Generac Power Systems XT8500EFI User manual

XT8500EFI Portable Generator
Owner’s Manual
Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(1-888-436-3722)
SAVE THIS MANUAL FOR FUTURE REFERENCE
010034
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.
BC

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
Replacement Hazard Labels ........... 3
Section 2 General Information and
Setup .............................................. 5
Know Your Generator ..................... 6
Emissions ........................................ 6
Connection Plugs ............................ 7
Hour Meter ...................................... 7
EFI Fault Indicator Light .................. 7
COsense® ...................................... 7
Remove Contents from Carton ....... 9
Assembly ......................................... 9
Battery Cable Connection ............. 10
Add Engine Oil .............................. 10
Fuel ............................................... 11
Section 3 Operation .................... 12
Operation and Use Questions ....... 12
Before Starting Engine .................. 12
Prepare Generator for Use ............ 12
Grounding the Generator When Used
as a Portable ................................. 12
Know Generator Limits .................. 13
Transporting/Tipping of the Unit .... 14
Starting Pull Start Engines ............ 14
Starting Electric Start Engines ...... 14
Generator Shut Down ................... 14
Low Oil Pressure Shutdown System .
14
Section 4 Maintenance and
Troubleshooting ..........................15
Maintenance ..................................15
Maintenance Schedule ..................15
Preventive Maintenance ................15
Engine Maintenance ......................15
Battery Replacement .....................17
Inspect Muffler and Spark Arrester 17
Valve Clearance ............................18
Storage ..........................................18
Troubleshooting .............................19
Fault Indicator Codes ....................20
(000393a)
WARNING
CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov.

Owner’s Manual for Portable Generator 1
Section 1 Introduction and Safety
Introduction
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.
(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.
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.
000657
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.
(000104)
DANGER
Electrocution. Water contact with a power
source, if not avoided, will result in death
or serious injury.
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. (000116)
DANGER
(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

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.
Electrical Hazards
(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)
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 operating machine, do not
touch hot surfaces. Keep machine away from
combustibles 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)
(000501)
Personal Injury. Fuel lines are pressurized.
Servicing the fuel lines may release high
pressure fuel and could result in death or
serious injury.
WARNING
000406
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.
(000178a)
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so
could result in death or serious injury.
WARNING
(000146)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
(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.

Owner’s Manual for Portable Generator 3
• 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.
• Once generator has been started outside,
connect electrical loads to extension
cord(s) inside.
Fire Hazards
• Allow at least 5 feet of clearance on all
sides of the generator when operating to
prevent overheating and fire.
• Do not operate the generator if connected
electrical devices overheat, if electrical out-
put is lost, if engine or generator sparks, or
if flames or smoke are observed while unit
is running.
• Keep a fire extinguisher near the generator
at all times.
Standards Index
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
6. CSA C22.2 100-14 Electric motors and
generators for installation and use, in
accordance with the Rules of the Cana-
dian Electrical Code
7. ANSI/PGMA G300 Safety and Perfor-
mance of Portable Generators. Portable
Generator Manufacturer’s Association,
www.pgmaonline.com
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.
Replacement Hazard Labels
The following replacement hazard labels are
available free from Generac:
•0H0115C
(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.
CAUTION
Equipment damage. Do not power sensitive electronic devices
(computers, televisions, microwaves...) when Idle Control switch is
ON (if equipped). Lower engine rpm operation results in low
voltage/frequency and may damage electronic devices.
(000591)
(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!
DO NOT FILL
ABOVE LIP!
DO NOT OVERFILL TANK
ALWAYS ALLOW ROOM FOR FUEL EXPANSION
DO NOT FILL WHILE RUNNING
NO LLENE TANQUE EXCESIVAMENTE
SIEMPRE DEJE ESPACIO PARA LA EXPANSIÓN DEL COMBUSTIBLE
NO LLENE MIENTRAS ESTÉ FUNCIONANDO
NE PAS TROP REMPLIR LE RÉSERVOIR
TOURJOURS ALLOUR DE L’ESPACE POUR L’EXPANSION DE CARBURANT
NE PAS REMPLIR PENDANT QUE L’APPAREL FONTIONNE
NO LLENE
POR ENCIMA
DEL REBORDE
NE PAS REMPLIR
AU-DESSUS
DE LA LÈVRE
¡ADVERTENCIA!
AVERTISSEMENT!

