DUROMAX DUAL FUEL XP4500IH, User Manual

Page 1: ...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 5pm PST Mon Fri 844 DuroMax User Manual REV XP4500iH 06012021 ...

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Page 3: ...8 Check the Gas Level 29 Starting the Generator Using Gasoline 30 Starting the Generator Using Propane 32 Starting the Generator Using Remote Start 36 Starting the Generator 2 Connect the Battery 22 Adding Oil 23 Adding Gasoline 24 Grounding the Generator 25 High Altitude Operation 25 Generator Setup 4 AC Usage 40 Connecting a Load to the Generator 42 Using the Generator CONTENTS ...

Page 4: ... Checking the Oil 48 Changing the Oil 49 Cleaning the Air Filter 50 Spark Plug Maintenance 52 Storage and Transportation 54 Specifications 55 60 Basic Troubleshooting 58 Maintenance and Care Warranty Troubleshooting 8 64 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: ...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: ...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 ...

Page 12: ...tor for your home the CO Alert tests the air for to keep you safe and healthy CO Detected If dangerous carbon monoxide levels are detected Generators are very convenient but they can also be very dangerous All fuel burning appliances and equipment release a poisonous gas called carbon monoxide Carbon monoxide also known as CO can be dangerous for humans and pets even in small amounts because it bl...

Page 13: ...QUICK START The Quick Start of your generator is the minimum necessary setup that will get you going as soon as possible ...

Page 14: ... side of the generator Rotate the valve counterclockwise to the Fuel ON RUN position to turn on the gasoline supply Add gasoline The fuel cap is located 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 3 Add oil The oil fill cap is located on the lower engine block...

Page 15: ...t power panel next to the breaker Flip the switch down to disable Low idle when starting the generator Press the start button The start button is located on the left side of the power panel Press the button down for 1 3 seconds to start the generator 8 Connect devices Connect your devices to the receptacles on the front panel Start with the largest loads first 10 Turn start switch on The start swi...

Page 16: ... right hand side of the generator Rotate the valve counterclockwise to the Fuel ON RUN position to turn on the gasoline supply Connect propane hose The LPG inlet is located on the right hand side of the generator Connect the propane hose to both the inlet and the propane tank Open the propane tank 3 Add oil The oil fill cap is located on the lower engine block to the right of the recoil start hous...

Page 17: ...ower panel next to the breaker Flip the switch down to disable Low idle when starting the generator Press the start button The start button is located on the left side of the power panel Press the button down for 1 3 seconds to start the generator 8 Connect devices Connect your devices to the receptacles on the front panel Start with the largest loads first 10 Turn start switch on The start switch...

Page 18: ...s allow for easy transportation over any terrain 7 Multimeter Provides information of Gasoline Level Hours Run Voltage Hertz and current load on the generator measured in kW 8 Circuit Breaker Resettable switch that protects the generator from electrical overload 9 Battery Tender Easily keep your battery charged when the generator is in storage by using the included 12v battery charger 10 120v GFCI...

Page 19: ... match the load to save on fuel and reduce noise levels 15 Start Button Starts and shuts down the generator 16 Start Up Switch Allows power to the starter and panel Prevents accidental starting 17 CO Alert Shuts down the engine in the event of CO buildup 19 14 Low Idle 12 Parallel Ports 13 USB Outlets 9 Battery Tender 8 Circuit Breaker 10 120v GFCI 11 120v 30A RV Receptacle 15 Start Button 16 Star...

Page 20: ... 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 12mm Used in spark plug maintenance inspection and installation Plug heads for the receptacles found on the generator are included to make or rewire your own cords...

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 ...

Page 22: ...oot b Reinstall the battery cover plate 3 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 2 a Remove the battery cover plate by removing the screw ...

Page 23: ...b Remove the Oil Fill cover c Unscrew the oil filler dipstick cap from the engine d 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 e Replace the oil filler cap Step 2 Adding Oil Engine oil recommended SAE 10W 30 Viscosity varies with regions and tem...

Page 24: ...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 XP4500iH Gas Tank Capacity 2 64 US Gal 10L DANGER DO NOT O...

Page 25: ...igh altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower 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 ...

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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: ... c Unscrew the oil filler dipstick cap d With a dry cloth wipe the oil off of the stick on the inside of the cap e 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...

