AC Tool Supply 005796-0 (XG6500) Owner's manual

Brand: AC Tool Supply

Model: 005796-0 (XG6500)

Category: Power generators

Type: Owner's manual

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introduction.............................................................1

Readthis iVlanualThoroughly.................................1

Safety Rules...........................................................1

StandardsIndex.............................................................3

Generalinformation................................................4

1.1 Unpacking......................................................................4

1.1.1 AccessoryBox..................................................4

1.2 Assembly.......................................................................4

1.2.1 AssemblingtheWheelKitand FrameFoot..........4

Operation................................................................5

2.1 Knowthe Generator.......................................................5

2.1.1 BatteryConnection(XG7000E& XG8000E).......6

2.2 Hourmeter......................................................................6

2.3 CordSetsand ConnectionPlugs....................................6

2.3.1 120 VAC,20 Amp, GFCIDuplexReceptacle.......6

2.3.2 120/240 VAC,30 Amp Receptacle.....................6

2.4 How to Usethe Generator..............................................7

2.4.1 SystemGround..................................................7

2.4.2 GroundingtheGenerator....................................7

2.4.3 Neutralto FrameGrounding...............................8

2.4.4 ConnectingElectricalLoads...............................8

2.5 Don't Overloadthe Generator..........................................8

2.6 WattageReferenceGuide...............................................8

2.7 BeforeStartingthe Generator.........................................9

2.7.1 AddingEngineOil ..............................................9

2.7.2 AddingGasoline.................................................9

2.8 ToStartthe Engine.......................................................10

2.8.1 Manual(Recoil)Starting..................................10

2.8.2 ElectricStarting (XG7000E& XG8000E)..........11

2.9 Stoppingthe Engine.....................................................11

2.10 Low Oil PressureShutdownSystem.............................11

2.10.1 Restarting........................................................11

2.11 Charginga Battery.......................................................11

Maintenance.........................................................11

3.1 MaintenanceSchedule.................................................11

3.2 ProductSpecifications..................................................11

3.2.1 GeneratorSpecifications..................................11

3.2.2 EngineSpecifications.......................................12

3.2.3 EmissionsInformation.....................................12

3.3 GeneralRecommendations...........................................12

3.3.1 GeneratorMaintenance....................................12

3.3.2 ToCleanthe Generator.....................................13

3.3.3 EngineMaintenance.........................................13

3.3.4 CheckingOilLevel...........................................13

3.3.5 Changingthe Oiland Oil Filter..........................13

3.3.6 Replacingthe SparkPlug.................................13

3.4 ServiceAir Cleaner.......................................................13

3.5 CleanSparkArrestorScreen.........................................14

3.6 General........................................................................14

3.7 LongTermStorage.......................................................14

3.8 OtherStorageTips.......................................................15

BatteryService.....................................................15

4.1 BatteryReplacement(XG7000E& XG8000E)...............15

Troubleshooting....................................................16

5.1 TroubleshootingGuide..................................................16

Notes....................................................................17

Warranty...............................................................18

iNTRODUCTiON

Thankyou for purchasingthis modelby GeneracPowerSystems,

Inc. This model is a compact, high performance, air-cooled,

engine driven generatordesigned to supply electrical power to

operateelectrical loads where no utility power is availableor in

placeof utility dueto a poweroutage.

BEADTHiSMANUALTHOROUGHLY

If any portion of this manual is not understood, contact the

nearest Authorized Dealerfor starting, operating and servicing

procedures.

The operator is responsible for proper and safe use of the

equipment.We strongly recommendthat the operator read this

manualandthoroughlyunderstandall instructionsbeforeusingthe

equipment.Wealsostronglyrecommendinstructingotherusersto

properlystart andoperatethe unit.This preparesthem ifthey need

to operatetheequipmentin an emergency.

Thegeneratorcan operatesafely,efficiently andreliablyonly if it

is properlylocated,operatedand maintained.Beforeoperatingor

servicingthe generator:

• Becomefamiliar with and strictly adhereto all local, stateand

nationalcodes and regulations.

• Study all safety warnings in this manual and on the product

carefully.

• Becomefamiliar with this manualandthe unit beforeuse.

Themanufacturercannot anticipateevery possible circumstance

that might involvea hazard.Thewarnings in this manual,andon

tags and decals affixedto the unit are,therefore,not all inclusive.

If usinga procedure,work method or operatingtechniquethatthe

manufacturerdoes not specifically recommend,ensurethat it is

safe for others. Also make sure the procedure,work method or

operatingtechniqueutilizeddoes not renderthe generatorunsafe.

THE INFORMATIONCONTAINEDHEREIN WAS BASED ON

MACHINESIN PRODUCTIONAT THE TIME OF PUBLICATION.

GENERACRESERVESTHERIGHTTOMODIFYTHISMANUALAT

ANYTIME.

SAFETYRULES

Throughoutthis publication,and on tags and decals affixedto the

generator,DANGER,WARNING,CAUTIONand NOTEblocks are

usedto alert personnelto special instructionsabout a particular

operation that may be hazardous if performed incorrectly or

carelessly. Observe them carefully. Their definitions are as

follows:

iNDICATESA HAZARDOUSSiTUATiONORACTIONWHICH,IF

NOTAVOIDED,WiLLRESULTiN DEATHORSERIOUSiNJURY.

Indicatesa hazardoussituationor actionwhich,ifnot

avoided, couldresultin deathor seriousinjury.

_CAUTION!

Indicatesa hazardoussituationor actionwhich,if not

avoided, couldresultin minoror moderateinjury.

NOTE:

Notescontainadditionalinformation importanttoa procedure

and will be found within the regular text bodyof this manual.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliancewith the special

instructionswhileperforming theaction or serviceareessentialto

preventingaccidents.

Four commonly used safety symbols accompany the DANGER,

WARNINGand CAUTIONblocks. The type of information each

indicatesis asfollows:

,_This symbol points out important safety

information that, if not followed, could

endanger personal safety and/or property of

others.

This symbol points out potential explosion

hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical

shock hazard.

GENERAL HAZARDS

• Neveroperatein an enclosedareaor indoors.

• For safety reasons, the manufacturer recommends that the

maintenanceof this equipmentis carried out by an Authorized

Dealer.Inspectthe generatorregularly,and contactthe nearest

AuthorizedDealerfor parts needingrepairor replacement.

• Operategeneratoronly onlevelsurfacesandwhereit will notbe

exposedto excessivemoisture,dirt, dust or corrosivevapors.

• Keep hands, feet, clothing, etc., away from drive belts, fans,

and othermoving parts. Neverremoveany fan guardor shield

whilethe unit isoperating.

• Certain parts of the generator get extremely hot during

operation. Keep clear of the generator until it has cooled to

avoidsevereburns.

• Do NOToperategeneratorinthe rain.

• Do not alter the construction of the generator or change

controlswhich might createan unsafeoperatingcondition.

• Never start or stop the unit with electrical loads connected

to receptaclesAND with connecteddevicesturned ON. Start

the engine and let it stabilize before connecting electrical

loads. Disconnectall electricalloads beforeshutting downthe

generator.

• Do notinsert objectsthrough unit's cooling slots.

• When working on this equipment, remain alert at all times.

Never work on the equipment when physically or mentally

fatigued.

• Neverusethegeneratororanyofitspartsasastep.Stepping

ontheunitcanstressandbreakparts,andmayresultin

dangerousoperatingconditionsfromleakingexhaustgases,

fuelleakage,oilleakage,etc.

• Onelectricstartmodels,disconnectthePOSITIVE(+)battery

cablefromtheenginestarterORtheNEGATIVE(-)battery

cablefromthebatteryterminal,whicheveriseasier,before

transportingthegenerator.

NOTE:

Thisgenerator is equipped with a spark arrestor muffler. The

spark arrestor must bemaintained in effectiveworking order

by the owner/operator. In theState of California, a spark

arrestoris requiredby law (Section4442 of the California

PublicResources Code). Otherstates may havesimilar laws.

Federal lawsapply on federallands.