4 Owner’s Manual for Portable Generator
• 0H8251B (Vertical CO Warning Decal)
• 0H4635C
• 10000033027 (Exhaust Direction User
Action Label)
5 FEET (1.5m)
MINIMUM
FROM OBJECTS
CARBON
MONOXIDE
CO
READ
MANUAL
!
!
!

Owner’s Manual for Portable Generator 5
Section 2 General Information and Setup
Figure 2-1. Features and Controls
Generator Components
Figure 2-2. Control Panel
21
12
15
13
16
9
18
14
23
10
19 20
17
11
22
010208
010034
24
26
25
29
1 Key Switch Ignition
2 120 Volt AC, 20 Amp GFCI Duplex
Receptacle
3 120/240 Volt AC, 30 Amp Locking
Receptacle
4 Circuit Breakers (AC)
5 Battery Charger Input
6 Hour Meter
7 EFI Fault Indicator Light
8Fuse
9 Grounding Lug
10 Spark Arrestor
11 Muffler
12 Fuel Cap
13 Recovery Hose
14 Carbon Canister
15 Air Filter
16 Recoil Starter
17 Handle
18 Fuel Gauge
19 Roll Over Valve
20 Fuel Tank
21 Oil Drain
22 Oil Fill/Dipstick
23 Battery
24 Fuel Pump
25 Ignition Keys
26 Battery Charger
27 COsense® Shut-Off (RED)
28 COsense® Fault (YELLOW)
29 Oil Filter
010035
1
8 5
4
7
6
4
2 3
28
27

6 Owner’s Manual for Portable Generator
Figure 2-3. Unit Identification Label
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
this engine/equipment to comply with exhaust
and evaporative emissions standards. Locate
the emissions compliance decal on the engine
to determine applicable standards. See the
included emissions warranty for emissions
warranty information. Follow the maintenance
specifications in this manual to ensure the
engine complies with applicable emissions
standards for the duration of the product’s life.
010210
(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.
Product Specifications
Generator Specifications
Rated Power 8.5 kW**
Surge Watts 10 KVA**
Rated AC Voltage 120/240
Rated AC Load (120 Volt / 240 Volt) 70.8 / 35.4 Amps**
Rated Frequency 60 Hz @ 3600 RPM
Phase Single Phase
Unit Weight (Dry) 214 lbs. (97 kg)
** Operating Temperature Range: -7 deg. C (20 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.
Engine Specifications
Displacement 459 cc
Spark Plug Part No. 0K20670117
Spark Plug Type F7RTC or Equivalent
Spark Plug Gap 0.028-0.031 inch (0.70-0.80mm)
Gasoline Capacity 30.3 L (8.0 U.S. gallons)
Oil Type See chart in Add Engine Oil.
Oil Capacity 1.0 L (1.05 qt.)
Run Time at 50% Load 9 Hours
* Go to www.generac.com or contact an IASD for replacement parts.

Owner’s Manual for Portable Generator 7
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 2-4. 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). It also pro-
vides protection with a Ground Fault Circuit
Interrupter with a press to TEST and RESET
button.
Figure 2-4. 120 VAC, 20 Amp, GFCI 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 one 30 Amp
2-pole circuit breaker.
Figure 2-5. 120/240 VAC, 30 Amp Receptacle
NEMA L14-30R
Hour Meter
The Hour Meter tracks hours of operation for
scheduled maintenance. See Figure 2-6.
• The SVC display will illuminate one hour
before and one hour after each 100 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.
• 100 hours - SVC — Change oil, oil filter, air
filter, and spark plug. Clean spark arrestor
screen (every 100 hrs).
NOTE: The hour glass icon will flash when the
engine is running. This signifies the meter is
recording hours of operation.
Figure 2-6. Hour Meter
EFI Fault Indicator Light
See Fault Indicator Codes. This unit is
equipped with an EFI Fault indicator light, that
will flash diagnostic codes in the event of a
failure for easy troubleshooting.
There are 3 levels of fault codes:
1. Level 1 will flash and the generator will
run. There may be a slight impact on per-
formance.
2. Level 2 will flash and the generator will
shut down if multiple errors are detected.
3. Level 3 will shut down the generator imme-
diately.
Call Generac Customer Service at 1-888-
GENERAC (1-888-436-3722) for assistance.
COsense®
Carbon Monoxide (CO) Detection
and Shut-off System (if equipped)
The COsense® module monitors for the accu-
mulation of poisonous CO gas found in engine
exhaust when the generator is running. If
COsense® detects increasing levels of CO
gas, it automatically shuts off the engine.
COsense® only monitors when the engine is
running. Generators are intended to be used
outdoors, far from occupied buildings and the
000203
000204
0000.0
000205

