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GENPortable Products
RAC°I
Portable
Generator
Owner's Manual
Model No. 9777-2 (4000 Watt AC Generator) Manual No. B4400 Revision 4 (9/20/2000)
Visit our
Generac
website:
www.generac-portables.com
This isthe
safety
alert symbol.follow
It is usedto
alert you
to potential
Obey
all safety
messagesthat
this symbol
to avoid
possiblepersonal
injuryor injury
death.hazards.
Generac
Portable
Products
4,000XL
Generator
SAFETY
EQUIPMENT
DESCRIPTION
This generator set was designed and manufactured for
specific applications. Do Not attempt to modify the unit
or use it for any application it was not designed for. If you
haveany questions about your generator's application, ask
your dealer/distributor or consult the factory.
This generator is an engine-driven, revolving field,
alternating current (AC) generator. It was designed to
supply electrical power for operating compatible electrical
lighting, appliance, tool, and motor loads.This manual
contains informationfor a generator that operates
120 and/or 240 Volt AC, single phase, 60 Hz devices that
require up to 4,000 watts (4.0 kW) of power that pull up
to 33.3 Amps at 120 Volts or 16.7 Amps at 240 Volts.
_hL
RULES
The manufacturer could not possibly anticipate every
circumstance that might involvea hazard. For that reason
warnings in the manual and warnings on tags or decals
affixed to the unit are not all-inclusive. If you intend to
handle, operate or service the unit by a procedure or
method not specifically recommended by the manufacturer,
first make sure that such a procedure or method will not
render this equipment unsafe or pose a threat to you and
others.
CAUTION!
Do capacity.Add
Not exceed up
the the
generator's
wattage/amperage
rated watts
of all devices you are connecting to generator
receptacles at one time. This total should not be
greater than 4,000 watts. In most casesrated watts
of the electrical device can be found on the device
nameplate. If the device nameplate gives only volts
and amps,multiply volts times amps to obtain watts
(volts X amps = watts).
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
The 4,000 watt generator has the following features:
• 120/240 Volt, 20 Amp locking receptacle and a 120 Volt,
30 Amp locking receptacle.
• 120 Volt, 15 Amp receptacles.
• 12 Volt DC, l0 Amp receptacle.
_hL
• Low Oil Shutdown: Automatically shuts down the engine
if oil drops below safe operation level.
used for backup power. Failure to isolate the
generator from the power utility may result
in injury or death to electric utility workers
and damage to the generator due to a backfeed
of electrical energy. Whenever unit is providing
backup power, the electric utility must be notified.
• Four gallon overhead fuel tank with fuel gauge.
• The generator's revolving field is driven at about
3,600 rpm by a Generac Power Systems 7.8 h.p. engine.
_hL
DANGER!
You by
must
isolatethe
generator
from
the electric utility
opening
the electrical
system's
main circuit breaker or main switch if this unit is
WARNING!
Not
tamper speeds
with engine
governed speed.Do
High
operating
are
dangerous and increaserisk of personal injuryor
damageto equipment The generator supplies
correct rated frequency and voltage only when
running at proper governed speed. Incorrect
frequency and/or voltage can damagesome
connected electrical loads.Operating at excessively
low speeds imposesa heavy load. When adequate
engine power is not availableengine life may be
shortened.
_
ANGER! carbon
Generator
exhaust
contain
DEADLY
monoxide
gas.gases
Carbon
monoxide, if breathed in sufficient
concentrations,
can cause unconsciousness or
death. Operate this equipment outdoors where
adequate ventilation is available.
The Emission Control System for this generator is
warranted for standards set by the Environmental
Protection Agency. For warranty information refer to the
engine owner's manual.
/
2
Generac Portable Products 4,000XL Generator
• The generator produces a very powerful voltage that can
cause serious injury or death by electrocution. Never
touch bare wires or receptacles. Never permit a child
or any unqualified person to operate the generator.
• Never operate the generator:
in rain; in any enclosedcompartment; when connected
electrical devices overheat; if electrical output is lost; if
engine or generator sparks; if flame or smoke is
observed while unit is running; if unit vibrates
excessively.
• Never handle any kind of electrical cord or device while
standing in water, while barefoot or while hands or feet
are wet Death or serious injury from electrocution may
result.
GROUNDING
THE
G EN ERATO R
• Use a ground fault circuit interrupter (GFCI) in any damp
or highly conductive area (such as metal decking or steel
work).
