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USER MANUAL XD5000E Generac

SAVE THIS MANUAL FOR FUTURE REFERENCE

000703Table of Contents

Section 1 Introduction and Safety 1

Introduction p. 1
Safety Rules p. 1
Safety Symbols and Meanings p. 1
Exhaust and Location Hazards p. 2
Electrical Hazards p. 3
Fire Hazards p. 3
Standards Index p. 3

Section 2 General Information and

Section 4 Maintenance and

Maintenance Schedule p. 14
Preventive Maintenance p. 14
Engine Maintenance p. 14
Engine Oil Recommendations p. 14
Battery Replacement (if applicable) 16 Valve Clearance p. 16
Storage p. 16
Troubleshooting p. 17
Notes (000394) WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. p. 19

Always start and operate the engine in a well-ventilated area.

If in an enclosed area, vent the exhaust to the outside.

Do not modify or tamper with the exhaust system.

Do not idle the engine except as necessary. For more information go to www.P65Warnings.ca.gov/diesel.Owner’s Manual for Portable Generator 1

Section 1 Introduction and Safety

Introduction Thank you for purchasing a Generac Power Systems Inc. product. This unit has been designed to provide high-performance, effi- cient operation, and years of use when main- tained properly. If any section of the manual is not understood, contact your nearest Independent Authorized Service Dealer (IASD), or contact Generac Customer Service at 1-888-GENERAC (1- 888-436-3722), or www.generac.com with any questions or concerns. The owner is responsible for proper mainte- nance and safe use of the equipment. Before operating, servicing or storing this generator:

Study all warnings in this manual and on the product carefully.

Become familiar with this manual and the unit before use.

Refer to the Assembly section of the man- ual for instructions on final assembly proce- dures. Follow the instructions completely. Save these instructions for future reference. ALWAYS supply this manual to any individual that will use this machine. The information in this manual is accurate based on products produced at the time of publication. The manufacturer reserves the right to make technical updates, corrections, and product revisions at any time without notice. Safety Rules The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, there- fore, not all inclusive. If using a procedure, work method or operating technique that the manufacturer does not specifically recom- mend, verify that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the equipment unsafe. Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be haz- ardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows: NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual. These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instruc- tions while performing the action or service are essential to preventing accidents. Safety Symbols and Meanings

If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air IMMEDIATELY. See a doctor, as you could have carbon monoxide poison- ing. (000100a) WARNING Consult Manual. Read and understand manualcompletely before using product. Failure to completely understand manual and productcould result in death or serious injury. (000001) DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. (000002) WARNING Indicates a hazardous situation which, if not avoided,could result in death or serious injury. (000003) CAUTION Indicates a hazardous situation which, if not avoided,could result in minor or moderate injury. DANGERUsing 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.

For safety reasons, it is recommended that the maintenance of this equipment be per- formed by an IASD. Inspect the generator regularly, and contact the nearest IASD for parts needing repair or replacement. Exhaust and Location Hazards

If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air IMMEDIATELY. See a doctor, as you could have carbon monoxide poison- ing.

NEVER run a generator indoors or in a partly enclosed area such as garages.

ONLY use outdoors and far away from win- dows, doors, vents, crawl spaces and in an area where adequate ventilation is avail- able and will not accumulate deadly exhaust gas.

Using a fan or opening a door will not pro- vide sufficient ventilation. (000179b) DANGER Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury. (000104)DANGERElectrocution. Water contact with a power source, if not avoided, will result in death or serious injury. (000116)DANGERElectrocution. Turn utility and emergencypower supplies to OFF before connecting power source and load lines. Failure to do so will result in death or serious injury. (000146) WARNING Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator. (000178a) Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury. WARNING (000250) WARNING Equipment and property damage. Do not operate unit on uneven surfaces, or areas of excessive moisture, dirt, dust or corrosive vapors. Doing so could result in death, serious injury, property and equipment damage. (000111)WARNINGMoving Parts. Keep clothing, hair, and appendagesaway from moving parts. Failure to do so could result in death or serious injury. (000108) WARNING Hot Surfaces. When operting machine, do not touch hot surfaces. Keep machine away from combustables during use. Hot surfaces could result in severe burns or fire. (000142a) Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage. WARNING WARNING Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to service this equipment and could result in death or serious injury. (000215) WARNING Injury and equipment damage. Do not use generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation, and could result in death or serious injury. (000216)

