Generac Power Systems XT8500EFI User manual

XT8500EFI Portable Generator

Owner’s Manual

WWW.GENERAC.COM

1-888-GENERAC

(1-888-436-3722)

SAVE THIS MANUAL FOR FUTURE REFERENCE

010034

MODEL:________________________

SERIAL:________________________

DATE PURCHASED:______________

(000209b)

WARNING

Loss of life. This product is not intended to

be used in a critical life support application.

Failure to adhere to this warning could result

in death or serious injury.

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

Replacement Hazard Labels ........... 3

Section 2 General Information and

Setup .............................................. 5

Know Your Generator ..................... 6

Emissions ........................................ 6

Connection Plugs ............................ 7

Hour Meter ...................................... 7

EFI Fault Indicator Light .................. 7

COsense® ...................................... 7

Remove Contents from Carton ....... 9

Assembly ......................................... 9

Battery Cable Connection ............. 10

Add Engine Oil .............................. 10

Fuel ............................................... 11

Section 3 Operation .................... 12

Operation and Use Questions ....... 12

Before Starting Engine .................. 12

Prepare Generator for Use ............ 12

Grounding the Generator When Used

as a Portable ................................. 12

Know Generator Limits .................. 13

Transporting/Tipping of the Unit .... 14

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

Starting Electric Start Engines ...... 14

Generator Shut Down ................... 14

Low Oil Pressure Shutdown System .

Section 4 Maintenance and

Troubleshooting ..........................15

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

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

Preventive Maintenance ................15

Engine Maintenance ......................15

Battery Replacement .....................17

Inspect Muffler and Spark Arrester 17

Valve Clearance ............................18

Storage ..........................................18

Troubleshooting .............................19

Fault Indicator Codes ....................20

(000393a)

WARNING

CANCER AND REPRODUCTIVE HARM

www.P65Warnings.ca.gov.

Owner’s Manual for Portable Generator 1

Section 1 Introduction and Safety

Introduction

The information in this manual is accurate

based on products produced at the time of

publication. The manufacturer reserves the

right to make technical updates, corrections,

and product revisions at any time without

notice.

Safety Rules

The manufacturer cannot anticipate every

possible circumstance that might involve a

hazard. The alerts in this manual, and on tags

and decals affixed to the unit, are not all inclu-

sive. If using a procedure, work method, or

operating technique that the manufacturer

does not specifically recommend, verify that it

is safe for others and does not render the

equipment unsafe.

Throughout this publication, and on tags and

decals affixed to the unit, DANGER, WARN-

ING, 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. Alert definitions are as follows:

NOTE: Notes contain additional information

important to a procedure and will be found

within the regular text of this manual.

These safety alerts cannot eliminate the haz-

ards that they indicate. Common sense and

strict compliance with the special instructions

while performing the action or service are

essential to preventing accidents.

Safety Symbols and Meanings

• 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.

(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.

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.

000657

Asphyxiation. Running engines produce

carbon monoxide, a colorless, odorless,

poisonous gas. Carbon monoxide, if not

avoided, will result in death or serious injury.

(000103)

DANGER

(000179b)

DANGER

Asphyxiation. The exhaust system must be properly

maintained. Do not alter or modify the exhaust system

as to render it unsafe or make it noncompliant with

local codes and/or standards. Failure to do so 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.

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. (000116)

DANGER

(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

2 Owner’s Manual for Portable Generator

• For safety reasons, it is recommended that

the maintenance of this equipment be per-

formed by an IASD. Inspect the generator

regularly, and contact the nearest IASD for

parts needing repair or replacement.

Exhaust and Location Hazards

• 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.

• NEVER run a generator indoors or in a

partly enclosed area such as garages.

• ONLY use outdoors and far away from win-

dows, doors, vents, crawl spaces and in an

area where adequate ventilation is avail-

able and will not accumulate deadly

exhaust gas.

• Using a fan or opening a door will not pro-

vide sufficient ventilation.

• Point muffler exhaust away from people

and occupied buildings.

Electrical Hazards

(000250)

WARNING

Equipment and property damage. Do not operate unit on

uneven surfaces, or areas of excessive moisture, dirt, dust

or corrosive vapors. Doing so could result in death, serious

injury, property and equipment damage.

(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 operating machine, do not

touch hot surfaces. Keep machine away from

combustibles during use. Hot surfaces could

result in severe burns or fire.

(000142a)

Personal injury. 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

Risk of injury. Do not operate or service this machine

if not fully alert. Fatigue can impair the ability to

service this equipment and could result in death or

serious injury. (000215)

WARNING

Injury and equipment damage. Do not use generator

as a step. Doing so could result in falling, damaged

parts, unsafe equipment operation, and could result

in death or serious injury. (000216)

(000501)

Personal Injury. Fuel lines are pressurized.

Servicing the fuel lines may release high

pressure fuel and could result in death or

serious injury.

