: ...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 ...

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Page 23: ...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 23 Note Shipping braces can be thrown away They will not be needed again ...

Page 24: ...al Install wheels a Place the wheels onto the axles 4 Install wheel axles a Place the smallest washer onto the wheel axle bolts b Insert wheel axle bolts through the frame and secure with the provided nut and wrenches 2 GENERATOR SETUP CONTINUED Install inside wheel washers a Place one of the large washers onto the axles 3 24 ...

Page 25: ...ckets on the frame using the provided bolts and nuts Do not overtighten the handles it will prevent free movement 7 Install cotter pins a Place the cotter pin through the hole at the end of the axle and bend it out to secure the wheel 6 Flip over assembled a Flip the assembled generator over onto its wheels and support brackets 8 ...

Page 26: ...ove and behind the battery One side is connected to ground and the other end needs to be connected to the battery b Route the free end to the negative battery terminal 2 Connect the negative cable a Push the black rubber boot up the wire to expose the connector b Securely connect the free end of the battery cable to the negative battery terminal using the screw and nut from the battery with the sc...

Page 27: ... 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 the oil filler cap Step 4 Adding Oil Engine oil recommended SAE 10W 30 Vis...

Page 28: ...uns smoothly use only FRESH UNLEADED GAS WITH AN OCTANE RATING OF 87 OR HIGHER 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 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 XP12000E Gas Tank Capacity 8 US Gal 30L DANGER DO NOT OVE...

Page 29: ...at 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 ...

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Page 31: ...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 32: ...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 it 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 ...

Page 33: ...the gas level Optional DANGER DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE EXPLOSION OR DEATH 1 5 WARNING Gasoline and gasoline fumes are highly flammable Do not fill the tank near an open flame Always allow the engine to cool for several minutes before refueling DO NOT overfill the fuel tank Fuel expands when shaken or heated ALWAY leave 11 2 space or more at the top of the tank ...

Page 34: ...e recoil start on the bottom of the fuel tank Rotate the valve clockwise to the vertical position to turn on the gas supply The choke lever is located above the air filter to the right of the recoil start Slide the lever to the left to cut the air supply and allow more gas into the engine to start The key switch is located on the left side of the front power panel Insert the key and turn to the st...

Page 35: ...ng 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 35 Turn engine switch to ON When the engine starts allow the engine switch to return to the ON position 5 Open choke Push the choke to the OPEN position as the engine warms up 6 ...

Page 36: ...switch to 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 The choke lever is located above the air filter to the right of the recoil start Slide the lever to the left to cut the air supply and allow more gas into the engine to start The key switch is located on the left side of the front...

Page 37: ...hile extended may cause harm to yourself or your equipment Close choke The choke lever is located above the air filter to the right of the recoil start Slide the lever to the left to cut the air supply and allow more gas into the engine to start 5 Open choke 7 Turn breaker ON Connect The breaker is located on the right side of the front power panel Flip the breaker up to allow the power to flow to...

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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 the rated 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...

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: ...ceptacles 1 2 42 USING THE GENERATOR CONTINUED Connecting a load to the generator NOTE Be sure to attach devices to the correct receptacle outlet 120v devices can be directly connected to the 120v ONLY receptacles 120v devices can be connected to the 120 240v receptacle using an appropriate adapter 240v devices can ONLY be connected to the 240v receptacle CAUTION Do not connect 50Hz or 3 phase loa...

Page 43: ...st be in the 120 240V position If only 120V appliances are being connected to the generator select the 120V ONLY position to double the 120v amperage and automatically balance the load 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 reco...

Page 44: ...ect the battery Connect positive receptacle Start Generator Connect one charging wire to the positive terminal on the battery and the other charging wire to the negative terminal on the battery Connect the free end of the positive wire to the positive receptacle outlet on the generator The start switch is located on the left side of the front power panel Push to the start position to start the gen...

Page 45: ...n charging a battery DANGER If battery acid gets on your skin flush with water If battery acid gets in your eyes flush with water and call a physician immediately DANGER If battery acid is swallowed drink large quantities of milk and call a Physician immediately 45 Connect negative receptacle Carefully connect the free end of the negative wire to the negative receptacle on the generator 4 Disconne...

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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: ...LACE SPARK ARRESTOR CLEAN IDLE SPEED CHECK ADJUST VALVE CLEARANCE CHECK ADJUST COMBUSTION CHAMBER CLEAN 500 HOURS FUEL TANK FILTER CLEAN FUEL TUBE CHECK EVERY 24 MO REPLACE IF NECESSARY TO BE PERFORMED AT MONTHS INDICATED OR HOUR INTERVAL WHICHEVER COMES FIRST 48 WARNING Improper maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously inju...

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

Page 50: ...ew 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 it 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...

Page 51: ...to an approved oil disposal container Contact your local auto parts store for information on oil disposal 2 Replace drain plug Replace the oil drain plug and tighten with a 12 mm hex wrench 3 51 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...

Page 52: ...r to enter the engine or dirty air to enter the engine causing overheating and engine wear Cleaning the air filter 52 Remove the filter cover Remove filter Clean out filter casing Release the clips on the top and bottom of the cover and remove the filter cover Remove the sponge like elements from the casing Wipe the dirt from inside the empty air cleaner casing 1 2 3 MAINTENANCE AND CARE CONTINUED...

Page 53: ...lace the cover 7 Washcleanerelement Wash the sponge like elements in household dish detergent and warm water 4 Drycleanerelement Pat dry on a dry cloth and allow the elements to dry completely 5 6 Addengineoiltoelements Soak the dry elements in a small amount of engine oil Ring out any excess oil ...

Page 54: ...lug Maintenance Remove spark plug cap Removesparkplug Inspectsparkplug 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 it with a new spark plug We recommend using an F6RTC spark plug such as NGK BPR6ES 1 2 3 SPARK PLUG CONSULTMANUA...

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

Page 56: ...e 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 If you have been using gasoline in your generator before storing your generator for extended periods of time you should drain your generator fuel tank of gasoline MAINTENANCE ...

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: ...valve to the OFF position 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 Clean the cup of all sediment using a rag or brush Reinstall the fuel filter cup 2 3 4 ...

Page 59: ...the unit to stall out 5 Turn off the key 6 Drain the fuel tank See Emptying the Gas Tank in the Maintenance section 7 Drain the carburetor a Remove the drain bolt from the carburetor b Drain the small amount of remaining fuel from the carburetor bowl 8 Oil the cylinder a Remove the spark plug b Put 2 tbsp of 10w30 motor oil directly into the spark plug hole c Pull the recoil start one time d Repla...

Page 60: ...oltage 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 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 5 hr 5 Gallon Noise Level 74db 60 ...

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

Page 62: ... 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 items to reduce ...

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: ...h 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 it 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: ...h 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 Insert and connect the 2 wires from the AVR be sure to connect and correctly Changing Inspecting the AVR Continued TROUBLESHOOTING CONTINUED 66 ...

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

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

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Page 70: ...EXPRESSED 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 eng...

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: ...sions 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 Equipment...

Page 73: ...or spacer if applicable ii EGR rate feedback and control system 5 Air Injection System i An 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 ...

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 5 pm 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 REV XP12000E 07072020 ...

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