DUROMAX XP6500E, XP8500E Owner's Manualanual

Gasoline Powered Generator

XP6500E and XP8500E

Owner’s Manual

Max Tool Customer Service

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Product Support (Product: information, application, service info & warranty questions)

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This manual provides information regarding the operation and maintenance of these prod ucts.
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.

or call 1-800-629-3325 (option 3) Monday -Thursday 6am to 7pm, Friday 6am to 5:30pm. PST

or call 1-800-629-3325 (option 3) Monday -Thursday 6am to 7pm, Friday 6am to 5:30pm. PST

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FEATURES

·

Powerful Enough to Run Essential Appliances

·

During Power Outages

·

120 and 240 Volt AC Outputs

·

12V DC Output for Automotive Battery Charging

·

Low Oil Automatic Shutoff

·

Circuit Breaker for Overload Protection

·

Max Fuel Tank Capacity

·

Handles and Wheels For Extra Mobility

·

Meets EPA and CARB emissions standards

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TABLE OF CONTENTS

GENERAL SAFETY PROCEDURES………………………………………………………………1
PACKAGE CONTENTS…………………………………………………………………………….4
GENERATOR COMPONENTS……………………………………………………………………..5

PREPARING THE GENERAT OR FOR USE....…...............………………………………………6

Using the Generator for the First Time....................................…………………………...6

Step 1-Add Oil.………………………………….…………………………………..6

Step 2- Add Gasoline.…………………………………………………....................7

Step 3- Ground the Generator...................……………………………………….7

Subsequent Use of the Generator.....................…………………………………………..8

Step 1- Check the Oil..........................……………………………………………..8

Step 2-- Check the Gas Level......................……………………………………...8

Step 3- Ground the Generator...................………………………………………..8

STARTING THE GENERATOR...................……………………………………………………….9

USING THE GENERATOR...................………………………………………………………….10

AC Usage........................…………………………………………………………………10

DC Usage......................…………………………………………………………………..12

STOPPING THE GENERATOR....................……………………………………………………13

MAINTENANCE / CARE.........................………………………………………………………13

Cleaning the Generator............................................……………………………………13

Checking the Oil.........................…………………………………………………………14

Changing/Adding Oil..………………………………………………………………………14

Air Cleaner Maintenance..……………………………………………………………..15

Fuel Filter Cup Cleaning…………………………………………………………………….16

Spark Plug Maintenance....………………………………………………………………..16

Emptying the Gas Tank..………………………………………………………………….17

STORAGE / TRANSPORT PROCEDURES.................................……………………………..17

SPECIFICATIONS.....................................................……………………………………………17

TROUBLESHOOTING .............................................……………………………………………18

WIRING DIAGRAM .................................................……………………………………………20

EXPLODED VIEW AND PARTS LIST....................................…............……………………….21

Notice Regarding Emissions

Engines that are certified to comply with California and 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).

GENERAL SAFETY PROCEDURES

Please familiarize yourself with the following safety symbols and words:
The safety alert symbol

is used with one of the safety words (DANGER, CAUTION, or
WARNING) to alert you to hazards. Please pay attention to these hazard notices both in this
manual and on the generator.

DANGER: Indicates a hazard that will result in serious injury or death if instructions are not
followed.

WARNING: Indicates a strong possibility of causing serious injury or death if instructions are not
followed.

CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not
followed.

DANGER: This generator produces poisonous carbon monoxide gas when
running. This gas is both odorless and colorless. Even if you do not see or smell
gas, carbon monoxide may still be present. Breathing this poison can lead to
headaches, dizziness, 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 can cause severe burns or even death. A nearby open flame can lead
to explosion even if not directly in contact with gas.

• Do not operate near 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. Loosen cap slowly to relieve pressure in tank.

• Do not overfill gas tank. Gas may expand during operation. Do not fill to the top of
the tank.

• Always check for spilled gas before operating.

• Empty the gasoline tank before storing or transporting the generator.

• Before transporting, turn fuel valve to off and disconnect the spark plug.

WARNING: This generator produces heat when running. Temperatures near

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.

CAUTION: Misuse of this generator can damage it or shorten its life.

• Operate only on dry, level surfaces.

• Shut off and disconnect any malfunctioning devices from generator.

• Do not exceed the Wattage capacity of the generator by plugging in more electrical

devices than the unit can handle (see "PRECAUTIONS-OVERLOADING THE
GENERATOR").

