Generac Portable Products 4000EXL User manual

Owner’s Manual
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Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
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Model No. 1645-0 (4,000 Watt AC Generator) Manual No. 189189GS Revision 1 (01/03/2002)
Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page
• Generator
• Wheel kit
• Battery
• Battery charge cables
• Battery float charger
• Locking 20 Amp plug
• Locking 30 Amp plug
• Engine oil
• Two packets of fuel stabilizer
• Owner's manual
• Engine manual
*If any parts are missing or damaged, call 1-800-270-1408.
Parts Included*Table of Contents

2
4000EXL Extended Life Generator
EQUIPMENT
DESCRIPTION
Read this manual carefully and become familiar
with your generator. Know its applications, its
limitations and any hazards involved.
This generator is an engine–driven, revolving field,
alternating current (AC) generator. It was designed to
supply electrical power for operating compatible electrical
lighting, appliances, tools and motor loads.The generator’s
revolving field is driven at about 3,600 rpm by a single-
cylinder engine.
CAUTION! Do Not exceed the generator’s
wattage/amperage capacity. See “Don’t Overload the
Generator” on page 10.
Every effort has been made to ensure that information in
this manual is accurate and current. However, Generac
reserves the right to change, alter or otherwise improve
the product and this document at any time without prior
notice.
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.
SAFETY RULES
The safety alert symbol ( ) is used with a signal word
(DANGER, CAUTION,WARNING), a pictorial and/or a
safety message to alert you to hazards. DANGER indicates
a hazard which, if not avoided, will result in death or serious
injury. WARNING indicates a hazard which, if not avoided,
could result in death or serious injury. CAUTION
indicates a hazard which, if not avoided, might result in
minor or moderate injury. CAUTION, when used
without the alert symbol, indicates a situation that could
result in equipment damage. Follow safety messages to
avoid or reduce the risk of injury or death.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
• Operate generator ONLY outdoors.
• Keep at least 2 feet of clearance on all sides of generator for
adequate ventilation.
• Do not operate generator inside any building or enclosure,
including the generator compartment of a recreational vehicle
(RV).
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide will cause nausea,
fainting or death.
DANGER
WHEN ADDING FUEL
• Turn generator OFF and let it cool at least 2 minutes before
removing gas cap. Loosen cap slowly to relieve pressure in tank.
• Fill fuel tank outdoors.
• Do not overfill tank.Allow space for fuel expansion.
• Keep gasoline away from sparks, open flames, pilot lights, heat,
and other ignition sources.
• Do not light a cigarette or smoke.
WHEN OPERATING EQUIPMENT
• Do not tip engine or equipment at angle which causes
gasoline to spill.
WHEN TRANSPORTING OR REPAIRING EQUIPMENT
• Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFF.
• Disconnect spark plug wire.
WHEN STORING GASOLINE OR EQUIPMENT WITH
FUEL IN TANK
• Store away from furnaces, stoves, water heaters, clothes
dryers or other appliances that have pilot light or other
ignition source because they can ignite gasoline vapors.
Gasoline and its vapors are extremely flammable
and explosive.
Fire or explosion can cause severe burns or
death.
WARNING

