Generac Power Systems XD5000E Manuale utente

XD5000E Diesel Portable Generator

Owner’s Manual

MODEL:________________________

SERIAL:________________________

DATE PURCHASED:______________

WWW.GENERAC.COM

1-888-GENERAC

SAVE THIS MANUAL FOR FUTURE REFERENCE

000703

Table of Contents

Section 1 Introduction and Safety 1

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

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

Safety Symbols and Meanings ........ 1

Exhaust and Location Hazards ....... 2

Electrical Hazards ........................... 2

Fire Hazards .................................... 3

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

Section 2 General Information and

Setup .............................................. 4

Know Your Generator ..................... 5

Emissions Information ..................... 5

Hour Meter ...................................... 6

Connection Plugs ............................ 6

Remove Contents from Carton ....... 7

Assembly ......................................... 7

Battery Installation (if equipped) ...... 8

Add Engine Oil ................................ 8

Fuel ................................................. 9

Section 3 Operation .................... 10

Operation and Use Questions ....... 10

Before Starting Engine .................. 10

Prepare Generator for Use ............ 10

Grounding the Generator When Used

as a Portable ................................. 10

Know Generator Limits .................. 10

Transporting/Tipping of the Unit .... 11

Starting Pull Start Engines ............ 12

Starting Electric Start Engines ...... 12

Low Oil Pressure Switch ............... 13

Section 4 Maintenance and

Troubleshooting ..........................14

Maintenance Recommendations ...14

Maintenance Schedule ..................14

Preventive Maintenance ................14

Engine Maintenance ......................14

Battery Replacement (if applicable) 15

Valve Clearance ............................16

Storage ..........................................16

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

Notes .............................................19

(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.

Operator’s Manual for Portable Generator 1

Section 1 Introduction and Safety

Introduction

Thank you for purchasing a Generac Power

Systems Inc. product. This unit has been

designed to provide high-performance, effi-

cient operation, and years of use when main-

tained properly.

If any section of the manual is not understood,

contact your nearest authorized dealer, or

contact Generac Customer Service at 1-888-

GENERAC, or www.generac.com with any

questions or concerns.

The owner is responsible for proper mainte-

nance and safe use of the equipment. Before

operating, servicing or storing this generator:

• Study all warnings in this manual and on

the product carefully.

• Become familiar with this manual and the

unit before use.

• Refer to the Assembly section of the man-

ual for instructions on final assembly proce-

dures. Follow the instructions completely.

Save these instructions for future reference.

ALWAYS supply this manual to any individual

that will use this machine.

THE INFORMATION CONTAINED HEREIN

WAS BASED ON MACHINES IN PRODUC-

TION AT THE TIME OF PUBLICATION. GEN-

ERAC RESERVES THE RIGHT TO MODIFY

THIS MANUAL AT ANY TIME.

Safety Rules

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, there-

fore, not all inclusive. If using a procedure,

work method or operating technique that the

manufacturer does not specifically recom-

mend, verify that it is safe for others. Also

make sure the procedure, work method or

operating technique utilized does not render

the equipment unsafe.

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 haz-

ardous if performed incorrectly or carelessly.

Observe them carefully. Their definitions are

as follows:

NOTE: Notes contain additional informa-

tion important to a procedure and will be

found within the regular text of this man-

ual.

These safety warnings cannot eliminate the

hazards that they indicate. Common sense

and strict compliance with the special instruc-

tions while performing the action or service

are essential to preventing accidents.

Safety Symbols and Meanings

(000100a)

WARNING

Consult Manual. Read and understand manual

completely before using product. Failure to

completely understand manual and product

could result in death or serious injury.

(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.

000657

DANGER

Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell.

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.

(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.

(000104)

DANGER

Electrocution. Water contact with a power source,

if not avoided, will result in death or serious injury.

2 Operator’s Manual for Portable Generator

• For safety reasons, it is recommended that

the maintenance of this equipment be per-

formed by an Authorized Service Facility.

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 exces-

sive moisture, dirt, dust or corrosive vapors.

• When working on this equipment, remain

alert at all times.

• Never work on the equipment when physi-

cally or mentally fatigued.

• 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 danger-

ous operating conditions from leaking

exhaust gases, fuel leakage, oil leakage,

etc.

Exhaust and Location Hazards

• This exhaust system must be properly

maintained. Do nothing that might render

the exhaust system unsafe or in noncompli-

ance with any local codes and/or stan-

dards.

• 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 poison-

ing.

Electrical Hazards

• The National Electric Code (NEC) requires

the frame and external electrically conduc-

tive parts of the generator be properly con-

nected 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).

(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.

(000111)

WARNING

Moving Parts. Keep clothing, hair, and appendages

away from moving parts. Failure to do so could

result in death or serious injury.

