Generac XG8000E-5747-0, XG8000-5800-0, XG7000E-5798-0, XG7000-5797-0, 5798-0 Owner’s Manual

...

GENERAC _

MODELS:

005796-0 (XG6500), 005797-0 (XG7000), 005798-0 (XG7OOOE),005800-0 (XGSO00),

005747-0 (XGS000E)

0wnsr's

XGSeries6,500-8,

L M|TED

WattPorta e Generator

introduction.............................................................1

Readthis iVlanualThoroughly.................................1

Safety Rules...........................................................1

StandardsIndex.............................................................3

Generalinformation................................................4

1.1 Unpacking......................................................................4

1.1.1 AccessoryBox..................................................4

1.2 Assembly.......................................................................4

1.2.1 Assemblingthe WheelKitand FrameFoot..........4

Operation................................................................5

2.1 Knowthe Generator.......................................................5

2.1.1 BatteryConnection(XG7000E& XG8000E).......6

2.2 Hourmeter......................................................................6

2.3 CordSetsandConnectionPlugs....................................6

2.3.1 120 VAC,20 Amp, GFCIDuplexReceptacle.......6

2.3.2 120/240 VAC,30Amp Receptacle.....................6

2.4 How to Usethe Generator..............................................7

2.4.1 SystemGround..................................................7

2.4.2 GroundingtheGenerator....................................7

2.4.3 Neutralto FrameGrounding...............................8

2.4.4 ConnectingElectricalLoads...............................8

2.5 Don't Overloadthe Generator..........................................8

2.6 WattageReferenceGuide...............................................8

2.7 BeforeStartingthe Generator.........................................9

2.7.1 AddingEngineOil ..............................................9

2.7.2 AddingGasoline.................................................9

2.8 ToStartthe Engine.......................................................10

2.8.1 Manual(Recoil)Starting..................................10

2.8.2 ElectricStarting(XG7000E& XG8000E)..........11

2.9 Stoppingthe Engine.....................................................11

2.10 Low Oil PressureShutdownSystem.............................11

2.10.1 Restarting........................................................11

2.11 Charginga Battery.......................................................11

Maintenance.........................................................11

3.1 MaintenanceSchedule.................................................11

3.2 ProductSpecifications..................................................11

3.2.1 GeneratorSpecifications..................................11

3.2.2 EngineSpecifications.......................................12

3.2.3 EmissionsInformation.....................................12

3.3 GeneralRecommendations...........................................12

3.3.1 GeneratorMaintenance....................................12

3.3.2 ToCleanthe Generator.....................................13

3.3.3 EngineMaintenance.........................................13

3.3.4 CheckingOilLevel...........................................13

3.3.5 Changingthe Oiland Oil Filter..........................13

3.3.6 Replacingthe SparkPlug.................................13

3.4 ServiceAir Cleaner.......................................................13

3.5 CleanSparkArrestorScreen.........................................14

3.6 General........................................................................14

3.7 LongTermStorage.......................................................14

3.8 OtherStorageTips.......................................................15

BatteryService.....................................................15

4.1 BatteryReplacement(XG7000E& XG8000E)...............15

Troubleshooting....................................................16

5.1 TroubleshootingGuide..................................................16

Notes....................................................................17

Warranty...............................................................18

iNTRODUCTiON

Thankyou for purchasingthis model by GeneracPowerSystems, Inc. This model is a compact, high performance, air-cooled, engine driven generatordesigned to supply electrical power to

operateelectrical loads where no utility power is availableor in placeof utility dueto a poweroutage.

BEADTHiSMANUALTHOROUGHLY

If any portion of this manual is not understood, contact the nearest Authorized Dealerfor starting, operating and servicing procedures.

The operator is responsible for proper and safe use of the equipment.We strongly recommendthat the operator read this manualandthoroughlyunderstandallinstructionsbeforeusingthe equipment.Wealsostronglyrecommendinstructingotherusersto properlystart andoperatethe unit.Thispreparesthem ifthey need

to operatetheequipmentin an emergency.

Thegeneratorcan operatesafely,efficiently and reliably only if it is properly located,operatedand maintained.Beforeoperatingor servicingthe generator:

• Becomefamiliar with and strictly adhereto all local, stateand nationalcodes and regulations.

• Study all safety warnings in this manual and on the product carefully.

• Becomefamiliar with this manual andthe unit beforeuse.

Themanufacturercannot anticipateevery possible circumstance that might involvea hazard.The warnings in this manual,and on tags and decals affixedto the unit are,therefore,not all inclusive.

If usingaprocedure,work method or operatingtechniquethat the

manufacturerdoes not specifically recommend,ensure that it is

safe for others. Also make sure the procedure,work method or

operatingtechniqueutilizeddoes not renderthe generatorunsafe.

THE INFORMATIONCONTAINEDHEREIN WAS BASED ON

MACHINESIN PRODUCTIONAT THE TIME OF PUBLICATION.

GENERACRESERVESTHERIGHTTOMODIFYTHIS MANUALAT

ANYTIME.