The National ElectricalCode requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of the
unit For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure I).
• Never use worn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damage from electrical shock may result.
• Gasoline is highly FLAMMABLE and its vapors
are EXPLOSIVE. Never allow smoking, open
flames, sparks or heat in the vicinity while
handling gasoline. Avoid spilling gasoline on a hot
engine.Comply with all laws regulating storage and
handling of gasoline.
• Do Not overfitl the fuel tank. Always allow room for
fuel expansion. If tank is overfilled, fuel can overflow
onto a hot engine and cause a FIRE or an
EXPLOSION.
• Never store a generator with fuel in the tank where
gasoline vaporsmight reach an open flame, spark or pilot
light (as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.
• The unit requires an adequateflow of cooling air for its
continued proper operation. Never operate the unit
insideany room or enclosure where the free flow of
cooling air into and out of the unit might be obstructed.
Allow at least2 feet of clearance on all sides of generator,
even while operating unitoutdoors, or you could damage
the unit See "Cold Weather Operation" on page 10.
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth-driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, localcodes
may vary widely. Consult with a localelectrician for
grounding requirements in your area.
• Never start or stop the unit with electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting any electrical loads. Disconnect all electrical
loadsbefore shutting down the generator.
Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
• Do Not insertany object through cooling slots of the
engine.You could damagethe unit or injureyourself.
/
3
Generac
Portable
Products
4,000XL
Generator
KNOW
YOUR
GENERATOR
Read this owner's manual and safety rules before operating your generator.
Compare the illustrations with your generator to familiarize yourself with the locations of various controls
adjustments. Save this manual for future reference.
and
FuelTank
Circuit
Breakers (AC)
Fuel Shut Off Valve
120 Volt AC, 30 Am
Receptacle
Run/Stop Switch
120/240 Volt AC,
20 Amp Receptacle
12 Volt DC, 10Amp
Receptacle
120 Volt AC, 15Amp,
Duplex Receptacle
Idle Control Switch
Grounding Wing Nut
12 Volt DC, I 0 Amp Receptacle -- Use this receptacle
with battery chargecablesto chargea 12 Volt battery.
Circuit Breakers (AC) -- Each receptacle is provided
with a circuit breaker to protect the generator against
electrical overload. Breakers are "push to reset" type.
120 Volt AC, I 5 Amp Duplex Receptacle -- May be
used to supply electrical power for the operation of
120 Volt AC, 15 Amp, single phase, 60 Hz electrical
lighting, appliance, tool and motor loads.
Fuel Shut Off Valve -- Controls fuel supply to engine.
Fuel Tank -- Capacity of 4 U.S.gallons (15 liters).
Grounding Wing Nut -- Provides a tie-point for
connecting the generator frame to earth ground.
120 Volt AC, 30 Amp Receptacle -- May be used to
supply electrical power for the operation of 120 Volt AC,
30 Amp, single phase, 60 Hz electrical lighting,appliance,
tool and motor loads.
Idle Control Switch -- The idle control runs the engine
at normal (high) speeds when there isan electrical toad
present and runs the engine at idle (tow) speeds when a
load is not present. This feature greatly improvesfuel
economy, extends the life of the engine, and reduces engine
noise.
120/240 Volt AC, 20 Amp Receptacle -- May be used
to supply electrical power for the operation of 120 and/or
240 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
RunlStop Switch -- Must be in "Run" position to start
engine. Set to "Stop" to stop a running engine.
/
4
Generac
Portable
Products
4,000XL
Generator
CONTENTS
Add Gasoline
Check all contents. If any parts are missing or damaged, call
the generator helpline at 1-800-270-1408. Review "Cold
Weather Operation" on page 8. Shipped with your
generator is:
_hL
ANGER!NeverExplosion
Hazard!
tank
indoors.
fill fuel tank
whenNever
enginefillisfuel
running
or hot. Do Not light a cigarette or smoke when
filling the fuel tank.
Main unit
20 Amp and 30 Amp locking plugs
_lk
Spare spark plug and air filter
• Use regular UNLEADED gasoline with the generator
engine. Do Not use premium gasoline. Do Not mix oil
with gasoline.
Spark plug wrench
Video tape
Oil
• Clean area around fuel fill cap, remove cap.
Engine and unit owner's manual
• Slowly add unleaded regular gasoline to fuel tank. Be
careful not to overfill. Allow about I/2" of tank space for
fuel expansion (Figure 2).
