Generac Power Systems XG, XG7000E, XG8000E, XG7000, XG6500 Owner's Manual

Owner'sIVlanuai

Series6,500-8,000WattPortableGenerator

GENERAC

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

ReadthisiVlanualThoroughly.................................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 WheelKit and FrameFoot..........4

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

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

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

2.2 Hourmeter=NoReset....................................................6

2.3 Hourmeter- With Reset..................................................6

2.4 CordSetsand ConnectionPlugs....................................7

2.4.1 120 VAC,20 Amp, GFCIDuplexReceptacle.......7

2.4.2 120/240 VAC,30 Amp Receptacle.....................7

2.5 How to Usethe Generator..............................................7

2.5.1 GroundingtheGeneratorWhenUsedasa

Portable.............................................................8

2.5.2 Connectingthe Generatorto a Building's

ElectricalSystem...............................................8

2.5.3 Neutralto FrameGrounding...............................8

2.5.4 ConnectingElectricalLoads...............................9

2.6 Don't Overloadthe Generator..........................................9

2.7 WattageReferenceGuide...............................................9

2.8 BeforeStartingthe Generator.......................................10

2.8.1 AddingEngineOil............................................10

2.8.2 AddingGasoline...............................................10

2.9 ToStartthe Engine.......................................................11

2.9.1 Manual(Recoil)Starting..................................11

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

2.10 Stoppingthe Engine.....................................................11

2.11 Low OilPressureShutdownSystem.............................11

2.11.1 Restarting........................................................12

2.12 Chargingthe Battery(XG7000E& XG8000E)................12

Maintenance.........................................................12

3.1 MaintenanceSchedule.................................................12

3.2 ProductSpecifications..................................................12

3.2.1 GeneratorSpecifications..................................12

3.2.2 EngineSpecifications.......................................13

3.2.3 EmissionsInformation.....................................13

3.3 GeneralRecommendations...........................................13

3.3.1 GeneratorMaintenance....................................13

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.................................14

3.4 ServiceAirFilter...........................................................14

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

3.6 General........................................................................15

3.7 LongTermStorage.......................................................15

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

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

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

Troubleshooting....................................................17

5.1 TroubleshootingGuide..................................................17

Notes....................................................................18

Warranty...............................................................20

Manualdelpropietario.....................................23

Manueld'entretien............................................45

iNTRODUCTiON

Thankyou for purchasingthis modelby 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 power outage.

READTHiSMANUALTHOROUGHLY

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
manualandthoroughlyunderstandall instructionsbeforeusingthe
equipment.Wealsostronglyrecommendinstructingotherusersto
properlystart andoperatethe unit.This preparesthemif they need

to operatethe equipmentin an emergency.

Thegeneratorcan operate safely,efficiently and reliablyonly if it
is properlylocated,operatedand maintained.Beforeoperatingor
servicingthe generator:

• Becomefamiliarwith and strictly adhereto all local, stateand
nationalcodes and regulations.

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

• Becomefamiliarwith this manualandthe unit beforeuse.

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

If usinga procedure,workmethod oroperatingtechniquethat the

manufacturerdoes not specifically recommend,ensurethat it is

safe for others. Also make sure the procedure,work methodor

operatingtechniqueutilizeddoes not renderthe generatorunsafe.

THE INFORMATIONCONTAINEDHEREIN WAS BASED ON

MACHINESIN PRODUCTIONAT THE TIME OF PUBLICATION.

GENERACRESERVESTHERIGHTTOMODIFYTHISMANUALAT

ANYTIME.

SAFETYRULES

Throughoutthis publication,and ontags and 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 hazardoussituationor actionwhich,if not

avoided, couldresultin minorormoderateinjury.

NOTE:

Notescontainadditionalinformationimportantto a procedure
and will be found within the regulartextbody ofthismanual

These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructionswhileperforming theaction orserviceareessentialto
preventingaccidents.

Four commonly used safety symbols accompany the 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 enclosed area, in a vehicle, or indoors
EVENIFdoors and windows areopen.

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

• Operategeneratoronly on levelsurfacesandwhereit will notbe
exposedto excessivemoisture,dirt, dust or corrosive vapors.

• Keephands, feet, clothing, etc., away from drive belts, fans,
and othermoving parts. 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 might createanunsafeoperatingcondition.

• Neverstart or stop the unit with electrical loads connected
to receptaclesANDwith connected devicesturned ON. Start

the engine and let it stabilize before connecting electrical
loads. Disconnectall electricalloads 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.

• Neverusethe generatoror anyof its parts as a step. Stepping
on the unit can stress and break parts, and may result in
dangerousoperating conditions from leakingexhaust gases,

fuel leakage,oil leakage,etc.

• Onelectric start models,disconnectthe POSITIVE(+) battery
cable from the engine starter ORthe NEGATIVE(=) battery
cable from the battery terminal, whichever is easier,before

transportingthe generator.

NOTE:

This generatoris equippedwith a spark arrestormuffler. The

spark arrestor must be maintained in effective working order

by the owner/operator.In the State of California, aspark
arrestor is requiredby law (Section 4442 ofthe California

Public Resources Code). Other states may have similarlaws.
Federal lawsapply on federallands.

