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GEN RAC°I

Portable Products

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. It is usedto alert you to potential personal injury hazards.

Obey all safety messagesthat follow this symbol to avoid possible injuryor death.

GeneracPortableProducts4,000XLGenerator

EQUIPMENT

DESCRIPTION

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

120and/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 120Volts or 16.7 Amps at 240 Volts.

_hL CAUTION! Do Not exceed the generator's

wattage/amperage capacity.Add up the 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 nameplategives only volts

and amps,multiply volts times amps to obtain watts

(volts X amps= watts).

The 4,000 watt generator has the following features:

•120/240 Volt, 20 Amp locking receptacle and a 120Volt,

30 Amp locking receptacle.

• 120Volt, 15Amp receptacles.

• 12Volt DC, l0 Amp receptacle.

• Low Oil Shutdown: Automatically shuts down the engine

if oil drops below safeoperation level.

• 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 WARNING! Do Not tamper with engine

governed speed.High operating speedsare

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 speedsimposesa heavyload.When adequate

engine power is not availableengine life may be

shortened.

SAFETY RULES

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.

The manufacturer could not possibly anticipate every

circumstance that might involvea hazard. For that reason

warnings in the manual and warnings on tagsor 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 unsafeor pose a threat to you and

others.

Read this manual carefully and become familiar

with your generator set. Know its applications, its

limitations and any hazards involved.

_hL DANGER! You must isolatethe generator from

the electric utility by opening the electrical system's

main circuit breaker or main switch if this unit is

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.

_ANGER! Generator exhaust gases contain

DEADLY carbon monoxide gas. Carbon

monoxide, if breathed in sufficient

concentrations, can cause unconsciousness or

death. Operate this equipment outdoors where

adequate ventilation is available.

The Emission Control Systemfor 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

causeserious injury or death by electrocution. Never

touch bare wires or receptacles. Never permit a child

or any unqualified person to operate the generator.

•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.

• Use a ground fault circuit interrupter (GFCI) in any damp

or highly conductive area (such as metal decking or steel

work).

•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 ahot 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 clearanceon all sides of generator,

even while operating unitoutdoors, or you could damage

the unit See"Cold Weather Operation" on page 10.

•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.

•Do Not insertany object through cooling slots of the

engine.You could damagethe unit or injureyourself.

•Never operate the generator:

in rain; in any enclosedcompartment;when connected

electricaldevices 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.

GROUNDING THE

G EN ERATO R

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).

Generally, connecting a No. 12AWG (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.

Properly grounding the generator helps prevent electrical

shock if a ground fault condition exists inthe generator or

in connected electrical devices. Proper grounding also helps

dissipate static electricity, which often builds up in

ungrounded devices.

/3

GeneracPortableProducts4,000XLGenerator

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 and

adjustments. Save this manual for future reference.

Circuit Breakers (AC)

FuelTank

120 Volt AC, 30 Am

Receptacle

Fuel Shut Off Valve

Run/Stop Switch

120/240 Volt AC,

20 Amp Receptacle

12Volt DC, 10Amp

Receptacle

120Volt AC, 15Amp, Idle Control Switch

Duplex Receptacle Grounding Wing Nut

12 Volt DC, I 0 Amp Receptacle -- Use this receptacle

with battery chargecablesto chargea 12Volt battery.

120 Volt AC, I 5 Amp Duplex Receptacle -- May be

used to supply electrical power for the operation of

120Volt AC, 15Amp, single phase,60 Hz electrical

lighting, appliance,tool and motor loads.

120 Volt AC, 30 Amp Receptacle -- May be used to

supply electrical power for the operation of 120Volt AC,

30 Amp, single phase,60 Hz electrical lighting,appliance,

tool and motor loads.

120/240 Volt AC, 20 Amp Receptacle -- May be used

to supply electrical power for the operation of 120and/or

240 Volt AC, 20 Amp, single phase,60 Hz electrical lighting,

appliance,tool and motor loads.

Circuit Breakers (AC) -- Each receptacle is provided

with a circuit breaker to protect the generator against

electrical overload. Breakers are "push to reset" type.

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.

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) speedswhen a

load is not present. This feature greatly improvesfuel

economy, extends the life of the engine, and reduces engine

noise.

