Generac Welding System 005747 0 XG8000E User Manual

MODELS: 005796-0 (XG6500), 005797-0 (XG7000),  
005798-0 (XG7000E), 005800-0 (XG8000),  
005747-0 (XG8000E)  
Owner's Manual  
XG Series 6,500-8,000 Watt Portable Generator  
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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.  
Indicates a hazardous situation or action which, if not  
avoided, could result in minor or moderate injury.  
NOTE:  
Notes contain additional information important to a procedure  
and will be found within the regular text body of this manual.  
These safety warnings cannot eliminate the hazards that they  
indicate. Common sense and strict compliance with the special  
instructions while performing the action or service are essential to  
preventing accidents.  
If any portion of this manual is not understood, contact the  
nearest Authorized Dealer for starting, operating and servicing  
procedures.  
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. 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.  
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.  
The generator can operate safely, efficiently and reliably only if it  
is properly located, operated and maintained. Before operating or  
servicing the generator:  
This symbol points out potential explosion  
hazard.  
Become familiar with and strictly adhere to all local, state and  
This symbol points out potential fire hazard.  
national codes and regulations.  
Study all safety warnings in this manual and on the product  
carefully.  
This symbol points out potential electrical  
shock hazard.  
Become familiar with this manual and the unit before use.  
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.  
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. Inspect the generator regularly, and contact the nearest  
Authorized Dealer for parts needing repair or replacement.  
THE INFORMATION CONTAINED HEREIN WAS BASED ON  
MACHINES IN PRODUCTION AT THE TIME OF PUBLICATION.  
GENERAC RESERVES THE RIGHT TO MODIFY THIS MANUAL AT  
ANY TIME.  
Operate generator only on level surfaces and where it will not be  
exposed to excessive moisture, dirt, dust or corrosive vapors.  
Keep hands, feet, clothing, etc., away from drive belts, fans,  
and other moving parts. Never remove any fan guard or shield  
while the unit is operating.  
Certain parts of the generator get extremely hot during  
operation. Keep clear of the generator until it has cooled to  
avoid severe burns.  
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:  
Do NOT operate generator in the rain.  
Do not alter the construction of the generator or change  
controls which might create an unsafe operating condition.  
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.  
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF  
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.  
Do not insert objects through unit’s cooling slots.  
When working on this equipment, remain alert at all times.  
Never work on the equipment when physically or mentally  
fatigued.  
Indicates a hazardous situation or action which, if not  
avoided, could result in death or serious injury.  
1
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Safety Rules  
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.  
On electric start models, disconnect the POSITIVE (+) battery  
cable from the engine starter OR the NEGATIVE (-) battery  
cable from the battery terminal, whichever is easier, before  
transporting the generator.  
ELECTRICAL HAZARDS  
The generator produces dangerously high voltage when in  
operation. Avoid contact withbare wires, terminals, connections,  
etc., while the unit is running, even on equipment connected  
to the generator. Ensure all appropriate covers, guards and  
barriers are in place before operating 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 MAY RESULT.  
The National Electric Code (NEC) 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).  
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.  
EXHAUST & LOCATION HAZARDS  
Do not use worn, bare, frayed or otherwise damaged electrical  
cord sets with the generator.  
• Never operate in an enclosed area or indoors! NEVER use in  
the home, or in partly enclosed areas such as garages, even  
if doors and windows are open! ONLY use outdoors and far  
from open windows, doors, vents, and in an area that will not  
accumulate deadly exhaust.  
Before performing any maintenance on the generator, disconnect  
the engine starting battery (if equipped) to prevent accidental  
start up. Disconnect the cable from the battery post indicated  
by a NEGATIVE, NEG or (–) first. Reconnect that cable last.  
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.  
FIRE HAZARDS  
• Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE.  
Do not permit smoking, open flames, sparks or heat in the  
vicinity while handling gasoline.  
Never add fuel while unit is running or hot. Allow engine to cool  
completely before adding fuel.  
• Never fill fuel tank indoors. Comply with all laws regulating  
storage and handling of gasoline.  
The engine exhaust fumes contain carbon monoxide, which  
can you cannot see or smell. This poisonous gas, if breathed  
in sufficient concentrations, can cause unconsciousness or  
even death.  
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.  
