MODEL: 005802-2
Owner's Manual
XG Professional Series Portable Generator
www.generac.com or 1-888-GENERAC
DEADLY EXHAUST FUMES! ONLY use OUTSIDE
far away from windows, doors and vents!
NOT INTENDED FOR USE IN CRITICAL LIFE
SUPPORT APPLICATIONS.
SAVE this Manual. Provide this manual to any
operator of the generator.
Tab l e o f Co n t e n t s
Introduction ............................................................. 1
Read this Manual Thoroughly ................................. 1
Safety Rules ........................................................... 1
Standards Index .............................................................3
General Information ................................................ 4
1.1 Unpacking ......................................................................4
1.2 Assembly .......................................................................4
Operation ................................................................ 5
2.1 Know the Generator .......................................................5
2.2 Hourmeter ......................................................................6
2.3 Cord Sets and Connection Plugs ....................................6
2.4 How to Use the Generator ..............................................7
2.5 Don’t Overload the Generator ..........................................8
2.6 Wattage Reference Guide ...............................................8
2.7 Before Starting the Generator .........................................9
2.8 Cold Weather Operation/De-icer ....................................10
2.9 To Star t the Engine .......................................................10
2.10 High Altitude Operation .................................................10
2.11 Stopping the Engine .....................................................11
2.12 Low Oil Pressure Shutdown System .............................11
2.13 Charging the Battery .....................................................11
Maintenance ......................................................... 11
3.1 Performing Scheduled Maintenance .............................11
3.2 Maintenance Schedule ................................................. 11
3.3 Product Specifications ..................................................11
3.4 General Recommendations ...........................................12
3.5 Service Air Filter ...........................................................13
3.6 Clean Spark Arrestor Screen.........................................13
3.7 General ........................................................................14
3.8 Long Term Storage .......................................................14
3.9 Other Storage Tips .......................................................14
Battery Service ..................................................... 14
4.1 Battery Replacement ....................................................14
Troubleshooting .................................................... 15
5.1 Troubleshooting Guide ..................................................15
Warranty ............................................................... 16
Engine exhaust and some of its constituents are known to the state of California to cause cancer,
This product contains or emits chemicals known to the state of California to cause cancer,
WARNING!
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birth defects, and other reproductive harm.
WARNING!
'EPMJSVRME4VSTSWMXMSR
birth defects, and other reproductive harm.
Safety Rules
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.
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. Save these instructions
for future reference. If you loan this unit to someone, ALWAYS loan
these instructions to the individual as well.
The generator can operate safely, efficiently and reliably only if it
is properly located, operated and maintained. Before operating or
servicing the generator:
Become familiar with and strictly adhere to all local, state and
national codes and regulations.
Study all safety warnings in this manual and on the product
carefully.
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.
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.
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 par ticular
operation that may be hazardous if performed incorrectly or
carelessly. Observe them carefully. Their definitions are as follows:
INDICATES A HAZARDOUS SITUATION OR ACTION
WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH
OR SERIOUS INJURY.
Indicates a hazardous situation or action which, if
not avoided, could result in death or serious injury.
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.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
This symbol points out important safety
information that, if not followed, could
endanger personal safety and/or property of
others.
This symbol points out potential explosion
hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical
shock hazard.
GENERAL HAZARDS
NEVER operate in an enclosed area, in a vehicle, or indoors
EVEN IF doors and windows are open.
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.
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.
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 star t or stop the unit with electrical loads connected
to receptacles AND with connected devices turned ON. Start
the engine and let it stabilize before connecting electrical
loads. Disconnect all electrical loads before shutting down the
generator.
Do not insert objects through unit’s cooling slots.
When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
1
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.
EXHAUST & LOCATION HAZARDS
• Never operate in an enclosed area or indoors! NEVER use
in the home, in a vehicle, 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.
ELECTRICAL HAZARDS
The generator produces dangerously high voltage when in
operation. Avoid contact with bare 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).
Do not use worn, bare, frayed or otherwise damaged electrical
cord sets with the generator.
