DUROMAX XP7500X User Manual
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DUROMAX XP7500X User Manual

DUROMAX XP7500X User Manual

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This manual provides information regarding the operation
and maintenance of these products. We have made every
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XP7500X
User Manual
Call our Customer Care Team Toll Free 8-5pm PST Mon-Fri
GENERATOR
5800 Ontario Mills Pkwy
Ontario, CA 91764 USA
www.duromaxpower.com
844-DUROMAX

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  • Page 1 XP7500X GENERATOR User Manual 5800 Ontario Mills Pkwy Ontario, CA 91764 USA This manual provides information regarding the operation www.duromaxpower.com and maintenance of these products. We have made every effort to ensure the accuracy of the information in this Call our Customer Care Team Toll Free 8-5pm PST Mon-Fri manual.

  • Page 3: Table Of Contents

    Introduction Introduction ........................6 General Safety Procedures ................... 8 Unit and Purchase Information................... 12 Carbon Monoxide Safety ....................13 Quick Start Quick Start Guide ......................16 Generator Components ....................18 Package Contents ......................20 Generator Setup Wheel Kit Installation ....................22 Connect the Battery ....................
  • Page 4 CONTENTS Maintenance and Care Maintenance Schedule ....................44 Maintenance Log ......................45 Checking the Oil ......................46 Changing the Oil ......................47 Cleaning the Air Filter ....................48 Spark Plug Maintenance ....................50 Storage and Transportation ..................52 Specifications ........................53 Troubleshooting Basic Troubleshooting ....................
  • Page 6 DUROMAX The DuroMax Way is more than just a brand, it is our understanding and appreciation of just how important power can be to someone without it… DUROMAX FOR HOME DUROMAX FOR WORK DUROMAX FOR PLAY Electricity in our home not...

  • Page 7: Introduction

    INTRODUCTION DuroMax Power Equipment is headquartered in Ontario, California and is the industry’s leader in Dual Fuel portable generator technology. In addition to a full assortment of portable generators ranging from digital inverters to large 15,000-watt portable standby units, their product line includes pressure washers, engines, pumps, and accessories.

  • Page 8: General Safety Procedures

    GENERAL SAFETY PROCEDURES SAFETY ALERT SYMBOL 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 this manual and on the generator. 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 not ●...
  • Page 9 WARNING: This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death. A nearby open flame can lead to an explosion even if not directly in contact with gasoline. Do not operate near an open flame. ●...
  • Page 10 GENERAL SAFETY PROCEDURES In addition to the above safety notices, please familiarize yourself with the safety and hazard markings on the generator. DANGER DO NOT OVERFILL 1.5” THE GAS TANK OVERFILLING CAN RESULT IN A FIRE, EXPLOSION, OR DEATH.
  • Page 11 CAUTION HIGH TEMPERATURE DON’T TOUCH HOT EXHAUST DANGER KEEP SAFE DISTANCE BURN RISK CARBON MONOXIDE SAFE DISTANCE DON’T TOUCH...
  • Page 12 “the silent killer.” CO-ALERT Description The DuroMax CO Alert system was created to protect our customers and their families from dangerous carbon monoxide. Just like the detector for your home the CO Alert tests the air for to keep you safe and healthy.

  • Page 13: Carbon Monoxide Safety

    As the only safe way to use a portable generator, taking your generator outside is absolutely mandatory to keep your family safe from carbon monoxide. But there’s even more you can do. By educating yourself about all carbon monoxide risks, you’ll be better prepared to protect your family from this colorless, odorless threat.

  • Page 14: Unit And Purchase Information

    UNIT AND PURCHASE INFORMATION Serial Number Serial Number The serial number is located on the engine block, above and to the left of the oil fill. Serial number format The serial number will be shown in two parts. The engine model, followed by the serial number.

  • Page 15: Quick Start

    QUICK START The Quick Start of your generator is the minimum necessary setup that will get you going as soon as possible. Be sure to read the instructions full setup.

  • Page 16: Quick Start Guide

    QUICK START GUIDE Add oil The oil fill cap is located on the lower engine block to the right of the recoil start housing. Remove the oil fill cap and fill with 20 oz of 10w30 oil. Add gasoline The fuel cap is located on top of the fuel tank. Fill the tank with fresh unleaded gasoline 87 octane or higher.
  • Page 17 Start generator The switch is located on the left side of the front power panel. Press the switch up to the start position to start the generator. Allow the switch to return to the run position once started. Open choke The choke lever is located above the air filter to the left of the recoil start.

  • Page 18: Generator Components

    GENERATOR COMPONENTS 5. Fuel Cap 4. Choke Lever 3. Fuel Valve 6. Ground Terminal 2. Air Cleaner 7. Battery 18. Recoil Start 8. Oil Fill and Dipstick 1. Recoil Start – Easy Pull Recoil Start to start the engine without the electric start. 2.
  • Page 19 15. Circuit Breaker - Resettable switch that protects the generator from electrical overload. 16. AC Breaker - 20A resettable breaker to protect the 20A GFCI Receptacle from accidental overload. 17. Power Boost – DuroMax exclusive Power Boost doubles the amperage available in “120v Only” for heavy loads like RV air conditioners.

