Generac Power Systems XP Series Bedienungsanleitung

www.generac.com or 1-888-436-3722

Owner's Manual

XP Series Portable Generator



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.

Introduction............................................................. 1

Read this Manual Thoroughly................................. 1

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

Standards Index .............................................................3

General Information................................................ 4

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

1.1.1 Accessory Box (6.5, 8 & 10kW)........................4

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

1.2.1 Assembling the Wheel Kit ..................................4

1.2.2 Battery Connection (if equipped)........................4

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

2.1 Know the Generator .......................................................5

2.1.1 Cold Weather Operation/De-icer .........................8

2.2 Hour Meter - With Reset.................................................9

2.3 Connection Plugs...........................................................9

2.3.1 250 VAC, 20 Amp Duplex Receptacle ................9

2.3.2 120/240 VAC, 30 Amp Receptacle.....................9

2.3.3 120/240 VAC, 50 Amp Receptacle (10kW) ......10

2.3.4 Ground Fault Sensing Module ..........................10

2.3.5 120 VAC, 30 Amp Receptacle..........................10

2.4 Automatic Idle Control (if equipped)..............................11

2.5 Voltage Selector Switch (3.6 & 6.5kW only) .................11

2.6 How to Use the Generator ............................................11

2.6.1 System Ground................................................11

2.6.2 Grounding the Generator..................................12

2.6.3 Connecting Electrical Loads.............................12

2.7 Overload Prevention .....................................................12

2.8 Wattage Reference Guide .............................................12

2.9 Before Starting the Generator .......................................13

2.9.1 Adding Engine Oil ............................................13

2.9.2 Adding Gasoline...............................................13

2.10 Starting the Engine (electric start only).........................14

2.11 Starting Pull Start Engines............................................14

2.12 Stopping the Engine .....................................................14

2.13 Low Oil Level Shutdown System ..................................15

2.14 Charging the Battery (if equipped) ................................15

Maintenance ......................................................... 15

3.1 Performing Scheduled Maintenance .............................15

3.2 Maintenance Schedule .................................................15

3.3 Product Specifications..................................................16

3.3.1 Generator Specifications ..................................16

3.3.2 Engine Specifications.......................................16

3.3.3 Emissions Information .....................................16

3.4 General Recommendations...........................................17

3.4.1 Generator Maintenance ....................................17

3.4.2 To Clean the Generator.....................................17

3.4.3 Engine Maintenance.........................................17

3.4.4 Checking Oil Level ...........................................17

3.4.5 Changing the Oil and Oil Filter ..........................17

3.4.6 Replacing the Spark Plug(s).............................17

3.4.7 Battery Replacement (if equipped) ...................18

3.4.8 Air Filter Replacement......................................18

3.4.9 Clean Spark Arrestor Screen ............................19

3.4.10 Adjusting Valve Clearance................................19

3.5 General ........................................................................20

3.6 Long Term Storage.......................................................20

Troubleshooting .................................................... 21

4.1 Troubleshooting Guide..................................................21

Manual del Usuario............................................... 23

Manuel de l'utilisateur .......................................... 47

(000004)

WARNING

California Proposition 65. Engine exhaust and some of

its constituents are known to the state of California to

cause cancer, birth defects, and other reproductive

harm.

(000005)

WARNING

California Proposition 65. This product contains or

emits chemicals known to the state of California to

cause cancer, birth defects, and other reproductive

harm.

Table of Contents

INTRODUCTION

Thank you for purchasing this model by Generac Power Systems,

Inc. This model is a compact, high performance, air-cooled,

engine driven generator designed to supply electrical power to

operate electrical loads where no utility power is available or in

place of utility due to a power outage.

READ THIS MANUAL THOROUGHLY

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 device

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.

SAFETY RULES

Throughout this publication, and on tags and decals affixed to the

generator, DANGER, WARNING, CAUTION and NOTE blocks are

used to alert personnel to special instructions about a particular

operation that may be hazardous if performed incorrectly or

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

(000001)

DANGER

Indicates a hazardous situation which, if not avoided, will

result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation 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.

