DUROMAX XP7HPX, User Manual

Page 1: ...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 U S E R M A N U A L 5800 Ontario Mills Pkwy Ontario CA 91764 USA www duromaxpower com Call our Customer Care Team Toll Free 8 5 pm PST Mon Fri 844 DUROMAX REV XP7HPX_rev04112022 ...

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Page 3: ...nce 40 Removing the Propane Hose 42 Emptying the Gas Tank 44 Storing the Engine for Same Day Use 46 Storing the Engine for Use Within 30 Days 47 Storing the Engine for Longer Than 30 Days 48 Maintenance and Care 3 Check the Oil 22 Check the Gas Level 23 Starting the Engine Using Gasoline 24 Starting the Engine Using Propane 26 Starting the Engine Using the Recoil Start 30 Starting the Engine 2 Add...

Page 4: ...CONTENTS 7 64 Warranty 8 68 Customer Service 6 Troubleshooting 61 5 Specifications 53 Adjustment and Torque 54 Engine Diagrams 55 Wiring Diagram 57 Specifications ...

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Page 6: ...y unavailable Equipment like table saws sanders and work lights are a necessity and portable power can play a critical role in getting a job done successfully and efficiently DUROMAX FOR PLAY Camping outdoors in a remote location can get one in touch with nature and allow them to forget the stress of the day to day grind Here portable power can provide comfort as well as safety With portable power...

Page 7: ... Powering Everyone Anywhere STOP Please do not return to the store DuroMax representatives are ready to help you with any questions concerns or issues about your new product We can guide you through assembly start up and how to operate your new generator We want you to be able to put your new generator to use right away CALL US BEFORE YOU CONSIDER RETURNING THE PRODUCT 1 844 DUROMAX TOLL FREE Engi...

Page 8: ... 65 C Do not touch hot surfaces Pay attention to warning labels on the engine denoting hot parts of the machine Allow engine to cool several minutes after use before touching engine or areas which heat during use GENERAL SAFETY PROCEDURES 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...

Page 9: ...e on a firm level surface Always turn the engine off before refueling Allow engine to cool for at least 2 minutes before removing the fuel cap Loosen cap slowly to relieve pressure in the tank Do not overfill the 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 engine...

Page 10: ...GENERAL SAFETY PROCEDURES 10 In addition to the above safety notices please familiarize yourself with the safety and hazard markings on the engine ...

Page 11: ...11 DON T TOUCH CAUTION HIGH TEMPERATURE DANGER HOT EXHAUST KEEP SAFE DISTANCE DON T TOUCH BURN RISK CARBON MONOXIDE SAFE DISTANCE ...

Page 12: ... service in the future If you have a paper receipt staple it here for easy reference If you purchased the unit online save the email receipt where you can access it and record your details here for convenience in the future Purchase Date ____________________________________________ Order Number ____________________________________________ Retailer Name _____________________________________________...

Page 13: ... that engages the starter motor with the turn of a key 7 Recoil Handle An easy grip handle used to pull the recoil starter rope 8 Starter Motor Electric motor that starts the generator electrically for easy starting 9 Muffler A noise dampening component that helps lower the engine decibel level 10 Engine Shaft A 3 4 diameter 2 3 8 long 3 16 key way 11 Oil Fill An easy access location to fill the o...

Page 14: ...with your engine Note Actual tools may differ in appearance or design from image shown Spark Plug Wrench Oil Funnel Engine Keys Used in spark plug maintenance inspection and installation Used to add oil to the engine without messy spills Used to start the engine Battery Leads Used to hook up a 12V battery to the starter motor 14 ...

Page 15: ...ENGINE SETUP Proper setup of your engine will get you going as soon as possible while making sure you and your equipment are safe and cared for 15 ...

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Page 17: ...left A small amount of oil from factory testing may be present on arrival Synthetic oil may be used after the 8 hour initial break in period Using synthetic oil does not increase the recommended oil change interval Full synthetic 5W 30 oil will aid in starting in cold temperatures 5ºC 41ºF ENGINE SETUP The engine requires engine oil to operate properly The engine when new from the package contains...

