XC6500E - Generator Generac - Free user manual and instructions

USER MANUAL XC6500E Generac

SAVE THIS MANUAL FOR FUTURE REFERENCE

MODEL:________________________ SERIAL:________________________ DATE PURCHASED:______________ (000209b) WARNING Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury.Table 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
• Lifting or Suspending Generator p. 3
• Standards Index p. 4

Section 2 General Information and

Section 4 Maintenance and

www.P65Warnings.ca.gov.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 alerts in this manual, and on tags and decals affixed to the unit, are not all inclu- sive. If using a procedure, work method, or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others and does not render the equipment unsafe. Throughout this publication, and on tags and decals affixed to the unit, DANGER, WARN- ING, CAUTION, and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Alert 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 alerts cannot eliminate the haz- ards that they indicate. Common sense and strict compliance with the special instructions 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.

(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.2 Owner’s Manual for Portable Generator

• 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.

• Point muffler exhaust away from people and occupied buildings. (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. (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. WARNINGOwner’s Manual for Portable Generator 3 Electrical Hazards

• The National Electric Code (NEC) requires the frame and external electrically conduc- tive 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. Fire Hazards

• 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.

• Allow at least 5 feet of clearance on all sides of the generator when operating to prevent overheating and fire. Lifting or Suspending Generator (000144)DANGERElectrocution. Contact with bare wires, terminals, and connections while generator is running 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. (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. (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. (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. WARNING WARNING Personal injury. Failure to properly connect lifting cables, chains, or straps could result in death, serious injury, or property damage. (000346) WARNING Personal injury. Failure to use cables, chains, or straps rated at 2000 lbs. (907 kg) working load or greater to raise or suspend unit could result in death, serious injury, or property damage. (000347) WARNING Personal injury. Never operate generator while suspended. Doing so could result in death, serious injury, or property damage. (000348) WARNING Personal Injury. Do not use lifting hook if there are signs of damage or corrosion. Doing so could result in death, serious injury, or property damage. (000349) WARNING Personal Injury. Do not use lifting hook other than as directed. Failure to do so could result in death, serious injury, or property damage. (000350) WARNING Personal Injury. Verify all fasteners are properly tightened prior to lifting unit. Failure to do so could result in death, serious injury, or property damage. (000351)4 Owner’s Manual for Portable Generator 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

6. Safety and Performance of Portable Gen-

erators ANSI/PGMA G300 available from pgmaonline.com

7. CSA C22.2 100-14 Electric motors and

generators for installation and use, in accordance with the Rules of Canadian Electrical Code. This list is not all inclusive. Check with the Authority Having Jurisdiction (AHJ) for any local codes or standards which may be appli- cable to your jurisdiction.Owner’s Manual for Portable Generator 5

Section 2 General Information and Setup

Figure 2-1. Features and Controls TABLE 1. Generator Components Figure 2-2. Unit Identification Label

1 120 Volt AC, 20 Amp Duplex Receptacle 2 120/240 Volt AC, 30 Amp Locking Receptacle 3 1-pole Circuit Breakers (AC) 4 2-pole Circuit Breaker 5 120 Volt AC, 30 Amp Locking Receptacle 6 Idle Control 7 Ground Fault Sensing Module 8 GFCI Module Circuit Breaker 9 Hour Meter 10 Choke Lever 11 Start/Run/Stop Switch (Electric start) (6.5kW, Run/Stop Switch, recoil start only) 12 Spark Plug 13 Oil Filter 14 Oil Drain 15 Oil Fill 16 Air Filter 17 Fuel Filter 18 Recoil Starter 19 Muffler 20 Spark Arrestor 21 Grounding Lug 22 Handles 23 Fuel Tank 24 Gas Cap 25 Fuel Gauge 26 Battery (if equipped) 27 Steel Lifting Pocket 28 Handle Release Knob 0034476 Owner’s Manual for Portable GeneratorFigure 2-3. XC Series Control Panel Know Your Generator Replacement owner’s manuals are available at www.generac.com. Emissions The United States Environmental Protection Agency (US EPA) (and California Air Resources Board (CARB), for engines/equip- ment certified to California standards) requires that this engine/equipment complies with exhaust and evaporative emissions stan- dards. Locate the emissions compliance decal on the engine to determine applicable stan- dards. For emissions warranty information, please reference the included emissions war- ranty. It is important to follow the maintenance specifications in the manual to ensure that the engine complies with the applicable emissions standards for the duration of the product’s life.