EXHAUST & LOCATIONHAZARDS

• Never operate in an enclosed area or indoors!NEVERuse
in the home,in a vehicle,or in partlyenclosedareas such

as garages, evenif doors andwindowsare open! ONLYuse
outdoors and far from open windows,doors,vents,andinan

areathat will notaccumulatedeadly 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 dangerouslyhigh voltage when in
operation.Avoidcontactwithbarewires,terminals,connections,
etc., while the unit is running, even on equipmentconnected
to the generator. Ensureall appropriate covers, guards and
barriersarein place beforeoperatingthegenerator.

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

DANGEROUSELECTRICALSHOCKMAYRESULT.

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

may also require proper grounding of the generator.Consult
with a localelectricianfor groundingrequirementsinthearea.

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

• Do not useworn, bare,frayed orotherwise damagedelectrical
cord setswith the generator.

• Beforeperforminganymaintenanceonthegenerator,disconnect
the enginestarting battery (if equipped)to prevent accidental
start up. Disconnectthe cablefrom 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,suchasa rope orboard,to freethe victim from the
live conductor.If the victim is unconscious,applyfirst aid and
getimmediatemedicalhelp.

NEVER use insidea home
or garage, EVEN IF doors
and windows are open.

• The engine exhaust fumes contain carbon monoxide, which

you cannot see or smell. This poisonous gas, if breathedin

sufficientconcentrations,can causeunconsciousnessor 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 operationof the
generator.The generatorMUSTbeoperatedoutdoors.

• Thisexhaust systemmust be properlymaintained.Do nothing

that mightrendertheexhaustsystemunsafeorinnoncompliance

with any localcodes and/orstandards.

• Alwaysusea battery operatedcarbonmonoxidealarmindoors,
installedaccordingto the manufacturersinstructions.

• If you start to feet sick, dizzy,or weak afterthe generatorhas
beenrunning,moveto fresh air IMMEDIATELYSeea doctor,as
you couldhavecarbon monoxidepoisoning.

Only use OUTSIDE and
far away from windows,

doors,and vents.

FIREHAZARDS

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

vicinitywhilehandlinggasoline.

• Neveraddfuel whileunit isrunning or hot. Allow engineto cool

completelybeforeaddingfuel.

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

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

with fuel in tank where gasolinevapors might reachan open
flame, spark or pilot light (as on a furnace, water heateror
clothes dryer). FIREor EXPLOSIONmay result. Allow unit to
cool entirelybeforestorage.

• Wipe up any fuel or oil spills immediately.Ensure that no
combustiblematerialsareleft on ornearthe generator.Keepthe
areasurroundingthe generatorclean andfree from debrisand
keepa clearanceof five (5) feet on allside to allow for proper
ventilationof the generator.

* Do not insertobjectsthrough unit's cooling slots.
* Do not operate the generator if connected electrical devices

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

* Keepa fire extinguishernearthe generatorat all times.

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

latestrevisionavailablefor the 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,2950Niles Road,
St. Joseph,MI49085.

Generator Identification

Uni± I]D

Loci±ions

CALIFORNIAPROPOSiTiON65 WARNING

Engineexhaustandsomeof its constituentsareknown

tothe Stateof Californiato causecancer,birth defects

and otherreproductiveharm.

CALIFORNIAPROPOSiTiON65 WARNING

Thisproductcontainsor emits chemicalsknownto the

StateofCaliforniato cause cancer,birth defectsand

otherreproductiveharm.

1.1 UNPACKING

• Removeall packagingmaterial.

• Removeseparateaccessorybox.

• Removecarton off the generator.

1.1.1 ACCESSORYBOX

Checkall contents(Figure1). Ifany parts aremissing or damaged
locateanauthorizeddealerat 1=888=436=3722.

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 VoltAdaptor PlugCharger

• 2- 1 QuartSAE30 Oil Bottles

Figure 1 - Accessory Boxes

• Referto Figure 2 and install the wheel kit and frame foot as

follows:

• Slidethe AxlePin throughthe Wheel,WheelSpacer (Washer)
andthe Frame.

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

• SecuretheVibrationMountsto theFrameFootwith the included
locking nuts.

• To install the Frame Foot, install the Frame Bolts though the
FrameWashers,FrameandFramefoot. Securewith the flange
nuts.

Figure 2 - Wheel and Foot Assembly

FOOT

SECUREWHEEL
ANDAXLEWITH

HAIRPIN

1.2 ASSEMBLY

Read entireOwner's Manual beforeattempting to assemble or
operate the generator. The generator requiressome assembly
prior to usingit. If problemsarise whenassemblingthe generator,
pleasecall the GeneratorHelplineat 1=888=436=3722.

1.2.1 ASSEMBLINGTHEWHEELKITANBFRAMEFOOT

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

NOTE:

The wheel kit is notintendedfor over-the-roaduse.

FRAME

WASHER

I FRAME
I BOLT

I
I

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 (Putt/Push).

2. EngineSwitch - Controls the 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. Panel LED's- Provideilluminationof the control panelwhile
thegeneratoris operating.

5. 120/240 Volt AC, 30 Amp LockingReceptacle- Supplies
electricalpowerfor the operationof 120 and/or240 Volt AC,

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 protect the generator

againstelectricaloverload.

8. Circuit Breakers (AC)- The 30 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 ServiceIntervals.

11. Battery Charger input (Electric Start Models) - This
receptacleallowsthe capabilityto rechargethe12 VDCengine
starting battery with the 12 Volt Adaptor Plug Charger.The

batteryisprotectedby a 1.50 Ampin-linefuse which is inside
thecontrol panel.

