DUROMAX MX4500 Owner'S Manual Download

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Gasoline Powered Generator

Owner’s Manual

MX4500
MX4500E

Summary of Contents for MX4500

Page 1: ...hursday 6am to 7pm Friday Saturday 6am to 3pm PST Product Support Product information application service info warranty questions support maxtool com or call 1 800 629 3325 option 3 Monday Thursday 6am to 7pm Friday Saturday 6am to 3pm PST Gasoline Powered Generator Owner s Manual MX4500 MX4500E ...

Page 2: ...oled Overhead Valve Engine Heavy Duty Steel Frame with Four Point Fully Isolated Motor Mounts for Smooth and Quiet Operation Wheel and Handle Kit for Easy Transporting Full Power Panel with Engine Shutoff Switch Volt Meter Circuit Breaker and Power Outlets 2 Fully Protected 120V Outlets 1 120V 240V Twist Lock Outlet 8 Hour Run Time All Steel 4 0 Gal Fuel Tank with EZ Read Gauge Low Oil Shut Off Pr...

Page 3: ...3 Ground the Generator 9 STARTING THE GENERATOR 9 USING THE GENERATOR 10 AC Usage 10 DC Usage 13 STOPPING THE GENERATOR 14 MAINTENANCE CARE 14 Cleaning the Generator 14 Checking the Oil 15 Changing Adding Oil 15 Air Cleaner Maintenance 16 Fuel Filter Cup Cleaning 17 Spark Plug Maintenance 17 Emptying the Gas Tank 18 STORAGE TRANSPORT PROCEDURE 18 GENERATOR SPECIFICATIONS 19 TROUBLESHOOTING 19 GENE...

Page 4: ...ness drowsiness and eventually death Use outdoors ONLY in non confined areas Keep several feet of clearance on all sides to allow proper ventilation of the generator WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING This generator may emit highly flammable and explosive gasoline vapors which ca...

Page 5: ...ces until after they are connected to the generator Turn off all connected electrical devices before stopping the generator WARNING This generator produces powerful voltage which can result in electrocution ALWAYS ground the generator before using it see the Grounding the Generator portion of the PREPARING THE GENERATOR FOR USE section Generator should only be plugged into electrical devices eithe...

Page 6: ...3 In addition to the above safety notices please familiarize yourself with the safety and hazard markings on the generator ...

Page 7: ...TENTS Your generator comes with the items listed below Please check to see that all of the following items may be included with your generator depending on your generator model Screwdriver Spanner Spark plug wrench ...

Page 8: ...3 Fuel Gauge Indicates the amount of fuel in the tank 4 Fuel Cap Access to the fuel tank for adding fuel 5 Circuit Breaker Reset switch that protects the generator from electrical overload 6 120 240 Volt AC Receptacle Use to connect electrical devices that run 120 and or 240 Volt 60Hz single phase AC current NEMA L14 30 7 Ground Terminal Connect grounding wires here to properly ground unit 8 120 V...

Page 9: ...p 1 Add oil The generator requires engine oil to operate properly The generator when new from the package contains no oil in the crankcase You must add the proper amount of oil before operating the generator for the first time This amount which is equal to the oil capacity of the engine crankcase can be found on the chart in figure 1 When filling the engine with oil in the future please refer to t...

Page 10: ...ap may be tight and hard to unscrew 3 Slowly add unleaded gasoline to the fuel tank Be careful not to overfill Please refer to the chart in figure 4 to find the gas capacity of your generator model The fuel gauge on the top of the generator indicates how much gasoline is in the generator gas tank NOTE Gas can expand Do not fill the gas tank to the very top 4 Replace fuel cap and wipe up any spille...

Page 11: ...uld check the oil level of the engine before each use to ensure that the engine crankcase has a sufficient amount To check the oil level 1 Make sure the generator is on a level surface 2 Unscrew the oil filler dipstick cap 3 With a dry cloth wipe the oil off of the stick on the inside of the cap 4 Insert the dipstick as if you were replacing the cap and then remove again There should now be oil on...