(000100a) WARNING Consult Manual. Read and understand manualcompletely before using product. Failure to completely understand manual and productcould result in death or serious injury. TABLE 2. Product Specifications

6.5 kW / 8.0 kW Generator Specifications

Rated Power @ 1.0 Power Factor 6.5kW** / 8.0kW**Starting Watts 8.13kVA** / 10kVA**Rated AC Voltage 120/240Rated AC Load (120 Volt / 240 Volt) 6.5 kW 8.0 kW54.2 / 27.1 Amps**66.7 / 33.3 Amps**Rated Frequency 60 Hz @ 3600 RPMPhase Single PhaseUnit Weight (Dry) 6.5 kW (recoil start only) 6.5 kW (electric start) 8.0 kW (electric start)246 lbs. (111.8 kg)260 lbs. (117.9 kg)** Operating Temperature Range: -18 deg. C (0 deg. F) to 40 Deg. C (104 Deg. F). When operatedabove 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 content, ambi- ent 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.Owner’s Manual for Portable Generator 7 Connection Plugs 120 VAC, 20 Amp, Duplex Receptacle The 120 Volt outlet is overload protected by a 20 Amp push-to-reset circuit breaker. See Fig- ure 2-4. 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). Figure 2-4. 120 VAC, 20 Amp, Duplex Receptacle NEMA 5-20R 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 2-5.

• Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps or 240 Volt AC, 60 Hz, single phase loads requiring up to 7200 watts (7.2 kW) of power at 30 Amps. The outlet is protected by a 2-pole 30 Amp rocker circuit breaker. Figure 2-5. 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 2-6. 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 2-6. 120 VAC, 30 Amp Receptacle

Displacement 426 cc Spark Plug Part No. 0G0767B Spark Plug Type Champion RC12YC or Equivalent Spark Plug Gap 0.020 inch (0.51mm) Gasoline Capacity 32 L (8.5 U.S. gallons) Oil Type See chart in Add Engine Oil. Oil Capacity with filter change without filter change

• Go to www.generac.com or contact an IASD for replacement parts. TABLE 2. Product Specifications

• The SVC display will illuminate one hour before and one hour after each 200 hour interval providing a two hour window to per- form service. 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.

• 200 hours - SVC — Change oil, oil filter, air filter, fuel filter, and spark plug. Clean spark arrestor screen. (Every 200 hrs) NOTE: The hour glass icon will flash when the engine is running. This signifies the meter is recording hours of operation. Figure 2-7. Hour Meter Ground Fault Sensing Module This unit is equipped with a ground fault circuit interrupter (GFCI). This device meets applica- ble federal, state and local codes. The ground fault sensing module covers all receptacles. In the event of a ground fault, the GFCI will trip and stop the flow of electricity to prevent seri- ous injury. The GFCI constantly monitors electricity flow- ing in a circuit. If current flowing through a cir- cuit varies from what is returning, the GFCI switches power off tripping the main circuit breaker on the generator's control panel. A GFCI does NOT protect against circuit over- loads, short circuits, or shocks. Electric shock can still occur if a person touches charged electrical wires while standing on a non-con- ducting surface, such as a wood floor. Test the GFCI module before each use. See Figure 2-8.

2. Plug a test lamp into duplex receptacle.

The lamp should be on.

3. Press TEST button on GFCI to trip the

device. The main breaker should ‘trip’. This is indicated by movement of the actu- ator handle to the OFF position.

4. This should stop the flow of electricity

making the lamp shut off. If the main breaker does not ‘trip’, the GFCI is not working and the generator should not be used. Contact an IASD.

5. To restore the flow of electricity, set the

main breaker actuator handle to the ‘ON’ position. The handles should remain latched in this position. If it does not, either the GFCI or the main breaker is failing and should be replaced. Contact an IASD.

6. This GFCI is protected against overload by

a 6.5kW, 30 Amp or 8.0kW, 35A/240V main breaker.