WARNING

000406

Asphyxiation. Running engines produce

carbon monoxide, a colorless, odorless,

poisonous gas. Carbon monoxide, if not

avoided, will result in death or serious injury.

(000103)

DANGER

(000179b)

DANGER

Asphyxiation. The exhaust system must be properly

maintained. Do not alter or modify the exhaust system

as to render it unsafe or make it noncompliant with

local codes and/or standards. Failure to do so will

result in death or serious injury.

(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

(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.

(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.

Owner’s Manual for Portable Generator 3

• 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.

• Once generator has been started outside,

connect electrical loads to extension

cord(s) inside.

Fire Hazards

• Allow at least 5 feet of clearance on all

sides of the generator when operating to

prevent overheating and fire.

• 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

6. CSA C22.2 100-14 Electric motors and

generators for installation and use, in

accordance with the Rules of the Cana-

dian Electrical Code

7. ANSI/PGMA G300 Safety and Perfor-

mance of Portable Generators. Portable

Generator Manufacturer’s Association,

www.pgmaonline.com

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.

Replacement Hazard Labels

The following replacement hazard labels are

available free from Generac:

•0H0115C

(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.

(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.

CAUTION

Equipment damage. Do not power sensitive electronic devices

(computers, televisions, microwaves...) when Idle Control switch is

ON (if equipped). Lower engine rpm operation results in low

voltage/frequency and may damage electronic devices.

(000591)

(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.

(000166b)

DANGER

Explosion and Fire. Do not overfill fuel tank. Fill to

1/2 inch from 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.

(000174)

DANGER

Risk of fire. Allow fuel spills to completely dry

before starting engine. Failure to do so will

result in death or serious injury.

(000142a)

Personal injury. 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

WARNING!

DO NOT FILL

ABOVE LIP!

DO NOT OVERFILL TANK

ALWAYS ALLOW ROOM FOR FUEL EXPANSION

DO NOT FILL WHILE RUNNING

NO LLENE TANQUE EXCESIVAMENTE

SIEMPRE DEJE ESPACIO PARA LA EXPANSIÓN DEL COMBUSTIBLE

NO LLENE MIENTRAS ESTÉ FUNCIONANDO

NE PAS TROP REMPLIR LE RÉSERVOIR

TOURJOURS ALLOUR DE L’ESPACE POUR L’EXPANSION DE CARBURANT

NE PAS REMPLIR PENDANT QUE L’APPAREL FONTIONNE

NO LLENE

POR ENCIMA

DEL REBORDE

NE PAS REMPLIR

AU-DESSUS

DE LA LÈVRE

¡ADVERTENCIA!

AVERTISSEMENT!

4 Owner’s Manual for Portable Generator

• 0H8251B (Vertical CO Warning Decal)

• 0H4635C

• 10000033027 (Exhaust Direction User

Action Label)

5 FEET (1.5m)

MINIMUM

FROM OBJECTS

CARBON

MONOXIDE

READ

MANUAL

Owner’s Manual for Portable Generator 5

Section 2 General Information and Setup

Figure 2-1. Features and Controls

Generator Components

Figure 2-2. Control Panel

19 20

010208

010034

1 Key Switch Ignition

2 120 Volt AC, 20 Amp GFCI Duplex

Receptacle

3 120/240 Volt AC, 30 Amp Locking

Receptacle

4 Circuit Breakers (AC)

5 Battery Charger Input

6 Hour Meter

7 EFI Fault Indicator Light

8Fuse

9 Grounding Lug

10 Spark Arrestor

11 Muffler

12 Fuel Cap

13 Recovery Hose

14 Carbon Canister

15 Air Filter

16 Recoil Starter

17 Handle

18 Fuel Gauge

19 Roll Over Valve

20 Fuel Tank

21 Oil Drain

22 Oil Fill/Dipstick

23 Battery

24 Fuel Pump

25 Ignition Keys

26 Battery Charger

27 COsense® Shut-Off (RED)

28 COsense® Fault (YELLOW)

29 Oil Filter

010035

8 5

2 3

6 Owner’s Manual for Portable Generator

Figure 2-3. Unit Identification Label

Know Your Generator

Replacement owner’s manuals are available

at www.generac.com.

Emissions

The United States Environmental Protection

Agency (US EPA) (and California Air

Resources Board (CARB), for engines/equip-

ment certified to California standards) requires

this engine/equipment to comply with exhaust

and evaporative emissions standards. Locate

the emissions compliance decal on the engine

to determine applicable standards. See the

included emissions warranty for emissions

warranty information. Follow the maintenance

specifications in this manual to ensure the

engine complies with applicable emissions

standards for the duration of the product’s life.

010210

(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.

