Generac Power Systems 5798-2 Owner's manual

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

ReadthisManualThoroughly.................................1

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

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

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

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

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

Maintenance.........................................................12

3.1 MaintenanceSchedule.................................................12

3.2 ProductSpecifications..................................................12

3.3 GeneralRecommendations...........................................13

3.4 ServiceAirFilter...........................................................14

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

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

3.7 LongTermStorage.......................................................15

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

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

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

2.2 Hourmeter- NoReset....................................................6

2.3 Hourmeter- With Reset..................................................6

2.4 CordSetsandConnectionPlugs....................................7

2.5 How to Usethe Generator..............................................7

2.6 Don't Overloadthe Generator..........................................9

2.7 WattageReferenceGuide...............................................9

2.8 BeforeStartingthe Generator.........................................9

2.9 ToStartthe Engine.......................................................10

2.10 Stoppingthe Engine.....................................................11

2.11 Low Oil PressureShutdownSystem.............................11

2.12 Chargingthe Battery(XG7OOOE& XG8OOOE)................11

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

4.1 BatteryReplacement(XG7OOOE&XG8OOOE)...............15

Troubleshooting....................................................17

5.1 TroubleshootingGuide..................................................17

Notes....................................................................18

Warranty...............................................................lg

Manualdelpropietario.....................................23

Manueld'entretien............................................45

WARNING!

California Proposition 65

Engine exhaust and some of its constituents are known to the state of California to cause cancer,

birth defects, and other reproductive harm.

WARNING!

California Proposition 65

This product contains or emits chemicals known to the state of California to cause cancer,

birth defects, and other reproductive harm.

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.

READTHiSMANUALTHOROUGHLY

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

manualandthoroughlyunderstandallinstructionsbeforeusingthe

equipment.Wealsostronglyrecommendinstructingotherusersto

properlystart andoperatethe unit.This preparesthem ifthey need

to operatetheequipmentin an emergency.

Thegeneratorcan operatesafely,efficiently and reliablyonly 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 possiblecircumstance

that might involvea hazard.Thewarnings in this manual,and on

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

If usinga procedure,work method or operatingtechniquethat the

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.

ACAUTION!

Indicatesa hazardoussituationor actionwhich,if not

avoided, couldresultin minoror moderateinjury.

NOTE:

Notescontainadditionalinformationimportanttoa procedure

and will be foundwithin theregulartextbodyofthismanual.

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 enclosedarea, in a vehicle, or indoors

EVENIFdoorsand windows areopen.

• For safety reasons, the manufacturer recommendsthat the

maintenanceof this equipmentis carried out by an Authorized

Dealer.Inspectthe generatorregularly,and contactthe nearest

AuthorizedDealerfor parts needingrepairor replacement.

• Operategeneratoronly on levelsurfacesandwhereit will notbe

exposedto excessivemoisture,dirt, dust or corrosivevapors.

• Keep hands, feet, clothing, etc., awayfrom 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:

This generatoris equippedwith a spark arrestormuffler. The

spark arrestor must be maintained in effective working order

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

arrestor is requiredby law (Section 4442 ofthe California

Public Resources Code). Other states may havesimilarlaws.

Federal lawsapply on federallands.

EXHAUST & LOCATIONHAZARDS

• Never operate in an enclosed area or indoors!NEVERuse

in the home,in a vehicle,or in partlyenclosedareassuch

as garages, evenif doors and windowsare open! ONLYuse

outdoors and far from open windows,doors,vents,andinan

areathatwill notaccumulatedeadly 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

you cannot see or smell. This poisonous gas, if breathedin

sufficientconcentrations,can causeunconsciousnessor 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 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 dangerously high voltage when in

operation.Avoidcontactwithbarewires,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 groundingrequirementsin thearea.

• 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. Reconnectthatcable 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

DIRECTCONTACTWITH THEVICTIM, 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 lank 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 reachan 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 onall 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, MO

65201.

4. ASAE EP-3634, INSTALLATIONAND MAINTENANCEOF

FARMSTANDBYELECTRICALSYSTEMS,availablefrom the

AmericanSocietyof AgriculturalEngineers,2950 Niles Road,

St. Joseph,MI49085.

MODELNO:

SERIALNO:

Generator Identification

Uni± I]D

Loci±ions

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=436=3722.

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. Securewith the flange

nuts.

Figure 2 - Wheel and Foot Assembly

FOOT

SECUREWHEEL

ANDAXLEWITH

HAIRPIN

1.2 ASSEMBLY

Read entireOwner's Manual beforeattempting to assemble or

operate the generator. The generator requiressome assembly

prior to usingit. If problemsarisewhenassemblingthe generator,

pleasecallthe GeneratorHelplineat 1=888=436=3722.

1.2.1 ASSEMBLINGTHEWHEELKITANBFRAMEFOOT

Thewheelkit is designedto greatly improvethe portability of the

generator.You will needthe following tools to install the wheel

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

(13mm) socket.

NOTE:

The wheel kit is notintendedfor over-the-roaduse.

