Benchmark BG4500i User manual

BG4500i
MANUAL
TM

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Thanks for choosing the BG4500i!
You're excited to get started, we'll keep this brief.
READ THIS ENTIRE GUIDE BEFORE USING THIS
PRODUCT AND SAVE FOR LATER USE.
This user guide contains important instructions including safety,
setup, operation, and maintenance that must be followed. All
information in this guide is based on information available at
the time of print. This guide or revised editions can be found on
our website for download. No part of this publication may be
reproduced without written permission.
THIS PRODUCT MEETS ALL CERTIFICATION REQUIREMENTS FROM:
The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.
©2022 Benchmark. All Rights Reserved.
BG4500I_Manual_EN_2022-05-25

TABLE OF CONTENTS
1. Safety 1
2. Learn About Your Generator 5
2.1 Component Identification 5
2.2 Control Panel 6
2.3 Control Functions 7
2.4 Make Sure You Have Everything 9
3. Pre-Operation Check 10
4. Starting the Engine 15
5. Generator Use 20
5.1 Output, Overload, and Oil Alert Indicator 20
5.2 DC Applications 21
5.3 AC Applications 22
5.4 AC Parallel Operation 23
5.5 Extending the Handle 24
6. Stopping the Engine 25
7. Maintenance 26
7.1 Maintenance Schedule 27
7.2 Changing the Oil 28
7.3 Cleaning the Air Filter 30
7.4 Spark Plug Service 31
7.5 Spark Arrester Maintenance 32
7.6 Fuel Filter Maintenance 33
7.7 How To Sync A New Remote (Remote Pairing) 34
7.8 Charging the Onboard Li-ion Battery 35
7.9 Replacing the Battery 36
7.10 Emission Control System 37
8. Transportation & Storage 39
9. Troubleshooting 41
10. Technical Specifications 43
11. Wiring Diagram 44
12. Appendix 45
13. Limited Warranty 46

1
1. SAFETY
DANGER!
Using a generator indoors can kill you in minutes.
Generator exhaust contains carbon monoxide. This is a poison
that you cannot see or smell.
NEVER use inside a home or garage.
WARNING!
This product can expose you to chemicals including carbon
monoxide, which is known to the State of California to cause
cancer and birth defects or other reproductive harm. For more
information go to www.P65Warnings.ca.gov
1.1 OPERATOR SAFETY
WARNING!
Always perform an oil, fuel and air lter check before starting the engine.
Properly clean and maintain the equipment.
Operate the generator according to instructions for safe and
dependable service.
Before operating the generator, read the user guide carefully. Otherwise,
personal injuries or equipment damage may result.
Never run the generator in an enclosed area to avoid harm from exhaust
emissions of a poisonous carbon monoxide gas.
Pay attention to the warning labels. The engine exhaust system will
become heated during operation and remain hot immediately after the
engine is stopped.
TOXIC FUMES HAZARD. Running engines give off
carbon monoxide, an odourless poisonous gas
that can cause nausea, fainting, or death. Do
not start engine indoors or in an enclosed area,
even if the windows and doors are open.
DANGER TOXIQUE. Faire fonctionner un moteur dégage de
l’oxyde de carbone, un gaz inodore toxique qui peut
provoquer la nausée, évanouissement ou la mort. Ne
démarrer pas le moteur à l’intérieur ou dans une espace clos,
meme si les fenêtres et les portes sont ouvertes.
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2
Gasoline is a highly ammable and explosive liquid. Refuel in a well
ventilated area with the engine stopped.
Use of gasoline with an ethanol content greater than 10% can damage
the engine and fuel system and will void the manufacturer’s warranty.
When refueling the generator, keep it away from cigarettes, open ames,
smoke and/or sparks.
Place the generator at least 3 feet away from buildings or other
equipment during operation.
Run the generator on a level surface. Tilting the generator may result in
fuel spills.
Do not touch the spark plug while the engine is operating or shortly after
the engine has been shut down.
Know how to stop the generator quickly and understand operation of
all the controls. Never permit anyone to operate the generator without
proper instructions.
Keep children, pets and machinery with rotating parts away during
operation.
Do not operate the generator in rain or snow.
Do not allow any moisture to come in contact with the generator.
1.2 AC SAFETY
WARNING!
Before connecting the generator to an electrical device or power cord:
Make sure that everything is in proper working order. Faulty devices or
power cords can lead to an electrical shock.
Turn off the generator immediately if the device begins to operate
abnormally. Then disconnect the device and investigate the problem.
To prolong engine life, do not exceed the rated running wattage.
Keep away from other electric cables or wires.
Make sure that the electrical rating of the device does not exceed
that of the generator. If the power level of the device is between the
maximum output power and the running power of the generator, the
generator should not be used for more than 30 minutes.
When an extension cable is required, be sure to use a tough rubber
sheathed exible cable (according to IEC245 or equivalent standards).
The maximum length of the extension cable: 196 feet (60 meters) for
cable of 15.5 gauge (1.5mm2); 328 feet (100 meters) for cable of 13.25
gauge (2.5mm2).

