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XD5000E Diesel Portable Generator. Manual - part 5

Operator’s Manual for Portable Generator

Inspect Engine Oil Level

Inspect engine oil level prior to each use, or

every 8 hours of operation.
1. Place generator on a level surface.
2. Clean area around oil fill.
3. See

Figure 4-2

. Remove oil fill cap and

wipe dipstick clean.

Figure 4-2. Engine Oil Fill

4. Screw dipstick into filler neck. Verify oil

level is within safe operating range. See

Figure 4-3

Figure 4-3. Safe Operating Range

5. Add recommended engine oil as neces-

sary.

6. Replace oil fill cap and hand-tighten.
NOTE: Some units have more than one oil

fill location. It is only necessary to use one

oil fill point.

Change Engine Oil

When using generator under extreme, dirty,

dusty conditions, or in extremely hot weather,

change oil more frequently.
NOTE: Don’t pollute. Conserve resources.

Return used oil to collection centers.

Change oil while engine is still warm from run-

ning, as follows:
1. Place generator on a level surface.
2. Clean area around oil fill, and oil drain

plug.

3. Remove oil fill cap.
4. Remove oil drain plug and drain oil com-

pletely into a suitable container.

5. Install oil drain plug and tighten securely.
6. Slowly pour oil into oil fill opening until oil

level is between the crosshatch marks on

dipstick. DO NOT overfill.

7. Install oil fill cap, and finger tighten.
8. Wipe up any spilled oil.
9. Properly dispose of oil in accordance with

all applicable regulations.

Air Filter

Engine will not run properly and may be dam-

aged if run with a dirty air filter. Service air fil-

ter more frequently in dirty or dusty conditions.
To service air filter:
1. See

Figure 4-4

. Turn knob (A) and remove

air filter cover.

2. Wash in soapy water. Squeeze filter dry in

clean cloth (DO NOT TWIST).

3. Clean air filter cover before re-installing it.
NOTE: To order a new air filter, contact the

nearest Authorized Service Facility at 1-

888-GENERAC.

Figure 4-4. Air Filter Assembly

Battery Replacement (if

applicable)

NOTE: A battery may lose some charge

when not in use for prolonged periods of

time.

The following tools are required to replace the

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

Figure 4-5

1. Disconnect negative (-) battery terminal

FIRST (A).

(000139)

WARNING

Risk of burns. Allow engine to cool before draining
oil or coolant. Failure to do so could result in death
or serious injury.

000115

000116

(000141)

WARNING

Accidental start-up. Disconnect spark plug wires when
working on unit. Failure to do so could result in death or
serious injury.

000715

(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.

Operator’s Manual for Portable Generator

2. Disconnect positive (+) battery terminal

SECOND (B).

3. Loosen wing nuts and remove battery

bracket and hardware.

4. Replace battery by following instructions in

the

"Battery Installation (if equipped)."

section.

Figure 4-5. Battery Connection

Inspect Muffler and Spark Arrestor
(if equipped)

NOTE: It is a violation of California Public

Resource Code, Section 4442, to use or

operate the engine on any forest-covered,

brush-covered, or grass-covered land

unless the exhaust system is equipped

with a spark arrestor, as defined in Section

4442, maintained in effective working

order. Other states or federal jurisdictions

may have similar laws.
Contact original equipment manufacturer,

retailer, or dealer to obtain a spark arrestor

designed for exhaust system installed on this

engine.
NOTE: Use ONLY original equipment

replacement parts.
Inspect muffler for cracks, corrosion, or other

damage. Remove spark arrestor, if equipped,

inspect for damage or carbon blockage.

Replace parts as required.

Valve Clearance

IMPORTANT: If uncomfortable about doing

this procedure, or the proper tools are not

available, take generator to the nearest ser-

vice center to have valve clearance adjusted.
Check valve clearance after the first fifty-hours

of operation. Contact Authorized Service

Facility.

Storage

General

It is recommended to start and run the genera-

tor for 30 minutes, every 30 days. If this is not

possible, refer to the following list to prepare

unit for storage.
• DO NOT place a storage cover on a hot

generator. Allow unit to cool to room tem-

perature before storage.

