Generac Welding System 005747 0 (XG8000E) User Manual

MODELS: 005796-0 (XG6500), 005797-0 (XG7000),  
005798-0 (XG7000E), 005800-0 (XG8000),  
005747-0 (XG8000E)  
Owner's Manual  
XG Series 6,500-8,000 Watt Portable Generator  
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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.  
Indicates a hazardous situation or action which, if not  
avoided, could result in minor or moderate injury.  
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.  
If any portion of this manual is not understood, contact the  
nearest Authorized Dealer for starting, operating and servicing  
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.  
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  
The generator can operate safely, efficiently and reliably only if it  
is properly located, operated and maintained. Before operating or  
servicing the generator:  
This symbol points out potential explosion  
Become familiar with and strictly adhere to all local, state and  
This symbol points out potential fire hazard.  
national codes and regulations.  
Study all safety warnings in this manual and on the product  
This symbol points out potential electrical  
shock hazard.  
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.  
Never operate in an enclosed area or indoors.  
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.  
Keep hands, feet, clothing, etc., away from drive belts, fans,  
and other moving parts. Never remove any fan guard or shield  
while the unit is operating.  
Certain parts of the generator get extremely hot during  
operation. Keep clear of the generator until it has cooled to  
avoid severe burns.  
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  
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.  
Never start or stop the unit with electrical loads connected  
to receptacles AND with connected devices turned ON. Start  
the engine and let it stabilize before connecting electrical  
loads. Disconnect all electrical loads before shutting down the  
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  
Indicates a hazardous situation or action which, if not  
avoided, could result in death or serious injury.  
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Safety Rules  
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.  
The generator produces dangerously high voltage when in  
operation. Avoid contact withbare 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.  
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.  
Use a ground fault circuit interrupter in any damp or highly  
conductive area (such as metal decking or steel work).  
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.  
Do not use worn, bare, frayed or otherwise damaged electrical  
cord sets with the generator.  
• Never operate in an enclosed area or indoors! NEVER use in  
the home, 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.  
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.  
• Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE.  
Do not permit smoking, open flames, sparks or heat in the  
vicinity while handling gasoline.  
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.  
The engine exhaust fumes contain carbon monoxide, which  
can you cannot see or smell. This poisonous gas, if breathed  
in sufficient concentrations, can cause unconsciousness or  
even death.  
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.  
• 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 on all side to allow for proper  
ventilation of the generator.  
This exhaust system must be properly maintained. Do nothing  
that might renderthe exhaustsystem unsafe or innoncompliance  
with any local codes and/or standards.  
Always use a battery operated carbon monoxide alarm indoors,  
installed according to the manufacturers 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.  
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Safety Rules  
Do not insert objects through unit’s cooling slots.  
• Do not 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.  
Generator Identification  
In the absence of pertinent standards, codes, regulations and  
laws, the published information listed below may be used as a  
guideline for operation of this equipment. Always reference the  
latest revision available for the standards listed.  
2. Article X, NATIONAL BUILDING CODE, available from the  
American Insurance Association, 85 John Street, New York,  
N.Y. 10038.  
3. AGRICULTURAL WIRING HANDBOOK, available from the Food  
and Energy Council, 909 University Avenue, Columbia, MO  
American Society of Agricultural Engineers, 2950 Niles Road,  
St. Joseph, MI 49085.  
Engine exhaust and some of its constituents are known  
to the State of California to cause cancer, birth defects  
and other reproductive harm.  
This product contains or emits chemicals known to the  
State of California to cause cancer, birth defects and  
other reproductive harm.  
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General Information  
Refer to Figure 2 and install the wheel kit and frame foot as  
Remove all packaging material.  
Remove separate accessory box.  
Remove carton off the generator.  
Slide the Axle Pin through the Wheel, Wheel Spacer (Washer)  
and the Frame.  
Install the Hair Pin to the Axle Pin to secure the wheel. Repeat  
for the opposite side.  
Secure the Vibration Mounts to the Frame Foot with the included  
locking nuts.  
To install the Frame Foot, install the Frame Bolts though the  
Frame Washers, Frame and Frame foot. Secure with the locking  
Check all contents (Figure 1). If any parts are missing or damaged  
locate an authorized dealer at 1-888-775-6937.  
Contents include:  
2 – Axle Pins  
Oil Filter  
Figure 2 Wheel and Foot Assembly  
2 – Wheel Spacers  
2 – Hair Pins  
Air Filter  
Spark Plug  
2 – Wheels  
Spark Plug Wrench  
Shop Towel  
2 – Frame Washers  
Oil Funnel  
1 – Frame Foot  
2 – Frame Bolts  
2 – Vibration Mounts  
4 – Flange Nuts  
12 Volt Adaptor Plug Charger  
2 – 1 Quart SAE 30 Oil Bottles  
Figure 1 Accessory Boxes  
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 1-888-775-6937.  