3
Connections for standby power to a building’s electrical system must
be done by a qualied electrician and must comply with all applicable
laws and electrical codes. Improper connections may cause serious
injuries to electrical workers during a power outage, and when the
utility power is restored, the generator may explode or cause res. The
generator shall be connected through transfer equipment that switches
all conductors other than the equipment grounding conductor. The
frame of the generator shall be connected to an approved grounding
electrode.
For power outages, permanently installed stationary generators are
better suited for providing backup power to the home. Even a properly
connected portable generator can become overloaded. This may result
in overheating or stressing the generator components, possibly leading
to a generator failure.
This unit is oating neutral. The generator (stator winding) is isolated
from the frame and from the AC receptacle ground pin.
Electrical devices that require a grounded receptacle pin connection will
not function if the receptacle ground pin is not functional.
1.3 MAINTENANCE SAFETY
WARNING!
After any maintenance is performed, wash immediately using soap and
clean water because repeated exposure to lubricant may cause skin
irritation.
Do not clean the lter element with ammable liquids like gasoline
because an explosion may occur.
Allow the generator set to cool down and turn off the engine before
performing any maintenance. Failure to do so can cause severe
personal injury or death.
Always wear safety glasses when cleaning the generator set with air.
Do not clean the generator set with a pressure washer because it can
damage the generator set.
When working with batteries, ventilate the area, use safety glasses, do
not smoke. Always disconnect the negative rst and reconnect it last.
Use rubber gloves when coming into contact with engine oil.
Always stop the generator set before removing the oil ller cap.
Only qualied maintenance personnel with knowledge of fuels,
electricity, and machinery hazards should perform maintenance
procedures.
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4
1.4 OTHER SAFETY TIPS
WARNING!
To avoid breathing in poisonous carbon monoxide from the exhaust
gases, adequate ventilation should be provided if the generator set is
running in a partially enclosed space.
If the generator set is stored outdoors, check all the electrical
components on the control panel before each use. Moisture can
damage the generator and can lead to an electric shock.
Do not connect an extension to the exhaust pipe.
Generators vibrate in normal use. During and after the use of the
generator, inspect the generator as well as extension cords and power
supply cords connected to it for damage resulting from vibration. Have
damaged items repaired or replaced as necessary. Do not use plugs or
cords that show signs of damage such as broken or cracked insulation
or damaged blades.
If you start to feel sick, dizzy, or weak after the generator has been
running, move to fresh air RIGHT AWAY. See a doctor. You could have
carbon monoxide poisoning.
TOXIC FUMES HAZARD. Running engines give off
carbon monoxide, an odourless poisonous gas
that can cause nausea, fainting, or death. Do
not start engine indoors or in an enclosed area,
even if the windows and doors are open.
DANGER TOXIQUE. Faire fonctionner un moteur dégage de
l’oxyde de carbone, un gaz inodore toxique qui peut
provoquer la nausée, évanouissement ou la mort. Ne
démarrer pas le moteur à l’intérieur ou dans une espace clos,
meme si les fenêtres et les portes sont ouvertes.