Page 29: ...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 30: ...s valve is located the right hand side of the generator Rotate the valve counterclockwise to the fuel on run position to turn on the gasoline supply The low idle is located on the left side of the front power panel next to the fuel selection switch Flip the switch down to disable low idle when starting the generator 2 3 4 30 Select gasoline fuel The fuel selector is located on the right side of th...

Page 31: ...tart switch on The start switch is located on the left side of the front power panel next to the low idle Press the switch up to the start position to allow the generator to start 5 Press the start button The start button is located on the left side of the power panel Press the button down for 1 3 seconds to start the generator 6 Turn breaker on The breaker is located on the center top of the fron...

Page 32: ...p the switch down to select LPG as a fuel source 2 STARTING THE GENERATOR CONTINUED Starting the Generator Using Propane Turn gas valve off Turn Breaker off The gas valve is located the right hand side of the generator Rotate the valve clockwise to the fuel off store position to turn off the gasoline supply The breaker is located in the top center of the front power panel Flip the breaker down to ...

Page 33: ...he low idle Press the switch up to the start position to allow the generator to start 6 5 Press the start button 7 Turn breaker on Connect The breaker is located in the top center 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 The start button is located on th...

Page 34: ... 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 36: ...and side of the generator Rotate the valve counterclockwise to the fuel off store position to turn off the gasoline for LPG or clockwise to fuel on run for gasoline Turn low idle off The low idle is located on the left side of the front power panel next to the fuel selection switch Flip the switch down to disable low idle when starting the generator Turn breaker on The breaker is located in the to...

Page 37: ...nd stop Press the start button two times in sucession to start the generator 6 5 Turn start switch on The start switch is located on the left side of the front power panel next to the low idle Press the switch up to the start position to allow the generator to start ...

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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: ... 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 Fuel Source Rated Running Wattage Surge Peak Wattage Gasoline 3600 4500 Propane 3240 4050 40 You may connect electrical devices running on AC curren...

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: ... 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 CAUTION Do not connect 50Hz or 3 phase loads to the generator Turn on connected devices Start or turn on appliances starting with the biggest loads first 3 ...

Page 43: ...f 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 14 14 10 1200 2400 16 16 14 14 12 15 1800 3600 14 14 12 12 10 20 2400 4800 14 12 12 12 10 25 3000 6000 12 12 10 10 8 30 3600 3240 12 10 10 10 8 40 4800 9600 10 8 8 NR NR 50 6000 12000 8 6 6 NR NR NR NOT RECOMMENDED Parallel Usage Double your power with the MaxPower Parallel ...

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Page 45: ...e and storage of your generator are 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 smoothly and efficiently for years to come 45 ...

Page 46: ...frequent service 46 WARNING Improper maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously injured or killed Always follow the inspection maintenance recommendations and schedules in this 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 re...

Page 47: ...MAINTENANCE LOG Date Generator Hours Maintenance Performed 47 ...

Page 48: ...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 49: ... oil Drain oil into 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 49 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...

Page 50: ...engine or dirty air to enter the engine causing overheating and engine wear MAINTENANCE AND CARE CONTINUED Cleaning the air filter 50 Remove the filter cover Remove filter Release the clip on the top of the cover and move the filter cover to allow access to the element Remove the sponge like elements from the casing 1 2 3 Washcleanerelement Wash the sponge like elements in household dish detergent...

Page 51: ...like elements in the air cleaner casing and replace the cover 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 52: ...ug 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 CONSULT MANUA...

Page 53: ...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 53 ...

Page 54: ...he fuel valve 4 Allow the unit to stall out 5 Turn off the start switch 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 th...

Page 55: ...C Rated Voltage 120V ACRatedFrequency 60 Hz AC Phase Single DC Voltage 5V DC Amperage 3 1A Engine Type 4 Stroke OHV Forced Air Ignition System Non Contact Transistor Displacement 223cc Starting Type Electric Fuel Tank Capacity 2 64 US Gal 10L Oil Capacity 20 fl oz 0 6L Run Time 50 Gasoline 11 hr Run Time 50 Propane 8 hr 5 Gallon Noise Level 65db ...

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Page 57: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator 57 ...

Page 58: ...Generator is not level 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 ...

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Page 60: ...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 2021 2022 year small off road engine In the United States and California new small off road eng...

Page 61: ...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 62: ...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 63: ...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 64: ...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 66: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DuroMax REV XP4500iH 06012021 ...