Generac Portable Generator 005605 0 User Manual

XP Professional Series  
Portable Generator  
Owner’s  
Manual  
• SAFETY  
• ASSEMBLY  
• OPERATION  
• TROUBLESHOOTING  
• WARRANTY  
COMMERCIAL • INDUSTRIAL • RESIDENTIAL  
MODELS: 005606-0 XP8000E  
005605-0 XP6500E  
AUTHORIZED DEALER SUPPORT:  
8,000 Watt Portable Generator  
6,500 Watt Portable Generator  
or  
1-888-GENERAC  
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We also strongly recommend instructing other users to properly  
start and operate the unit. This prepares them if they need to  
operate the equipment in an emergency.  
INTRODUCTION  
Thank you for purchasing this model by Generac Power Systems,  
Inc. This model is a compact, high performance, air-cooled,  
engine driven generator designed to supply electrical power to  
operate electrical loads where no utility power is available or in  
place of utility due to a power outage.  
DANGER  
Using a generator indoors WILL KILL YOU IN  
MINUTES. Exhaust contains carbon monoxide, a  
poison gas you cannot see or smell.  
READ THIS MANUAL THOROUGHLY  
If any portion of this manual is not understood, contact the  
nearest Authorized Dealer for starting, operating and servicing  
procedures.  
NEVER use in the home, or in partly enclosed  
areas such as garages. ONLY use outdoors and  
far from open windows, doors, vents, and in an  
area that will not accumulate deadly exhaust  
gas.  
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 hazardous if performed incorrectly or  
carelessly. Observe them carefully. Their definitions are as  
follows:  
DANGER  
Using a generator indoors WILL KILL YOU IN MINUTES. Exhaust contains  
carbon monoxide, a poison gas you cannot see or smell.  
DANGER  
After this heading, read instructions that, if  
not strictly complied with, will result in serious  
personal injury, including death and/or property  
damage.  
NEVER use in the home or in partly enclosed areas such as garages.  
ONLY use outdoors and far from open windows, doors and vents.  
Always disconnect the spark plug wire and  
place the wire where they cannot contact the  
After this heading, read instructions that, if not  
strictly complied with, may result in serious  
personal injury and/or property damage.  
spark plug to prevent accidental starting when  
setting up, transporting, adjusting or making  
repairs to the generator.  
• The generator produces dangerously high voltage that can  
cause extremely hazardous electrical shock. Avoid contact with  
bare wires, terminals, etc. Never permit any unqualified person  
to operate or service the generator.  
• Never handle any kind of electrical cord or device while  
standing in water, while barefoot or while hands or feet are wet.  
Dangerous electrical shock will result.  
• The National Electric Code requires the frame and external  
electrically conductive parts of the generator be properly  
connected 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).  
• Do not use worn, bare, frayed or otherwise damaged electrical  
cord sets with the generator.  
• Operate generator only on level surfaces and where it will not be  
exposed to excessive moisture, dirt, dust or corrosive vapors.  
• Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE.  
Do not permit smoking, open flames, sparks or heat in the  
vicinity while handling gasoline. Avoid spilling gasoline on a hot  
engine. Comply with all laws regulating storage and handling  
of gasoline.  
After this heading, read instructions that, if not  
strictly complied with, could result in damage to  
equipment and/or property.  
NOTE:  
After this heading, read explanatory statements that require  
special emphasis.  
These safety warnings cannot eliminate the hazards that they  
indicate. Common sense and strict compliance with the special  
instructions while performing the service are essential to preventing  
accidents.  
Four commonly used safety symbols accompany the DANGER,  
WARNING and CAUTION blocks. The type of information each  
indicates is as follows:  
This symbol points out important safety  
information that, if not followed, could endanger  
personal safety and/or property of others.  
This symbol points out potential explosion  
hazard.  
This symbol points out potential fire hazard.  
This symbol points out potential electrical shock  
hazard.  
• Never add fuel while unit is running or hot. Allow engine to cool  
entirely before adding fuel.  
The operator is responsible for proper and safe use of the  
equipment. We strongly recommend that the operator read this  
manual and thoroughly understand all instructions before using  
the equipment.  
Do not overfill the fuel tank. Always allow room  
for fuel expansion. If tank is over-filled, fuel can  
overflow onto a hot engine and cause FIRE or  
an EXPLOSION.  
1
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IMPORTANT SAFETY INSTRUCTIONS  
Portable Generator System  
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit's  
installation site. Safety should be stressed to all operators and potential operators of this equipment.  
• Never store generator with fuel in tank where gasoline vapors  
Study these SAFETY RULES carefully before installing, operating  
or servicing this equipment. Become familiar with this manual  
and with the unit. The generator can operate safely, efficiently and  
reliably only if it is properly installed, operated and maintained.  
Many accidents are caused by failing to follow simple and  
fundamental rules or precautions.  
might reach an open flame, spark or pilot light (as on a furnace,  
water heater or clothes dryer). FIRE or EXPLOSION may  
result.  
• Generator exhaust gases contain DEADLY carbon monoxide gas.  
This dangerous gas, if breathed in sufficient concentrations, can  
cause unconsciousness or even death. Operate this equipment  
only in the open air where adequate ventilation is available.  
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, therefore, not all inclusive.  
If using a procedure, work method or operating technique that the  
manufacturer does not specifically recommend, ensure that it is  
safe for others. Also make sure the procedure, work method or  
operating technique utilized does not render the generator unsafe.  
DANGER  
NEVER operate the generator indoors, in a garage, near an  
open window, or in an area that could accumulate exhaust  
gas.  
• Allow at least five (5) feet, or greater, of clearance on all sides  
of generator or damage could be done to the unit. Never operate  
the unit inside any room or enclosure.  
• Never start or stop the unit with electrical loads connected  
to receptacles AND with connected devices turned ON. Start  
the engine and let it stabilize before connecting electrical  
loads. Disconnect all electrical loads before shutting down the  
generator.  
• Do not insert objects through unit's cooling slots.  
• Never operate generator: in rain; indoors or in any enclosed  
compartment; if connected electrical devices overheat; if  
electrical output is lost; if engine or generator sparks; if flames  
or smoke are observed while unit is running; if unit vibrates  
excessively.  
DANGER  
Despite the safe design of this generator,  
operating this equipment imprudently,  
neglecting its maintenance or being careless  
can cause possible injury or death. Permit only  
responsible and capable persons to operate or  
maintain this equipment.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators. Do not touch hot surfaces such as  
the muffler. Severe burns can occur on contact.  
Allow generator to cool before touching.  
NOTE:  
This generator is equipped with a spark arrestor muffler. The  
spark arrestor must be maintained in effective working order by  
the owner/ operator. In the State of California, a spark arrestor  
is required by law (Section 4442 of the California Public  
Resources Code). Other states may have similar laws. Federal  
laws apply on federal lands.  
GENERAL HAZARDS   
• Never operate in an enclosed area or indoors.  
