How To Assemble A Portable Generac Generator

Below is a video on how to assemble a portable Generac generator

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Today we will be showing you how to assemble a Generac generator and get it ready for use. For this video we are using the Generac XG7000E portable generator. This is the XG series and a 7000 running watt generator with the electric start and that is why there is an E at the end. There is also a XG8000E and a XG10,000E depending on your power needs.


The reason we went with the XG series is it has a larger fuel tank a 9 gallon one, 10” never flat tires (solid hard plastic) and has the pressurized oil system and uses a spin on oil filter like a car oil filter.


I think generac is slowly dropping the XG series for some reason as there are less and less models for sale on there website. I believe they are replacing it with the XT series. So differences between the XG and the XT are that the XT series has a smaller fuel tank a 7 gallon tank and 9.5” semi solid wheels and splash lubrication to lubricate the engine. One thing that the XT has over the XG series is that it has the idle control. What this does is if the generator is not needing to put out any power it lowers the idle of the generator and saves you some fuel and also some decibels on the noise of the exhaust.


So just wanted to mention with that idle control no matter what your using and how little it draws off the generator once it sees a demand for power it will ramp up and run at the 3600RPM. Also most people think the battery charges as the generator runs and with this model it doesn’t you need to use your ac/dc converter to charger the battery.


So things that come with this generator are Ac/Dc converter battery tender, Extra oil filter for the 30hrs break in oil change, Fuel treatment, hardware for our front foot, some hardware for attaching our wheels, a rag and a paper funnel to put the oil in as the unit is shipped without oil in it. An extra air filter and spark plug used at your 200hr service and you should change your oil at 100 hrs also. Then your wheels and 2 qts of oil one quart for now and one for the 30hrs break in oil change.


To start well remove our oil fill cap and then grab our paper funnel and insert it into the oil fill hole. You will want to fill the generator up just to the bottom of the threads on the oil fill cap. Once we have a full quart in the generator it should be right at that line. Next we can wipe the area where we filled it and reinstall our oil fill cap.

Next we can grab an ⅜ socket and put in on a ¼ ratchet and remove the nut and the washer. Once we have the washer and nut removed we can push back the red insulator on the wire from the battery and put the eyelet on the stud and then put the washer on and then start our nut. Next we can take the socket and ratchet and tighten the nut down and slide the red insulator back over the eyelet.


With the connection tight on the starter we can grab a wheel and the wheel stud and slide the wheel stud into the wheel with the offset side closest to the generator frame. Next we can grab the wheel shim or flat washer put that on and then lift the generator and slide the pin though the hollow spot in the generator frame. Once we have the wheel lug though we can grab the cotter pin and slide it through the hole on the wheel lug. We can repeat the process to put the other wheel on.


Once we have the wheels installed we can attach the front foot. Well grab the front foot and lift the generator and slide the foot under it and align the holes in the frame with the foot. Once we have it aligned we can put the bolt through the washer and then though the frame of the generator and then the foot and then put the nut on it. Once we have on side done we can align the other hole and put the bolt and washer down though and then start that nut. Once we have both nuts on and started by hand we can take a ½ socket and put it on our ratchet and also grab a wrench to hold the nut so we can tighten the bolt with the socket and ratchet.


Once we have the front bolted on and tight we are almost ready to push the generator outside and fire it up. First we run through a quick checklist. We have the generator full of oil also check around oil filter and oil drain hose and fitting for leaks, front foot on, rear wheels on and cotter pin in place, starter wire attached also the battery level is good enough to start the generator.


Alright so we pushed the generator outside and we are now ready to fuel it up. Well remove the gas cap and fill it up. We are using 98 octane without ethanol in it. If you can only get gas with ethanol in it you should use a gas treatment.


Now that the generator is full of fuel we can open the fuel valve wait 5 seconds or so for the gas to get from the tank to the carb. Then pull the choke out and start it. If it doesn’t start within 2-3 of trying to start it wait 5 minutes and then try again. On some of these they have a problem where the gas line gets kinked or crushed restricting the flow of gas. Its an easy fix remove the front faceplate and reposition the gas line.


Alright once its started well let it run for a bit and shut the choke off and then we can test it to ensure it produces electricity. So well open the plug cover check the GFI and see if it needs to be reset if so well press it. Next we can grab a item with a cord we grabbed this circular saw. Well plug it into each outlet to ensure its working and ready to go for our next project or when the power goes out.


Alright its working as it should so we can go ahead and shut it down. If we were going to be storing the generator or not going to be using it for a while I would add some fuel treatment to the gas tank before I was done using it so that way it can mix in with the gas. I also would shut the fuel valve and  let the engine use all the fuel out of the carburetor as when ethanol gas sits in the carburetor it draws in moisture and the ethanol turns into a varnish of sorts and easily clogs the jets within the carburetor and then most likely cover the generator.


So that’s it we have just shown you how to assemble a portable Generac generator









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