7. The GFCI has Auto-Monitor and End-of-

Life indications with LED status lights. Figure 2-8. Test the GFCI Automatic Idle Control (if equipped) This feature improves fuel economy. When this switch is turned ON, the engine will run at a normal fast governed engine speed when electrical load is connected. When load is removed, the engine will run at a reduced speed. With the switch OFF, the engine con- tinually runs at a normal fast engine speed. Always have the switch OFF when starting and stopping the engine. See Figure 2-8. Remove Contents from Carton

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:

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.

• 13mm Wrench (2) See Figure 2-9. Install lifting pocket assembly as follows:

1. Install each halve of lifting pocket (3)

underneath frame and loosely assemble with 45mm bolt (7) and nut (11) through holes in frame.

2. Install 20mm bolt (10) and nut (11) through

top holes of lifting pocket halves.

3. Tighten all bolts securely.

4. Align each top cover (8) with bottom lifting

pocket (3) holes. Insert binding post (9) barrel and secure with binding post screw (9). Figure 2-9. Steel Lifting Pocket Assembly NOTE: The wheels are not intended for over- the-road use. See Figure 2-10. Install wheels as follows:

1. Slide axle (5) through generator frame

2. Slide wheel (1) and one 5/8" flat washer

3. Secure with hair pin (4). Repeat on oppo-

site side. Install frame foot assembly as follows:

1. Align frame foot (2) with holes in frame

and secure with 45mm bolts (7). Item Qty. Main Unit 1 Owner’s Manual 1 Engine Manual 1 Quart SAE Oil 1 Oil Filter 1 Air Filter 1 Spark Plug 1 Spark Plug Wrench 1 Shop Towel 1 Top Cover (8) 2 Wheel (1) 2 Frame Foot (2) 2 Steel Lifting Pocket (3) 2 Hardware Bag Qty. Hair Pin (4) 2 Axle (5) 1 5/8” Flat Washer (6) 2 45mm Bolt (7) 8 Binding Post Assembly (9) 2 20mm Bolt (10) 2 Nut (11) 6 (000100a) WARNING Consult Manual. Read and understand manualcompletely before using product. Failure to completely understand manual and productcould result in death or serious injury.

910 Owner’s Manual for Portable Generator Figure 2-10. Wheel and Foot Assembly Battery Cable Connection (if equipped) The unit has been shipped with the battery cables disconnected. You will need two 8mm box wrenches to con- nect the battery cables. See Figure 4-5.

1. Cut off cable ties securing battery cables

and remove red cover from battery termi- nal.

2. First, connect the red cables to the positive

(+) battery terminal with the bolt and nut supplied.

3. Make sure connections are secure and

slide rubber boot over the positive (+) bat- tery terminal and connection hardware.

4. Connect the black cables to the negative

(-) battery terminal with the bolt and nut supplied. Slide rubber boot over the neg- ative (-) battery terminal and connection hardware.

5. Make sure all connections are secure.

NOTE: If the battery is unable to start the engine, charge it with an appropriate 12V charger or manually start the generator and let run until charged. 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 2-11. Figure 2-11. Remove Dipstick

4. Add recommended engine oil. Climate

determines proper engine oil viscosity. See chart to select correct viscosity. NOTE: Use petroleum based oil (supplied) for engine break-in before using synthetic oil.

(000167a) CAUTION Equipment damage. Do not make battery connections in reverse. Doing so will result in equipment damage. (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. 000115Owner’s Manual for Portable Generator 11

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.

6. See Figure 2-12. Remove dipstick and ver-

ify oil level is within safe operating range. Figure 2-12. Safe Operating Range

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

Fuel Fuel requirements are as follows:

• Clean, fresh, unleaded gasoline.

• Minimum rating of 87 octane/87 AKI (91 RON).

• Up to 10% ethanol (gasohol) is acceptable (where available; non-ethanol-premium fuel is recommended).

• DO NOT use a gas oil mix.

• DO NOT modify engine to run on alternate fuels. Stabilize fuel prior to storage.

1. Verify unit is OFF and cooled for a mini-

mum of two minutes prior to fueling.