FRAME

WASHER

I FRAME

I BOLT

I

WHEELSPACER

(WASHER)

FLANGE

SLIDEAXLE

THROUGHWHEEL

ANDWHEEL

SPACER

2.1 KNOWTHEGENERATOR

Read the entire Owner's Manual and Safety Rules before

operatingthisgenerater.

Compare the generator to Figures 3 through 6 to become

familiarizedwith thelocationsof variouscontrolsandadjustments.

Savethis manualfor future reference.

1. ChokeKnob- Usedwhen startinga coldengine (Putt/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 andcarburetor.Turn

off and run carburetoroutof fuelfor extendedstorage.

4. Panel LED'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.

9. PowerBar- Indicatesthe amountof power being usedfrom

thegenerator;each sectionisapproximately25%

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 levelin tank.

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

loadedbuttonto move handles.

15. Oil Fill - Checkoil levelandadd oil here.

16. 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 Filter- Filtersintakeair as it is drawn intothe engine.

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

crankcase.

22. RecoilStarter - Useto start enginemanually.

23. Roll OverValve- Passesfuel vaporsto the engine.

24. Recovery Hose - Install between roll over valve and the

engine.

Figure 3 - Generator Locations

1 2 5 B 9 10 11

@ [_ , ,,,. ,, , ,:, @

4 7

12

13

17

15 18

24

23

18

1

22

2O

2.1.1 BATTERYCONNECtiONfXGTOOOE& XGSOOOE)

NOTE:

The battery shippedwith the generatorhasbeen fully charged.

A battery may losesomeof itschargewhennot in use for

prolongedperiodsoftime. ifthe battery is unable to crank

the engine,pluginthe 12V chargerincludedin the accessory

box (seethe Chargingthe 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

2.2 HOURIVIETER-NO BESET

The Hourmeter tracks hours of operation

maintenance:

for scheduled

Therewill be a onetime breakin "CHGOIL"messagethat flashes

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 hour window to perform the

service.

Therewill be a subsequent"CHGOIL"messageevery 100 hours.

Themessagewilt flash one hour beforeand one hourafter each

100 hour interval,again providinga two hourwindow to perform

service.

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

thedisplay will flash. Themessagewill flash one hourbeforeand

onehour aftereach200 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-- OilOhangeInterval(Every100 hrs)

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

2.3 HOURIVlETFR-WiTHRESET

TheHourmetertrackshoursofoperationforscheduledmaintenance

(seechart) (Figure5).

Operation: Pushand releasethe reset button to toggle between

screens. The hours count backwards from the set interval as

shown in the chart.

Whenthe meter reaches5 hours,thetext"CHGOIL"(or "SVCAIR

FILTER"or "OHGPLUG")will flash continuallyfor two minutes.

Afterthis time,the meterwill go backto displayingthetotal hours

of the unit (for 2 minutes). This cyte will repeatfor the entire 5

hours.

When the service interval reaches zero hours, the text "NOW"

replacesthe hoursremaining.

Fora newgeneratorfor instance,the messagewill say"OHGOIL"

thenflash "in30". This meansthat in 30 hours, theoil wilt needto

be changed. Pressingthe button a few moretimes will bring the

meter backto the screenthat shows thetotal hoursrun.

Reset: Toggleto the alert that you wish to reset then hold the

buttondownfor 9 seconds.Themaintenancehoursareresetwhen

thedisplay shows "0000.0".

Note:

Thehourglass graphicwillflash on and offwhenthe engine

is running.Thissignifiesthatthe meteristrackinghoursof

operation.

Message

CHGOIL

SVCAIRFILTER

CHGPLUG

Nourmeter(With Reset)Chart

Duration ofmessageFrequencyof Message

Initial break-inperiod

Re-occuring

interval

First30 Hours

100 hours

200 hours

ON/OFFfor 2 minutesin a5

hour period

Figure 5 - Hourmeter

0000.0

HOURGLASS RESETBUTTON

GRAPHIC (IF EQUIPPED)

2.4 CORDSETSANOCONNECTIONPLUGS

2.4.1 120VAC,20 AMP,GFC/DUPLEXRECEPTACLE

This is a 120 Volt outletprotectedagainst overloadby a 20 Amp

push-to-resetcircuitbreaker(Figure6). Useeachsocketto power

120 VoltAO,singlephase,60 Hzelectricalloadsrequiringupto a

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

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 preventvoltagedrop and possibleoverheatingof

wires.

2.4.2 120/240VAC,30 AMPRECEPTACLE

Use a NEMA L14-30 plug with this receptacle (rotate to lock!

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

andto thedesiredtoad.Thecordset shouldbe ratedfor 250 Volts

ACat30 Amps (or greater)(Figure6).

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.

Figure 6 - Generator Receptacles

120VAC20A

GFC]RECEPTACLE

O

120/240VAC30A

RECEPTACLE

2.5 HOW TOUSETHEGENERATOR

Seethe "To Startthe Engine"sectionfor how to safelystart and

stop the generatorand how to connect and disconnect loads. If

there are any problems operatingthe generator,pleasecall the

generatorhelplineat 1-888-436-3722.

