DuroStar DUROMAX DUAL FUEL XP8500EH User Manual Download Page 71

Page: 71 / 84

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.

Summary of Contents for DUROMAX DUAL FUEL XP8500EH

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

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Page 3: ...tor 3 Remove Shipping Braces 21 Wheel Kit Installation 22 Connect the Battery 24 Adding Oil 25 Adding Gasoline 26 Grounding the Generator 27 High Altitude Operation 27 Generator Setup 5 AC Usage 42 Connecting the Generator to a Home 45 Connecting a Load to the Generator 46 Choosing the Right Power Cord 47 Using the Digital Multimeter 48 Idle Control Usage 49 Voltage Selector Switch 50 Using the Ge...

Page 4: ...enerator for Same Day Use 64 Storing the Generator for Use Within 30 Days 65 Storing the Generator for Longer than 30 Days 66 Specifications 68 78 Basic Troubleshooting 70 Changing Inspecting the Carbon Brushes 71 Changing Inspecting the AVR 73 Wiring Diagram 76 Maintenance and Care Warranty Troubleshooting 9 82 Contact Information For more information and resources on this model scan the QR code ...

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Page 6: ...y unavailable Equipment like table saws sanders and work lights are a necessity and portable power can play a critical role in getting a job done successfully and efficiently DUROMAX FOR PLAY Camping outdoors in a remote location can get one in touch with nature and allow them to forget the stress of the day to day grind Here portable power can provide comfort as well as safety With portable power...

Page 7: ...yone 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 1 844 DUROMAX TOLL FREE Engines that are c...

Page 8: ...r exhaust 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 Please familiarize yourself with the following safety symbols and words DANGER Indicates a hazard that will result in serious injury or death if instructio...

Page 9: ...l valve 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 The generator should only be plugged into electrical devices either directly or with an extension cord NEVER connect to a building ele...

Page 10: ...DURES 10 In addition to the above safety notices please familiarize yourself with the safety and hazard markings on the generator DANGER DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE EXPLOSION OR DEATH 1 5 ...

Page 11: ...11 DON T TOUCH CAUTION HIGH TEMPERATURE DANGER HOT EXHAUST KEEP SAFE DISTANCE DON T TOUCH BURN RISK CARBON MONOXIDE SAFE DISTANCE ...

Page 12: ...ssary for warranty parts or service 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 __________________...

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: ...GENERATOR COMPONENTS To help you get familiar with your new DuroMax generator please see this component section for easy reference on all the generator s individual features 15 ...

Page 16: ...k All metal 7 9 gallon gasoline fuel tank 5 Power Panel Contains the start switch plugs meters and circuit breakers 6 Handles Longest handles of any DuroMax model allow easy movement across any surface 7 Battery 12V DC battery that powers the electric start system 8 Oil Fill and Dipstick Use to add or check the oil 9 Propane Inlet Provides a regulated LPG fuel supply to the engine Intended for use...

Page 17: ...Breaker Protects the panel from overload and short circuits 16 Multimeter Displays voltage hertz and time running 17 240V 30A Receptacle Use to connect electrical devices that run 120 or 240 volt 60 Hz single phase ac current NEMA L14 30 18 120V 3 Prong GFCI Receptacle Use to connect electrical devices that run 120 volt 60 Hz single phase ac current NEMA 5 20 19 12V DC Automotive 12V DC Output for...

Page 18: ... or design from the image shown Double Sided Screw 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 10mm 12mm 13mm 15mm and 17mm 19mm Used in spark plug maintenance inspection and installation Plug heads fo...

Page 19: ...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 ...

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Page 21: ...e pad 1 Step 1 Remove Shipping Braces Remove braces a The shipping braces prevent engine movement 2 Note Shipping braces can be thrown away they will not be needed again CAUTION NEVER attempt this if you have put fuel or oil in the generator 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 21 ...

Page 22: ...nuts 1 Install inside wheel washers a Place one of the large washers onto both sides of the axle behind the wheel 4 Install wheel axle a Insert wheel axle bolts through the frame and secure with the provided nut and wrenches 2 Install wheel axle bracket a Insert wheel axle bracket bolts through the frame and secure with the provided nut and wrenches 3 ...

Page 23: ... secure the wheels 7 Install outside wheel washers a Place the other large washers onto each side the axle in front of the wheel 6 Install handles a Attach the handles to the brackets on the frame using the provided bolts and nuts b Flip the assembled generator over onto its wheels and support brackets Do not over tighten the handles it will prevent free movement 8 ...

Page 24: ...her 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 screwdriver and wrench from the toolkit 3 a The generator battery is di...

Page 25: ... 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 Engine oil recommended SAE 10W 30 Viscosity varies with regions and temperatures Choose your oil viscosity using the chart to the left A small amount of oil from factory testing may be present on...

Page 26: ...ns 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 XP8500EH Gas Tank Capacity 7 9 US gal 30 L DANGER DO NOT O...