SAFETYRULES

Throughoutthis publication,and ontagsand decals affixedto the

generator,DANGER,WARNING,CAUTIONand NOTEblocks are

usedto alert personnelto special instructionsabout a particular

operation that may be hazardous if performed incorrectly or

carelessly. Observe them carefully. Their definitions are as follows:

iNDICATESA HAZARDOUSSiTUATiONORACTIONWHICH,IF

NOTAVOIDED,WiLLRESULTiN DEATHORSERIOUSiNJURY.

Indicatesa hazardoussituationor actionwhich,if not

avoided, couldresultin deathor seriousinjury.

_CAUTION!

Indicatesa hazardoussituationoractionwhich,if not

avoided, couldresultin minoror moderateinjury.

NOTE:

Notescontainadditionalinformation importanttoa procedure

and will be found within the regular text bodyof this manual.

These safety warnings cannot eliminatethe hazards that they indicate. Common sense and strict compliancewith the special instructionswhileperforming the action or service areessentialto preventingaccidents.

Four commonly used safety symbols accompanythe DANGER, WARNINGand CAUTIONblocks. The type of information each

indicatesis asfollows:

,_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.

GENERAL HAZARDS

• Neveroperatein an enclosedareaorindoors.

• For safety reasons, the manufacturer recommends that the maintenanceof this equipmentis carried out by an Authorized Dealer.Inspectthe generatorregularly,and contactthe nearest AuthorizedDealerfor parts needingrepairorreplacement.

• Operategeneratoronly on levelsurfacesandwhereit will not be exposedto excessivemoisture,dirt, dust or corrosivevapors.

• Keep hands, feet, clothing, etc., awayfrom drive belts, fans, and othermovingparts. Neverremoveany fan guardor shield whilethe unit isoperating.

• Certain parts of the generator get extremely hot during operation. Keep clear of the generator until it has cooled to

avoidsevereburns.

• Do NOToperategeneratorinthe rain.

• Do not alter the construction of the generator or change controlswhich mightcreatean unsafeoperatingcondition.

• Never start or stop the unit with electrical loads connected to receptaclesANDwith connecteddevicesturned ON. Start the engine and let it stabilize before connecting electrical loads. Disconnectallelectricalloads beforeshutting downthe generator.

• Do notinsert objectsthrough unit's cooling slots.

• When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

• Neverusethegeneratororanyofitspartsasastep.Stepping ontheunitcanstressandbreakparts,andmayresultin dangerousoperatingconditionsfromleakingexhaustgases,

fuelleakage,oilleakage,etc.

• Onelectricstartmodels,disconnectthePOSITIVE(+)battery cablefromtheenginestarterORtheNEGATIVE(-)battery cablefromthebatteryterminal,whicheveris easier,before

transportingthegenerator.

NOTE:

Thisgenerator 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

arrestoris requiredby law (Section4442 of the California

PublicResources Code). Otherstates may havesimilar laws.

Federal lawsapply on federallands.

EXHAUST & LOCATIONHAZARDS

• Never operate inan enclosed areaor indoors!NEVERuse in the home,or in partly enclosedareas suchas garages, even

if doors and windowsare open! ONLYuse outdoors and far fromopenwindows,doors, vents,andin anareathatwill not accumulatedeadly exhaust.

Using a generator indoors CAN KiLL YOU iN MINUTES. Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell,

ELECTRICALHAZARDS

• The generator produces dangerously high voltage when in operation.Avoidcontactwith barewires,terminals,connections, etc., while the unit is running,even on equipmentconnected to the generator. Ensure all appropriate covers, guards and barriersarein placebeforeoperatingthegenerator.

• Never handle any kind of electrical cord or device while standinginwater,while barefootorwhile handsor feet arewet.

DANGEROUSELECTRICALSHOCKMAYRESULT.

• TheNationalElectricCode(NEC)requirestheframe andexternal electrically conductive parts of the generator be properly connectedto an approvedearthground.Local electricalcodes

may also requireproper grounding of the generator.Consult with a localelectricianfor groundingrequirementsin thearea.

• Use a ground fault circuit interrupter in any damp or highly conductivearea(such as metaldecking or steelwork).

• Do not useworn, bare,frayed or otherwisedamagedelectrical cord setswith the generator.

• Beforeperforminganymaintenanceonthegenerator,disconnect the enginestarting battery (if equipped)to prevent accidental start up. Disconnectthe cable from the batterypost indicated by aNEGATIVE,NEGor (-) first. Reconnectthat cable last.

• In caseof accidentcausedby electricshock, immediatelyshut down the source of electrical power.If this is not possible,

attempt to free the victim from the live conductor. AVOID DIRECTCONTACTWITH THEVICTIM, Use a non-conducting

implement,such asa rope or board,to freethevictim from the live conductor.If the victim is unconscious,applyfirst aid and getimmediatemedical help.

NEVER use insidea home

or garage, EVEN IF doors

and windows are open.

• The engine exhaustfumes contain carbon monoxide, which can you cannot see or smell. Thispoisonous gas, if breathed

in sufficient concentrations, can cause unconsciousness or evendeath.

• 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 generatorMUSTbeoperatedoutdoors.

• This exhaustsystemmust be properly maintained.Do nothing

that mightrendertheexhaustsystemunsafeorinnoncompliance

with any localcodes and/orstandards.

• Alwaysusea battery operatedcarbonmonoxidealarm indoors, installedaccordingto themanufacturersinstructions.