_t ever operate in an enclosed area or indoors!

NEVER use in the home, in a vehicle, 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.

_t The engine exhaust fumes contain carbon

monoxide, which can you cannot see or smell.

This poisonous gas, if breathed in sufficient

concentrations, can cause unconsciousness or

even death.

_t 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.

_t 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.

_t Always use a battery operated carbon

monoxide alarm indoors, installed 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 inside a home

or garage, EVEN IF doors

and windows are open.

Only use OUTSIDE and

far away from windows,

doors, and vents.

2.5.1 GROUNDINGTHEGENERATORWHENUSEDASA

PORTABLE

This generator has an equipment ground that connects the

generatorframe componentsto the ground terminals on the AC

output receptacles (see NEC 250.34 (A) for explanation).This

allows the generatorto be used as a portablewithout grounding

the frame ofthe generatorasspecifiedin NEC250.34.

SpecialRequirements

There may be Federalor State OccupationalSafety and Health

Administration(OSHA)regulations,localcodes,or ordinancesthat

applyto the intendeduse ofthe generator.

Pleaseconsult a qualified electrician,electrical inspector, 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 beobserved.

2.5.2 CONNECTINGTHEGENERATORTO,4BU/LD/NG'S

ELECTRICALSYSTEM

When connecting directly to a building's electrical system, it is

recommended that a manualtransfer switch is used. Connectionsfor

a portable generatorto a building's electricalsystem must be made by

a qualifiedelectrician andin strict compliancewith all national andlocal

electricalcodesand laws.

Figure7 - GeneratorGroundLocation

LOCATION

XG6500&XG7000 GROUNDLOCATION

ANDBRUSHEDALTERNATORXG8000

2.5.3 NEUTRALTOFRAMEGROUNDING

If service work is performed on the alternator,DO NOTdiscard

the white jumper wires from the terminal block to the alternator

ground, located on the rear bearingcarrier. Always make sure

the wires are properlyconnectedbeforeusingthe generatorafter

alternatorservicework is done (Figure8).

Figure8 - NeutraltoFrameGround

NEUTRALTO FRAMEGROUND

DONOTDISCARD

WIRES!

XG7000& 8000 BRUSHLESSALTERNATORONLY

DONOTDISCARD

WIRES!

NEUTRALTO FRAMEGROUNDXG6500,

7000 AND8000 BRUSHEDALTERNATOR

//_Failure to reconnect these wires may create a

potential shock hazard when the generator is

running!

2.5.4 CONNECTINGELECTR/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 AO, 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

2.6 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 be takenfrom light bulbs. The

ratedwattageof tools, appliancesand motors can usually be

found on a datalabelor decalaffixedto the device.

* If the appliance,toot or motor does not givewattage, 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

such motors.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 itemsthe generatorcan operateatonetime.

IMPORTANT:Donotoverloadthe generator.Also, do not overload

individual panel receptacles.These outlets are protectedagainst

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

OverloadtheGenerator"carefully.

NOTE:

All figuresare approximate.Seedatalabel onappliancefor

wattage requirements.

2.7 WATTAGEREFERENCEGUIDE

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

*Air Conditioner(12,000 Btu).......................... 1700

*Air Conditioner(24,000 Btu).......................... 3800

*Air Conditioner(40,000 Btu).......................... 6000

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

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

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

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

*Clothes Dryer(Electric) ............................. 5750

*Clothes Dryer(Gas) ................................. 700

*Clothes Washer ................................... 1150

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

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

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

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

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

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

Disc Sander(9").................................... 1200

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

Electric Blanket...................................... 400

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

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

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

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

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

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

Hair Dryer......................................... 1200

HandDrill .................................... 250to 1100

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

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

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

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

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

LightBulb.......................................... 100

Microwave Oven............................... 700to 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................................. 800to 1050

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

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

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

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

* Allow 3 times thelistedwatts for starting these devices.

2.8 BEFORESTARTINGTHEGENERATOR

Priorto operatingthe generator,engineoil and gasolinewill need

to be added,asfollows:

2.8.1 ABB/flGEflG/flEO/L

All oil should meet minimum 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,use synthetic5W-30

Any attempt tocrankor startthe enginebeforeit has

been properlyserviced with therecommendedoil may

resultin an engine failure.

TEMPERATURE iN DEGREES FAHRENHEIT (°F)

=30 =20 =10 0 1G 20 32 40 55 70+

=30 =20 =10 0 10 20

TEMPERATURE iN DEGREES CELSIUS (°C)

• Placegeneratoron a levelsurface (not to exceed15° in any

direction).

• 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,seeFigure9)

• Installoil fill capandfingertighten securely.

• Checkengineoil levelbeforestarting eachtime thereafter.

Figure9 - Oil Level

J m

I ....... J

L__

-- _-Jd

FILLCRANKCASETO

THE BOTTOMOFTHESE

THREADSWITHTHE

RECOMMENDED

ENGINEOIL

u

!

