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

Operator’s Manual for Portable Generator 9
4. Add recommended engine oil.
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 2-14. Remove dipstick and ver-
ify oil level is within safe operating range.
7. Install oil fill cap/dipstick and hand-tighten.
Figure 2-14. Safe Operating Range
Fuel
IMPORTANT! 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.
000116
(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.

10 Operator’s Manual for Portable Generator
Section 3 Operation
Operation and Use Questions
Call Generac customer service at 1-888-GEN-
ERAC 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 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.
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.
(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.
(000178)
DANGER
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so will
result in death or serious injury.
SUPERCEDED
(000179)
DANGER
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.
(000118)
DANGER
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.
000707

Operator’s Manual for Portable Generator 11
• 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
motor.
2. Add to that figure the running watts of all
other connected loads.
The Wattage Reference Guide is provided to
assist in determining how many items the gen-
erator can operate at one time.
NOTE: All figures are approximate. See
data label on appliance for wattage require-
ments.
Table 3. Wattage Reference Guide
Transporting/Tipping of the Unit
Do not operate, store or transport the unit at
an angle greater than 15 degrees.
Device Running
Watts
*Air Conditioner (12,000 Btu) 1700
*Air Conditioner (24,000 Btu) 3800
*Air Conditioner (40,000 Btu) 6000
Battery Charger (20 Amp) 500
Belt Sander (3") 1000
Chain Saw 1200
Circular Saw (6-1/2") 800 to 1000
*Clothes Dryer (Electric) 5750
*Clothes Dryer (Gas) 700
*Clothes Washer 1150
Coffee Maker 1750
*Compressor (1 HP) 2000
*Compressor (3/4 HP) 1800
*Compressor (1/2 HP) 1400
Curling Iron 700
*Dehumidifier 650
Disc Sander (9") 1200
Edge Trimmer 500
Electric Blanket 400
Electric Nail Gun 1200
Electric Range (per element) 1500
Electric Skillet 1250
*Freezer 700
*Furnace Fan (3/5 HP) 875
*Garage Door Opener 500 to 750
Hair Dryer 1200
Hand Drill 250 to 1100
Hedge Trimmer 450
Impact Wrench 500
Iron 1200
*Jet Pump 800
Lawn Mower 1200
Light Bulb 100
Microwave Oven 700 to 1000
*Milk Cooler 1100
Oil Burner on Furnace 300
Oil Fired Space Heater (140,000
Btu) 400
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) 150
Radio 50 to 200
*Refrigerator 700
Slow 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 2000
Television 200 to 500
Toaster 1000 to 1650
Weed Trimmer 500
* Allow 3 times the listed watts for starting these
devices.

12 Operator’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.
3. Turn main breaker switch Off (A). See Fig-
ure 3-2.
4. Turn fuel valve On (B). See Figure 3-2.
.
Figure 3-2. Main Breaker Switch and
Fuel On/Off Valve
5. See Figure 3-3. Switch engine control lever
to Run (B).
.
Figure 3-3. Engine Control Lever
6. See Figure 3-4. Press control panel engine
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: Do not overload the generator.
Also, do not overload individual panel recepta-
cles. These outlets are protected against over-
load 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.
4. Turn fuel valve On (A). See Figure 3-2.
5. See Figure 3-3. Switch engine control lever
to Run (B).
6. Squeeze primer bulb 5-10 times until firm.
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
"Troubleshooting."
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.
000708
B
A
000712
B
000714
D
C
A
(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.

Operator’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 Operator’s Manual for Portable Generator
Section 4 Maintenance and Troubleshooting
Maintenance Recommendations
Regular maintenance will improve perfor-
mance and extend generator life. See a quali-
fied dealer for service.
Generator warranty does not cover items sub-
jected to operator abuse or negligence. To
receive full warranty value, operator must
maintain generator as instructed in this man-
ual, including proper storage as detailed in the
"Storage." section.
NOTE: Call 1-888-GENERAC with ques-
tions 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 adjust-
ments should be each season as detailed
in the following 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 sys-
tem and cause problems. If water enters
generator through cooling air slots, some
water will be retained in voids and crevices
of rotor and stator winding insulation.
Water and dirt buildup on generator inter-
nal windings will decrease insulation resis-
tance of windings.
Engine Maintenance
Engine Oil Recommendations
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 4-1.
Figure 4-1. Oil Recommendations
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
ǂChange oil after first 50 hours of operation,
then every season.
* Change oil and oil filter every month when
operating under heavy load or in high tem-
peratures.
** Clean more often under dirty or dusty oper-
ating conditions. Replace air filter parts if
they cannot be adequately cleaned.
*** Check valve clearance and adjust if neces-
sary after first 50 hours of operation and
every 400 hours thereafter.
(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 °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