• For safety reasons, the manufacturer recommends that the  
maintenance of this equipment is carried out by an Authorized  
Dealer.  
• The engine exhaust fumes contain carbon monoxide, which  
can be DEADLY. This dangerous gas, if breathed in sufficient  
concentrations, can cause unconsciousness or even death. This  
exhaust system must be properly maintained. Do nothing that  
might render the exhaust system unsafe or in noncompliance  
with any local codes and/or standards.  
• Keep hands, feet, clothing, etc., away from drive belts, fans,  
and other moving or hot parts. Never remove any fan guard  
while the unit is operating.  
WARNING  
The engine exhaust from this product contains  
chemicals known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
• Adequate, unobstructed flow of cooling and ventilating air  
is critical to correct generator operation. Do not alter the  
installation or permit even partial blockage of ventilation  
provisions, as this can seriously affect safe operation of the  
generator. The generator MUST be operated outdoors.  
WARNING  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
2
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IMPORTANT SAFETY INSTRUCTIONS  
Portable Generator System  
• When working on this equipment, remain alert at all times. Never  
work on the equipment when physically or mentally fatigued.  
• Inspect the generator regularly, and contact the nearest  
Authorized Dealer for parts needing repair or replacement.  
• Before performing any maintenance on the generator, disconnect  
its battery cables to prevent accidental start up. Disconnect the  
cable from the battery post indicated by a NEGATIVE, NEG or  
(–) first. Reconnect that cable last.  
• 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  
dangerous operating conditions from leaking exhaust gases,  
fuel leakage, oil leakage, etc.  
FIRE HAZARDS   
• For fire safety, the generator must be operated and maintained  
properly. Operation must always comply with applicable codes,  
standards, laws and regulations. Adhere strictly to local,  
state and national electrical and building codes. Comply with  
regulations the Occupational Safety and Health Administration  
(OSHA) has established. Also, ensure that the generator is  
operated in accordance with the manufacturer’s instructions  
and recommendations. Do not alter the construction of the  
generator or change controls which might create an unsafe  
operating condition.  
• Do NOT operate generator in the rain.  
• Keep a fire extinguisher near the generator at all times.  
Extinguishers rated ABC” by the National Fire Protection  
Association are appropriate for use on the standby electric  
system. Keep the extinguisher properly charged and be familiar  
with its use. If there are any questions pertaining to fire  
extinguishers, consult the local fire department.  
• Gasoline is extremely FLAMMABLE. Never add fuel while unit is  
running or hot. Allow engine/unit to cool entirely before adding  
fuel. Do not over fill fuel tank. Allow room for fuel expansion.  
Wipe up fuel spills immediately. If tank is overfilled, fuel can  
overflow onto a hot engine and cause FIRE. Never fill fuel tank  
indoors.  
ELECTRICAL HAZARDS   
• All generators covered by this manual produce dangerous  
electrical voltages and can cause fatal electrical shock. Utility  
power delivers extremely high and dangerous voltages as does  
the generator when it is in operation. Avoid contact with bare  
wires, terminals, connections, etc., while the unit is running.  
Ensure all appropriate covers, guards and barriers are in place  
before operating the generator. If work must be done around  
an operating unit, stand on an insulated, dry surface to reduce  
shock hazard.  
• Do not handle any kind of electrical device while standing  
in water, while barefoot, or while hands or feet are wet.  
DANGEROUS ELECTRICAL SHOCK MAY RESULT.  
• The National Electrical Code (NEC) requires the frame and  
external electrically conductive parts of the generator to be  
connected to an approved earth ground. Local electrical codes  
also may require proper grounding of the generator electrical  
system.  
EXPLOSION HAZARDS   
• Do not smoke around the generator. Wipe up any fuel or oil spills  
immediately. Ensure that no combustible materials are left on or  
near the generator, as FIRE or EXPLOSION may result. Keep the  
area surrounding the generator clean and free from debris.  
• Gasoline is extremely EXPLOSIVE.  
STANDARDS INDEX  
• In case of accident caused by electric shock, immediately shut  
down the source of electrical power. If this is not possible,  
attempt to free the victim from the live conductor. AVOID  
DIRECT CONTACT WITH THE VICTIM. Use a non-conducting  
implement, such as a rope or board, to free the victim from the  
live conductor. If the victim is unconscious, apply first aid and  
get immediate medical help.  
• Never wear jewelry when working on this equipment. Jewelry  
can conduct electricity resulting in electric shock, or may get  
caught in moving components causing injury.  
In the absence of pertinent standards, codes, regulations and laws,  
the published information listed below may be used as a guideline  
for operation of this equipment. Always reference the latest revision  
available for the standards listed.  
1. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC  
CODE.  
2. Article X, NATIONAL BUILDING CODE, available from the  
American Insurance Association, 85 John Street, New York,  
N.Y. 10038.  
3. AGRICULTURAL WIRING HANDBOOK, available from the Food  
and Energy Council, 909 University Avenue, Columbia, MO  
65201.  
4. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF  
FARM STANDBY ELECTRICAL SYSTEMS, available from the  
American Society of Agricultural Engineers, 2950 Niles Road,  
St. Joseph, MI 49085.  
5. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS  
CODE.  
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Section 1 – General Information  
Portable Generator System  
• Open end of accessory box to remove contents.  
• Slide the axle through the holes on the axle brackets.  
• Slide one wheel with flat washer to the outside.  
• Insert retaining pin and using pliers, bend out the ends to  
prevent the pins from falling out of the axle. Repeat for other  
side.  
1.1 UNPACKING  
• Remove all packaging material.  
• Remove separate accessory box.  
• Remove carton off the generator.  
1.1.1 ACCESSORY BOX  
Check all contents (Figure 1). If any parts are missing or damaged  
locate an authorized dealer at 1-888-436-3722.  
• Lift the engine side of the generator to pull out the insert.  
Figure 2 – Wheel Assembly  
Contents include:  
• Wheel Axle  
• Oil Funnel  
• 2 – Washers  
• 2 – Cotter Pins  
• 2 – Wheels  
• Extension Cord  
• Spark Plug  
• Air Filter  
• Oil Filte  
• 12 Volt Adaptor Plug Charger  
• Spark Plug Wrench  
• Shop Towel  
Flat Washer  
Cotter Pin  
®
• 1 oz. Pouch of Stabil  
• 2 – 1 Quart SAE 30 Oil  
Bottles  
Figure 1 – Accessory Boxes  
Axle  
Wheel  
1.2.2 BATTERY CONNECTION  
NOTE:  
The battery shipped with the generator has been fully charged.  
A battery may loose some of it's charge when not in use for  
prolonged periods of time.  
This wire was deliberately left detached for shipping. To operate  
unit, attach this wire to terminal on starter motor as shown. Do not  
overtighten. See Figure 3.  
Figure 3 - Battery Connections  
1.2 ASSEMBLY  
Read entire Owner's Manual before attempting to assemble or  
operate the generator. The generator requires some assembly  
prior to using it. If problems arise when assembling the generator,  
please call the Generator Helpline at 1-888-436-3722.  