EXHAUST & LOCATIONHAZARDS

• Never operate in an enclosed areaor indoors!NEVERuse in

the home,or in partlyenclosedareas suchas garages, even

if doors and windowsare open! ONLYuse outdoors and far

fromopenwindows,doors, vents,andin anareathatwill not

accumulatedeadly exhaust.

Using a generator indoors CAN KiLL YOU iN MINUTES.

Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell,

NEVER use insidea home

or garage, EVEN IF doors

and windows are open.

Only use OUTSIDE and

far away from windows,

doors, and vents.

• The engine exhaustfumes contain carbon monoxide, which

can you cannot see or smell. This poisonous gas, if breathed

in sufficient concentrations, can cause unconsciousnessor

evendeath.

• Adequate, unobstructed flow of cooling and ventilating air

is critical to correct generator operation. Do not alter the

installation or permit even partial blockage of ventilation

provisions, as this can seriously affect safe operationof the

generator.ThegeneratorMUSTbeoperatedoutdoors.

• This exhaustsystemmust be properlymaintained.Do nothing

that mightrendertheexhaustsystemunsafeorinnoncompliance

with any localcodes and/orstandards.

• Alwaysusea batteryoperatedcarbonmonoxidealarmindoors,

installedaccordingto themanufacturersinstructions.

• If you start to feet sick, dizzy,or weak after the generatorhas

beenrunning,moveto fresh air IMMEDIATELYSeea doctor,as

you couldhavecarbonmonoxidepoisoning.

ELECTRICALHAZARDS

• The generator produces dangerouslyhigh voltage when in

operation.Avoidcontactwith barewires,terminals,connections,

etc., while the unit is running,even on equipmentconnected

to the generator. Ensureall appropriate covers, guards and

barriersarein placebeforeoperatingthegenerator.

• Never handle any kind of electrical cord or device while

standinginwater,while barefootorwhile handsor feet arewet.

DANGEROUSELECTRICALSHOCKMAYRESULT.

• TheNationalElectricCode(NEC)requirestheframe andexternal

electrically conductive parts of the generator be properly

connectedto an approvedearthground.Local electricalcodes

may also require proper grounding of the generator.Consult

with a localelectricianfor groundingrequirementsinthearea.

• Use a groundfault circuit interrupter in any damp or highly

conductivearea(such as metaldecking or steelwork).

• Do not useworn, bare,frayed or otherwisedamagedelectrical

cord setswith the generator.

• Beforeperforminganymaintenanceonthegenerator,disconnect

the enginestarting battery (if equipped)to prevent accidental

start up. Disconnectthe cablefrom the batterypost indicated

by a NEGATIVE,NEGor (-) first. Reconnectthat cable last.

• In caseof accidentcausedby electricshock, immediatelyshut

down the source of electrical power. If this is not possible,

attempt to free the victim from the live conductor. AVOID

DIRECTCONTACTWITHTHEVICTIM, Use a non-conducting

implement,such asa rope or board,to freethevictim from the

live conductor.If the victim is unconscious,applyfirst aid and

getimmediatemedical help.

FIREHAZARDS

• GasolineishighlyFLAMMABLEand itsvaporsare EXPLOSIVE.

Do not permitsmoking,open flames, sparksor heat in the

vicinitywhilehandlinggasoline.

• Neveraddfuel whileunit isrunning or hot. Allow engineto cool

completelybeforeaddingfuel.

• Never fill fuel tank indoors, Comply with all laws regulating

storageand handlingof gasoline.

• Do not overfill the fuel tank. Always allow roomfor fuel

expansion. If tank is over=filled,fuel can overflow onto a hot

engineandcauseFIREor an EXPLOSION.Neverstoregenerator

with fuel in tank where gasolinevapors might reach an open

flame, spark or pilot light (as on a furnace, water heateror

clothes dryer). FIREor EXPLOSIONmay result. Allow unit to

cool entirelybeforestorage.

• Wipe up any fuel or oil spills immediately.Ensure that no

combustiblematerialsareleft on or nearthegenerator.Keepthe

areasurroundingthe generatorcleanandfree from debrisand

keepa clearanceof five (5) feet on all side to allow for proper

ventilationofthe generator.

* Donot insert objectsthrough unit's coolingslots.

* Do not operate the generatorif connected electrical devices

overheat,ifelectricaloutputis lost,if engineor generatorsparks

or if flamesor smokeare observedwhile unit is running.

* Keepa fire extinguishernearthe generatorat all times.

STAtVDARDS/#DEX

In the absence of pertinent standards, codes, regulations and

laws, the publishedinformation listed below may be used as a

guidelinefor operation of this equipment. Always referencethe

latestrevisionavailablefor the standardslisted.

1. NFPANo. 70, NFPAHANDBOOKOF NATIONALELECTRIC

CODE.

2. Article X, NATIONALBUILDINGCODE,available from the

American InsuranceAssociation, 85 John Street, NewYork,

N.Y.10038.

3. AGRICULTURALWIRINGHANDBOOK,availablefrom the Food

and EnergyCouncil, 909 UniversityAvenue, Columbia, Me

65201.

4. ASAE EP-3634, INSTALLATIONAND MAINTENANCEOF

FARMSTANDBYELECTRICALSYSTEMS,availablefrom the

AmericanSocietyof AgriculturalEngineers,2950 Niles Road,

St. Joseph,MI49085.

MODELNO:

SERIALNO:

Generator Identification

Unit ID

Locations

CALIFORNIAPROPOSiTiON65 WARNING

Engineexhaustand someof its constituentsareknown

tothe Stateof Californiato causecancer,birth defects

and otherreproductiveharm.

CALIFORNIAPROPOSITION65 WARNING

Thisproduct containsor emitschemicalsknownto the

StateofCaliforniato cause cancer,birthdefectsand

otherreproductiveharm.

1.1 UNPACKING

• Removeall packagingmaterial.

• Removeseparateaccessorybox.

• Removecarton off the generator.

1.1.1 ACCESSORYBOX

Checkall contents(Figure1). If anyparts aremissing or damaged

locatean authorizeddealerat 1-888-775-6937.

Contentsinclude:

• 2-Axle Pins • Oil Filter

• 2- WheelSpacers • Air Filter

• 2- HairPins • SparkPlug

• 2- Wheels • SparkPlugWrench

• 1 - FrameFoot • ShopTowel

• 2 - FrameBolts • 2 - FrameWashers

• 2-Vibration Mounts • Oil Funnel

• 4 - FlangeNuts 12 VoltAdaptorPlugCharger

• 2 - 1 QuartSAE30 Oil Bottles

Figure 1 - Accessory Boxes

• Referto Figure2 and install the wheel kit and frame foot as

follows:

• Slidethe AxlePin throughthe Wheel,WheelSpacer(Washer)

andthe Frame.

• Installthe Hair Pinto the Axle Pinto securethe wheel. Repeat

forthe oppositeside.

• SecuretheVibrationMountsto theFrameFootwith theincluded

locking nuts.

• To install the Frame Foot, install the Frame Bolts though the

FrameWashers,Frameand Framefoot. Securewiththelocking

nuts.

Figure 2 - Wheel and Foot Assembly

FOOT

SECUREWHEEL

ANDAXLEWITH

HAIRPIN

1.2 ASSEMBLY

Read entireOwner's Manual beforeattemptingto assemble or

operatethe generator. The generator requiressome assembly

prior to usingit. If problemsarisewhenassemblingthe generator,

pleasecallthe GeneratorHelplineat 1-888-775-6937.

1.2.1 ASSEMBLINGTIlE WHEELKITANDFRAMEFOOT

Thewheelkit is designedto greatly improvethe portability of the

generator.You will needthe following tools to install the wheel

kit: Pliers,1/2" (13mm) wrench and a socket wrench with a 1/2"

(13mm) socket.

NOTE:

The wheel kit is not intendedfor over-the-road use.

FRAME

WASHER

FRAME

BOLT

WHEELSPACER

(WASHER)

SLIDEAXLE

THROUGHWHEEL

ANDWHEEL

SPACER

2.1 KNOWTHEGENERATOR

Read the entire Owner's Manual and Safety Rules before

operatingthisgenerator.