Introduction

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.

(000111)

WARNING

Moving Parts. Keep clothing, hair, and appendages

away from moving parts. Failure to do so could

result in death or serious injury.

• 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.

(000116)

DANGER

Electrocution. Turn utility and emergency

power supplies to OFF before connecting power

source and load lines. Failure to do so will result

in death or serious injury.

• Do not insert objects through unit’s cooling slots.

• When working on this equipment, remain alert at all times.

Never work on the equipment when physically or mentally

fatigued.

• Lifting Warning Hazard: A falling generator can result in death,

bodily injury, and/or property damage. Stand clear of generator.

Lift is designed to carry only the weight of the generator. DO

NOT overload lifting bracket. Apply lifting strap or hook through

lift bar hole(s) only. DO NOT lift while generator is running.

• 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.

NOTE: This generator is equipped with a spark arrestor muffler.

The spark arrestor must be maintained in effective working

order by the owner/ operator. In the State of California, a spark

arrestor is required by law (Section 4442 of the California

Public Resources Code). Other states may have similar laws.

Federal laws apply on federal lands.

EXHAUST & LOCATION HAZARDS

• 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.

(000103)

DANGER

Asphyxiation. Running engines produce carbon

monoxide, a colorless, odorless, poisonous gas.

Carbon monoxide, if not avoided,

will result in death or serious injury.

• 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 manufacturer's 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.

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.

Safety Rules

• 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.

FIRE HAZARDS

(000105)

DANGER

Explosion and Fire. Fuel and vapors are extremely

ammable and explosive. Add fuel in a well

ventilated area. Keep re and spark away. Failure to

do so will result in death or serious injury.

• 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 (1.5 meters) on all sides to

allow for proper ventilation of the generator.

• Do not insert objects through unit cooling slots.

• NEVER 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.

• DO NOT operate in a hazardous location where there may be a

risk of expolsion of petrol fumes, leaking fuel or explosive dusts.

STANDARDS INDEX

1. National Fire Protection Association (NFPA) 70: The NATIONAL

ELECTRIC CODE (NEC) available from www.nfpa.org

2. National Fire Protection Association (NFPA) 5000: BUILDING

CONSTRUCTION AND SAFETY CODE available from www.

nfpa.org

3. International Building Code available from www.iccsafe.org

4. Agricultural Wiring Handbook available from www.rerc.org ,

Rural Electricity Resource Council P.O. Box 309 Wilmington,

OH 45177-0309

5. ASAE EP-364.2 Installation and Maintenance of Farm Standby

Electric Power available from www.asabe.org, American

Society of Agricultural & Biological Engineers 2950 Niles

Road, St. Joseph, MI 49085

This list is not all inclusive. Check with the Authority Having Local

Jurisdiction (AHJ) for any local codes or standards which may be

applicable to your jurisdiction.

MODEL NO:

SERIAL NO:

Unit ID Location

Safety Rules

1.1 UNPACKING

• Remove all packaging material.

• Remove separate accessory box.

• Remove carton off the generator.

1.1.1 ACCESSORY BOX

Check all contents (Figure 1). If any parts are missing or damaged

locate an authorized dealer at 1-888-436-3722.

Contents include:

• 2 – Wheels*** • Oil Funnel

• 2 – Hair Pins*** • 2 – Frame Feet***

• Spark Plug (Qty. 2 for 10kW) • 12 Volt Adaptor Plug Charger***

• Air Filter • Spark Plug Wrench

• Oil Filter • Shop Towel

• 4 – Hex Nuts • 2 – Axle Brackets

• 2 – 5/8" Flat Washers (thin)* • 2 – 5/8" Flat Washers (thick)*

• 4 – Bolts x 45mm** • 4 – Bolts x 50mm**

• 2 – 1 Quart SAE 30 Oil Bottles (Qty. 1 for XP4000)

* 6.5 and 8kW Only

** 10kW Only

*** All except 3.6kW

1.2 ASSEMBLY

Read entire Owner's Manual before attempting to assemble or

operate the generator. The generator requires some assembly

prior to using it. If problems arise when assembling the generator,

please call the Generator Helpline at 1-888-436-3722.