Starter Wire  
(RED to Contactor)  
1.2.1 ASSEMBLING THE WHEEL KIT  
The wheel kit is designed to greatly improve the portability of the  
generator. A pair of pliers is needed for assembling the wheel kit.  
NOTE:  
The wheel kit is not intended for over-the-road use.  
• Refer to Figure 2 and install the wheel kit as follows:  
• Generator will be resting on an accessory box after box is cut  
back.  
4
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Section 2 – Operation  
Portable Generator System  
14. Handles – Pivot and retract for storage. Press the spring-  
loaded button to move handles (14A).  
15. Gas Cap – Fuel fill location.  
16. Fuel Gauge – Shows fuel level in tank.  
17. Oil Fill – Check oil level and add oil here.  
18. Recoil Starter – Use to start engine manually.  
19. Spark Plug – Ignites Air/Fuel Mixture (End & Side panel  
removed - 4 Torx Screws "T27").  
2.1 KNOW THE GENERATOR  
Read the Owner’s Manual and Safety Rules before operating  
this generator.  
Compare the generator to Figures 4 through 6 to become  
familiarized with the locations of various controls and adjustments.  
Save this manual for future reference.  
1. Battery Charger Input – This receptacle allows the capability  
to recharge the 12 volt DC storage battery provided with  
the 12 Volt Adaptor Plug Charger which is included in the  
Accessory Box. Located behind the battery charger input is  
a 1.50 Amp in-line fuse which is inside the control panel to  
protect the battery.  
Figure 5 - Generator Controls  
15  
2. 120 Volt AC, 20 Amp, GFCI Duplex Receptacle – Supplies  
electrical power for the operation of 120 Volt AC, 20 Amp,  
single-phase, 60 Hz electrical lighting, appliance, tool and  
motor loads. It also provides protection with an Integral  
Ground Fault Circuit Interrupter, complete with a press to  
"Test" and "Reset" button.  
16  
3. 120/240 Volt AC, 30 Amp Locking Receptacle – Supplies  
electrical power for the operation of 120 and/or 240 Volt AC,  
30 Amp, single-phase, 60 Hz, electrical lighting, appliance,  
tool and motor loads.  
13  
4. Circuit Breakers (AC) – Each 20 Amp receptacle is provided  
with a push-to-reset circuit breaker to protect the generator  
against electrical overload. The 30 Amp receptacle is protected  
by a 2-pole lever circuit breaker rated at 27.1 Amps for the  
XP6500E and 30 Amps for the XP8000E.  
5. Hourmeter – Provides operating hours for Service Intervals.  
6. Fuel Shut Off – Valve between fuel tank and carburetor. Turn  
off and run carburetor out of fuel for extended storage.  
7. Choke Knob – Used when starting a cold engine (Pull/Push).  
8. Start/Run/Stop Switch – Controls the operation of the  
generator.  
19  
11  
12  
Figure 6 - Generator Controls  
9. Air Cleaner – Filters intake air as it is drawn into the engine.  
10. Fuel Tank – Tank holds 9 U.S. gallons of fuel.  
11. Grounding Lug – Ground the generator to an approved earth  
ground here. See "Grounding the Generator" for details.  
12. Muffler – Includes the spark arrestor and quiets the engine.  
13. Battery – Powers the electric starter (End panel removed - 4  
Torx Screws "T27").  
10  
14A  
Figure 4 - Control Panel  
7
8
2
3
1
9
17  
6
4
5
18  
14  
5
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Section 2 – Operation  
Portable Generator System  
2.3.2 120/240 VAC, 30 AMP RECEPTACLE  
2.2 HOURMETER  
Use a NEMA L14-30 plug with this receptacle (rotate to lock/  
unlock). Connect a suitable 4-wire grounded cord set to the plug  
and to the desired load. The cord set should be rated for 250 Volts  
AC at 30 Amps (or greater) (Figure 8).  
The Hourmeter tracks hours of operation for scheduled  
maintenance:  
There will be a one time break in "CHG OIL" message that flashes  
with the elapsed time in hours and tenths after the first 30 hours  
of operation.  
Figure 8 - 120/240 VAC, 30 Amp Receptacle  
This message will actually begin flashing at 29 hours and disable  
itself at 31 hours providing a two hour window to perform the  
service.  
There will be a subsequent "CHG OIL" message every 100 hours.  
The message will flash one hour before and one hour after each  
100 hour interval, again providing a two hour window to perform  
service.  
Every 200 hours the "SVC" icon on the lower left hand corner of  
the display will flash. The message will flash one hour before and  
one hour after each 200 hour interval providing a two hour window  
to perform service.  
When the hour meter is in the Flash Alert mode, the maintenance  
message will always 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 resets itself.  
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 either a  
27 Amp (6.5kW) or a 30 Amp (8.0kW) circuit breaker.  
• 30 hours - CHG OIL — Break-in Interval (First 30 hrs only)  
• 100 hours - CHG OIL — Oil Change Interval (Every 100 hrs)  
• 200 hours - SVC — Air Filter Interval (Every 200 hrs)  
2.4 HOW TO USE THE GENERATOR  
If there are any problems operating the generator, please call the  
generator helpline at 1-888-436-3722.  
2.3 CORD SETS AND CONNECTION PLUGS  
2.3.1 120 VAC, 20 AMP, GFCI DUPLEX RECEPTACLE  
2.4.1 GROUNDING THE GENERATOR  
This is a 120 Volt outlet protected against overload by a 20 Amp  
push-to-reset circuit breaker (Figure 7). Use each socket to power  
120 Volt AC, single phase, 60 Hz electrical loads requiring up to a  
combined 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).  
The National Electrical Code requires that the frame and  
external electrically conductive parts of this generator be  
properly connected to an approved earth ground (Figure 9).  
Local electrical codes may also require proper grounding of the  
unit. For that purpose, connecting a No. 10 AWG (American Wire  
Gauge) stranded copper wire to the grounding lug and to an  
earth-driven copper or brass grounding rod (electrode) provides  
adequate protection against electrical shock. However, local codes  
may vary widely. Consult with a local electrician for grounding  
requirements in the area.  
Keep extension cords as short as possible, preferably less than  
15 feet long, to prevent voltage drop and possible overheating of  
wires.  
Figure 7 - 120 Volt AC, 20 Amp, GFCI Duplex Receptacle  
Figure 9 - Grounding the Generator  
6
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Section 2 – Operation  
Portable Generator System  
Proper grounding of the generator will help prevent electrical  
shock in the event of a ground fault condition in the generator  
or in connected electrical devices. Proper grounding also helps  
dissipate static electricity, which often builds up in ungrounded  
devices.  
2.6 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 (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 (handheld). . . . . . . . . . . . . . . . . . . . . . . . . 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.  