4000EXL Extended Life Generator
3
• Do not allow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a battery.
• Wear protective goggles, rubber apron, and rubber gloves.
Storage batteries give off explosive hydrogen gas
during recharging.
Hydrogen gas stays around battery for a long
time after battery has been charged.
Slightest spark will ignite hydrogen and cause
explosion.
You can be blinded or severely injured.
Battery electrolyte fluid contains acid and is
extremely caustic.
Contact with battery fluid will cause severe
chemical burns.
DANGER
• When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
• National Electric Code requires generator to be properly
grounded to an approved earth ground. Call an electrician for
local grounding requirements.
• Use a ground circuit fault interrupter (GFCI) in any damp or
highly conductive area, such as metal decking or steel work.
• Do not touch bare wires or receptacles.
• Do not use generator with electrical cords which are worn,
frayed, bare or otherwise damaged.
• Do not operate generator in the rain.
• Do not handle generator or electrical cords while standing in
water, while barefoot, or while hands or feet are wet.
• Do not allow unqualified persons or children to operate or
service generator.
Generator produces powerful voltage.
Failure to properly ground generator can result
in electrocution.
Failure to isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
WARNING
• Do not touch hot surfaces.
• Allow equipment to cool before touching.
Running engines produce heat.Temperature of
muffler and nearby areas can reach or exceed
150°F (65°C).
Severe burns can occur on contact.
WARNING
• Do not tamper with governed speed. Generator supplies
correct rated frequency and voltage when running at governed
speed.
• Do not modify generator in any way.
Excessively high operating speeds increase risk of injury
and damage to generator.
Excessively low speeds impose a heavy load.
CAUTION
• See “Don’t Overload Your Generator” on page 10.
• Start generator and let engine stabilize before connecting
electrical loads.
• Connect electrical loads in OFF position, then turn ON for
operation.
• Turn electrical loads OFF and disconnect from generator
before stopping generator.
Exceeding generators wattage/amperage capacity can
damage generator and/or electrical devices connected
to it.
CAUTION
• Use generator only for intended uses.
• If you have questions about intended use, ask dealer or
contact Snapper.
• Operate generator only on level surfaces.
• Do not expose generator to excessive moisture, dust, dirt, or
corrosive vapors.
• Do not insert any objects through cooling slots.
• If connected devices overheat, turn them off and disconnect
them from generator.
• Shut off generator if:
-electrical output is lost;
-equipment sparks, smokes, or emits flames;
-unit vibrates excessively.
Improper treatment of generator can damage it and
shorten its life.
CAUTION

4
4000EXL Extended Life Generator
CHECK BATTERY / ATTACH
NEGATIVE BATTERY
WIRE
The sealed battery on the generator is fully charged and
pre–installed except for the negative (black) battery cable.
To install:
• Cut off tie wrap securing loose end of negative (black)
cable.
• Connect the negative (black) battery cable to the
negative (–) terminal on the battery (Figure 1).
• Verify that the connections to the battery and generator
are correct and secure.
BEFORE STARTING THE
ENGINE
Add Oil
CAUTION! Any attempt to crank or start the engine
before it has been properly filled with the recommended
oil may result in an engine failure.
To fill your engine with oil:
• Place generator on a level surface.
• Follow the oil grade recommendations and oil fill
instructions given in the engine owner’s manual.
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.
Add Gasoline
WARNING! Never fill fuel tank indoors. Never
fill fuel tank when engine is running or hot.Allow
unit to cool for two minutes before refueling. Do
Not light a cigarette or smoke when filling the fuel
tank.
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 fill above the baffle.This allows adequate
space for fuel expansion (Figure 2).
• Install fuel 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 indicates that alcohol–blended fuels (called
gasohol, ethanol or methanol) can attract moisture, which
leads to separation and formation of acids during storage.
Acidic fuel can damage the fuel system of an engine while
in storage. Be sure to review the precautions given in
“Storage” on page 12.
Never use engine or carburetor cleaner products in the
fuel tank or permanent damage may occur.
Figure 1 — Negative Battery Connection
Positive
battery
cable
Negative
battery
cable
FUEL
TANK
Figure 2 — Typical Fuel Expansion Space
Baffle