Battery charge cables
BEFORE STARTING
ENGINE
1/2" Air Space
Add Oil
_hL
WARNING!
Do for
Notfuel
overfill
the fuel tank.
Always allow room
expansion.
Tank
WARNING!
attempt
to crank
or with
startthe
the
engine before it Any
has been
properly
filled
recommended oil may result in an engine failure.
To fill your engine with oil:
• PJace
generator on
a Jevel surface.
• Clean area around oil fill and remove oil fill cap.
• Select the oil's viscosity grade and fill engine with oil
following the instructions given in the engine owner's
manual. Do Not overfil!!
• Installfuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in essential fuel system parts such as the
carburetor, fuel filter, fuel hose or tank during storage.
Also, experience indicatesthat alcohol-blended fuels (called
gasohol, ethanol or methanol) can attract moisture, which
leadsto separation and formation of acids during storage.
Acidic gascan damage the fuel system of an engine while in
storage.
• Install oil fill cap.
NOTE: The generator's revolving field rides on a prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer.See "Storage"
on page I I. Never use engine or carburetor cleaner
products in the fuel tank as permanent damagemay occur.
/
5
Generac
Portable
Products
4,000XL
Generator
OPERATING
THE
GENERATOR
5.
Grasp the recoil handle and pull slowly until slight
resistance is felt. Then pull rapidly one time only to
start engine.
• If enginestarts, proceed to step7.
_k
• If engine fails to start, proceed to step 6.
electrical
AUTION!loads connected
Never startto orthestop
unitthe
andengine
with the
with
connected devices turned ON.
Starting
6.
the Engine
Move the choke lever to "Half'
pull recoil handle twice.
choke position, and
• If engine fails to start, repeat steps 4 thru 6.
Disconnect all electrical loadsfrom the generator. Use the
following start instructionsteps by numerical order:
I.
Make sure the Idle Control switch is in "Off" position.
2.
Turn the fuel valve to the "On" position (Figure 3).
7.
Move choke lever to "Run" position. If engine falters,
move choke lever to "Half" choke position until the
engine runs smoothly, and then to "Run" position.
NOTE: If engine still fails to start after 3 pulls, check for
proper oil level in crankcase.This unit is equipped with a
Low Oil Shutdown System. See engine manual.
Connecting
Electrical
Loads
• Let engine stabilize and warm up for a few minutes after
starting.
• Plug in and turn on the desired 120 and/or 240Volt AC,
single phase, 60 Hertz electrical loads.
3.
Set the Run/Stop switch to "Run"
position
(Figure 4).
• Do Not connect 240 Volt loadsto 120 Volt receptacles.
• Do Not connect 3-phase loadsto the generator.
• Do Not connect 50Hz loadsto the generator.
• DO NOT OVERLOAD THE GENERATOR. Add up
the rated watts (or amps) of all loads to be connected at
one time. This total should not be greater than the rated
wattage/amperage capacity of the generator. See "Don't
Overload the Generator" on page I I.
Stopping
4.
the Engine
• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with electrical
devices plugged in and turned on.
Placethe choke lever in the "Full" choke position
(Figure 5).
• Put the Idle Control switch in the "Oft"' position.
• Let engine run at no-load for 30 seconds to stabilize the
internal temperatures of engine and generator.
Position
• Move Run/Stop switch to "Stop".
• Close the fuel shut-off valve.
/
6
Generac
Portable
Products
4,000XL
Generator
Operating
Automatic
To recharge
Idle Control
12 Volt batteries, proceed as follows:
This switch is designed to greatly improvefuel economy.
When this switch is turned ON, the engine will only
run at its normal high governed engine speed when an
electrical load is connected. When the load is removed,
the engine will run at a reduced speed. With the switch
OFF, the engine will run at the normal high engine speed.
Always have the switch oft when starting and
stopping the engine.
• Check fluid level in all battery cells. If necessary,add
ONLY distilled water to cover separators in battery
cells. Do Not use tap water.
Charging
• Connect battery charge cable clamp with red handle to
the positive (+) battery terminal (Figure 6).
A
A
• If the battery is equipped with vent caps, make sure they
are installedand are tight.
• If necessary,clean battery terminals.