RunlStop Switch -- Must be in "Run" position to start

engine. Set to "Stop" to stop a running engine.

/4

GeneracPortableProducts4,000XLGenerator

CONTENTS

Check all contents. If any parts are missing or damaged,call

the generator helpline at 1-800-270-1408. Review "Cold

Weather Operation" on page8. Shippedwith your

generator is:

Main unit

20 Amp and 30 Amp locking plugs

Spare spark plug and air filter

Spark plug wrench

Video tape

Oil

Engineand unit owner's manual

Battery charge cables

BEFORE STARTING ENGINE

Add Oil

_hL WARNING! Any attempt to crank or start the

engine before it has been properly filledwith the

recommended oil mayresult in an enginefailure.

To fill your engine with oil:

•PJace generator on aJevel 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!!

• Install oil fill cap.

NOTE: The generator's revolving field rides on a pre-

lubricated and sealed ball bearing that requires no

additional lubrication for the life of the bearing.

Add Gasoline

_hL ANGER! Explosion Hazard! Never fill fuel tank

indoors. Never fill fuel tank when engine is running

or hot. Do Not light a cigarette or smoke when

filling the fuel tank.

_lk WARNING! Do Not overfill the fuel tank.

Always allow room for fuel expansion.

• Use regular UNLEADED gasoline with the generator

engine. Do Not use premium gasoline. Do Not mix oil

with gasoline.

• Clean area around fuel fill cap, remove cap.

• 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).

1/2" Air Space Tank

•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.

To avoid engine problems, the fuel system should be

emptied before storage of 30 daysor longer.See "Storage"

on page I I. Never use engine or carburetor cleaner

products inthe fuel tank as permanent damagemay occur.

/5

GeneracPortableProducts4,000XLGenerator

OPERATING THE

GENERATOR

_k AUTION! Never start or stop the engine withelectrical loads connected to the unit and with the

connected devices turned ON.

Starting the Engine

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).

3. Set the Run/Stop switch to "Run" position (Figure 4).

4. Placethe choke lever in the "Full" choke position

(Figure 5).

Position

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.

• If engine fails to start, proceed to step 6.

6. Move the chokelever to "Half' chokeposition, and

pull recoil handletwice.

• If engine fails to start, repeat steps 4 thru 6.

7. Move choke leverto "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 levelin crankcase.This unit is equipped with a

Low Oil Shutdown System. Seeengine manual.

Connecting Electrical Loads

•Let engine stabilize and warm up for a few minutes after

starting.

• Plug in and turn on the desired 120and/or 240Volt AC,

single phase, 60 Hertz electrical loads.

•Do Not connect 240 Volt loadsto 120Volt 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 the Engine

• Unplug all electrical loads from generator panel

receptacles. Never start or stop engine with electrical

devices pluggedin and turned on.

• 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.

• Move Run/Stop switch to "Stop".

• Close the fuel shut-off valve.

/6

GeneracPortableProducts4,000XLGenerator

Operating Automatic Idle Control

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 enginewill run at the normal high engine speed.

Always have the switch oft when starting and

stopping the engine.

Charging a Battery

AANGER! Storage batteries give off explosive

hydrogen gaswhile recharging.This explosive

mixture will remain around the battery for a long

time after it has been charged.The slightest spark

can ignite the hydrogen and causean explosion. Such

anexplosion can shatter the battery and cause

blindnessor other serious injury.

ADANGER! Oo Not permit smoking, open flame,

sparks or any other source of 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 causesevere burns. If spill occurs,

flush area with clear water immediately.

Your generator hasthe capability of recharging a discharged

12Volt 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.

To recharge 12 Volt batteries, proceed as follows:

• Check fluid level in all battery cells. If necessary,add

ONLY distilled water to cover separators in battery

cells. Do Not use tap water.

• 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 identifiedby the words "12-VOLT D.C."

• Connect battery charge cable clamp with red handle to

the positive (+) battery terminal (Figure 6).

12 VOLT D.C.

RECEPTACLE

+

POS NEG

12 VOLT 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 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.

In an emergency,use the original shipping box as a

temporary shelter:

•Cut off all flaps.

