DUROMAX XP7HPX User Manual
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DUROMAX XP7HPX User Manual

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XP7HPX
U
S
E
R
M
A
N
U A
L
REV: XP7HPX_rev04112022
5800 Ontario Mills Pkwy
This manual provides information regarding the
Ontario, CA 91764 USA
operation and maintenance of these products. We
www.duromaxpower.com
have made every effort to ensure the accuracy of the
Call our Customer Care Team Toll Free 8-5 pm PST Mon-Fri
information in this manual. We reserve the right to
844-DUROMAX
change this product at any time without prior notice.

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Summary of Contents for DUROMAX XP7HPX

  • Page 1 XP7HPX REV: XP7HPX_rev04112022 5800 Ontario Mills Pkwy This manual provides information regarding the Ontario, CA 91764 USA operation and maintenance of these products. We www.duromaxpower.com have made every effort to ensure the accuracy of the Call our Customer Care Team Toll Free 8-5 pm PST Mon-Fri information in this manual.

  • Page 3: Table Of Contents

    CONTENTS Introduction Introduction ........................6 General Safety Procedures .................... 8 Unit and Purchase Information................... 12 Engine Components ..................... 13 Package Contents ......................14 Engine Setup Adding Oil ........................17 Connect the Battery ...................... 18 Adding Gasoline ......................19 High Altitude Operation ....................20 Starting the Engine Check the Oil .........................
  • Page 4 CONTENTS Specifications Specifications ......................... 53 Adjustment and Torque ....................54 Engine Diagrams ......................55 Wiring Diagram ......................57 Troubleshooting ......................61 Warranty .......................... 64 Customer Service ......................68...
  • 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, WARNING, or CAUTION) to alert you of hazards. Please pay attention to these hazard notices both in this manual and on the engine. Please familiarize yourself with the following safety symbols and words: ●...
  • Page 9 WARNING: This engine 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 engine.
  • 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: Unit And Purchase Information

    UNIT AND PURCHASE INFORMATION Serial Number Serial number The serial number is located on the engine block, 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. Engine Model: _____________________________________________ Serial Number: _____________________________________________ STAPLE RECEIPT HERE...

  • Page 13: Engine Components

    ENGINE COMPONENTS 2. Air Filter 4. Fuel Tank 7. Recoil Handle 1. Propane Regulator 8. Starter Motor 9. Muffler 10. Engine Shaft 6. Key Switch Box 3. Carburetor 11. Oil Fill 5. Recoil Starter 12. Oil Drain Plug 1. Propane Regulator - A propane regulator with included hose that easily installs on a propane tank.

  • Page 14: Package Contents

    PACKAGE CONTENTS Your engine comes with the items listed below. Please check to see that all of the following items are included with your engine. Spark Plug Wrench Oil Funnel Engine Keys Used in spark plug Used to add oil to the engine Used to start the engine.

  • Page 15: Engine Setup

    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.

  • Page 17: Adding Oil

    . 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: Model Number XP7HPX Engine Oil Capacity 20.3 fl. oz (0.6L) WARNING: Do not apply engine oils with additives or 2-stroke gasoline engine oils;...

  • Page 18: Connect The Battery

    ENGINE SETUP (CONTINUED) Step 2 - Connect the Battery Connect positive battery lead Remove the outer nut of the starter solenoid and slide the ring terminal end of the red positive lead over the outer solenoid bolt. Reinstall outer nut on starter solenoid outer bolt. Connect negative battery lead Connect the ring terminal end of the black negative battery lead to any bolt location on the non-painted...

  • Page 19: Adding Gasoline

    Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill. Replace fuel cap and wipe up any spilled gasoline with a dry cloth. Model Number XP7HPX Gas Tank Capacity 0.76 US gal. (2.885 L) DANGER DO NOT OVERFILL 1.5”...

  • Page 20: High Altitude Operation

    Operation at altitudes below 3,000 feet (900 meters) with a modified carburetor may cause the engine to overheat and result in serious engine damage. Note: Jet kits available for purchase upon request, please contact us at 844-DUROMAX to set up your parts order.