(000103) DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. (000179b) DANGER Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury. (000178a) Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury. WARNING (000146) WARNING Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.Owner’s Manual for Portable Generator 3

Point muffler exhaust away from people and occupied buildings. Electrical Hazards

National Electric Code (NEC) requires the frame and external electrically conductive parts of the generator be properly con- nected to an approved earth ground. Local electrical codes may also require proper grounding of the generator. Consult with a local electrician for grounding requirements in the area.

Use a ground fault circuit interrupter (GFCI) in any damp or highly conductive area (such as metal decking or steel work).

Once generator has been started outside, connect electrical loads to extension cord(s) inside. Fire Hazards

Allow at least 5 feet of clearance on all sides of the generator when operating to prevent overheating and fire.

Do not operate the generator if connected electrical devices overheat, if electrical out- put is lost, if engine or generator sparks, or if flames or smoke are observed while unit is running.

Keep a fire extinguisher near the generator at all times. Standards Index

TION AND SAFETY CODE available from www.nfpa.org

3. International Building Code available from

nance of Farm Standby Electric Power available from www.asabe.org, American Society of Agricultural & Biological Engi- neers 2950 Niles Road, St. Joseph, MI

generators for installation and use, in accordance with the Rules of the Cana- dian Electrical Code

7. ANSI/PGMA G300 Safety and Perfor-

mance of Portable Generators. Portable Generator Manufacturer’s Association, www.pgmaonline.com IMPORTANT NOTE: This list is not all inclu- sive. Check with the Authority Having Jurisdiction (AHJ) for any local codes or standards which may be applicable to your jurisdiction. (000144)DANGERElectrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury. (000104) DANGER Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury. (000145) DANGER Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury. (000105) DANGER Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury. (000166b) DANGER Explosion and Fire. Do not overfill fuel tank. Fill to 1/2 inch from top of tank to allow for fuel expansion. Overfilling may cause fuel to spill onto engine causing fire or explosion, which will result in death or serious injury. (000174) DANGER Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury. (000142a) Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage. WARNING4 Owner’s Manual for Portable Generator

Section 2 General Information and Setup

Figure 2-1. Features and Controls Generator Components Figure 2-2. Control Panel

23Owner’s Manual for Portable Generator 5 Figure 2-3. Identification Label Know Your Generator Replacement owner’s manuals are available at www.generac.com. Emissions Information The U.S. Environmental Protection Agency, EPA, (and California Air Resource Board, CARB, for equipment certified to CA stan- dards) require the generator comply with exhaust emission standards. The generator is certified to meet applicable EPA and CARB emission levels using Ultra Low Sulfur fuel, Diesel No. 2. Any other use may be a violation of federal and/or local laws. To ensure the engine complies with applicable emission standards for the duration of the engine’s life, it is important to follow the maintenance speci- fications in Maintenance Section. Tampering with or altering the emission control sys- tem may increase emissions and may be a violation of Federal or California Law. (000100a) WARNING Consult Manual. Read and understand manualcompletely before using product. Failure to completely understand manual and productcould result in death or serious injury. Product Specifications Generator Specifications Rated Power Rated 5000 Watts** Surge Power Surge Rating 5500 Watts Rated AC Voltage 120/240 Rated AC Load Current @ 240V Current @ 120V

Rated Frequency 60 Hz @3600 RPM Phase Single Phase ** Operating Temperature Range : -18 deg. C (0 deg. F) to 40 Deg. C (104 Deg. F). When operated above 25 deg. C (77 deg. F) there may be a decrease in power. ** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu con- tent, ambient temperature, altitude, engine condition, etc.. Maximum power decreases about 3.5% for each 1,000 feet above sea level; and will also decrease about 1% for each 6° C (10° F) above 16° C (60° F) ambient temperature.