1.2.1 ASSEMBLING THE WHEEL KIT

The wheel kit is designed to greatly improve the portability of the

generator. A 10mm and a 13mm wrench are needed to install the

frame feet and axle bracket.

NOTE: The wheel kit is not intended for over-the-road use.

6.5, 8, and 10kW

Refer to Figure 1 and install the feet and wheels as follows:

1. Align the holes in the frame foot to the holes in the frame.

Secure foot with two hex nuts and the 45mm long bolts.

Repeat procedure for other foot.

2. Align the holes in the axle bracket to the holes in the frame.

Secure bracket with 50mm long bolts. Repeat procedure for

other bracket.

3. Slide the axle through the axle bracket holes.

4. Slide on one 5/8” flat washer (thick), the wheel, and a 5/8” flat

washer (thin) onto the axle.

5. Secure with hair pin and repeat for the other wheel.

Figure 1 – Wheel Assembly (6.5, 8 & 10kW)

BOLT X 45MM

LONG

FRAME FOOT

BOLT X 50MM

LONG

HEX NUT

AXLE

BRACKET

HAIR PIN

WHEEL

AXLE

5/8” FLAT WASHER

(THICK)

5/8” FLAT WASHER

(THIN)

1.2.2 BATTERY CONNECTION (IF EQUIPPED)

NOTE: The battery shipped with the generator has been fully

charged. A battery may lose some of its charge when not in use

for prolonged periods of time. If the battery is unable to crank

the engine, plug in the 12V charger included in the accessory

box (see the Charging a Battery section). RUNNING THE

GENERATOR WILL CHARGE THE BATTERY.

The unit has been deliberately shipped with the battery cables

disconnected. You will need two 8mm wrenches to secure the

battery cables.

See Figure 2 for connection details.

1. Cut off cable ties securing the battery cables.

2. First, connect the red battery cable and the red battery charger

wire to the positive (+) battery terminal. Use the supplied

screw and lock nut.

3. Connect the black battery cable and the black battery charger

wire to the negative (-) battery terminal. Use the supplied

screw and lock nut.

4. Make sure all connections are secure. Slide the rubber boots

over the terminals and connection hardware.

General Information

Figure 2 - Battery Connections

2.1 KNOW THE GENERATOR

Read the Owner’s Manual and Safety Rules before operating

this generator.

Compare the generator to Figures 3 through 7 to become

familiarized with the locations of various controls and adjustments.

Save this manual for future reference.

1. 120 Volt AC, 20 Amp, 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.

2. 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.

3. Circuit Breakers (AC) (6.5 & 8kW) – Each receptacle is

provided with a push-to-reset circuit breaker to protect the

generator against electrical overload.

4. 2-Pole Circuit Breaker (6.5, 8 & 10kW) – this 30 Amp 2-pole

circuit breaker protects the 120/240 Volt locking receptacle.

NOTE: The 10kW uses both a 30 and 42 Amp 2-pole circuit

breaker.

5. 120 Volt AC, 30 Amp Locking Receptacle – Supplies

electrical power for the operation of 120 Volt AC, 30 Amp,

single-phase, 60Hz electrical lighting, appliance, tool and

motor loads.

6. Idle Control – with the switch in the “ON” position, the idle

control runs the engine at normal (high) speeds when there

is an electrical load present and runs the engine at idle (low)

speeds when a load is not present.

7. Fuse (6.5, 8 & 10kW) – this 1.5 Amp fuse protects the

Battery Charger Input jack.

8. Ground Fault Sensing Module – supplies ground fault to

protect electrical power for all receptacles on the control

panel.

9. GFCI Circuit Breaker – Use to reset the full control panel GFCI

electrical system.

