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DUROMAX XP15000E, User Manual

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DUROMAX XP15000E User Manual Download Page 47

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.

47

Summary of Contents for XP15000E

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 XP15000E 03262018 ...

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Page 3: ...ecking the Oil 22 Check the Gas Level 23 Starting the Generator Using Gasoline 24 Starting the Generator 2 Unpacking 16 Wheel Kit Installation 17 Adding Oil 18 Adding Gasoline 19 Grounding the Generator 20 High Altitude Operation 20 Generator Setup 4 AC Usage 28 Connecting a Load to the Generator 30 Choosing a Power Cord 31 Using the Generator 3 ...

Page 4: ...g the Oil 37 Cleaning the Air Filter 38 Spark Plug Maintenance 40 Storage and Transportation 42 Specifications 43 54 Basic Troubleshooting 46 Changing Inspecting the Carbon Brushes 47 Changing Inspecting the AVR 49 Maintenance and Care Warranty Troubleshooting 4 8 58 Contact Information ...

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Page 6: ...torm that knocks out power dewatering 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 n...

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: ...ated on top of the fuel tank Fill the tank with fresh unleaded gasoline 87 octane or higher The tank is full when you see fuel in the bottom of the fuel filter cup DO NOT overfill the tank 2 Turn gas valve on The gas valve is located to the left of the front panel Rotate the valve counter clockwise to the horizontal position to turn on the gas supply 4 Turn breaker off The breaker is located on th...

Page 11: ...the front panel Start with the largest loads first 9 Start generator The key switch is located on the left side of the front power panel Insert the key and turn to the start position to start the generator Allow the key to return to the run position once started 6 Turn breaker on The breaker is located on the right side of the front power panel Flip the breaker up to allow power to flow to the rec...

Page 12: ...ter Provides reading of voltage output and tracks operating hours 7 Circuit Breaker Resettable switch that protects the generator from electrical overload 8 120 240v 4 Prong Receptacle Use to connect electrical devices that run 120 or 240 Volt 60Hz single phase AC current NEMA 14 50 9 Ground Terminal Connect a ground wire here to properly ground the generator 10 120 240v 4 Prong Twist Lock Use to ...

Page 13: ...il Fill Dipstick Opening where you add oil to the generator 15 Fuel Gauge Indicates the amount of fuel in the gasoline tank 16 Hoist Bar Used to lift via crane into trucks and docks 17 Muffler Quiets the motor and reduces pollution 18 Motor Mounts Reduces vibration to decrease noise as well as wear and tear 19 AVR Automatic Voltage Regulator provides stable AC power 17 Muffler 18 Motor Mounts 19 A...

Page 14: ...uded with your generator Note Actual tools may differ in appearance or design from image shown Spark Plug Wrench Propane Hose Oil Funnel Engine Keys Used in spark plug maintenance inspection and installation Connects generator to propane tank Used to add oil to the generator without messy spills Used to start the generator 14 ...

Page 15: ...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: ...RATOR SETUP Unpack a Cut the strapping on the box b Slide the top of the box off the generator c Continue with the following steps BEFORE taking the generator off the pallet 1 Step 1 Unpack the Generator 16 ...

Page 17: ...rap around the generator frame next to the handles and then pass the pin through the strap to secure it to the frame 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 1 ...

Page 18: ...e life a Make sure the generator is on a level surface b Unscrew the oil filler cap from the engine c Using a funnel add the appropriate amount of oil into the crankcase You can check the oil level of the generator with the dipstick located below the oil filler cap Simply pull the dipstick out and the indicated oil level is on the end of the stick d Replace oil filler cap 1 Step 3 Adding Oil Engin...

Page 19: ...e 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 make it hard to ...

Page 20: ...altitude that 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 5 000 feet 1 500 meters have a dealer perform this carburetor modification This engine when operated at high altitude with the carburetor m...

Page 21: ...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 22: ... With a dry cloth wipe the oil off of the stick d Insert the dipstick completely back into its hole in the engine case the pull it out 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 dipstick when fini...

Page 23: ...ister with less than 1 3 fuel tank full 1 Step 2 Check the gas level 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 olde...

Page 24: ...d to the left of the front panel Rotate the valve counter clockwise to the horizontal position to turn on the gas supply The choke lever is located to the left of the panel Pull out to cut the air supply and allow more gas into the engine to start 2 3 24 Turn engine switch to START The key switch is located on the left side of the front power panel Insert the key and turn to the start position to ...

Page 25: ... motor If the engine fails to start release the switch and wait 10 seconds before operating the starter again 25 Turn engine switch to ON When the engine starts allow the engine switch to return to the ON position 5 Open choke The choke lever is located to the left of the panel Push in to open the choke and increase air into the carburetor for normal running 6 ...