• If you start to feet sick, dizzy,or weak afterthe generator has beenrunning,moveto freshair IMMEDIATELYSeea doctor,as you couldhavecarbonmonoxidepoisoning.

Only use OUTSIDE and far away from windows,

doors, and vents.

FIREHAZARDS

• GasolineishighlyFLAMMABLEand itsvaporsare EXPLOSIVE. Do notpermitsmoking,open flames, sparksor heat in the

vicinitywhilehandlinggasoline.

• Neveraddfuel whileunit isrunningor hot. Allow engineto cool completelybeforeaddingfuel.

• Never fill fuel tank indoors, Comply with all laws regulating storageand handlingof gasoline.

• Do not overfill the fuel tank. Always allow roomfor fuel expansion. If tank is over=filled,fuel can overflow onto a hot engineandcauseFIREor an EXPLOSION.Neverstoregenerator

with fuel in tank where gasolinevapors might reach an open flame, spark or pilot light (as on a furnace, water heater or clothes dryer). FIREor EXPLOSIONmay result. Allow unit to cool entirelybefore storage.

• Wipe up any fuel or oil spills immediately.Ensure that no combustiblematerialsareleftonor nearthegenerator.Keepthe areasurroundingthe generatorcleanandfree from debrisand keepaclearanceof five (5)feet on all side to allow for proper ventilationof the generator.

* Donot insert objectsthrough unit's coolingslots. * Do notoperate the generatorif connected electrical devices

overheat,ifelectricaloutputis lost,if engineor generatorsparks or if flamesor smokeare observedwhile unit is running.

* Keepafire extinguishernearthe generatorat alltimes.

MODELNO: SERIALNO:

STAtVDARDS/#DEX

In the absence of pertinent standards, codes, regulations and laws, the publishedinformation listed below may be used as a guidelinefor operation of this equipment. Always referencethe

latestrevisionavailableforthe standardslisted.

1. NFPANo. 70, NFPAHANDBOOKOF NATIONALELECTRIC CODE.

2. Article X, NATIONALBUILDINGCODE, available from the American InsuranceAssociation, 85 John Street, NewYork,

N.Y.10038.

3. AGRICULTURALWIRINGHANDBOOK,availablefromthe Food and EnergyCouncil, 909 UniversityAvenue, Columbia, Me

65201.

4. ASAE EP-3634, INSTALLATIONAND MAINTENANCEOF FARMSTANDBYELECTRICALSYSTEMS,availablefrom the AmericanSocietyof AgriculturalEngineers,2950 NilesRoad, St. Joseph,MI49085.

Generator Identification

Unit ID

Locations

CALIFORNIAPROPOSiTiON65WARNING

Engineexhaustand someof its constituentsareknown

tothe Stateof Californiato causecancer,birth defects

and otherreproductiveharm.

CALIFORNIAPROPOSITION65WARNING

Thisproduct containsor emitschemicalsknownto the

StateofCaliforniato cause cancer,birthdefectsand

otherreproductiveharm.

1.1 UNPACKING

• Removeall packagingmaterial.

• Removeseparateaccessory box.

• Removecarton off the generator.

1.1.1 ACCESSORYBOX

Checkall contents(Figure1). If anypartsaremissing ordamaged locatean authorizeddealerat 1-888-775-6937.

Contentsinclude:

• 2-Axle Pins • Oil Filter

• 2- WheelSpacers • Air Filter

• 2- Hair Pins • SparkPlug

• 2- Wheels • SparkPlugWrench

• 1 - FrameFoot • ShopTowel

• 2 - FrameBolts • 2 - FrameWashers

• 2-Vibration Mounts • Oil Funnel

• 4 - FlangeNuts 12 VoltAdaptorPlugCharger

• 2 - 1 Quart SAE30 Oil Bottles

Figure 1- Accessory Boxes

• Referto Figure2 and install the wheel kit andframe foot as

follows:

• Slidethe AxlePinthroughthe Wheel,Wheel Spacer(Washer) andthe Frame.

• Installthe Hair Pinto the Axle Pinto securethe wheel. Repeat forthe oppositeside.

• SecuretheVibrationMountsto theFrameFootwiththeincluded locking nuts.

• To install the Frame Foot, install the Frame Bolts though the FrameWashers,Frameand Framefoot.Securewith thelocking nuts.

Figure 2 - Wheel and Foot Assembly

FOOT

SECUREWHEEL ANDAXLEWITH

HAIRPIN

1.2 ASSEMBLY

Read entireOwner's Manual before attemptingto assemble or operatethe generator. The generator requiressome assembly prior to usingit. If problemsarisewhenassemblingthe generator, pleasecall the GeneratorHelplineat 1-888-775-6937.

1.2.1 ASSEMBLINGTIlE WHEELKITANDFRAMEFOOT

Thewheelkit is designedto greatly improvethe portability of the generator.You will needthe following tools to install the wheel kit: Pliers,1/2" (13mm) wrench and a socketwrench with a 1/2" (13mm) socket.

NOTE:

The wheel kit is not intendedfor over-the-road use.

FRAME

WASHER

FRAME

BOLT

WHEELSPACER

(WASHER)

SLIDEAXLE

THROUGHWHEEL

ANDWHEEL

SPACER

2.1 KNOWTHEGENERATOR

Read the entire Owner's Manual and Safety Rules before operatingthisgenerator.