12. FuelTank- Tankholds9 U.S.gallons offuel.

13. FuelGauge- Showsfuel levelintank.

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 ignitesthe Air/Fuel
Mixture(Sidepanelmust beremoved).

lg. Engine Oil Filter- Filtersengineoil; see Section 3.1 for the

properservice intervals.

20. Air Filter- Filters intakeair as it is drawn intothe engine.

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

22. RecoilStarter- Useto start enginemanually.

23. Roll OverValve- Passesfuel vaporsto the engine.

24. Recovery Hose - Install between roll over valve and the
engine.

Figure 3 - Generator Locations

1 2 5 6 9 10 11

,

@

@

4 7

12

13

17

15

24

16

23

18

2O

2.1.1 BATTERYCONNECtiONfXG7OOOE&XG8OOOE)

NOTE:

The battery shippedwith the generatorhasbeen fully charged.

A battery may losesome of itschargewhennot in use for
prolongedperiodsoftime. if the battery is unable to crank
the engine,plugin the 12V chargerincludedinthe accessory
box (seethe Chargingthe Battery section).RUNNINGTHE

GENERATORDOESNOTCHARGETHEBATTERY.
The positive battery wire was deliberately left detached for

shipping. To operatethe unit, attach this wire to the terminal on

the startermotor as shown.Do notovertighten.Slidethe attached

rubber bootover the starterterminal.SeeFigure4.

Figure4 - Battery Connection

2.2 HOURIVIETER-NO BESET

The Hourmeter tracks hours of operation
maintenance:

Therewill be aonetime break in "CHGOIL"messagethatflashes
with the elapsedtime in hoursand tenths afterthefirst 30 hours
of operation.

This messagewill actuallybeginflashing at 29 hours and disable
itself at 31 hours providing a two hour window to perform the

service.

for scheduled

Therewill be asubsequent"CHGOIL"messageevery 100 hours.
Themessagewilt flash one hour beforeand one hour after each
100 hour interval,again providinga two hour window to perform

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

thedisplay will flash. Themessagewill flash one hourbeforeand
onehouraftereach200 hourintervalprovidingatwo hourwindow
to performservice.

Whenthe hour meter is inthe FlashAlert mode, the maintenance
message will always alternate with elapsedtime in hours and
tenths. The hours wilt flash four times, then alternate with the
maintenancemessagefourtimes untilthemeter resets itself.

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

2.3 HOURIVlETFR-WiTHRESET

TheHourmetertrackshoursofoperationforscheduledmaintenance
(seechart) (Figure5).

Operation: Pushand releasethe reset button to toggle between
screens. The hours count backwards from the set interval as

shown in the chart.
Whenthe meter reaches5 hours,thetext"CHGOIL"(or"SVCAIR

FILTER"or "OHGPLUG")will flash continuallyfor two minutes.
Afterthis time,the meterwill go backto displayingthe total hours
of the unit (for 2 minutes). This cyte will repeatfor the entire 5

hours.
When the service interval reaches zero hours, the text "NOW"

replacesthe hours remaining.
Fora new generatorfor instance,the messagewill say "OHGOIL"

thenflash "in 30". This meansthat in 30 hours,theoil wilt needto
be changed. Pressingthe button a few moretimes will bring the

meter backto the screenthat shows thetotal hoursrun.
Reset: Toggleto the alert that you wish to reset then hold the

buttondownfor 9 seconds.Themaintenancehours areresetwhen
thedisplay shows "0000.0".

Note:

Thehourglassgraphicwill flash on and off whenthe engine
is running.This signifiesthatthe meter istrackinghoursof

operation.

Message

CHGOIL
CHGOIL

SVCAIRFILTER

CHGPLUG

Initial break-inperiod

Nourmeter(With Reset)Chart

Re-occuring
Re-occuring

Re-occuring

interval

First30 Hours

100 hours
200 hours

200 hours

Duration ofmessageFrequencyof Message

ON/OFFfor 2 minutes in a 5

hour period

Figure 5 - Hourmeter

0000.0

HOURGLASS RESETBUTTON
GRAPHIC (IF EQUIPPED)

2.4 CORDSETSANOCONNECTIONPLUGS

2.4.1 120VAC,20 AMP,GFC/DUPLEXRECEPTACLE

This is a 120 Volt outletprotectedagainst overloadby a 20 Amp
push-to-resetcircuitbreaker(Figure6). Useeachsocketto power
120 VoltAO, singlephase,60 Hzelectricalloadsrequiringupto a
combined 2400 watts (2.4 kW) or 20 Amps of current. Useonly
high quality,well-insulated, 3-wire grounded cord sets rated for
125 Volts at 20 Amps (or greater).

Keep extensioncords as short as possible, preferablylessthan
15 feet long, to preventvoltage drop and possibleoverheatingof

wires.

2.4.2 120/240 VAC,30 AMPRECEPTACLE

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

andto the desiredtoad.The cordset shouldbe ratedfor 250 Volts
ACat30 Amps (or greater)(Figure6).

Use this receptacleto operate120 Volt AC, 60 Hz, single phase
loads requiringup to 3600 watts (3.6 kW) of powerat 30 Amps
or 240 VoltAC,60 Hz,single phaseloads requiring6,500 to 8000
watts of power,dependingonthemodel.Theoutletis protectedby
a 30 Ampcircuit breaker.