Compare the generator to Figures 3 through 6 to become

familiarizedwith thelocationsof variouscontrolsandadjustments.

Savethis manualfor futurereference.

1. ChokeKnob- Usedwhen startinga coldengine (Pull/Push).

2. EngineSwitch - Controlsthe operationof the generator.On

electric start models the switch is Start/Run/Stop.On recoil

start modelsthe switch is On/Off.

3. FuelShut Off - Valvebetweenfueltank and carburetor.Turn

off and run carburetoroutof fuelfor extendedstorage.

4. PanelLED's- Provideilluminationof the control panelwhile

thegeneratoris operating.

5. 120/240 Volt AC, 30 Amp LockingReceptacle- Supplies

electricalpowerfor the operationof 120 and/or240 VoltAC,

30 Amp, single-phase,60 Hz, electrical lighting, appliance,

tool andmotor loads.

5. 120 Volt AC,20 Amp,GFCiDuplexReceptacle- Supplies

electrical power for the operationof 120 Volt AC, 20 Amp,

single-phase, 60 Hz electrical lighting, appliance, tool and

motor loads. It also provides protection with an Integral

Ground Fault Circuit Interrupter, complete with a press to

"Test"and "Reset"button.

7. Circuit Breakers (AC)- Each20 Amp receptacleis provided

with a push-to-reset circuit breakerto protectthe generator

againstelectricaloverload.

8. Circuit Breakers (AC)- The30 Amp receptacleis protected

with a pair of push-to-reset circuit breakersto protect the

generatoragainstelectricaloverload.

g. PowerBar- Indicatesthe amountof power being usedfrom

thegenerator;each sectionis approximately25%

10. Hourmeter- Providesoperatinghoursfor Service Intervals.

11. Battery Charger input (Electric Start Models) - This

receptacleallowsthecapabilityto rechargethe12 VDCengine

starting battery with the 12 Volt Adaptor Plug Charger.The

batteryisprotectedby a 1.50 Ampin-linefuse which is inside

thecontrol panel.

12. FuelTank- Tankholds9 U.S.gallonsoffuel.

13. FuelGauge- Showsfuel levelintank.

14. Handles - Pivot and retractfor storage. Press the spring-

loadedbuttonto move handles.

15. Oil Fill- Checkoil levelandadd oil here.

18. GroundingLug- Groundthe generatorto an approvedearth

groundhere.See"GroundingtheGenerator"for details.

17. Muffler- Includesthe sparkarrestor andquietsthe engine.

18. Spark Plug Location - The spark plug ignites the Air/Fuel

Mixture(Sidepanelmust be removed).

lg. Engine Oil Filter- Filtersengineoil; seeSection 3.1 for the

properservice intervals.

20. Air Cleaner- Filtersintakeair as it is drawn intothe engine.

21. Oil Drain- Drain valveto remove used oil from the engine

crankcase.

22. Recoil Starter - Useto start enginemanually.

Figure 3 - GeneratorLocations

2 5 8 9 10

3 4 7 8 4

2.1.1 BATTERYCONNECtiONfXG7OOOE&XG8OOOE)

NOTE:

The battery shippedwiththe generator hasbeenfully charged.

A battery may losesomeof itschargewhennot in use for

prolongedperiodsof time. If the battery isunable to crank

the engine, pluginthe 12V chargerincludedinthe accessory

box(see theChargingthe Battery section).RUNNINGTHE

GENERATORDOESNOTCHARGETHEBATTERY.

The positive battery wire was deliberately left detached for

shipping. To operatethe unit, attachthis wire to the terminal on

the startermotor as shown.Do notovertighten.Slidethe attached

rubber bootoverthe starterterminal.SeeFigure4.

Figure4 - Battery Connection

/ L_'! / //// /fi BATTERYCABLE_

2.2 HOUBMETEB

The Hourmeter tracks hours of operation for scheduled

maintenance:

Therewilt be a onetime breakin "CHGOIL"messagethatflashes

with the elapsedtime in hoursand tenths after thefirst 30 hours

of operation.

This messagewill actuallybeginflashing at 29 hoursand disable

itself at 31 hours providing a two hourwindow to perform the

service.

Therewill be a subsequent"CHGOIL"messageevery100 hours.

Themessagewill flash one hour beforeand one hour after each

100 hour interval,again providinga two hour window to perform

service.

Every200 hoursthe "SVC"icon on the lower left handcorner of

the display will flash. Themessagewill flashone hourbeforeand

onehourafter each200 hourintervalprovidingatwo hourwindow

to perform service.

Whenthe hour meter is inthe FlashAlert mode, the maintenance

message will always alternate with elapsedtime in hours and

tenths. The hours wilt flash four times, then alternate with the

maintenancemessagefourtimes untilthemeter resetsitself.

* 100 hours- CHGOIL-- OilChangeInterval(Every100 hrs)

* 200 hours- SVC-- Air FilterInterval(Every200 hrs)

2.3 CORDSETSAND CONNECTIONPLUGS

2.3.1 120VAC,20AMP,GFC/DUPLEXRECEPTACLE

This is a 120 Volt outlet protectedagainst overloadby a 20 Amp

push-to-resetcircuitbreaker(Figure5). Useeachsocketto power

120 VoltAC, singlephase,60 Hzelectricalloadsrequiringupto a

combined 2400 watts (2.4 kW) or 20 Amps of current.Use only

high quality,well-insulated, 3-wire grounded cord sets ratedfor

125 Volts at 20 Amps (or greater).

Keep extensioncords as short as possible, preferablyless than

15 feet long, to preventvoltage drop and possibleoverheatingof

wires.

2.3.2 120/240VAC,30AMP RECEPTACLE

Use a NEMAL14-30 plug with this receptacle (rotate to lock!

unlock). Connecta suitable4-wire groundedcord set to the plug

andto thedesiredtoad.Thecordset shouldbe ratedfor 250Volts

ACat 30 Amps (or greater)(Figure5).

Use this receptacleto operate120 Volt AC, 60 Hz, singlephase

loads requiringup to 3600 watts (3.6 kW) of powerat 30 Amps

or 240 VoltAC,60 Hz,singlephaseloadsrequiring6,500 to 8000

watts of power,dependingonthemodel.Theoutletis protectedby

a 30 Ampcircuit breaker.

Figure5 - GeneratorReceptacles

Kin

, a

120 VAC20A

GFCIRECEPTACLE

120/240 VAC30A

RECEPTACLE

2.4 HOW TO USETHEGENERATOR

If thereare any problems operatingthe generator,pleasecall the

generatorhelplineat 1-888-436-3722.

,l_ Never operate in an enclosed area or indoors!

NEVER use in the home, or in partly enclosed

areas such as garages, even if doors and

windows are open! ONLY use outdoors and far

from open windows, doors, vents, and in an

area that will not accumulate deadly exhaust.

,l_The engine exhaust fumes contain carbon

monoxide, which can you cannot see or smell.

This poisonous gas, if breathed insufficient

concentrations, can cause unconsciousness or

even death.

Adequate, unobstructed flow of cooling and

ventilating air is critical to correct generator

operation. Do not alter the installation or permit

even partial blockage of ventilation provisions,

as this can seriously affect safe operation

of the generator. The generator MUST be

operated outdoors.

,l_This exhaust system must be properly

maintained. Do nothing that might render the

exhaust system unsafe or in noncompliance

with any local codes and/or standards.

,l_The manufacturer recommends installing

a battery operated carbon monoxide alarm

indoors, according to the manufacturers

instructions.

Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell.

NEVER use insidea home

or garage, EVEN iF doors

and windows areopen,

Only use OUTSIDE and

far away from windows,

doors, and vents.

2.4.1 SYSTEMGROUND

Thegeneratorhas a system groundthat connectsthe generator

frame components to the ground terminals on the AC output

receptacles. Thesystem groundis bondedto theAC neutralwire

in the generatorcontrol panelvia a jumperwire.

SpecialRequirements

There may be Federalor State OccupationalSafety and Health

Administration(OSHA)regulations,localcodes,or ordinancesthat

applyto the intendeduse ofthe generator.