Compare the generator to Figures 3 through 6 to become

familiarizedwith thelocationsof variouscontrolsandadjustments.

Savethis manualfor future reference.

1. ChokeKnob- Usedwhen startinga coldengine (Pull/Push).

2. EngineSwitch - Controlsthe operationof the generator.On electric start models the switch is Start/Run/Stop.On recoil start modelsthe switch is On/Off.

3. FuelShut Off - Valvebetweenfuel tank and carburetor.Turn off and run carburetoroutof fuelfor extendedstorage.

4. PanelLED's- Provideilluminationof the control panelwhile thegeneratoris operating.

5. 120/240 VoltAC, 30 Amp LockingReceptacle- Supplies electricalpowerfor the operationof 120 and/or240 VoltAC, 30 Amp, single-phase,60 Hz, electrical lighting, appliance,

tool andmotor loads.

5. 120 Volt AC, 20 Amp,GFCiDuplexReceptacle- Supplies electrical power for the operationof 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)- Each20 Amp receptacleis provided with a push-to-reset circuit breakerto protectthe generator againstelectricaloverload.

8. Circuit Breakers (AC)- The30 Amp receptacleis protected with a pair of push-to-reset circuit breakersto protect the generatoragainstelectricaloverload.

g. PowerBar- Indicatesthe amountof power being usedfrom

thegenerator;each sectionis approximately25%

10. Hourmeter - Providesoperatinghoursfor Service Intervals.

11. Battery Charger input (Electric Start Models) - This receptacleallowsthe capabilityto rechargethe12 VDCengine starting battery with the 12 Volt Adaptor Plug Charger.The batteryisprotectedby a1.50 Amp in-linefuse whichis inside thecontrol panel.

12. FuelTank- Tankholds 9 U.S.gallonsoffuel.

13. FuelGauge- Showsfuel levelin tank.

14. Handles - Pivot and retractfor storage. Press the spring- loadedbuttonto move handles.

15. Oil Fill- Checkoil levelandadd oil here.

18. GroundingLug- Groundthe generatorto an approvedearth groundhere.See"GroundingtheGenerator"for details.

17. Muffler- Includesthe sparkarrestor andquietsthe engine.

18. Spark Plug Location - The spark plug ignites the Air/Fuel Mixture(Sidepanelmust beremoved).

lg. EngineOil Filter- Filtersengineoil; seeSection3.1 for the

properservice intervals.

20. Air Cleaner- Filtersintakeair as it is drawn intothe engine.

21. Oil Drain- Drain valveto remove used oil from the engine crankcase.

22. Recoil Starter- Useto start enginemanually.

Figure 3 - GeneratorLocations

2 5 8 9 10

3 4 7 8 4

2.1.1 BATTERYCONNECtiONfXG7OOOE& XG8OOOE)

NOTE:

The battery shippedwiththe generator hasbeen fully charged.

A battery may losesomeof itschargewhennot in use for

prolongedperiodsof time.If the battery isunable to crank

the engine, pluginthe 12V chargerincludedinthe accessory

box(see the Chargingthe Battery section).RUNNINGTHE

GENERATORDOESNOTCHARGETHEBATTERY.

Whenthe hour meter is inthe FlashAlert mode,the maintenance message will always alternate with elapsed time in hours and tenths. The hours wilt flash four times, then alternate with the maintenancemessagefourtimes untilthemeterresetsitself.

* 100 hours- CHGOIL-- OilChangeInterval(Every100 hrs) * 200 hours- SVC-- Air FilterInterval(Every200 hrs)

2.3 CORDSETSAND CONNECTIONPLUGS

The positive battery wire was deliberately left detached for shipping. To operatethe unit, attachthis wire to the terminal on

the startermotor as shown.Do not overtighten.Slidethe attached

rubber bootoverthe starterterminal.SeeFigure4.

Figure4 - Battery Connection

/ L_'! / //// /fi BATTERYCABLE_

2.2 HOUBMETEB

The Hourmeter tracks hours of operation for scheduled maintenance:

Therewilt be aonetime breakin "CHGOIL"messagethat flashes with the elapsedtime in hours and tenths after thefirst 30 hours of operation.

This messagewill actually beginflashing at 29 hoursand disable itself at 31 hours providing a two hour window to perform the

service. Therewill be a subsequent"CHGOIL"messageevery 100 hours.

Themessagewill flash one hour before and one hour after each 100 hour interval,again providingatwo hour window to perform

service. Every200 hours the "SVC"icon on the lower left hand corner of

the displaywill flash. Themessagewill flashone hourbeforeand

onehourafter each 200 hourintervalprovidingatwo hourwindow

to perform service.

2.3.1 120VAC,20AMP,GFC/DUPLEXRECEPTACLE

This is a 120 Volt outletprotectedagainst overloadby a 20 Amp push-to-resetcircuitbreaker(Figure5). Useeachsocketto power 120 VoltAC,singlephase,60 Hzelectricalloadsrequiringupto a combined 2400 watts (2.4 kW) or 20 Amps of current.Use only high quality,well-insulated,3-wire grounded cord sets ratedfor 125 Volts at 20 Amps (or greater).

Keep extensioncords as short as possible, preferablyless than 15 feet long, to preventvoltage dropand possibleoverheatingof wires.