10. 10. Voltage Selector Switch (3.6 & 6.5kW only) - Allows the

user to choose between 120/240 volts, or 120 volt only. When

in the 120 volt only position, the total generator output is

available through any of the 120 volt outlets. In the 120/240V

position, receptacles of 120 and 240 volts AC can be used

simultaneously. The voltage selector switch provides the user

with more usable power and improved flexibility.

NOTE: NEVER switch the voltage selector switch with the main

breaker turned on! Doing this can cause arcing and can damage

the generator. First turn off all tools and appliances, turn off the

main circuit, and then operate the voltage selector switch.

11. Hour Meter – Tracks hours of operation and alerts to service

intervals.

12. 120/240 Volt AC, 50 Amp Receptacle (10kW only) - Supplies

electrical power for the operation of 120/240 Volt AC, 42 Amp,

Single Phase, 60 Hz welder or motor loads.

13. Choke Knob – Used when starting a cold engine.

14. Start Switch (6.5, 8, & 10kW) - Use to start engine from the

starter motor.

NOTE: The switch must be in the “On” position when starting

the engine from the recoil starter.

15. 3600 Watt On/Off Switch

16. Spark Plug(s) - See the Maintenance Schedule and Engine

Specification sections for details.

17. Oil Filter - See the Maintenance Schedule and Engine

Specification sections for details.

18. Summer/Winter Valve (10kW Engine ONLY) - Directs hot

engine air to the carburetor when the engine is running in cold

weather conditions. Move the valve to the left when operating

in temperatures above 40 ºF (4.4 °C). When operating in

temperatures below 40 ºF (4.4 °C), move the summer/winter

valve to the right.

19. Oil Dipstick (10kW ONLY) - Check oil level in the engine.

Always make sure that the oil level is at the FULL mark before

starting engine.

20. Oil Drain – Use to drain engine oil.

21. Oil Fill – Add oil here.

22. Air Filter – Filters intake air as it is drawn into the engine.

23. Recoil Starter (3.6, 6.5 & 8kW) - Use to start engine

manually.

24. Muffler – Quiets the engine.

25. Spark Arrestor – Reduces fire hazards by containing sparks.

26. Grounding Lug – Ground the generator to an approved earth

ground here. See "Grounding the Generator" for details.

27. Handles – Pivot and retract for storage. Press the spring-

loaded button to move handles.

28. Fuel Tank – See generator Specifications for tank capacity.

29. Gas Cap – Fuel fill location.

30. Fuel Gauge – Shows fuel level in tank.

31. Battery (6.5, 8 & 10kW) - Powers the electric starter motor.

32. Battery Charger Input (6.5, 8 & 10kW) - This receptacle

allows the capability to recharge the battery from the adaptor

plug charger.

33. Lifting Device – use to lift and store the generator after use.

See Lifting Safety notes in the beginning of this manual.

Operation

000293

Figure 3 - 3,600 Watt Control Panel

15 11 1 8 9

6 5 3 2 10

2 1 5 10

000294

Figure 4 - 6,500 Watt Control Panel

32 7 4 6 3 11 8 9

Operation

000296

Figure 6 - 10,000 Watt Control Panel

000295

Figure 5 - 8,000 Watt Control Panel

2 15 11

32 7 46 3 8 9

32 1 4

512

34 3 35

8 2

34. Fuel Shut Off – Valve between fuel tank and carburetor.

35. Fuse (10kW ONLY) - This 5 Amp fuse protects the starting

circuit from overload.

2.1.1 COLD WEATHER OPERATION/DE-ICER

Under certain weather conditions (temperatures below 40 °F (4.4

°C) and a high dew point), the engine may experience icing of the

carburetor and/or the crankcase breather system. To eliminate

this problem, this generator engine is fitted with a winter/summer

valve. This directs hot air into the carburetor during cold weather

operation. Always make sure the winter/summer valve is in the

correct location relative to the weather conditions (Figure 8).

Figure 8 – Winter/Summer Valve

Operation

220cc Engine for

3.6kW Model

410cc Engine for

6.5 & 8kW Models 530cc Engine for

10kW Model

Figure 7 - Generator Controls

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