DuroStar XP12000E Service Manual
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DuroStar XP12000E Service Manual

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XP12000E
S
E
R
V
I
C
E
M
A
N
U A
L
REV: XP12000E-06272022
5800 Ontario Mills Pkwy
This manual provides information regarding the
Ontario, CA 91764 USA
operation and maintenance of these products. We
www.duromaxpower.com
have made every effort to ensure the accuracy of the
Call our Customer Care Team Toll Free 8-5 pm PST Mon-Fri
information in this manual. We reserve the right to
844-DUROMAX
change this product at any time without prior notice.

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  • Page 1 XP12000E REV: XP12000E-06272022 5800 Ontario Mills Pkwy This manual provides information regarding the Ontario, CA 91764 USA operation and maintenance of these products. We www.duromaxpower.com have made every effort to ensure the accuracy of the Call our Customer Care Team Toll Free 8-5 pm PST Mon-Fri information in this manual.

  • Page 3: Table Of Contents

    CONTENTS Generator Components Generator Components ....................6 Maintenance and Care Maintenance Schedule ....................8 Break-In Period ....................... 9 High Altitude Operation ....................9 Changing the Carburetor Main Jet ................10 Checking the Oil ......................14 Changing the Oil ......................15 Cleaning the Air Filter ....................
  • Page 4 CONTENTS Generator Diagrams Common Engine Parts ....................39 Wiring Diagram ......................46 Maintenance Log Maintenance Log......................47...

  • Page 6: Generator Components

    GENERATOR COMPONENTS 20. 240V 4-Prong Twist Lock 8. 120V 3-Prong 19. 120V 3-Prong Receptacle Twist Lock 2. Choke Lever 21. Idle Control 5. Circuit Breaker 10. Volt Meter 1. Power Boost 16. Fuel Valve 7. Ground Terminal 1. Air Filter 11.
  • Page 7 15. Fuel Filter Cup 3. Fuel Gauge 4. Fuel Cap 17. Spark Plug 18. Muffler 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.

  • Page 8: Maintenance And Care

    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, maintenance recommendations, and schedules in this instruction manual.

  • Page 9: Break-In Period

    Break-In 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. ●...

  • Page 10: Changing The Carburetor Main Jet

    MAINTENANCE AND CARE (CONTINUED) Changing the Carburetor Main Jet Unclip the cover and element Unclip and remove the air filter cover, then remove the air filter elements. NOTE: Carburetor should be drained of all gasoline prior to servicing. Unbolt element holder Remove all 6 bolts of the element holder with an 8mm socket wrench, then remove the element holder.
  • Page 11 Remove air filter hose Remove air filter hose clip with pliers and remove hose from behind air filter. Remove carburetor solenoid Remove both Phillips screws attaching carburetor solenoid with a standard Phillips screwdriver. Remove carburetor bowl bolt Remove the carburetor bowl bolt located under the solenoid with a 14 mm socket wrench.
  • Page 13 MAINTENANCE AND CARE (CONTINUED) Changing the Carburetor Main Jet (Continued) Determine main jet location The carburetor jet is located inside the center metal tube of the carburetor. Remove main jet Remove the main jet with a flat head screwdriver. If necessary gently tap the carburetor to allow the jet and emulsion tube to fall out.

  • Page 14: Checking The Oil

    (see “Adding Oil” portion of the “Maintenance” section). The oil will be visible in the oil fill spout when full. Be sure to replace the cap when finished checking oil. Model Number XP12000E Engine Oil Capacity 40.5 fl. oz (1.2 L)

  • Page 15: Changing The Oil

    Changing the Oil 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 become contaminated with water or dirt.

  • Page 16: Cleaning The Air Filter

    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. CAUTION: Improper maintenance may cause less air to enter the engine or dirty air to enter the engine causing overheating and engine wear.
  • Page 17 Wash cleaner element Wash the sponge-like elements in household dish detergent and warm water. Dry cleaner element Pat dry on a dry cloth and allow the elements to dry completely. Add engine oil to elements Soak the dry elements in a small amount of engine oil. Ring out any excess oil.

  • Page 18: Spark Plug Maintenance

    MAINTENANCE AND CARE (CONTINUED) Spark Plug Maintenance The spark plug is important for proper engine operation. SPARK PLUG A good spark plug should be intact, free of deposits, and CONSULT MANUAL properly gapped. BEFORE REMOVING CAUTION: Improper maintenance may cause reduced fuel economy, misfires, trouble starting, or damage to the spark plug threads.
  • Page 19 Measure plug gap Measure the plug gap with a gauge. The gap should be 0.7-0.8 mm (0.028-0.031 in). 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.