• Connect battery charge cable connector plug to panel
receptacle identified by the words "12-VOLT D.C."
a Battery
ANGER!gaswhile
Storage
batteries This
give off
explosive
hydrogen
recharging.
explosive
mixture will remain around the battery for a long
time after it has been charged. The slightest spark
can ignite the hydrogen and cause an explosion. Such
an explosion can shatter the battery and cause
blindness or other serious injury.
12 VOLT D.C.
RECEPTACLE
DANGER!
Not
permit
open
flame,
sparks or any Oo
other
source
of smoking,
heat around
a battery.
Wear protective goggles,rubber apron and rubber
gloves when working around a battery. Battery
electrolyte fluid is an extremely caustic sulfuric acid
solution that can cause severe burns. If spill occurs,
flush area with clear water immediately.
+
POS
NEG
12 VOLT BATTERY
Your generator hasthe capability of recharging a discharged
12 Volt automotive or utility style storage battery. Do Not
use the unit to charge any 6 Volt batteries. Do Not use
the unit to crank an engine having a discharged battery.
• Connect battery charge cable clamp with black handle
to the negative (-) battery terminal (Figure 6).
• Start engine. Let the engine run while battery recharges.
• When battery has charged, shut down engine
NOTE: Use an automotive hydrometer to test battery
state of charge and condition. Follow the hydrometer
manufacturer's instructionscarefully. Generally, a battery is
considered to be at 100%state of charge when specific
gravity of its fluid (as measured by hydrometer) is 1.260 or
higher.
,mmm
7
Generac Portable Products 4,000XL Generator
Cold Weather
• Ensure a minimum of two feet clearance between open
side of box and nearest object.
Operation
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your Generac generator
max experience icing of the carburetor and/or the
crankcase breather system.
• Face exposed end away from wind and elements.
• Enclosure should hold enough heat created by the
generator to prevent problems.
In an emergency, use the original shipping box as a
temporary shelter:
_
• Cut off all flaps.
AUTION!
NEVER
run than
unit indoors;
Do Not
enclose
generator
any more
shown. Remove
shelter when temperatures
• Cut out one of the long sides of the box to expose
exhaust side of unit Ensure a minimum of two feet
are above 40°F [4°C].
RECEPTACLES
clearance between open side of box and nearest object.
• Cut appropriate slots to access receptacles of unit
120 Volt AC, 15 Amp Receptacles
• Start unit, then place box over it.
Eachof these outlets is protected against overload by
15 Amp push-to-reset type circuit breakers (Figure 8).
IMPORTANT: Remove shelter when temperature is
above 40°F [4°C].
For a more permanent shelter, build a structure that will
enclose three sides and the top of the generator:
II
• Make sure entire muffler-side of generator isexposed
(Figure 7).
I
Wind
II
i
Use each outlet to operate 120 Volt, 60 Hz, single phase
loads requiring 1,800 (I.8 kW) watts at 15 Amps of
current.
I
8
Generac
Portable
Products
4,000XL
Generator
120/240 Volt AC,
Receptacle
20 Amp
Locking
120 Volt AC, 30 Amp
Receptacle
Use a N EMA LI4-20 plug with this receptacle. Connect a
4-wire cord set rated for 250 Volts at 20 Amps (or greater)
(Figure 9). You can use the same 4-wire cord if you plan to
run a 120 Volt load.
Locking
Use a NEMA L5-30 plug with this receptacle. Connect a
3*wire cord set rated for 125 Volts AC at 30 Amps to the
plug (Figure 10).
I[e_
IP,Te]kV_mF.'T__
3-Wire Cord Set
_m
4-Wire Cord Set
r--
Neutml
120V
Hot
NEMA L5-30
Y (Hot)
x (Hot)
Use this receptacle to operate 120 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts (3.6 kW) of power
at 30 Amps. The outlet is protected by a 30 Amp
Ground
N EMA L14-20
(Green)
push-to-reset
This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 2,400 watts of power at
20 Amps for 120 Volts; 4,000 watts of power (4.0 kW) at
16.7Amps for 240 Volts. The outlet is protected by a
20 Amp push-to-reset circuit breaker.
12 Volt
circuit breaker.
DC,
10 Amp
Receptacle
This connector (identified by the legend"12-VOLT D.C:')
supplies 12 Volts DC at 10Amps through battery charging
cables for recharging 12Volt batteries (Figure I I). See
"Charging a Battery" on page 7.
iBm
9
Generac Portable Products 4,000XL Generator
DON'T OVERLOAD
GENERATOR
THE
• If the appliance, tool or motor does not give wattage,
multiply 120 Volts times ampere rating to determine
watts (volts x amps = watts).