• 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. Never store generator  
with fuel in tank where gasoline vapors might reach an open  
flame, spark or pilot light (as on a furnace, water heater or  
clothes dryer). FIRE or EXPLOSION may result. Allow unit to  
cool entirely before storage.  
Wipe up any fuel or oil spills immediately. Ensure that no  
combustible materials are left on or near the generator. Keep the  
area surrounding the generator clean and free from debris and  
keep a clearance of five (5) feet on all side to allow for proper  
ventilation of the generator.  
This exhaust system must be properly maintained. Do nothing  
that might renderthe exhaustsystem unsafe or innoncompliance  
with any local codes and/or standards.  
Always use a battery operated carbon monoxide alarm indoors,  
installed according to the manufacturers instructions.  
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 poisoning.  
2
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Safety Rules  
Do not insert objects through unit’s cooling slots.  
• Do not operate the generator if connected electrical devices  
overheat, if electrical output is lost, if engine or generator sparks  
or if flames or smoke are observed while unit is running.  
MODEL NO:  
SERIAL NO:  
Keep a fire extinguisher near the generator at all times.  
Generator Identification  
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.  
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CALIFORNIA PROPOSITION 65 WARNING  
Engine exhaust and some of its constituents are known  
to the State of California to cause cancer, birth defects  
and other reproductive harm.  
CALIFORNIA PROPOSITION 65 WARNING  
This product contains or emits chemicals known to the  
State of California to cause cancer, birth defects and  
other reproductive harm.  
3
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General Information  
Refer to Figure 2 and install the wheel kit and frame foot as  
follows:  
Remove all packaging material.  
Remove separate accessory box.  
Remove carton off the generator.  
Slide the Axle Pin through the Wheel, Wheel Spacer (Washer)  
and the Frame.  
Install the Hair Pin to the Axle Pin to secure the wheel. Repeat  
for the opposite side.  
Secure the Vibration Mounts to the Frame Foot with the included  
locking nuts.  
To install the Frame Foot, install the Frame Bolts though the  
Frame Washers, Frame and Frame foot. Secure with the locking  
nuts.  
Check all contents (Figure 1). If any parts are missing or damaged  
locate an authorized dealer at 1-888-775-6937.  
Contents include:  
2 – Axle Pins  
Oil Filter  
Figure 2 Wheel and Foot Assembly  
2 – Wheel Spacers  
2 – Hair Pins  
Air Filter  
Spark Plug  
2 – Wheels  
Spark Plug Wrench  
Shop Towel  
2 – Frame Washers  
Oil Funnel  
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1 – Frame Foot  
2 – Frame Bolts  
2 – Vibration Mounts  
4 – Flange Nuts  
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12 Volt Adaptor Plug Charger  
2 – 1 Quart SAE 30 Oil Bottles  
Figure 1 Accessory Boxes  
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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 1-888-775-6937.  
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The wheel kit is designed to greatly improve the portability of the  
generator. You will need the following tools to install the wheel  
kit: Pliers, 1/2" (13mm) wrench and a socket wrench with a 1/2"  
(13mm) socket.  
NOTE:  
The wheel kit is not intended for over-the-road use.  
4
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Operation  
Figure 3 Generator Locations  
Read the entire Owner’s Manual and Safety Rules before  
operating this generator.  
Compare the generator to Figures 3 through 6 to become  
familiarized with the locations of various controls and adjustments.  
Save this manual for future reference.  
1. Choke Knob – Used when starting a cold engine (Pull/Push).  
2. Engine Switch – Controls the operation of the generator. On  
electric start models the switch is Start/Run/Stop. On recoil  
start models the switch is On/Off.  
3. Fuel Shut Off – Valve between fuel tank and carburetor. Turn  
off and run carburetor out of fuel for extended storage.  
4. Panel LED's – Provide illumination of the control panel while  
the generator is operating.  
5. 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.  
6. 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.  
7. Circuit Breakers (AC) – Each 20 Amp receptacle is provided  
with a push-to-reset circuit breaker to protect the generator  
against electrical overload.  
8. Circuit Breakers (AC) – The 30 Amp receptacle is protected  
with a pair of push-to-reset circuit breakers to protect the  
generator against electrical overload.  