2.4.2 CONNECTING ELECTRICAL LOADS  
DO NOT connect 240 Volt loads to 120 Volt receptacles. DO NOT  
connect 3-phase loads to the generator. DO NOT connect 50 Hz  
loads to the generator.  
• Let engine stabilize and warm up for a few minutes after  
starting.  
• Plug in and turn on the desired 120 or 240 Volt AC, single  
phase, 60 Hz electrical loads.  
• Add up the rated watts (or amps) of all loads to be connected  
at one time. This total should not be greater than (a) the rated  
wattage/amperage capacity of the generator or (b) circuit  
breaker rating of the receptacle supplying the power. See "Don't  
Overload the Generator".  
2.5 DON’T OVERLOAD THE GENERATOR  
Overloading a generator in excess of its rated wattage capacity  
can result in damage to the generator and to connected electrical  
devices. Observe the following to prevent overloading the unit:  
• Add up the total wattage of all electrical devices to be connected  
at one time. This total should NOT be greater than the  
generator's wattage capacity.  
• The rated wattage of lights can be taken from light bulbs. The  
rated wattage of tools, appliances and motors can usually be  
found on a data label or decal affixed to the device.  
• If the appliance, tool or motor does not give wattage, multiply  
volts times ampere rating to determine watts (volts x amps =  
watts).  
• Some electric motors, such as induction types, require about  
three times more watts of power for starting than for running.  
This surge of power lasts only a few seconds when starting  
such motors. Make sure to allow for high starting wattage when  
selecting electrical devices to connect to the generator:  
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 generator can operate at one time.  
NOTE:  
All figures are approximate. See data label on appliance for  
wattage requirements.  
7
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Section 2 – Operation  
Portable Generator System  
• Use regular UNLEADED gasoline with the generator engine. Do  
not use premium gasoline. Do not mix oil with gasoline.  
• Do not use gasoline with more than 10% alcohol such as E85  
or Methanol.  
2.7 BEFORE STARTING THE GENERATOR  
Prior to operating the generator, engine oil and gasoline will need  
to be added, as follows:  
• Clean area around fuel fill cap, remove cap.  
2.7.1 ADDING ENGINE OIL  
• Slowly add unleaded regular gasoline to fuel tank. Fill to bottom  
of screen filter. Be careful not to overfill (Figure 10).  
• Install fuel cap and wipe up any spilled gasoline.  
All oil should meet minimum American Petroleum Institute (API)  
Service Class SJ, SL or better. Use no special additives. Select  
the oil's viscosity grade according to the expected operating  
temperature (also see chart).  
Figure 10 - Fuel Tank  
• Above 40° F, use SAE 30  
• Below 40° F and down to 10° F, use 10W-30  
• Below 10° F, use synthetic 5W-30  
Fuel Tank  
Any attempt to crank or start the engine  
before it has been properly serviced with the  
recommended oil may result in an engine  
failure.  
DO NOT Fill Above Lip  
Fuel  
IMPORTANT: It is important to prevent gum deposits from forming  
in fuel system parts such as the carburetor, fuel hose or tank  
during storage. Alcohol-blended fuels (called gasohol, ethanol  
or methanol) can attract moisture, which leads to separation and  
formation of acids during storage. Acidic gas can damage the fuel  
system of an engine while in storage. To avoid engine problems,  
the fuel system should be emptied before storage of 30 days or  
longer. See the "Storage" section. Never use engine or carburetor  
cleaner products in the fuel tank as permanent damage may  
occur.  
SAE 30  
10W-30  
Synthetiic 5W-30  
• Place generator on a level surface.  
2.8 TO START THE ENGINE  
• Clean area around oil fill and remove oil fill cap.  
• Slowly fill engine with oil through the oil fill opening until it  
reaches the full mark. Stop filling occasionally to check oil  
level. (Engine oil is full when level is up to the threads of the  
oil fill plug.)  
• Install oil fill cap and finger tighten securely.  
• Check engine oil level before starting each time thereafter.  
Never start or stop engine with electrical  
devices plugged into the receptacles AND  
devices turned on.  
• Unplug all electrical loads from the unit's receptacles before  
starting the engine.  
2.7.2 ADDING GASOLINE  
• Make sure the unit is in a level position.  
• Open the fuel shut-off valve (Figure 11).  
DANGER  
Figure 11 - Fuel Shut-off Valve  
Never fill fuel tank indoors. Never fill fuel tank  
when engine is running or hot. Allow engine to  
cool entirely before filling fuel tank. DO NOT  
light a cigarette or smoke when filling the fuel  
tank.  
Do not overfill the fuel tank. Always leave room  
for fuel expansion. Wipe up any spilled fuel  
immediately.  
8
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Section 2 – Operation  
Portable Generator System  
• Pull engine CHOKE knob outward to “Full Choke” position  
2.10 LOW OIL PRESSURE SHUTDOWN SYSTEM  
(Figure 12).  
The engine is equipped with a low oil pressure sensor that shuts  
down the engine automatically when the oil pressure drops below  
5 psi. If the engine shuts down by itself and the fuel tank has  
enough gasoline, check engine oil level.  
Figure 12 - Choke Position  
2.10.1 INITIAL START-UP  
A delay built into the low oil shutdown system allows oil pressure  
to build during starting. The delay allows the engine to run for  
about 10 seconds before sensing oil pressure.  
2.10.2 SENSING LOW OIL PRESSURE  
If the system senses low oil pressure during operation, the engine  
shuts down.  
Choke  
2.10.3 RESTARTING  
If trying to restart the engine within 10 seconds after it shuts down,  
the engine may NOT start. The system needs 5 to 10 seconds to  
reset.  
• To start engine, press and hold the Start/Run/Stop switch in  
the “Start” position. The engine will crank and attempt to start.  
When the engine starts, release the switch to the run position.  
• When the engine starts, push choke knob to “1/2 Choke”  
position until the engine runs smoothly and then fully in to the  
“Run” position. If engine falters, pull choke knob back out to  
“1/2 Choke” position until the engine runs smoothly and then  
to “Run” position.  
If the engine is restarted after such a shutdown and the low oil  
pressure has not been corrected, the engine will run for about 10  
seconds as described above and then stop.  
• This generator is also equipped with a manual recoil starter  
which may be used if the battery is discharged.  
2.11 CHARGING A BATTERY  
NOTE:  
DANGER  
The switch must be in the RUN position.  
Storage batteries give off explosive hydrogen  
gas while recharging. An explosive mixture will  
• To start manually, firmly grasp the recoil handle and pull slowly  
until increased resistance is felt. Pull rapidly up and away to  
start engine. Then follow the same choke sequence listed  
above.  
remain around the battery for a long time after  
it has been charged. The slightest spark can  
ignite the hydrogen and cause an explosion.  
Such an explosion can shatter the battery and  
cause blindness or other serious injury.  
NOTE:  
If engine fires, but does not continue to run, pull choke knob to  
“Full Choke” and repeat starting instructions.  