• Some electric motors, such as induction types, require
about three times more watts of power for starting than
for running. This surge of power lasts for only a few
seconds when starting such motors. Be sure you allow
for this high starting wattage when selecting electrical
devices to connect to your generator. First estimate the
watts needed to start the largestmotor. Add to that
figure the running watts of all other connected loads.
Overloading a generator in excess of its rated wattage
capacity can result in damageto the generator and/or
connected electrical devices. Observe the following, to
prevent overloading the unit:
• Add up the total wattage of all electrical devices to be
connected at one time. This total should NOT be
greater than the generator's wattage capacity.
• The rated wattage of lightscan be taken from light bulbs.
The rated wattage of tools, appliancesand motors can
usually be found on a data plate or decal affixed to the
device.
Recreational/Home
• The wattage reference guide (Figure I I) is provided to
help you to determine how many items the generator
can operate at one time.
Professional/C ontractor Uses
Uses
Tool/Appliance .................................................... Watts
"1/3 hp airlesssprayer .............................................................
600
3/8" hammer drill .....................................................................
600
Tool/Appliance
....................................................
Watts
AM/FM clock radio .....................................................................50
Light bulb ....................................................................................100
Fan................................................................................................200
Variable speedSawzalt®..........................................................
960
V2"power drill .........................................................................
1000
Quartz-halogen work light...................................................
1000
Belt sander...............................................................................
1200
7 ¼" circularsaw ...................................................................
1500
7 ¼" worm drive saw............................................................
1600
20" color TV ..............................................................................400
*Deep freezer ............................................................................500
Personal computer and 15" monitor ...................................800
*1/3 hp furnace fan blower .....................................................800
Microwave oven ........................................................................800
*1 V2hp air compressor ........................................................
1800
* I0" power miter saw...........................................................
1800
6" bench grinder .....................................................................
1800
"6" table planer .......................................................................
1800
*10" table/radial arm saw .....................................................
2000
Wire feed welder ...................................................................
2400
*18 cuft refrigerator ...............................................................800
Sump pump ..............................................................................1000
Electric skillet ..........................................................................1250
*_/2hp water well pump ........................................................1400
* 12,000 Btu window air conditioner .................................1400
Space heater ............................................................................1800
Electric water heater .............................................................4000
* allow 3 times listed watts for starting this device
I
I0
Generac Portable Products 4,000XL Generator
SPECIFICATIONS
To Clean
the Generator
Maximum Surge Watts ...............
5,000 Watts
• Use a damp cloth to wipe exterior
Continuous Wattage Capacity .........
Power Factor .............................
4,000 Watts
1.0
• Soft, bristle brush may be used to loosen caked on dirt
or oil.
Rated Maximum Continuous Load Current
At 120 Volts ......................
At 240 Volts ......................
• A vacuum cleaner may be used to pick up loose dirt and
debris.
33.3 Amps
16.7Amps
Phase ................................
Rated Frequency ......................
• Low pressure air (not to exceed 25 psi) may be used to
blow away dirt. Inspect cooling air slots and opening on
generator. These openings must be kept clean and
unobstructed.
I-phase
60 Hertz
Fuel Tank Capacity .................
4 U.S.gallons
GENERAL MAINTENANCE
RECOMMENDATIONS
STORAGE
Generator
Maintenance
Generator
and
dry.
• Check that cooling air slots and openings on generator
are open and unobstructed.
Maintenance
maintenance
Operate
environment
where
it wit{
dirt,
moisture
slots
in the generator
Water
slots,
Not
can enter
addition,
and dirt
eventually
must
foreign
buildup
not
become
and cause
through
Engine
will be retained
and stator
winding
generator
the insulation
In
Other
air
internal
resistance
Water
windings
Storage
Tips
• Do Not store gasoline from one season to another.
in voids and
insulation.
Storage
See engine owner's manual for instructions.
problems.
cooling
DANGER!
Storagecover
covers
canabe
Not
place a storage
over
hotflammable.
generator.Do
Let
the unit cool for a sufficient time before placing the
cover on the unit.
air
with snow,
hose to clean generator.
generator
decrease
Cooling
clogged
material.
fuel system
on the
_
clean
dry
to excessive
vapors.
enters
rotor
the unit
in a clean
be exposed
engine
of the water
of the
not
use a garden
if water
some
cracks
of keeping
the unit
or any corrosive
leaves or any other
Do
consists
and store
dust,
NOTE:
Storage
• Clean the generator as outlined in "To Clean the
Generator"
See engine manual for instructions.