9. PowerBar – Indicates the amount of power being used from  
the generator; each section is approximately 25%  
10. Hourmeter – Provides operating hours for Service Intervals.  
11. Battery Charger Input (Electric Start Models) – This  
receptacle allows the capability to recharge the 12 VDC engine  
starting battery with the 12 Volt Adaptor Plug Charger. The  
battery is protected by a 1.50 Amp in-line fuse which is inside  
the control panel.  
12. Fuel Tank – Tank holds 9 U.S. gallons of fuel.  
13. Fuel Gauge – Shows fuel level in tank.  
14. Handles – Pivot and retract for storage. Press the spring-  
loaded button to move handles.  
15. Oil Fill – Check oil level and add oil here.  
16. Grounding Lug – Ground the generator to an approved earth  
ground here. See "Grounding the Generator" for details.  
17. Muffler – Includes the spark arrestor and quiets the engine.  
18. Spark Plug Location – The spark plug ignites the Air/Fuel  
Mixture (Side panel must be removed).  
19. Engine Oil Filter – Filters engine oil; see Section 3.1 for the  
proper service intervals.  
20. Air Cleaner – Filters intake air as it is drawn into the engine.  
21. Oil Drain – Drain valve to remove used oil from the engine  
crankcase.  
22. Recoil Starter – Use to start engine manually.  
5
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Operation  
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.  
NOTE:  
The battery shipped with the generator has been fully charged.  
A battery may lose some of its charge when not in use for  
prolonged periods of time. If the battery is unable to crank  
the engine, plug in the 12V charger included in the accessory  
box (see the Charging the Battery section). RUNNING THE  
GENERATOR DOES NOT CHARGE THE BATTERY.  
100 hours - CHG OIL — Oil Change Interval (Every 100 hrs)  
200 hours - SVC — Air Filter Interval (Every 200 hrs)  
The positive battery wire was deliberately left detached for  
shipping. To operate the unit, attach this wire to the terminal on  
the starter motor as shown. Do not overtighten. Slide the attached  
rubber boot over the starter terminal. See Figure 4.  
This is a 120 Volt outlet protected against overload by a 20 Amp  
push-to-reset circuit breaker (Figure 5). 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).  
Figure 4 Battery Connection  
Keep extension cords as short as possible, preferably less than  
15 feet long, to prevent voltage drop and possible overheating of  
wires.  
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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 5).  
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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 6,500 to 8000  
watts of power, depending on the model. The outlet is protected by  
a 30 Amp circuit breaker.  
Figure 5 Generator Receptacles  
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.  
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.  
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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.  
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Operation  
There may be Federal or State Occupational Safety and Health  
Administration (OSHA) regulations, local codes, or ordinances that  
apply to the intended use of the generator.  
If there are any problems operating the generator, please call the  
generator helpline at 1-888-436-3722.  
Please consult a qualified electrician, electrical inspector, or the  
local agency having jurisdiction:  
Never operate in an enclosed area or indoors!  
NEVER use in the home, or in partly enclosed  
areas such as garages, even if doors and  
windows are open! ONLY use outdoors and far  
from open windows, doors, vents, and in an  
area that will not accumulate deadly exhaust.  
In some areas, generators are required to be registered with  
local utility companies.  
If the generator is used at a construction site, there may be  
additional regulations which must be observed.  
The engine exhaust fumes contain carbon  
monoxide, which can you cannot see or smell.  
This poisonous gas, if breathed in sufficient  
concentrations, can cause unconsciousness or  
even death.  
Connections for standby power to a building’s electrical system  
must be made by a qualified electrician. The connection must  
isolate the generator power from utility power or other alternative  
power sources and must comply with all applicable laws and  
electrical codes.  
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.  
The National Electrical Code requires that the  
frame and external electrically conductive parts  
of this generator be properly connected to an  
approved earth ground.  
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.  
Local electrical codes may also require proper grounding of  
the unit (Figure 6). 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.  
The manufacturer recommends installing  
a battery operated carbon monoxide alarm  
indoors, according to the manufacturers  
instructions.  
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.  
Figure 6 Generator Ground Location  
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The generator has a system ground that connects the generator  
frame components to the ground terminals on the AC output  
receptacles. The system ground is bonded to the AC neutral wire  
in the generator control panel via a jumper wire.  
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Operation  
Add up the rated watts (or amps) of all loads to be connected  
at one time. This total should no 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  
If service work is performed on the alternator, DO NOT discard  
the white jumper wires from the terminal block to the alternator  
ground, located on the rear bearing carrier. Always make sure  
the wires are properly connected before using the generator after  
alternator service work is done (Figure 7).  