Pleaseconsult a qualified electrician, electricalinspector, or the

local agencyhavingjurisdiction:

* In some areas, generators are requiredto be registeredwith

local utilitycompanies.

* If the generatoris used at a construction site, there may be

additionalregulationswhich must be observed.

Connectingto aBuilding'sElectricalSystem

Connectionsfor standby power to a building's electricalsystem

must be made by a qualified electrician. The connection must

isolatethe generatorpower from utility power or otheralternative

power sources and must comply with all applicable laws and

electricalcodes.

2.4.2 GROUND/NG TIlE GENERATOR

The National Electrical Code requires that the

frame and external electrically conductive parts

of this generator be properly connected to an

approved earth ground.

Local electrical codes may also require proper grounding of

the unit (Figure6). Forthat purpose,connectinga No.10 AWG

(AmericanWireGauge)strandedcopperwireto the groundinglug

and to an earth=drivencopperor brass groundingrod (electrode)

provides adequateprotection against electrical shock. However,

local codes may vary widely.Consultwith a localelectricianfor

grounding requirements in the area.

Proper groundingof the generatorwill help preventelectrical

shockin theeventof a groundfault conditioninthe generatoror in

connectedelectricaldevices.Propergroundingalsohelpsdissipate

static electricity,which often buildsup in ungroundeddevices.

Figure6 - GeneratorGroundLocation

LOCATION

XG6500& XG7000

GROUNDLOCATION

2.4.3 NEUTRAL70FRAMEGROUNDING

If service work is performed on the alternator,DO NOTdiscard

the white jumper wires from the terminal blockto the alternator

ground, located on the rear bearing carrier. Always make sure

the wires are properlyconnectedbeforeusingthe generatorafter

alternatorservicework is done (Figure7).

Failure to reconnect these wires may create a

potential shock hazard when the generator is

running!

Figure7- NeutraltoFrameGround

NEUTRALTO FRAMEGROUND

XG7000& 8000

DONOTDISCARD

WIREST

DONOTDISCARD

3EWIREST

NEUTRALTO FRAMEGROUNDXG6500

2.4.3 CONNECT/NGELECTR/CALLOADS

DONOTconnect240 Volt loadsto 120 Voltreceptacles.

DONOTconnect3 phaseloadsto the generator.

DONOTconnect50 Hzloadsto the generator.

* Let engine stabilize and warm up for a few minutes after

starting.

* Plug in and turn on the desired 120 or 240 Volt AC, single

phase,60 Hzelectricalloads.

Add up the ratedwatts (or amps) of all loadsto be connected

at one time. This total should no be greaterthan (a) the rated

wattage/amperagecapacity of the generator or (b) circuit

breakerratingofthereceptaclesupplyingthepower.See"Don't

OverloadtheGenerator

2.5 DON'TOVERLOADTHEGENERATOR

Overloadinga generatorin excess of its ratedwattage capacity

can result in damageto the generatorandto connectedelectrical

devices.Observethefollowing to preventoverloadingthe unit:

* Addupthetotal wattageofall electricaldevicesto be connected

at one time. This total should NOT be greater than the

generator'swattagecapacity.

* The ratedwattageof lights can betaken from light bulbs.The

ratedwattageof tools, appliancesand motors can usually be

foundon a datalabelor decalaffixedto the device.

* If the appliance,tool or motor does not give wattage,multiply

voltstimes ampereratingto determinewatts (voltsx amps =

watts).

* Some electric motors, such as induction types, require about

threetimes morewatts of powerfor startingthan for running.

This surge of power lasts only a few seconds when starting

suchmotors. Makesureto allowfor high startingwattagewhen

selectingelectricaldevicesto connectto the generator:

1. Figurethe watts neededto start the largestmotor.

2. Add to that figure the running watts of all other connected

loads.

TheWattageReferenceGuideis providedto assist in determining

how many itemsthegeneratorcan operateatonetime.

NOTE:

All figuresare approximate.See datalabel onappliancefor

wattagerequirements.

2.6 WATTAGEREFERENCEGUIDE

Device................................... RunningWatts

*AirConditioner(12,000Btu).......................... 1700

*AirConditioner(24,000Btu).......................... 3800

*AirConditioner(40,000Btu).......................... 6000

BatteryCharger(20Amp).............................. 500

BeltSander(3").................................... 1000

ChainSaw........................................ 1200

CircularSaw(6-1/2")........................... 800to 1000

*ClothesDryer(Electric)............................. 5750

*ClothesDryer(Gas)................................. 700

*ClothesWasher................................... 1150

CoffeeMaker...................................... 1750

*Compressor(1 HP)................................. 2000

*Compressor(3/4HP)............................... 1800

*Compressor(1/2HP)............................... 1400

CurlingIron......................................... 700

*Dehumidifier....................................... 650

DiscSander(9").................................... 1200

EdgeTrimmer....................................... 500

ElectricBlanket...................................... 400

Electric NailGun.................................... 1200

Electric Range(per element)........................... 1500

Electric Skillet...................................... 1250

*Freezer............................................ 700

*FurnaceFan(3/5 HP) ................................ 875

*GarageDoorOpener............................ 500to 750

HairDryer......................................... 1200

Hand Drill.................................... 250 to 1100

HedgeTrimmer...................................... 450

Impact Wrench...................................... 500

Iron.............................................. 1200

*Jet Pump ......................................... 800

Lawn Mower....................................... 1200

Light Bulb.......................................... 1O0

Microwave Oven............................... 700 to 1000

*Milk Cooler....................................... 1100

OilBurneron Furnace................................. 300

OilFiredSpaceHeater(140,000 Btu) ..................... 400

OilFiredSpaceHeater(85,000 Btu) ...................... 225

OilFiredSpaceHeater(30,000 Btu) ...................... 150

*Paint Sprayer,Airless (1/3 HP) ......................... 600

PaintSprayer,Airless (handheld)......................... 150

Radio......................................... 50 to 200

*Refrigerator........................................ 700

SlowCooker........................................ 200

*SubmersiblePump (1-1/2 HP) ........................ 2800

*SubmersiblePump (1 HP) ........................... 2000

*SubmersiblePump (1/2 HP).......................... 1500

*Sump Pump................................. 800 to 1050

*Table Saw(10") ............................. 1750 to 2000

Television..................................... 200to 500

Toaster..................................... 1000 to 1650

WeedTrimmer ...................................... 500

* Allow 3 times thelistedwatts for starting these devices.

2.7 BEFORESTARTINGTHEGENERATOR

Prior to operating the generator, engine oil and gasoline will need

to be added, as follows:

2,7,1 AD#/NGEflG/NEO/L

All oil should meetminimum American PetroleumInstitute (API)

Service Class SJ, SL or better.Use no special additives. Select

the oil's viscosity grade according to the expected operating

temperature(also seechart).

• Above40° F,useSAE30

• Below40° Fand downto 10° F,use10W-30

• Below10° F,usesynthetic5W-30

,_Any attempt tocrankor startthe enginebeforeit has

been properlyserviced with the recommendedoil may

resultin an enginefailure.

TEMPERATURE IN DEGREES FAHRENHEIT (°F)

=30 =20 ='tO 0 10 20 32 40 55 70+

||||

=30 =20 =10 0 10 20

TEMPERATURE IN DEGREES CELSIUS (°C)

• Placegeneratorona levelsurface.

• Cleanareaaroundoil fill andremoveoil fill cap.

• Slowly fill engine with oil through the oil fill opening until it

reachesthefull mark.Stopfilling occasionallyto checkoil level.

(Engineoil is full when levelis up to the threadsof the oil fill

plug,seeFigure8)

• Installoil fill capandfingertighten securely.

• Checkengineoil levelbeforestarting eachtimethereafter.

Figure 8 - Off Level

--J

FILLCRANKCASETO

THE BOTTOMOFTHESE

-- THREADSWiTHTHE

RECOMMENDED

ENGINEOIL

2.7,2 ADD/NGGASOLINE

ADO NOTlighta cigaretteor smokewhen filling the fuel

tank.

,_ Neverfiil fuel tankindoors.Neverfiil fuel tankwhen

engineis running or hot.Avoid spillinggasoline on a hot

engine.Allow engineto coolentirelybeforefilling fuel

tank.