Figure 6 - Generator Receptacles

2.5 HOW TO USETHEGENERATOR

Seethe "To Start the Engine"sectionfor how to safely start and
stop the generatorand how to connect and disconnect loads. If
there are any problems operatingthe generator,pleasecall the
generatorhelplineat 1-888-436-3722.

_t ever 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.

_t 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.

_t 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.

_t Always use a battery operated carbon

monoxide alarm indoors, installed 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.

O

120/240VAC30A

RECEPTACLE

120VAC20A

GFC]RECEPTACLE

NEVER use inside a home
or garage, EVEN IF doors

and windows are open,

Only use OUTSIDE and
far away from windows,

doors, and vents.

2.5.1 GROUNDINGTHEGENERATORWHENUSEDAS A

PORTABLE

This generator has an equipment ground that connects the
generatorframe componentsto the ground terminals on the AC
output receptacles (see NEC 250.34 (A) for explanation).This
allows the generatorto be used as a portablewithout grounding

the frameof the generatorasspecifiedin NEC250.34.

SpecialRequirements

There may be Federalor State OccupationalSafety and Health
Administration(OSHA)regulations,localcodes,or ordinancesthat
applyto the intendeduse ofthe generator.

Pleaseconsult a qualified electrician,electrical inspector,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.

2.5.2 CONNECTINGTHEGENERATORTOA BU/LO/NG'S
ELECTRICALSYSTEM

Connectionsfor standby power to a building's electricalsystem
must be made by a qualifiedelectricianand in strict compliance

with all national and local electrical codes and laws. The
connectionmust isolatethegeneratorpowerfrom utility poweror

otheralternativepowersources.

NOTE:

Figure7 - GeneratorGroundLocation

LOCATION

XG6500& XG7000

GROUNDLOCATION

2.5.3 NEUTRALTOFRAMEGROUNDING

If service work is performed on the alternator,DO NOTdiscard
the white jumper wires from the terminal block to the alternator

ground, located on the rear bearing carrier.Always make sure
thewires are properlyconnectedbefore usingthe generatorafter
alternatorservicework is done (Figure8).

Figure8 - Neutral toFrameGround

Becausethe generatorequipmentgroundis bondedto the AC
neutralwires in the generator (see Figure8), either a 3-pole
transferswitchor a 2poletransferswitchwitha switching
neutralkit isrequiredto connectthisgenerator to a building
load. in this application thegenerator becomesa separately
derived system(see NEC250.20 (D)), and mustbe grounded

in accordancewith thenationalor localelectricalcode
requirements.

GroundingtheGeneratorina BuildingStandbyApplication

,_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 (Figure7). Forthat purpose, connectinga No. 10 AWG

(AmericanWireGauge)strandedcopperwire to the groundinglug
and to an earth=drivencopperor brass groundingrod (electrode)
provides adequateprotection against electrical shock. However,
local codesmay varywidely. Consultwith a localelectrician for
grounding requirementsinthe area.

Proper groundingof the generator will help preventelectrical
shockin theeventof a groundfault conditioninthe generatoror in
connectedelectricaldevices.Propergroundingalsohelpsdissipate
static electricity,which often builds up in ungroundeddevices.

DONOTDISCARD

WIREST

NEUTRALTO FRAMEGROUND

XG7000& 8000

DONOTDISCARD

SEWIREST

NEUTRALTO FRAMEGROUNDXG6500

2.7 WATTAGEREFERENCEGUIDE

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

running!

2.5.4 CONNECtiNGELECTRICALLOADS

DONOTconnect240 Volt loadsto 120 Volt receptacles.
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 AO, single

phase,60 Hzelectricalloads.

* Add upthe ratedwatts (or amps) of all loadsto be connected

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

Overloadthe Generator

2.6 DON'TOVERLOADTHEGENERATOR

Overloadinga generator in excessof its rated wattage capacity
can resultin damageto the generatorandto connectedelectrical

devices.Observethefollowing to preventoverloadingthe unit:

* Addupthetotal wattageof all electricaldevicestobe connected

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

* The ratedwattageof lights can betakenfrom light bulbs. The

ratedwattageof tools, appliancesandmotors can usuallybe

found on a datalabelor decal affixedto the device.

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

voltstimes ampereratingto determinewatts (voltsx amps =
watts).

* Some electric motors, such as inductiontypes, require about

threetimes morewatts of powerfor starting than for running.

This surge of power lasts only a few seconds when starting
such motors.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 indetermining
how manyitems the generatorcanoperateat onetime.

IMPORTANT:Donot overloadthe generator.Also, do not overload
individual panelreceptacles.These outlets are protectedagainst
overload with push-to-reset-type circuit breakers. Read "Don't
OverloadtheGenerator"carefully.

NOTE:

Aft figuresare approximate.See data label onappliancefor

wattagerequirements.

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

*Air Conditioner(12,000 Btu).......................... 1700

*Air Conditioner(24,000 Btu).......................... 3800

*Air Conditioner(40,000 Btu).......................... 6000

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

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

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

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

*Clothes Dryer(Electric) ............................. 5750

*Clothes Dryer(Gas) ................................. 700

*Clothes Washer ................................... 1150

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

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

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

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

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

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

Disc Sander (9").................................... 1200

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

Electric Blanket...................................... 400

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

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

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

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

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

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

Hair Dryer......................................... 1200

HandDrill .................................... 250to 1100

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

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

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

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

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

LightBulb.......................................... 100

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

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

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

OilFiredSpaceHeater(140,000 Btu) ..................... 400

OilFiredSpaceHeater(85,000 Btu) ...................... 225

OilFiredSpaceHeater(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

*Submersible Pump (1/2 HP).......................... 1500

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

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

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

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

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

* Allow 3 times the listedwatts for startingthese devices.