Page 12: ...nnect all electrical loads from the generator before attempting to start To start your generator perform the following steps 1 Make sure no electrical devices are connected to the generator Such devices can make it difficult for the engine to start 2 Check that the generator is properly grounded see page 13 Ground the Generator 3 Turn the fuel valve to the ON position see figure 6 4 Move the choke...

Page 13: ...rt bursts of extra power in addition the rated wattage listed by the device to stop and start their motors The surge wattage ability of the generator covers this extra power requirement Model Number Rated Running Wattage Surge Wattage MX4500 3500 4500 MX4500E 3500 4500 Figure 9 generator wattage by model number The total running wattage requirement of the electrical devices connected to the genera...

Page 14: ...yer VCD 100 0 Common light bulb 75 0 Figure 10 Estimated wattage requirements of common electrical devices Once you have found the rated wattage requirement 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 devic...

Page 15: ...on the generator VOLTAGE SELECTOR SWITCH MX4500 MX4500E The voltage selector switches the main power carrying 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 a 120V appliance is being connected to any of the 120V 3 prong receptacles select the 120V ONLY position 120 240V The 12...

Page 16: ...receptacle 1 Connect one charging wire to the positive terminal on the battery and the other charging wire to the negative terminal 2 Connect the free end of the positive wire to the positive receptacle outlet on the generator 3 Start the generator 4 Carefully connect the free end of the negative wire to the negative receptacle on the generator 5 When disconnecting always disconnect the wires from...

Page 17: ...t during use CAUTION Allowing gas to sit in the generator tank for long periods of time without use can make it difficult to start the generator in the future Never store generator for extended periods of time with fuel in the tank MAINTENANCE CARE Proper routine maintenance of your generator will help prolong the life of your machine Please perform maintenance checks and operations according the ...

Page 18: ...l off of the stick on the inside of the cap 4 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 Changing Adding Oil in this section 5 Be sure to replace cap when finished checking oil Figure 14 Checking th...

Page 19: ... detergent motor oil to the crankcase We recommend SAE 10W30 motor oil for general use When full the oil level should come close in the top of the oil fill opening see figure 17 NOTE Never dispose of used motor oil in the trash or down a drain Please call your local recycling center or auto garage to arrange oil disposal Air Cleaner Maintenance Routine maintenance of the air cleaner helps maintain...

Page 20: ...rush 4 Reinstall the fuel filter cup Figure 19 Removing the Fuel Filter Cup Spark Plug Maintenance The spark plug is important for proper engine operation A good spark plug should be intact free of deposits and properly gapped To inspect you spark plug 1 Pull on the spark plug cap to remove it 2 Unscrew the spark plug from the generator using the spark plug wrench included with this product see fi...

Page 21: ...is section 3 Empty the fuel filter cup of any fuel 4 With a receptacle underneath the generator to catch the gas turn the fuel valve to the ON position Drain all the gas from the generator 5 Turn the fuel valve to the OFF position 6 Replace the fuel filter cup 7 Store the emptied gasoline in a suitable place CAUTION Do not store fuel from one season to another STORAGE TRANSPORT PROCEDURES CAUTION ...

Page 22: ...ark plug is dirty Clean spark plug MX4500 MX4500E Rated Wattage 3500W 3500W Surge Wattage 4500W 4500W Rated Voltage 120 240V 120 240V Rated Frequency 60Hz 60Hz Phase Single Single MX4500 MX4500E Voltage 12V 12V Amperage 8 3A 8 3A Dimensions in Length 23 2 Width 17 Height 17 Length 23 2 Width 17 Height 17 MX4500 MX4500E Engine type 4 stroke OHV single cylinder with forced air cooling system Ignitio...

