Index Engines XD5000E Diesel Portable Generator - service manual

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XD5000E Diesel Portable Generator. Manual - part 1

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 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

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.

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.

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