5
2. LEARN ABOUT YOUR GENERATOR
This section will show you how to identify key parts of your generator. Going over
the terminology below will make sure we’re on the same page.
2.1 COMPONENT IDENTIFICATION
Telescoping Handle
Control Panel
Air Filter
Maintenance
Panel
Recoil Grip
Oil
Maintenance
Panel
Fuel Cap
Rear Carrying
Handle
Mufer & Spark
Arrester
Battery
Maintenance
Panel
Front Carrying
Handle
Never Flat Wheels
BG4500i

6
2.2 CONTROL PANEL
BG4500i
19
67
8
1
23
4
5
910 11
12
13
14 15 16 17 18
20
1. Master Breaker
2. 120V 20A (5-20) Outlet
3. 20A AC Breaker
4. Hour Meter
5. 120V 30A (TT-30) Outlet
6. Electric Start Button
7. Fuel Valve
8. 30A AC Breaker
9. EcoMode
10. Battery Power Switch
11. Ready to Use Indicator
12. Overload Indicator
13. Low Oil Indicator
14. 5V 4.8A USB-C and USB-A Ports
15. Parallel Ports
16. 8A DC Breaker
17. 12V 8A DC Outlet
18. Remote Start Ready Indicator
19. Onboard Battery Charging Port
20. Ground Terminal

7
2.3 CONTROL FUNCTIONS
AC Circuit Breakers
While the generator is running, the breakers should be put in the ON
position.
If the current has exceeded its limits it will automatically pop out to the
OFF position. Reduce the electrical load on the generator and push the
button back to the ON position.
Battery Charging Port
When the generator will be stored for an extended period of time plug
the battery charger into a 120V outlet every two months to top up the
battery and prolong its life.
Battery Power Switch
Disconnects the circuit to the electric start battery to reduce battery
drain while not in use.
DC Circuit Breakers
The DC circuit breaker automatically shuts off when the charging circuit
is overloaded.
If the current has exceeded its limits the breaker will automatically pop
out to the OFF position. Reduce the electrical load on the generator and
push the button back to the ON position.
Hour Meter
Display shows total run time. Use this to perform maintenance at the
proper intervals according to the ‘Maintenance Schedule’ section of this
manual.
EcoMode (Economy Control Switch)
Turning EcoMode to ON is recommended for minimizing fuel
consumption. In this mode the engine will dynamically meet the demand
of the current electrical load and will automatically go into an idle state if
all electrical loads are disconnected.
Before connecting or removing a high load device to the generator, turn
EcoMode to OFF until that device has reached running power.
When EcoMode is OFF, the engine runs at full speed.
BG4500i

8
Ground Terminal
WARNING!
Before using the ground terminal consult a qualified electrician,
electrical inspector, or local agency having jurisdiction for local
laws and codes that apply to the intended use of the generator.
The ground terminal is connected to the non-current carrying metal
parts (such as the fuel tank), the frame, and the ground terminals of the
AC outlets. Floating Neutral.
AC Parallel Ports
These ports allow two approved i-Series inverter generators to be
connected for additional power. The parallel kit is an optional accessory.
To purchase, contact your local Home Hardware store or visit us online.
Low Oil Indicator Light
The oil alert system is designed to prevent engine damage caused by
an insufcient amount of oil in the crankcase. Before the oil level in the
crankcase reaches an unsafe limit, the oil alert system will automatically
shut down the engine (the battery power switch remains in the ON
position).
If the oil alert system shuts down the engine, the low oil indicator light
(red) will turn on. Check the engine oil level.
Output and Overload Indicator
In normal operation, the green output indicator light (READY TO USE)
will remain on.
If the generator is overloaded (producing more than running wattage) or
a connected appliance has short-circuited, the output indicator light will
turn off and the overload indicator light will turn on.
Electric Start
One touch start and stop electric start.
Remote Ready Indicator
Lights up green when the generator is ready to be remotely started.
Start your generator from up to 100 feet away with the remote.