5.5 / 6.5 Engine Specifications

Displacement 435 cc (26.5 in

Fuel Capacity 45.4 L (12 U.S. gallons) Oil Type See chart in the Add Engine Oil section. Oil Capacity 1.6L (1.7 qt) Run Time at 50% Load 32 Hours Battery Purchase Locally (not included) Battery Type 12V 35Ah Battery, Group U1

Go to Generac.com or contact an Authorized Service Dealer for replacement parts.6 Owner’s Manual for Portable Generator Hour Meter The Hour Meter tracks hours of operation for scheduled maintenance. See Figure 2-4.

The CHG OIL display will illuminate every 100 hours. The message will flash one hour before and one hour after each 100 hour interval, providing a two hour window to perform service.

The SVC display will illuminate every 100 hours. The message will flash one hour before and one hour after each 200 hour interval providing a two hour window to per- form service. Figure 2-4. Hour Meter When the hour meter is in flash alert mode, the maintenance message will alternate with elapsed time in hours and tenths. The hours will flash four times, then alternate with the maintenance message four times until the meter automatically resets.

100 hours - CHG OIL — Oil Change Inter- val (Every 100 hrs)

200 hours - SVC — Service Air Filter (Every 200 hrs) NOTE: The hour glass icon will flash when the engine is running. This signifies the meter is recording hours of operation. Connection Plugs 120 VAC, 20 Amp, GFCI Duplex Receptacle The 120 Volt outlet is overload protected by a 20 Amp push-to-reset circuit breaker. See Fig- ure 2-5. Each receptacle will power 120 Volt AC, single phase, 60 Hz electrical loads requiring up to 2400 watts (2.4 kW) or 20 Amps of current. Use only high quality, well- insulated, 3-wire grounded cord sets rated for 125 Volts at 20 Amps (or greater). NOTE: Limit length of extension cords to fif- teen feet, or less, to prevent voltage drop and overheating of wires. Figure 2-5. 120 VAC, 20 Amp, Duplex Receptacle 120/240 VAC, 30 Amp Receptacle Use a NEMA L14-30 plug with this receptacle (rotate to lock/unlock). Connect a suitable 4- wire grounded cord set to plug and desired load. The cord set should be rated 250 Volts AC at 30 Amps (or greater). See Figure 2-6. Use this receptacle to operate 240 Volt AC, 60 Hz, single phase loads requiring up to 5000 watts (5.0 kW) of power at 20.8 Amps. Figure 2-6. 120/240 VAC, 30 Amp Receptacle 120 VAC, 30 Amp Receptacle Use a NEMA L5-30 plug with this receptacle (rotate to lock/unlock). Connect a suitable 3- wire cord set to the plug and to desired load. The cord set should be rated for 125 Volts AC at 30 Amps (or greater). See Figure 2-7. Use this receptacle to operate 120 Volt AC, 60Hz, single phase loads requiring up to 3600 watts (3.6kW) of power at 30 Amps. The outlet is protected by a 30 Amp push-to-reset circuit breaker. Figure 2-7. 120 VAC, 30 Amp Receptacle

1. Open carton completely by cutting each

corner from top to bottom.

2. Remove and verify carton contents prior to

assembly. Carton contents should contain the following: Contents Portability Kit (optional)

3. Call Generac Customer Service 1-888-

GENERAC (1-888-436-3722) with the unit model and serial number for any missing carton contents.

4. Record model, serial number, and date of

purchase on front cover of this manual. Assembly Call Generac Customer Service at 1-888- GENERAC (1-888-436-3722) for any assem- bly issues or concerns. Please have model and serial number available. The following tools are required to install the accessory kit.

Ratchet with 10mm and 13mm sockets

13mm box wrenches NOTE: The wheels are not intended for over- the-road use. Install wheels as follows. See Figure 2-8.