2. Place unit on level ground in a well venti-

3. Clean area around fuel cap and remove

4. Slowly add recommended fuel. Do not fill

Figure 2-13. Add Recommended Fuel NOTE: Allow spilled fuel to evaporate before starting unit. IMPORTANT NOTE: It is important to pre- vent gum deposits from forming in fuel system parts such as the carburetor, fuel hose or tank during storage. Alcohol- blended fuels (called gasohol, ethanol or methanol) can attract moisture, which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. See the Storage section. Never use engine or carburetor cleaner products in the fuel tank as permanent damage may occur. SAE 3010W-30Synthetic 5W-30000399

(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.

Operation and Use Questions Call Generac Customer Service at 1-888- GENERAC (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 unit is secure on level ground, with

proper clearance and is outdoors in a well ventilated area. Prepare Generator for Use Grounding the Generator When Used as a Portable The generator is equipped with a terminal for the connection of a grounding electrode sys- tem. Article 250.34 (A) does not require the frame of the generator to be connected to a grounding electrode system when the genera- tor only supplies power to cord and plug con- nected equipment through the receptacles on the generator. When the generator supplies power to a 3- pole manual transfer switch or distribution panel boards for temporary power, a ground- ing electrode system shall be installed and connected to the grounding electrode terminal on the generator. See NEC 250.30, 250.34 and 250.52 for clarification. See Figure 3-1.

• Neutral Bonded to Frame Figure 3-1.Grounding the Generator Special Requirements Review all Federal and State Occupational Safety and Health Administration (OSHA) reg- ulations, local codes, and ordinances applica- ble to the intended use of the generator. Additional regulations may apply if the genera- tor is used at a construction site. Consult a qualified electrician, electrical inspector, or the local agency having jurisdic- tion for additional requirements that may be unique to your area, such as whether the gen- erator is required to be registered with local utility. Connecting the Generator to a Building Electrical System It is recommended to use a manual transfer switch when connecting directly to a building electrical system. Connecting a portable gen- erator to a building electrical system must be made in strict compliance with all national and local electrical codes and laws, and be com- pleted by a qualified electrician. 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 (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. (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 (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. 000227Owner’s Manual for Portable Generator 13 Connecting Electrical Loads DO NOT connect 240 Volt loads to 120 Volt receptacles. DO NOT connect 3-phase loads to generator. DO NOT connect 50 Hz loads to generator. Let engine stabilize and warm up for a few minutes after starting. Plug in and turn on the desired 120 or 240 Volt AC, single phase, 60 Hz electrical loads. Add up the rated watts (or amps) of all loads to be connected at one time. This total should not be greater than (a) the rated wattage/ amperage capacity of the generator or (b) cir- cuit breaker rating of the receptacle supplying the power. See Know Generator Limits. 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 does not 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

Oil Fired Space Heater (85,000 Btu) 225 Oil Fired Space Heater (30,000 Btu) 150 *Paint Sprayer, Airless (1/3 HP) 600 Paint Sprayer, Airless (hand-held) 15014 Owner’s Manual for Portable Generator Transporting/Tipping of the Unit Do not store or transport the unit at an angle greater than 15 degrees. Starting Pull Start Engines

1. Unplug all electrical loads from the unit's

receptacles before starting engine.

2. Place generator on a level surface.

3. Rotate the fuel shut-off valve (A) counter-

clockwise to the ON (open) position. See Figure 3-2.

4. Turn engine STOP/RUN switch to RUN.

Figure 3-2.Engine Controls

5. Slide engine choke lever (B) to Full

CHOKE position (left). See Figure 3-2.

6. See Figure 3-2. Firmly grasp recoil handle

(C) and pull slowly until increased resis- tance is felt. Pull rapidly up and away.

7. When engine starts, move choke lever to

1/2 CHOKE position until engine runs smoothly, then fully into OPEN (right) posi- tion. If engine falters, move choke lever back to 1/2-CHOKE position until engine runs smoothly, then to OPEN (right) posi- tion. NOTE: If engine fires, but does not continue to run, move choke lever to Full CHOKE (left) and repeat starting instructions. IMPORTANT NOTE: Do not overload gener- ator or individual panel receptacles. These outlets are overload protected with push- to-reset circuit breakers. If amperage rat- ing 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. Unplug all electrical loads from the unit's

receptacles before starting the engine.