9
2.4 MAKE SURE YOU HAVE EVERYTHING
Make sure your generator has everything listed in the table below.
Part Name Quantity
Inverter Generator 1
User Guide 1
Spark Plug Wrench 1
Oil Funnel 1
Electric Start Battery 1
Starting Battery Wall Charger 1
Maintenance Screwdriver 1
Remote 1
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10
3. PRE-OPERATION CHECK
Set the generator on a level surface and turn the fuel valve to closed.
3.1 ADD OIL
1. Remove the oil maintenance panel.
2. Unscrew the oil dipstick and wipe it off.
3. Remove the dipstick and ll the oil to the maximum oil mark. Check the oil
level by reinserting the dipstick without rethreading it.
4. Reinsert the dipstick and tighten securely. Replace the oil maintenance
panel and screws.
NOTE
SAE 10W-30 or SAE Synthetic 5W-30 is recommended for general use.
Use of synthetic oil does not change maintenance intervals.
Oil Capacity: 20 . oz. / 0.6 L
DO NOT OVERFILL.

Max Oil Level
Min Oil Level
Oil Capacity
20 . Oz / 0.6L
Oil Cap &
Dipstick
0°C 10 20 30 40 50-10-20-30
20 32°F 40 60 80 100 120
°C
°F0-20
15W-50
10W-30
Synthetic 5W-30
5W-30
Effective Viscosity Range of Engine Oils
Max Oil Level
Min Oil Level
Oil Capacity
20 . Oz / 0.6L
Oil Cap &
Dipstick
0°C 10 20 30 40 50-10-20-30
20 32°F 40 60 80 100 120
°C
°F0-20
15W-50
10W-30
Synthetic 5W-30
5W-30
Effective Viscosity Range of Engine Oils

11
3. PRE-OPERATION CHECK
Set the generator on a level surface and turn the fuel valve to closed.
3.1 ADD OIL
1. Remove the oil maintenance panel.
2. Unscrew the oil dipstick and wipe it off.
3. Remove the dipstick and ll the oil to the maximum oil mark. Check the oil
level by reinserting the dipstick without rethreading it.
4. Reinsert the dipstick and tighten securely. Replace the oil maintenance
panel and screws.
NOTE
SAE 10W-30 or SAE Synthetic 5W-30 is recommended for general use.
Use of synthetic oil does not change maintenance intervals.
Oil Capacity: 20 . oz. / 0.6 L
DO NOT OVERFILL.

Max Oil Level
Min Oil Level
Oil Capacity
20 . Oz / 0.6L
Oil Cap &
Dipstick
0°C 10 20 30 40 50-10-20-30
20 32°F 40 60 80 100 120
°C
°F0-20
15W-50
10W-30
Synthetic 5W-30
5W-30
Effective Viscosity Range of Engine Oils
Max Oil Level
Min Oil Level
Oil Capacity
20 . Oz / 0.6L
Oil Cap &
Dipstick
0°C 10 20 30 40 50-10-20-30
20 32°F 40 60 80 100 120
°C
°F0-20
15W-50
10W-30
Synthetic 5W-30
5W-30
Effective Viscosity Range of Engine Oils
Do not tilt the generator when adding engine oil. This could result in
overlling and damage to the engine.
Use high quality 4-stroke engine oil, certied to meet or exceed API
standard SG, SF, SAE ratings with strong detergents. Using non-
detergent or 2-stroke oil could shorten the engine’s working life.
Do not mix different engine oils.
Handle and store the engine oil with care, avoid getting dirt or dust into
the engine oil.
Before the engine oil falls below the safety margin, the low oil alert
system will automatically shut off the engine. The low oil light will
turn on.
To avoid the inconvenience of unexpected engine shutoff, check the oil
level as often as possible.
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12
3.2 ADD FUEL
DANGER!
Gasoline is highly flammable and explosive under certain
conditions. Refuel in a well-ventilated area with the engine
stopped. Do not smoke or allow open flames or sparks in the
area where the generator is being refueled or where gasoline
is stored. Do not overfill the tank. Be careful not to spill fuel
when refueling. Wipe up any spilled gasoline and let the area dry
before starting the engine.
Gasoline substitutes such as gasohol are not recommended.
They may be harmful to the fuel system components.
NOTE
Use of gasoline with an ethanol content greater than 10% can damage
the engine and the fuel system and will void the manufacturer’s
warranty.
Only use unleaded gasoline (Octane 85 or higher).
Never use stale or contaminated gasoline, or an oil/gasoline mixture.
Avoid getting dirt or water into the fuel tank.
Do not use a mixture of gasoline containing methanol. This will cause
serious damage to the engine.
Upper Limit
Mark (Red)Fuel Cap
OPEN
Fuel Capacity: 3.2 Gal / 12 L

