Generac Power Systems XD5000E User manual

XD5000E Diesel Portable Generator
Owner’s Manual
MODEL:________________________
SERIAL:________________________
DATE PURCHASED:______________
Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
SAVE THIS MANUAL FOR FUTURE REFERENCE
000703

Table of Contents
Section 1 Introduction and Safety 1
Introduction ..................................... 1
Safety Rules .................................... 1
Safety Symbols and Meanings ........ 1
Exhaust and Location Hazards ....... 2
Electrical Hazards ........................... 2
Fire Hazards .................................... 3
Standards Index .............................. 3
Section 2 General Information and
Setup .............................................. 4
Know Your Generator ..................... 5
Emissions Information ..................... 5
Hour Meter ...................................... 6
Connection Plugs ............................ 6
Remove Contents from Carton ....... 7
Assembly ......................................... 7
Battery Installation (if equipped) ...... 8
Add Engine Oil ................................ 8
Fuel ................................................. 9
Section 3 Operation .................... 10
Operation and Use Questions ....... 10
Before Starting Engine .................. 10
Prepare Generator for Use ............ 10
Grounding the Generator When Used
as a Portable ................................. 10
Know Generator Limits .................. 10
Transporting/Tipping of the Unit .... 11
Starting Pull Start Engines ............ 12
Starting Electric Start Engines ...... 12
Low Oil Pressure Switch ............... 13
Section 4 Maintenance and
Troubleshooting ..........................14
Maintenance Recommendations ...14
Maintenance Schedule ..................14
Preventive Maintenance ................14
Engine Maintenance ......................14
Battery Replacement (if applicable) 15
Valve Clearance ............................16
Storage ..........................................16
Troubleshooting .............................17
Notes .............................................19
(000004)
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.
(000005)
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.

Operator’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 authorized dealer, or
contact Generac Customer Service at 1-888-
GENERAC, 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 CONTAINED HEREIN
WAS BASED ON MACHINES IN PRODUC-
TION AT THE TIME OF PUBLICATION. GEN-
ERAC RESERVES THE RIGHT TO MODIFY
THIS MANUAL AT ANY TIME.
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 informa-
tion important to a procedure and will be
found within the regular text of this man-
ual.
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
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could 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.
000657
DANGER
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.
(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.
(000104)
DANGER
Electrocution. Water contact with a power source,
if not avoided, will result in death or serious injury.

2 Operator’s Manual for Portable Generator
• For safety reasons, it is recommended that
the maintenance of this equipment be per-
formed by an Authorized Service Facility.
Inspect the generator regularly, and contact
the nearest Authorized Dealer for parts
needing repair or replacement.
• Operate generator only on level surfaces
and where it will not be exposed to exces-
sive moisture, dirt, dust or corrosive vapors.
• When working on this equipment, remain
alert at all times.
• Never work on the equipment when physi-
cally or mentally fatigued.
• Never use the generator or any of its parts
as a step. Stepping on the unit can stress
and break parts, and may result in danger-
ous operating conditions from leaking
exhaust gases, fuel leakage, oil leakage,
etc.
Exhaust and Location Hazards
• This exhaust system must be properly
maintained. Do nothing that might render
the exhaust system unsafe or in noncompli-
ance with any local codes and/or stan-
dards.
• 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.
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.
• Use a ground fault circuit interrupter in any
damp or highly conductive area (such as
metal decking or steel work).
(000116)
DANGER
Electrocution. Turn utility and emergency
power supplies to OFF before connecting power
source and load lines. Failure to do so will result
in death or serious injury.
(000111)
WARNING
Moving Parts. Keep clothing, hair, and appendages
away 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.
(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.
(000142)
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
(000107)
WARNING
Hearing Loss. Hearing protection is recommended
when using this machine. Failure to wear hearing
protection could result in permanent hearing loss.
(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.
(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
(000144)
DANGER
Electrocution. 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.