DANGER  
IMPORTANT: Do not overload the generator. Also, do not overload  
individual panel receptacles. These outlets are protected against  
overload 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 “Don’t Overload the  
Generator” carefully.  
Do not permit smoking, open flame, sparks or  
any other source of heat around a battery. Wear  
protective goggles, rubber apron and rubber  
gloves when working around a battery. Battery  
electrolyte fluid is an extremely corrosive  
sulfuric acid solution that can cause severe  
burns. If spill occurs flush area with clear water  
immediately.  
2.9 STOPPING THE ENGINE  
• Shut off all loads, then unplug the electrical loads from generator  
panel receptacles. Never start or stop the engine with electrical  
devices plugged in and turned on.  
• Let engine run at no-load for several minutes to stabilize the  
internal temperatures of engine and generator.  
• Move Start/Run/Stop switch to “Off” position.  
• Close fuel valve.  
Use battery charger plug to keep the battery charged and ready for  
use. Battery charging should be done in a dry location.  
1. Plug charger into “Battery Charger Input” jack, located on the  
control panel. Plug wall receptacle end of the battery charger  
into a 120 Volt AC wall outlet (Figure 13).  
9
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Section 3 — Maintenance  
Portable Generator System  
Figure 13 - Battery Charger Jack  
3.2.2 ENGINE SPECIFICATIONS  
Rated Horsepower @ 3600 RPM....................................................14.5  
Displacement............................................................................... 410cc  
Spark Plug Type...................................Champion RC14YC or Equivalent  
Spark Plug Gap............................................... 0.030 inch or (0.76 mm)  
Gasoline Capacity ............................................................ 9 U.S. gallons  
Oil Type....................................See Chart in "Adding Engine Oil" Section  
Oil Capacity ................................................ w/ Filter Change = 1.5 Qts.  
w/o Filter Change = 1.2 Qts.  
Run Time/Fuel Consumption-1/2 Load  
8 kW ................................................. 12 Hours / .73 gallons per hour  
6.5 kW .............................................. 14 Hours / .64 gallons per hour  
Class II Emission Certified  
2. Unplug battery charger from wall outlet and control panel jack  
when generator is going to be in use.  
NOTE:  
3.3 GENERAL RECOMMENDATIONS  
Do not use the battery charger for more than 48 hours at one  
charge.  
The warranty of the generator does not cover items that have been  
subjected to operator abuse or negligence. To receive full value  
from the warranty, the operator must maintain the generator as  
instructed in this manual.  
3.1 MAINTENANCE SCHEDULE  
Follow the calendar intervals. More frequent service is required  
when operating in adverse conditions noted below.  
Some adjustments will need to be made periodically to properly  
maintain the generator.  
All adjustments in the Maintenance section of this manual should  
be made at least once each season. Follow the requirements in the  
"Maintenance Schedule".  
Check Oil Level  
At Each Use  
*Every Season  
Every Season  
***Every Season  
**Every Season  
Every Season  
Change Oil and Oil Filter‡  
Clean Spark Arrestor Screen  
Check Valve Clearance  
Service Air Cleaner  
NOTE:  
Once a year replace the spark plug and replace the air filter.  
A new spark plug and clean air filter assure proper fuel-air  
mixture and help the engine run better and last longer.  
Replace Spark Plug  
*
Change oil after first 30 hours of operation then every season.  
Change oil and oil filter every month when operating under heavy load or in high  
temperatures.  
3.3.1 GENERATOR MAINTENANCE  
** Clean more often under dirty or dusty operating conditions. Replace air cleaner  
parts if very dirty.  
*** Check valve clearance and adjust if necessary after first 50 hours of  
operation and every 100 hours thereafter.  
Generator maintenance consists of keeping the unit clean and dry.  
Operate and store the unit in a clean dry environment where it will  
not be exposed to excessive dust, dirt, moisture or any corrosive  
vapors. Cooling air slots in the generator must not become clogged  
with snow, leaves, or any other foreign material.  
3.2 PRODUCT SPECIFICATIONS  
Check the cleanliness of the generator frequently and clean when  
dust, dirt, oil, moisture or other foreign substances are visible on  
its exterior surface.  
3.2.1 GENERATOR SPECIFICATIONS  
Model #................................................................ 005606-0/005605-0  
Rated Max. Power...................................................8.0 kW**/6.5 kW**  
Surge Power..................................................................12 kW/9.75 kW  
Rated AC Voltage......................................................................120/240  
Rated Max AC Load  
Never insert any object or tool through the air  
cooling slots, even if the engine is not running.  
Current @ 240V.......................................33.3 Amps**/27.1 Amps**  
Current @ 120V.......................................66.7 Amps**/54.2 Amps**  
Rated Frequency.................................................... 60 Hz @ 3600 RPM  
Phase ................................................................................Single Phase  
Rated DC Voltage...................................................................... 12 Volts  
NOTE:  
DO NOT use a garden hose to clean generator. Water can enter  
the engine fuel system and cause problems. In addition, if water  
enters the generator through cooling air slots, some water will  
be retained in voids and crevices of the rotor and stator winding  
insulation. Water and dirt buildup on the generator internal  
windings will eventually decrease the insulation resistance of  
these windings.  
** Maximum wattage and current are subject to, and limited by, such factors  
as fuel Btu content, ambient 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.  
10  
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Section 3 — Maintenance  
Portable Generator System  
• Fill oil sump with recommended oil. (See “Before Starting the  
Generator” for oil recommendations).  
• Wipe up any spilled oil.  
3.3.2 TO CLEAN THE GENERATOR  
• Use a damp cloth to wipe exterior surfaces clean.  
• A soft, bristle brush may be used to loosen caked on dirt, oil,  
etc.  
• Dispose of used oil at a proper collection center.  
• A vacuum cleaner may be used to pick up loose dirt and  
3.3.6 REPLACING THE SPARK PLUG  
debris.  
Use Champion RC14YC spark plug or equivalent. Replace the  
plug once each year. This will help the engine start easier and  
run better.  
• Low pressure air (not to exceed 25 psi) may be used to  
blow away dirt. Inspect cooling air slots and openings  
on the generator. These openings must be kept clean and  
unobstructed.  
1. Stop the engine and pull the spark plug wire off of the spark  
plug.  
3.3.3 ENGINE MAINTENANCE  
2. To gain access, remove the four (4) Torx screws "T27" and  
take off side panel.  
DANGER  
3. Clean the area around the spark plug and remove it from the  
cylinder head.  
4. Set the spark plug's gap to .76 mm (0.030 in.). Install the  
correctly gapped spark plug into the cylinder head (Figure  
14).  
When working on the generator, always  
disconnect negative cable from battery. Also  
disconnect spark plug wires from spark plug  
and keep wire away from spark plug.  
5. Push the boot firmly on the spark plug and install side panel.  
3.3.4 CHECKING OIL LEVEL  
Figure 14 - Spark Plug Gap  
See the “BEFORE STARTING THE GENERATOR” section for  
information on checking the oil level. The oil level should be  
checked before each use, or at least every eight hours of operation.  