  • Page 21: Starting The Engine

    STARTING THE ENGINE If this is not your first time using the engine 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 “ENGINE SETUP”...

  • Page 22: Check The Oil

    (see “Adding Oil” portion of the “Maintenance” section). Be sure to replace the cap when finished checking oil. Model Number XP7HPX Engine Oil Capacity 20.3 fl. oz (0.6 L)

  • Page 23: 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 gasoline level should always be under the red fuel level indicator located on the bottom of the fuel filter cup.

  • Page 24: Starting The Engine Using Gasoline

    STARTING THE ENGINE Starting the Engine Using Gasoline Move gas 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 position to allow gasoline to flow to the engine carburetor. Move choke lever ON The choke lever is located above the gas valve.
  • Page 25 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. Adjust the throttle lever Adjust the throttle lever to the proper position for the desired speed and the engine is ready for use.

  • Page 26: Starting The Engine Using Propane

    STARTING THE ENGINE (CONTINUED) Starting the Engine Using Propane Move gasoline fuel valve OFF The gas valve is located above the carburetor bowl. Move the gasoline fuel valve lever all the way to the left-hand position to stop the flow of gasoline to the carburetor. Connect propane hose to tank Screw the open ACME nut connection on the propane hose to your propane tank and turn the tank on.
  • Page 27 Purge the propane regulator Hold the propane regulator purge button for 3-5 seconds to remove excess air from the propane line. Turn key switch to START Turn 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.
  • Page 28 STARTING THE ENGINE (CONTINUED) Starting the Engine Using Propane (Continued) WARNING: WHEN USING THE ENGINE WITH LPG, MAKE SURE THERE IS NO POSSIBLE IGNITION SOURCE CLOSE TO THE ENGINE. 1. Before using, make sure all of the LPG connectors and hoses are well connected and sealed.

  • Page 30: Starting The Engine Using The Recoil Start

    STARTING THE ENGINE (CONTINUED) Starting the Engine Using the Recoil Start Select your fuel If gasoline is preferred: See step 1 on page 24. If propane is preferred: See step 1-5 on page 26. Move choke lever to 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.
  • Page 31 Pull the recoil start handle Pull the recoil handle slowly until resistance is felt, then quickly pull the recoil handle until fully extended. Continue this step until the engine starts as needed. CAUTION: Release the recoil handle only after the cord has retracted. Releasing the recoil handle while extended may cause harm to yourself or your equipment.

  • Page 33: Maintenance And Care

    MAINTENANCE AND CARE Proper maintenance 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.

  • Page 34: Maintenance Schedule

    MAINTENANCE AND CARE Proper routine maintenance of your engine 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 35: Break-In Period

    Break-In 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. ●...

  • Page 36: 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 XP7HPX Engine Oil Capacity 20.3 fl. oz (0.6 L)

  • Page 37: Changing The Oil

    Changing the Oil 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 become contaminated with water or dirt.

  • Page 38: Changing The Air Filter

    Remove old filter element Remove the wing nut on top of the air filter element and slide filter element off center bolt. This filter is paper and is not reusable. Please call 1-844-DUROMAX to order a replacement filter for your engine.
  • Page 39 Replace new filter element Slide new filter element over center bolt, and replace wing nut. Tighten wing nut hand tight to keep filter in place. Replace filter cover Replace plastic air filter cover over the air filter base. Secure filter cover Fasten the air filter cover with the air filter cover wing nut and tighten about hand tight.

  • Page 40: Spark Plug Maintenance

    MAINTENANCE AND CARE (CONTINUED) Spark Plug Maintenance The spark plug is important for proper engine operation. SPARK PLUG A good spark plug should be intact, free of deposits, and CONSULT MANUAL properly gapped. BEFORE REMOVING CAUTION: Improper maintenance may cause reduced fuel economy, misfires, trouble starting, or damage to the spark plug threads.
  • Page 41 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 42: Removing The Propane Hose

    MAINTENANCE AND CARE (CONTINUED) Removing the Propane Hose (Optional) The propane hose is removable if needed. If the propane hose is removed please follow the instructions below for the removal. CAUTION: If propane hose is removed from the carburetor, then the carburetor connection point should be covered with the provided port plug to avoid debris from entering the engine and causing internal damage.
  • Page 43 Install cap on carburetor Install the provided propane port cap on the carburetor to ensure no dirt gets inside the carburetor.