1. Insert cotter pin (E) to one end of axle (B).

2. In this order; slide washer (D), wheel (A),

washer, (D), axle mount (2-C), washer (D), wheel (A), washer (D), and cotter pin (E) onto axle.

3. Place wheel assembly under frame so

axle mounts align with holes in cradle frame.

4. Secure with M6 screws (L).

Figure 2-8. Wheel Assembly Install frame foot and rubber bumpers as shown in Figure 2-9.

1. Slide onto M8 screw (Q), flat washer (M),

2. Slide assembly through frame foot (J). Add

M8 flat washer (N), and secure with M8-

4. Slide M8 flat washers (N) onto M8-

1.25x110 screws (T) and insert through foot bracket assembly and cradle.

5. Secure with M8 flat washer (N) and M8

locknut (P). Item Qty. Main Unit 1 Owner’s Manual 1 Liter Oil SAE 30 2 Product Registration Card 3 Service Warranty 1 Emissions Warranty 1 Muffler Extension 1 Battery Bracket Assembly 1 Portability Kit (Model No. G0069100) Qty. 10” Wheel (A) 2 Axle (B) 1 Axle Mount (C) 2 5/8” Flat Washer (D) 4 Cotter Pin (E) 2 Handle (F) 1 Handle Mount (G) 2 Handle Grip (H) 2 Frame Foot (J) 2 Rubber Feet (K) 2 M6-1x50mm Screw (L) 4 .344”x1.0” Flat Washer (M) 2 M8 Flat Washer (N) 10 M8-1.25 Locknut (P) 6 M8-1.25x30 Screw (Q) 2 M8-1.25x45 Screw (R) 2 M8-1.25x50 Screw (S) 2 M8-1.25x110 Screw (T) 2 5/16x1.25 Pin Release (U) 1 Lanyard 1 (000100a) WARNING Consult Manual. Read and understand manualcompletely before using product. Failure to completely understand manual and productcould result in death or serious injury.

Figure 2-9. Frame Foot Assembly Install handle as shown in Figure 2-10.

1. Place a M8 flat washer (N) onto M8-

1.25x45 screw (R) and through handle bracket and handle (A).

2. Secure with M8 flat washer (N) and M8

Figure 2-10. Handle Assembly Battery Installation The following tools are required to install the battery.

7/16” (11mm) ratchet, socket and wrench Install the battery as follows. See Figure 2-11.

1. Place battery onto battery tray with the

positive terminal on the right.

2. Connect red battery wire to positive (+) ter-

minal with a bolt, washer and nut.

3. Slide red battery terminal post cover over

terminal and hardware.

4. Connect black battery wire to negative (-)

terminal with a bolt, washer and nut.

5. Slide black battery terminal post cover

over terminal and hardware.

6. Slide one spacer onto each screw.

7. Slide these assemblies through holes in

8. Place bracket assembly over top of bat-

tery. Do not to touch battery terminal hard- ware. The screws will pass through holes on battery tray.

9. Place washer, lock washer and wing nut

10. Tighten wing nuts until the lock washers

are compressed to being flat. NOTE: The battery charges while the engine is running. Figure 2-11. Battery Installation Add Engine Oil

1. Place generator on a level surface.

2. Verify oil fill area is clean.

3. Remove oil fill cap and wipe dipstick clean.

See Figure 2-12. Figure 2-12. Remove Dipstick

4. Add recommended engine oil as shown in

the following chart. NOTE: Some units have more than one oil fill location. It is only necessary to use one oil fill point.

5. Thread dipstick into oil filler neck. Oil level

is checked with dipstick fully installed.

(000135) CAUTION Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage.

-4 °F (-20 °C) 14 °F (-10 °C) 32 °F (0 °C) 50 °F (10 °C) 68 °F (20 °C) 86 °F (30 °C) 104 °F (40 °C) SAE 15W-40 SAE 20W SAE 30 SAE 40 SAE 10-W30 SAE 20W SAE 10W 000578Owner’s Manual for Portable Generator 9

6. See Figure 2-13. Remove dipstick and ver-

ify oil level is within safe operating range.

