DUROMAX XP16HP, Owner'S Manual

Page 1: ...f 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 Please keep this manual available to all users during the entire life of the engine info duromaxpower com or call 844 DUROMAX Monday Friday 7am to 5 00pm PST support duromaxpower com or call 844 DUROMAX Monday Friday 7am to...

Page 2: ...PERATION INSPECTION 4 OPERATING AT HIGH ALTITUDE 9 SHUTTING DOWN 9 CHANGING THE ENGINE OIL 11 LOW OIL SENSOR 8 CLEANING THE AIR CLEANER 12 CLEANING THE DEPOSIT CUP 13 CARBURETOR IDLE ADJUSTMENT 14 SPECIFICATIONS 17 I START ENGINE DIFFICULTLY 17 SERVICE AFTER STORAGE 16 IV STOPS SUDDENLY WHEN RUNNING 20 III GASOLINE ENGINE WILL NOT RUN SMOOTHLY 19 EXPLODED VIEW AND PARTS LIST 16HP 27 EXPLODED VIEW ...

Page 3: ...pets to avoid accidents 3 Operator of engine has been specially trained 4 Refuel in a well ventilated area with the engine stopped and in places refueling or storing gasoline no smoking and any flames or sparks 5 Refuel the fuel tank not too full so as to avoid fuel s spilling out If there is spilled fuel around be sure to clean it thoroughly before starting 6 Locate the engine on a level working ...

Page 4: ...3 PARTS DESCRIPTION The main parts of engine are located as follows ...

Page 5: ...a physician at once Electrolyte is poisonous If swallowed drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and oil a physician Keep out of reach of children CAUTION Do not add tap water to the battery instead of distilled water or the battery life will be short need Do not add distilled water over electrolyte upper level mark or electrolyte will spill out t...

Page 6: ... engine oil Oil capacity 0 5liters for 190N 0 3liters for 170N Check the oil lever in the following order 1 Remove the dipstick and clean it 2 Reinsert the dipstick without screwing it in and then check oil level 3 If the oil level is too low add the recommended engine oil until it arrives the upper level mark 4 Reinstall the dipstick AIR CLEANER I Double core type Dismantle the air cleaner housin...

Page 7: ...ngine oil Make sure the fuel is free of dirt and water Gasoline Containing Alcohol If you decide to use a gasoline containing alcohol fuel blend be sure its octane rating is at least as high as that recommended by the company There are two types of gasohol One contains ethanol and the other contains methanol Neither gasoline containing more than 10 ethanol nor 5 methanol is allowed to be used If m...

Page 8: ... be no fuel in the filler neck After refueling make sure the fuel filler cap is set back securely Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before starting the engine Avoid repeated or prolonged contact with skin or breathing of fuel vapor Keep out of reach of children STARTING THE ENGINE 1 Push the fuel cock ...

Page 9: ... ON CAUTION Use the engine switch not more than 5 minutes each time to avoid damage of the engine Try once more 10 minutes later after last attempt failures RUNNING THE ENGINE 1 Preheat the engine and push back the choke lever to OPEN 2 Set the throttle lever in proper position to ensure the engine runs at required velocity ENGINE OIL ALARM The engine oil alarm is designed to function when the eng...

Page 10: ...rk plug to result in starting the engine difficultly This problem can be solved by amending the carburetor technological status If always using on highlands with a height above sea level of 1800 meters ask your dealer for doing the job CAUTION Amended engine applicable to highlands may be damaged seriously in area below altitude of 1800 meters for overheating because its mixture ratio is too small...

Page 11: ...ement without so high quality as the original may impair the exhaust the exhaust control system in effectiveness 3 Modifying Modifying the exhaust control system may make actual exhaust emissions exceeding statutory limit values Illegal modification as such a Dismantle or modify any part of air intake or exhaust system b Modify or take off speed adjusting connection device or speed adjustment devi...

Page 12: ...paper core air cleaners Every two years or 600 hours later for dust collecting air cleaners More often than that in the schedule if in dusty circumstances Should be done by your dealer unless you are specially trained and is well equipped with tools WARNING Stall the engine before service If service is required with the engine running be sure to keep good ventilation in the area The exhaust emissi...

Page 13: ...xplosion may happen CAUTION Never run the engine without an air cleaner or air with dirt and dust may enter the engine so speed the engine s wear Dual element type Unscrew the wing nut dismantle the air cleaner housing Check if the two cores are damaged if so replace with new one a Foam filter element clean with home detergents and warm water or non flammable or high flash point cleansing solvents...

Page 14: ... oil until saturated squeeze excess oil or the engine will exhaust smoke in starting stage 4 Reinstall the filter element and air cleaner housing Oil bath type 1 Remove the nut and air cleaner housing and take out the filter element 2 Clean with home detergents or high flash point cleansing solvents and warm water and dry up 3 Soak in clean engine oil until saturated Squeeze excess oil or the engi...

Page 15: ... 6 Check if the spark plug gasket is in good conditions or replace with a new one Screw on the spark plug to the bottom first by hand and then screw in by a spark plug wrench If a new spark plug is used twist 1 2 more turns after impacting the gasket if reinstall the original one just twist 1 8 1 4 more turns CAUTION The spark plug must be tightened securely or it may become very hot to damage the...

Page 16: ...ighten securely d Drain the carburetor by loosening the drain screw Drain the gasoline into a suitable container WARNING Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flames or sparks in the area 2 Replace engine oil 3 Disconnect the spark plug Fill about a spoon of fresh engine oil from the spark plug mount hole into the cylinder Crank the engine ...