2.3.2 120/240VAC,30AMP RECEPTACLE

Use a NEMA L14-30 plug with this receptacle (rotate to lock! unlock). Connecta suitable4-wire groundedcord set to the plug

andto thedesiredtoad.The cordsetshouldberatedfor 250 Volts ACat 30 Amps (or greater)(Figure5).

Use this receptacleto operate 120 Volt AC, 60 Hz, singlephase loads requiringup to 3600 watts (3.6 kW) of powerat 30 Amps or 240 VoltAC,60 Hz,singlephaseloadsrequiring6,500 to 8000 watts of power,dependingonthemodel.The outletis protectedby a 30 Ampcircuit breaker.

Figure5- GeneratorReceptacles

Kin

, a

120 VAC20A

GFCIRECEPTACLE

120/240 VAC30A

RECEPTACLE

2.4 HOW TO USETHEGENERATOR

If thereareany problems operatingthe generator,pleasecall the generatorhelplineat 1-888-436-3722.

,l_ 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.

,l_The engine exhaust fumes contain carbon

monoxide, which can you cannot see or smell. This poisonous gas, if breathed insufficient 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.

,l_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.

,l_The manufacturer recommends installing

a battery operated carbon monoxide alarm

indoors, according to the manufacturers

instructions.

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell.

SpecialRequirements

There may be Federalor State OccupationalSafety and Health Administration(OSHA)regulations,localcodes,or ordinancesthat

applyto the intendeduse ofthe generator. Pleaseconsult a qualified electrician, electricalinspector, or the

local agencyhavingjurisdiction:

* In some areas, generators are requiredto be registeredwith

local utilitycompanies.

* If the generatoris used at a construction site, there may be

additionalregulationswhich must be observed.

Connectingto a Building'sElectricalSystem

Connectionsfor standby power to a building's electricalsystem must be made by a qualified electrician. The connection must isolatethe generatorpower from utility power or other alternative power sources and must comply with all applicable laws and

electricalcodes.

2.4.2 GROUND/NG TIlE GENERATOR

The National Electrical Code requires that the frame and external electrically conductive parts

of this generator be properly connected to an approved earth ground.

Local electrical codes may also require proper grounding of the unit (Figure6). Forthat purpose, connecting a No. 10 AWG

(AmericanWireGauge)strandedcopperwire to the groundinglug and to an earth=drivencopperor brass groundingrod (electrode) provides adequateprotection against electrical shock. However, local codesmayvary widely.Consultwith a localelectricianfor

grounding requirements inthe area. Proper groundingof the generatorwill help preventelectrical

shockin the eventof a groundfault conditioninthe generatoror in connectedelectricaldevices.Propergroundingalsohelpsdissipate static electricity,which often builds up in ungroundeddevices.

Figure6 - GeneratorGroundLocation

NEVER use insidea home

or garage, EVEN iF doors and windows areopen,

Only use OUTSIDE and far away from windows,

doors, and vents.

2.4.1 SYSTEMGROUND

Thegeneratorhas a system groundthat connectsthe generator

frame components to the ground terminals on the AC output

receptacles. The system groundis bondedto theAC neutralwire in the generatorcontrol panelvia ajumperwire.

LOCATION

XG6500& XG7000

GROUNDLOCATION

2.4.3 NEUTRAL70FRAMEGROUNDING

If service work is performedon the alternator,DO NOTdiscard

the white jumper wires from the terminal blockto the alternator

ground, located on the rear bearingcarrier. Always make sure

the wires areproperlyconnected beforeusingthe generatorafter

alternatorservicework is done (Figure7).

Failure to reconnect these wires may create a potential shock hazard when the generator is

running!

Figure7- NeutraltoFrameGround

DONOTDISCARD

WIREST

NEUTRALTO FRAMEGROUND

XG7000& 8000

Add up the ratedwatts (or amps) of all loadsto be connected

at onetime. This total should no begreaterthan (a) the rated wattage/amperagecapacity of the generator or (b) circuit breakerratingofthereceptaclesupplyingthepower.See"Don't

OverloadtheGenerator

2.5 DON'TOVERLOADTHEGENERATOR

Overloadinga generator in excess of its rated wattage capacity can resultindamageto the generatorandto connectedelectrical

devices.Observethefollowingto preventoverloadingthe unit:

* Addupthetotal wattageofallelectricaldevicesto be connected

at one time. This total should NOT be greater than the generator'swattagecapacity.

* The ratedwattageof lights can betaken from light bulbs. The

ratedwattageof tools, appliancesand motors can usually be foundona datalabelor decalaffixedto the device.

* If the appliance,tool or motor does not give wattage,multiply

voltstimes ampereratingto determinewatts (volts x amps = watts).

* Some electric motors, such as inductiontypes, require about

threetimes morewatts of power for startingthan for running. This surge of power lasts only a few seconds when starting suchmotors. Makesureto allowfor high startingwattagewhen selectingelectrical devicesto connectto the generator:

1. Figurethe watts neededto start the largestmotor.

2. Add to that figure the running watts of all other connected loads.

TheWattageReferenceGuideis providedto assist in determining how manyitemsthe generatorcan operateatonetime.