7. Install oil fill cap/dipstick and hand-tighten.

Figure 2-13. Safe Operating Range Fuel IMPORTANT NOTE: DO NOT use Home Heating Oil or Bio-Diesel Fuel. Use No. 2D diesel fuel when temperatures are above freezing. When temperatures are below freezing, blend No.1D diesel fuel and No. 2D diesel fuel together for a climate adjusted fuel ratio. Diesel fuel must meet the following require- ments:

Sulfur content of 15 parts per million (ppm) maximum.

Minimum Cetane index of 40. NOTE: Low ambient temperatures as well as engine operation at high altitudes may require the use of fuels with higher Cetane ratings. Fuel Maintenance

Always treat diesel fuel for long term stor- age. Use the approved fuel additive and water abatement material. Test stored fuel every 90 days and provide additional treat- ment if required. Periodically check and dry abatement material as necessary.

(000105) DANGER Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury. (000166b) DANGER Explosion and Fire. Do not overfill fuel tank. Fill to 1/2 inch from top of tank to allow for fuel expansion. Overfilling may cause fuel to spill onto engine causing fire or explosion, which will result in death or serious injury.10 Owner’s Manual for Portable Generator

Operation and Use Questions Call Generac customer service at 1-888-GEN- ERAC (1-888-436-3722) with questions or concerns about equipment operation and maintenance. Before Starting Engine

1. Verify engine oil level is correct.

2. Verify fuel level is correct.

3. Verify battery is installed.

NOTE: The generator will not start without the battery installed.

4. Verify unit is secure on level ground, with

proper clearance and is in a well ventilated area. Prepare Generator for Use Grounding the Generator When Used as a Portable The generator is equipped with an equipment ground connecting the generator frame and the ground terminals on the AC output recep- tacles (see NEC 250.34 (A). This allows the generator to be used as a portable without grounding the frame of the generator as spec- ified in NEC 250.34. See Figure 3-1.

Neutrals bonded to frame. Figure 3-1.Grounding the Generator Special Requirements Review all Federal or State Occupational Safety and Health Administration (OSHA) reg- ulations, local codes, or ordinances that apply to the intended use of the generator. Consult a qualified electrician, electrical inspector, or the local agency having jurisdic- tion:

In some areas, generators are required to be registered with local utility companies.

If the generator is used at a construction site, there may be additional regulations which must be observed. Connecting the Generator to a Building Electrical System When connecting directly to a building electri- cal system, it is recommended that a manual transfer switch be used. Connections for a portable generator to a building electrical sys- tem must be made by a qualified electrician and in strict compliance with all national and local electrical codes and laws. Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.(000103) DANGER (000178a)Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury.WARNING (000179b) DANGER Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury. WARNING (000118a) Risk of fire. Do not use generator without spark arrestor installed. Failure to do so could result in death or serious injury. (000110) WARNING Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury. (000108) WARNING Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire. (000136) CAUTION Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage. 000707Owner’s Manual for Portable Generator 11 Know Generator Limits Overloading a generator can result in damage to the generator and connected electrical devices. Observe the following to prevent overload:

Add up the total wattage of all electrical devices to be connected at one time. This total should NOT be greater than the gener- ator's wattage capacity.

The rated wattage of lights can be taken from light bulbs. The rated wattage of tools, appliances, and motors can be found on a data label or decal affixed to the device.

If the appliance, tool, or motor doesn’t give wattage, multiply volts times ampere rating to determine watts (volts x amps = watts).

Some electric motors, such as induction types, require about three times more watts of power for starting than for running. This surge of power lasts only a few seconds when starting such motors. Make sure to allow for high starting wattage when select- ing electrical devices to connect to the gen- erator:

1. Figure the watts needed to start the largest

2. Add to that figure the running watts of all

Allow 3 times the listed watts for starting these devices.12 Owner’s Manual for Portable Generator Starting Pull Start Engines

1. Unplug all electrical loads from the unit's

receptacles before starting engine.