• Cut out one of the long sides of the box to expose

exhaust side of unit Ensure a minimum of two feet

clearance between open side of box and nearest object.

• Cut appropriate slots to accessreceptacles of unit

• Start unit, then place box over it.

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:

• Make sure entire muffler-side of generator isexposed

(Figure 7).

Wind

•Ensure a minimum of two feet clearance between open

side of box and nearest object.

• Face exposed end away from wind and elements.

• Enclosure should hold enough heat created by the

generator to prevent problems.

_AUTION! NEVER run unit indoors; Do Not

enclose generator any more than shown. Remove

shelter when temperatures are above 40°F [4°C].

RECEPTACLES

120 Volt AC, 15 Amp Receptacles

Eachof these outlets is protected againstoverload by

15Amp push-to-reset type circuit breakers (Figure 8).

II

I

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.

I8

GeneracPortableProducts4,000XLGenerator

120/240 Volt AC, 20 Amp Locking

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 same4-wire cord if you plan to

run a 120Volt load. I[e_ IP,Te]kV_mF.'T__ _m

4-Wire Cord Set

Y(Hot) x(Hot)

Ground

NEMA L14-20 (Green)

This receptacle powers 120/240 Volt AC, 60 Hz, single

phase loads requiring up to 2,400 watts of power at

20 Amps for 120Volts; 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.

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5-30 plug with this receptacle. Connect a

3*wire cord set rated for 125Volts AC at 30 Amps to the

plug (Figure 10).

3-Wire Cord Set

r-- Neutml

120V

Hot

NEMA L5-30

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

push-to-reset circuit breaker.

12 Volt DC, 10 Amp Receptacle

This connector (identified by the legend"12-VOLT D.C:')

supplies 12Volts DC at 10Amps through battery charging

cablesfor recharging 12Volt batteries (Figure I I). See

"Charging a Battery" on page 7.

iBm

9

Generac Portable Products 4,000XL Generator

DON'T OVERLOAD THE

GENERATOR

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.

•If the appliance, tool or motor does not give wattage,

multiply 120Volts 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.

• The wattage reference guide (Figure I I) is provided to

help you to determine how many items the generator

can operate at one time.

Recreational/Home Uses

Tool/Appliance .................................................... Watts

AM/FM clock radio .....................................................................50

Light bulb....................................................................................100

Fan................................................................................................200

20" color TV ..............................................................................400

*Deep freezer ............................................................................500

Personal computer and 15" monitor ...................................800

*1/3 hp furnace fan blower .....................................................800

Microwave oven ........................................................................800

*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

Professional/C ontractor Uses

Tool/Appliance .................................................... Watts

"1/3 hp airlesssprayer.............................................................600

3/8" hammerdrill .....................................................................600

Variable speedSawzalt®..........................................................960

V2"power drill .........................................................................1000

Quartz-halogen work light...................................................1000

Belt sander...............................................................................1200

7¼" circularsaw ...................................................................1500

7¼" worm drive saw............................................................1600

*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

* allow 3 times listed watts for starting this device

I

I0

Generac Portable Products 4,000XL Generator

SPECIFICATIONS

Maximum SurgeWatts ............... 5,000 Watts

Continuous Wattage Capacity ......... 4,000 Watts

Power Factor ............................. 1.0

Rated Maximum Continuous Load Current

At 120Volts ...................... 33.3 Amps

At 240 Volts ...................... 16.7Amps

Phase ................................ I-phase

Rated Frequency ...................... 60 Hertz

Fuel Tank Capacity ................. 4 U.S.gallons

GENERAL MAINTENANCE

RECOMMENDATIONS

The Owner/Operator is responsible for making sure that

all periodic maintenance tasks are completed on atimely

basis;that all discrepancies are corrected; and that the unit

is kept clean and properly stored. Never operate a

damaged or defective generator.

Engine Maintenance

See engine manual for instructions.

Generator Maintenance

Generator maintenance consists of keeping the unit clean

and dry. Operate and store the unit in a clean dry

environment where it wit{ not be exposed to excessive

dust, dirt, moisture or any corrosive vapors. Cooling air

slots in the generator must not become clogged with snow,

leaves or any other foreign material.

NOTE: Do Not use a garden hose to clean generator.