2.8 BEFORESTARTINGTHEGENERATOR

Priorto operatingthe generator,engineoil and gasolinewill need

to be added,as follows:

2.8.1 ADD/NGENG/NEO/L

All oil should meet minimum American PetroleumInstitute (API)

Service Class SJ, SL or better. Use no special additives. Select
the oil's viscosity grade according to the expected operating
temperature(also seechart).

* Above40° F,use SAE30
* Below 40° Fand downto 10° F,use 10W-30
* Below 10° F,usesynthetic5W-30

,_ Anyattempt tocrankor start the enginebefore it has

been properlyserviced with the recommended oil may

resultin anenginefailure.

TEMPERATURE IN DEGREES FAHRENHEIT (°F)

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

Figureg - Oil Level

_H FILLCRANKCASETO

J _lJl THE BOTTOMOFTHESE

_/S)_ J J _ _----- THREADSWITHTHE

(/d/ )1 F ,' II RECOMMENDED

I ,

2.8.2 IIDD/NGGA$OL/NE

D0 NOTlighta cigaretteor smokewhenfilling thefuel
tank.

,_ Neverfill fuel tankindoors.Neverfill fuel tankwhen

engineis runningor hot.Avoid spillinggasoline on a hot
engine.Allowengineto coolentirelybeforefilling fuel

tank.

=30 =20 =10 0 10 20

TEMPERATURE IN DEGREES CELSIUS (°C)

* Place generatoron a level surface (not to exceed15° in any

direction).

* Cleanareaaroundoilfill andremoveoil fill cap.
* Slowly fill engine with oil through the oil fill opening until it

reachesthefull mark.Stopfilling occasionallyto checkoil level.
(Engineoil is full when level is up to the threadsof the oil fill

plug,seeFigure9)

* Install oil fill capandfingertighten securely.
* Checkengineoil levelbefore starting eachtime thereafter.

Do notoverfill thefuel tank.Always leave roomfor fuel
expansion. If thefuel tankis overfilled, fuel canoverflow

ontoa hotengineand 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 such as E85

or Methanol.

* Cleanareaaroundfuelfill cap, removecap.
* Slowly addunleadedregulargasolineto fueltank. Fillto bottom

of screenfilter.Becarefulnot to overfill(Figure10).

* Install fuelcap andwipe upany spilledgasoline.

Figure 10 - FuelFillLevel

DONOTFILL
ABOVELIP!

1o

IMPORTANT:It isimportantto preventgumdepositsfromforming

in fuel system parts such as the carburetor, fuel hose or tank

during storage. Alcohol-blended fuels (called gasohol, ethanol

or methanol)can attractmoisture, which leadsto separationand
formation of acids duringstorage.Acidic gascandamagethe fuel

system of an enginewhile in storage.To avoid engineproblems,
the fuel system should be emptiedbefore storageof 30 daysor

longer.Seethe "Storage"section. Neveruseengineor carburetor

cleanerproductsinthefuel tank aspermanentdamagemayoccur.

2.9 TOSTABTTHEENGINE

Never startor stopenginewithelectrical devicespluggedinto

thereceptaclesANDdevicesturnedon.

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

• Makesure the unit is in a levelposition (notto exceed15° in
anydirection).

• Openthefuel shut-offvalve (Figure11).

• Pull engine CHOKEknob outward to "Full Choke" position
(Figure12).

Figure 11 - Fuel Shut-off Valve

2.9.1 MANUAL_ STARTING

* To startthe generator,putthe on/off switch in the ONposition.
* Firmly grasp the recoil handle and pull slowly until increased

resistanceisfelt. Pull rapidlyup andawayto 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 smoothlyand then
to "Run" position.

NOTE:

If engine fires,butdoesnot continuetorun,pull chokeknob
to "Furl Choke" andrepeat startinginstructions.

2.9.2 ELECTRICSTARTING_XGTOOOE& XGSOOOE)___

* Tostart the engine,pressand holdtheStart/Run/Stopswitch in

the"Start" position. Theenginewill crankand attemptto start.
Whenthe enginestarts, releasethe switch to the run position.

* 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 smoothlyand then
to "Run" position.

* This generator is also equippedwith a manual recoil starter

which may be usedif the batteryis discharged.

NOTE:

I

Theswitchmust be inthe RUN position.Use one of the
generator's receptacleoutlets alongwiththe includedbattery
chargerto chargethe battery while the generator is running.

2.10STOPPINGTHEENGINE

• Shut off all loads, then unplug the electrical loads from
generatorpanelreceptacles.Neverstart or stopthe enginewith

electricaldevices pluggedin andturned on.

• Let engine run at no-load for several minutes to stabilizethe
internaltemperaturesof engineandgenerator.

• MoveStart/Run/Stopor On/Offswitch to the "Off" position.

• Closefuelvalve.