  • Page 20: Emptying The Gas Tank

    MAINTENANCE AND CARE (CONTINUED) Emptying the Gas Tank If you have been using gasoline in your generator, before storing your generator for extended periods of time you should drain your generator fuel tank of gasoline. CAUTION: Do not store fuel from one season to another.
  • Page 21 Drain gas from the generator With a funnel underneath the fuel valve to catch the gas, turn the fuel valve to the “ON” position. Drain all the gas from the generator. Shut fuel valve OFF Turn the fuel valve to the “OFF” position. Replace fuel filter cup Reinstall the fuel filter cup.

  • Page 22: Cleaning The Fuel Filter Cup

    MAINTENANCE AND CARE (CONTINUED) Cleaning the Fuel Filter Cup Shut fuel valve off Turn the fuel valve to the “OFF” position. Remove fuel filter cup Unscrew the fuel filter cup from the fuel valve using a wrench. Clean filter cup Clean the cup of all sediment using a rag or brush.

  • Page 23: Transporting The Generator

    Transporting the Generator Empty the gas tank Fully drain your gas tank as shown in “Emptying the Gas Tank” on page 20-21. Disconnect the spark plug Pull on spark plug cap to disconnect spark plug from ignition wire. CAUTION: Do not obstruct any ventilation openings and keep the generator in a cool dry area.

  • Page 24: Storing The Generator For Same Day Use

    MAINTENANCE AND CARE (CONTINUED) Storing the Generator for Same Day Use Turn the main breaker OFF Move the main breaker to the “OFF” position. Run the generator Allow the generator to run for 3-5 minutes. Turn the key switch OFF Turn the key switch counter-clockwise to the “OFF”...

  • Page 25: Storing The Generator For Use Within 30 Days

    Storing the Generator for Use Within 30 Days Turn breaker OFF and run Follow steps 1 and 2 as shown on “Storing the Generator For Same Day Use” on page 24. Shut fuel valve OFF and run dry Shut the fuel valve “OFF” and allow generator to run until it stalls out.

  • Page 26: Storing The Generator For Longer Than 30 Days

    MAINTENANCE AND CARE (CONTINUED) Storing the Generator for Longer Than 30 Days Turn breaker OFF and run Follow steps 1 and 2 as shown on “Storing the Generator for Same Day Use” on page 24. Shut fuel valve OFF and run dry Shut the fuel valve “OFF”...
  • Page 27 Drain the carburetor Remove drain bolt from carburetor and drain small amount of fuel in carburetor bowl. Remove spark plug Remove spark plug as shown in “Spark Plug Maintenance” on page 18. Add oil to cylinder Add 2 tablespoons of 10W-30 motor oil directly into the spark plug hole, and pull the recoil to lubricate cylinder.

  • Page 28: Check And Adjust Valve Clearance

    MAINTENANCE AND CARE (CONTINUED) Check and Adjust Valve Clearance The engine intake and exhaust valve clearance should be checked and if necessary adjusted every 300 hours of use or 12 month period, whichever comes first. CAUTION: If the valve clearance isn’t maintained, this can cause the engine to run less efficiently and potentially cause engine damage.
  • Page 29 Set valves to top dead center Place screwdriver into spark plug hole to help determine the position of the piston, then slowly pull the recoil rope until the piston rises to the top position and both valves are closed (compression step). Check intake valve clearance The intake valve is on the right side of the cylinder head.

  • Page 30: Specifications

    SPECIFICATIONS Model Number XP12000E AC Rated Wattage 9,500 W AC Surge Wattage 12,000 W AC Rated Voltage 120/240V Dimensions 30”L x 30”W x 26”H Weight 217 lbs Recommended Oil 10W-30 Engine Displacement 457 cc Gasoline Capacity 8.3 gal Oil Capacity 40.5 fl.

  • Page 31: Torque Values

    Torque Values Part Description Torque Value Oil Drain Bolt 18.5 ± 1.5 ft. lbs. (24 ± 2 N·m) Crankcase Cover Bolt 20.5 ± 1.5 ft. lbs. (28 ± 2 N·m) Flywheel Nut 70 ± 3 ft. lbs. (95 ± 4 N·m) Ignition Coil Bolt 7.5 ±...

  • Page 33: Troubleshooting

    TROUBLESHOOTING Problem Description Solution Engine switch is “OFF” Set engine switch to “ON” Fuel valve is “CLOSED” Turn the fuel valve to “OPEN” Choke is open Close the choke The engine is out of fuel Add fuel The engine will not Fuel is old or contaminated Change fuel start...

  • Page 34: Changing/Inspecting The Carbon Brushes

    TROUBLESHOOTING (CONTINUED) 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 the 2 bolts of the generator cover then pull the cover off the generator.
  • Page 35 Install new brush Install new carbon brush with bolt. Connect AVR wires Insert and connect the 2 wires from the AVR, be sure to connect + and – correctly. Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts.