  • Page 44: Emptying The Gas Tank

    MAINTENANCE AND CARE (CONTINUED) Emptying the Gas Tank 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 gasoline. CAUTION: Do not store fuel from one season to another.
  • Page 45 Turn fuel valve ON and drain Turn the fuel valve to “ON” and allow gasoline to drain into the container until the gas tank is empty. Shut fuel valve OFF Once the gasoline is fully drained, move the fuel valve back to the OFF position.

  • Page 46: Storing The Engine For Same Day Use

    MAINTENANCE AND CARE (CONTINUED) Storing the Engine for Same Day Use Run the engine Allow the engine to run for 3-5 minutes. Turn key switch to OFF Move the key switch to the OFF position to shut the engine off. Store engine After the engine shuts off and cools, then you can store the engine.

  • Page 47: Storing The Engine For Use Within 30 Days

    Storing the Engine for Use Within 30 Days Run the engine Allow the engine to run for 3-5 minutes. Shut fuel valve OFF and run dry Shut the fuel valve off and allow engine to run until it stalls out. Turn the key switch OFF Move the key switch to the OFF position to shut the engine off.

  • Page 48: Storing The Engine For Longer Than 30 Days

    MAINTENANCE AND CARE (CONTINUED) Storing the Engine for Longer Than 30 Days Run the engine Allow the engine to run for 3-5 minutes. Shut fuel valve OFF and run dry Shut the fuel valve off and allow engine to run until it stalls out. Turn the key switch OFF Move the key switch to the OFF position to shut the engine off.
  • Page 49 Remove spark plug Remove spark plug as shown in “Spark Plug Maintenance” on page 40. Add oil to cylinder Add 2 tablespoons of 10W-30 motor 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”...
  • 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.

  • Page 53: Specifications

    SPECIFICATIONS Displacement 212 cc Fuel Type ≥87 octane, ≤10% ethanol, unleaded gasoline, propane Dry Weight 48 lbs Maximum Torque 13.2 N·m @ 2500 rpm Compression Ratio Bore X Stroke 70 mm x 55 mm Engine Oil Capacity 20.3 fl. oz (0.6 L) Fuel Tank Capacity 0.76 gal.

  • Page 54: Adjustment And Torque

    SPECIFICATIONS (CONTINUED) Adjustment and Torque Adjustment Specification 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 ±...

  • Page 55: Engine Diagrams

    Engine Diagrams...

  • Page 57: Wiring Diagram

    Wiring Diagram 1. Control Box 8. Oil Level Switch Black 2. Rectifier 9. Charging Coil Yellow Gray 3. Fuse 10. Ignition Coil 4. Circuit Breaker 11. Spark Plug White 5. Engine Switch 12. Starter Motor Bl/W Black/White 6. Oil Alert Unit 13.
  • Page 59 TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your Engine.

  • Page 61: Troubleshooting

    TROUBLESHOOTING Mode Description Solution Engine switch is “OFF” Set engine switch to “ON” Fuel valve is “OFF” Turn fuel valve to “ON” 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 63 WARRANTY This section of the manual is to help you understand your warranty.

  • 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 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 As the small off-road engine owner, you should be aware that the DuroMax Power Equipment may deny you warranty coverage if your small off-road engine or a part has failed due to abuse, neglect, or improper maintenance or unapproved modifications.
  • Page 66 The use of any non-exempted add-on or modified parts will be grounds for disallowing a warranty claim made in accordance with this Article. DuroMax Power Equipment will not be liable under this Article to warrant failures of warranted parts caused by the use of an add-on or modified part.
  • Page 67 17. Canister Mounting Brackets 18. Carburetor Purge Port Connector * Note: As they relate to the evaporative emission control system. DuroMax Power Equipment will furnish with each new engine written instructions for the maintenance and use of the engine by the owner...

  • Page 68: Customer Service

    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: XP7HPX_rev04112022...

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