NOTE:

DONOTDISCARD

3EWIREST

NEUTRALTO FRAMEGROUNDXG6500

2.4.3 CONNECT/NGELECTR/CALLOADS

DONOTconnect240 Volt loadsto 120 Voltreceptacles. DONOTconnect3 phaseloadsto the generator. DONOTconnect50 Hzloadsto 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 Hzelectrical loads.

All figuresare approximate.See datalabel onappliancefor

wattagerequirements.

2.6 WATTAGEREFERENCEGUIDE

Device................................... RunningWatts

*AirConditioner(12,000Btu).......................... 1700

*AirConditioner(24,000Btu).......................... 3800

*AirConditioner(40,000Btu).......................... 6000

BatteryCharger(20Amp).............................. 500

BeltSander(3").................................... 1000

ChainSaw........................................ 1200

CircularSaw(6-1/2")........................... 800to 1000

*ClothesDryer(Electric)............................. 5750

*ClothesDryer(Gas)................................. 700

*ClothesWasher................................... 1150

CoffeeMaker...................................... 1750

*Compressor(1HP)................................. 2000

*Compressor(3/4HP)............................... 1800

*Compressor(1/2HP)............................... 1400

CurlingIron......................................... 700

*Dehumidifier....................................... 650

DiscSander(9").................................... 1200

EdgeTrimmer....................................... 500

ElectricBlanket...................................... 400

Electric NailGun.................................... 1200

Electric Range(per element)........................... 1500

Electric Skillet...................................... 1250

*Freezer............................................ 700

*FurnaceFan(3/5 HP) ................................ 875

*GarageDoor Opener............................ 500to 750

HairDryer......................................... 1200

Hand Drill.................................... 250 to 1100

HedgeTrimmer...................................... 450

Impact Wrench...................................... 500

Iron.............................................. 1200

*Jet Pump ......................................... 800

Lawn Mower....................................... 1200

Light Bulb.......................................... 1O0

Microwave Oven............................... 700 to 1000

*Milk Cooler....................................... 1100

OilBurneron Furnace................................. 300

OilFiredSpace Heater(140,000 Btu) ..................... 400

OilFiredSpace Heater(85,000 Btu) ...................... 225

OilFiredSpace Heater(30,000 Btu) ...................... 150

*Paint Sprayer,Airless(1/3 HP) ......................... 600

PaintSprayer,Airless (handheld)......................... 150

Radio......................................... 50 to 200

*Refrigerator........................................ 700

SlowCooker........................................ 200

*SubmersiblePump (1-1/2 HP) ........................ 2800

*SubmersiblePump (1 HP) ........................... 2000

*SubmersiblePump (1/2 HP).......................... 1500

*Sump Pump................................. 800 to 1050

*Table Saw(10") ............................. 1750 to 2000

Television..................................... 200to 500

Toaster..................................... 1000to 1650

WeedTrimmer ...................................... 500

* Allow 3 times the listedwatts for startingthese devices.

2.7 BEFORESTARTINGTHEGENERATOR

Prior to operating the generator, engine oil and gasoline will need

to be added, as follows:

2,7,1 AD#/NGEflG/NEO/L

TEMPERATURE IN DEGREES FAHRENHEIT (°F)

=30 =20 ='tO 0 10 20 32 40 55 70+

||||

=30 =20 =10 0 10 20

TEMPERATURE IN DEGREES CELSIUS (°C)

• Placegeneratoron a levelsurface.

• Cleanareaaroundoil fill andremoveoilfill cap.

• Slowly fill enginewith oil through the oil fill opening until it

reachesthe full mark.Stopfilling occasionallyto check oil level. (Engineoil is full when levelis up to the threadsof the oil fill

plug,seeFigure8)

• Installoilfill cap andfingertighten securely.

• Checkengineoil levelbeforestarting eachtime thereafter.

Figure 8 - Off Level

FILLCRANKCASETO

THE BOTTOMOFTHESE

-- THREADSWiTHTHE RECOMMENDED

ENGINEOIL

--J

All oil should meet minimum AmericanPetroleumInstitute (API) Service Class SJ, SL or better.Useno special additives. Select

the oil's viscosity grade according to the expected operating temperature(also seechart).

• Above40° F,useSAE30

• Below40° Fand downto 10° F,use10W-30

• Below10° F,usesynthetic5W-30

,_Any attempt to crankor start the enginebeforeit has

been properlyserviced with the recommendedoil may

resultin anenginefailure.

2.7,2 ADD/NGGASOLINE

ADO NOTlighta cigaretteor smokewhen filling the fuel

tank.

,_ Neverfiil fuel tankindoors.Neverfiil fuel tankwhen

engineis runningor hot.Avoid spillinggasoline on a hot engine.Allow engineto coolentirelybeforefilling fuel

tank.

Donot overfill the fuel tank.Alwaysleave roomfor fuel expansion,if thefuel tank isoverfilled,fuel canoverflow

onto ahot engine and causeFiREor EXPLOSION.Wipe up anyspilledfuel immediately.

• Use regularUNLEADEDgasolinewith the generatorengine. Do not usepremiumgasoline.Do not mix oil with gasoline.

• Do not usegasolinewith morethan 10% alcohol suchas E85 or Methanol.

• Cleanareaaroundfuel fill cap, removecap.