I

2.8.2 AL}D/NGGASOLINE

D0 NOTlighta cigaretteor smoke whenfilling the fuel

tank.

,_ Neverf!ll fuel tankindoors.Never fill fuel tankwhen

engine is runningor hot. Avoid spillinggasoline on a hot

engine.Allowengineto coolentirelybeforefilling fuel

tank.

Do notoverfill the fuel tank.Alwaysleave roomfor fuel

expansion, ifthe fuel 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.Becarefulnotto overfill (Figure10).

• Installfuelcap andwipe up any spilledgasoline.

Figure 10 - Fuel Fill Level

DONOTFILL

ABOVELIP!

IMPORTANT:Itis importantto preventgum depositsfrom 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

formationof acids duringstorage.Acidic gascandamagethefuel

system of an enginewhile in storage.Toavoid engineproblems,

the fuel system should be emptiedbefore storage of 30 days or

longer.Seethe "Storage"section. Neveruseengineor carburetor

cleanerproductsinthefueltank aspermanentdamagemay occur.

2.9 TOSTARTTHEENGINE

Never startor stopengine withelectrical devicespluggedinto

thereceptaclesANDdevices turnedon.

• Unplug all electrical loads from the unit's receptaclesbefore

startingthe engine.

• Make surethe unit is in a levelposition (notto exceed15° in

anydirection).

• Openthefuel shut-off valve (Figure11).

• Pull engine CHOKEknob outward to "Full Choke" position

(Figure12).

1o

Figure 11 - Fuel Shut-off Valve

I

2.g.1 MANUAL_ STARTING

• Tostartthe generator,putthe on/off switch inthe 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 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.

NOTE:

If engine fires,butdoesnotcontinueto run, pull chokeknob

to "Full Choke" andrepeat starting instructions.

2.9.2 ELECTRICSTARtiNG(XGTOOOE& XGSOOOE)__

* Tostartthe engine,pressandhold theStart/Run/Stopswitch in

the "Start" position.Theenginewill crankand attemptto start.

Whenthe enginestarts, releasetheswitch to the runposition.

* 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:

Theswitchmustbe in theRUNposition.Use one of the

generator's receptacleoutletsalongwiththe includedbattery

chargerto chargethe battery while thegenerator is running.

2.10STOPPINGTHEENGINE

* Shut off all loads, then unplug the electrical loads from

generatorpanelreceptacles.Neverstart or stopthe enginewith

electricaldevicespluggedin andturned on.

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

internaltemperaturesof engineandgenerator.

* Move Start/Run/Stopor On/Offswitch to the "Off" position.

* Closefuelvalve.

2.11LOWOILPBESSUBESHUTDOWNSYSTEM

Theengineis equippedwith a low oil pressuresensorthat shuts

downthe engineautomaticallywhentheoil pressuredropsbelow

5 psi. A delaybuilt 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.

2.1I.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,theenginewill run for about10

secondsas describedaboveandthenstop.

2.12CHABGINGTHEBATTEBY(XG7OOOE&XGBOOOE)

,_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.

11

Use batterychargerplugto keepthe batterychargedand ready

for use. Batterychargingshouldbe done in a dry location.

1. Plugchargerinto "Battery ChargerInput"jack, locatedon the

control panel.Plug wall receptacleend of the batterycharger

into a 120 VoltACwalt outlet.

2. Unplugbatterychargerfrom walt outletand control paneljack

whengeneratoris goingto be in use.

NOTE:

Donot usethebattery chargerfor morethan48 hoursat one

charge.

3.1 MAINTENANCESCHEDULE

Follow the calendar intervals. More frequent service is required

whenoperatingin adverseconditionsnotedbelow.

CheckOil Level

ChangeOil and OilFilter:!:

CleanSparkArrestor Screen

ServiceAir Filter

ReplaceSparkPlug

$

"k

At EachUse

*Every Season/Every100 Hours

**Every Season/Every100 Hours

**Every Season/Every200 Hours

EverySeason

Changeoil after first 30 hours of operationthenevery season.

Changeoil and oil filter every month when operatingunder heavyload or in

high temperatures.

Cleanmore often under dirty or dusty operating conditions. Replaceair filter

parts if very dirty.

3.2 PRODUCTSPECIFICATIONS

3.2.1 GENERATORSPEC/F/CATIONS

Model # ...................................................................... 005800, 005747

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, 005798

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# .................................................................................... 005796

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%foreach6° C(10° F)above16° C(60° F)

ambienttemperature.

3.2.2 ENGINESPEC/F/CATiONS

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

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

SparkPlugType................................... ChampionRC14YCor Equivalent

SparkPlug PartNo.................................................................... 0E7585

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.

Oil FilterPart No...................................................................... 070185B

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

Class IIEmissionCertified

3.2.3 EMISSIONS/NFORMATiON

The EnvironmentalProtection Agency (EPA) requires that this

generatorcomplywith exhaustandevaporativeemissionstandards.