Product Specifications

Generator Specifications

Rated Power 8.5 kW**

Surge Watts 10 KVA**

Rated AC Voltage 120/240

Rated AC Load (120 Volt / 240 Volt) 70.8 / 35.4 Amps**

Rated Frequency 60 Hz @ 3600 RPM

Phase Single Phase

Unit Weight (Dry) 214 lbs. (97 kg)

** Operating Temperature Range: -7 deg. C (20 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.

Engine Specifications

Displacement 459 cc

Spark Plug Part No. 0K20670117

Spark Plug Type F7RTC or Equivalent

Spark Plug Gap 0.028-0.031 inch (0.70-0.80mm)

Gasoline Capacity 30.3 L (8.0 U.S. gallons)

Oil Type See chart in Add Engine Oil.

Oil Capacity 1.0 L (1.05 qt.)

Run Time at 50% Load 9 Hours

* Go to www.generac.com or contact an IASD for replacement parts.

Owner’s Manual for Portable Generator 7

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 2-4. 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). It also pro-

vides protection with a Ground Fault Circuit

Interrupter with a press to TEST and RESET

button.

Figure 2-4. 120 VAC, 20 Amp, GFCI Duplex

Receptacle NEMA 5-20R

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 2-5.

Use this receptacle to operate 120 Volt AC, 60

Hz, single phase loads requiring up to 3600

watts (3.6 kW) of power at 30 Amps or 240

Volt AC, 60 Hz, single phase loads requiring

up to 7200 watts (7.2 kW) of power at 30

Amps. The outlet is protected by one 30 Amp

2-pole circuit breaker.

Figure 2-5. 120/240 VAC, 30 Amp Receptacle

NEMA L14-30R

Hour Meter

The Hour Meter tracks hours of operation for

scheduled maintenance. See Figure 2-6.

• The SVC display will illuminate one hour

before and one hour after each 100 hour

interval providing a two hour window to per-

form service.

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 - SVC — Change oil, oil filter, air

filter, and spark plug. Clean spark arrestor

screen (every 100 hrs).

NOTE: The hour glass icon will flash when the

engine is running. This signifies the meter is

recording hours of operation.

Figure 2-6. Hour Meter

EFI Fault Indicator Light

See Fault Indicator Codes. This unit is

equipped with an EFI Fault indicator light, that

will flash diagnostic codes in the event of a

failure for easy troubleshooting.

There are 3 levels of fault codes:

1. Level 1 will flash and the generator will

run. There may be a slight impact on per-

formance.

2. Level 2 will flash and the generator will

shut down if multiple errors are detected.

3. Level 3 will shut down the generator imme-

diately.

Call Generac Customer Service at 1-888-

GENERAC (1-888-436-3722) for assistance.

COsense®

Carbon Monoxide (CO) Detection

and Shut-off System (if equipped)

The COsense® module monitors for the accu-

mulation of poisonous CO gas found in engine

exhaust when the generator is running. If

COsense® detects increasing levels of CO

gas, it automatically shuts off the engine.

COsense® only monitors when the engine is

running. Generators are intended to be used

outdoors, far from occupied buildings and the

000203

000204

0000.0

000205

8 Owner’s Manual for Portable Generator

exhaust pointed away from personnel and

buildings. However, if mis-used and operated

in a location that results in the accumulation of

CO, like indoors or in a partially enclosed

area, COsense® shuts off the engine, notifies

the user of what has happened and directs the

user to read the instruction action label for

steps to take. See Figure 2-7. COsense® is

not a substitute for an indoor carbon monox-

ide alarm.

See Figure 2-8. After a shut-off, a blinking

RED light in the COsense® badge on the side

of the generator provides notification that the

generator was shut off due to an accumulating

CO hazard. The RED light will blink for at least

five minutes after a CO shut-off. Move the

generator to an open, outdoor area and point

the exhaust away from people and occupied

buildings. Once relocated to a safe area, the

generator can be restarted and the proper

electrical connections made to supply electri-

cal power. The RED light will stop blinking

automatically upon engine re-start. Introduce

fresh air and ventilate the location where the

generator had shut down.

See Figure 2-8. If a COsense® system fault

has occurred and no longer provides protec-

tion, the portable generator is shut off auto-

matically and the YELLOW light will blink for at

least five minutes in the COsense® badge to

notify the user of the fault. The COsense®

module can only be diagnosed and repaired

by a trained technician at the dealer. The gen-

erator can be re-started, but may continue to

shut-off.

COsense® will detect the accumulation of

Carbon Monoxide from other fuel burning

sources such as engine powered tools or pro-

pane heaters used in the area of operation.

For example, if another generator is used and

the exhaust is pointed at a COsense®

equipped generator, COsense® may initiate a

shut-off due to rising CO levels. This is not an

error. Hazardous Carbon Monoxide has been

detected. The user must take action to move

and re-direct these devices to better dissipate

Carbon Monoxide far away from personnel

and occupied buildings.

Figure 2-7. Instruction Action Label

Figure 2-8. Instruction Badge

010211

010212

Table of contents

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