2.11LOW01LPBESSUBESHUTDOWNSYSTEM

Theengineis equippedwith a low oil pressuresensorthat shuts
downthe engineautomaticallywhen theoil pressuredrops below
5 psi. A delay built into the low oil shutdown system allows oil
pressureto buildduring starting. The delayallows the engineto
run for about10 secondsbeforesensingoil pressure.Ifthe engine
shutsdown by itselfandthe fueltank hasenoughgasoline,check
engineoillevel.

11

2.11.1RESTARtiNG

Iftryingto restartthe enginewithin 10 seconds afterit shutsdown,
the enginemay NOTstart.The system needs5 to 10 secondsto

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

pressurehas not beencorrected,the enginewill run for about10
secondsas describedaboveandthenstop.

2.12CHARGINGTHEBATTERY(XG700OE&XGBOOOE)

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.

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 battery chargedandready
for use.Batterychargingshouldbe done in a dry location.

1. Plugchargerinto "Battery ChargerInput"jack, locatedon the
control panel.Plug wall receptacleendof the batterycharger

into a120 VoltACwatt outlet.

2. Unplugbattery chargerfrom walt outletand control paneljack
whengeneratoris goingto be in use.

NOTE:

Donot usethe battery chargerfor more than 48 hours at one

charge.

3.1 MAINTENANCESCHEDULE

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

CheckOil Level
ChangeOiland OilFilter:!:

CleanSparkArrestorScreen
ServiceAirFilter

*Every Season/Every100 Hours
**Every Season/Every100 Hours
**Every Season/Every200 Hours

ReplaceSparkPlug

$

Changeoil after first 30 hours of operationthenevery season.

"k

Changeoil and oil filter every month when operatingunder heavy load or in
high temperatures.

Cleanmore often under dirty or dusty operating conditions. Replaceair filter
parts if very dirty.

At EachUse

EverySeason

3.2 PRODUCTSPECIFICATIONS

3.2.1 GENERATORSPECIFICATIONS

Model # ...................................................................... 005800, 005747

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, 005798

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 # .................................................................................... 005796

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.

3.2.2 ENGINESPECIFICAtiONS

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

Displacement............................................................................... 41Occ

SparkPlugType................................... ChampionRC14YCor Equivalent

SparkPlug PartNo.................................................................... 0E7585

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

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

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

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

w/o FilterChange= 1.2 Qts.

Oil FilterPart No...................................................................... 070185B

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

12

3.2.3 EMiSS/ONS/NFORMAT/ON

The EnvironmentalProtection Agency (EPA) requires that this
generatorcomplywith exhaustandevaporativeemissionstandards.
This generatoris certified to meet the applicable EPAemission
levelson gasoline.Theemission control systemon this generator

consists of the following:

• Fuel System • Air Induction System
Carburetor - IntakePipe/manifold

FuelTank!cap - Air Filter
FuelLines o Ignition System

EvaporativeVent Lines _ Sparkplug

Exhaust System - Ignitionmodule

ExhaustManifold • Exhaust System
Muffler _ ExhaustManifold

It is importantto perform the servicespecifiedinthe Maintenance
Scheduleto ensurethatthe generatorcomplieswith the applicable
emissionstandardsfor the durationof its useful life. Additionally,
emissions critical maintenancemust be performed as scheduled
in orderfor the EmissionsWarrantyto be valid. Emissionscritical
maintenanceconsists of servicingthe air filter and sparkplugs in
accordancewith the MaintenanceSchedule.Serviceand repairs
may be performedby any capablepersonor repairshop.

3.3 GENERALRECOMMENDATIONS

Thewarranty of thegeneratordoes notcover itemsthathave been
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 adjustmentsin the Maintenancesectionof this manual should
be madeat leastonceeachseason.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.

NOTE:

DONOTusea garden hoseto clean generator. Water can

enter the engine fuel system and cause problems. In addition,
ff 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.

3.3.2 TOCLEANTHEGENERATOR

• Usea dampcloth to wipe exteriorsurfacesclean.

• Asoft, bristlebrushmay beusedto loosencakedondirt, oil,etc.

• Avacuumcleanermay be usedto pick up loosedirt anddebris.

• Low pressure air (not to exceed 25 psi) may be used to
blow away dirt. Inspectcooling air slots and openings on the
generator.Theseopeningsmustbekeptcleanandunobstructed.

3.3.3 ENGINEMAINTENANCE
,_ CAUTION!

When workingon thegenerator, always disconnect
negativecable from battery. Also disconnect sparkplug

wire from sparkplugand keep wire away from spark

plug.

3.3.4 CHECKINGOILLEVEL

See the "BEFORESTARTINGTHE GENERATOR"section for
information on checking the oil level. The oil level should be

checkedbeforeeachuse,or at leasteveryeighthoursof operation.
Keepthe oil levelmaintained.

3.3.5 CHANGINGTHEOILANDOILFILTER

Changethe oil and filter after the first 30 hours of operation.
Changethe oil every 100 hours or every season thereafter. If

running this unit under dirty or dusty conditions, or in extremely
hotweather,changethe oil moreoften.

3.3.1 GENERATORMAINTENANCE

Generatormaintenanceconsists of keepingthe unitcleanand dry.
Operateandstorethe unit in acleandry environmentwhereit will

not beexposedto excessivedust, dirt, moistureor any corrosive
vapors.Coolingairslotsin the generatormustnot becomeclogged
with snow, leaves,or any otherforeign material.