This generatoris certified to meet the applicable EPAemission

levelson gasoline.Theemission control systemon this generator

consists ofthe following:

• FuelSystem • Air InductionSystem

Carburetor - IntakePipe/manifold

FuelTank!cap - AirFilter

FuelLines * IgnitionSystem

EvaporativeVentLines _ Sparkplug

ExhaustSystem - Ignitionmodule

ExhaustManifold • ExhaustSystem

Muffler _ ExhaustManifold

It is importantto perform the servicespecifiedin the Maintenance

Scheduleto ensurethatthe generatorcomplieswith the applicable

emissionstandardsfor the durationof its useful life. Additionally,

emissions critical maintenancemust be performed as scheduled

in orderfor the EmissionsWarrantyto be valid. Emissionscritical

maintenanceconsists of servicingthe air filter andspark plugsin

accordancewith the MaintenanceSchedule.Service and repairs

may be performedby any capablepersonor repairshop.

12

3.3 GENERALRECOIVIIVlENDATIONS

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 yearreplacethesparkplugand replacetheairfilter.

A new spark plug and cleanair filter assure properfuel-air

mixture and helpthe enginerunbetter and lastlonger.

3.3.1 GENERATOR/V/A/NTENANCE

Generatormaintenanceconsistsof keepingthe unitcleanand dry.

Operateand storethe unit in a cleandry environmentwhereit will

not be exposedto excessivedust,dirt, moistureor any corrosive

vapors.Coolingair slotsin thegeneratormustnot becomeclogged

with snow, leaves,or anyotherforeign material.

Checkthe cleanlinessof the generatorfrequentlyand cleanwhen

dust, dirt, oil, moistureor otherforeign substancesarevisible on

its exteriorsurface.

,ACAUTION!

,iA Never insertany object or toolthroughthe air cooling

slots,evenif theengineis notrunning.

NOTE:

DONOTusea garden hosetocleangenerator. Water can

entertheengine fuel systemand causeproblems. In addition,

if water entersthegeneratorthroughcoolingair slots, some

water will be retainedin voidsandcrevicesof the rotor

and stator winding insulation. Wateranddirt builduponthe

generator internalwindings will eventuallydecreasethe

insulationresistanceofthesewindings.

3.3.2 TOCLEANTHEGENERATOR

• Usea dampcloth to wipe exteriorsurfaces clean.

• A soft, bristlebrushmay beusedto loosencakedon dirt, oil,etc.

• A vacuumcleanermay be usedto pick up loosedirt anddebris.

• Low pressure air (not to exceed 25 psi) may be used to

blow away dirt. Inspect cooling air slots and openingson the

generator.Theseopeningsmustbekeptcleanandunobstructed.

3.3.3 ENGINEMAINTENANCE

,ACAUTION!

,l_ When workingon thegenerator,alwaysdisconnect

negativecablefrombattery. Also disconnect sparkplug

wire from sparkplugand keepwire away fromspark

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 CHANGINGTHEOILANDOILFILTER

Changethe oil and filter after the first 30 hours of operation.

Changethe oil every 100 hours or every season thereafter. If

running this unit under dirty or dusty conditions, or in extremely

hotweather,changethe oil moreoften.

,l_ Not oil may causeburns. Allow engineto coolbefore

draining oil. Avoid prolongedor repeatedskin exposure

with usedoil. Thoroughlywashexposed areaswithsoap.

Use the following instructionsto changethe oil:

• Cleanareaaroundoil draincap.

• Removeoil draincapfrom 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.

• Filloil sumpwith recommendedoil and replacethe oil fill 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 eachyear. 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 gappedsparkplug intothe cylinderhead(Figure13).

5. Pushthe bootfirmly on the sparkplug and install sidepanel.

13

Figure 13 - Spark P/ug Gap

3.4 SERVICEAiRFILTER

Theenginewill not run properlyand may be damagedif using a

dirty air filter.Cleanor replacethe air filter paperfilter every 200

hours or once a year (Figure14). Cleanor replacemore often if

operating under dusty conditions. To clean or replacepaper air

filter:

* Removeairfilter cover andremove paperfilter (Figure14).

* Cleanpaperfilter by tapping it gently on a solid surface. If the

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

filter properly.

* Cleanair filter cover.Nextinsert new paperfilter intothe base

of theair filter.Re-installair filter cover.

NOTE:

Toorder a new air filter, pleasecontactthe nearestauthorized

servicecenterat 1-888-GENERAC.Theair filter part number

is 073111.

Figure14- Air Filter

AIRFILTER

COVER

3.5 CLEANSPARKARRESTORSCREEN

The engine exhaustmuffler has a spark arrestorscreen. Inspect

andcleanthe screenat leastonceeachyear (Figure15). If unit is

usedregularly,inspectandcleanmore often.

&if 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.

Cleanandinspectthe sparkarrestorwhentheengineisat ambient

temperatureasfollows:

* Loosenthe clamp and removethe spark arrestor screenfrom

the muffler.