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Page 27: ...re 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: ...d 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 29: ...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 30: ...nnected the 240v receptacle Plug in devices Turn breaker on Turn on connected devices Plug in devices to the appropriate receptacle When using the generator in 120 240v mode 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 applian...

Page 31: ...ctrical 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 10 8 15 1800 3600 14 12 10 8 6 20 2400 4800 12 10 8 6 4 25 3000 6000 10 8 6 4 4 30 3600 7200 8 6 4 4 NR 40 4800 9600 6 4 4 NR NR 50 6000 1200 4 4 2 NR NR NR NOT R...

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Page 33: ...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 33 ...

Page 34: ... 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 35: ...MAINTENANCE LOG Date Generator Hours Maintenance Performed 35 ...

Page 36: ... level surface b Remove dipstick c With a dry cloth wipe the oil off of the stick d Insert the dipstick completely back into its hole in the engine case the pull it out 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...

Page 37: ...nated with water or dirt Remove drain plug Drain oil Replace drain plug Using a 10 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 38: ... and engine wear MAINTENANCE AND CARE CONTINUED Cleaning the air filter Unclip filter cover Remove filter cover Remove filter Unhinge the fpur clasps of the air filter cover There are two clips on each side of the cover Remove the plastic air filter cover by sliding it out underneath the generator s frame Remove the filter from on top of the engine This filter is paper and is not reusable Please c...

Page 39: ...n into the air filter compartment on top of the engine 4 Replace filter cover Slide the filter cover back in place between the frame and the engine 5 6 Secure filter cover Fasten the filter cover to the engine with the clips found on each side of the cover ...

Page 40: ...d fuel economy misfires trouble starting or damage to the spark 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...

Page 41: ...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 41 ...

Page 42: ...inutes 3 Turn off the fuel valve 4 Allow the unit to stall out 5 Turn off the key 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 key 6 Drain the fuel tank See Emptying the Gas Tank in the ...

Page 43: ...60 Hz AC Phase Single Dimensions LENGTH 35 in WIDTH 24 5 in HEIGHT 38 in Engine Type Fuel Injected V Twin 4 Stroke OHV Ignition System Non Contact Transistor Displacement 713cc Starting Type Electric Fuel Tank Capacity 10 3 US Gal 40L Oil Capacity 54 fl oz 1 6L Run Time 50 Gasoline 8 hr Noise Level 78db 43 ...

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Page 45: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator 45 ...

Page 46: ...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 47: ...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 47 ...

Page 48: ...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 48 ...

Page 49: ...tor is overheated or overloaded the AVR may be damaged and require replacement Unbolt the AVR Cut zipties Disconnect AVR wire clip Remove the 2 bolts of the AVR located behind the power panel Remove the back cover see step 1 on page 53 Cut the zip ties connecting the AVR to the brush system Disconnect the wire clip 1 2 3 49 ...

Page 50: ...R wire to brush system 4 Replace cover Replace the rear cover of the generator 5 6 Replace new AVR Bolt the new replacement AVR onto the back of the power panel Changing Inspecting the AVR Continued TROUBLESHOOTING CONTINUED 50 ...

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Page 52: ...WIRING DIAGRAM 52 ...

Page 53: ...53 ...

Page 54: ...NTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The U S Environmental Protection Agency EPA California Air Resources Board and Imperial Industrial Supply Co LTD DuroMax Power Equipment are pleased to explain the emissions control system s warranty on your 2017 small off road engine In California new equipment that use small off road engines must be designed built and equipped to meet the State ...

Page 55: ... any questions regarding your warranty coverage contact us at 844 DUROMAX or email support duromaxpower com DEFECTS WARRANTY REQUIREMENTS The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser and extends for a period of Two Years GENERAL EMISSIONS WARRANTY COVERAGE DuroMax Power Equipment warrants to the ultimate purchaser and each subsequent owner th...

Page 56: ... provided at all manufacturer 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 The manufacturer is liable for damages to other engine components proximately caused by a failure ...

Page 57: ...her device used to capture particulate emissions 8 Electronic controls 9 Vacuum temperature and time sensitive valves and switches 10 Hoses belts connectors and assemblies 11 Evaporative Emission Warranty Part List i Fuel Tank ii Fuel Cap iii Fuel Line iv Fuel Line Fittings v Clamps vi Pressure Relief Valves vii Control Valves viii Control Solenoids ix Electronic Controls x Vacuum Control Diaphrag...

Page 58: ...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 customer_service duromaxpower com ...

Page 59: ......

Page 60: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX ...

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