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:  
Failure to reconnect these wires may create a  
potential shock hazard when the generator is  
running!  
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.  
Figure 7 Neutral to Frame Ground  
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.  
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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.  
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All figures are approximate. See data label on appliance for  
wattage requirements.  
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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  
2)986%0ꢀ83ꢀꢀ*6%1)ꢀ+6392(ꢀ<+ꢄꢅꢆꢆ  
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.  
8
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Operation  
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.  
8)14)6%896)ꢀ-2ꢀ()+6))7ꢀ*%,6)2,)-8ꢀꢁꢀ*ꢂ  
8)14)6%896)ꢀ-2ꢀ()+6))7ꢀ')07-97ꢀꢁꢀ'ꢂ  
Place generator on a level surface.  
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, see Figure 8)  
Install oil fill cap and finger tighten securely.  
Check engine oil level before starting each time thereafter.  
Figure 8 Oil Level  
Prior to operating the generator, engine oil and gasoline will need  
to be added, as follows:  
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).  
Above 40° F, use SAE 30  
Below 40° F and down to 10° F, use 10W-30  
Below 10° F, use synthetic 5W-30  
DO NOT light a cigarette or smoke when filling the fuel  
tank.  
Never fill fuel tank indoors. Never fill fuel tank when  
engine is running or hot. Avoid spilling gasoline on a hot  
engine. Allow engine to cool entirely before filling 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.  
9
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Operation  
Do not overfill the fuel tank. Always leave room for fuel  
Figure 10 Fuel Shut-off Valve  
expansion. If the fuel tank is overfilled, fuel can overflow  
onto a hot engine and cause FIRE or EXPLOSION. Wipe  
up any spilled fuel immediately.  
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.  
Clean area around fuel fill cap, remove cap.  
Slowly add unleaded regular gasoline to fuel tank. Fill to bottom  
of screen filter. Be careful not to overfill (Figure 9).  
Install fuel cap and wipe up any spilled gasoline.  
Figure 9 Fuel Fill Level  
Figure 11 Choke Operation  
(3ꢀ238ꢀ*-00  
%&3:)ꢀ0-4ꢊꢀ  
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.  
To start the generator, put the on/off switch in the ON position.  
Firmly grasp the recoil handle and pull slowly until increased  
resistance is felt. Pull rapidly up and away to start engine.  
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.  
Never start or stop engine with electrical devices plugged into  
the receptacles AND devices turned on.  
NOTE:  
If engine fires, but does not continue to run, pull choke knob  
Unplug all electrical loads from the unit's receptacles before  
starting the engine.  
to Full Chokeand repeat starting instructions.  
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. Read “Don’t  
Overload the Generator” carefully.  
Make sure the unit is in a level position.  
Open the fuel shut-off valve (Figure 10).  
Pull engine CHOKE knob outward to “Full Choke” position  
(Figure 11).  
10  
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Maintenance  
Storage batteries give off explosive hydrogen  
gas while recharging. An explosive mixture will  
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.  
To start the 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.  
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.  
This generator is also equipped with a manual recoil starter  
which may be used if the battery is discharged.  
2. Unplug battery charger from wall outlet and control panel jack  
when generator is going to be in use.  
NOTE:  
The engine Start/Run/Stop switch must be in the RUN  
position when using the manual recoil starter.  
NOTE:  
Do not use the battery charger for more than 48 hours at one  
charge.  
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 or On/Off switch to the “Off” position.  
Close fuel valve.  
Follow the calendar intervals. More frequent service is required  
when operating in adverse conditions noted below.  
Check Oil Level  
At Each Use  
*Every Season/Every 100 Hours  
*Every Season/Every 100 Hours  
**Every Season/Every 200 Hours  
Every Season  
Change Oil and Oil Filter‡  
Clean Spark Arrestor Screen  
Service Air Cleaner  
Replace Spark Plug  
The engine is equipped with a low oil pressure sensor that shuts  
down the engine automatically when the oil pressure drops below  
5 psi. 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. If the engine  
shuts down by itself and the fuel tank has enough gasoline, check  
engine oil level.  
*
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.  