Keep the oil level maintained.  
3.3.5 CHANGING THE OIL AND OIL FILTER  
Change the oil and filter after the first 30 hours of operation.  
Change the oil every 100 hours or every season thereafter. If  
running this unit under dirty or dusty conditions, or in extremely  
hot weather, change the oil more often.  
3.4 SERVICE AIR CLEANER  
The engine will not run properly and may be damaged if using a  
dirty air cleaner. Clean or replace the air cleaner paper filter once  
a year (Figure 15). Clean or replace more often if operating under  
dusty conditions.  
Hot oil may cause burns. Allow engine to cool  
before draining oil. Avoid prolonged or repeated  
skin exposure with used oil. Thoroughly wash  
exposed areas with soap.  
Figure 15 - Air Cleaner  
NOTE:  
Whenever possible, run engine for approximately 5 minutes to  
get the engine oil hot. This will aid in draining the oil.  
BASE  
Use the following instructions to change the oil while the engine  
is still warm:  
• Clean area around oil drain plug.  
• Remove oil drain plug from engine and oil fill plug to drain oil  
completely into a suitable container.  
• When oil has completely drained, install oil drain plug and  
tighten securely.  
• Place a suitable container beneath the oil filter and turn  
filter counterclockwise to remove. Discard according to local  
regulations.  
• Coat gasket of new filter with clean engine oil. Turn filter  
clockwise until gasket contacts lightly with filter adapter. Then  
tighten an additional 3/4 turn.  
FILTER  
COVER  
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Section 3 — Maintenance  
Portable Generator System  
To clean or replace paper air filter:  
3.6 ADJUSTING VALVE CLEARANCE  
After the first 50 hours of operation, check the valve clearance  
in the engine and adjust if necessary.  
• Remove air cleaner cover; then remove foam pre-filter (service  
if necessary) and remove paper filter.  
• Clean paper filter by tapping it gently on a solid surface. If the  
filter is too dirty, replace it with a new one. Dispose of the old  
filter properly.  
• Clean air cleaner cover then slip pre-cleaner over filter. Next  
insert new paper filter into the base of the air cleaner. Re-install  
air cleaner cover.  
Important: If feeling uncomfortable about doing this procedure or  
the proper tools are not available, please take the generator to the  
nearest service center to have the valve clearance adjusted. This is  
a very important step to insure longest life for the engine.  
To check valve clearance:  
• Make sure the engine is at room temperature (60° - 80° F).  
• Make sure that the spark plug wire is removed from the spark  
plug and out of the way. Remove spark plug.  
NOTE:  
To order a new air filter, please contact the nearest authorized  
service center at 1-888-436-3722.  
• Remove the four screws attaching the valve cover.  
• Make sure the piston is at Top Dead Center (TDC) of its  
compression stroke (both valves closed). To get the piston  
at TDC, remove the intake screen at the front of the engine to  
gain access to the flywheel nut. Use a large socket and socket  
wrench to rotate the nut and hence the engine in a clockwise  
direction while watching the piston through the spark plug hole.  
The piston should move up and down. The piston is at TDC  
when it is up as high as it can go.  
• Insert a 0.002 - 0.004 inch (0.05 - 0.1mm) feeler gauge  
between the rocker arm and valve stem. Correct clearance is  
when a slight drag is felt when sliding the gauge back and forth.  
If the clearance is either excessively loose or tight the rocker  
arms will need adjusting.  
3.5 CLEAN SPARK ARRESTOR SCREEN  
The engine exhaust muffler has a spark arrestor screen. Inspect  
and clean the screen at least once each year (Figure 16). If unit is  
used regularly, inspect and clean more often.  
NOTE:  
If using the generator on any forest-covered, brush-covered  
or grass-covered unimproved land, it must equipped with a  
spark arrestor. The spark arrestor must be maintained in good  
condition by the owner/operator.  
Clean and inspect the spark arrestor when the engine is at  
ambient temperature as follows:  
• Remove muffler heat shield from muffler by removing the four  
screws.  
• Remove spark arrestor from muffler by removing the four  
screws.  
• Inspect screen and replace if torn, perforated or otherwise  
damaged. DO NOT USE a defective screen. If screen is not  
damaged, clean it with commercial solvent.  
• Replace the spark arrestor and muffler heat shield.  
To adjust valve clearance:  
• Loosen the rocker jam nut (Figure 17). Use an 10mm allen  
wrench to turn the pivot ball stud while checking clearance  
between the rocker arm and the valve stem with a feeler gauge.  
Correct clearance is 0.002-0.004 inch (0.05-0.1 mm).  
Figure 17 - Valve Clearance Adjustment  
Figure 16 - Spark Arrestor  
Spark Arrestor  
Heat Shield  
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Section 3 — Maintenance  
Portable Generator System  
NOTE:  
DANGER  
The rocker arm jam nut must be held in place as the pivot ball  
stud is turned.  
Drain fuel into approved container outdoors,  
away from open flame. Be sure engine is cool.  
Do not smoke in the vicinity or light a cigarette.  
When valve clearance is correct, hold the pivot ball stud in place  
with the allen wrench and tighten the rocker arm jam nut. Tighten  
the jam nut to 174 in/lbs. torque. After tightening the jam nut,  
recheck valve clearance to make sure it did not change.  
• Start and run engine until engine stops from lack of fuel.  
• While engine is still warm, drain oil from crankcase. Refill with  
recommended grade.  
• Remove spark plugs and pour about 1/2 ounce (15 ml) of  
engine oil into the cylinders. Cover spark plug hole with rag. Pull  
the recoil starter a couple times to lubricate the piston rings and  
cylinder bore..  
• Install new valve cover gasket.  
• Re-attach the valve cover.  
NOTE:  
Start all four screws before tightening or it will not be possible  
to get all the screws in place. Make sure the valve cover gasket  
is in place. Replace spark plug.  
• Re-attach the spark plug wire to the spark plug.  
Avoid spray from spark plug holes when  
cranking engine.  
3.7 GENERAL  
• Install and tighten spark plugs. Do not connect spark plug  
wires.  
• Clean the generator outer surfaces. Check that cooling air slots  
and openings on generator are open and unobstructed.  
• Store the unit in a clean, dry place.  
The generator should be started at least once every seven days and  
be allowed to run at least 30 minutes. If this cannot be done and  
the unit must be stored for more than 30 days, use the following  
information as a guide to prepare it for storage.  
DANGER  
3.9 OTHER STORAGE TIPS  
NEVER store engine with fuel in tank indoors  
• Do not store gasoline from one season to another.  
• Replace the gasoline can if it starts to rust. Rust and/or dirt in  
the gasoline will cause problems with the carburetor and fuel  
system.  
or in enclosed, poorly ventilated areas where  
fumes may reach an open flame, spark or pilot  
light as on a furnace, water heater, clothes dryer  
or other gas appliance.  