2. Place generator on a level surface.

Run/Stop switch to Run (C).

7. Squeeze primer bulb 5-10 times until firm.

The fuel filter should show fuel level at least half full.

8. Firmly grasp recoil handle and pull slowly

until increased resistance is felt. Flip red decompression lever on top of engine. Pull rapidly up and away. – Repeat this procedure until the engine starts. If the engine does not start within 5 pulls, confirm steps 1-6 and perform step 7 again.

Figure 3-4.Engine Run/Stop Switch

1. Allow engine to run for at least 10 sec-

onds, then turn main breaker On (A). See Figure 3-2 or Figure 3-4.

2. Select voltage rating with voltage selector

(D). See Figure 3-4. IMPORTANT NOTE: Do not overload the generator. Also, do not overload individual panel receptacles. These outlets are pro- tected against overload with push-to-reset type circuit breakers. If amperage rating of any circuit breaker is exceeded, that breaker opens and electrical output to that receptacle is lost. Read Know Generator Limits carefully. Starting Electric Start Engines

1. Turn main breaker switch to Off (A). See

Figure 3-2 or Figure 3-4.

2. Unplug all electrical loads from the unit's

receptacles before starting engine.

3. Place generator on a level surface.

The fuel filter should show fuel level at least half full.

7. Press and hold the Engine Start switch (C)

until engine starts. See Figure 3-4. Release Engine Start switch if engine does not start within 5 seconds. If engine does not start within 5 seconds, review start-up procedure again before attempt- ing start. If problems persist, refer to Trou- bleshooting.

8. Turn Main Breaker to On.

9. Select voltage rating with Voltage Selector

(D). (000183) WARNING Recoil Hazard. Recoil could retract unexpectedly.Kickback could result in death or serious injury. (000136) CAUTION Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.

(000136) CAUTION Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.Owner’s Manual for Portable Generator 13 Generator Shut Down

1. Turn main breaker switch Off.

2. Switch engine start switch to Off.

3. Turn fuel valve Off.

Emergency Shutdown Procedure

1. Press down on small red lever on lower

engine controls (near recoil handle and dipstick) to the Stop position.

2. Turn main breaker switch Off.

3. Switch engine start switch to Off.

4. Turn fuel valve Off.

To re-start engine, the engine control lever must be moved to Run (B). See Figure 3-3. Low Oil Pressure Switch The engine is equipped with a low oil pressure switch that shuts down the engine automati- cally when the oil level drops below a speci- fied level. The engine will not run until the oil has been filled to the proper level. If the engine shuts down and there is sufficient fuel, check engine oil level. (000136) CAUTION Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.14 Owner’s Manual for Portable Generator

Section 4 Maintenance and Troubleshooting

Maintenance Regular maintenance will improve perfor- mance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing. To obtain emissions control warranty service free of charge, the work must be performed by an IASD. See the emissions warranty. NOTE: Call 1-888-GENERAC (1-888-436- 3722) with questions about component replacement. Maintenance Schedule Follow maintenance schedule intervals, whichever occurs first according to use. NOTE: Adverse conditions will require more frequent service. NOTE: All required service and adjustments should be each season as detailed in the fol- lowing chart. Preventive Maintenance Dirt or debris can cause improper operation and equipment damage. Clean generator daily or before each use. Keep area around and behind muffler free from combustible debris. Inspect all cooling air openings on generator.

Use a damp cloth to wipe exterior surfaces clean.

Use a soft bristle brush to loosen caked on dirt, oil, etc.

Use a vacuum to pick up loose dirt and debris.