Page 23: ...ner is dirty Clean or replace air cleaner GENERATOR ASSEMBLY AND MOUNTING Generator is supplied with a wheel kit If you want to install the wheel kit on your unit please follow the instructions below If you will not be using the wheel kit skip this section 1 Place the bottom of the generator cradle on a flat even surface Temporarily place unit on blocks to ease assembly 2 Secure the support leg to...

Page 24: ...21 Figure 25 Figure 26 Figure 27 Figure 28 CHANGE THE CARBON BRUSH ...

Page 25: ...22 CHANGE THE AVR ...

Page 26: ...23 WIRING DIAGRAM MX4500 ...

Page 27: ...24 WIRING DIAGRAM MX4500E ...

Page 28: ...0 16 PCS 2 2 CLDH2 HEAD GASKET PCS 1 3 CLDH3 BOLT GB5789 M8 55 PCS 4 4 CLDH4 BOLT STUD EX PCS 2 5 CLDH5 PAPER WASHER EXHAUST OPENING PCS 1 6 CLDH6 PACKING HEAD COVER PCS 1 7 CLDH7 BOLT GB5787 M6 14 PCS 4 8 CLDH8 PLUG SPARK F7TC PCS 1 9 CLDH9 BOLT STUD PCS 2 10 CLDH10 COVER CYLINDER HEAD PCS 1 11 CLDH11 CYLINDER HEAD PCS 1 Series No Part Code English Name Unit Quantity for One Unit 1 KRKS1 CRANKCAS...

Page 29: ...KRKS11 BOLT GB5787 M6 16 PCS 2 12 KRKS12 DOWEL PIN 8 14 PCS 2 Series No Part Code English Name Unit Quantity for One Unit 1 KSKVR1 CRANKCASE COVER PCS 1 2 KSKVR2 OIL SEAL 25 41 25 6 PCS 1 3 KSKVR3 BEARING GB276 6205 PCS 1 4 KSKVR4 GASKET CRANKCASE COVER PCS 1 5 KSKVR5 OIL DIPSTICK SINGLE UNIT ENGINE PCS 1 6 KSKVR6 BOLT GB5787 M8 32 PCS 6 Series No Part Code English Name Unit Quantity for One Unit ...

Page 30: ...DE PCS 1 7 KMSHFT7 RETAINER IN VALVE SPRING PCS 1 8 KMSHFT8 LIFTER VALVE PCS 2 9 KMSHFT9 ROD PUSH PCS 2 10 KMSHFT10 PLATE PUSH ROD GUIDE PCS 1 11 KMSHFT11 ARM VALVE ROCKER ASSEMBLY INCLUDING BOLT AND NUT SET 2 12 KMSHFT12 BOLT PIVOT ARM PCS 2 13 KMSHFT13 NUT PIVOT ADJUSTING PCS 2 14 KMSHFT14 PIVOT ROCKER ARM PCS 2 15 KMSHFT15 ROCKER ARM PCS 2 16 KMSHFT16 CAMSHAFT PCS 1 Series No Part Code English ...

Page 31: ...R10 RATCHET STARTER PCS 2 11 STR11 GUIDE RATCHET PCS 1 12 STR12 SCREW SETTING PCS 1 13 STR13 COVER STARTER PCS 1 14 STR14 ROPE PCS 1 Series No Part Code English Name Unit Quantity for One Unit 1 PLT1 PLATE SIDE PCS 1 2 PLT2 ALERT UNIT OIL PCS 1 3 PLT3 BOLT GE5787 M6 12 PCS 1 4 PLT4 WIRE CLIP PCS 1 5 PLT5 POD PCS 1 6 PLT6 BOLT GE5787 M6 12 PCS 2 7 PLT7 BOLT GE5787 M6 20 PCS 1 Series No Part Code En...