** Clean more often under dirty or dusty operating conditions. Replace air  
cleaner parts if very dirty.  
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.  
Model #...............................................................005800-0, 005747-0  
Rated Max. Power...................................................................8.0 kW**  
Surge Power................................................................................10 kW  
Rated AC Voltage......................................................................120/240  
Rated Max AC Load  
Current @ 240V.............................................................33.3 Amps**  
Current @ 120V.............................................................66.7 Amps**  
Rated Frequency .................................................... 60 Hz @ 3600 RPM  
Phase ................................................................................Single Phase  
Rated DC Voltage...................................................................... 12 Volts  
Battery Type.................................................................... 10 AH, 12VDC  
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.  
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.  
11  
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Maintenance  
Model #...............................................................005797-0, 005798-0  
Rated Max. Power...................................................................7.0 kW**  
Surge Power.............................................................................8.75 kW  
Rated AC Voltage......................................................................120/240  
Rated Max AC Load  
Current @ 240V.............................................................29.2 Amps**  
Current @ 120V.............................................................58.3 Amps**  
Rated Frequency .................................................... 60 Hz @ 3600 RPM  
Phase ................................................................................Single Phase  
Rated DC Voltage...................................................................... 12 Volts  
Battery Type.................................................................... 10 AH, 12VDC  
Fuel System  
Fuel Tank  
Air Induction System  
~ Intake pipe/manifold  
~ Air cleaner  
Ignition System  
~ Spark plug  
~ Ignition module  
Exhaust System  
~ Pulse Air Injection Valve  
~ Muffler  
Fuel Cap  
Carburetor  
Fuel Lines  
Evaporative Control System  
Carbon Canister  
Vapor Hoses  
The Emissions Compliance Period referred to on the Emissions  
Compliance Label indicates the number of operating hours for  
which the engine has been shown to meet Federal and California  
emission requirements. See the table below to determine the  
compliance period for your generator. The displacement of your  
generator is listed on the Emissions Compliance Label.  
Model #................................................................................ 005796-0  
Rated Max. Power...................................................................6.5 kW**  
Surge Power.............................................................................8.13 kW  
Rated AC Voltage......................................................................120/240  
Rated Max AC Load  
Current @ 240V.............................................................27.1 Amps**  
Current @ 120V.............................................................54.2 Amps**  
Rated Frequency .................................................... 60 Hz @ 3600 RPM  
Phase ................................................................................Single Phase  
Rated DC Voltage...................................................................... 12 Volts  
Displacement  
Category  
Compliance Period  
500 Hours  
A
B
C
A
B
C
66 cc - < 225 cc  
250 Hours  
125 Hours  
** 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.  
1000 Hours  
500 Hours  
225 cc  
250 Hours  
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.  
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.  
Some adjustments will need to be made periodically to properly  
maintain the generator.  
Run Time/Fuel Consumption-1/2 Load .. 10 Hours / .73 gallons per hour  
Class II Emission Certified  
All adjustments in the Maintenance section of this manual should  
be made at least once each season. Follow the requirements in the  
"Maintenance Schedule".  
NOTE:  
The Environmental Protection Agency (EPA) and California Air  
Resource Board (CARB) require that your generator comply with  
exhaust and evaporative emission standards. This generator is  
certified to meet the applicable EPA and CARB emission levels.  
Additional information regarding the requirements set by EPA and  
CARB is as follows:  
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.  
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.  
It is important that you follow the maintenance specifications  
provided in this manual to ensure that your engine complies with  
the applicable emission standards for the duration of the engine’s  
life. This engine is certified to operate on gasoline. The emission  
control system on your generator consists of the following:  
Check the cleanliness of the generator frequently and clean when  
dust, dirt, oil, moisture or other foreign substances are visible on  
its exterior surface.  
Never insert any object or tool through the air cooling  
slots, even if the engine is not running.  
12  
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Maintenance  
NOTE:  
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.  
Filloilsumpwithrecommendedoilandreplacetheoilfillplug. (See  
“Before Starting the Generator” for oil recommendations).  
Wipe up any spilled oil.  
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.  
Dispose of used oil at a proper collection center.  
Use Champion RC14YC spark plug or equivalent. Replace the  
plug once each year. This will help the engine start easier and  
run better.  
Use a damp cloth to wipe exterior surfaces clean.  