(000108)

WARNING

Hot Surfaces. When operting machine, do not

touch hot surfaces. Keep machine away from

combustables during use. Hot surfaces

could result in severe burns or fire.

(000146)

WARNING

Equipment and property damage. Do not alter

construction of, installation, or block ventilation for

generator. Failure to do so could result in unsafe

operation or damage to the generator.

(000142)

Do not insert any object through the air cooling slots.

Generator can start at any time and could result in

death, serious injury and unit damage.

WARNING

(000107)

WARNING

Hearing Loss. Hearing protection is recommended

when using this machine. Failure to wear hearing

protection could result in permanent hearing loss.

(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.

(000146)

WARNING

Equipment and property damage. Do not alter

construction of, installation, or block ventilation for

generator. Failure to do so could result in unsafe

operation or damage to the generator.

(000178a)

Asphyxiation. Always use a battery operated carbon

monoxide alarm indoors and installed according to

the manufacturer’s instructions. Failure to do so could

result in death or serious injury.

WARNING

(000144)

DANGER

Electrocution. Contact with bare wires, terminals,

and connections while generator is running will

result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power source,

if not avoided, will result in death or serious injury.

(000145)

DANGER

Electrocution. In the event of electrical accident,

immediately shut power OFF. Use non-conductive

implements to free victim from live conductor. Apply

first aid and get medical help. Failure to do so will

result in death or serious injury.

Operator’s Manual for Portable Generator 3

Fire Hazards

• Wipe up any fuel or oil spills immediately.

Verify 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 sides to allow for proper ventila-

tion of the generator.

• Do not operate the generator if connected

electrical devices overheat, if electrical out-

put 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.

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 CONSTRUC-

TION 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 Wilming-

ton, OH 45177-0309

5. ASAE EP-364.2 Installation and Mainte-

nance of Farm Standby Electric Power

available from www.asabe.org, American

Society of Agricultural & Biological Engi-

neers 2950 Niles Road, St. Joseph, MI

49085

This list is not all inclusive. Check with the

Authority Having Jurisdiction (AHJ) for any

local codes or standards which may be appli-

cable to your jurisdiction.

(000130)

WARNING

Accidental Start-up. Disconnect the negative battery

cable, then the positive battery cable when working

on unit. Failure to do so could result in death or serious

injury.

(000105)

DANGER

Explosion and Fire. Fuel and vapors are extremely

flammable and explosive. Add fuel in a well

ventilated area. Keep fire and spark away. Failure to

do so will result in death or serious injury.

(000166)

DANGER

Do not overfill fuel tank. Fill to 1/2 in. of top of tank to

allow for fuel expansion. Overfilling may cause fuel to

spill onto engine causing fire or explosion, which will

result in death or serious injury.

(000142)

Do not insert any object through the air cooling slots.

Generator can start at any time and could result in

death, serious injury and unit damage.

WARNING

4 Operator’s Manual for Portable Generator

Section 2 General Information and Setup

Figure 2-1. Features and Controls

TABLE 1. Generator Components

Figure 2-2. Control Panel

000711

000703

719

12 14

1 120 Volt AC, 20 Amp, GFCI Duplex

Receptacle

2 120/240 Volt AC, 30 Amp Locking

Receptacle

3 120 Volt AC, 30 Amp Locking Receptacle

4 20 Amp Circuit Breakers

5 30 Amp Circuit Breaker

6OilDrain

7 Air Filter

8 Decompression Lever

9 Fuel Tank

10 Grounding Lug

11 Start/Run Switch

12 Muffler

13 Fuel Cap/Fuel Gauge

14 Oil Fill (2 locations)

15 Recoil Starter

16 Main 23 Amp Breaker Switch

17 Fuel Return Hose

18 Hour Meter

19 Battery (if equipped)

20 Fuel Filter

21 Engine On/Off Lever

22 Fuel On/Off

23 Voltage Selector Switch

24 Fuel Primer Bulb

000714

11 18

4 5

Operator’s Manual for Portable Generator 5

Figure 2-3. Identification Label

Know Your Generator

Replacement owner’s manuals are available

at www.generac.com.

Emissions Information

The U.S. Environmental Protection Agency,

EPA, (and California Air Resource Board,

CARB, for equipment certified to CA stan-

dards) require the generator comply with

exhaust emission standards. The generator is

certified to meet applicable EPA and CARB

emission levels using Ultra Low Sulfur fuel,

Diesel No. 2. Any other use may be a violation

of federal and/or local laws. To ensure the

engine complies with applicable emission

standards for the duration of the engine’s life,

it is important to follow the maintenance speci-

fications in Maintenance Section. Tampering

with or altering the emission control sys-

tem may increase emissions and may be a

violation of Federal or California Law.

