*Gasoline & Propane Tank Not Included XP5500EH GENERATOR User Manual REV: XP5500EH-06142019 This manual provides information regarding the operation and maintenance 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.
CONTENTS 1. Introduction Introduction ..................................................................................................................... 6 General Safety Procedures ............................................................................................ 7 Quick Start Guide (Gasoline) ....................................................................................... 10 Quick Start Guide (Propane).....................................................................................
CONTENTS 5. Maintenance and Care Maintenance Schedule................................................................................................... 40 Maintenance Log ........................................................................................................... 41 Checking the Oil ............................................................................................................. 42 Changing the Oil..................................................................................
INTRODUCTION DuroMax has cemented its reputation as one of the markets leading power equipment companies who are headquartered in the US. All of our products are manufactured to the strictest guidelines and go through countless testing in all phases of production. Evolving our strong engine line, DuroMax has complemented its offerings to include Pressure Washers, Water Pumps, Engines and now offering V-Twin engines.
GENERAL SAFETY PROCEDURES SAFETY ALERT SYMBOL 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 this manual and on the generator. Please familiarize yourself with the following safety symbols and words: ●● DANGER: Indicates a hazard that will result in serious injury or death if instructions are not followed.
GENERAL SAFETY PROCEDURES WARNING: This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death. A nearby open flame can lead to an explosion even if not directly in contact with gas. ●● Do not operate near an open flame. ●● Do not smoke near generator. ●● Always operate on a firm, level surface. ●● Always turn generator off before refueling. ●● Allow generator to cool for at least 2 minutes before removing fuel cap.
GENERAL SAFETY PROCEDURES In addition to the above safety notices, please familiarize yourself with the safety and hazard markings on the generator.
QUICK START GUIDE (GASOLINE) 1. Remove shipping braces The shipping braces prevent engine movement during shipment. Flip the generator over and remove the brightly colored brace between the motor and the frame, and the wood brace under the generator. 2. Add oil The oil fill cap is located on the lower engine block to the right of the recoil start housing. Remove the oil fill cap and fill with 20 oz of 10w30 oil. 3. Add gasoline The fuel cap is located on top of the fuel tank.
6. 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. 7. Start generator The 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. 8. Open choke The choke lever is located above the air filter to the right of the recoil start.
QUICK START GUIDE (PROPANE) 1. Remove shipping braces The shipping braces prevent engine movement during shipment. Flip the generator over and remove the brightly colored brace between the motor and the frame, and the wood brace under the generator. 2. Add oil The oil fill cap is located on the lower engine block to the right of the recoil start housing. Remove the oil fill cap and fill with 20 oz of 10w30 oil. 3. Turn breaker off The breaker is located on the right side of the front power panel.
6. Connect propane tank The propane hose is located on the left side of the regulator, below the OHV valve cover. Screw the open ACME nut connection to your propane tank and turn the tank on. 7. Adjust choke The choke lever is located above the air filter to the right of the recoil start. Slide the lever to the right to open the choke and increase air into the carburetor for normal running. 8. Start The switch is located on the left side of the front power panel.
GENERATOR COMPONENTS 6. 120/240v 4-Prong Receptacle 8. 120v 3-Prong Receptacle 10. Volt Meter 2. Choke Lever 20. Power Boost 16. Fuel Valve 5. Circuit Breaker 1. Air Cleaner 7. Ground Terminal 11. 12v DC Charging Posts 9. Battery 12. Oil Fill and Dipstick 14. Recoil Start 19. Propane Connector 13. Engine Switch 1. Air Cleaner - a removable, cleanable, oiled, sponge-like element that cleans the air going into the engine. 2.
. Fuel Filter Cup 4. Fuel Cap 3. Fuel Gauge 17. Spark Plug 18. Muffler 11. 12v DC Charging Posts – DC Output for charging batteries or running small DC powered items. 12. Oil Fill and Dipstick - Use to add or check the oil. 13. Engine Switch – 3 Position Switch to “Start”, “Run”, or turn “Off” the generator. 14. Recoil Start – Easy Pull Recoil Start to start the engine without the electric start. 15. Fuel Filter Cup - Traps dirt and debris in gasoline before it enters the engine. 16.
PACKAGE CONTENTS Your generator comes with the items listed below. Please check to see that all of the following items are included with your generator. Double Sided Screw Driver Spanner Spark Plug Wrench Phillips and slot blade screwdriver used for generator maintenance. Assorted wrenches used in generator maintenance and assembly. Commonly 8mm, 10mm, 13mm, and 15mm. Used in spark plug maintenance, inspection, and installation.
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.