• Do not turn on electrical devices until after they are connected to 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, either directly or with an
extension cord. NEVER connect to a building electrical system without a qualified
electrician. Such connections must comply with local electrical laws and codes.
Failure to comply can create a backflow of power, which may result in serious injury
or death to utility workers.

• Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as metal

• Do not touch bare wires or receptacles (outlets).

• Do not allow children or non-qualified persons to operate.

decking or steel work. GFCIs are available in-line with some extension cords.

• Do not use uncovered in rainy or wet conditions.

• Use the generator only for its intended purposes.

• Allow generator to run for 3 - 5 minutes before connecting any electrical devices.

• Turn off all connected electrical devices, and turn off the breaker, before stopping

the generator.

5

In addition to the above safety notices, please familiarize yourself with the safety and hazard
markings on the generator.

6

Screw driver

Spanner

Spark plug wrench

Your generator comes with the items listed below. Please check to see that all of the

PACKAGE CONTENTS

following items are included with your generator.

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(1) Air cleaner- a removable, cleanable, sponge-like element that limits the amount of dirt
pulled into the engine.
(2) Choke lever- Adjusts the amount of air let into the engine.
(3) Fuel Gauge- Indicates the amount of fuel in the tank.

(4) Fuel Cap- Access to the fuel tank for adding fuel.
(5) Volt Meter- Provides reading of voltage output.
(6) 120 Volt AC Receptacle- Use to connect electrical devices that run 120 Volt, 60 Hz,

switch.

(8) 120/ 240 Volt AC Receptacle- Use to connect electrical devices that run 120 and/or 240

(9) Circuit Breaker- Reset switch that protects the generator from electrical overload.
(10) Ground Terminal- Connect grounding wires here to properly ground unit .

Please familiarize yourself with the locations and functions of the various components and

GENERATOR COMPONENTS

controls of your generator.

240 Volt, 60Hz, single phase, AC current (NEMA L14-30R).

single phase, AC current (2×duplex NEMA L5-20R).

(7) Voltage selector - To choose the correct voltage of 120V or 120V/240V by flipping the

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(11) Idle Control Switch-Put the Idle Control Switch to “ON” position to save fuel when there
is no load; Otherwise keep the switch to “OFF” position.

(15) Oil Fill and Dipstick- Location for checking and filling engine oil.
(16) Engine Switch- Used to start/stop engine.
(17) Recoil Starter- Pull-cord for starting engine.
(18) Fuel Filter Cup- Traps dirt and water from fuel before it enters the engine.
(19) Fuel Cock- Allows fuel to enter engine.
(20) Spark plug- Provides proper engine ignition.
(21) Muffler- Reduces engine noise.

PREPARING THE GENERATOR FOR USE

Using the Generator for the First Time

If you are using the generator for the first time, there are a few steps you must take to prepare
it for operation.

Step 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 this chart.

Model number XP6500E XP8500E

Engine oil capacity

37 fluid oz. 37 fluid oz.

Figure 1- Generator Oil Capacity

CAUTION:

● Do not apply engine oil with additives or

2-stroke gasoline engine oil, as they haven’t
enough lubrication, which may shorten the
engine’s service life.

● Engine oil recommended: SAE 10W-30.

As viscosity varies with regions and
temperatures, so the lubricant has to be
selected in accordance with our
recommendation.

(12) 12V DC battery.
(13) 12V DC Receptacle- Use for charging 12 Volt automotive-type batteries only.
(14) Oil Filler Cap- Use to Add oil.

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To add oil, follow these steps:
l. Make sure the generator is on a level surface.

2. Unscrew the oil filler/dipstick cap from the engine as shown in figure 2.

3. Using a funnel, add the appropriate amount of oil, as found in figure 1, 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 (see figure 3).

4. Replace oil filler cap.

Figure 2- Unscrewing the oil cap Figure 3 - Adding oil

Step 2- Add Gasoline

WARNING: Gasoline and gas fumes are highly flammable.

● Do not fill tank near an open flame.

● 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. To add gasoline:

1. Make sure the generator is on a level surface.

2. Unscrew gas cap and set aside (NOTE: the gas cap 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 spilled gasoline with a dry clothe.

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 start up the generator in the future.

Never store generator for extended periods of time with fuel in the tank.

Model number XP6500E XP8500E

Gas tank capacity

25L(6.6 us. gallons)

Figure 4 - Gas Tank Capacity