Generator
INSTRUCTIONS
The generator should be started at least once every seven
days and allowed to run at least 30 minutes. If this cannot
be done and you must store the unit for more than 30
days, use the following guidelines to prepare it for storage.
The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on a timely
basis;that all discrepancies are corrected; and that the unit
is kept clean and properly stored. Never operate a
damaged or defective generator.
Engine
surfaces clean.
• Replace your gasoline can if it starts to rust. Rust and/or
dirt in a gasoline can cause problems when you use
contaminated fuel with this unit.
wit{
of these
windings.
• Store in clean and dry area.
I
II
Generac Portable Products 4,000XL Generator
TROUBLESHOOTING
Problem
Engine is running,
no AC output is
available.
but
Engine runs good but
bogs clown when loads
are connected.
Engine will not start; or
starts and runs rough.
Cause
Solution
I.
2.
3.
Circuit breaker is open.
Poor connection or defective cord set.
Connected device is bad.
I.
Reset circuit breaker.
2.
3.
Check and repair.
Connect another device that is in good
condition.
4.
I.
2.
Fault in generator.
Short circuit in a connected
Generator is overloaded.
4.
I.
2.
Contact Generac service facility.
Disconnect shorted electricalload.
See "Don't Overload the Generator"
3.
4.
I.
2.
3.
4.
5.
Enginespeed istoo slow.
Shortedgenerator circuit.
Run/Stop switch set to "Stop".
Dirty air cleaner.
Out of gasoline.
Stalegasoline.
Spark plug wire not connected to spark
plug.
Bad spark plug.
Waterin gasoline.
Overchoking.
3.
4.
I.
on page 10.
Contact Generac service facility.
Contact Generac service facility.
Set switch to "Run".
2.
3.
Clean or replace air cleaner.
Fill fuel tank.
4.
Drain gas tank and fill with fresh fuel.
Connect
wire to spark
plug.
6.
7.
8.
9.
10.
II.
12.
Engine shuts down
during operation.
Engine
lacks power.
Engine
falters.
"hunts"
load.
Low oil level.
5.
6.
7.
8.
Replacespark plug.
Drain gastank; fill with fresh fuel.
Put choke lever to "No Choke"
position.
9. Fill crankcase to proper level.
10. Contact Generac service facility.
I I. Contact Generac service facility.
12. Contact Generac service facility.
I.
2.
Excessively rich fuel mixture.
Intake valve stuck open or closed.
Engine has lost compression.
Out of gasoline.
Low oil level
2.
Fill crankcase to proper level.
3.
I.
Fault in engine.
Load is too high.
3.
I.
Contact Generac service facility.
See "Don't Overload the Generator"
2.
3.
I.
Dirty air filter.
Engine needs to be serviced.
Choke is opened too soon.
2.
3.
I.
on page 10.
Replace air filter.
Contact Generac service facility.
Move choke to halfway position till
Carburetor
lean.
2.
engine runs smoothly.
Contact Generac service facility.
I. Fill fuel tank.
or
2.
is running too rich or too
/
12
Generac Portable Products 4,000XL Generator
NOTES
/
13
Generac
Portable
Products
4,000XL
Generator
ID3__TI_
ELECTRICAL
SCHEMATIC
REGULATOR
DPE
POWERBOARD
Uu
!
F
H
E
D
•
D
L]OJ
G
A
E
2
G
N
A
_Y_TEM
CONTROL
GRH
3
SLU
LOP
SWITCH
ENG,
IGNITION
BATTERY
BLE
55
BRN
66
AUTO
CHARGE
RED
13
BRN
77
BLK
55
I
14
z
_
/
Generac Portable Products 4,000XL Generator
WIRING
ID_I_I_
DIAGRAM
RED
13
U(
GRN
GRY
GRY
GRN
GATE
EIGNAL
3
LOW
OIL
PRESSURE
SWITCH
PIN
LOW
OIL
PRESSURE
LED
ENGINE
RUN
SWITCH
CATHODE
pq
NUT
BATTERY
CHARGE
RECTIFIER
I
15
ON
ENGINE
BLOCK
Generac Portable Products 4,000XL Generator
I
?//_
EXPLODED
J
VIEW
- HAIN
UNIT
65
5O
f -_
48
DETAIL
\47
" X "
SEE
DETAIL " Y "
lO
52
62
8
\
1 f
56
12
S5
I
\\\
52
11
J
/
2O
SEE
DETAIL
-X,,
26
q
22
14
65
27_
15
16
/
16
Generac Portabte Products 4,000XL Generator
l/!
