DUROMAX XP9HP, User Manual

Page 1: ...t to ensure the accuracy of the information in this manual We reserve the right to change this product at any time without prior notice 5800 Ontario Mills Pkwy Ontario CA 91764 USA www duromaxpower com Call our Customer Care Team Toll Free 8 5pm PST Mon Fri 844 DUROMAX REV XP9HP_rev05252022 XP9HP U S E R M A N U A L ...

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Page 3: ...Spark Plug Maintenance 32 Emptying the Gas Tank 34 Storing the Engine for Same Day Use 36 Storing the Engine for Use Within 30 Days 37 Storing the Engine for Longer Than 30 Days 38 Maintenance and Care 3 Check the Oil 20 Check the Fuel Level 21 Starting the Engine 22 Starting the Engine 2 Adding Oil 16 Adding Gasoline 17 High Altitude Operation 18 Engine Setup 5 Specifications 43 Adjustment and To...

Page 4: ...For more information and resources on this model scan the QR code below to link to our website product information page CONTENTS 7 8 6 54 Warranty 58 Customer service Troubleshooting 51 ...

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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: ...ust can exceed 150 F 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 The safety alert symbol is used with one of the safety words DANGER CAUTION or WARNING to alert you of hazards Please pay attention to these hazard notices both in thi...

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: ...In addition to the above safety notices please familiarize yourself with the safety and hazard markings on the engine GENERAL SAFETY PROCEDURES CONTINUED 1 5 10 ...

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Page 12: ... or 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: ...e An easy grip handle used to pull the recoil starter rope 6 Start Switch An easy to use switch used to turn the engine on or off 7 Muffler A noise dampening component that helps lower the engine decibel level 8 Engine Shaft A 0 984 diameter 2 48 long 0 276 keyway 9 Oil Fill An easy access location to fill the oil for the engine 10 Oil Drain Plug An easy to remove oil plug that is used to drain th...

Page 14: ...k to see that all of the following items are included with your engine Note Actual tools may differ in appearance or design from image shown Spark Plug Wrench Oil Funnel Used in spark plug maintenance inspection and installation Used to add oil to the Engine without messy spills ...

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 ...

Page 16: ...ngine requires engine oil to operate properly The engine when new from the package contains no oil in the crankcase You must add the proper amount of oil before operating the engine for the first time This amount is equal to the oil capacity of the engine crankcase a Make sure the engine is on a level surface b Unscrew the oil filler cap from the engine c Using a funnel add the appropriate amount ...

Page 17: ...GHER 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 XP9HP Gas Tank Capacity 1 3 US gal 4 92 L DANGER DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE EXPLOSION OR DEATH 1...

Page 18: ...buretor modification This 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 modificati...

Page 19: ... 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 19 ...

Page 20: ...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 21: ...NK OVERFILLING CAN RESULT IN A FIRE EXPLOSION OR DEATH 1 5 WARNING Gasoline and gasoline fumes are highly flammable Do not fill the tank near an open flame Always allow the engine to cool for several minutes before refueling DO NOT overfill the fuel tank Fuel expands when shaken or heated ALWAY leave 11 2 space or more at the top of the tank ALWAYS use fresh fuel or stabilized fuel Old gasoline ol...

Page 22: ...necessary 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 engine switch to ON Turn the engine switch to the ON position to allow the engine to start 3 Starting the Engine Move fuel valve to ON The gas valve is located above the carburetor bowl Move the gasoline fuel valve lever all the way to the right hand positi...

Page 23: ...just the throttle lever 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 to the proper position for the desired speed and the engine is ready for use 6 7 CAUTION Release the recoil handle only after the cord has retracted Releasing the recoil handle while extended may cause har...

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Page 25: ...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 25 ...

Page 26: ...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 26 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 ...

Page 27: ...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 28: ...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 29: ...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 30: ...NANCE AND CARE CONTINUED 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 paper ...

Page 31: ...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 32: ...rk 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 plu...