GENERATOR SETUP Step 1 - Remove Shipping Braces 1. Unpack a. Remove the generator from the box. b. Place the largest piece of packing foam on a flat surface. c. Flip the generator upside down on the pad. CAUTION: NEVER Attempt this if you have put fuel or oil in the generator. 2. Remove braces a. Completely remove each of the 4 bolts holding the orange metal brace in place. b. Remove the brace. c. Cut the nylon tie strap holding the wood brace in place. d.
Step 2 - Wheel Kit Installation (Optional) 1. Install support legs Secure the support legs to the frame with provided bolts and lock nuts. 2. Install wheels a. Secure the axle bracket welded to axle to the frame with the provided bolts and lock nuts. b. Secure the loose axle bracket to the frame with the provided bolts and lock nuts. c. Slide one wheel over each axle end and secure with the provided retaining pins. 3.
GENERATOR SETUP (CONTINUED) Step 3 - Adding 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 is equal to the oil capacity of the engine crankcase: Model Number XP5500EH Engine Oil Capacity 20 fl. oz (0.6L) WARNING: Do not apply engine oils with additives or 2-stroke gasoline engine oils.
Step 4 - Adding Gasoline WARNING: Gasoline and gas fumes are highly flammable. ●● Do not fill tank near an open flame. ●● Do not overfill. Always check for fuel spills. To ensure that the generator runs smoothly use only FRESH, UNLEADED GAS WITH AN OCTANE RATING OF 87 OR HIGHER. 2. Add Gasoline a. Make sure the generator is on a level surface. b. Unscrew gas cap and set aside (NOTE: the gas cap may be tight and hard to unscrew). c. Slowly add unleaded gasoline to the fuel tank.
GENERATOR SETUP (CONTINUED) Step 5 - Grounding the Generator 1. Attach grounding wire a. Ground the generator by tightening the grounding nut against a grounding wire. b. Connect the other end to a copper or brass grounding rod that’s driven into the earth. A generally acceptable grounding wire is a No. 12 AWG (American Wire Gauge) stranded copper wire. Grounding codes can vary by location. Please contact a local electrician to check the grounding regulations for your area.
STARTING THE GENERATOR If this is not your first time using the generator there 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.
BEFORE YOU START YOUR GENERATOR Step 1 - Check the oil 1. Check the oil The generator is equipped with an automatic shutoff to protect it from damage due to low oil. Nonetheless, you should 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: a. Make sure the 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.
Step 2 - Check the gas level 1. Check Fuel Level Before starting the generator, check to see that there is sufficient gasoline in the fuel tank. The fuel gauge on top of the tank will give a rough estimate of the gasoline level. The gauge will appear white then fill red as the tank is filled. Note: Fuel gauge may not register with less than 1/3 fuel tank full. WARNING: Gasoline and gasoline fumes are highly flammable. ●● Do not fill tank near an open flame.
STARTING THE GENERATOR Starting the Generator Using Gasoline 1. Shut 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. 2. Turn gas valve 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. 3. Close choke The choke lever is located above the air filter to the right of the recoil start.
5. Allow switch return to RUN When the engine starts, allow the engine switch to return to the “RUN” position. 6. Open choke Push the choke to the OPEN position as the engine warms up. 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 damage the motor.
STARTING THE GENERATOR (CONTINUED) Starting the Generator Using Propane 1. 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. 2. Turn gas valve off The gas valve is located above the recoil start on the bottom of the fuel tank. Rotate the valve counter clockwise to the horizontal position to stop the flow of gasoline to the carburetor. 3.
5. Adjust choke The choke lever is located above the air filter to the right of the recoil start. Slide the lever to the right to open the choke and increase air into the carburetor for normal running. 6. Start the generator The engine switch is located on the left side of the front power panel. Press the switch up to the “START” Position. 7. Allow switch return to RUN When the engine starts, allow the engine switch to return to the “RUN” position. 8.
STARTING THE GENERATOR (CONTINUED) Starting the Generator Using Propane WARNING: WHEN USING THE GENERATOR WITH LPG, MAKE SURE THERE IS NO POSSIBLE IGNITION SOURCE CLOSE TO THE GENERATOR. 1. Before using, make sure all of the LPG connectors and hoses are well connected and sealed. 2. Connect electrical devices to generator ONLY after the engine runs smoothly. (There may be remnant gasoline in the carburetor; this can cause unsteady engine performance for several minutes) 3.
USING THE GENERATOR If this is not your first time using the generator there 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.