Page 18: ...e ring terminal end of the black negative battery lead to any bolt location on the non painted metal engine casting Connect both leads to battery 3 a First slide the positive battery terminal clamp lead end to a 12V battery positive terminal and tighten the battery terminal clamp b Reinstall outer nut on starter solenoid outer bolt b Then take the negative battery terminal clamp lead end to a 12V ...

Page 19: ...ipe up any spilled gasoline with a dry cloth IMPORTANT To ensure that the engine runs smoothly use only FRESH UNLEADED GAS WITH AN OCTANE RATING OF 87 OR HIGHER 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 engine in the future Never store engine for extended periods of time with fuel in the...

Page 20: ...is engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease by about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made When the car...

Page 21: ... 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 ENGINE SETUP If you have not yet read this section go back and read it now 21 ...

Page 22: ...e oil filler dipstick cap c With a dry cloth wipe the oil off of the stick on the inside of the cap d Insert the dipstick as if you were replacing the cap and then remove it again There should now be oil on the stick If there is no oil on the stick or oil only at the very end of the stick you should add oil until the engine crankcase is filled see Adding Oil portion of the Maintenance section e Be...

Page 23: ...DO NOT overfill the fuel tank Fuel expands when shaken or heated ALWAYS leave 11 2 space or more at the top of the tank ALWAYS use fresh fuel or stabilized fuel Old gasoline older than 30 days can cause permanent damage to the fuel system Always check for fuel spills Check fuel level If running the engine on gasoline check to see that there is sufficient gasoline in the fuel tank The gasoline leve...

Page 24: ...lve Move the choke lever to the left hand side to the ON position to start Please note that if the engine is hot turning the choke on is unnecessary The throttle lever is located above and to the right of the choke lever Adjust the throttle lever to the low speed position 2 4 Turn key switch to START Turn the engine key switch to the START position to engage the starter motor and start the engine ...

Page 25: ... switch and wait 10 seconds before operating the starter again 25 After allowing the engine to preheat move the choke lever to the right hand side to the RUN position to steady the idle speed and run the engine Adjust the throttle lever Adjust the throttle lever to the proper position for the desired speed and the engine is ready for use 6 Move the choke lever to RUN 5 ...

Page 26: ...hose to tank Move choke lever to ON Screw the open ACME nut connection on the propane hose to your propane tank and turn the tank on The choke lever is located above the gas valve Move the choke lever to the left hand side to the ON position to start Please note that if the engine is hot turning the choke on is unnecessary 2 3 Adjust the throttle lever The throttle lever is located above and to th...

Page 27: ...urn the engine key switch to the START position to engage the starter motor and start the engine After the engine starts release the key to allow it to return to the ON position 5 Move the choke lever to RUN After allowing the engine to preheat move the choke lever to the right hand side to the RUN position to steady the idle speed and run the engine 7 27 ...

Page 28: ...othly There may be remnant gasoline in the carburetor this can cause unsteady engine performance for several minutes 3 If the propane gas leaks shut off the LPG supply immediately 4 When stopping the engine turn off the LPG Supply After the engine has stopped turn the key switch to the OFF position WARNING Operating the starter motor for more than 5 seconds can damage the motor If the engine fails...

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Page 30: ...ever to the left hand side to the ON position to start Please note that if the engine is hot turning the choke on is unnecessary The throttle lever is located above and to the right of the choke lever Adjust the throttle lever to the low speed position if using gasoline or the high speed position if using propane 2 4 Turn key switch to ON Turn the engine key switch to the ON position to allow the ...

Page 31: ... move the choke lever to the right hand side to the RUN position to steady the idle speed and run the engine Adjust the throttle lever to the proper position for the desired speed and the engine is ready for use NOTE If using propane disregard this step the throttle should always be in the high speed position while using propane 6 7 CAUTION Release the recoil handle only after the cord has retract...

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Page 33: ...ntenance and storage of your engine is essential to ensure trouble free use of your engine when you need it By following the maintenance and care requirements you can keep your engine running smooth and efficient for years to come 33 ...

Page 34: ...AIR CLEANER CHECK CHECK CHANGE CHANGE SPARK PLUG CLEAN ADJUST CLEAN ADJUST SPARK ARRESTOR CHECK CLEAN IDLE SPEED CHECK ADJUST VALVE CLEARANCE CHECK ADJUST FUEL TUBE CHECK CHECK REPLACE FUEL TANK FILTER CLEAN COMBUSTION CHAMBER CLEAN 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...

