DUROMAX XP7HPE Service Manual
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DUROMAX XP7HPE Service Manual

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XP7HPE
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V
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REV: XP7HPE_rev05092023
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 8-5pm 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 XP7HPE

  • Page 1 XP7HPE REV: XP7HPE_rev05092023 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 8-5pm PST Mon-Fri information in this manual.

  • Page 3: Table Of Contents

    CONTENTS Engine Components Engine Components ....................... 7 Maintenance and Care Maintenance Schedule ....................8 Break-In Period ....................... 9 High Altitude Operation ....................9 Changing the Carburetor Main Jet ................10 Checking the Oil ......................14 Changing the Oil ......................15 Cleaning the Air Filter ....................
  • Page 4 CONTENTS Common Engine Parts Common Engine Parts ....................36 Maintenance Log Maintenance Log......................41...

  • Page 7: Engine Components

    ENGINE COMPONENTS 1. Air Filter 3. Fuel Tank 6. Recoil Handle 8. Muffler 7. Starter Motor 9. Engine Shaft 5. Key Switch Box 2. Carburetor 10. Oil Fill 4. Recoil Starter 11. Oil Drain Plug 1. Air Filter - A removable, cleanable, oiled, element that cleans the air going into the engine. 2.

  • Page 8: Maintenance And Care

    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 9: Break-In Period

    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 10: Changing The Carburetor Main Jet

    MAINTENANCE AND CARE (CONTINUED) Changing the Carburetor Main Jet Turn fuel valve OFF Turn the fuel valve OFF. Remove carburetor drain bolt Remove the outward angled bolt that is located on the bottom of the carburetor. Place funnel below drain port Place funnel with container to catch the gasoline under the drain port location and put drained gasoline in a gasoline safe container.
  • Page 11 Remove carburetor bowl Remove carburetor bowl from carburetor. Determine main jet location The carburetor jet is located inside the center metal tube of the carburetor. Remove main jet Remove the main jet with a flat head screwdriver. If necessary gently tap the carburetor to allow the jet and emulsion tube to fall out.
  • Page 13 MAINTENANCE AND CARE (CONTINUED) Changing the Carburetor Main Jet (Continued) Reassemble engine Once the new jet is installed, reverse the above instructions to reassemble carburetor.

  • Page 14: 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 XP7HPE Engine Oil Capacity 20.3 fl. oz (0.6 L)

  • Page 15: 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 16: Cleaning 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 17 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 18: 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 19 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 20: 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 21 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 22: 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 23: 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 24: 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 25 Remove spark plug Remove spark plug as shown in “Spark Plug Maintenance” on page 18. 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 26: Check And Adjust Valve Clearance

    MAINTENANCE AND CARE (CONTINUED) Check and Adjust Valve Clearance The engine intake and exhaust valve clearance should be checked and if necessary adjusted every 300 hours of use or 12 month period, whichever comes first. CAUTION: If the valve clearance isn’t maintained, this can cause the engine to run less efficiently and potentially cause engine damage.
  • Page 27 Remove valve cover Remove all 4 bolts on the valve cover with an 8 mm socket wrench, then remove the valve cover. Set valves to top dead center Place screwdriver into spark plug hole to help determine the position of the piston, then slowly pull the recoil rope until the piston rises to the top position and both valves are closed (compression step).
  • Page 29 MAINTENANCE AND CARE (CONTINUED) Check and Adjust Valve Clearance (Continued) Reinstall parts Reinstall the valve cover, spark plug, and ignition coil wire. The valve cover should be tightened to 8 ft/lbs ± 1.5 ft/lbs (11 ± 2 N·m). The spark plug should be tightened to 18.5 ft/lbs ± 3.5 ft/lbs (25 ±...

  • Page 30: Specifications

    SPECIFICATIONS Displacement 208cc Fuel Type ≥87 octane, ≤10% ethanol, unleaded gasoline Dry Weight 38 lbs Maximum Torque 13.2 N·m @ 2500 RPM Compression Ratio 8.5:1 Bore X Stroke 70mm x 55mm Engine Oil Capacity 20.3 fl. oz (0.6 L) Fuel Tank Capacity 1 gal.

  • Page 31: Adjustment And Torque Specifications

    Adjustment and Torque Specifications Adjustment Specification 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 1600 ±...

  • Page 32: Engine Diagrams

    ENGINE DIAGRAMS Engine Diagrams...

  • Page 34: Wiring Diagram

    ENGINE DIAGRAMS (CONTINUED) Wiring Diagram 1. Control Box 8. Oil Level Switch Black Yellow 2. Rectifier 9. Charging Coil Gray 3. Fuse 10. Ignition Coil 4. Circuit Breaker 11. Spark Plug White 5. Engine Switch 12. Starter Motor Bl/W Black/White 6.

  • Page 35: 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 36 COMMON ENGINE PARTS Common Engine Parts 1. Crankcase 240210 2. Oil Drain Bolt 91816 3. Oil Protector 245104 4. Starting Motor Assembly 97402 5. Crankshaft Bearing 93009 6. Crankcase Cover Gasket 96041 7. Crankcase Cover DJ168F-11001-C 8. Oil Fill Cap/Dipstick 245601-276 9.
  • Page 37 10. Breather Tube DJ170N-11013-A 11. Valve Cover 241107 12. Spark Plug 97108 13. Valve Cover Gasket 96045 14. Cylinder Head Assembly 241011 15. Cylinder Head Gasket 96058 34 35 16. Crankshaft Assembly 240346 17. Piston Rings 241606 18. Pin Clip 241301 19.
  • Page 38 COMMON ENGINE PARTS (CONTINUED) Common Engine Parts (CONTINUED) 22. Recoil Assembly 247445-072 23. Ignition Coil Assembly 97514 24. Charge Coil Assembly DJ188F-18101-A 25. Camshaft Assembly DJ170N-13100-B 26. Carburetor/Air Filter Gasket 94229 27. Carburetor Assembly 242816 28. Spacer/Carburetor Gasket 96051 29. Spacer Gasket 242301 30.
  • Page 39 34 35 32. Muffler Gasket 96054 33. Muffler Assembly DJ170N-14400-A 34. Throttle Return Spring DJ170N-15008-A 35. Governor Spring 244103 36. Key Switch Assembly 245005-072 37. Negative Battery Cable 512012 38. Positive Battery Cable 512003 39. Fuel Tank Assembly 243103L-072 40. Fuel Tank Cap DJ190N-14301-A 41.
  • Page 40 COMMON ENGINE PARTS (CONTINUED) Common Engine Parts (CONTINUED) 43. Air Filter Element 5059 44. Air Filter Assembly 242975...
  • Page 41 MAINTENANCE LOG Maintenance Log As a best practice it’s recommended to keep a log of the engine hours and maintenance to ensure your engine is always operating to its full potential. Date Engine Hours Maintenance Performed...
  • Page 42 MAINTENANCE LOG (CONTINUED) Date Engine Hours Maintenance Performed...
  • Page 43 Date Engine Hours Maintenance Performed...
  • Page 44 MAINTENANCE LOG (CONTINUED) Date Engine Hours Maintenance Performed...
  • Page 45 Date Engine Hours Maintenance Performed...
  • Page 46 5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX REV: XP7HPE_rev05092023...

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