Page 33: ...an 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 ...

Page 34: ...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 35: ...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 35 ...

Page 36: ...ngs and keep the engine in a cool dry area 36 Store engine After the engine shuts off and cools then you can store the engine 3 Storing the Engine for Same Day Use Run the engine Turn engine switch to OFF Allow the engine to run for 3 5 minutes Move the engine switch to the OFF position to shut the engine off 1 2 ...

Page 37: ...es 1 Shut fuel valve OFF and run dry Turn the engine switch OFF Add fuel stabilizer and store Shut the fuel valve OFF and allow engine to run until it stalls out Move the engine 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 ...

Page 38: ...n the engine switch OFF Empty the gas tank Shut the fuel valve OFF and allow engine to run until it stalls out Move the engine switch to the OFF position to shut the engine off Fully drain your gas tank as shown in Emptying the Gas Tank on page 34 35 2 3 4 Run the engine Allow the engine to run for 3 5 minutes 1 ...

Page 39: ...tor 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 33 6 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 41: ...SPECIFICATIONS A quick reference to useful information on your new DuroMax engine please see this section for more details on this engine s specifications 41 ...

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Page 43: ... L Lowest Idling Speed 1700 rpm 100 rpm Dimensions LENGTH 16 4 in WIDTH 13 2 in HEIGHT 15 1 in Engine Type 4 Stroke OHV Forced Air Ignition System Non contact transistor Lubrication Mode Splash Starting Type Recoil Fuel Delivery System Carburetor Bearing Type Stainless steel ball bearing Shaft Rotation Counter clockwise Shaft Size 0 984 diameter 2 48 long 0 276 keyway Shaft End M10 x 1 25 drilled ...

Page 44: ...que Value Spark Plug Clearance 027 031 in 0 7 0 8 mm Spark Plug Type 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 Adjustment and Torque Specifications SPECIFICATIONS CONTINUED 44 ...

Page 45: ...Engine Diagrams 45 ...

Page 46: ...SPECIFICATIONS CONTINUED 46 ...

Page 47: ...Wiring Diagram 47 1 Engine Switch 2 Oil Alert Unit 3 Type With Oil Alert Unit 4 Oil Level Switch 5 Ignition Coil 6 Spark Plug Bl Black Y Yellow Y G Yellow Green 47 ...

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Page 49: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your engine 49 ...

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Page 51: ... engine 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 batter...

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Page 53: ...WARRANTY This section of the manual is to help you understand your warranty 53 ...

Page 54: ...ES EXPRESSED OR IMPLIED U S EPA AND CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board The United States Environmental Protection Agency US EPA and DuroMax Power Equipment are pleased to explain the emission control system warranty on your 2022 2023 year small off road engine In the United States and California new small off road ...

Page 55: ...L 1 844 387 6629 WEBSITE www duromaxpower com ADDRESS 5800 Ontario Mills Pkwy Ontario CA 91764 This telephone number is only for the engines which the company name DuroMax Power Equipment on the emission label DEFECTS WARRANTY REQUIREMENTS a The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser b General Emissions Warranty Coverage DuroMax Power Equip...

Page 56: ...ovisions of Subsection 4 above warranty services or repairs must be provided at all DuroMax Power Equipment distribution centers that are franchised to service the subject engines 6 The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective provided that such diagnostic work is performed at a warranty station 7 DuroMax Power Equipm...

Page 57: ...retor spacer if applicable ii EGR rate feedback and control system 5 Air Injection System i An air pump or pulse valve ii Valves affecting the distribution of flow iii Distribution manifold 6 Catalyst or Thermal Reactor System i Catalytic converter ii Thermal reactor iii Exhaust manifold 7 Particulate Controls i Traps filters precipitators and any other device used to capture particulate emissions...

Page 58: ...en they need to 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 p m PST Mon Fri Website www duromaxpower com Email customerservice duromaxpower com ...

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Page 60: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX REV XP9HP_rev05252022 ...