2. Place generator on a level surface.

3. Rotate the fuel shut-off valve (A) counter-

clockwise to the ON (open) position. See Figure 3-2.

4. Slide engine choke lever (B) to Full

CHOKE position (left). See Figure 3-2.

6. When engine starts, move choke lever to

1/2 CHOKE position until engine runs smoothly, then fully into OPEN (right) posi- tion. If engine falters, move choke lever back to 1/2-CHOKE position until engine runs smoothly, then to OPEN (right) posi- tion. NOTE: If engine fires, but does not continue to run, move choke lever to Full CHOKE (left) and repeat starting instructions. Radio 50 to 200*Refrigerator 700Slow Cooker 200*Submersible Pump (1-1/2 HP) 2800*Submersible Pump (1 HP) 2000*Submersible Pump (1/2 HP) 1500*Sump Pump 800 to 1050*Table Saw (10") 1750 to 2000Television 200 to 500Toaster 1000 to 1650Weed Trimmer 500* Allow 3 times the listed watts for starting these devices. (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.

CLOSED (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 15 Generator Shut Down

1. Shut off all loads and unplug electrical

loads from generator panel receptacles.

2. Let engine run at no-load for several min-

utes to stabilize internal temperatures of engine and generator.

3. Move START/RUN/STOP switch to STOP.

4. Rotate fuel shut-off valve clockwise to the

OFF (closed) position. NOTE: Under normal conditions, close fuel valve and allow generator to run carburetor bowl out of fuel. For emergencies, switch to STOP. Low Oil Pressure Shutdown System The engine is equipped with a low oil pressure sensor that shuts down the engine automati- cally when the oil pressure drops below speci- fications. 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.16 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: Go to Generac.com or contact an IASD for replacement parts. 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) 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 UseCheck engine oil levelEvery 100 Hours or Every Season*Clean spark arrestor screenEvery SeasonCheck valve clearance***Every 200 Hours or Every SeasonChange oil ǂReplace spark plugReplace fuel filterInspect/clean air cleaner filter**ǂ Change oil after first 25 hours of operation,then every season.* Change oil and oil filter every month whenoperating under heavy load or in high tem-peratures.** Clean more often under dirty or dusty oper-ating conditions. Replace air filter parts ifthey cannot be adequately cleaned.*** Check valve clearance and adjust if neces-sary after first 50 hours of operation andevery 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. WARNING(000141) WARNING Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury.Owner’s Manual for Portable Generator 17

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. Remove

dipstick and 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 and Oil Filter 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 cool as follows:

1. Place generator on a level surface.

2. Disconnect the spark plug wire from the

spark plug and place the wire where it cannot contact spark plug.

3. Clean area around oil fill, and oil drain

4. Remove oil fill cap.

5. Remove oil drain hose cap and drain oil

completely into a suitable container.

6. Install oil drain hose cap and tighten

7. Place a suitable container beneath the oil

filter and turn filter counterclockwise to remove. Discard according to local regula- tions.

8. Coat gasket of new filter with clean engine

oil. Turn filter clockwise until gasket con- tacts lightly with filter adapter. Then tighten an additional 3/4 turn.

9. Slowly pour oil into oil fill opening until oil

level is in safe operating range on dipstick. DO NOT overfill.

10. Install oil fill cap, and finger tighten.

11. Wipe up any spilled oil.

12. 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:

1. See Figure 4-3. Remove air filter cover (A)

2. Gently tap filter on a solid surface. If too

dirty, replace with new filter.

3. Clean air filter cover before installation.

NOTE: To order a new air filter, contact the nearest IASD at 1-888-GENERAC (1-888- 436-3722). SAE 3010W-30Synthetic 5W-30000399 (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.

003620(000141) WARNING Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury. (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.18 Owner’s Manual for Portable GeneratorFigure 4-3. Air Filter Assembly Service Spark Plug To service spark plug:

1. Clean area around spark plug.

2. Remove and inspect spark plug.

3. Inspect electrode gap with wire feeler

gauge and reset spark plug gap to 0.020 in (0.51 mm). See Figure 4-4. Figure 4-4. Spark Plug NOTE: Replace spark plug if electrodes are pitted, burned or porcelain is cracked. Use ONLY recommended replacement plug. See Specifications.