000705

(000100a)

WARNING

Consult Manual. Read and understand manual

completely before using product. Failure to

completely understand manual and product

could result in death or serious injury.

TABLE 2. Product Specifications

Generator Specifications

Rated Power Rated 5000 Watts**

Surge Power Surge Rating 5500 Watts

Rated AC Voltage 120/240

Rated AC Load

Current @ 240V

Current @ 120V 20.8 Amps**

41.7 Amps**

Rated Frequency 60 Hz @3600 RPM

Phase Single Phase

** Operating Temperature Range : -18 deg. C (0 deg. F) to 40 Deg. C (104 Deg. F). When operated

above 25 deg. C (77 deg. F) there may be a decrease in power.

** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambi-

ent temperature, altitude, engine condition, etc.. Maximum power decreases about 3.5% for each

1,000 feet above sea level; and will also decrease about 1% for each 6° C (10° F) above 16° C (60°

F) ambient temperature.

5.5 / 6.5 Engine Specifications

Displacement 435 cc (26.5 in3)

Fuel Capacity 45.4 L (12 U.S. gallons)

Oil Type See chart in the "Add Engine Oil." section.

Oil Capacity 1.6L (1.7 qt)

Run Time at 50% Load 32 Hours

6 Operator’s Manual for Portable Generator

Hour Meter

The Hour Meter tracks hours of operation for

scheduled maintenance. See Figure 2-4.

• The CHG OIL display will illuminate every

100 hours. The message will flash one hour

before and one hour after each 100 hour

interval, providing a two hour window to

perform service.

• The SVC display will illuminate every 100

hours. The message will flash one hour

before and one hour after each 200 hour

interval providing a two hour window to per-

form service.

Figure 2-4. Hour Meter

When the hour meter is in flash alert mode,

the maintenance message will alternate with

elapsed time in hours and tenths. The hours

will flash four times, then alternate with the

maintenance message four times until the

meter automatically resets.

• 100 hours - CHG OIL — Oil Change Inter-

val (Every 100 hrs)

• 200 hours - SVC — Service Air Filter

(Every 200 hrs)

NOTE: The hour glass icon will flash when

the engine is running. This signifies the

meter is recording hours of operation.

Connection Plugs

120 VAC, 20 Amp, GFCI Duplex

Receptacle

The 120 Volt outlet is overload protected by a

20 Amp push-to-reset circuit breaker. See Fig-

ure 2-5. Each receptacle will power 120 Volt

AC, single phase, 60 Hz electrical loads

requiring up to 2400 watts (2.4 kW) or 20

Amps of current. Use only high quality, well-

insulated, 3-wire grounded cord sets rated for

125 Volts at 20 Amps (or greater).

NOTE: Limit length of extension cords to

fifteen feet, or less, to prevent voltage drop

and overheating of wires.

Figure 2-5. 120 VAC, 20 Amp, Duplex

Receptacle

120/240 VAC, 30 Amp Receptacle

Use a NEMA L14-30 plug with this receptacle

(rotate to lock/unlock). Connect a suitable 4-

wire grounded cord set to plug and desired

load. The cord set should be rated 250 Volts

AC at 30 Amps (or greater). See Figure 2-6.

Use this receptacle to operate 240 Volt AC, 60

Hz, single phase loads requiring up to 5000

watts (5.0 kW) of power at 20.8 Amps.

Figure 2-6. 120/240 VAC, 30 Amp Receptacle

120 VAC, 30 Amp Receptacle

Use a NEMA L5-30 plug with this receptacle

(rotate to lock/unlock). Connect a suitable 3-

wire cord set to the plug and to desired load.

The cord set should be rated for 125 Volts AC

at 30 Amps (or greater). See Figure 2-7.

Use this receptacle to operate 120 Volt AC,

60Hz, single phase loads requiring up to 3600

watts (3.6kW) of power at 30 Amps. The outlet

is protected by a 30 Amp push-to-reset circuit

breaker.

Figure 2-7. 120 VAC, 30 Amp Receptacle

0000.0

000205

000203

000204

000844

Operator’s Manual for Portable Generator 7

Remove Contents from Carton

1. Open carton completely by cutting each

corner from top to bottom.

2. Remove and verify carton contents prior to

assembly. Carton contents should contain

the following:

TABLE 3. Contents

TABLE 4. Portability Kit (optional)

3. Call Generac Customer Service 1-888-

GENERAC with the unit model and serial

number for any missing carton contents.

4. Record model, serial number, and date of

purchase on front cover of this manual.

Assembly

Call Generac Customer Service at 1-888-

GENERAC for any assembly issues or con-

cerns. Please have model and serial number

available.