Donot overfill the fuel tank.Alwaysleave roomfor fuel

expansion,ifthefuel tankisoverfilled,fuel canoverflow

onto a hot engine and causeFiREor EXPLOSION.Wipe

up anyspilledfuel immediately.

• Use regularUNLEADEDgasolinewith the generatorengine.Do

not usepremiumgasoline.Do notmix oil with gasoline.

• Do not usegasolinewith morethan 10% alcohol such as E85

or Methanol.

• Cleanareaaroundfuelfill cap, removecap.

• Slowly addunleadedregulargasolineto fueltank. Fillto bottom

of screenfilter.Be carefulnot to overfill (Figure9).

• Installfuel cap andwipe up any spilledgasoline.

Figure g- Fuel Fill Level

DONOTFILL

AB( LIP!

IMPORTANT:It isimportantto preventgumdepositsfrom forming

in fuel system parts such as the carburetor,fuel hose or tank

during storage. Alcohol-blendedfuels (called gasohol, ethanol

or methanol)can attract moisture, which leadsto separationand

formation of acids duringstorage.Acidic gascandamagethefuel

system of an enginewhile in storage.Toavoid engineproblems,

the fuel system should be emptiedbefore storageof 30 days or

longer.Seethe "Storage"section.Neveruseengineor carburetor

cleaner products in the fuel tank as permanent damage may

occur.

2.8 TOSTARTTHEENGINE

Never startor stopenginewithelectricaldevicespluggedinto

the receptacles ANDdevices turnedon.

• Unplug all electrical loads from the unit's receptaclesbefore

startingthe engine.

• Makesurethe unitis in a levelposition.

• Openthefuel shut-off valve (Figure10).

• Pull engine CHOKEknob outward to "Full Choke" position

(Figure11).

Figure 10 - Fuel Shut-off Valve

2.8.1 MANUAL_ STARTING

• Tostartthe generator,putthe on/off switch in the ONposition.

• Firmly grasp the recoil handle and pull slowly until increased

resistanceisfelt. Pull rapidlyup and awayto start engine.

• When the engine starts, push choke knob to "1/2 Choke"

position untilthe engine runssmoothly and thenfully into the

"Run" position. If enginefalters, pull choke knob back out to

"1/2 Choke"position until the engine runs smoothly and then

to "Run" position.

NOTE:

If enginefires,but doesnot continuetorun, pull chokeknob

to "Furl Choke" and repeatstartinginstructions.

IMPORTANT:Donotoverloadthe generator.Also, do not overload

individual panel receptacles.Theseoutlets are protectedagainst

overload with push-to-reset-type circuit breakers. Read "Don't

OverloadtheGenerator"carefully.

2.8.1 ELECTRICSTARtiNG(XG7OOOE&XGSOOOE)

• Tostartthe engine,pressandholdtheStart/Run/Stopswitch in

the "Start" position.Theenginewill crankandattemptto start.

Whenthe enginestarts, releasetheswitch to the run position.

• When the engine starts, push choke knob to "1/2 Choke"

position untilthe engine runssmoothly andthenfully in to the

"Run" position. If enginefalters, pull choke knob back out to

"1/2 Choke"position until the engine runs smoothly and then

to "Run" position.

• This generatoris also equippedwith a manual recoil starter

which may be usedif the batteryis discharged.

NOTE:

TheengineStart/Run/Stop switch mustbe in the RUN

position whenusingthe manualrecoil starter.

2.9 STOPPINGTHEENGINE

* Shutoffall loads,thenunplugtheelectricalloadsfrom generator

panelreceptacles.Neverstart or stop theenginewith electrical

devicespluggedin andturnedon.

* Let engine run at no-load for several minutes to stabilizethe

internaltemperaturesof engineandgenerator.

, Move Start/Run/Stopor On/Offswitch tothe "Off" position.

* Closefuelvalve.

2.10LOWOILPRESSURESHUTDOWNSYSTEM

Theengineis equippedwith a low oil pressuresensor that shuts

downthe engineautomaticallywhentheoil pressuredropsbelow

5 psi. A delay built into the low oil shutdown system allows oil

pressureto build during starting. The delayallows the engineto

run for about10 secondsbeforesensingoil pressure.If theengine

shutsdown by itselfandthe fueltank hasenoughgasoline,check

engineoil level.

2.10.1RESTARtiNG

Iftrying to restartthe enginewithin 10secondsafterit shutsdown,

the enginemay NOTstart. Thesystem needs5 to 10 secondsto

reset.

If the engine is restartedafter such a shutdown and the low oil

pressurehas not beencorrected,the enginewill run for about10

secondsas describedaboveandthen stop.

2.11CHARGINGTHEBATTERY(XGTOOOE&XG8OOOE)

Do not permit smoking, open flame, sparks

or any other source of heat around a battery.

Wear protective goggles, rubber apron and

rubber gloves when working around a battery.

Battery electrolyte fluid is an extremely

corrosive sulfuric acid solution that can cause

severe burns, if spill occurs flush area with

clear water immediately.

Storage batteries give off explosive hydrogen

gas while recharging. An explosive mixture will

remain around the battery for a long time after

it has been charged. The slightest spark can

ignite the hydrogen and cause an explosion.

Such an explosion can shatter the battery and

cause blindness or other serious injury.

Use batterychargerplugto keepthe batterychargedandready

for use. Batterychargingshouldbe done in a dry location.

1. Plugchargerinto "BatteryChargerInput" jack, locatedon the

control panel.Plugwall receptacleend of the batterycharger

into a 120 VoltACwall outlet.

2. Unplugbatterychargerfromwall outlet andcontrol paneljack

whengeneratoris goingto be in use.

NOTE:

Donot use the battery chargerfor more than 48 hoursat one

charge.

3.1 MAINTENANCESCHEDULE

Follow the calendar intervals. More frequent service is required

whenoperatingin adverseconditionsnotedbelow.

CheckOil Level

ChangeOiland OilFilter:!:

CleanSparkArrestorScreen

ServiceAir Cleaner

ReplaceSparkPlug

At EachUse

*Every Season/Every100 Hours

**Every Season/Every200 Hours

EverySeason

Changeoil after first 30 hours of operationthen every season.

Changeoil and oil filter every month when operating underheavy load or in

high temperatures.

Clean more often under dirty or dusty operating conditions. Replaceair

cleanerparts if very dirty.

3.2 PRODUCTSPECIFICATIONS

3.2.1 GENERATORSPEC/F/CATIONS

Model # ............................................................... 005800-0, 005747-0

RatedMax.Power................................................................... 8.0 kW**

SurgePower................................................................................ 10 kW

RatedACVoltage...................................................................... 120/240

RatedMax AC Load

Current@ 240V............................................................. 33.3 Amps**

Current@ 120V............................................................. 66.7 Amps**

RatedFrequency.................................................... 60 Hz@ 3600 RPM

Phase................................................................................ SinglePhase

RatedDCVoltage...................................................................... 12 Volts

BatteryType.................................................................... 10 AH, 12VDC

Model # ............................................................... 005797-0, 005798-0

RatedMax.Power................................................................... 7.0 kW**

SurgePower............................................................................. 8.75 kW

RatedACVoltage...................................................................... 120/240

RatedMax ACLoad

Current@ 240V............................................................. 29.2 Amps**

Current@ 120V............................................................. 58.3 Amps**

RatedFrequency.................................................... 60 Hz@ 3600 RPM

Phase................................................................................ SinglePhase

RatedDCVoltage...................................................................... 12 Volts

BatteryType.................................................................... 10 AH, 12VDC

Model # ................................................................................ 885796-0

RatedMax.Power................................................................... 6.5 kW**

SurgePower............................................................................. 8.13 kW

RatedACVoltage...................................................................... 120/240

RatedMax ACLoad

Current@ 240V............................................................. 27.1 Amps**

Current@ 120V............................................................. 54.2 Amps**

RatedFrequency.................................................... 60 Hz@ 3600 RPM

Phase................................................................................ SinglePhase

RatedDCVoltage...................................................................... 12 Volts

** Maximumwattageandcurrentaresubjectto,andlimitedby,suchfactors

asfuelBtucontent,ambienttemperature,altitude,enginecondition,etc..