Page 35: ...Period As the best practice for any new combustion motor it s recommended to perform the break in procedure as follows Run the engine for the first 6 8 hours on conventional oil then change the oil After the break in period synthetic oil may be used During the break in period of the first 6 8 hours keep the engine speed under 50 for optimal results Check and clean the air filter if necessary after...

Page 36: ...the oil filler dipstick cap c With a dry cloth wipe the oil off of the stick on the inside of the cap d Insert the dipstick as if you were replacing the cap and then remove it again There should now be oil on the stick If there is no oil on the stick or oil only at the very end of the stick you should add oil until the engine crankcase is filled see Adding Oil portion of the Maintenance section e ...

Page 37: ...o an approved oil disposal container Contact your local auto parts store for information on oil disposal 2 Replace drain plug Replace the oil drain plug and tighten with a 10 mm hex wrench 3 CAUTION Worn out or dirty oil does not cool the engine 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 becom...

Page 38: ...overheating and engine wear Changing the Air Filter Remove filter cover wing nut Remove filter cover Remove old filter element Remove the wing nut located on the top of the air filter cover Remove the plastic air filter cover by lifting the cover upwards to expose the air filter element Remove the wing nut on top of the air filter element and slide filter element off center bolt This filter is pap...

Page 39: ...t and replace wing nut Tighten wing nut hand tight to keep filter in place 4 Replace filter cover Replace plastic air filter cover over the air filter base 5 6 Secure filter cover Fasten the air filter cover with the air filter cover wing nut and tighten about hand tight ...

Page 40: ...spark plug cap to remove it Unscrew the spark plug from the engine using the spark plug wrench included with this product Visually inspect the spark plug If it is cracked or chipped discard and replace it with a new spark plug We recommend using an F6RTC spark plug such as NGK BPR6ES 1 2 3 CAUTION Improper maintenance may cause reduced fuel economy misfires trouble starting or damage to the spark ...

Page 41: ...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 5 Install spark plug Replace spark plug cap Screw the spark plug back into its place on the engine using the spark plug wrench Replace the spark plug cap 6 7 41 ...

Page 42: ...ered with the provided port plug to avoid debris from entering the engine and causing internal damage Locate carburetor connection Loosen the hose clamp Remove the propane hose First follow the propane hose until you run into the connection point on the carburetor Locate the hose clamp at the connection point and loosen the bolt on the clamp Once the hose clamp is loose you can remove the propane ...

Page 43: ...43 Install cap on carburetor Install the provided propane port cap on the carburetor to ensure no dirt gets inside the carburetor 4 ...

Page 44: ...ntainer to catch the gasoline under the drain port location 1 2 3 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 If you have been using gasoline in your engine before storing your engine for extended periods of time you should drain your engine fuel tank of ...

Page 45: ...s tank is empty 4 Shut fuel valve OFF Replace carburetor drain bolt Store emptied gasoline Once the gasoline is fully drained move the fuel valve back to the OFF position Reinstall the carburetor drain bolt Store the emptied gasoline in a suitable place and add fuel stabilizer to keep fuel fresh and usable 5 6 7 45 ...

Page 46: ...an store the engine 3 Storing the Engine for Same Day Use CAUTION Do not obstruct any ventilation openings and keep the engine in a cool dry area 46 Run the engine Turn key switch to OFF Allow the engine to run for 3 5 minutes Move the key switch to the OFF position to shut the engine off 1 2 ...

Page 47: ...es 1 Shut fuel valve OFF and run dry Turn the key switch OFF Add fuel stabilizer and store Shut the fuel valve off and allow engine to run until it stalls out Move the key switch to the OFF position to shut the engine off Add fuel stabilizer to gas remaining in tank and store the engine 2 3 4 47 ...

Page 48: ...gas tank Shut the fuel valve off and allow engine to run until it stalls out Move the key switch to the OFF position to shut the engine off Fully drain your gas tank as shown in Emptying the Gas Tank on page 44 45 2 3 4 MAINTENANCE AND CARE CONTINUED 48 Run the engine Allow the engine to run for 3 5 minutes 1 ...