4000EXL Extended Life Generator
5
KNOWYOUR 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.
120 Volt AC, 15 Amp
Duplex Receptacle
Fuel Tank
Idle Control Switch
Choke Lever
Recoil Starter
12 Volt DC, 10 Amp
Receptacle
Run/Stop Switch
120 Volt AC, 30 Amp
Receptacle
Circuit Breakers (AC)
120/240 Volt AC,
20 Amp Receptacle
Spark Arrester Muffler
Air Cleaner
Grounding Wing Nut
Start Button
12 Volt DC,10 Amp Receptacle — Recharge a
discharged 12 Volt automotive type battery through this
receptacle.
120 Volt AC, 15 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.
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.
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.
Air Cleaner — Uses a dry type filter element and foam
pre–cleaner to limit the amount of dirt and dust sucked
into the engine.
Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — Each receptacle is provided
with a "push to reset" circuit breaker to protect the
generator against electrical overload.
Fuel Tank — Capacity of 4.5 U.S. gallons.
Grounding Wing Nut — Used for proper grounding of
unit.
Idle Control Switch — With this switch set to ON,
printed circuit board in control panel automatically reduces
engine speed when no load is connected and increases
engine to proper speed when load is applied. However, be
sure switch is OFF when starting engine.
Oil Fill Cap — Add oil to engine here.
Recoil starter — Used to start the engine manually.
Run/Stop Switch — Set this switch to "Run" before
using recoil starter. Set switch to "Stop" to switch OFF
engine.
Spark Arrester Muffler — Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.
Start Button — When pressed, cranks engine to start.
Oil Fill Cap

6
4000EXL Extended Life Generator
GROUNDING THE
GENERATOR
The National Electrical Code 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 3).
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, local codes
may vary widely. Consult with a local electrician for
grounding requirements in your area.
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.
OPERATING THE
GENERATOR
CAUTION! Never start or stop unit with
electrical loads connected AND with the connected
devices turned ON.
IMPORTANT: Always unplug the battery float charger
before starting the generator.
Starting the Engine
Disconnect all electrical loads from the generator. Follow
these start instruction steps in numerical order:
1. Turn the fuel valve to the “On” position (Figure 4).
2. Make sure the Idle Control switch is in “Off” position
(Figure 5).
3. Set the Run/Stop switch to “Run” position (Figure 6).
4. Place the choke lever in the “Full” choke position
(Figure 7).
Figure 4 — Fuel Shut-offValve
Figure 5 — Idle Control Switch
Figure 6 — Run/Stop Switch
Figure 7 — Choke Lever
“Full” choke
Position
Figure 3 — Grounding Wing Nut
Grounding
Wing Nut

4000EXL Extended Life Generator
7
5A. For electric starting, press start switch on
generator cradle.To prolong the life of the starter
components, press the starter button for no more
than 15 seconds, and pause for 30 seconds.
5B. For manual starting, grasp the recoil handle and pull
slowly until slight resistance is felt.Then pull rapidly
one time only to start engine.
• If engine starts, proceed to step 7.
• If engine fails to start, proceed to step 6.
6. Move the choke lever to “Half” choke position, and
press start button or pull recoil handle twice.
• If engine fails to start, repeat steps 4 thru 6.
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.
Refer to the engine owner’s manual for complete
starting instructions.
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 240 Volt AC,
single phase, 60 Hz electrical loads.
•Do Not connect 240 Volt loads to the 120 Volt
receptacles.
•Do Not connect 3–phase loads to the generator.
•Do Not connect 50 Hz loads to the generator.
•DO NOT OVERLOAD THE GENERATOR. See
“Don’t Overload the Generator” on page 10.
Stopping the Engine
• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with electrical
devices plugged in and turned on.
• Put the idle control switch in the “Off” 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.
Operating Automatic Idle Control
This switch is designed to greatly improve fuel 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 an electrical 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 off when
starting and stopping the engine.
Charging a Battery
WARNING! Storage batteries give off explosive
hydrogen gas while recharging.An 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, resulting in
blindness or other serious injury.
WARNING! Do 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 cause severe burns. If
spill occurs flush area with clear water immediately.
Your generator has the capability of recharging a
discharged 12 Volt automotive or utility style storage
battery. Do Not use the unit to charge any 6Volt
batteries. Do Not use the unit to crank an engine having a
discharged battery.
To recharge 12Volt 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 installed and are tight.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to panel
receptacle identified by the words “12-VOLTS D.C.”.
• Connect battery charge cable clamp with red handle to
the positive (+) battery terminal (Figure 8).
• Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 8).