Checkthe cleanlinessof the generatorfrequentlyand cleanwhen
dust, dirt, oil, moistureor other foreign substancesarevisible on

its exteriorsurface.

_,CAUTION!

Never insertany object or toolthroughthe air cooling

slots, evenif the engineis notrunning.

Not oil may causeburns. Allow engineto coolbefore

draining oil. Avoidprolongedor repeatedskin exposure

with usedoil. Thoroughlywashexposedareaswith soap.

Usethe following instructionsto changethe oil:

• Cleanareaaroundoil draincap.

• Removeoil draincapfrom the drainhoseandoilfill plugto drain
oil completely intoa suitablecontainer.

• Whenoil hascompletelydrained,installoil draincap andtighten
securely.

• Place a suitable container beneath the oil filter and turn
filter counterclockwiseto remove. Discardaccording to local

regulations.

13

• Coat gasket of new filter with clean engine oil. Turn filter
clockwise until gasketcontactslightly with filter adapter.Then

tighten an additional3/4 turn.

• Filloil sumpwith recommendedoil andreplacethe oil fill plug.
(See"BeforeStartingthe Generator"for oil recommendations).

• Wipeup anyspilled oil.

• Disposeof usedoil at a propercollection center.

3.3.6 REPLACINGTHESPARKPLUG

Use Champion RC14YCspark plug or equivalent. Replace the
plug once each year. This will help the engine start easier and

run better.

1. Stopthe engineand pullthe spark plug wire off of the spark

plug.

2. Togainaccess, removethe four (4) socket headscrews and

takeoffthe side panel.

3. Cleanthe areaaroundthe spark plugand remove it from the

cylinder head.

4. Set the spark plug's gap to .76 mm (0.030 in.). Install the

correctly gappedsparkplugintothecylinderhead(Figure13).

5. Pushthe bootfirmly on the spark plugand install sidepanel.

Figure 13 - Spark Mug Gap

3.4 SERVICEAIRFILTER

Theenginewill not run properly and may be damaged if using a
dirty air filter.Cleanor replacethe airfilter paperfilter every 200

hours or once a year (Figure14). Cleanor replacemore often if
operating under dusty conditions. To clean or replacepaper air

filter:

• Removeairfilter cover andremove paperfilter (Figure14).

• Cleanpaperfilter by tapping it gently on a solid surface.If the

filter is too dirty, replaceit with a new one.Disposeof the old
filter properly.

• Cleanair filter cover. Nextinsert new paperfilter intothe base
of theair filter.Re-installair filter cover.

NOTE:

Toordera new air filter, pleasecontactthe nearestauthorized

service centerat 1-888-GENERAC.Theair filter part number
is 073111.

Figure 14- Air Filter

AIR FILTER

3.5 CLEANSPARKARRESTORSCREEN

The engineexhaustmuffler has a spark arrestor screen. Inspect

andcleanthe screenat leastonce eachyear (Figure15). If unit is
usedregularly,inspectandcleanmore often.

i/_klf 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.

Cleanandinspectthe sparkarrestorwhentheengineisat ambient

temperatureas follows:

• Loosenthe clamp and removethe spark arrestorscreenfrom
the muffler.

• Inspect screen and replace if torn, perforated or otherwise
damaged. DO NOTUSEa defectivescreen. If screen is not
damaged,cleanitwith commercial solvent.

• Replacethe sparkarrestor andsecurewith the clamp.

Figure 15 - Spark Arrestor Screen

ARRESTOR

SCREEN

CLAMP

ARRESTOR

SPARK

SCREEN

14

3.6 GENERAL

Thegeneratorshould be started at leastonce every30 days and
be allowedto run at least30 minutes.If this cannot be doneand

the unit must be stored for morethan 30days, usethe following
informationas a guideto prepareitfor 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.

,l_AIIow unit to cool entirely before storage.

3.7 LONGTERMSTORAGE

It is importantto preventgum depositsfrom forming in essential
fuel systemparts such as the carburetor,fuel hoseor tank during
storage. To avoid engine problems, the fuel system should be
emptiedbeforestorageof 30 days or longer,asfollows:

• Removeall gasolinefromthe fueltank.

,_ CAUTION!

,_ Drainfuel into approvedcontaineroutdoors,awayfrom

openflame. Besureengine iscool.Donot smokeinthe

vicinityor lighta cigarette.

* Start andrun engineuntil enginestopsfrom lack offuel.
* Allow the engineto cool, then drain oil from crankcase. Refill

with recommendedgrade.

* Removesparkplugandpourabout 1/2ounce (15 ml) of engine

oil into the cylinder.Cover spark plug hole with rag. Pull the
recoil starter a couple times to lubricatethe piston rings and

cylinder bore.

,_ CAUTION!

,l_Avoid spray from spark plug hole when

cranking engine.

* Install and tighten spark plug. Do not connectthe spark plug

wire.

* Cleanthegeneratoroutersurfaces. Checkthat coolingair slots

and openingson generatorareopen and unobstructed.

* Store theunit in a clean,dry place.

3.8 OTHERSTORAGETiPS

• Donot storegasolinefrom one seasonto another.

• Replaceanygasolinecan that starts to rust. Rustand/or dirt in
the gasolinewill cause problemswith the carburetorand fuel

system.

• Ifpossible, storetheunit indoorsandcover it to give protection
from dust and dirt. Coverthe unit with a suitable protective

coverthatdoes notretainmoisture.