  • Page 20: Package Contents

    PACKAGE CONTENTS Your generator comes with the items listed below. Please check to see that all of the following items are included with your generator. Double-Sided Spanner Spark Plug Wrench Screw Driver Phillips and slot blade Assorted wrenches used in Used in spark plug screwdriver used for generator generator maintenance and...

  • Page 21: Generator Setup

    GENERATOR SETUP Proper setup of your generator will get you going as soon as possible while making sure you and your equipment are safe and cared for.

  • Page 22: Wheel Kit Installation

    GENERATOR SETUP (CONTINUED) Step 1 - Wheel Kit Installation (Optional) Install support legs Secure the support legs to the frame with the provided lock nuts. Install wheel axle Insert wheel axle bolts through the frame and secure with the provided nut and wrenches. Install wheel axle bracket Insert wheel axle bracket bolts through the frame and secure with the provided nut and wrenches.
  • Page 23 Install wheels Place the wheels onto either side of the axle. Install outside wheel washers Place the other large washers onto each side the axle in front of the wheel. Install cotter pins Place a cotter pin through the hole in each end of the axle and bend it out to secure the wheels.

  • Page 24: Connect The Battery

    GENERATOR SETUP (CONTINUED) Step 2 - Connect the Battery Disconnected on arrival The generator battery is disconnected on arrival to prevent discharge or accidental starting in storage and transportation. Locate the cable Locate the battery cable clip. Connect the cable Securely connect the battery cable clip.

  • Page 25: Adding Oil

    . You must add the proper amount of oil before operating the generator for the first time. This amount is equal to the oil capacity of the engine crankcase: Model Number XP7500X Engine Oil Capacity 24 fl. oz (0.7L) WARNING: Do not apply engine oils with additives or 2-stroke gasoline engine oils. They don’t have enough lubrication and may shorten the engine’s service life.

  • Page 26: Adding Gasoline

    Replace fuel cap and wipe up any spilled gasoline with a dry cloth. Model Number XP7500X Gas Tank Capacity 5.3 US Gal. (20 L) DANGER DO NOT OVERFILL 1.5”...

  • Page 27: Grounding The Generator

    Step 5 - Grounding the Generator Attach grounding wire Ground the generator by tightening the grounding nut against a grounding wire. Connect the other end to a copper or brass grounding rod that’s driven into the earth. A generally acceptable grounding wire is a No. 12 AWG (American Wire Gauge) stranded copper wire.

  • Page 29: Starting The Generator

    STARTING THE GENERATOR If this is not your first time using the generator there are 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 “GENERATOR SETUP”...

  • Page 30: Checking The Oil

    (see “Adding Oil” portion of the “Maintenance” section). Be sure to replace the cap when finished checking oil. Model Number XP7500X Engine Oil Capacity 24 fl. oz (0.7L)

  • Page 31: Check The Gas Level

    Step 2 - Check the gas level (Optional) Check fuel level If running the engine on gasoline check to see that there is sufficient gasoline in the fuel tank. The fuel gauge on top of the tank will give a rough estimate of the gasoline level. The gauge will appear white then fill red as the tank is filled.

  • Page 32: Starting The Generator Using Gasoline

    STARTING THE GENERATOR Starting the Generator Shut breaker off The breaker is located on the right side of the front power panel. Flip the breaker down to prevent accidental load when starting the generator. Turn gas valve on The gas valve is located above the recoil start on the bottom of the fuel tank.
  • Page 33 Allow switch return to RUN When the engine starts, allow the engine switch to return to the “RUN” position. Open choke Push the choke to the OPEN position as the engine warms up. Turn breaker on / connect The breaker is located on the right side of the front power panel.

  • Page 34: Starting The Generator Using Recoil Start

    STARTING THE GENERATOR (CONTINUED) Starting the Generator Using Recoil Start Shut breaker off The breaker is located on the right side of the front power panel. Flip the breaker down to prevent accidental load when starting the generator. Select your fuel. If using gasoline, see step 2 on pg.
  • Page 35 Pull the recoil start The recoil start is located on the left side panel next to the air filter. Pull the recoil handle slowly until resistance is felt, then quickly pull the recoil handle until fully extended. Open choke After the engine has started. Push the choke to the OPEN position as the engine warms up.

  • Page 37: Using The Generator

    USING THE GENERATOR If this is not your first time using the generator, there are 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 “GENERATOR SETUP”;...

  • Page 38: Ac Usage

    USING THE GENERATOR AC Usage ● You may connect electrical devices running on AC current according to their wattage requirements. The chart below shows the rated and surge wattage of your generator according to its model ● number. ● The rated wattage corresponds to the maximum wattage the generator can output on a continuous basis.
  • Page 39 Tool or Appliance Rated (Running) Watts Additional Surge Watts Electric water heater (40 gal) 4000 Hot plate 2500 Radial arm saw 2000 2000 Electric Stove 1500 Circular Saw 1500 1500 Air compressor (1 HP) 1500 3000 Window air conditioner 1200 1800 Miter saw 1200...

