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