• Slowly addunleadedregulargasolineto fueltank. Fillto bottom of screenfilter. Be carefulnot to overfill (Figure9).

• Installfuel cap andwipe up any spilled gasoline.

Figure g- Fuel Fill Level

DONOTFILL AB( LIP!

Figure 10- Fuel Shut-off Valve

IMPORTANT:Itisimportantto preventgumdepositsfrom forming in fuel system parts such as the carburetor, fuel hose or tank during storage. Alcohol-blendedfuels (called gasohol, ethanol or methanol)can attract moisture, which leads to separationand

formation of acids duringstorage.Acidic gascandamagethefuel

system of an enginewhile in storage.Toavoid engineproblems,

the fuel system should be emptiedbefore storageof 30 days or

longer.Seethe "Storage"section. Neveruseengineor carburetor cleaner products in the fuel tank as permanent damage may

occur.

2.8 TOSTARTTHEENGINE

Never startor stopenginewithelectricaldevices pluggedinto the receptacles ANDdevices turnedon.

• Unplug all electrical loads from the unit's receptaclesbefore startingthe engine.

• Makesurethe unit is in a levelposition.

• Openthefuel shut-off valve (Figure10).

• Pull engine CHOKEknob outward to "Full Choke" position (Figure11).

2.8.1 MANUAL_ STARTING

• Tostartthe generator,put the on/off switch in the ONposition.

• Firmly grasp the recoil handleand pull slowly until increased resistanceisfelt. Pull rapidlyup and awayto start engine.

• When the engine starts, push choke knob to "1/2 Choke" position untilthe engine runssmoothly and thenfully in to the "Run" position. If enginefalters, pull choke knob back out to "1/2 Choke" position until the engine runs smoothlyandthen to "Run" position.

NOTE:

If enginefires, but doesnot continuetorun,pull chokeknob

to "Furl Choke" and repeatstartinginstructions.

IMPORTANT:Do notoverloadthe generator.Also, donot overload individual panelreceptacles.These outlets are protectedagainst overload with push-to-reset-typecircuit breakers. Read "Don't OverloadtheGenerator"carefully.

2.8.1 ELECTRICSTARtiNG(XG7OOOE&XGSOOOE)

• Tostart the engine,pressandholdtheStart/Run/Stopswitch in the "Start" position.Theenginewill crankand attemptto start.

Whenthe enginestarts, releasetheswitch to the run position.

• When the engine starts, push choke knob to "1/2 Choke"

position untilthe engine runssmoothly andthenfully in to the "Run" position. If enginefalters, pull choke knob back out to

"1/2 Choke" position until the engine runs smoothlyandthen

to "Run" position.

• This generatoris also equippedwith a manual recoil starter

which may be usedif the battery is discharged.

NOTE:

TheengineStart/Run/Stop switch mustbe in the RUN

position whenusingthe manualrecoil starter.

2.9 STOPPINGTHEENGINE

* Shutoff all loads,thenunplugtheelectricalloadsfrom generator

panelreceptacles.Neverstart or stoptheenginewithelectrical devicespluggedin andturnedon.

* Let engine run at no-load for several minutes to stabilizethe

internaltemperaturesof engineandgenerator. , Move Start/Run/StoporOn/Offswitch to the "Off" position. * Closefuel valve.

2.10LOWOILPRESSURESHUTDOWNSYSTEM

Theengineis equippedwith a low oil pressuresensorthatshuts downthe engineautomaticallywhentheoil pressuredropsbelow 5 psi. A delay built into the low oil shutdown system allows oil

pressureto build during starting. The delayallows the engineto run for about10 secondsbeforesensingoilpressure.If the engine

shutsdown by itselfandthe fueltank hasenoughgasoline,check engineoil level.

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.

Use batterychargerplugto keepthe batterychargedand ready for use.Batterychargingshouldbedonein a dry location.

1. Plugchargerinto "BatteryChargerInput" jack, locatedon the control panel.Plugwall receptacleendof the batterycharger

into a120VoltACwall outlet.

2. Unplugbattery chargerfrom wall outlet andcontrolpaneljack whengeneratoris goingto be inuse.

NOTE:

Donot use the battery chargerfor more than 48 hoursat one

charge.

3.1 MAINTENANCESCHEDULE

Follow the calendar intervals. More frequent service is required whenoperatingin adverseconditionsnotedbelow.

CheckOil Level ChangeOilandOilFilter:!:

CleanSparkArrestor Screen ServiceAir Cleaner

*Every Season/Every100 Hours *Every Season/Every100 Hours

**Every Season/Every200 Hours

ReplaceSparkPlug

Changeoil after first 30 hours of operationthenevery season.

Changeoil 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 cleanerparts if very dirty.

At EachUse

EverySeason

3.2 PRODUCTSPECIFICATIONS

2.10.1RESTARtiNG

Iftrying to restartthe enginewithin 10secondsafterit shutsdown,

the enginemay NOTstart. Thesystem needs5 to 10 secondsto

reset. If the engineis restarted after such a shutdown and the low oil

pressurehas not beencorrected,the enginewill run for about10 secondsas describedaboveandthen stop.

2.11CHARGINGTHEBATTERY(XGTOOOE&XG8OOOE)

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.