8 Owner’s Manual for Portable Generator
exhaust pointed away from personnel and
buildings. However, if mis-used and operated
in a location that results in the accumulation of
CO, like indoors or in a partially enclosed
area, COsense® shuts off the engine, notifies
the user of what has happened and directs the
user to read the instruction action label for
steps to take. See Figure 2-7. COsense® is
not a substitute for an indoor carbon monox-
ide alarm.
See Figure 2-8. After a shut-off, a blinking
RED light in the COsense® badge on the side
of the generator provides notification that the
generator was shut off due to an accumulating
CO hazard. The RED light will blink for at least
five minutes after a CO shut-off. Move the
generator to an open, outdoor area and point
the exhaust away from people and occupied
buildings. Once relocated to a safe area, the
generator can be restarted and the proper
electrical connections made to supply electri-
cal power. The RED light will stop blinking
automatically upon engine re-start. Introduce
fresh air and ventilate the location where the
generator had shut down.
See Figure 2-8. If a COsense® system fault
has occurred and no longer provides protec-
tion, the portable generator is shut off auto-
matically and the YELLOW light will blink for at
least five minutes in the COsense® badge to
notify the user of the fault. The COsense®
module can only be diagnosed and repaired
by a trained technician at the dealer. The gen-
erator can be re-started, but may continue to
shut-off.
COsense® will detect the accumulation of
Carbon Monoxide from other fuel burning
sources such as engine powered tools or pro-
pane heaters used in the area of operation.
For example, if another generator is used and
the exhaust is pointed at a COsense®
equipped generator, COsense® may initiate a
shut-off due to rising CO levels. This is not an
error. Hazardous Carbon Monoxide has been
detected. The user must take action to move
and re-direct these devices to better dissipate
Carbon Monoxide far away from personnel
and occupied buildings.
Figure 2-7. Instruction Action Label
Figure 2-8. Instruction Badge
!
!
!
010211
!
®
010212

Owner’s Manual for Portable Generator 9
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:
3. Call 1-888-GENERAC (1-888-436-3722) with
the unit model and serial number for any
missing carton contents.
4. Record model, serial number, and date of
purchase on front cover of this manual.
Accessories
Assembly
Call 1-888-GENERAC (1-888-436-3722) for
any assembly issues or concerns. Please
have model and serial number available.
The following tools are required to install the
accessory kit.
• Ratchet Wrench (1)
• 8mm Wrench (2)
• 10mm Wrench (1)
• 13mm Wrench (1)
• 8mm Socket (1)
• 12mm Socket (1)
• 13mm Socket (1)
• Needle Nosed Pliers (1)
NOTE: The wheels are not intended for over-
the-road use.
See Figure 2-9.
Install wheels as follows:
1. Slide axle pin (D) through the wheel (C)
and generator frame axle holes.
2. Slide one 5/8" flat washer (B) onto axle
and secure with cotter pin (A). Repeat on
opposite side.
Figure 2-9. Wheel Assembly
See Figure 2-10.
Install frame foot assembly as follows:
1. Slide M8 hex bolts (G) through holes in
frame.
2. Slide frame foot (E) on to hex head bolts
(G).
3. Install locking flange nuts (F) and tighten
with a ratchet, 12mm socket and 13mm
wrench.
Install gasket and control guard as follows:
1. Place gasket (H) and control guard (J) in
place against side panel opening.
2. Loosely install Allen screws (K). Tighten
with 4mm Allen wrench.
Item Qty.
Main Unit 1
Owner’s Manual 1
Product Registration Card 1
Warranty and Emission Sheets 1
Quart SAE Oil 1
Battery Charger 1
Oil Funnel 1
Hardware Bag Qty.
Cotter Pin (A) 2
Washers (B) 2
Never-flat Wheels (C) 2
Axle Pins (D) 2
Frame Foot Assembly (E) 2
Hex Flanged Nuts (M8) (F) 4
Hex Bolts (M8) (G) 4
Gasket (H) 1
Control Guard (J) 1
Allen Screw (4 mm) (K) 4
Handle Assembly (L) (not in hardware
bag)
1
Hex Bolt (M8 x 55 mm) (M) 2
Nylon Washer (N) 4
Hex Lock Nut (P) 2
Allen Hex Wrench (4 mm) not shown 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.
A
D
C
B010213