• BESURE TO EMPTYTHE FUELTANK,If it is not practical
to emptythe fuel tank and the unit is to be stored for some

time, usea commercially availablefuel stabilizer addedto the

gasolineto increasethe life of the gasoline.

ACAUTION!

,l_ NEVER cover the generator while engine and

exhaust area are warm.

4.1 BATTERYREPLACEMENT(XG7000E&XGS000E)

NOTE:

The batteryshippedwiththe generator has beenfully charged.

Abatterymay losesome of itschargewhennot in usefor
prolongedperiodsoftime. If the batteryis unableto crank
the engine, plugin the 12V chargerincludedintheaccessory
box(seethe Charginga Batterysection).RUNNINGTHE

GENERATORDOESNOTCHARGETHEBATTERY.

The battery shipped with the generator has been providedfully
charged.Toreplacethe battery (SeeFigure16):

* Remove the side panel as shown. Remove the four bolts

securingthe fuel tank.

* Turnthe fuel valve on the control panelto the "OFF"position.

Pull the fuel tank back slightly and removethe fuel hosethat
runsfrom the engineto thefuelvalve.

_,CAUTION!

,_ Drainfuel into approvedcontaineroutdoors, away from

open flame. Besureengine is cool.Donot smokein the
vicinityor lighta cigarette.

* Disconnectthe recoveryhosefrom the rollovervalve.Pushthe

hosethroughthe grommet in the corner of the fuel tank. This
will allowfor removalofthe fueltank.

* Pushthe fuel valvefrom thecontrol paneland removethefuel

tank.

* Removethe batterywire connections(blackwire first) andthe

batteryhold=downbracket.

* Replacethe battery,connectingthe REDwire to the POSITIVE

(+) terminalandthe BLACKwireto the NEGATIVE(-) terminal

NOTE:

Start all four screws on the side panel before tighteningor it

maynot bepossible toget all the screwsinplace.

15

Figure 16 - Battery Remova/

It

ENGINE

STARTING

1_ FUELTANK

ASSEMBLY

BATTERY

BRACKET

SIDE

PANEL

16

5.1TBOUBLESHOOTINGGUIDE

Engineis running,but noAC output
isavailable.

1. Circuitbreakeris open.

2. Poorconnectionor defectivecord set.

3. Connecteddeviceis bad.

4. Faultin generator.

5. GFCItrips the 20 Amp outlet.

1. Resetcircuit breaker.

2. Checkand repair.

3. Connectanotherdevicethat is in goodcondition.

4. ContactAuthorizedServiceFacility.

5. Repairthe "short" and resetthe GFCI.

Engineruns good but bogs down 1. Short circuit in a connectedload. 1. Disconnectshorted electricalload.
whenloadsare connected. 2. Generatoris overloaded. 2. See"Don't Overloadthe Generator".

3. Enginespeedis too slow. 3. ContactAuthorizedServiceFacility.

4. Shorted generatorcircuit. 4. ContactAuthorizedServiceFacility.

I I

Enginewill not crank. 1. Battery weakor dead. 1. Rechargeor replacebattery (see"NoBattery

ChargerDCoutput"at bottom of guide).

2. Start enginemanuallyusing recoil starter.

Enginewiil notstart; or starts and
runsrough.

1. Fuelshut-off is OFE 1.

2. Dirty airfilter. 2.

3. Outof gasoline. 3.

,

Stalegasoline. 4.

5.

Sparkplug wire not connected to sparkplug. 5.

6.

Bad spark plug. 6.

7. Waterin gasoline.

8. Over-choking.

9. Low oil level.

10. Excessiverichfuel mixture.

11. Intakevalve stuck open or closed.

12. Enginehas lostcompression.

TurnFuelshut-off ON.

Cleanor replaceairfilter.
Fillfuel tank.

Drainfueltank andfill with freshfuel.
Connectwire to sparkplug.

Replacesparkplug.

7. Drainfueltank;fill with fresh fuel.

8. Putchoke knob to No Chokeposition.

9. Fillcrankcaseto properlevel.

10. Contact AuthorizedService Facility.

11. Contact AuthorizedService Facility.

12. Contact AuthorizedService Facility.

Engineshuts downduring 1. Outof gasoline. 1. Fillfuel tank.
operation. 2. Low oil level. 2. Fillcrankcaseto properlevel.

3. Faultin engine. 3. ContactAuthorizedServiceFacility.

m u

Enginelacks power. 1. Load is too high. 1. See"Don'tOverloadthe Generator".

2. Dirty airfilter. 2. Replaceair filter.

3. Engineneedsto be serviced. 3. ContactAuthorizedServiceFacility.

Engine"hunts" or falters. 1. Chokeis openedtoo soon. 1. Movechoke to halfway position until engineruns

2. Carburetoris runningtoo rich or too lean. smoothly.

2. ContactAuthorizedServiceFacility.

NoBatteryChargerDOoutput. 1. Battery posts arecorroded.

2. Battery cableis bad.

3. Battery is defective.

4. Receptacleis bad.

5. Battery Chargerin-line fuse (1.5A)melted open.

1. Cleanbattery posts.

2. Replacecable.

3. Checkbattery condition; replaceif defective.

4. ContactAuthorizedServiceFacility.

5. Replacefuse with identical 1.5A replacementfuse
only (located insidecontrol panel).

1"7

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