Page 27: ...epower will decrease by about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made When the carburetor has been modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 3 000 feet 900 meters with a modified carburetor may cause t...

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Page 29: ...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 30: ... is on a level surface b 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 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 port...

Page 31: ...he 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 ALWAYS leave 11 2 space or more at the top of the tank ...

Page 32: ... on the right side of the front power panel Flip the breaker down to prevent accidental load when starting the generator 1 Turn gas valve ON Close choke The gas valve is located above the recoil start on the bottom of the fuel tank Rotate the valve counter clockwise to the vertical position to turn on the gas supply The choke lever is located above the air filter to the left of the recoil start Sl...

Page 33: ...ft side of the front power panel Press the switch up to the START Position Once the engine starts allow the switch to return to the RUN position 5 CAUTION LPG must be shut off when using gasoline CAUTION Gasoline must be shut off when using LPG CAUTION Disconnect all electrical loads from the generator before attempting to start WARNING Operating the starter motor for more than 5 seconds can damag...

Page 34: ...CME nut connection to your propane tank and turn the tank on 3 4 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 1 Turn the gas valve OFF The gas valve is located above the recoil start on the bottom of the fuel tank Rotate the valve clockwise to the horizontal position to stop the flow ...

Page 35: ...ine switch is located on the left side of the front power panel Press the switch up to the START Position When the engine starts allow the engine switch to return to the RUN position 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 gas into the engine to start 5 Start the generator 6 Open ch...

Page 36: ... 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 Breaker and then turn off the LPG Supply After the engine has stopped turn the Battery Switch to the OFF position CAUTION Disconn...

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Page 38: ...ator 1 Select your fuel Turn engine switch to RUN If using gasoline see step 2 on pg 32 If using propane see steps 2 4 on pg 34 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 mor...

Page 39: ...cated on the right side of the front power panel Flip the breaker up to allow the power to flow to the receptacles Connect your devices to the receptacles on the front panel Start with the largest loads first 8 CAUTION Release the recoil handle only after the cord has retracted Releasing the recoil handle while extended may cause harm to yourself or your equipment Turn idle control OFF The idle co...

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Page 41: ...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 42: ...uirement of each electrical device add these numbers to find the total rated wattage you wish to draw from the generator If this number exceeds the rated wattage of the generator DO NOT connect all these devices Select a combination of electrical devices which has a total rated wattage lower than or equal to the rated wattage of the generator You may connect electrical devices running on AC curren...

Page 43: ...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...

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Page 45: ...cally switches power over to your generator during an outage Requires an electrician to install Once you choose which circuits you want to power you re locked into your configuration Interlock kit Choose what circuits you want to run Requires an electrician to install but you have the flexibility of switching up your circuits depending on your power needs More hands on and some electrical knowledg...

Page 46: ... receptacle using an appropriate adapter 240V devices can ONLY be connected to the 240V receptacle CAUTION Do not connect 50 Hz or 3 phase loads to the generator Connecting a Load to the Generator Plug in devices Turn breaker ON 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...

Page 47: ...7200 10 10 10 8 NR 40 4800 9600 8 8 6 6 NR 50 6000 12000 6 6 6 NR NR NR NOT RECOMMENDED Gauge based on twisted copper wire Length 120V 15A 240V 30A 240V 50A 14 Gauge 12 Gauge 10 Gauge 6 Gauge Single Outlet Single Outlet Triple Outlet Single Outlet Triple Outlet L14 30P L14 30R 14 50P CS6364 10 ft XP3010GC 15 ft XP5015GC 25 ft XPC14025A XPC12025A XPC12025C XPC10025A XPC10025C XP3025GC XP5025GC 50 f...

Page 48: ...s run The number of hours the engine has currently been running When the generator is started the display will read the current voltage Press the MODE button to cycle through the multimeter functions 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 runni...

Page 49: ...to provide usable power Turn on the idle control when using intermittent loads like power tools and air compressors The idle control feature is designed for gasoline only use Idle Control Usage WARNING Power is unusable when idle control is engaged DO NOT use the idle control function when using the generator for backup house power Idle control function will cause massive fluctuations in voltage a...

Page 50: ...ser the ability to double the power in the generator for more heavy duty applications The voltage selector switches the dual 120V AC windings of the generator to produce 120V ONLY or 120 240V If a 240V appliance is connected to the 4 prong receptacle the switch must be in the 120 240V position If only 120V appliances are being connected to the generator select the 120V ONLY position to double the ...

Page 51: ...enance and storage of your generator is essential to ensure trouble free use of your generator when you need it By following the maintenance and care requirements you can keep your generator running smooth and efficient for years to come ...