10 Owner’s Manual for Portable Generator
Figure 2-10. Frame Foot and Control Guard
Assembly
Install the handle (L) as follows:
1. Place handle brackets between the frame
tabs.
2. Slide hex bolt (M) through frame, nylon
washers (N), and handle bracket. Place
washers (N) on each side of the handle
brackets and frame.
3. Install hex lock nut (P) and tighten with a
ratchet, 13mm socket and 13mm wrench.
Figure 2-11. Handle Assembly
Battery Cable Connection
The unit has been shipped with the battery
cables disconnected.
See Figure 4-5. You will need two 8mm box
wrenches to connect the battery cables.
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: With key in RUN position, the fault
indicator light will flash rapidly if battery power
is too low and the engine will not start. Charge
battery with appropriate 12V charger.
Add Engine Oil
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. Verify oil fill area is clean.
4. Remove oil fill cap/dipstick and wipe dip-
stick clean. See Figure 2-12.
Figure 2-12. Remove Dipstick
5. Slowly pour oil into oil fill opening. DO
NOT overfill. 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.
.
NOTE: Some units have more than one oil fill
location. It is only necessary to use one oil fill
point.
E
J
G
F
K
H
010043
N
M
LP
010214
(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.
000115
SAE 30
10W-30
Synthetic 5W-30
000399

Owner’s Manual for Portable Generator 11
6. Thread dipstick into oil filler neck. Oil level
is checked with dipstick fully installed.
7. See Figure 2-13. Remove dipstick and ver-
ify oil level is within safe operating range.
Figure 2-13. Safe Operating Range
8. 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 E85.
• 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-
lated area.
3. Clean area around fuel cap and remove
cap slowly.
4. See Figure 2-14. Slowly add recom-
mended fuel. Do not fill above inner lip (A).
5. Install fuel cap.
Figure 2-14. 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 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 emp-
tied 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.
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.
(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.
000230
A

12 Owner’s Manual for Portable Generator
Section 3 Operation
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.
There is a permanent conductor between the
generator (stator winding) and frame. See Fig-
ure 3-1.
• Neutral Bonded to Frame
Figure 3-1. Grounding the Generator
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.
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/
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.
010036

Owner’s Manual for Portable Generator 13
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 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 approximately 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 selecting electrical devices to con-
nect to the generator:
1. Calculate 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 requirements.
Wattage Reference Guide
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 (7-1/4") 1250 to 4000
*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

14 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
IMPORTANT NOTE: Electronic system
requires 10V minimum at battery connec-
tions for pull starting. The engine will not
start unless the battery connections have
the required voltage for the electronics and
fuel pump. If the EFI fault indicator light
flashes rapidly with key in RUN position,
the generator will not start. Charge battery
prior to starting.
1. Unplug all electrical loads from the unit's
receptacles before starting engine.
2. Place generator on a level surface.
3. Rotate key to RUN. The RUN light will stay
on. See Figure 3-2.
.
Figure 3-2. Rotate Key
4. Firmly grasp recoil handle and pull slowly
until increased resistance is felt. Pull rap-
idly up and away.
NOTE: Running the generator will charge the
battery.
Do not overload generator or individual panel
receptacles. These outlets are overload pro-
tected by 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 Lim-
its 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 key to RUN, wait 1 second. Rotate
key to START until engine starts. See Fig-
ure 3-2.
NOTE: The key will automatically return to
RUN and the fault light will turn off.
Generator Shut Down
1. Shut off all loads and unplug electrical
loads from the unit's receptacles.
2. Let engine run at no-load for several min-
utes to stabilize internal temperatures of
engine and generator.
3. Turn key to OFF.
NOTE: Leaving key in the RUN position will
drain battery power. Turn key OFF for any pur-
pose.
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.
If the engine shuts down and there is sufficient
fuel, check engine oil level.The engine will not
run if the oil is below proper level.
See Inspect Engine Oil Level.
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.
(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.
010216
(000136)
CAUTION
Equipment and property damage. Disconnect electrical
loads prior to starting or stopping unit. Failure to do so
could result in equipment and property damage.
(000136)
CAUTION
Equipment and property damage. Disconnect electrical
loads prior to starting or stopping unit. Failure to do so
could result in equipment and property damage.