• If possible, store the unit indoors and cover it to give protection  
from dust and dirt. BE SURE TO EMPTY THE FUEL TANK.  
• If it is not practical to empty the fuel tank and the unit is to be  
stored for some time, use a commercially available fuel stabilizer  
added to the gasoline to increase the life of the gasoline.  
• Cover the unit with a suitable protective cover that does not  
retain moisture.  
3.8 LONG TERM STORAGE  
It is important to prevent gum deposits from forming in essential  
fuel system parts such as the carburetor, fuel hose or tank during  
storage. Also, experience indicates that alcohol-blended fuels  
(called gasohol, ethanol or methanol) can attract moisture, which  
leads to separation and formation of acids during storage. Acidic  
gas can damage the fuel system of an engine while in storage.  
To avoid engine problems, the fuel system should be emptied  
before storage of 30 days or longer, as follows:  
DANGER  
NEVER cover the generator while engine and  
• Remove all gasoline from the fuel tank.  
exhaust area are warm. Allow unit to cool  
entirely.  
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Section 4 — Battery Service  
Portable Generator System  
Figure 18 - Battery Connections  
4.1 BATTERY SERVICE (REPLACEMENT)  
The battery shipped with the generator has been provided fully  
charged. Caution must be taken when connecting the battery.  
BATTERY CHARGER  
(BLACK)  
NOTE:  
GROUND  
(GREEN)  
NUT  
A battery may lose some of it’s charge when not in use for  
prolonged periods of time. (See the "Know the Generator"  
section.)  
LOCK WASHER  
FLAT WASHER  
NEGATIVE BATTERY  
CABLE (BLACK)  
To replace the battery:  
• Remove end panel as shown in Figure 5 in the "Know the  
Generator" section.  
BATTERY CHARGER  
(RED)  
• Remove hold-down bracket.  
• Disconnect the RED battery cable to the battery Positive  
terminal (+).  
• Disconnect the BLACK battery cable to the battery Negative  
terminal (–).  
POSITIVE BATTERY  
CABLE (RED)  
CABLE BOOT  
SCREW  
• To install a new battery:  
• Reverse the steps above and follow Figure 18.  
• Double check all connections to ensure they are in the correct  
location and secure. See Figure 18.  
Battery Type: CP12-10, 12V, 10AH  
14  
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Section 5 — Troubleshooting  
Portable Generator System  
5.1 TROUBLESHOOTING GUIDE  
PROBLEM  
CAUSE  
CORRECTION  
Engine is running, but no AC output 1. Circuit breaker is open.  
1. Reset circuit breaker.  
2. Check and repair.  
is available.  
2. Poor connection or defective cord set.  
3. Connected device is bad.  
4. Fault in generator.  
5. GFCI trips the 20 Amp outlets.  
3. Connect another device that is in good condition.  
4. Contact Authorized Service Facility.  
5. Repair the "short" and reset the GFCI.  
Engine runs good but bogs down  
when loads are connected.  
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 “Don’t Overload the Generator” .  
3. Contact Authorized Service Facility.  
4. Contact Authorized Service Facility.  
Engine will not crank.  
1. Battery weak or dead.  
1. Recharge or replace battery (see "No Battery  
Charger DC output" at bottom of guide).  
2. Start engine manually using recoil starter.  
Engine will not start; or starts and  
runs rough.  
1. Fuel shut-off is OFF.  
2. Dirty air cleaner.  
3. Out of gasoline.  
1. Turn Fuel shut-off ON.  
2. Clean or replace air cleaner.  
3. Fill fuel tank.  
4. Stale gasoline.  
5. Spark plug wire not connected to spark plug.  
6. Bad spark plug.  
4. Drain fuel tank and fill with fresh fuel.  
5. Connect wire to spark plug.  
6. Replace spark plug.  
7. Water in gasoline.  
8. Over-choking.  
9. Low oil level.  
10. Excessive rich fuel mixture.  
11. Intake valve stuck open or closed.  
12. Engine has lost compression.  
7. Drain fuel tank; fill with fresh fuel.  
8. Put choke knob to No Choke position.  
9. Fill crankcase to proper level.  
10. Contact Authorized Service Facility.  
11. Contact Authorized Service Facility.  
12. Contact Authorized Service Facility.  
Engine shuts down during  
operation.  
1. Out of gasoline.  
2. Low oil level.  
3. Fault in engine.  
1. Fill fuel tank.  
2. Fill crankcase to proper level.  
3. Contact Authorized Service Facility.  
Engine lacks power.  
1. Load is too high.  
2. Dirty air filter.  
1. See “Don’t Overload the Generator”.  
2. Replace air filter.  
3. Engine needs to be serviced.  
3. Contact Authorized Service Facility.  
Engine “hunts” or falters.  
No Battery Charger DC output.  
1. Choke is opened too soon.  
2. Carburetor is running too rich or too lean.  
1. Move choke to halfway position until engine runs  
smoothly.  
2. Contact Authorized Service Facility.  
1. Battery posts are corroded.  
2. Battery cable is bad.  
1. Clean battery posts.  
2. Replace cable.  
3. Battery is defective.  
4. Receptacle is bad.  
5. Battery Charger in-line fuse (1.5A) melted open.  
3. Check battery condition; replace if defective.  
4. Contact Authorized Service Facility.  
5. Replace fuse with identical 1.5A replacement fuse  
only (located inside control panel).  
15  
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Section 6 – Warranty  
Portable Generator System  
FEDERAL EMISSION CONTROL WARRANTY STATEMENT  
YOUR WARRANTY RIGHTS AND OBLIGATIONS  
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the  
Emission Control System warranty on your new 2008 and later equipment. New equipment that use small spark-ignited engines  
must be designed, built, and equipped to meet stringent anti-smog standards for the federal government. Generac will warrant  
the emission control system on your generator for the period of time listed below provided there has been no abuse, neglect,  
unapproved modification or improper maintenance of your equipment.  
Your emission control system may include parts such as the: carburetor, ignition system, fuel system, catalytic converter, and other  
associated emission-related components (if equipped).  
MANUFACTURER’S WARRANTY COVERAGE:  
This emission control system is warranted for two years. If, during such warranty period, any emission-related part on your  
equipment is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac  
Authorized Warranty Service Dealer.  
OWNER'S WARRANTY RESPONSIBILITIES:  
As the generator owner, you are responsible for the completion of all required maintenance as listed in your factory supplied  
Owner's Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your  
generator, but Generac cannot deny warranty solely due to the lack of receipts.  
As the generator owner, you should be aware that Generac may deny any and/or all warranty coverage or responsibility if your  
generator, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or  
the use of counterfeit and/or "grey market" parts not made, supplied or approved by Generac.  
You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs. The warranty  
repairs should be completed in a reasonable amount of time, not to exceed 30 days.  