Water can enter engine fuel system and cause problems. In

addition, if water enters generator through cooling air

slots, some of the water will be retained in voids and

cracks of the rotor and stator winding insulation. Water

and dirt buildup on the generator internal windings wit{

eventually decrease the insulation resistance of these

windings.

To Clean the Generator

•Use a damp cloth to wipe exterior surfaces clean.

• Soft, bristle brush may be used to loosen caked on dirt

or oil.

• A vacuum cleaner may be used to pick up loose dirt and

debris.

• Low pressure air (not to exceed 25 psi) may be used to

blow awaydirt. Inspect cooling air slots and opening on

generator. These openings must be kept clean and

unobstructed.

STORAGE INSTRUCTIONS

The generator should be started at least once every seven

daysand 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.

Generator Storage

•Clean the generator as outlined in "To Clean the

Generator"

• Check that cooling air slots and openings on generator

are open and unobstructed.

_DANGER! Storage covers can be flammable. Do

Not place a storage cover over a hot generator. Let

the unit cool for asufficient time before placing the

cover on the unit.

Engine Storage

Seeengine owner's manual for instructions.

Other Storage Tips

•Do Not store gasoline from one season to another.

• Replace your gasoline can if it starts to rust. Rust and/or

dirt in agasoline can cause problems when you use

contaminated fuel with this unit.

• Store in clean and dry area.

I

II

Generac Portable Products 4,000XL Generator

TROUBLESHOOTING

Problem

Engine is running, but

no AC output is

available.

Engine runs good but

bogs clown when loads

are connected.

Cause

I. Circuit breaker is open.

2. Poor connection or defective cord set.

3. Connected device is bad.

4. Fault in generator.

I. Short circuit in a connected load.

2. Generator is overloaded.

3. Enginespeed istoo slow.

4. Shortedgenerator circuit.

I. Run/Stop switch set to "Stop".

2. Dirty air cleaner.

3. Out of gasoline.

4. Stalegasoline.

5. Spark plug wire not connected to spark

Solution

I. Reset circuit breaker.

2. Check and repair.

3. Connect another device that is in good

condition.

4. Contact Generac service facility.

I. Disconnect shorted electricalload.

2. See "Don't Overload the Generator"

on page 10.

3. Contact Generac service facility.

4. Contact Generac service facility.

I. Set switch to "Run".

2. Clean or replace air cleaner.

3. Fill fuel tank.

4. Drain gas tank and fill with fresh fuel.

5. Connect wire to spark plug.

Engine will not start; or

starts and runs rough.

plug.

6. Badspark plug.

7. Waterin gasoline.

8. Overchoking.

9. Low oil level.

10.

II.

12.

Excessively rich fuel mixture.

Intake valve stuck open or closed.

Engine has lost compression.

6. Replacespark plug.

7. Drain gastank; fill with fresh fuel.

8. Put choke leverto "No Choke"

position.

9. Fill crankcaseto proper level.

10. Contact Generac service facility.

I I. Contact Generac service facility.

12. Contact Generac service facility.

Engine shuts down

during operation.

Engine lacks power.

Engine "hunts" or

falters.

I. Out of gasoline.

2. Low oil level

3. Fault in engine.

I. Load is too high.

2. Dirty air filter.

3. Engine needs to be serviced.

I. Choke is opened too soon.

2. Carburetor is running too rich or too

lean.

I. Fill fuel tank.

2. Fill crankcase to proper level.

3. Contact Generac service facility.

I. See "Don't Overload the Generator"

on page 10.

2. Replace air filter.

3. Contact Generac service facility.

I. Move choke to halfway position till

engine runs smoothly.

2. Contact Generac service facility.

/

12

Generac Portable Products 4,000XL Generator

NOTES

/13

GeneracPortableProducts4,000XLGenerator

ID3__TI_

ELECTRICAL SCHEMATIC

3

LOP

SWITCH

POWERBOARD !