Owner’s Manual for Portable Generator 15
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
At Each Use
Check engine oil level
Every 3 months
Charge battery for 12 hours
Every 100 Hours or Every Year*
Change oil ǂ
Clean oil filter
Clean spark arrestor screen
Every Year
Check valve clearance***
Every 200 Hours or Every Year
Replace spark plug
Inspect/clean air cleaner filter**
ǂChange oil after first 25 hours of operation,
then every year.
* 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 300 hours thereafter.
(000501)
Personal Injury. Fuel lines are pressurized.
Servicing the fuel lines may release high
pressure fuel and could result in death or
serious injury.
WARNING
(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.

16 Owner’s Manual for Portable Generator
and funnel. These kits can be obtained from
an Independent Authorized Service Dealer
(IASD).
Inspect Engine Oil Level
Inspect engine oil level prior to each use, or
every 8 hours of operation.
1. Place unit 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.
4. See Figure 4-1. Remove oil fill cap/dipstick
and wipe dipstick clean.
Figure 4-1. Engine Oil Fill
5. Thread dipstick into filler neck. Oil level is
checked with dipstick fully installed.
6. See Figure 4-2. Remove dipstick and verify
oil level is within safe operating range.
Figure 4-2. Safe Operating Range
7. Add recommended engine oil as neces-
sary. See Add Engine Oil.
8. Install oil fill cap/dipstick 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 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
plug.
4. Remove oil fill cap/dipstick.
5. Remove oil drain plug and drain oil com-
pletely into a suitable container.
6. Install oil drain plug and tighten securely.
7. Remove crankcase oil filter and wipe off
excess oil.
8. Clean filter element with aerosol carbure-
tor or brake cleaner, solvent/degreasing
agent, or warm water and dish soap.
9. Use compressed air to remove excess
cleaning agent or let filter air dry. Reinstall
oil filter.
10. Slowly pour oil into oil fill opening until oil
level is in safe operating range on dipstick.
DO NOT overfill.
11. Install oil fill cap/dipstick and hand tighten.
12. Wipe up any spilled oil.
13. 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)
and filter (B).
2. Wash filter in soapy water. Squeeze filter
dry in clean cloth (do not twist). If too dirty,
replace with new filter.
SAE 30
10W-30
Synthetic 5W-30
000399
(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.
(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.

Owner’s Manual for Portable Generator 17
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).
Figure 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. See Figure 4-4. Inspect electrode gap with
feeler gauge and reset spark plug gap to
0.028-0.031 in (0.70-0.80 mm).
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
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 the battery.
1. See Figure 4-5. Disconnect and remove
the battery connecting hardware (8mm)
and BLACK wire (B) from the battery’s
NEGATIVE (-) terminal.
2. Remove the red rubber boot (A) and dis-
connect the battery connecting hardware
(8mm) and RED wire (A) from the battery’s
POSITIVE (+) terminal.
3. Remove screws and bracket from battery
tray to remove battery.
4. Install new battery and replace battery
bracket and screws.
5. Connect RED wire to the POSITIVE (+)
battery terminal (A). Slide rubber boot over
connection hardware.
6. Connect BLACK wire to the NEGATIVE (-)
battery terminal (B).
Figure 4-5. Battery Connection
Battery Charger Fuse Replacement
The charging port is protected by a 3.0 Amp
replaceable in-line fuse. If the charger is not
charging the battery, check the fuse.
NOTE: To order a new fuse, contact the near-
est IASD at 1-888-GENERAC (1-888-436-
3722).
The battery charger fuse is located behind the
control panel.
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.
B
A
010217
000211
(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.
B
A
006476
(000163a)
WARNING
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can
cause burns and blindness. If electrolyte contacts
skin or eyes, flush with water and seek immediate
medical attention.
WARNING
(000228)
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.

18 Owner’s Manual for Portable Generator
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.
Inspect Spark Arrester Screen
1. Loosen clamp (A) and remove screw. See
Figure 4-6.
2. Inspect screen (B) and cone (C). Replace
if torn, perforated or otherwise damaged. If
screen is not damaged, clean with com-
mercial solvent.
3. Replace spark arrestor cone (C) and
screen (B). Secure with clamp and screw.
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 — 0.15 ± 0.02 mm (0.006" ± 0.001"
inch)
• Exhaust — 0.20 ± 0.02 mm (0.008" ±
0.001" 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.
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.
(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.
000586
A
B
C
(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.