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer. To  
locate the Generac Authorized Warranty Service Dealer nearest you, call our toll free number:  
1-800-333-1322  
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty  
(ECS Warranty), which is provided to you by Generac pursuant to federal law. See also the "Generac Limited Warranties for  
Generac Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by Generac. Note that this  
warranty shall not apply to any incidental, consequential or indirect damages caused by defects in materials or workmanship or  
any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties, expressed or implied.  
Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Some states do not  
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.  
The ECS Warranty applies only to the emission control system of your new equipment. If there is any conflict in terms between the  
ECS Warranty and the Generac Warranty, the Generac Warranty shall apply. Both the ECS Warranty and the Generac Warranty  
describe important rights and obligations with respect to your new engine.  
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service,  
evidence must be presented showing the date of the sale to the original purchaser/owner.  
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following  
address:  
ATTENTION WARRANTY DEPARTMENT  
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 297 • WHITEWATER, WI 53190  
Part 1  
Part No. 0H1911 Rev. A 01/09  
16  
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Section 6 – Warranty  
Portable Generator System  
EMISSION CONTROL SYSTEM WARRANTY  
Emission Control System Warranty (ECS warranty) for equipment using small spark-ignited engines:  
(a) Applicability: This warranty shall apply to equipment that uses small off-road engines. The ECS Warranty period shall begin  
on the date the new equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24  
consecutive months thereafter.  
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or  
equipment and to each subsequent purchaser/owner that the ECS when installed was:  
(1) Designed, built and equipped so as to conform with all applicable regulations; and  
(2) Free from defects in materials and workmanship which cause the failure of a warranted part at any time during the ECS  
Warranty Period.  
(c) The warranty on emissions-related parts will be interpreted as follows:  
(1) Any warranted part that is not scheduled for replacement as required maintenance in the Owner's Manual shall be  
warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or  
replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall  
be warranted for the remainder of the ECS Warranty Period.  
(2) Any warranted part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted  
for the ECS Warranty Period. A statement in the Owner’s Manual to the effect of "repair or replace as necessary" shall not  
reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the  
remainder of the ECS Warranty Period.  
(3) Any warranted part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted  
for the period of time prior to first scheduled replacement point for that part. If the part fails prior to the first scheduled  
replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-  
related part repaired or replaced under the ECS warranty shall be warranted for the remainder of the period prior to the  
first scheduled replacement point for that part.  
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge  
to the owner at a Generac Authorized Warranty Service Facility.  
(5) Notwithstanding the provisions of subsection (4) above, warranty services or repairs must be provided at Generac  
Authorized Service Facilities.  
(6) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held  
responsible for diagnostic costs if the repair is deemed warrantable.  
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to  
meet the expected demand for such parts.  
(8) Any Generac authorized and approved emission-related replacement parts may be used in the performance of any ECS  
warranty maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce  
Generac ECS Warranty obligations.  
(9) Unapproved, add-on, modified, counterfeit and/or "grey market" parts may not be used to modify or repair a Generac  
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac  
shall not be held liable hereunder for failures of any warranted parts of Generac equipment caused by the use of such an  
unapproved, add-on, modified, counterfeit and/or "grey market" part.  
EMISSION RELATED PARTS MAY INCLUDE THE FOLLOWING (IF EQUIPPED):  
1) FUEL METERING SYSTEM  
A. CARBURETOR AND INTERNAL PARTS  
B. PRESSURE REGULATOR  
2) AIR INDUCTION SYSTEM  
A. INTAKE MANIFOLD  
4) AIR INJECTION SYSTEM  
A. PULSE AIR VALVE  
5) EXHAUST SYSTEM  
A. CATALYST  
B. THERMAL REACTOR  
C. EXHAUST MANIFOLD  
B. AIR FILTER  
3) IGNITION SYSTEM  
A. SPARK PLUGS  
B. IGNITION COILS / MODULE  
Part 2  
Part No. 0H1911 Rev. A 01/09  
17  
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Section 6 – Warranty  
Portable Generator System  
GENERAC POWER SYSTEMS “THREE YEAR” LIMITED WARRANTY FOR  
XP SERIES PORTABLE GENERATORS  
For a period of three years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its XP Series generators will be free from defects in materials and  
workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a  
Generac Authorized Warranty Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the  
nearest Generac Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/  
owner. This warranty applies only to Generac XP Series portable generators and is not transferable from original purchaser. Save your proof-of-purchase receipt. If you do not  
provide proof of the initial purchase date, the manufacturer’s shipping date of the product will be used to determine the warranty period.  
WARRANTY SCHEDULE  
Consumer applications are warranted for three (3) years. Commercial and Rental applications are warranted for two (2) years or 1500 hours maximum, whichever comes first.  
CONSUMER APPLICATION  
YEARS ONE and TWO - 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):  
• Engine- All Components  
• Alternator- All Components  
YEAR THREE- 100% (one hundred percent) coverage on Part(s) listed (proof of purchase and maintenance is required):  
• Engine- All Components  
• Alternator- All Components  
COMMERCIAL/RENTAL APPLICATION  
YEARS ONE and TWO – 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):  
• Engine- All Components  
• Alternator- All Components  
NOTE: For the purpose of this warranty “consumer use” means personal residential household or recreational use by original purchaser. This warranty does not apply to  
units used for Prime Power in place of utility where utility power service is present or where utility power service does not normally exist. Once a generator has  
experienced commercial or rental use, it shall thereafter be considered a non-consumer use generator for the purpose of this warranty.  
All warranty expense allowances are subject to the conditions defined in Generac’s Warranty Policies, Procedures and Flat Rate Manual.  
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:  
• Generac portable generators that utilize non-Generac replacement parts.  
• Costs of normal maintenance and adjustments.  
• Failures caused by any contaminated fuels, oils or lack of proper oil levels.  
• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac Power Systems.  
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper use. As with all mechanical devices, the Generac engines need periodic  
part(s) service and replacement to perform as designed. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.  
• Failures caused by any act of God and other force majeure events beyond the manufactures control.  
• Damage related to rodent and/or insect infestation.  
• Products that are modified or altered in a manner not authorized by Generac in writing.  
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).  
• Failure due to misapplication.  
• Telephone, cellular phone, facsimile, internet access or other communication expenses.  
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.  
• Expenses related to “customer instruction” or troubleshooting where no manufacturing defect is found.  
• Rental equipment used while warranty repairs are being performed.  
• Overnight freight or special shipping costs for replacement part(s).  
• Overtime, holiday or emergency labor.  
• Starting batteries, fuses, light bulbs and engine fluids.  
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO  
THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express  
warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.  
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC POWER SYSTEMS  
BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.  
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/owner. Purchaser/owner  
agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner specific legal rights. Purchaser/owner also may  
have other rights that vary from state to state.  
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 8 • Waukesha, WI 53187  
Ph: (888) GENERAC (436-3722) • Fax: (262) 544-4851  
Part No. 0G9452  
Revision B (01/09/09)  
Revision C (01/13/09)  
Printed in U.S.A.  
Manual Part No. 0G9556  
Printed in U.S.A.  
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