Page 17: ...e year Drain out original fuel of the fuel tank and refuel Empty the fuel cup in the carburetor Empty the deposit cup Screw off the drain plug and drain out fuel in the carburetor Turn off the engine switch first disconnect the deposit cup and empty it Note for the sake of environmental protection we recommend to fill the discarded fuel into a closed container and bring to local recycling station ...

Page 18: ...on L W H in 14 25 12 3 13 2 17 7 16 17 4 TORQUE OF IMPORTANT BOLTS S N Item Specifications Torque Value N m 1 Cylinder head bolt M8 1 25 24 2 2 Crankcase cover bolt M8 1 25 24 2 3 Tie rod bolt M7 1 12 2 4 Flywheel bolt 70 80 5 8 10 TROUBLESHOOTING I START ENGINE DIFFICULTLY 1 By using kick starter TROUBLE CAUSE REMEDY There is no enough fuel in fuel tank of fuel cock is closed Fill fuel open fuel ...

Page 19: ...tions Improper electrodes gap Adjust to proper value High pressure coil is damaged Replace Ignition coil is damaged Replace 1 Normal cylinder compression 2 Normal fuel supply 3 No high pressure coil spark 4 Normal spark plug Magneto loses magnetism Replace Piston ring is worn to or even over its wear limit Replace Piston ring is broken Replace Piston ring is sticking Clear up carbon fouling Spark ...

Page 20: ... In carburetor needle valve hole and main oil flow hole clogged Clean and blow to get through Fuel cock is clogged up Clean replace damaged part Too much carbon deposit in combusting chamber Clear away Too much carbon fouling in muffler and exhaust pipe Clear away Fuel supply system Air cleaner is clogged up Clean air cleaner filter elemi Intake pipe is leaking Repair or replace Piston or cylinder...

Page 21: ...king Repair Fuel supply system Needle valve sticks Dismantle float chamber and criminate it Spark plug is struck through or short circuited by carbon deposit Replace spark plug Side electrode of spark plug is dropped out Replace spark plug High pressure wire is dropped out Weld on Ignition coil is struck through to be short circuited Replace ignition coil Ignition system Parking wire is located on...

Page 22: ...se is about 60 under the magneto If temperatures surpass the limits it is an indication that the gasoline engine is excessively hot VI THERE EXISTS ABNORMAL NOISE WHEN ENGINE RUNNING TROUBLE CAUSE REMEDY Piston piston ring or cylinder is worn Replace the worn Tie rod or piston pin and piston pin hole is worn Replace the worn Crankshaft main bearing is worn Replace Abnormal noise Piston ring is bro...

Page 23: ...22 WIRING DIAGRAM ...

Page 24: ...23 Note The diagram for other types may be different with the exception of electric start type ...

Page 25: ...24 EXPLODED VIEW AND PARTS LIST 7HP ...

Page 26: ...5 14 35 7 14 GBT5787 B8 60 4 Flange bolt M8 60 58 GBT5787 B8 35 6 bolt M8 35 15 DJ168F 18500 B 1 Spark Plug F7TC 59 DJ168F 18100 C 1 Ignition Coil 16 DJ170F 11200 B 1 Head comp cylinder 60 GBT5787 B6 25 2 bolt M6 25 17 DJ168F 14006 C 1 Outlet Gasket 61 DJ168F 11012 A 1 Air leading Cover 18 DJ170N 14400 A 1 Muffer Assembly 62 DJ170N 15200 A 1 speed adjuster 19 DJ168F 14002 A 2 Bolt head M8 35 63 DJ...

Page 27: ...ip 37 DJ170F 12002 A 1 Pin piston 81 DJ170N 14007 A 1 Outlet pipeφ6 φ10 295 38 DJ170F 12001 B 1 Piston 82 DJ168F 18300 A 1 Amplifier 39 DJ168F 13002 A 1 Intake Valve 83 DJ168F 18200 A 1 Oil Sensor Assembly 40 DJ168F 13001 A 1 Exhaust Valve 84 GBT5787 B6 16 2 bolt M6 16 41 DJ170F 13008 A 2 Rod push 85 DJ168F 11004 A 2 Drain Plug Washer 42 DJ170F 13009 A 2 Tappet Litter Valve 86 DJ168F 11005 A 2 Was...

Page 28: ...27 EXPLODED VIEW AND PARTS LIST 16HP ...

Page 29: ...lt head 8 105 20 DJ188F 18200 A 1 Oil Sensor 63 DJ190N 14003 B 1 Packing carburetor 21 DJ188F 11001 D 1 Crankcase cover 64 DJ190N 14004 A 1 Insulator carburetor 22 GBT5787 B8 35 7 Bolt Flange M8 35 65 DJ188F 14005 B 1 Packing insulator 23 DJ190F 12200 B 1 Connecting rod assy 66 DJ190N 14100 A 1 Carburetor assy 24 DJ190F 12002 A 1 Pin piston 67 DJ188F 14027 A 1 Gasket Air Cleaner 25 DJ188F 12003 A ...

Page 30: ... 8 4 flat washer 93 DJ188F 13002 A 1 EX Valve 94 DJ190N 14001 B 1 Bolt head 8 120 95 DJ188F 11017 A 1 Clip wire 96 GB276 89 6202 2 Radial ball bearing 6202 97 DJ188F 11039 C O Ring 98 DJ190N 15200 A 1 speed adjuster 99 DF2500H 34118 A 1 Clip wire 100 DJ188F 11006 A 1 Dipstick cover 101 DJ188F 11007 A Dipstick 102 DJ168F 11002 D 1 Pin Φ7x14 103 DJ168F 11002 F 1 Pin Φ9x14 104 DJ188F 15009 A 1 Oil Se...