USING THE GENERATOR AC Usage ●● You may connect electrical devices running on AC current according to their wattage requirements. ●● The chart below shows the rated and surge wattage of your generator according to its model number. ●● The rated wattage corresponds to the maximum wattage the generator can output on a continuous basis. ●● The surge wattage corresponds to the maximum amount of power the generator can output for a short period of time.
Tool or Appliance Rated (Running) Watts Additional Surge Watts Electric water heater (40 gal) 4000 0 Hot plate 2500 0 Radial arm saw 2000 2000 Electric Stove 1500 0 Circular Saw 1500 1500 Air compressor (1 HP) 1500 3000 Window air conditioner 1200 1800 Miter saw 1200 1800 Microwave 1000 2000 Well water pump 1000 1500 Reciprocating saw 960 1040 Sump pump 800 1200 Refrigerator freezer 800 1200 Furnace blower 800 1300 Computer 800 0 Electric drill 600 900 Tele
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 the 240v receptacle. CAUTION: Do not connect 50Hz or 3-phase loads to the generator. 1. Plug in devices Plug in devices to the appropriate receptacle.
Voltage Selector Switch This generator features Power Boost Technology, which gives the user 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.
USING THE GENERATOR (CONTINUED) DC Usage CAUTION: The DC receptacle is for recharging 12 Volt automotive-type batteries only. Do not connect any other device to this receptacle. CAUTION: Never try to jump start a car with your generator. 1. Connect the battery Connect one charging wire to the positive terminal on the battery and the other charging wire to the negative terminal on the battery. 2.
4. Connect negative receptacle Carefully connect the free end of the negative wire to the negative receptacle on the generator. 5. Disconnecting When disconnecting, always disconnect the wires from the generator first to avoid a spark. DANGER - Stored batteries emit highly explosive hydrogen gas when charged. Batteries also contain acid, which can cause severe chemical burns. DANGER - Do not allow open flames or cigarettes nearby for several minutes after charging a battery.
MAINTENANCE AND CARE Proper maintenance 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.
MAINTENANCE AND CARE Proper routine maintenance of your generator is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. 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 and maintenance recommendations and schedules in this instruction manual. ●● Make sure the engine is off before you begin any maintenance or repairs.
MAINTENANCE LOG Date Generator Hours Maintenance Performed 41
MAINTENANCE AND CARE (CONTINUED) Checking the oil 1. Check the oil The generator is equipped with an automatic shutoff to protect it from damage due to low oil. Nonetheless, you should 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: a. Make sure the 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.
Changing the oil 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 contaminated with water or dirt. 2. Remove 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. 2.
MAINTENANCE AND CARE (CONTINUED) Cleaning the air filter 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. Note: Improper maintenance may cause less air to enter the engine or dirty air to enter the engine causing overheating and engine wear. 1. Open filter cover Unhinge the clasps at the top and bottom of the air cleaner cover. 2.
4. Wash filter element Wash the sponge-like elements in household dish detergent and warm water. 5. Dry filter element Allow the elements to dry completely. 6. Add engine oil to elements Soak the dry elements in a small amount of engine oil. Ring out any excess oil. 7. Replace elements in casing Replace the sponge-like elements in the air cleaner casing and replace the cover.
MAINTENANCE AND CARE (CONTINUED) 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. Improper maintenance may cause reduced fuel economy, misfires, trouble starting, or damage to the spark plug threads. 1. Remove spark plug cap Pull on the spark plug cap to remove it. 2. Remove spark plug Unscrew the spark plug from the generator using the spark plug wrench included with this product. 3.
4. Measure plug gap Measure the plug gap with a gauge. The gap should be 0.7-0.8 mm (0.028-0.031 in). 5. Clean 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. 6. Replace spark plug Screw the spark plug back into its place on the generator using the spark plug wrench. 7. Replace spark plug cap Replace the spark plug cap.
MAINTENANCE AND CARE (CONTINUED) Emptying the Gas Tank Before storing your generator for extended periods of time, you should drain your generator of gasoline. 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. 1. Shut fuel valve off Turn the fuel valve to the “OFF” position. 2.
4. Drain gas from generator 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. Shut fuel valve off Turn the fuel valve to the “OFF” position. 6. Replace fuel filter cup Reinstall the fuel filter cup. 7. Store emptied gas Store the emptied gasoline in a suitable place and add fuel stabilizer to keep fuel fresh and usable.
MAINTENANCE AND CARE (CONTINUED) Cleaning the fuel filter cup 1. Shut fuel valve off Turn the fuel valve to the “OFF” position. 2. Remove fuel filter cup Unscrew the fuel filter cup from the fuel valve using a wrench. Turn the valve towards you to unscrew 3. Clean filter cup Clean the cup of all sediment using a rag or brush. 4. Replace fuel filter cup Reinstall the fuel filter cup.