Low pressure air (not to exceed 25 psi [172 kPa]) may be used to blow away dirt. Inspect cooling air slots and openings on generator. These openings must be kept clean and unobstructed. NOTE: DO NOT use a garden hose to clean generator. Water can enter engine fuel system and cause problems. If water enters generator through cooling air slots, some water will be retained in voids and crevices of rotor and sta- tor winding insulation. Water and dirt buildup on generator internal windings will decrease insulation resistance of windings. Engine Maintenance Engine Oil Recommendations To maintain the product warranty, the engine oil should be serviced in accordance with the recommendations of this manual. For your convenience, maintenance kits designed and intended for use on this product are available from the manufacturer that include engine oil, oil filter, air filter, spark plug(s), a shop towel and funnel. These kits can be obtained from an Independent Authorized Service Dealer (IASD). At Each Use Check engine oil level Every Season Check valve clearance*** Every 200 Hours or Every Season Inspect/clean air cleaner filter** Change oil and oil filter ǂ* Check engine speed control Drain fuel tank & replace outlet fuel filter Every 1000 Hours Check compression Every 1500 Hours Inspect, clean & test fuel injection nozzle Every 2000 Hours Check & replace fuel hoses ǂ Change oil after first 50 hours of opera- tion, then every season.

Change oil and oil filter every month when operating under heavy load or in high temperatures. ** Clean more often under dirty or dusty operating conditions. Replace air filter parts if they cannot be adequately cleaned. *** Check valve clearance and adjust if necessary after first 50 hours of operation and every 400 hours thereafter. (000142a)Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage. WARNINGOwner’s Manual for Portable Generator 15 Inspect Engine Oil Level Inspect engine oil level prior to each use, or every 8 hours of operation.

1. Place generator on a level surface.

2. Clean area around oil fill.

3. See Figure 4-1. Remove oil fill cap and

wipe dipstick clean. Figure 4-1. Engine Oil Fill

4. Screw dipstick into filler neck. Verify oil

level is within safe operating range. See Figure 4-2. Figure 4-2. Safe Operating Range

5. Add recommended engine oil as neces-

NOTE: Some units have more than one oil fill location. It is only necessary to use one oil fill point. Change Engine Oil When using generator under extreme, dirty, dusty conditions, or in extremely hot weather, change oil more frequently. NOTE: Don’t pollute. Conserve resources. Return used oil to collection centers. Change oil while engine is still warm from run- ning, as follows:

1. Place generator on a level surface.

2. Clean area around oil fill, and oil drain

3. Remove oil fill cap.

4. Remove oil drain plug and drain oil com-

pletely into a suitable container.

5. Install oil drain plug and tighten securely.

6. Slowly pour oil into oil fill opening until oil

level is between the crosshatch marks on dipstick. DO NOT overfill.

7. Install oil fill cap, and finger tighten.

8. Wipe up any spilled oil.

9. Properly dispose of oil in accordance with

all applicable regulations. Air Filter Engine will not run properly and may be dam- aged if run with a dirty air filter. Service air fil- ter more frequently in dirty or dusty conditions. To service air filter:

2. Wash in soapy water. Squeeze filter dry in

clean cloth (DO NOT TWIST).

3. Clean air filter cover before re-installing it.

NOTE: To order a new air filter, contact the nearest Authorized Service Dealer at 1-888- GENERAC (1-888-436-3722). (000135) CAUTION Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage. -4 °F(-20 °C)14 °F(-10 °C)32 °F(0 °C)50 °F(10 °C)68 °F(20 °C)86 °F(30 °C)104 °F(40 °C)SAE 15W-40SAE 20WSAE 30SAE 40SAE 10-W30SAE 20WSAE 10W000578 (000139) WARNING Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.

(000130) WARNING Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury.16 Owner’s Manual for Portable GeneratorFigure 4-3. Air Filter Assembly Battery Replacement (if applicable) NOTE: A battery may lose some charge when not in use for prolonged periods of time. The following tools are required to replace the battery.

7/16” (11mm) ratchet, socket and wrench See Figure 4-4.

2. Disconnect positive (+) battery terminal

3. Loosen wing nuts and remove battery

bracket and hardware.