Page 52: ... CHECK CHECK CHANGE CHANGE SEDIMENT CUP CLEAN CLEAN SPARK PLUG CLEAN ADJUST CLEAN ADJUST SPARK ARRESTOR CHECK CLEAN IDLE SPEED CHECK ADJUST VALVE CLEARANCE CHECK ADJUST FUEL TUBE CHECK CHECK REPLACE FUEL TANK FILTER CLEAN COMBUSTION CHAMBER CLEAN WARNING Improper maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously injured or killed Alw...

Page 53: ...n Period As the best practice for any new combustion motor it s recommended to perform the break in procedure as follows Run the generator for the first 6 8 hours on conventional oil then change the oil After the break in period synthetic oil may be used During the break in period of the first 6 8 hours keep the generator load under 50 for optimal results Check and clean the air filter if necessar...

Page 54: ...e generator is on a level surface b 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 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 Addi...

Page 55: ...o 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 CAUTION 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 be...

Page 56: ... Remove the sponge like elements from the casing Wipe the dirt from inside the empty air cleaner casing 1 2 3 Routine maintenance of the air cleaner helps maintain proper airflow to the carburetor Check that the air cleaner is free of excessive dirt after every use CAUTION Improper maintenance may cause less air to enter the engine or dirty air to enter the engine causing overheating and engine we...

Page 57: ...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 58: ...ark 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 CAUTION Improper maintenance may cause reduced fuel economy misfires trouble starting or damage to the spark...

Page 59: ...n and re gap If you are re using the spark plug use a wire brush to clean any dirt from around the spark plug base and then re gap the spark plug 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 ...

Page 60: ...p 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 If you have been using gasoline in your generator before storing your generator for extended periods of time you should drain your generator ...

Page 61: ... valve 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 ...

Page 62: ...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 63: ...e Gas Tank on page 60 61 Pull on spark plug cap to disconnect spark plug from ignition wire 1 2 CAUTION Do not obstruct any ventilation openings and keep the generator in a cool dry area CAUTION Never place any type of storage cover on the generator while it is still hot Transporting the Generator ...

Page 64: ...o run for 3 5 minutes 1 2 Move rocker switch to STOP Move the rocker switch to the STOP position to turn the generator off 3 Turn fuel valve OFF Store Turn the fuel valve clockwise to the horizontal position to shut off the flow of gasoline to the carburetor then store the generator CAUTION Do not obstruct any ventilation openings and keep the generator in a cool dry area 4 64 ...

Page 65: ...e generator 4 Turn breaker OFF and run Follow steps 1 and 2 as shown on Storing the Generator For Same Day Use on page 64 1 Shut fuel valve OFF and run dry Shut the fuel valve OFF and allow generator to run until it stalls out 2 Move rocker switch to STOP Move the rocker switch to the STOP position to turn the generator off 3 65 ...

Page 66: ...on page 64 1 Shut fuel valve OFF and run dry Empty the gas tank Shut the fuel valve OFF and allow generator to run until it stalls out Fully drain your gas tank as shown in Emptying the Gas Tank on page 60 61 2 4 MAINTENANCE AND CARE CONTINUED 66 Move rocker switch to STOP Move the rocker switch to the STOP position to turn the generator off 3 ...

Page 67: ...der Remove battery and charge Remove spark plug as shown in Spark Plug Maintenance on page 58 Add 2 tablespoons of 10W 30 motor oil directly into the spark plug hole and pull the recoil to lubricate cylinder After lubricating cylinder reinstall the spark plug Remove the generator battery and place it on a 12V battery tender indoors 6 7 8 67 ...

Page 68: ...2 fl oz 1 1 L Bore 90 mm Stroke 66 mm Engine Speed 3600 rpm Oil Cooling Type Splash Bearing Type Stainless steel ball bearing Cylinder Sleeve Cast iron sleeve Fuel Delivery System Carburetor Valve Type OHV Engine Type 4 Stroke Engine Cooling Type Forced air Run Time 50 Gasoline 12 hr Run Time 50 Propane 8 hr 40 lb Starting Type Electric Recoil Noise Level 72 dB Neutral System Floating AC Rated Fre...

Page 69: ...69 TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator ...

Page 70: ... level Move the generator to a level surface Oil is low Add change the oil Engine runs but there is no electrical output The 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 The generator runs but does not support all electrical devices connected Generator is overloaded ...

Page 71: ...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 ...

Page 72: ...Brushes Cont Install new brush 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 ...

Page 73: ...rator 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 ...

Page 74: ... 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 Insert and connect the 2 wires from the AVR be sure to connect and correctly Changing Inspecting the AVR Continued ...

Page 75: ...75 Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts 8 ...

Page 76: ...76 WIRING DIAGRAM ...

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Page 78: ...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 2022 2023 year small off road engine In the United States and California new small off road eng...

Page 79: ...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 80: ...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 81: ...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 82: ...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 Mon Fri Website www duromaxpower com Email customerservice duromaxpower com ...

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Page 84: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX REV XP8500EH 07272022 ...

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