The wheel kit is designed to greatly improve the portability of the  
generator. You will need the following tools to install the wheel  
kit: Pliers, 1/2" (13mm) wrench and a socket wrench with a 1/2"  
(13mm) socket.  
The wheel kit is not intended for over-the-road use.  
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Figure 3 Generator Locations  
Read the entire Owner’s Manual and Safety Rules before  
operating this generator.  
Compare the generator to Figures 3 through 6 to become  
familiarized with the locations of various controls and adjustments.  
Save this manual for future reference.  
1. Choke Knob – Used when starting a cold engine (Pull/Push).  
2. Engine Switch – Controls the operation of the generator. On  
electric start models the switch is Start/Run/Stop. On recoil  
start models the switch is On/Off.  
3. Fuel Shut Off – Valve between fuel tank and carburetor. Turn  
off and run carburetor out of fuel for extended storage.  
4. Panel LED's – Provide illumination of the control panel while  
the generator is operating.  
5. 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.  
6. 120 Volt AC, 20 Amp, GFCI 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. It also provides protection with an Integral  
Ground Fault Circuit Interrupter, complete with a press to  
"Test" and "Reset" button.  
7. Circuit Breakers (AC) – Each 20 Amp receptacle is provided  
with a push-to-reset circuit breaker to protect the generator  
against electrical overload.  
8. Circuit Breakers (AC) – The 30 Amp receptacle is protected  
with a pair of push-to-reset circuit breakers to protect the  
generator against electrical overload.  
9. PowerBar – Indicates the amount of power being used from  
the generator; each section is approximately 25%  
10. Hourmeter – Provides operating hours for Service Intervals.  
11. Battery Charger Input (Electric Start Models) – This  
receptacle allows the capability to recharge the 12 VDC engine  
starting battery with the 12 Volt Adaptor Plug Charger. The  
battery is protected by a 1.50 Amp in-line fuse which is inside  
the control panel.  
12. Fuel Tank – Tank holds 9 U.S. gallons of fuel.  
13. Fuel Gauge – Shows fuel level in tank.  
14. Handles – Pivot and retract for storage. Press the spring-  
loaded button to move handles.  
15. Oil Fill – Check oil level and add oil here.  
16. Grounding Lug – Ground the generator to an approved earth  
ground here. See "Grounding the Generator" for details.  
17. Muffler – Includes the spark arrestor and quiets the engine.  
18. Spark Plug Location – The spark plug ignites the Air/Fuel  
Mixture (Side panel must be removed).  
19. Engine Oil Filter – Filters engine oil; see Section 3.1 for the  
proper service intervals.  
20. Air Cleaner – Filters intake air as it is drawn into the engine.  
21. Oil Drain – Drain valve to remove used oil from the engine  
22. Recoil Starter – Use to start engine manually.  
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When the hour meter is in the Flash Alert mode, the maintenance  
message will always 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 resets itself.  
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 the Battery section). RUNNING THE  
100 hours - CHG OIL — Oil Change Interval (Every 100 hrs)  
200 hours - SVC — Air Filter Interval (Every 200 hrs)  
The positive battery wire was deliberately left detached for  
shipping. To operate the unit, attach this wire to the terminal on  
the starter motor as shown. Do not overtighten. Slide the attached  
rubber boot over the starter terminal. See Figure 4.  
This is a 120 Volt outlet protected against overload by a 20 Amp  
push-to-reset circuit breaker (Figure 5). Use each socket to power  
120 Volt AC, single phase, 60 Hz electrical loads requiring up to a  
combined 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).  
Figure 4 Battery Connection  
Keep extension cords as short as possible, preferably less than  
15 feet long, to prevent voltage drop and possible overheating of  
Use a NEMA L14-30 plug with this receptacle (rotate to lock/  
unlock). Connect a suitable 4-wire grounded cord set to the plug  
and to the desired load. The cord set should be rated for 250 Volts  
AC at 30 Amps (or greater) (Figure 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 6,500 to 8000  
watts of power, depending on the model. The outlet is protected by  
a 30 Amp circuit breaker.  
Figure 5 Generator Receptacles  
The Hourmeter tracks hours of operation for scheduled  
There will be a one time break in "CHG OIL" message that flashes  
with the elapsed time in hours and tenths after the first 30 hours  
of operation.  
This message will actually begin flashing at 29 hours and disable  
itself at 31 hours providing a two hour window to perform the  
There will be a subsequent "CHG OIL" message every 100 hours.  
The message will flash one hour before and one hour after each  
100 hour interval, again providing a two hour window to perform  
Every 200 hours the "SVC" icon on the lower left hand corner of  
the display will flash. The message will flash one hour before and  
one hour after each 200 hour interval providing a two hour window  
to perform service.  
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