Page 49: ... oil directly into the spark plug hole and pull the recoil to lubricate cylinder After lubricating cylinder reinstall the spark plug as shown in Spark Plug Maintenance on page 41 6 49 Store engine The engine is ready to be stored in a cool dry area 7 CAUTION Do not obstruct any ventilation openings and keep the engine in a cool dry area ...

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Page 51: ...SPECIFICATIONS A quick reference to useful information on your new DuroMax engine please see this section for more details on this engine s specifications 51 ...

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Page 53: ...ons LENGTH 16 14 in WIDTH 11 5 in HEIGHT 14 76 in Engine Type 4 Stroke OHV Forced Air Ignition System Non contact transistor Lubrication Mode Splash Starting Type Electric Recoil Shaft Rotation Counter clockwise Shaft Size 3 4 diameter 2 3 8 long 3 16 key way Shaft End 5 16 size 24 UNF drilled and tapped Gasoline Consumption 395 g kWh Center of Shaft to Base 4 175 Bearing Type Stainless steel ball...

Page 54: ...ue Value Spark Plug Clearance 027 031 in 0 7 0 8 mm Spark Plug Type F6RTC Torch F6TC Torch BPR6ES NGK RN9YC Champion WR7DC Bosch W20EPR U Denso Valve Clearance Cold Intake 006 in 001 in 0 15 mm 0 02 mm Exhaust 008 in 001 in 0 20 mm 0 02 mm Carburetor Idling 1800 300 rpm Adjustment Specification SPECIFICATIONS CONTINUED 54 Adjustment and Torque ...

Page 55: ...Engine Diagrams 55 ...

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Page 57: ...Breaker 5 Engine Switch 6 Oil Alert Unit 7 Type With Oil Alert Unit Bl Black Y Yellow Gr Gray R Red W White Bl W Black White Bl R Black Red 8 Oil Level Switch 9 Charging Coil 10 Ignition Coil 11 Spark Plug 12 Starter Motor 13 Starter Solenoid 14 Battery 12V 57 ...

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Page 59: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your Engine 59 ...

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Page 61: ...ine to a level surface Oil is low Add change oil Engine starts but shuts off after running for short time Oil level is low Add change oil Fuel is old or contaminated Change fuel Engine is on incline exceeding 15 Disconnect low oil sensor Electric key switch doesn t start or shut off engine Key switch separated from frame of engine Run ground wire from engine block to key switch Negative battery or...

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Page 63: ...WARRANTY This section of the manual is to help you understand your warranty 63 ...

Page 64: ...ATIONS The U S Environmental Protection Agency EPA California Air Resources Board and DuroMax Power Equipment are pleased to explain the emissions control system s warranty on your 2022 2023 small off road engine In California new small off road engines must be designed built and equipped to meet the State s stringent anti smog standards DuroMax Power Equipment must warrant the emissions control s...

Page 65: ... all applicable regulations adopted by the Air Resources Board and 2 Free from defects in materials and workmanship that causes the failure of a warranted part for a period of two years The warranty on emissions related parts will be interpreted as follows 1 Any warranted part that is not scheduled for replacement as required maintenance in the Owner s Manual must be warranted for the warranty per...

Page 66: ...the exhaust or evaporative emissions of the engine or emissions control system must be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner Such use will not reduce the warranty obligations of DuroMax Power Equipment 10 Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add...

Page 67: ... Fuel Tank 2 Fuel Cap 3 Fuel Line for liquid fuel and fuel vapors 4 Fuel Line Fittings 5 Clamps 6 Pressure Relief Valves 7 Control Valves 8 Control Solenoids 9 Electronic Controls 10 Vacuum Control Diaphragms 11 Control Cables 12 Control Linkages 13 Purge Valves 14 Gaskets 15 Liquid Vapor Separator 16 Carbon Canister 17 Canister Mounting Brackets 18 Carburetor Purge Port Connector Note As they rel...

Page 68: ...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 5 pm PST Mon Fri Website www duromaxpower com Email customerservice duromaxpower com ...

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Page 70: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX REV XP7HPX_rev04112022 ...