Maximumpowerdecreasesabout3.5%foreach1,000feetabovesealevel;

andwillalsodecreaseabout1%for each6° C(10° F)above16° C(60° F)

ambienttemperature.

3.2.2 ENGINESPECIFICAtiONS

RatedHorsepower@ 3600 RPM.................................................... 14.5

Displacement............................................................................... 410cc

SparkPlugType................................... ChampionRO14YOor Equivalent

SparkPlug Gap............................................... 0.030 inch or (0.76 mm)

GasolineCapacity............................................................ 9 U.S.gallons

OilType.................................... SeeChart in "AddingEngineOil"Section

OilCapacity................................................ w/Filter Change= 1.5 Qts.

w/o FilterChange= 1.2 Qts.

RunTime/FuelConsumption-l/2 Load.. 10 Hours/ .73 gallonsper hour

ClassI1EmissionCertified

3.2.3 EM/SS/ONS/NFORMATiON

The EnvironmentalProtection Agency (EPA) and CaliforniaAir

ResourceBoard (CARB)requirethat your generatorcomply with

exhaust and evaporativeemission standards. This generator is

certified to meet the applicable EPAand CARB emission levels.

Additionalinformationregardingthe requirementsset by EPAand

CARBis asfollows:

It is important that you follow the maintenance specifications

providedin this manualto ensurethat your enginecomplies with

the applicableemissionstandardsfor the durationof the engine's

life. This engine is certified to operateon gasoline.The emission

control system on yourgeneratorconsistsof thefollowing:

* FuelSystem * Air InductionSystem

FuelTank - Intakepipe/manifold

FuelCap - Aircleaner

Carburetor • IgnitionSystem

FuelLines - Sparkplug

* EvaporativeControl System - Ignitionmodule

CarbonCanister * ExhaustSystem

VaporHoses _ PulseAir InjectionValve

Muffler

The Emissions Compliance Period referredto on the Emissions

Compliance Label indicates the number of operating hours for

which the enginehas been shown to meet FederalandCalifornia

emission requirements. See the table below to determine the

compliance period for your generator.The displacement of your

generatoris listed onthe EmissionsComplianceLabel.

Displacement Category CompliancePeriod

A 500 Hours

_>66 cc- < 225 cc B 250 Hours

C 125 Hours

A 1000 Hours

_>225 cc B 500 Hours

C 250 Hours

3.3 GENERALRECOMMENDATIONS

Thewarrantyof thegeneratordoes notcover itemsthat havebeen

subjectedto operator abuseor negligence.To receivefull value

from the warranty, the operator must maintain the generatoras

instructed inthis manual.

Some adjustmentswilt need to be made periodically to properly

maintainthegenerator.

All adjustmentsin the Maintenancesectionof this manualshould

be madeat leastonceeachseason.Followthe requirementsinthe

"MaintenanceSchedule".

NOTE:

Oncea year replace the spark plug and replace the air filter.

A new spark plug andclean air filter assure proper fuel-air

mixture and help the engine run better andlastlonger.

3.3.1 GENERATORMAINTENANCE

Generatormaintenanceconsistsof keepingthe unitcleanand dry.

Operateandstorethe unit in a cleandry environmentwhereit will

not be exposedto excessivedust,dirt, moistureor any corrosive

vapors.Coolingairslotsin thegeneratormustnot becomeclogged

with snow, leaves,or anyotherforeign material.

Checkthe cleanlinessof the generatorfrequentlyand cleanwhen

dust, dirt, oil, moistureor otherforeign substancesarevisible on

its exteriorsurface.

,&CAUTION!

,_ Never insertany object or toolthroughthe air cooling

slots, even if the engine is notrunning.

NOTE:

DONOTuse a garden hoseto cleangenerator. Water can

enterthe enginefuelsystem and cause problems. In addition,

if water entersthegeneratorthroughcoolingair slots,some

water will be retainedin voidsand crevicesoftherotor

and stator winding insulation.Waterand dirtbuildupon the

generatorinternal windings will eventuallydecreasethe

insulationresistanceof thesewindings.

3.3.2 TOCLEANTHEGENERATOR

• Usea dampcloth to wipe exteriorsurfaces clean.

• A soft, bristlebrush may be usedto loosencaked on dirt, oil,

etc.

• A vacuum cleaner may be used to pick up loose dirt and

debris.

• Low pressureair (notto exceed25 psi) may be usedto blow

awaydirt. Inspectcoolingairslotsandopeningsonthegenerator.

Theseopeningsmust bekept cleanand unobstructed.

3.3.3 ENG/NEMA/NTENANCE

,A CAUTION!

,_ When workingonthegenerator,alwaysdisconnect

negativecablefrombattery.Alsodisconnectsparkplug

wire from sparkplugand keepwire away from spark

plug.

3.3.4 CHECKINGOILLEVEL

See the "BEFORESTARTINGTHE GENERATOR"section for

information on checking the oil level. The oil level should be

checkedbeforeeachuse,or at leasteveryeighthoursof operation.

Keepthe oil levelmaintained.

3.3.5 CHANG/NGTIlE O/LANOOILFILTER

Changetheoil andfilterafterthefirst30 hoursof operation.Change

the oil every 100 hoursor every seasonthereafter.If runningthis

unit underdirty or dusty conditions, or in extremelyhot weather,

changethe oil moreoften.

,_ Hotoilmay causeburns.Allow engine to coolbefore

draining oil.Avoid prolongedor repeatedskin exposure

with usedoil. Thoroughlywashexposedareaswith soap.

Usethe following instructionsto changethe oil:

• Cleanareaaroundoil draincap.

• Removeoildraincapfrom thedrainhoseandoilfill plugto drain

oil completely intoa suitablecontainer.

• Whenoil hascompletelydrained,installoil draincapandtighten

securely.

• Place a suitable container beneath the oil filter and turn

filter counterclockwiseto remove. Discardaccording to local

regulations.

• Coat gasket of new filter with clean engine oil. Turn filter

clockwise until gasketcontacts lightly with filter adapter.Then

tightenan additional3/4 turn.

• Filloilsumpwithrecommendedoilandreplacetheoilfill plug.(See

"BeforeStartingthe Generator"for oil recommendations).

• Wipeup anyspilledoil.

• Disposeof usedoil at a propercollectioncenter.

3.3.6 REPLACINGTHESPARKPLUG

Use Champion RC14YCspark plug or equivalent.Replace the

plug once each year. This will help the engine start easier and

run better.

1. Stopthe engineand pull the spark plug wire off of the spark

plug.

2. Togain access,removethe four (4) socket head screws and

takeoff theside panel.

3. Cleanthe area aroundthe spark plug and remove it from the

cylinder head.

4. Set the spark plug's gap to .76 mm (0.030 in.). Install the

correctly gapped spark plug into the cylinder head (Figure

12).

5. Pushthe bootfirmly on the sparkplug and install sidepanel.

Figure 12 - Spark Plug Gap

3.4 SERVICEAIRCLEANER

Theenginewill not run properlyand may be damagedif usinga

dirty air cleaner.Cleanor replacethe air cleanerpaperfilter every

200 hoursor oncea year (Figure15). Cleanor replacemore often

if operatingunderdusty conditions.To cleanor replacepaper air

filter:

• Removeair cleanercover andremove paperfilter (Figure13).

• Cleanpaperfilter bytapping it gentlyon a solid surface. If the

filter istoo dirty, replaceit with a new one. Disposeof the old

filter properly.

• Cleanaircleanercover.Nextinsert newpaperfilter intothebase

of theair cleaner.Re-installaircleanercover.

NOTE:

Toorder a new air filter,please contact the nearestauthorized

service center at 1-888-GENERAC.

Figure 13- Air Filter

AIRFILTER

3.5 CLEANSPARKARRESTORSCREEN

Theengine exhaustmuffler has a spark arrestor screen. Inspect

and cleanthe screenat leastonceeachyear(Figure14). If unitis

usedregularly,inspectand cleanmoreoften.

i_lf using the generator on any forest=covered,

brush=covered or grass=covered unimproved

land, it must equipped with a spark arrestor.