* Inspect screen and replace if torn, perforated or otherwise

damaged. DO NOT USEa defective screen. If screen is not

damaged,cleanitwith commercialsolvent.

* Replacethe sparkarrestor andsecurewith the clamp.

Figure 15 - Spark Arrestor Screen

ARRESTOR

SCREEN

CLAMP

SPARK

ARRESTOR

SCREEN

3.6 GENERAL

The generatorshould be started at leastonce every 30 days and

be allowedto run at least30 minutes. If this cannotbe done and

the unit must be storedfor morethan 30 days, usethefollowing

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.

,_AIIow unit to cool entirely before storage.

14

3.7 LONGTERMSTORAGE

It is importantto preventgum depositsfrom forming in essential

fuel systemparts such asthe carburetor,fuel hoseor tank during

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

emptiedbeforestorageof 30 daysor longer,asfollows:

• Removeall gasolinefrom the fueltank.

,_ CAUTION!

,A Drainfuel intoapproved containeroutdoors,away from

openflame. Besureengine iscool.Donot smokein the

vicinityor lighta cigarette.

• Start and run engineuntil enginestopsfrom lack offuel.

• Allow the engineto cool, then drainoil from crankcase. Refill

with recommendedgrade.

• Removesparkplugandpour about1/2ounce(15 ml) 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.

_,CAUTION!

,l_Avoid spray from spark plug hole when

cranking engine.

• Install and tighten spark plug. Do not connectthe spark plug

wire.

• Cleanthegeneratoroutersurfaces. Checkthat coolingair slots

and openingson generatorareopen and unobstructed.

• Storetheunit in a clean,dry place.

3.8 OTHERSTORAGETiPS

• Do notstore gasolinefrom oneseasonto 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 storedfor some

time, usea commerciallyavailablefuel stabilizeraddedto the

gasolineto increasethe lifeof thegasoline.

_,CAUTION!

,l_ NEVER cover the generator while engine and

exhaust area are warm.

4.1 BATTERYREPLACEMENT(XGT000E&XGS000E)

NOTE:

The batteryshippedwiththe generatorhas beenfully charged.

Abattery may losesomeof itschargewhennot in usefor

prolongedperiodsof time. ifthe batteryis unabletocrank

the engine, plugin the 12V chargerincludedin theaccessory

box (seethe 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

securingthe fueltank.

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

Pull the fuel tank backslightly and removethe fuel hosethat

runsfrom theengineto thefuelvalve.

,A CALITION!

,A Drainfuel intoapprovedcontaineroutdoors, away from

openflame. Be sureengineis cool.Donotsmokein the

vicinityor lighta cigarette.

• Disconnectthe recoveryhosefrom the rollovervalve.Pushthe

hosethroughthe grommet in the cornerof the fuel tank. This

will allowfor removalofthe fueltank.

• Pushthe fuel valvefrom thecontrol paneland removethefuel

tank.

• Removethe batterywire connections (blackwire first) andthe

batteryhold-downbracket.

• Replacethe battery,connectingthe REDwire to the POSITIVE

(+) terminalandthe BLACKwireto the NEGATIVE(-) terminal

NOTE:

Start all fourscrews on theside panel beforetighteningor fl

maynot bepossibletoget all the screwsin place.

15

Figure 16 - Battery Remova/

1_ FUELTANK

ASSEMBLY

It

ENGINE

STARTING

BATTERY

BRACKET

SIDE

PANEL

16

5.1TBOUBLESHOOTINGGUIDE

Engineis running,but noAC output

isavailable.

1. Circuitbreakeris open.

2. Poorconnectionor defectivecord set.

3. Connecteddeviceis bad.

4. Faultin generator.

5. GFCItrips the 20 Amp outlet.

1. Resetcircuit breaker.

2. Checkand repair.

3. Connectanotherdevicethat is in goodcondition.

4. ContactAuthorizedServiceFacility.

5. Repairthe "short" andresetthe GFCI.

Engineruns good but bogsdown 1. Short circuit in a connectedload. 1. Disconnectshorted electricalload.

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

3. Enginespeedis too slow. 3. ContactAuthorizedServiceFacility.

4. Shorted generatorcircuit. 4. ContactAuthorizedServiceFacility.

I I

Enginewill not crank. 1. Battery weakor dead. 1. Rechargeor replacebattery (see"NoBattery

ChargerDCoutput"at bottom of guide).

2. Start enginemanuallyusing recoil starter.

Enginewiil notstart; or starts and

runsrough.

1. Fuelshut-off is OFE 1.

2. Dirty airfilter. 2.

3. Outof gasoline. 3.

Stalegasoline. 4.

Sparkplug wire not connectedto sparkplug. 5.

Bad sparkplug. 6.

TurnFuelshut-off ON.

Cleanor replaceairfilter.

Fillfuel tank.

Drainfueltank andfill with freshfuel.

Connectwire to sparkplug.

Replacesparkplug.

,

5.

6.