4. Replace battery by following instructions in

the Battery Installation section. Figure 4-4. Battery Connection Inspect Muffler and Spark Arrestor (if equipped) NOTE: It is a violation of California Public Resource Code, Section 4442, to use or oper- ate the engine on any forest-covered, brush- covered, or grass-covered land unless the exhaust system is equipped with a spark arrestor, as defined in Section 4442, main- tained in effective working order. Other states or federal jurisdictions may have similar laws. Contact original equipment manufacturer, retailer, or dealer to obtain a spark arrestor designed for exhaust system installed on this engine. NOTE: Use ONLY original equipment replace- ment parts. Inspect muffler for cracks, corrosion, or other damage. Remove spark arrestor, if equipped, inspect for damage or carbon blockage. Replace parts as required. Valve Clearance Important: Please contact an Independent Authorized Service Dealer for service assis- tance. Proper valve clearance is essential for prolonging the life of the engine. Storage General It is recommended to start and run the genera- tor for 30 minutes, every 30 days. If this is not possible, refer to the following list to prepare unit for storage.

DO NOT place a storage cover on a hot generator. Allow unit to cool to room tem- perature before storage.

DO NOT store fuel from one season to another unless properly treated.

Replace fuel container if rust is present. Rust in fuel will cause fuel system prob- lems.

Cover unit with a suitable protective, mois- ture resistant cover.

Store unit in a clean and dry area.

Always store generator and fuel away from heat and ignition sources. Prepare Fuel System for Storage

(000130) WARNING Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury.

(000143) DANGER Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Store fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury. (000109) WARNING Risk of Fire. Verify machine has properly cooled before installing cover and storing machine. Hot surfaces could result in fire. (000181) WARNING Vision Loss. Eye protection is required to avoid spray from spark plug hole when cranking engine. Failure to do so could result in vision loss.Owner’s Manual for Portable Generator 17 Recoil Start

1. Push and hold decompression down and

slowly pull recoil starter 2 to 3 times. Do not start engine.

2. Pull decompression lever up. Pull recoil

slowly until resistance is felt. This will close valves so moisture cannot enter engine cylinder. Gently release recoil. Electric Start

1. Push and hold decompression lever down.

2. Push Start/Run/Stop switch to turn the

engine for 2 to 3 seconds. Do not start engine.

3. Pull decompression lever up. Pull recoil

slowly until resistance is felt. This will close valves so moisture cannot enter engine cylinder. Gently release recoil.

4. Completely drain fuel tank or completely

fill fuel tank to proper level. NOTE: Always treat diesel fuel for long term storage. Use the approved fuel additive and water abatement material. Test stored fuel every 90 days and provide additional treat- ment if required. Periodically check and dry abatement material as necessary. Change Oil Change engine oil before storage. See Change Engine Oil Return Engine to Service

1. Refer to the Before Starting Engine sec-

2. Start engine and run at no load for 5 to 10

minutes while checking: – oil pressure – fuel, engine oil or coolant leaks – proper operation of indicators/gauges NOTE: Avoid prolonged operation at minimum or maximum engine speeds and loads for the first hour of operation. Troubleshooting

PROBLEM CAUSE CORRECTION

Engine is running, but AC output is not available.

1. Circuit breaker OPEN.

2. Poor connection or defective

3. Connected device is bad.

4. Fault in generator.

5. Main breaker switch is OFF.

6. Voltage selector switch is OFF.

7. Generator is overloaded.

8. GFCI outlet has tripped.

1. Reset circuit breaker.

2. Check and repair.

3. Connect another device that is

4. Contact Authorized Service

to desired voltage output.

8. Correct ground fault in circuit

and reset GFCI. Engine runs well at no-load, but bogs when load is applied.

1. Short circuit in a connected

2. Generator is overloaded.

3. Engine speed is too slow.

4. Shorted generator circuit.

1. Disconnect shorted electrical

3. Contact Authorized Service

4. Contact Authorized Service

Dealer.18 Owner’s Manual for Portable Generator Engine will not start; or starts and runs rough.