Operator’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 4-2. Remove oil fill cap and
wipe dipstick clean.
Figure 4-2. Engine Oil Fill
4. Screw dipstick into filler neck. Verify oil
level is within safe operating range. See
Figure 4-3.
Figure 4-3. Safe Operating Range
5. Add recommended engine oil as neces-
sary.
6. Replace oil fill cap and hand-tighten.
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
plug.
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:
1. See Figure 4-4. Turn knob (A) and remove
air filter cover.
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 Facility at 1-
888-GENERAC.
Figure 4-4. 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 4-5.
1. Disconnect negative (-) battery terminal
FIRST (A).
(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.
000115
000116
(000141)
WARNING
Accidental start-up. Disconnect spark plug wires when
working on unit. Failure to do so could result in death or
serious injury.
000715
A
(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 Operator’s Manual for Portable Generator
2. Disconnect positive (+) battery terminal
SECOND (B).
3. Loosen wing nuts and remove battery
bracket and hardware.
4. Replace battery by following instructions in
the "Battery Installation (if equipped)."
section.
Figure 4-5. Battery Connection
Inspect Muffler and Spark Arrestor
(if equipped)
NOTE: It is a violation of California Public
Resource Code, Section 4442, to use or
operate 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, maintained 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
replacement 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: If uncomfortable about doing
this procedure, or the proper tools are not
available, take generator to the nearest ser-
vice center to have valve clearance adjusted.
Check valve clearance after the first fifty-hours
of operation. Contact Authorized Service
Facility.
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
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.
000716
B
A
(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.

Operator’s Manual for Portable Generator 17
NOTE: Always treat diesel fuel for long
term storage. Use the approved fuel addi-
tive and water abatement material. Test
stored fuel every 90 days and provide addi-
tional treatment if required. Periodically
check and dry abatement material as nec-
essary.
Change Oil
Change engine oil before storage. See
"Change Engine Oil."
Return Engine to Service
1. Refer to the "Before Starting Engine."
section.
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 mini-
mum 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
cord set.
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
in good condition.
4. Contact Authorized Service
Facility.
5. Switch main breaker ON.
6. Switch voltage selector switch
to desired voltage output.
7. See "Know Generator Lim-
its."
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
load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Disconnect shorted electrical
load.
2. See "Know Generator Lim-
its."
3. Contact Authorized Service
Facility.
4. Contact Authorized Service
Facility.
Engine will not start; or
starts and runs rough.
1. Incorrect start sequence.
2. Fuel valve is OFF.
3. Dirty air filter.
4. Out of fuel.
5. Stale or contaminated fuel.
6. Low oil level.
7. Excessive rich fuel mixture.
8. Dirty fuel filter.
9. Air in fuel system.
10. Engine is under electrical load.
1. Review & follow starting pro-
cedure.
2. Turn fuel valve ON.
3. Clean or replace air filter.
4. Fill fuel tank.
5. Drain fuel tank and fill with
fresh fuel.
6. Fill crankcase to correct level.
7. Contact Authorized Service
Facility.
8. Replace fuel filter.
9. Contact Authorized Service
Facility.
10. Remove all equipment from
receptacles. Make sure the
main breaker switch is OFF.

18 Operator’s Manual for Portable Generator
Engine shuts down
during operation.
1. Out of fuel.
2. Low oil level.
3. Fault in engine.
4. Ambient temp too high.
1. Fill fuel tank. Prime fuel sys-
tem. See "Starting Pull Start
Engines." or "Starting Elec-
tric Start Engines."
2. Fill crankcase to correct level.
3. Contact Authorized Service
Facility.
4. Move unit to cooler location
and allow engine to cool
before running again.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
4. Excessive valve lash.
5. Dirty fuel filter.
6. Fuel injector clogged.
1. Reduce load. See "Know
Generator Limits."
2. Clean or replace air filter.
3. Contact Authorized Service
Facility.
4. Contact Authorized Service
Facility.
5. Replace fuel filter.
6. Contact Authorized Service
Facility.
Engine surges or
stumbles.
1. Governor/throttle assembly is
not adjusted properly.
2. Air in fuel system.
1. Contact Authorized Service
Facility.
2. Contact Authorized Service
Facility.
PROBLEM CAUSE CORRECTION