yG_
I
J/_
Ii
m
PARTS LIST - MAIN
Item
1
2
3
4
5
6
7
8
Io
II
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
30
32
33
34
35
36
Part #
A93199
A84021
NSP
66365
84141J
83540J
65791
96796
86307
47480
84508
52858
83208
B4986
66476
89476
70644
84346
40976
83083
83071
81917
66825-B
85652
67989
74908
86308
65795
66849A
67022
84132
Qty
4
I
2
8
I
I
2
I
I
3
2
I
I
I
I
2
2
4
4
I
I
I
I
37
38
39
41
42
66386
66849
B4871
86494
86292
I
2
I
I
I
43
44
77395
83465
4
4
UNIT
Item
46
47
48
49
50
51
52
53
54
55
56
60
61
62
63
64
65
66
67
68
69
Description
CRADLE, XL
SUPPORT,Engine
ENGINE
HOUSING, Engine Adapter
ASSEMBLY,Rotor
ASSEMBLY,Stator
BEARING
WASHER, M8 Ftat
HHMS, 5/16-24 x 3/4
HHCS, 5/16-24 x 7"
MOUNT, Vibration 45 °
NUT, M8 Locking
BRACKET, Muffler
DECAL, Ground
HHMS, LW M6 1.00x 12
GASKET, Exhaust
PPHMS,M8 1.25 x 20
PPHMS,M8 x 35
SHCS, M8 1.25 x 20
SCREEN,Spark Arrest
MUFFLER
PIN, Roll M4 x 10
CARRIER, Rear Bearing
MOUNT, Vibration
NUT, M8 FlangedSerrated
TAPTITE, M5-0.8 x 10
BOLT, M6 - 1.0 x 115
RECTIFIER,Battery Charge
TAPTITE, M5 0.8 x 20
GROMMET, Rubber
ASSEMBLY,Drive Module Pwr
Reg.
ASSEMBLY,Brush Holder
TAPTITE, M5 0.8 x 16
COVER, Bearing Carrier
SCREW, M6 -I .0 x 16 Wing
HHCS, l0 - 16 x 3/4" Setf
Driller
NUT, M6 FlangeLock
GROMMET, Tank
Part #
78831B
80270
78299
85134
88325
B84042
84687
85000
14353621
23762
26850
B4399
92982
B4398
93826
73054
20566
77816
87116
B2153
84409
Qty
4
2
I
I
2
I
I
I
I
I
4
I
Parts Not Illustrated:
37806
43483
65787
72347
78601
84882
B4400
B4572
BB3061
NSP
Optional
/
17
Description
HHMS, M6 1.0x 60
VALVE,Tank
BUSHING, Plastic Tank
GAUGE, Fuel
TANK, Fuel
SHIELD, Heat
INSULATION, #2- I/4" Thick
CLIP, Insulation
WIRE, Ground
WASHER, Shakeproof # I 0
WASHER, M6 Shakeproof
DECAL, Control Panel
DECAL, Danger
DECAL, Heat Shield
DECAL, Operating Instructions
DECAL, Fuel Shut Off
DECAL, Generac 1-800
DECAL, Caution Hot Muffler
ASSY.,Control Panel
HHCS, 12 - 14 x 7/8 Self Drill
SLEEVING, Flexo, HW I/2" x
.83 ft.
120 Volt AC 30 Amp Plug
120/240 Volt AC 20 Amp Plug
Battery Charge Cable
Spark Plug
Air Filter
Spark Plug Wrench
Owner's Manual
Video
Oil, 28 oz.
Engine Owner's Manual
Accessories Not Included:
84883
Cord Wrap
84895
Storage Cover
Generac Portable Products 4,000XL Generator
I
//_
I
EXPLODED
VIEW
AND
PARTS LIST - CONTROL
PANEL
14
8
\\\
8
/
I
F
18
24
'\
7 11
17
15
1
'\
\
\
17
17
26
10
\
3
13
_9
Item
I
2
3
4
5
Part #
83976
83975
66818
66821
68867C
6
68868C
7
8
9
10
I1
12
75207A
75207G
82538
84134
83514
83970
Qty.