3.2.1 GENERATORSPEC/F/CATIONS

Model # ............................................................... 005800-0, 005747-0

RatedMax. Power................................................................... 8.0 kW**

SurgePower................................................................................ 10 kW

RatedACVoltage...................................................................... 120/240

RatedMax ACLoad

Current@ 240V............................................................. 33.3 Amps**

Current@ 120V............................................................. 66.7 Amps**

RatedFrequency.................................................... 60 Hz @ 3600 RPM

Phase................................................................................ SinglePhase

RatedDCVoltage...................................................................... 12 Volts

BatteryType.................................................................... 10 AH, 12VDC

Model # ............................................................... 005797-0, 005798-0

RatedMax. Power................................................................... 7.0 kW**

SurgePower............................................................................. 8.75 kW

RatedACVoltage...................................................................... 120/240

RatedMax ACLoad

Current@ 240V............................................................. 29.2 Amps**

Current@ 120V............................................................. 58.3 Amps**

RatedFrequency.................................................... 60 Hz @ 3600 RPM

Phase................................................................................ SinglePhase

RatedDCVoltage...................................................................... 12 Volts

BatteryType.................................................................... 10 AH, 12VDC

Model # ................................................................................ 885796-0

RatedMax. Power................................................................... 6.5 kW**

SurgePower............................................................................. 8.13 kW

RatedACVoltage...................................................................... 120/240

RatedMax ACLoad

Current@ 240V............................................................. 27.1 Amps**

Current@ 120V............................................................. 54.2 Amps**

RatedFrequency.................................................... 60 Hz @ 3600 RPM

Phase................................................................................ SinglePhase

RatedDCVoltage...................................................................... 12 Volts

** Maximumwattageandcurrentaresubjectto,andlimitedby,suchfactors

asfuelBtucontent,ambienttemperature,altitude,enginecondition,etc.. Maximumpowerdecreasesabout3.5%foreach1,000feetabovesealevel; andwillalsodecreaseabout1%for each6° C(10° F)above16°C(60° F) ambienttemperature.

* FuelSystem * Air InductionSystem

FuelTank - Intakepipe/manifold FuelCap - Aircleaner Carburetor • IgnitionSystem FuelLines - Sparkplug

* EvaporativeControl System - Ignitionmodule

CarbonCanister * ExhaustSystem VaporHoses _ PulseAir InjectionValve

Muffler

The EmissionsCompliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the enginehas beenshown to meetFederalandCalifornia

emission requirements.See the table below to determinethe compliance periodfor your generator.The displacementof your generatoris listed onthe EmissionsComplianceLabel.

Displacement Category CompliancePeriod

A 500 Hours

_>66 cc- < 225 cc B 250 Hours

C 125 Hours A 1000 Hours

_>225 cc B 500 Hours

C 250 Hours

3.2.2 ENGINESPECIFICAtiONS

RatedHorsepower@ 3600 RPM.................................................... 14.5

Displacement............................................................................... 410cc

SparkPlugType................................... ChampionRO14YOor Equivalent

SparkPlug Gap............................................... 0.030 inch or (0.76 mm)

GasolineCapacity............................................................ 9 U.S.gallons

OilType.................................... SeeChart in"AddingEngineOil"Section

OilCapacity................................................ w/Filter Change= 1.5 Qts.

w/o FilterChange= 1.2Qts.

RunTime/FuelConsumption-l/2 Load.. 10 Hours/ .73 gallons per hour ClassI1EmissionCertified

3.2.3 EM/SS/ONS/NFORMATiON

The Environmental Protection Agency (EPA) and California Air ResourceBoard(CARB)requirethat your generatorcomply with exhaust and evaporativeemission standards. This generator is certified to meet the applicable EPAand CARB emission levels. Additionalinformationregardingthe requirementsset by EPAand

CARBis asfollows: It is important that you follow the maintenance specifications

providedinthis manualto ensurethat your enginecomplies with the applicableemissionstandardsfor the duration of the engine's life. This engine is certified to operateon gasoline.The emission control system onyourgeneratorconsistsof the following:

3.3 GENERALRECOMMENDATIONS

Thewarranty of thegeneratordoes notcover itemsthat havebeen subjectedto operator abuseor negligence.To receivefull value

from the warranty,the operator must maintain the generatoras instructed inthis manual.

Some adjustmentswilt need to be made periodically to properly maintainthegenerator.

All adjustmentsinthe Maintenancesectionof this manual should be madeat leastonce eachseason.Followthe requirementsinthe

"MaintenanceSchedule".

NOTE:

Oncea year replace the spark plug and replace the air filter.

A new sparkplug and clean air filter assure proper fuel-air

mixture and help the engine run better and last longer.

3.3.1 GENERATORMAINTENANCE

Generatormaintenanceconsists of keepingtheunitcleanand dry. Operateandstorethe unit ina cleandry environmentwhereit will not beexposedto excessivedust,dirt, moistureor any corrosive

vapors.Coolingair slotsin thegeneratormustnot becomeclogged with snow, leaves,or any otherforeign material.

Checkthe cleanlinessof the generatorfrequentlyand clean when dust, dirt, oil, moisture or otherforeign substancesarevisible on

its exteriorsurface.

,&CAUTION!

,_ Never insertany object or toolthroughthe air cooling

slots, even if the engine is notrunning.

+ 30 hidden pages