  • Page 40: Connecting A Load To The Generator

    USING THE GENERATOR (CONTINUED) Connecting a load to the generator NOTE: Be sure to attach devices to the correct receptacle (outlet). 120v devices can be directly connected to the 120v ONLY receptacles. ● 120v devices can be connected to the 120/240v receptacle using an appropriate adapter. ●...

  • Page 41: Voltage Selection Switch

    Voltage Selector Switch This generator features Power Boost Technology, which gives the user the ability to double the power in the generator for more heavy duty applications. The voltage selector switches the dual 120v AC windings of the generator to produce “120V ONLY” or “120/240V”. If a 240V appliance is connected to the 4-prong receptacle, the switch must be in the “120/240V”...

  • Page 43: Maintenance And Care

    MAINTENANCE AND CARE Proper maintenance and storage of your generator are essential to ensure trouble-free use of your generator when you need it. By following the maintenance and care requirements, you can keep your generator running smoothly and efficiently for years to come.

  • Page 44: Maintenance Schedule

    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 45: Maintenance Log

    MAINTENANCE LOG Date Generator Hours Maintenance Performed...

  • Page 46: 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 XP7500X Engine Oil Capacity 24 fl. oz (0.7L)

  • Page 47: Changing The Oil

    Changing the oil 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 48: 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. Note: Improper maintenance may cause less air to enter the engine or dirty air to enter the engine causing overheating and engine wear.
  • Page 49 Inspect cleaner element Inspect the air cleaner element for damage or excess dirt. Replace the air cleaner element with a new one if damaged or dirty. Replace cleaner element Place the air cleaner element in the housing. Attach the air cleaner cover Close the air cleaner clips on the left hand side of the air cleaner.

  • Page 50: Spark Plug Maintenance

    MAINTENANCE AND CARE (CONTINUED) Spark Plug Maintenance The spark plug is important for proper engine operation. A good spark plug should be intact, free of deposits, and properly gapped. SPARK PLUG CONSULT MANUAL Improper maintenance may cause reduced fuel economy, BEFORE REMOVING misfires, trouble starting, or damage to the spark plug threads.
  • Page 51 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 52: Storage And Transportation

    MAINTENANCE AND CARE (CONTINUED) Storage and Transportation CAUTION: Never place any type of storage cover on the generator while it is still hot. When transporting your generator: Empty the gas tank (see “Emptying the Gas Tank” in the “Maintenance” section). ●...

  • Page 53: Specifications

    SPECIFICATIONS AC Rated Wattage 6500W AC Surge Wattage 7500W AC Rated Voltage 120/240V AC Rated Frequency 60 Hz AC Phase Single DC Voltage DC Amperage 4.2A Dimensions LENGTH 27in. WIDTH 21in. HEIGHT 20in. Engine Type 4-Stroke OHV Forced-Air Ignition System Non-Contact Transistor Displacement 274cc...

  • Page 55: Troubleshooting

    TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator.

  • Page 56: Basic Troubleshooting

    TROUBLESHOOTING Mode Description Engine Switch is “Off” Set engine switch to “run” Fuel Valve is “Closed” Turn fuel valve to “open” Choke is open Close the choke Engine is out of fuel Add fuel Engine will not start Fuel is old or contaminated Change fuel Spark Plug is dirty Clean spark plug...

  • Page 57: Changing / Inspecting The Carbon Brushes

    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 58: Changing / Inspecting The Avr

    TROUBLESHOOTING (CONTINUED) Changing / Inspecting the Carbon Brushes (Cont.) 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 59 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 60 TROUBLESHOOTING (CONTINUED) Changing / Inspecting the AVR (Continued) 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 61 Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts.

  • Page 62: Wiring Diagram

    WIRING DIAGRAM...

  • Page 64: Warranty

    OEM parts. Warranty Limitations DuroMax Power Equipment does not claim or hold any obligation to loss of time, freight charges, use of the product, or any incidental damages from the use of this product. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED.
  • Page 65 Equipment cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the small off-road engine owner, you should, however, be aware that DuroMax Power Equipment may deny you warranty coverage if your small off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 66 If the part fails prior to the first scheduled replacement, the part must be repaired or replaced by DuroMax Power Equipment according to Subsection (4) below. Any such part repaired or replaced under warranty must be warranted for the remainder of the period prior to the first scheduled replacement point for the part.
  • Page 67 (iii) Distribution manifold. (6) Catalyst or Thermal Reactor System (i) Catalytic converter. (ii) Thermal reactor. (iii) Exhaust manifold. DuroMax Power Equipment will furnish with each new engine written instructions for the maintenance and use of the engine by the owner...

  • Page 68: Contact Information

    CUSTOMER SERVICE Duromax Power Equipment is committed to ensuring that our products perform when they need to. Our generators are your lifeline in the event of an emergency. Should you have any problems, please contact our customer service department: DUROMAX POWER EQUIPMENT...
  • Page 70 5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX REV: XP7500X-10082021...

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