The spark arrestor must be maintained in good

condition by the owner/operator.

Cleanandinspectthespark arrestorwhentheengineisatambient

temperatureasfollows:

* Loosenthe clamp and removethe spark arrestor screenfrom

the muffler.

* Inspect screen and replace if torn, perforated or otherwise

damaged. DO NOTUSEa defective screen. If screen is not

damaged,cleanit with commercialsolvent.

* Replacethe spark arrestorand securewith the clamp.

Figure 14 - Spark Arrestor Screen

ARRESTOR

SCREEN

CLAMP

SPARK

ARRESTOR

SCREEN

3.6 GENERAL

The generatorshould be started at least once every seven days

andbe allowedto run at least30 minutes. If this cannot be done

and the unit must be stored for more than 30 days, use the

following informationas a guideto prepareit for storage.

NEVER store engine with fuel in tank indoors

or in enclosed, poorly ventilated areas where

fumes may reach an open flame, spark or pilot

light as on a furnace, water heater, clothes

dryer or other gas appliance.

,l_AIIow unit to cool entirely before storage.

3.7 LONGTERMSTORAGE

It is importantto preventgum depositsfrom forming in essential

fuel system parts such asthe carburetor,fuel hoseor tank during

storage. To avoid engine problems, the fuel system should be

emptiedbeforestorageof 30 days or longer,asfollows:

* Removeallgasolinefrom thefueltank.

_,CAUTION!

,l& Drainfuel intoapprovedcontaineroutdoors,away from

openflame. Besure engineisc00i. Donotsmokein the

vicinityor lighta cigarette.

* Start andrun engineuntilenginestopsfrom lack of fuel.

* Allow the engineto cool, then drain oil from crankcase.Refill

with recommendedgrade.

* Removesparkplugand pourabout1/2 ounce(15ml) of engine

oil into the cylinder.Cover spark plug hole with rag. Pull the

recoil starter a coupletimes to lubricatethe piston rings and

cylinder bore.

A CAUTION!

,l_Avoid spray from spark plug hole when

cranking engine.

* Installand tighten spark plug. Do not connect the spark plug

wire.

* Cleanthegeneratoroutersurfaces.Checkthat coolingair slots

and openingson generatorare openand unobstructed.

* Storethe unitin a clean,dry place.

3.8 OTHERSTORAGETiPS

• Do notstore gasolinefrom one seasonto another.

• Replaceanygasolinecanthat starts to rust. Rustand/ordirt in

the gasolinewill cause problems with the carburetor and fuel

system.

• If possible,storethe unitindoorsand coverit to giveprotection

from dust and dirt. Cover the unit with a suitable protective

coverthat doesnot retainmoisture.

• BE SURETO EMPTYTHE FUELTANK.If it is not practical

to empty the fuel tank and the unit is to be stored for some

time, usea commerciallyavailablefuel stabilizeraddedto the

gasolineto increasethe lifeof thegasoline.

,A CAUTION!

,_ NEVER cover the generator while engine and

exhaust area are warm,

4.1 BATTERYREPLACEMENT(XG7000E&XGS000E)

NOTE:

The batteryshippedwiththe generatorhasbeenfully charged.

Abatterymay losesomeof itschargewhennot in use for

prolongedperiodsof time. If the batteryisunableto crank

the engine,pluginthe 12V chargerincludedinthe accessory

box(see the Charginga Batterysection).RUNNINGTHE

GENERATORDOESNOTCHARGETHEBATTERY.

The battery shipped with the generatorhas been providedfully

charged.Toreplacethe battery (SeeFigure16):

• Remove the side panel as shown. Remove the four bolts

securingthefueltank.

• Turnthe fuel valve on the control panelto the "OFF"position.

Pull the fuel tank back slightly and removethe fuel hosethat

runs from the engineto thefuel valve.

_CAUTION!

,_ Drainfuel intoapprovedcontaineroutdoors,awayfrom

open flame. Besureengineiscool.Donot smokein the

vicinityor lighta cigarette.

• Pushthefuel valvefrom the control paneland removethe fuel

tank.

• Removethe batterywire connections(black wirefirst) and the

batteryhold-down bracket.

• Replacethe battery,connectingthe REDwire to the POSITIVE

(+) terminal andthe BLACKwire to the NEGATIVE(-) terminal

NOTE:

Start aft fourscrews ontheside panel beforetighteningor it

may notbe possible toget all the screws in place.

SIDE

PANEL

Figure16- Battery Removal

1_ FUELTANK

ASSEMBLY

ENGINE

STARTIN(

BATTERY

BRACKET

5.1 TBOUBLESHOOTINGGUIDE

Engineis running,but noAC output

is available.

1. Circuit breakeris open.

2. Poorconnection or defectivecord set.

3. Connecteddevice is bad.

4. Faultin generator.

5. GFCItrips the 20 Amp outlet.

1. Resetcircuit breaker.

2. Checkand repair.

3. Connectanotherdevicethatis in good condition.

4. ContactAuthorizedServiceFacility.

5. Repairthe "short" and resetthe GFCI.

. =

Engineruns good but begs down 1. Short circuit in a connectedload. 1. Disconnectshortedelectricalload.

whenloads areconnected. 2. Generatoris overloaded. 2. See"Don't Overloadthe Generator".

3. Enginespeedistoo slow. 3. ContactAuthorizedServiceFacility.

4. Shorted generatorcircuit. 4. ContactAuthorizedServiceFacility.

Enginewill not crank. 1. Battery weakor dead. 1. Rechargeor replacebattery (see"No Battery

ChargerDCoutput" atbottom of guide).

2. Start enginemanuallyusing recoil starter.

Enginewiil notstart; or starts and

runsrough.

Fuelshut-off is OFE 1.

Dirty air cleaner. 2.

Outof gasoline. 3.

Stale gasoline. 4.

Sparkplug wire not connectedto sparkplug. 5.

Bad sparkplug. 6.

TurnFuelshut-off ON.

Cleanor replaceair cleaner.

Fillfuel tank.

Drainfuel tank andfill with fresh fuel.

Connectwire to spark plug.

Replacesparkplug.

7. Water in gasoline.

8. Over-choking.

9. Low oil level.

10. Excessiverich fuel mixture.

11. Intakevalvestuck open or closed.

12. Enginehas lost compression.

7. Drainfuel tank; fill with fresh fuel.

8. Put chokeknobto No Chokeposition.

9. Fill crankcaseto proper level.

10. ContactAuthorizedServiceFacility.

11. ContactAuthorizedServiceFacility.

12. ContactAuthorizedServiceFacility.

i i

Engineshuts downduring 1. Outof gasoline. 1. Fillfuel tank.

operation. 2. Low oil level. 2. Fill crankcaseto proper level.

3. Faultin engine. 3. ContactAuthorizedServiceFacility.

Enginelacks power. 1. Load is too high. 1. See"Don't OverloadtheGenerator".

2. Dirty air filter. 2. Replaceairfilter.

3. Engineneedsto beserviced. 3. ContactAuthorizedServiceFacility.

Engine"hunts" or falters. 1. Chokeis openedtoo soon. 1. Movechoke to halfway positionuntil engineruns

2. Carburetoris runningtoo rich or too lean. smoothly.

2. ContactAuthorizedServiceFacility.

NoBatteryChargerDOoutput. 1. Battery posts arecorroded.

2. Battery cable is bad.

3. Battery is defective.

4. Receptacleis bad.

5. Battery Chargerin-line fuse (1.5A) meltedopen.

1. Cleanbattery posts.

2. Replacecable.

3. Checkbattery condition; replaceif defective.

4. ContactAuthorizedServiceFacility.

5. Replacefusewith identical1.5A replacementfuse

only (locatedinsidecontrol panel).

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CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac

Power Systems, Inc. (Generac), are pleased to explain the Emission Control System warranty on your new 2008 and later

generator. New equipment that use small spark-ignited engines must be designed, built, and equipped to meet stringent anti-

smog standards for the state of California and the federal government. Generac will warrant the emission control system on your

generator for the period of time listed below provided there has been no abuse, neglect, unapproved modification or improper

maintenance of your equipment.