7. Waterin gasoline.

8. Over-choking.

9. Low oil level.

10. Excessiverichfuel mixture.

11. Intakevalvestuck openor closed.

12. Enginehas lostcompression.

7. Drainfueltank;fill with fresh fuel.

8. Putchoke knobto No Chokeposition.

9. Fillcrankcaseto properlevel.

10. ContactAuthorizedService Facility.

11. ContactAuthorizedService Facility.

12. ContactAuthorizedService Facility.

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

operation. 2. Low oil level. 2. Fillcrankcaseto properlevel.

3. Faultin engine. 3. ContactAuthorizedServiceFacility.

m u

Enginelacks power. 1. Loadis too high. 1. See"Don't Overloadthe Generator".

2. Dirty airfilter. 2. Replaceair filter.

3. Engineneedsto be serviced. 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. Batterycableis bad.

3. Batteryis defective.

4. Receptacleis bad.

5. BatteryChargerin-line fuse (1.5A)melted open.

1. Cleanbatteryposts.

2. Replacecable.

3. Checkbattery condition;replaceif defective.

4. ContactAuthorizedServiceFacility.

5. Replacefuse with identical 1.5A replacementfuse

only (locatedinsidecontrol panel).

1"7

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U,S, EPA EMiSSiON CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLiGATiONS

TheUnited StatesEnvironmentalProtectionAgency (EPA)andGeneracPowerSystems,Inc. (Generac)arepleasedto explainthe EmissionControl

SystemWarranty(ECSWarranty) on yournew 2011 and laterequipment.New equipmentthat use smallspark-ignitedenginesmust bedesigned,built,

andequippedto meetstringentanti-smog standardsfor the federalgovernment.Generacwill warrantthe emission control systemon your equipment

for the periodof time listed belowprovidedthere has beenno abuse, neglect,unapprovedmodificationor impropermaintenanceofyour equipment.

Theemission control systemon this equipmentincludes all componentswhose failurewould increasethe emissionsof anyregulatedpollutant.These

componentsarelisted in the Emissions Information sectionofthis manual.

MANUFACTURER'S WARRANTY COVERAGE:

This ECSWarrantyis validfor two years,or for the sameperiod as specifiedin the GeneracLimitedWarranty,whicheveris longer. Forequipmentwith

hourmeters,the warranty period is a number of hours equalto halfthe UsefulLifeto whichthe equipmentis certified, or the warrantyperiod specified

abovein years,whicheveris less.TheUsefulLife can befound on the EmissionControlLabelon the engine.If, during suchwarranty period,any

emission-relatedpart on yourequipment isfound to be defectivein materialsor workmanship, repairs or replacementwill be performedby a Generac

AuthorizedWarrantyServiceDealer.

OWNER'S WARRANTY RESPONSiBiLiTiES:

Asthe equipmentowner,you areresponsiblefor the completion of all requiredmaintenanceas listed in your factory suppliedOwner'sManual.For

warranty purposes,Generacrecommendsthat you retainall receiptscovering maintenanceon your generator,but Generaccannotdeny warranty

solelydueto the lackof receipts.

Youshould beawarethat Generacmay deny anyand/or all warrantycoverageor responsibilityif your equipment,or apart!componentthereof,has

failed due to abuse,neglect, impropermaintenance,or unapprovedmodifications.

Youare responsible for contactingaGeoeracAuthorized Warranty Dealeras soonas a problemoccurs.Thewarranty repairsshouldbe

completed in a reasonable amount of time, not to exceed 30 days.

Warrantyservice can bearrangedby contacting eitheryour sellingdealeror aGeneracAuthorizedWarrantyServiceDealer.Tolocate the Generac

AuthorizedWarrantyServiceDealernearestyou, call ourtoll free numberbelow, oremail [email protected].

1-800-333-1322

IMPORTANTNOTE:This warranty statementexplainsyour rights and obligationsunder the EmissionControlSystemWarranty,which is providedto

you by Generacpursuantto federal law. Seealsothe "GeneracLimitedWarrantiesfor GeneracPowerSystems,Inc.," which is enclosedherewith on a

separatesheet,also providedto you byGenerac.Notethat this warranty shall not apply to any incidental,consequentialor indirect damagescaused

bydefects in materialsor workmanship orany delayin repairor replacementof the defectivepart(s). This warranty is in place of all other warranties,

expressedor implied.Specifically,Generacmakesno other warrantiesas to the merchantabilityor fitness for a particular purpose.Any implied

warrantieswhich areallowed by law, shallbe limited in durationto the terms of the expresswarranty providedherein.Somestates do not allow

limitationson how long an impliedwarrantylasts, sothe abovelimitation may not applyto you.

TheECSWarranty appliesonly to the emissioncontrol system of your newequipment.Boththe ECSWarrantyandthe GeneracWarrantydescribe

importantrights and obligationswith respectto your new engine.

Warrantyservice can beperformed onlyby a GeneracAuthorizedWarrantyServiceFacility.When requestingwarranty service,evidencemust be

presentedshowingthe dateofthe saleto the originalpurchaser/owner.