Operator’s Manual for Portable Generator 3
Fire Hazards
• Wipe up any fuel or oil spills immediately.
Verify that no combustible materials are left
on or near the generator. Keep the area
surrounding the generator clean and free
from debris and keep a clearance of five (5)
feet on all sides to allow for proper ventila-
tion of the generator.
• 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
1. National Fire Protection Association
(NFPA) 70: The NATIONAL ELECTRIC
CODE (NEC) available from www.nfpa.org
2. National Fire Protection Association
(NFPA) 5000: BUILDING CONSTRUC-
TION AND SAFETY CODE available from
www.nfpa.org
3. International Building Code available from
www.iccsafe.org
4. Agricultural Wiring Handbook available
from www.rerc.org , Rural Electricity
Resource Council P.O. Box 309 Wilming-
ton, OH 45177-0309
5. ASAE EP-364.2 Installation and Mainte-
nance of Farm Standby Electric Power
available from www.asabe.org, American
Society of Agricultural & Biological Engi-
neers 2950 Niles Road, St. Joseph, MI
49085
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.
(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.
(000166)
DANGER
Do not overfill fuel tank. Fill to 1/2 in. of 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.
(000142)
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

4 Operator’s Manual for Portable Generator
Section 2 General Information and Setup
Figure 2-1. Features and Controls
TABLE 1. Generator Components
Figure 2-2. Control Panel
000711
000703
15
13
719
10
14
21
22
9
8
12 14
6
20
17
24
1 120 Volt AC, 20 Amp, GFCI Duplex
Receptacle
2 120/240 Volt AC, 30 Amp Locking
Receptacle
3 120 Volt AC, 30 Amp Locking Receptacle
4 20 Amp Circuit Breakers
5 30 Amp Circuit Breaker
6OilDrain
7 Air Filter
8 Decompression Lever
9 Fuel Tank
10 Grounding Lug
11 Start/Run Switch
12 Muffler
13 Fuel Cap/Fuel Gauge
14 Oil Fill (2 locations)
15 Recoil Starter
16 Main 23 Amp Breaker Switch
17 Fuel Return Hose
18 Hour Meter
19 Battery (if equipped)
20 Fuel Filter
21 Engine On/Off Lever
22 Fuel On/Off
23 Voltage Selector Switch
24 Fuel Primer Bulb
000714
11 18
16
3
1
4 5
2
23

Operator’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.
000705
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
TABLE 2. 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 20.8 Amps**
41.7 Amps**
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 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.
5.5 / 6.5 Engine Specifications
Displacement 435 cc (26.5 in3)
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

6 Operator’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
fifteen 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
0000.0
000205
000203
000204
000844

Operator’s Manual for Portable Generator 7
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:
TABLE 3. Contents
TABLE 4. Portability Kit (optional)
3. Call Generac Customer Service 1-888-
GENERAC 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 for any assembly issues or con-
cerns. 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),
rubber foot (K).
2. Slide assembly through frame foot (J). Add
M8 flat washer (N), and secure with M8-
1.25 Locknut (P).
3. Place foot bracket assembly under cradle.
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 (optional) 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 manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
000704
B
L
E
C
D
C
A

8 Operator’s Manual for Portable Generator
.
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
locknut (P).
3. Install handle grips (H).
.
Figure 2-10. Handle Assembly
Battery Installation (if equipped)
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
top of bracket.
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
onto screw.
10. Tighten wing nuts until the lock washers
are compressed to being flat.
NOTE: If the battery is unable to start the
engine, charge it with the 12V charger
included in the accessory box (see the
"Charging a Battery" section for details).
Figure 2-11. Battery Installation
Add Engine Oil
Use high detergent, premium quality motor oil
certified for service class CI-4 or CJ-4. SAE
20W-40 is recommended for general, all tem-
perature use. See Figure 2-12.
Figure 2-12. Oil Recommendations
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 2-13.
Figure 2-13. Remove Dipstick
000710
M
P
P
N
Q
KT
J
000706
F
R
H
P
N
000716
A
B
(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
000578
000115