Item
13
14
15
16
17
18
19
21
22
23
24
25
26
Description
PANEL, Control
BOX, Control
OUTLET 120 Volts AC
OUTLET 12 Volts DC
OUTLET 120/240 Volts, 20 Amp
Locking
OUTLET, 120 Volts, 30 Amp
Locking
CIRCUIT BREAKER,30 Amp
CIRCUIT BREAKER, 18 Amp
SWITCH, On/Off Rocker
GROMMET, Rubber
CIRCUIT BREAKER, 10 Amp
CONTROL BOARD, System
/
18
Part #
84028
67022
85584
84543A
84543C
84198
84197
75476
22264
51715
84543B
84335
82542
Qty.
I
I
I
2
9
3
I
2
4
4
10
I
I
Description
TRANSFORMER, Idle Control
GROMMET, Rubber
BAR, Bus
SCREW, 3.0 x 12mm
SCREW, 3.5 x 18mm
SHIELD, Circuit Breaker
BAR, Circuit Breaker Retaining
SCREW, 4.15 x 16mm
WASHER, M4 Lock
NUT, M3 Hex
SCREW, 3.5 x 12mm
WIRE HARNESS
BAR, DC Outlet Retaining
Generac Portable Products 4,000XL Generator
NOTES
/
19
LIMITED
FOR
"GN"
ENGINE
WARRANTY
DRIVEN
PORTABLE
GENERATORS
GENERAC PORTABLEPRODUCTS (hereafter referred to as the COMPANY) warrants to the original purchaser that the
alternator and control panel for its portable generator wilt be free from defects in materials or workmanship for the items
and period set forth below from the date of original purchase. This warranty is not transferable and applies only to portable
generators driven by a GN-Series engine.
Consumer*
Commercial*
Alternator
Engine
2 years (2rid year parts only)
I year
Warranted solely by the engine manufacturer
With the exception of European Community Countries, all units bound for export shall be warranted for One (I)
Year in Consumer applications, end 90 days in Commercial applications as defined below.
*NOTE: For the purpose of this warranty "consumer use" means personal residential household use by
original purchaser. This warranty does not apply to units used for Prime Power in place of utility.
"Commercial
Use" means all other uses, including rental, construction, commercial and income producing
purposes. Once a generator has experienced commercial use, it shall thereafter be considered a
commercial use generator for the purposes of this warranty.
During said warranty period, the COMPANY wilt, at isoption, repair or replace any part which, upon examination by the
COMPANY, isfound to be defective under normal use and service**. Starting batteries are not warranted by the
COMPANY. All transportation costs under warranty, includingreturn to the factory if necessary,are to be borne by the
purchaser and prepaid by the purchaser. This warranty does not cover normal maintenance and service and does not apply
to a generator set, alternator, or parts which have been subjected to improper or unauthorized installation or alteration,
misuse, negligence, accident, overloading, overspeeding, improper maintenance, repair or storage so as, in the COMPANY's
judgement, to adversely affect its performance and reliability.
**NORMAL WEAR: As with all mechanical devices, the generator need periodic parts service and
replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of
a part or generator.
THERE IS NO OTHER EXPRESSWARRANTY. THE COMPANY HEREBY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND
FITNESSFOR A PARTICULAR PURPOSETO THE EXTENT PERMITTED BY LAW. THE DURATION OF
ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO THE TIME PERIOD AS
SPECIFIEDIN THE EXPRESSWARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL
DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS
ANY RESPONSIBILITYFOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, SUCH AS THE LOSSOF
TIME OR THE USE OF THE POWER EQUIPMENT, OR ANY COMMERCIAL LOSS DUE TO THE FAILURE
OF THE EQUIPMENT: AND ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS
WRITTEN WARRANTY.
Some states do not allow limitations on how long an impliedwarranty lasts, or the exclusion or limitation of incidentalor
consequential damages,so the above limitationsor exclusions may not apply to you. This warranty gives you specific legal
rights and you may also haveother rights, which vary from state to state.
For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Warranty service can
be performed only by a COMPANY authorized service facility. This warranty will not apply to service at any other facility.
At the time of requesting warranty service, evidence of original purchase date must be presented.
GENERAC
PORTABLE
Jefferson,
Wisconsin
PRODUCTS
53549
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