4. Install spark plug finger tight, and tighten

an additional 3/8 to 1/2 turn using spark plug wrench. Battery Replacement (if applicable) NOTE: The battery shipped with the generator has been fully charged. A battery may lose some charge when not in use for prolonged periods of time. The battery may have to be charged before the first use. Running the gen- erator will charge battery. See Figure 4-5.

1. Disconnect and remove the battery con-

necting hardware (8mm) and BLACK wire (B) from the battery’s NEGATIVE (-) termi- nal.

2. Remove the red rubber boot (A) and dis-

connect the battery connecting hardware (8mm) and RED wire (C) from the bat- tery’s POSITIVE (+) terminal.

3. Install new battery. Secure battery with

battery terminal (C). Slide rubber boot (A) over connection hardware.

5. Connect BLACK wire to the NEGATIVE (-)

battery terminal (B). Figure 4-5. Battery Connection Inspect Muffler and Spark Arrester 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 arrester, 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 arrester 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 arrester, if equipped, inspect for damage or carbon blockage. Replace parts as required.

(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.

WARNING Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result inenvironmental damage, death or serious injury.(000228)Owner’s Manual for Portable Generator 19 Inspect Spark Arrester Screen

rated or otherwise damaged. If cone is not damaged, clean with commercial solvent.

3. Replace spark arrestor cone (C) and collar

(B). Secure with clamp (A). Figure 4-6. Spark Arrestor Screen 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. Check valve clearance after the first fifty-hours of operation. Adjust as necessary.

• Intake — 0.05 to 0.08 mm (0.002" to 0.003" inch)

• Exhaust — 0.05 to 0.08 mm (0.002" to 0.003" inch) 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 Fuel stored over 30 days can go bad and damage fuel system components. Keep fuel fresh, use fuel stabilizer. If fuel stabilizer is added to fuel system, pre- pare and run engine for long term storage. Run engine for 10-15 minutes to circulate sta- bilizer throughout fuel system. Adequately prepared fuel can be stored up to 24 months. NOTE: If fuel has not been treated with fuel stabilizer, it must be drained into an approved container. Run engine until it stops from lack of fuel. Use of fuel stabilizer in fuel storage container is recommended to keep fuel fresh.

1. Change engine oil.

2. Remove spark plug.

3. Pour tablespoon (5-10cc) of clean engine

oil or spray a suitable fogging agent into cylinder.

4. Pull starter recoil several times to distrib-

ute oil in cylinder.

5. Install spark plug.

6. Pull recoil slowly until resistance is felt.

This will close valves so moisture cannot enter engine cylinder. Gently release recoil. Change Oil Change engine oil before storage. See Change Engine Oil and Oil Filter. (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.

(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.20 Owner’s Manual for Portable Generator 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.

2. Check and repair.

3. Connect another device that is

5. Correct ground fault and press

reset button on GFCI breaker module. 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.

5. Dirty fuel filter.

6. Clogged spark arrestor.

1. Disconnect shorted electrical

Engine will not start; or starts and runs rough.

1. Fuel shut-off is OFF.

5. Spark plug wire not connected

10. Excessive rich fuel mixture.

12. Engine lost compression.

13. Dirty fuel filter.

1. Turn fuel shut-off ON.

4. Drain fuel tank and fill with

5. Connect wire to spark plug.

6. Replace spark plug.

7. Drain fuel tank; fill with fresh

9. Fill crankcase to correct level.

Engine shuts down during operation.

2. Fill crankcase to correct level.

Engine lacks power. 1. Load is too high.

2. Dirty air filter.

3. Engine needs to be serviced.

4. Dirty fuel filter.

1. Choke is opened too soon.

2. Carburetor is running too rich

1. Set choke to halfway position

until engine runs smoothly.

2. Contact IASD.Part No. 10000004327 Rev. B 05/14/2018

5. ASAE EP-364.2, Installation and

Maintenance of Farm Standby Electric Power, consultable sur www.asabe.org, ou auprès de l’American Society of Agricultural & Biological Engineers, 2950 Niles Road, St. Joseph, MI 49085, États-Unis

6. Safety and Performance of Portable