Your emission control system may include parts such as the: carburetor, ignition system, catalytic converter, fuel tank, fuel lines,

fuel cap, valves, carbon canister, filters, vapor hoses, clamps, connectors, and other associated emission-related components (if

equipped).

MANUFACTURER'S WARRANTY COVERAGE:

This emission control system is warranted for two years. If, during such warranty period, any emission-related part on your

equipment is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized

Warranty Service Dealer.

OWNER'S WARRANTY RESPONSIBILITIES:

As the generator owner, you are responsible for the completion of all required maintenance as listed in your factory supplied

Owner's Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your

generator, but Generac cannot deny warranty solely due to the lack of receipts.

As the generator owner, you should be aware that Generac may deny any and/or all warranty coverage or responsibility if your

generator, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or

the use of counterfeit and/or "grey market" parts not made, supplied or approved by Generac.

You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs. The warranty

repairs should be completed in a reasonable amount of time, not to exceed 30 days,

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer. To

locate the Generac Authorized Warranty Service Dealer nearest you, call our toll free number:

1=800=333=1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty

(ECS Warranty), which is provided to you by Generac pursuant to California and federal law. See also the "Generac Limited

Warranties for Generac Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by Generac.

Note that this warranty shall not apply to any incidental, consequential or indirect damages caused by defects in materials or

workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties,

expressed or implied. Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

The ECS Warranty applies only to the emission control system of your new equipment. Ifthere is any conflict in terms between

the ECS Warranty and the Generac Warranty, the Generac Warranty shall apply. Both the ECS Warranty and the Generac Warranty

describe important rights and obligations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service,

evidence must be presented showing the date of the sate to the original purchaser/owner.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

RO. BOX 297 ', WHITEWATER, WI 53190

Part 1

PartNo. 0H1913 Rev.A 01/09

EMiSSiON CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS warranty) for equipment using small spark-ignited engines:

(a) Applicability: This warranty shall apply to equipment that uses small off-road engines. The ECS Warranty period shall begin

on the date the new equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24

consecutive months thereafter.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or

equipment and to each subsequent purchaser/owner that the ECS when installed was:

(1) Designed, built and equipped so as to conform with all applicable regulations; and

(2) Free from defects in materials and workmanship which cause the failure of a warranted part at any time during the ECS

Warranty Period.

(1) Any warranted part that is not scheduled for replacement as required maintenance in the Owner's Manual shall be

warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or

replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall

be warranted for the remainder of the ECS Warranty Period.

(2) Any warranted part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted

for the ECS Warranty Period. A statement in the Owner's Manual to the effect of "repair or replace as necessary" shall not

reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the

remainder of the ECS Warranty Period.

(3) Any warranted part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted

for the period of time prior to first scheduled replacement point for that part. If the part fails prior to the first scheduled

replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-

related part repaired or replaced under the ECS warranty shall be warranted for the remainder of the period prior to the first

scheduled replacement point for that part.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to

the owner at a Generac Authorized Warranty Service Facility.

(5) Notwithstanding the provisions of subsection (4) above, warranty services or repairs must be provided at Generac

Authorized Service Facilities.

(6) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held

responsible for diagnostic costs if the repair is deemed warrantable.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to

meet the expected demand for such parts.

(8) Any Generac authorized and approved emission-related replacement parts may be used in the performance of any ECS

warranty maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce

Generac ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or "grey market" parts may not be used to modify or repair a Generac

engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac

shall not be held liable hereunder for failures of any warranted parts of Generac equipment caused by the use of such an

unapproved, add-on, modified, counterfeit and/or "grey market" part.

EMISSION RELATED PARTS MAY INCLUDE THE FOLLOWING (IF EQUIPPED)"

1) FUEL SYSTEM 3) FUEL METERING SYSTEM

A. FUEL TANK A. CARBURETOR AND INTERNAL PARTS

B. FUEL CAP B. PRESSURE REGULATOR

C. FUEL LINE 4) AIR INDUCTION SYSTEM

D. FUEL LINE FITTINGS A. INTAKE MANIFOLD

E. CLAMPS* B. AIR FILTER

F. PRESSURE RELIEF VALVES* 5) IGNITION SYSTEM

2) EVAPORATIVE CONTROL SYSTEM A. SPARK PLUGS

A. CARBON CANISTER B. IGNITION COILS / MODULE

B. CANISTER MOUNTING BRACKETS 6) AIR INJECTION SYSTEM

C. CARBURETOR PURGE PORT A. PULSE AIR VALVE

D. CONTROL VALVES* 7) EXHAUST SYSTEM

E. VAPOR HOSES A. CATALYST

F. PURGE VALVES B. THERMAL REACTOR

G. LIQUID / VAPOR SEPARATOR C. EXHAUST MANIFOLD

H. VACUUM CONTROL DIAPHRAGMS*

*NOTE: As they relate to the Emission Control System.

Part 2

PartN0.0H1913 Rev.A 01/09

GENERAC POWER SYSTEMS "TWO YEAR" LiMiTED WARRANTY FOR

XG SERIES PORTABLE GENERATORS

For a period of two years from the dateof original sale, GeneracPower Systems, Inc. (Generac) warrants its XG Series generators will befree from defects in materials

and workmanship for the items and period set forth below. Generacwill, at its option, repair or replace any part which, upon examination, inspection and testing by

Generacor a GeneracAuthorized Warranty Service Dealer,is found to be defective.Any equipment that the purchaser/owner claims to be defective must be returnedto

and examined by the nearest GeneracAuthorized Warranty Service Dealer.All transportation costs under the warranty, including return to the factory, areto be borne and

prepaid by the purchaser/owner. This warranty applies only to GeneracXG Series portable generators and is nottransferable from original purchaser. Saveyour proof-of-

_urchasereceipt. If you do not provide proof of the initial purchase date, the manufacturer's shipping date of the product will be used to determine the warranty period.

WARRANTY SCHEDULE

;onsumerapplicationsarewarrantedfor two (2)years.CommercialandRentalapplicationsarewarrantedfor one(1)yearor 1000hoursmaximum,whichevercomes

first.

CONSUMER APPLiCATiON

YEARONE- 100%(onehundredpercent)coverageonLaborandPart(s)(proofofpurchaseandmaintenanceis required):

, AllComponents

YEARTWO-100%(onehundredpercent)coverageonPart(s)(proofof purchaseandmaintenanceisrequired):

, AllComponents

COMMERCiAL/RENTAL APPLiCATiON

YEARONE- 100%(onehundredpercent)coverageonLaborandPart(s)(proofofpurchaseandmaintenanceis required):

,AllComponents

NOTE: Forthe purpose ofthis warranty "consumer use" means personal residential household or recreational use by original purchaser. This warranty does not apply

to units usedfor Prime Power in place of utility where utility power service is present or where utility power service does not normally exist. Once agenerator

has experienced commercial or rentaluse, it shall thereafter be considered a non-consumer use generator for the purpose ofthis warranty.

All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat RateManual.

THiS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

Generacportable generators that utilizenon-Generac replacement parts.

Costs of normal maintenance and adjustments.

Failurescausedby any contaminatedfuels, oils or lack of proper oil levels.

Repairs or diagnostics performed by individuals otherthan Guardian/Generacauthorized dealersnot authorized in writing by GeneracPowerSystems.

Failuresdue, butnot limited, to normal wear andtear, accident, misuse, abuse, negligence or improper use. As with all mechanical devices,the Generacengines need

periodic part(s) service and replacement to perform asdesigned. This warranty will not cover repairwhen normal use has exhaustedthe life of a part(s) or engine.

Failurescausedby any act of God and otherforce majeure eventsbeyond the manufactures control.

Damage relatedto rodent and/or insect infestation.

Productsthat aremodified or altered in a manner not authorizedby Generacin writing.

Any incidental, consequential or indirect damagescaused by defects in materials or workmanship, or any delay in repair or replacementof the defective part(s).

Failuredueto misapplication.

Telephone,cellular phone, facsimile, internet access or other communication expenses.