Page 32: ...tity for One Unit 1 FLYWL1 NUT GB6177 M14 PCS 1 2 FLYWL2 STARTING FLANGE PCS 1 3 FLYWL3 FAN COOLING PCS 1 4 FLYWL4 FLYWHEEL COMP PCS 1 5 FLYWL5 COIL ASSY IGNITION SET 1 6 FLYWL6 BOLT GB5787 M6 25 PCS 2 7 FLYWL7 CAP ASSY NOISE SUPPRESS PCS 1 8 FLYWL8 COIL IGNITION PCS 1 Series No Part Code English Name Unit Quantity for One Unit 1 RGLTRA1 THROTTLE CONTROL ASSY PCS 1 2 RGLTRA2 SPRING GOVERNOR PCS 1 ...

Page 33: ...IR CLEANER COVER PCS 1 3 KLNR3 PRIMARY FOAM ELEMENT PCS 1 4 KLNR4 FINE MESH FOAM ELEMENT PCS 1 5 KLNR5 AIR CLEANER PEDESTAL PCS 1 6 KLNR6 STEADIER PCS 1 7 KLNR7 BOLT GB5787 M6 12 PCS 4 8 KLNR8 NUT GB6177 M6 PCS 2 Series No Part Code English Name Unit Quantity for One Unit 1 MFLR1 PROTECTOR COMP MUFFLER OUTER PCS 1 2 MFLR2 MUFFLER PCS 1 3 MFLR3 STAY COMP MUFFLER PCS 1 4 MFLR4 BOLT GB5787 M8 16 PCS ...

Page 34: ...art Code English Name Unit Quantity for One Unit 1 TK1 FUEL TANK COMP SET 1 2 TK2 METER COMP FUEL PCS 1 3 TK3 METAL CAP PCS 1 4 TK4 FUEL FILTER PCS 1 5 TK5 FUEL TUBE 4 8 145 PCS 1 6 TK6 CLIP TUBE PCS 2 7 TK7 ATTACHMENT WASHER 6 25 2 PCS 4 8 TK8 BOLT GB5787 M6 25 PCS 4 9 TK9 FUEL COMP COCK PCS 1 Series No Part Code English Name Unit Quantity for One Unit 1 FRM1 FRAME COMP PCS 1 ...

Page 35: ...AR END COVER OF ALTERNATOR PCS 1 2 OTLTR2 BOLT GB5789 M5 12 PCS 2 3 OTLTR3 REGULATOR ASSY AUTOMATIC VOLTAGE PCS 1 4 OTLTR4 BOLT GB5789 M6 130 PCS 4 5 OTLTR5 REAR END SUPPORTER OF ALTERNATOR PCS 1 6 OTLTR6 BOLT GB5782 M8 180 1 PCS 1 7 OTLTR7 ROTOR COMP PCS 1 8 OTLTR8 STATOR ASSY PCS 1 9 OTLTR9 BRUSH ASSY PCS 1 10 OTLTR10 BOLT GB5789 M5 12 PCS 2 11 OTLTR11 BOLT GB5789 M5 12 PCS 1 12 OTLTR12 HOLD DOW...

Page 36: ...PL5 VOLTAGE METER ASSY PCS 1 6 PL6 CIRCUIT BREAKER PCS 1 7 PL7 SOCKET EURO STYLE PCS 1 8 PL8 DC OUTPUT TERMINAL PCS 2 9 PL9 LOW OIL LIGHT PCS 1 10 PL10 VOLTAGE SWITCH PCS 1 11 PL11 TWIN SOCKETS PCS 1 12 PL12 PROTECTOR PCS 1 OPTIONAL FOR MX4500E ONLY Series No Part Code English Name Unit Quantity for One Unit 1 PLE1 FLYWHEEL COMP ELECTRIC START PCS 1 2 PLE2 STARTER MOTOR PCS 1 ...

Page 37: ...ROL PANEL ELECTRIC START PCS 1 4 PLE4 LOCK BLOCK OF WIRE PCS 1 5 PLE5 PLATE SIDE ELECTRIC START PCS 1 6 PLE6 CHARGE COIL ASSY ELECTRIC START PCS 1 7 PLE7 STARTER COMP ELECTRIC START PCS 1 8 PLE8 CHARGING LIGHT PCS 1 ...

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