13
3.3 CHECK THE AIR FILTER
Examine the air lter before your rst use. Check the maintenance section for a
complete cleaning guide.
1. Unscrew and remove the air lter maintenance panel.
2. Undo the clasps and remove the paper air lter.
3. If dirty clean the dirt/dust out with compressed air.
4. Insert lter back into air lter housing and secure clasps.
NOTE
Running the engine without the air lter or a dirty air lter will quickly
degrade the engine.
1 2
Air Filter
Housing
Clips
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14
3.4 CONNECT THE LI-ION BATTERY
WARNING!
The improper use of a lithium-ion battery can cause battery
damage and/or endanger personal safety. Please read carefully,
use correctly and take precautions. Do not expose to extreme
temperatures. Users must not dismantle or service. Do not
dispose in household trash. Dispose and transport according to
local lithium-ion battery guidelines.
1. Loosen the four screws of the battery maintenance cover and remove it.
2. Slide the battery into place until it clicks and replace the cover.
3.
NOTE
Be sure to connect the battery to the generator set before operation.
1 2

15
4. STARTING THE ENGINE
DANGER!
Using a generator indoors WILL KILL YOU IN MINUTES.
Generator exhaust contains high levels of carbon monoxide
(CO), a poisonous gas you cannot see or smell. If you can smell
the generator exhaust you are breathing CO. Even if you cannot
smell the exhaust, you could be breathing CO.
NEVER use a generator inside a home, garage, crawlspace, or
other partly enclosed area, deadly levels of carbon monoxide
can build up in these areas. Using a fan or opening windows and
doors will NOT supply enough fresh air.
ONLY use a generator outdoors and far away from open windows,
doors, and vents. These openings can pull in generator exhaust.
Even when you use a generator correctly, CO may leak into the
home. ALWAYS use a CO alarm in your home.
If you start to feel sick, dizzy, or weak after the generator has
been running, move to fresh air RIGHT AWAY and seek medical
attention. You could have carbon monoxide poisoning. Never
run the generator in an enclosed or even partially enclosed area
where people may be present.
BG4500i

16
4.1 STARTING YOUR GENERATOR
WARNING!
Before using the generator, a ground wire may need to be
connected to the ground terminal. The terminal is located on the
front panel. Before using the ground terminal consult a qualified
electrician.
NOTE
Shipping restrictions for li-ion batteries require the batteries to be
shipped at a low state of charge. It is recommended to manually recoil
start the generator when starting the rst time.
If there is no battery in the generator or the battery has died, the
generator can only be started using the recoil method. If there is a
battery and it is drained, running the generator will slowly recharge the
battery.
4.1.1 Remote Start
1. Push the battery power switch to ON.
2. Rotate the fuel valve to OPEN.
3. Check the Remote Start Ready light is on. Generator will remain in remote
start standby mode for 10 days.
4. Press the START button for no more than 2 seconds to re up the generator.
If it does not start after 5 attempts consult the troubleshooting chapter.
OPEN
ON
OPEN
START
ON
1
4
2 3
1 2 3