A soft, bristle brush may be used to loosen caked on dirt, oil,  
etc.  
A vacuum cleaner may be used to pick up loose dirt and  
1. Stop the engine and pull the spark plug wire off of the spark  
plug.  
debris.  
Low pressure air (not to exceed 25 psi) may be used to blow  
awaydirt. Inspect cooling air slotsand openings on the generator.  
These openings must be kept clean and unobstructed.  
2. To gain access, remove the four (4) socket head screws and  
take off the side panel.  
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  
12).  
5. Push the boot firmly on the spark plug and install side panel.  
When working on the generator, always disconnect  
negative cable from battery. Also disconnect spark plug  
wire from spark plug and keep wire away from spark  
plug.  
Figure 12 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.  
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.  
The engine will not run properly and may be damaged if using a  
dirty air cleaner. Clean or replace the air cleaner paper filter every  
200 hours or once a year (Figure 15). Clean or replace more often  
if operating under dusty conditions. To clean or replace paper air  
filter:  
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.  
Remove air cleaner cover and remove paper filter (Figure 13).  
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. Next insert new paper filter into the base  
of the air cleaner. Re-install air cleaner cover.  
Use the following instructions to change the oil:  
Clean area around oil drain cap.  
Remove oil drain cap from the drain hose and oil fill plug to drain  
oil completely into a suitable container.  
When oil has completely drained, install oil drain cap and tighten  
securely.  
NOTE:  
To order a new air filter, please contact the nearest authorized  
service center at 1-888-GENERAC.  
Place a suitable container beneath the oil filter and turn  
filter counterclockwise to remove. Discard according to local  
regulations.  
13  
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Maintenance  
Figure 13 Air Filter  
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.  
NEVER store engine with fuel in tank indoors  
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.  
'3:)6  
Allow unit to cool entirely before storage.  
%-6ꢀ*-08)6  
It is important to prevent gum deposits from forming in essential  
fuel system parts such as the carburetor, fuel hose or tank during  
storage. To avoid engine problems, the fuel system should be  
emptied before storage of 30 days or longer, as follows:  
The engine exhaust muffler has a spark arrestor screen. Inspect  
and clean the screen at least once each year (Figure 14). If unit is  
used regularly, inspect and clean more often.  
Remove all gasoline from the fuel tank.  
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.  
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.  
Start and run engine until engine stops from lack of fuel.  
Allow the engine to cool, then drain oil from crankcase. Refill  
with recommended grade.  
Clean and inspect the spark arrestor when the engine is at ambient  
temperature as follows:  
Loosen the clamp and remove the spark arrestor screen from  
Remove spark plug and pour about 1/2 ounce (15 ml) of engine  
oil into the cylinder. Cover spark plug hole with rag. Pull the  
recoil starter a couple times to lubricate the piston rings and  
cylinder bore.  
the muffler.  
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 secure with the clamp.  
Avoid spray from spark plug hole when  
cranking engine.  
Figure 14 Spark Arrestor Screen  
Install and tighten spark plug. Do not connect the spark plug  
wire.  
Clean the generator outer surfaces. Check that cooling air slots  
and openings on generator are open and unobstructed.  
%66)7836  
7'6))2  
'0%14  
Store the unit in a clean, dry place.  
74%6/  
%66)7836  
7'6))2  
14  
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Battery Service  
Figure 16 Battery Removal  
Do not store gasoline from one season to another.  
Replace any gasoline can that starts to rust. Rust and/or dirt in  
the gasoline will cause problems with the carburetor and fuel  
system.  
*9)0ꢀ8%2/  
%77)1&0=  
If possible, store the unit indoors and cover it to give protection  
from dust and dirt. Cover the unit with a suitable protective  
cover that does not retain moisture.  
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.  
)2+-2)  
78%68-2+  
&%88)6=  
&%88)6=  
&6%'/)8  
NEVER cover the generator while engine and  
exhaust area are warm.  
NOTE:  
The battery shipped with the generator has been fully charged.  
A battery may lose some of its charge when not in use for  
prolonged periods of time. If the battery is unable to crank  
the engine, plug in the 12V charger included in the accessory  
box (see the Charging a Battery section). RUNNING THE  
GENERATOR DOES NOT CHARGE THE BATTERY.  