The following tools are required to install the

accessory kit.

• Ratchet with 10mm and 13mm sockets

• 13mm box wrenches

NOTE: The wheels are not intended for

over-the-road use.

Install wheels as follows. See Figure 2-8.

1. Insert cotter pin (E) to one end of axle (B).

2. In this order; slide washer (D), wheel (A),

washer, (D), axle mount (2-C), washer (D),

wheel (A), washer (D), and cotter pin (E)

onto axle.

3. Place wheel assembly under frame so

axle mounts align with holes in cradle

frame.

4. Secure with M6 screws (L).

Figure 2-8. Wheel Assembly

Install frame foot and rubber bumpers as

shown in Figure 2-9.

1. Slide onto M8 screw (Q), flat washer (M),

rubber foot (K).

2. Slide assembly through frame foot (J). Add

M8 flat washer (N), and secure with M8-

1.25 Locknut (P).

3. Place foot bracket assembly under cradle.

4. Slide M8 flat washers (N) onto M8-

1.25x110 screws (T) and insert through

foot bracket assembly and cradle.

5. Secure with M8 flat washer (N) and M8

locknut (P).

Item Qty.

Main Unit 1

Owner’s Manual 1

Liter Oil SAE 30 2

Product Registration Card 3

Service Warranty 1

Emissions Warranty 1

Muffler Extension 1

Battery Bracket Assembly 1

Portability Kit (optional) Qty.

10” Wheel (A) 2

Axle (B) 1

Axle Mount (C) 2

5/8” Flat Washer (D) 4

Cotter Pin (E) 2

Handle (F) 1

Handle Mount (G) 2

Handle Grip (H) 2

Frame Foot (J) 2

Rubber Feet (K) 2

M6-1x50mm Screw (L) 4

.344”x1.0” Flat Washer (M) 2

M8 Flat Washer (N) 10

M8-1.25 Locknut (P) 6

M8-1.25x30 Screw (Q) 2

M8-1.25x45 Screw (R) 2

M8-1.25x50 Screw (S) 2

M8-1.25x110 Screw (T) 2

5/16x1.25 Pin Release (U) 1

Lanyard 1

(000100a)

WARNING

Consult Manual. Read and understand manual

completely before using product. Failure to

completely understand manual and product

could result in death or serious injury.

000704

8 Operator’s Manual for Portable Generator

Figure 2-9. Frame Foot Assembly

Install handle as shown in Figure 2-10.

1. Place a M8 flat washer (N) onto M8-

1.25x45 screw (R) and through handle

bracket and handle (A).

2. Secure with M8 flat washer (N) and M8

locknut (P).

3. Install handle grips (H).

Figure 2-10. Handle Assembly

Battery Installation (if equipped)

The following tools are required to install the

battery.

• 7/16” (11mm) ratchet, socket and wrench

Install the battery as follows. See Figure 2-11.

1. Place battery onto battery tray with the

positive terminal on the right.

2. Connect red battery wire to positive (+) ter-

minal with a bolt, washer and nut.

3. Slide red battery terminal post cover over

terminal and hardware.

4. Connect black battery wire to negative (-)

terminal with a bolt, washer and nut.

5. Slide black battery terminal post cover

over terminal and hardware.

6. Slide one spacer onto each screw.

7. Slide these assemblies through holes in

top of bracket.

8. Place bracket assembly over top of bat-

tery. Do not to touch battery terminal hard-

ware. The screws will pass through holes

on battery tray.

9. Place washer, lock washer and wing nut

onto screw.

10. Tighten wing nuts until the lock washers

are compressed to being flat.

NOTE: If the battery is unable to start the

engine, charge it with the 12V charger

included in the accessory box (see the

"Charging a Battery" section for details).

Figure 2-11. Battery Installation

Add Engine Oil

Use high detergent, premium quality motor oil

certified for service class CI-4 or CJ-4. SAE

20W-40 is recommended for general, all tem-

perature use. See Figure 2-12.

Figure 2-12. Oil Recommendations

1. Place generator on a level surface.

2. Verify oil fill area is clean.

3. Remove oil fill cap and wipe dipstick clean.

See Figure 2-13.

Figure 2-13. Remove Dipstick

000710

000706

000716

(000135)

CAUTION

Engine damage. Verify proper type and quantity of

engine oil prior to starting engine. Failure to do so

could result in engine damage.

-4 °F

(-20 °C)

14 °F

(-10 °C)

32 °F

(0 °C)

50 °F

(10 °C)

68 °F

(20 °C)

86 °F

(30 °C)

104 °F

(40 °C)

SAE 15W-40

SAE 20W

SAE 30

SAE 40

SAE 10-W30

SAE 20W

SAE 10W

000578

000115

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