• DO NOT store fuel from one season to

another unless properly treated.

• Replace fuel container if rust is present.

Rust in fuel will cause fuel system prob-

lems.

• Cover unit with a suitable protective, mois-

ture resistant cover.

• Store unit in a clean and dry area.
• Always store generator and fuel away from

heat and ignition sources.

Prepare Fuel System for Storage

Recoil Start
1. Push and hold decompression down and

slowly pull recoil starter 2 to 3 times. Do

not start engine.

2. Pull decompression lever up. Pull recoil

slowly until resistance is felt. This will

close valves so moisture cannot enter

engine cylinder. Gently release recoil.

Electric Start
1. Push and hold decompression lever down.
2. Push Start/Run/Stop switch to turn the

engine for 2 to 3 seconds. Do not start

engine.

3. Pull decompression lever up. Pull recoil

slowly until resistance is felt. This will

close valves so moisture cannot enter

engine cylinder. Gently release recoil.

4. Completely drain fuel tank or completely

fill fuel tank to proper level.

000716

(000143)

DANGER

Explosion and Fire. Fuel and vapors are extremely
flammable and explosive. Store fuel in a well
ventilated area. Keep fire and spark away. Failure to
do so will result in death or serious injury.

(000109)

WARNING

Risk of Fire. Verify machine has properly cooled
before installing cover and storing machine.
Hot surfaces could result in fire.

(000181)

WARNING

Vision Loss. Eye protection is required to avoid
spray from spark plug hole when cranking engine.
Failure to do so could result in vision loss.

Operator’s Manual for Portable Generator

NOTE: Always treat diesel fuel for long

term storage. Use the approved fuel addi-

tive and water abatement material. Test

stored fuel every 90 days and provide addi-

tional treatment if required. Periodically

check and dry abatement material as nec-

essary.

Change Oil

Change engine oil before storage. See

"Change Engine Oil."

Return Engine to Service

1. Refer to the

"Before Starting Engine."

section.

2. Start engine and run at no load for 5 to 10

minutes while checking:
• oil pressure
• fuel, engine oil or coolant leaks
• proper operation of indicators/gauges

NOTE: Avoid prolonged operation at mini-

mum or maximum engine speeds and

loads for the first hour of operation.

Troubleshooting

PROBLEM

CAUSE

CORRECTION

Engine is running, but

AC output is not

available.

1. Circuit breaker OPEN.
2. Poor connection or defective

cord set.

3. Connected device is bad.
4. Fault in generator.
5. Main breaker switch is OFF.
6. Voltage selector switch is OFF.
7. Generator is overloaded.
8. GFCI outlet has tripped.

1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is

in good condition.

4. Contact Authorized Service

Facility.

5. Switch main breaker ON.
6. Switch voltage selector switch

to desired voltage output.

7. See

"Know Generator Lim-

its."

8. Correct ground fault in circuit

and reset GFCI.

Engine runs well at

no-load, but bogs when

load is applied.

1. Short circuit in a connected

load.

2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.

1. Disconnect shorted electrical

load.

2. See

"Know Generator Lim-

its."

3. Contact Authorized Service

Facility.

4. Contact Authorized Service

Facility.

Engine will not start; or

starts and runs rough.

1. Incorrect start sequence.
2. Fuel valve is OFF.
3. Dirty air filter.
4. Out of fuel.
5. Stale or contaminated fuel.
6. Low oil level.
7. Excessive rich fuel mixture.
8. Dirty fuel filter.
9. Air in fuel system.
10. Engine is under electrical load.

1. Review & follow starting pro-

cedure.

2. Turn fuel valve ON.
3. Clean or replace air filter.
4. Fill fuel tank.
5. Drain fuel tank and fill with

fresh fuel.

6. Fill crankcase to correct level.
7. Contact Authorized Service

Facility.

8. Replace fuel filter.
9. Contact Authorized Service

Facility.

10. Remove all equipment from

receptacles. Make sure the
main breaker switch is OFF.