The battery shipped with the generator has been provided fully  
charged. To replace the battery (See Figure 16):  
7-()  
4%2)0  
Remove the side panel as shown. Remove the four bolts  
securing the fuel tank.  
Turn the fuel valve on the control panel to the "OFF" position.  
Pull the fuel tank back slightly and remove the fuel hose that  
runs from the engine to the fuel valve.  
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.  
Push the fuel valve from the control panel and remove the fuel  
tank.  
Remove the battery wire connections (black wire first) and the  
battery hold-down bracket.  
Replace the battery, connecting the RED wire to the POSITIVE  
(+) terminal and the BLACK wire to the NEGATIVE (-) terminal  
NOTE:  
Start all four screws on the side panel before tightening or it  
may not be possible to get all the screws in place.  
15  
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Troubleshooting  
PROBLEM  
CAUSE  
CORRECTION  
Engine is running, but no AC output  
is available.  
1. Circuit breaker is open.  
1. Reset circuit breaker.  
2. Check and repair.  
3. Connect another device that is in good condition.  
4. Contact Authorized Service Facility.  
5. Repair the "short" and reset the GFCI.  
2. Poor connection or defective cord set.  
3. Connected device is bad.  
4. Fault in generator.  
5. GFCI trips the 20 Amp outlet.  
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.  
1. Turn Fuel shut-off ON.  
2. Clean or replace air cleaner.  
3. Out of gasoline.  
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).  
16  
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Notes  
17  
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Warranty  
CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT  
YOUR WARRANTY RIGHTS AND OBLIGATIONS  
The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac  
Power Systems, Inc. (Generac), are pleased to explain the Emission Control System warranty on your new 2008 and later  
generator. New equipment that use small spark-ignited engines must be designed, built, and equipped to meet stringent anti-  
smog standards for the state of California and 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, catalytic converter, fuel tank, fuel lines,  
fuel cap, valves, carbon canister, filters, vapor hoses, clamps, connectors, and other associated emission-related components (if  
equipped).  
MANUFACTURERS 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 California and 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. 0H1913 Rev. A 01/09  
18  
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Warranty  
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 Owners 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 SYSTEM  
3) FUEL METERING SYSTEM  
A. CARBURETOR AND INTERNAL PARTS  
B. PRESSURE REGULATOR  
4) AIR INDUCTION SYSTEM  
A. INTAKE MANIFOLD  
A. FUEL TANK  
B. FUEL CAP  
C. FUEL LINE  
D. FUEL LINE FITTINGS  
E. CLAMPS*  
B. AIR FILTER  
F. PRESSURE RELIEF VALVES*  
2) EVAPORATIVE CONTROL SYSTEM  
A. CARBON CANISTER  
B. CANISTER MOUNTING BRACKETS  
C. CARBURETOR PURGE PORT  
D. CONTROL VALVES*  
E. VAPOR HOSES  
5) IGNITION SYSTEM  
A. SPARK PLUGS  
B. IGNITION COILS / MODULE  
6) AIR INJECTION SYSTEM  
A. PULSE AIR VALVE  
7) EXHAUST SYSTEM  
A. CATALYST  
F. PURGE VALVE S  
G. LIQUID / VAPOR SEPARATOR  
H. VACUUM CONTROL DIAPHRAGMS*  
B. THERMAL REACTOR  
C. EXHAUST MANIFOLD  
*NOTE: As they relate to the Emission Control System.  
Part 2  
Part No. 0H1913 Rev. A 01/09  
19  
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Warranty  
GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR  
XG SERIES PORTABLE GENERATORS  
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its XG 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 XG 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 two (2) years. Commercial and Rental applications are warranted for one (1) year or 1000 hours maximum, whichever comes  
first.  
CONSUMER APPLICATION  
YEAR ONE - 100% (one hundred percent) coverage on Labor and Part(s) (proof of purchase and maintenance is required):  
• All Components  
YEAR TWO- 100% (one hundred percent) coverage on Part(s) (proof of purchase and maintenance is required):  
• All Components  
COMMERCIAL/RENTAL APPLICATION  
YEAR ONE – 100% (one hundred percent) coverage on Labor and Part(s) (proof of purchase and maintenance is required):  
•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, filters, 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. 0H5472  
Revision B (10/20/09)  
Printed in U.S.A.  
Manual Part No. 0H3530  
Revision E (09/30/10)  
Printed in U.S.A.  
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