8
4000EXL Extended Life Generator
• 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 instructions carefully. 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.
COLD WEATHER
OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icing of the carburetor and/or the crankcase
breather system.
Build a structure that will enclose three sides and the top
of the generator:
• Make sure entire muffler-side of generator is exposed.
Note that your generator may appear different from that
shown in Figure 9.
• 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.
CAUTION!Neverrun unit indoors. Do Not
enclose generator any more than shown. Remove
generator from shelter when temperature is above
40°F [4°C].
How to Use the Battery Charger
Use battery float charger jack to keep the starting battery
charged and ready for use. Battery charging should be done
in a dry location, such as inside a garage.
• Plug the charger into the unit’s “Battery Float Charger”
jack, which is located on the starter switch (Figure 10).
Plug battery charger into a 120Volt AC wall receptacle.
• Unplug the charger from the unit and the wall outlet
when generator is being started and while it is in
operation.
• Keep this charger plugged in when generator is not in
use to prolong battery life.The charger has a built in
float equalizer and will not overcharge the battery, even
when plugged in for an extended period of time.
IMPORTANT: See “Battery Maintenance” on page 11 for
additional information.
Figure 10 — Battery Charger Jack
Figure 9 — Permanent Cold Weather Shelter
Wind
Figure 8 — Battery Connections

4000EXL Extended Life Generator
9
RECEPTACLES
120 Volt AC, 15 Amp Receptacles
Each of these outlets is protected against overload by
15 Amp push-to-reset type circuit breakers (Figure 11).
Use each outlet to operate 120 Volt, 60 Hz, single phase
loads requiring 1,800 (1.8 kW) watts at 15 Amps of current.
120/240 Volt AC, 20 Amp Locking
Receptacle
Use a NEMA L14-20 plug with this receptacle. Connect a
4-wire cord set rated for 250 Volts at 20 Amps (or greater)
(Figure 12).You can use the same 4-wire cord if you plan to
run a 120 Volt load.
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
16.7 Amps for 240 Volts.The outlet is protected by a
20 Amp push-to-reset circuit breaker.
CAUTION! Although this outlet is rated for
240 Volt 20 Amp (up to 4,800 watts), the generator
is only rated for 4,000 watts. Powering loads that
exceed the wattage/amperage capacity of the
generator can damage it or cause serious injuries.
240 Volt loads powered through this outlet should
not exceed 16.7 Amps of current draw.
120 Volt AC, 30 Amp Locking
Receptacle
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 13).
Use this receptacle to operate 120Volt 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 12 Volts DC at 10 Amps through battery charging
cables for recharging 12 Volt batteries (Figure 14). See
“Charging a Battery” on page 8.
Figure 11 — 120Volt AC, 15 Amp Duplex Receptacle
Figure 12 — 120/240 Volt AC, 20 Amp Receptacle
4-Wire Cord Set
240V
120V 120V W (Neutral)
X (Hot)
Y (Hot)
NEMA L14-20 Ground (Green)
Figure 13 — 120 Volt AC, 30 Amp, Locking Receptacle
3-Wire Cord Set
Neutral
120V
Hot
Ground (Green)
NEMA L5-30
Figure 14 — 12Volt DC, 10 Amp Receptacle