Ifyou haveany questionsregardingyour warranty rightsand responsibilities,you shouldcontact Generacatthe following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 * WHITEWATER, WI 53190

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19

EMiSSiON CONTROL SYSTEM WARRANTY

EmissionControlSystemWarranty (ECSWarranty)for equipmentusing small spark-ignitedengines:

(a) Applicability: This warrantyshall applyto equipmentthat usessmall off-road engines.TheECSWarranty periodshallbeginon the datethe new

equipmentis purchasedby/deliveredto its original, end-usepurchaser/ownerandshall continue forthe lesserof:

(1) The periodof time specifiedin the GeneracLimitedWarrantyenclosedherewith,but not lessthan24 months,or

(2) Forenginesequippedwith hour meters,a numberof operatinghours equalto half ofthe engine'susefullife. The usefullife is specifiedon the

EmissionsControl Labelon the engine.

(b) GeneralEmissionsWarrantyCoverage:Generacwarrantsto the original,end-usepurchaser/ownerof the newengineor equipment andto each

subsequentpurchaser/ownerthat the ECSwhen installedwas:

(1) Designed,built and equippedso as to conform with all applicableregulations;and

(2) Freefrom defectsin materialsand workmanship which causethe failureof a warrantedpart at anytime duringthe ECSWarrantyPeriod.

(c) Thewarranty on emissions-relatedparts will be interpretedas follows:

(1) Any warrantedpart that is not scheduledfor replacementas requiredmaintenancein the Owner'sManualshall bewarrantedfor the ECS

WarrantyPeriod.If any such partfails during the ECSWarrantyPeriod, it shall be repairedor replacedby Generacaccordingto Subsection

(4) below. Any such part repairedor replacedunderthe EOSWarrantyshallbewarrantedforthe remainderof the ECSWarrantyPeriod.

(2) Any warrantedpart that is scheduledonlyfor regularinspection asspecifiedin the Owner'sManualshallbe warrantedfor the EOSWarranty

Period.Astatementin the Owner's Manualtothe effectof "repair or replace asnecessary"shall not reducethe ECSWarrantyPeriod.Any

such part repairedor replacedunderthe ECSWarrantyshallbewarrantedfor the remainderofthe ECSWarranty Period.

(3) Any warrantedpart that is scheduledfor replacementasrequired maintenancein the Owner'sManualshall be warrantedfor the periodof time

priorto first scheduledreplacementpointfor that part. Ifthe part fails prior to thefirst scheduledreplacement,the part shall berepairedor

replacedby Generacaccordingto Subsection(4) below.Any such emissions-relatedpart repairedor replacedunderthe ECSwarranty shall

bewarrantedfor the remainderof the periodprior to thefirst scheduledreplacementpointfor thatpart.

(4) Repairor replacementof anywarranted,emissions-relatedpart underthis ECSWarrantyshall beperformedat no chargetothe ownerat a

GeneracAuthorizedWarrantyServiceFacility.

(5) Notwithstandingthe provisions of subsection(4) above,warranty services or repairsmust beprovidedat GeneracAuthorizedService

Facilities.

(6) Whenthe engineis inspectedby a GeneracAuthorizedWarrantyServiceFacility,the purchaser/ownershall not beheld responsiblefor

diagnosticcosts if the repairis deemedwarrantable.

(7) Throughoutthe ECSWarrantyPeriod, Generacshall maintainasupply of warrantedemission-relatedparts sufficient to meetthe expected

demandfor such parts.

(8) Any Generacauthorizedand approvedemission-relatedreplacementparts may beusedin the performanceof any ECSWarrantymaintenance

or repairsandwill beprovidedwithout chargeto the purchaser/owner.Such useshall not reduceGenerac'sEOSWarrantyobligations.

(9) No modifications,other thanthose explicitlyapproved by Generac,may be madeto the generator.Unapprovedmodificationsvoid this ECS

Warrantyand shall be sufficientgroundfor disallowingan EOSWarrantyclaim.

(10) Generacshall not be heldliablehereunderfor failures of any non-authorizedreplacementparts, or failures of anyauthorizedparts causedby

the use of non-authorizedreplacementparts.

EMiSSiON RELATED PARTS MAY iNCLUDE THE FOLLOWING (iF EQUIPPED):

1) FUELMETERINGSYSTEM 3) IGNITIONSYSTEM

A. CARBURETORANDINTERNALPARTS A. SPARKPLUGS

B. FUELTANK/CAP B. IGNITIONCOILS/MODULE

C. FUELLINES 4) AIRINJECTIONSYSTEM

D. EVAPORATIVEVENTLINES A. PULSEAIRVALVE

E. REGULATOR(GASEOUSFUELS) 5) EXHAUSTSYSTEM

2) AIR INDUCTIONSYSTEM A. CATALYST

A. INTAKEMANIFOLD B. EXHAUSTMANIFOLD

B. AIR FILTER

Part2 of 2

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PartNo. 0J3335 Rev.C 11/11

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