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.
The engine exhaust fumes contain carbon monoxide, which
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.
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.
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.
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.
• 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.
2
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.
Keep a fire extinguisher near the generator at all times.
In the absence of per tinent 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.
MODEL NO:
SERIAL NO:
Generator Identification
3
General Information
Remove all packaging material.
Remove separate accessory box.
Remove carton off the generator.
Check all contents (Figure 1). If any par ts are missing or damaged
locate an authorized dealer at 1-888-436-3722.
Contents include:
1 – Axle (secured to frame) Oil Filter
2 – Wheel Spacers Air Filter
2 – Hair Pins Spark Plugs
2 – Wheels Shop Towel
1 – Frame Foot 2 – Large Washers
2 – Carriage Bolts 2 – Small Washers
2 – Vibration Mounts Oil Funnel
4 – Flange Nuts 2 – Hex Head Bolts (long)
2 – 1 Quart SAE 30 Oil Bottles 2 – Hex Head Bolts
12 Volt Adaptor Plug Charger (short)
2 Spacers or 4 Large Washers
Figure 1 Accessory Box
The wheel kit is designed to greatly improve the portability of the
generator. You will need the following tools to install the wheel kit:
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.
Refer to Figure 2 and install the wheel kit and frame foot as
follows:
Slide the Axle through the Wheel, Spacer or Large Washer and
the Frame. Note orientation of wheel.
Add Washer outside of Wheel and install the Hair Pin to the Axle
to secure the Wheel. Repeat for the opposite side.
Secure the Vibration Mounts to the Frame Foot with the included
hardware.
To install the Frame Foot, install the bolts through the Washers,
Frame and Frame foot. Secure with the flange nuts.
Figure 2 Wheel and Foot Assembly
Read entire Owner's Manual before attempting to assemble or
operate the generator. The generator requires some assembly
prior to using it. If problems arise when assembling the generator,
please call the Generator Helpline at 1-888-436-3722.
4
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
this electric start model the switch is Start/Run/Stop.
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. 120/240 Volt AC, 50 Amp Receptacle – Supplies electrical
power for the operation of 120/240 Volt AC, 42 Amp, singlephase, 60 Hz motor loads.
8. Circuit Breakers (AC) – Each 20 Amp receptacle is provided
with a push-to-reset circuit breaker to protect the generator
against electrical overload.
9. Circuit Breakers (AC) – The 30 Amp receptacle is protected
with a push-to-reset circuit breaker to protect the generator
against electrical overload. The 50 Amp receptacle and one 30
Amp receptacle use toggle reset circuit breakers. The 42 Amp,
2-pole circuit breaker adjacent to the 50 Amp receptacle must
be in the ON position for all the other receptacles to provide
output power.
10. PowerBar – Indicates the amount of power being used from
the generator; each section is approximately 25%.
11. Hourmeter – Provides operating hours for Service Intervals.
12. Battery Charger Input – 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.
13. Fuel Tank – Tank holds 10 U.S. gallons of fuel.
14. Fuel Gauge – Shows fuel level in tank.
15. Handles – Pivot and retract for storage. Press the spring-
loaded button to move handles.
16. Oil Fill – Check oil level and add oil here.
17. Engine Oil Filter – Filters engine oil; see Section 3.1 for the
proper service intervals.
18. Air Filter – Filters intake air as it is drawn into the engine.
19. Spark Plug Location – The spark plugs ignite the Air/Fuel
Mixture.
20. Muffler – Includes the spark arrestor and quiets the engine.
21. Oil Drain – Drain valve to remove used oil from the engine
crankcase.
Operation
22. 12 Volt (18 Amp Sealed Battery) – Used to start engine.
23. Grounding Lug – Ground the generator to an approved earth
ground here. See "Grounding the Generator" for details.
24. Roll Over Valve - Passes fuel vapors to the engine.
25. Evap Hose - Installed between the roll over valve and the
engine.
Figure 3 Generator & Engine Locations
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