  • Page 36: Changing/Inspecting The Avr

    TROUBLESHOOTING (CONTINUED) 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. Remove generator cover Remove the 2 bolts of the generator cover then pull the cover off the generator.
  • Page 37 Disconnect wires from brush Remove the 2 wires from the AVR on the carbon brush. Install new AVR Install the new AVR with the 2 bolts. Reconnect wires to brush Insert and connect the 2 wires from the AVR, be sure to connect + and –...
  • Page 38 TROUBLESHOOTING (CONTINUED) Changing/Inspecting the AVR (Continued) Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts.
  • Page 39 COMMON ENGINE PARTS Common Engine Parts 1. Flywheel Fan DJ188F-16002-A 2. Flywheel Assembly DJ192F-16200-G 3. Oil Seal 93512 4. Starter Motor Assembly DJ188F-18600-A 5. Crankcase Assembly 270203 6. Oil Drain Plug DJ188F-11004-A 7. Oil Sensor Amplifier 245104 8. Air Filter Assembly DJ192FD-14200 9.
  • Page 40 COMMON ENGINE PARTS (CONTINUED) Common Engine Parts (Continued) 10. Breather Tube DJ188FD-11013-A 11. Valve Cover DJ188F-11300-B 12. Valve Cover Gasket DJ188F-11011-A 13. Spark Plug 97108 14. Cylinder Head Assembly DJ192F-11200-B 15. Cylinder Head Gasket DJ192F-11010-C 16. Muffler/Cylinder Head Gasket DJ188F-14006-A 17.
  • Page 41 22. Camshaft Assembly DJ192F-13100-C 23. Crankshaft Assembly DJ192F-12100-BB 24. Balancing Shaft Assembly DJ192F-12004-A 25. Crankcase Cover Gasket DJ192F-11003-B 26. Bearing GB276-89-6207 27. Crankcase Cover DJ190F-11001-B 28. Oil Cap/Dipstick 265604-295 29. Oil Seal 93512 30. Recoil Assembly 274727-072 31. Ignition Coil Assembly DJ188F-18100-C...
  • Page 42 COMMON ENGINE PARTS (CONTINUED) Common Engine Parts (Continued) 32. Air Filter/Carburetor Gasket DJ188F-14027-A 33. Carburetor DJ190FD-14100-A 34. Carburetor/Spacer Gasket DJ188F-14005-B 35. Spacer Gasket DJ192FD-14004-A 36. Gasoline Feed Hose 14034 37. Spacer/Cylinder Gasket DJ188F-14003-B 38. Throttle Return Spring DJ188F-15008-A 39. Governor Arm Spring DJ192F-15007-A 40.
  • Page 43 44. Breather Valve 245405 45. Breather Valve Gasket DJ168F-14804-A 46. Fuel Valve Assembly 518614 47. Fuel Tank 700826-072 48. Fuel Filter 518801 49. Fuel Tank Cap 14306 50. Stator and Rotor Assembly 750041 51. Stator Support DF6500H-33005-A 52. Brush Assembly DF3800H-33001-A 53.
  • Page 44 COMMON ENGINE PARTS (CONTINUED) Common Engine Parts (Continued) 56 57 58 59 60 61 55. Key Switch Assembly 34203-002 56. Main Circuit Breaker 6434-35 57. Voltage Meter 6416 58. 120V 30A Outlet 34204-002 59. 120V 20A GFCI Outlet 34204-007 60. 240V 30A Outlet 6241 61.
  • Page 45 67. Wheel 523679 68. Cotter Pin 548201 69. Axle DF6500H-31018-I 70. Axle Nut GBT6187-N-12 71. Vibration Pad 531903 72. Support Leg DF6500H-31020-A 73. Handle Assembly 526901-010 74. Handle Grips 528601 75. Positive Battery Cable 512001 76. Battery 31110-Y9X0110-0000 77. Negative Battery Cable 512013...
  • Page 46 WIRING DIAGRAM...
  • Page 47 MAINTENANCE LOG Maintenance Log As a best practice it’s recommended to keep a log of the engine hours and maintenance to ensure your engine is always operating to its full potential. Date Engine Hours Maintenance Performed...
  • Page 48 MAINTENANCE LOG (CONTINUED) Date Engine Hours Maintenance Performed...
  • Page 49 Date Engine Hours Maintenance Performed...
  • Page 50 MAINTENANCE LOG (CONTINUED) Date Engine Hours Maintenance Performed...
  • Page 51 Date Engine Hours Maintenance Performed...
  • Page 52 MAINTENANCE LOG (CONTINUED) Date Engine Hours Maintenance Performed...
  • Page 54 5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX REV: XP12000E-03142023...

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