REGULATOR

DPE Uu

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F H

E

D•

D

G

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CONTROL

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ENG,

IGNITION

BATTERY CHARGE

BRN

66

RED

AUTO 13

BLE

55

BLK

55

BRN

77

I

14

Generac Portable Products 4,000XL Generator ID_I_I_

WIRING DIAGRAM

U(

RED

13

GRN

GRY

GRY

GRN

BATTERY

CHARGE

RECTIFIER

GATE

EIGNAL

pq

LOW OIL

PRESSURE

3 PIN SWITCH

LOW OIL

PRESSURE

LED

ENGINE CATHODE

RUN

SWITCH

NUT ON ENGINE BLOCK

I

15

I

?//_ J

Generac Portable Products 4,000XL Generator

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Generac Portabte Products 4,000XL Generator l/!

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PARTS LIST

Item Part # Qty

1 A93199

2 A84021

3 NSP

4 66365

5 84141J

6 83540J

7 65791

8 96796

Io 86307 4

II 47480 I

12 84508 2

13 52858 8

14 83208 I

15 B4986 I

16 66476 2

17 89476 I

18 70644 I

19 84346 3

20 40976 2

21 83083 I

22 83071 I

23 81917 I

25 66825-B I

26 85652 2

27 67989 2

30 74908 4

32 86308 4

33 65795 I

34 66849A I

35 67022 I

36 84132 I

37 66386 I

38 66849 2

39 B4871 I

41 86494 I

42 86292 I

43 77395 4

44 83465 4

- MAIN UNIT

Description

CRADLE, XL

SUPPORT,Engine

ENGINE

HOUSING, EngineAdapter

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, BearingCarrier

SCREW,M6 -I .0 x 16Wing

HHCS, l0 - 16 x 3/4" Setf

Driller

NUT, M6 FlangeLock

GROMMET, Tank

Item

46

47

48

49

50

51

52

53

54

55

56

60

61

62

63

64

65

66

67

68

69

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

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2

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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.

Parts Not Illustrated:

37806

43483

65787

72347

78601

84882

B4400

B4572

BB3061

NSP

120Volt AC 30 Amp Plug

120/240 Volt AC 20 Amp Plug

Battery Charge Cable

Spark Plug

Air Filter

Spark PlugWrench

Owner's Manual

Video

Oil, 28 oz.

EngineOwner's Manual

Optional Accessories Not Included:

84883 Cord Wrap

84895 Storage Cover

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Generac Portable Products 4,000XL Generator

EXPLODED VIEW AND PARTS LIST - CONTROL PANEL

14

88/

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18

7 17

11

15

24

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17 17

26

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13

_9

10

Item

I

2

3

4

5

6

7

8

9

10

I1

12

Part #

83976

83975

66818

66821

68867C

68868C

75207A

75207G

82538

84134

83514

83970

Qty. Description

PANEL, Control

BOX, Control

OUTLET 120Volts AC

OUTLET 12Volts DC

OUTLET 120/240 Volts, 20 Amp

Locking

OUTLET, 120Volts, 30 Amp

Locking

CIRCUIT BREAKER,30 Amp

CIRCUIT BREAKER, 18Amp

SWITCH, On/Off Rocker

GROMMET, Rubber

CIRCUIT BREAKER, 10Amp

CONTROL BOARD, System

Item Part #

13 84028

14 67022

15 85584

16 84543A

17 84543C

18 84198

19 84197

21 75476

22 22264

23 51715

24 84543B

25 84335

26 82542

Qty. Description

ITRANSFORMER, Idle Control

IGROMMET, Rubber

I BAR, Bus

2 SCREW,3.0 x 12mm

9 SCREW,3.5 x 18mm

3 SHIELD,Circuit Breaker

IBAR, Circuit Breaker Retaining

2 SCREW,4.15 x 16mm

4 WASHER, M4 Lock

4 NUT, M3 Hex

10 SCREW,3.5 x 12mm

I WIRE HARNESS

I BAR, DC Outlet Retaining

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Generac Portable Products 4,000XL Generator

NOTES

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LIMITED WARRANTY

FOR "GN" ENGINE 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 2 years (2rid year parts only) I year

Engine 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 anddoes 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 HEREBYDISCLAIMS 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 IMPLIEDWARRANTIES WHICH CANNOT BEDISCLAIMED 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 givesyou specific legal

rights andyou 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 purchasedate must be presented.

GENERAC PORTABLE PRODUCTS

Jefferson, Wisconsin 53549