Storage and Transportation CAUTION: Never place any type of storage cover on the generator while it is still hot. When transporting your generator: ●● Empty the gas tank (see “Emptying the Gas Tank” in the “Maintenance” section). ●● Disconnect the spark plug. ●● Do not obstruct any ventilation openings & keep the generator in a cool dry area. Storage Period Storage Preparation If you plan on starting the same day. 1. 2. 3. 4. Turn off the main breaker. Allow the unit to run 3 - 5 minutes.
SPECIFICATIONS AC Rated Wattage (Gasoline) 4500W AC Rated Wattage (Propane) 4275W AC Surge Wattage (Gasoline) 5500W AC Surge Wattage (Propane) 5225W AC Rated Voltage 120/240V AC Rated Frequency 60 Hz AC Phase Single DC Voltage 12V DC Amperage 8.3A Dimensions LENGTH 23.2in. WIDTH 17in. HEIGHT 17in. Engine Type 4-Stroke OHV Forced-Air Ignition System Non-Contact Transistor Displacement 224cc Starting Type Electric Fuel Tank Capacity 3.96 US Gal. (15L) Oil Capacity 20 fl.
TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator.
TROUBLESHOOTING Mode Engine will not start Engine runs, but there is no electrical output. Generator runs, but does not support all electrical devices connected.
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. 1. Remove generator cover Remove the 2 bolts of the generator cover then pull the cover off the generator. 2. Remove bolt from brush Remove the bolt holding the carbon brush. 3.
TROUBLESHOOTING (CONTINUED) Changing / Inspecting the Carbon Brushes (Cont.) 4. Install new brush Install new carbon brush with bolt. 5. Connect AVR wires Insert and connect the 2 wires from the AVR, be sure to connect + and – correctly.. 6. Replace generator cover Replace the back cover of the generator and secure with the 2 bolts.
Changing / Inspecting the AVR The carbon brushes in conjunction with the AVR regulates power from the generator. If the generator is overheated or overloaded, the AVR may be damaged and require replacement. 1. Remove generator cover Remove the 2 bolts of the generator cover then pull the cover off the generator. 2. Remove AVR bolts Remove the 2 bolts holding the AVR. 3. Disconnect AVR wire clip Disconnect the wire clip.
TROUBLESHOOTING (CONTINUED) Changing / Inspecting the AVR (Continued) 4. Disconnect wires from brush Remove the 2 wires from the AVR on the carbon brush. 5. Install new AVR Install the new AVR with the 2 bolts. 6. Reconnect wires to brush Reconnect the wire clip. 7. Reconnect the AVR wire clip Insert and connect the 2 wires from the AVR, be sure to connect + and – correctly.
8. Replace generator cover Replace the back cover of the generator and secure with the 2 bolts.
WIRING DIAGRAM 60
WARRANTY 3-year Warranty All DuroMax Power Equipment warrant the original purchasers to a 3-year Parts Warranty (Residential Use ONLY: Unusually heavy or commercial use is covered for a period of 1-year) in the event of failure due to defects in electrical or mechanical components. Freight on any items submitted for replacement or repair under the Warranty are the responsibility of the equipment owner. This warranty is non-transferable and only valid to the original purchaser.
OWNER’S WARRANTY RESPONSIBILITIES: ●● As the small off-road engine owner, you are responsible for performance of the required maintenance listed in your owner’s manual. DuroMax Power Equipment recommends that you retain all receipts covering maintenance on your small off-road engine, but DuroMax Power Equipment cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.
WARRANTY (CONTINUED) 1. Any warranted part that is scheduled only for regular inspection in the Owner’s Manual must be warranted for the warranty period stated above. A statement in such written instructions to the effect of “repair or replace as necessary” will not reduce the period of warranty coverage. Any such part repaired or replaced under warranty must be warranted for the remaining warranty period. 2.
Exhaust Emission Warranty Parts List. 1. Fuel Metering System i. Carburetor and internal parts (and/or pressure regulator or fuel injection system). ii. Air/fuel ratio feedback and control system. iii. Cold start enrichment system. 2. Air Induction System i. Controlled hot air intake system. ii. Intake manifold. 3. Ignition System i. Spark Plugs. ii. Magneto or electronic ignition system. iii. Spark advance/retard system. 4. Air Injection System i. Air pump or pulse valve. ii.
CUSTOMER SERVICE Duromax Power Equipment is comitted to ensuring that our products perform when they need to. Our generators 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: customerservice@duromaxpower.
5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX
