XP7500X GENERATOR User Manual This manual provides information regarding the operation and maintenance of these products. We have made every 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. 5800 Ontario Mills Pkwy Ontario, CA 91764 USA www.duromaxpower.
1. Introduction Introduction ..................................................................................................................... 6 General Safety Procedures ............................................................................................ 8 Unit and Purchase Information................................................................................... 12 Carbon Monoxide Safety ................................................................................................
CONTENTS 6. Maintenance and Care Maintenance Schedule................................................................................................... 44 Maintenance Log ........................................................................................................... 45 Checking the Oil ............................................................................................................. 46 Changing the Oil..................................................................................
THE DUROMAX WAY 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 Electricity in our home not only provides comfort but safety as well. From keeping the heat or A/C on to keeping our food cold, power is essential to our daily lives. Inevitability when disaster strikes and we are left without power for a prolonged period of time, our way of life is put at risk.
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. The foundation of our company is built on quality, reliability, durability, and customer service.
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 followed.
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. ● Do not smoke near the generator. ● Always operate on a firm, level surface. ● Always turn the generator off before refueling. ● Allow generator to cool for at least 2 minutes before removing the fuel cap. Loosen cap slowly to relieve pressure in the tank.
GENERAL SAFETY PROCEDURES In addition to the above safety notices, please familiarize yourself with the safety and hazard markings on the generator. DANGER 1.5” DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE, EXPLOSION, OR DEATH.
CAUTION HIGH TEMPERATURE DON’T TOUCH EXHAUST DANGER HOT KEEP SAFE DISTANCE BURN RISK CARBON MONOXIDE DON’T SAFE DISTANCE TOUCH 11
CARBON MONOXIDE SAFETY Carbon Monoxide Generators are convenient, but they can also be dangerous. All fuelburning appliances and equipment release a poisonous gas called carbon monoxide. Carbon monoxide (also known as CO) can be dangerous for humans and pets, even in small amounts, because it blocks oxygen from getting into your body. Carbon monoxide poisoning can lead to death in a very short time. It is odorless, tasteless and invisible, so you may be exposed without knowing it.
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. Visit takeyourgeneratoroutside.com for more 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. Engine Model: _____________________________________________ Serial Number: _____________________________________________ STAPLE RECEIPT HERE A purchase receipt may be necessary for warranty parts or service in the future.
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.
QUICK START GUIDE 1. 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. 2. Add gasoline The fuel cap is located on top of the fuel tank. Fill the tank with fresh unleaded gasoline 87 octane or higher. The tank is full when you see fuel in the bottom of the fuel filter cup. DO NOT overfill the tank. 3. Turn breaker off The breaker is located on the right side of the front power panel.
6. 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. 7. Open choke The choke lever is located above the air filter to the left of the recoil start. Slide the lever to the right to open the choke and increase air into the carburetor for normal running. 8. Turn breaker on The breaker is located on the right side of the front power panel.
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. Air Cleaner - a removable, cleanable, oiled, element that cleans the air going into the engine 3. Fuel Valve - On/Off Valve that allows gasoline into the engine. 4.
14. 120/240v 4-Prong Twist Lock 9. Engine Switch 12. Multimeter 11. Low Oil Alert 13. 120v 3-Prong GFCI Receptacles 10. 5v USB 16. AC Breaker 17. Power Boost 15. Circuit Breaker 12. Multimeter - Provides reading of voltage output, hertz, and hours run. 13. 120v 3-Prong Receptacles - Use to connect electrical devices that run 120 Volt, 60 Hz, single phase, AC current (NEMA 5-20). 14.
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 Screw Driver Phillips and slot blade screwdriver used for generator maintenance. Spanner Spark Plug Wrench Assorted wrenches used in generator maintenance and assembly. 10mm/12mm and 13mm/15mm, Used in spark plug maintenance, inspection, and installation.
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.
GENERATOR SETUP (CONTINUED) Step 1 - Wheel Kit Installation (Optional) 1. Install support legs a. Secure the support legs to the frame with the provided lock nuts. 2. Install wheel axle a. Insert wheel axle bolts through the frame and secure with the provided nut and wrenches. 3. Install wheel axle bracket a. Insert wheel axle bracket bolts through the frame and secure with the provided nut and wrenches. 4. Install inside wheel washers a.
5. Install wheels a. Place the wheels onto either side of the axle. 6. Install outside wheel washers a. Place the other large washers onto each side the axle in front of the wheel. 7. Install cotter pins a. Place a cotter pin through the hole in each end of the axle and bend it out to secure the wheels. 8. Install handles a. Attach the handles to the brackets on the frame using the provided bolts and nuts. b. Flip the assembled generator over onto its wheels and support brackets.
GENERATOR SETUP (CONTINUED) Step 2 - Connect the Battery 1. Disconnected on arrival The generator battery is disconnected on arrival to prevent discharge or accidental starting in storage and transportation. 2. Locate the cable a. Locate the battery cable clip. 3. Connect the cable a. 24 Securely connect the battery cable clip.
Step 3 - Adding Oil The generator requires engine oil to operate properly. The generator, when new from the package, contains no oil in the crankcase*. 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.
GENERATOR SETUP (CONTINUED) Step 4 - Adding Gasoline (Optional) Add Gasoline a. Make sure the generator is on a level surface. b. Unscrew gas cap and set aside (NOTE: the gas cap may be tight and hard to unscrew). c. Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill. The fuel gauge on the top of the gas tank indicates how much gasoline is in the generator gas tank. d. Replace fuel cap and wipe up any spilled gasoline with a dry cloth.
Step 5 - Grounding the Generator Attach grounding wire a. Ground the generator by tightening the grounding nut against a grounding wire. b. 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. Grounding codes can vary by location. Please contact a local electrician to check the grounding regulations for your area.
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” If you have not yet read this section, go back and read it now.
BEFORE YOU START YOUR GENERATOR Step 1 - Check the oil Check the oil The generator is equipped with an automatic shutoff to protect it from damage due to low oil. Nonetheless, you should check the oil level of the engine before each use to ensure that the engine crankcase has a sufficient amount. To check the oil level: 30 a. Make sure the generator is on a level surface. b. Unscrew the oil filler/dipstick cap. c. With a dry cloth, wipe the oil off of the stick on the inside of the cap. d.
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. Note: Fuel gauge may not register with less than 1/3 fuel tank full. DANGER 1.5” DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE, EXPLOSION, OR DEATH.
STARTING THE GENERATOR Starting the Generator 1. 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. 2. Turn gas valve on The gas valve is located above the recoil start on the bottom of the fuel tank. Rotate the valve counterclockwise to the vertical position to turn on the gas supply. 3. Close choke The choke lever is located above the air filter to the left of the recoil start.
5. Allow switch return to RUN When the engine starts, allow the engine switch to return to the “RUN” position. 6. Open choke Push the choke to the OPEN position as the engine warms up. 7. Turn breaker on / connect The breaker is located on the right side of the front power panel. Flip the breaker up to allow the power to flow to the receptacles. Connect your devices to the receptacles on the front panel. Start with the largest loads first.
STARTING THE GENERATOR (CONTINUED) Starting the Generator Using Recoil Start 1. 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. 2. Select your fuel. If using gasoline, see step 2 on pg. 36. If using propane see steps 2 - 4 on pg. 38. 3. Close choke The choke lever is located above the air filter to the left of the recoil start.
5. 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. 6. Open choke After the engine has started. Push the choke to the OPEN position as the engine warms up. 7. Turn breaker on / connect The breaker is located on the right side of the front power panel. Flip the breaker up to allow the power to flow to the receptacles.
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”; if you have not yet read this section, go back and read it now.
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. ● The surge wattage corresponds to the maximum amount of power the generator can output for a short period of time.
Tool or Appliance Rated (Running) Watts Additional Surge Watts Electric water heater (40 gal) 4000 0 Hot plate 2500 0 Radial arm saw 2000 2000 Electric Stove 1500 0 Circular Saw 1500 1500 Air compressor (1 HP) 1500 3000 Window air conditioner 1200 1800 Miter saw 1200 1800 Microwave 1000 2000 Well water pump 1000 1500 Reciprocating saw 960 1040 Sump pump 800 1200 Refrigerator freezer 800 1200 Furnace blower 800 1300 Computer 800 0 Electric drill 600 900 Tele
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. ● 240v devices can ONLY be connected to the 240v receptacle. CAUTION: Do not connect 50Hz or 3-phase loads to the generator. 1. Plug in devices Plug in devices to the appropriate receptacle.
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” position.
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.
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. ● Make sure the engine is off before you begin any maintenance or repairs.
MAINTENANCE LOG Date Generator Hours Maintenance Performed 45
MAINTENANCE AND CARE (CONTINUED) Checking the oil Check the oil The generator is equipped with an automatic shutoff to protect it from damage due to low oil. Nonetheless, you should check the oil level of the engine before each use to ensure that the engine crankcase has a sufficient amount. To check the oil level: 46 a. Make sure the generator is on a level surface. b. Unscrew the oil filler/dipstick cap. c. With a dry cloth, wipe the oil off of the stick on the inside of the cap. d.
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. 1. Remove drain plug Using a 12 mm hex wrench, unscrew the oil drain plug, which is located on the crankcase underneath the oil filler/dipstick cap. Allow all the oil to drain from the generator. 2.
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. 1. Open the air cleaner cover Open the air cleaner cover clips on the right hand side of the air cleaner. 2.
4. 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. 5. Replace cleaner element Place the air cleaner element in the housing. 6. Attach the air cleaner cover Close the air cleaner clips on the left hand side of the air cleaner.
MAINTENANCE AND CARE (CONTINUED) Spark Plug Maintenance SPARK PLUG CONSULT MANUAL BEFORE REMOVING The spark plug is important for proper engine operation. A good spark plug should be intact, free of deposits, and properly gapped. Improper maintenance may cause reduced fuel economy, misfires, trouble starting, or damage to the spark plug threads. 1. Remove spark plug cap Pull on the spark plug cap to remove it. 2.
4. Measure plug gap Measure the plug gap with a gauge. The gap should be 0.7-0.8 mm (0.028-0.031 in). 5. 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. 6. Install spark plug Screw the spark plug back into its place on the generator using the spark plug wrench. 7. Replace spark plug cap Replace the spark plug cap.
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). ● Disconnect the spark plug. ● Do not obstruct any ventilation openings & keep the generator in a cool dry area. Storage Period Storage Preparation If you plan on starting the same day. 1. 2. 3. 4. Turn off the main breaker.
SPECIFICATIONS AC Rated Wattage 6500W AC Surge Wattage 7500W AC Rated Voltage 120/240V AC Rated Frequency 60 Hz AC Phase Single DC Voltage 5v 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 Starting Type Electric Fuel Tank Capacity 5.3 US Gal. (20L) Oil Capacity 24 fl. oz. (0.7L) Run Time @ 50% 10 hr.
TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator.
TROUBLESHOOTING Mode Engine will not start Engine runs, but there is no electrical output Generator runs, but does not support all electrical devices connected 56 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 Fuel is old or contaminated Change fuel Spark Plug is dirty Clean spark plug Spark Plug is broken Replace spark plug Generator is not level Move generator to
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. 1. Remove generator cover Remove the 2 bolts of the generator cover then pull the cover off the generator. 2. Remove bolt from brush Remove the bolt holding the carbon brush. 3.
TROUBLESHOOTING (CONTINUED) Changing / Inspecting the Carbon Brushes (Cont.) 4. Install new brush Install new carbon brush with bolt. 5. Connect AVR wires Insert and connect the 2 wires from the AVR, be sure to connect + and – correctly. 6. Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts.
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. 1. Remove generator cover Remove the 2 bolts of the generator cover then pull the cover off the generator. 2. Remove AVR bolts Remove the 2 bolts holding the AVR. 3. Disconnect AVR wire clip Disconnect the wire clip.
TROUBLESHOOTING (CONTINUED) Changing / Inspecting the AVR (Continued) 4. Disconnect wires from brush Remove the 2 wires from the AVR on the carbon brush. 5. Install new AVR Install the new AVR with the 2 bolts. 6. Reconnect wires to brush Insert and connect the 2 wires from the AVR, be sure to connect + and – correctly. 7. Reconnect the AVR wire clip Reconnect the wire clip.
8. Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts.
WIRING DIAGRAM 62
WARRANTY 5-year Warranty All DuroMax Power Equipment warrant the original purchasers to a 5-year Parts Warranty (Residential Use ONLY: Unusually heavy or commercial use is covered for a period of 1-year) in the event of failure due to defects in electrical or mechanical components. Freight on any items submitted for replacement or repair under the Warranty is the responsibility of the equipment owner. This warranty is non-transferable and only valid to the original purchaser.
maintenance listed in your owner’s manual. DuroMax Power Equipment recommends that you retain all receipts covering maintenance on your small off-road engine, but DuroMax Power Equipment cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
WARRANTY (CONTINUED) Subsection (4) below. Any such part repaired or replaced under the warranty must be warranted for the remaining warranty period. (2) Any warranted part that is scheduled only for regular inspection in the written instructions required by subsection(d)must be warranted for the warranty period defined in Subsection(b) (2). A statement in such written instructions to the effect of “repair or replace as necessary” will not reduce the period of warranty coverage.
Exhaust Emission Warranty Parts List. (1) Fuel Metering System (i) Carburetor and internal parts (and/or pressure regulator or fuel injection system). (ii) Air/fuel ratio feedback and control system. (iii) Cold start enrichment system. (iv) Fuel tank. (2) Air induction system (i) Controlled hot air intake system. (ii) Intake manifolds. (iii) Air filter. (3) Ignition System (i) Spark Plugs. (ii) Magneto or electronic ignition system. (iii) Spark advance/retard system.
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 5800 Ontario Mills Parkway Ontario, CA 91764 Customer Service: 844-DUROMAX Customer Service Hours: 8-5 pm PST Website: www.duromaxpower.com Email: customerservice@duromaxpower.
5800 Ontario Mills Parkway Ontario, CA 91764 United States 844-DUROMAX REV: XP7500X-10082021