10
4000EXL Extended Life Generator
DON'T OVERLOADYOUR
GENERATOR
Capacity
You must make sure your generator can supply enough
rated (running) and surge (starting) watts for the items you
will power at the same time. Follow these simple steps:
1. Select the items you will power at the same time.
2. Total the rated (running) watts of these items.This is
the amount of power your generator must produce to
keep your items running. See Figure 15.
3. Estimate how many surge (starting) watts you will
need. Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliances such as a circular saw or refrigerator.
Because not all motors start at the same time, total
surge watts can be estimated by adding only the
item(s) with the highest additional surge watts to the
total rated watts from step 2.
Example:
Total Rated (Running) Watts = 3075
Highest Additional Surge Watts = 1800
Total Generator Output Required = 4875
Power Management
To prolong the life of your generator and attached devices,
it is important to take care when adding electrical loads to
your generator.There should be nothing connected to the
generator outlets before starting it's engine.The correct
and safe way to manage generator power is to sequentially
add loads as follows:
1. With nothing connected to the generator, start the
engine as described in this manual.
2. Plug in and turn on the first load, preferably the largest
load you have.
3. Permit the generator output to stabilize (engine runs
smoothly and attached device operates properly.
4. Plug in and turn on the next load.
5. Again, permit the generator to stabilize.
6. Repeat steps 4 and 5 for each additional load.
Never add more loads than the generator capacity.Take
special care to consider surge loads in generator capacity,
as described above.
*Wattages listed are approximate only. Check tool or
appliance for actual wattage.
Tool or Appliance Rated (Running)
Watts Additional Surge (Starting) Watts
Window Air
Conditioner 1200 1800
Refrigerator 800 1600
Deep Freezer 500 500
Television 500 -
Light (75 Watts) 75 -
3075 Total
Running Watts 1800 Highest Surge Watts
Tool or Appliance
Rated*
(Running)
Watts
Additional
Surge
(Starting)
Watts
Essentials
Light Bulb -75 watt
75
-
Deep Freezer
500
500
Sump Pump
800
1200
Refrigerator/Freezer -18 Cu. Ft.
800
1600
Water Well Pump -1/3 HP
1000
2000
Heating/Cooling
Window AC -10,000 BTU
1200
1800
Window Fan
300
600
Furnace Fan Blower -1/2 HP
800
1300
Kitchen
Microwave Oven -1000 Watt
1000
-
Coffee Maker
1500
-
Electric Stove -Single Element
1500
-
Hot Plate
2500
-
Family Room
DVD/CD Player
100
-
VCR
100
-
Stereo Receiver
450
-
Color Television -27”
500
-
Personal Computer w/17” monitor
800
-
Other
Security System
180
-
AM/FM Clock Radio
300
-
Garage Door Opener -1/2 HP
480
520
Electric Water Heater -40 Gallon
4000
-
DIY/Job Site
Quartz Halogen Work Light
1000
-
Airless Sprayer -1/3 HP
600
1200
Reciprocating Saw
960
960
Electric Drill -1/2 HP
1000
1000
Circular Saw -7 1/4”
1500
1500
Miter Saw -10”
1800
1800
Table Planer -6”
1800
1800
Table Saw/Radial Arm Saw -10”
2000
2000
Air Compressor -1-1/2 HP
2500
2500
Figure 15 - Wattage Reference Chart

4000EXL Extended Life Generator
11
SPECIFICATIONS
Maximum Surge Watts . . . . . . . . . . . . . . . 6,600 Watts
Continuous Wattage Capacity . . . . . . . . . . 4,000 Watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Rated Maximum Continuous Load Current
At 120 Volts . . . . . . . . . . . . . . . . . . . . . . 33.3 Amps
At 240 Volts . . . . . . . . . . . . . . . . . . . . . . 16.7 Amps
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-phase
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . 60 Hertz
Fuel Tank Capacity . . . . . . . . . . . . . . . . . 4.5 U.S. gallons
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . 129 lbs.
GENERAL MAINTENANCE
RECOMMENDATIONS
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.
NOTE: The proper tire inflation operating range should be
15-40 PSI.
Engine Maintenance
See engine owner’s manual for instructions.
CAUTION! Avoid prolonged or repeated skin
contact with used motor oil. Used motor oil has
been shown to cause skin cancer in certain
laboratory animals.Thoroughly wash exposed areas
with soap and water.
KEEP OUT OF REACH OF CHILDREN. DON'T
POLLUTE. CONSERVE RESOURCES. RETURN
USED OIL TO COLLECTION CENTERS.
Generator Maintenance
Generator maintenance consists of keeping the unit clean
and dry. Operate and store the unit in a clean dry
environment where it will 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 will
eventually decrease the insulation resistance of these
windings.
Fuel Valve Maintenance
The fuel valve is equipped with a fuel sediment cup, screen,
retaining ring and o-ring that need to be cleaned every
6 months or 100 hours (whichever occurs first).
• Move the fuel valve to the “Off” position.
• Remove the sediment cup from the fuel valve. Remove
the o-ring, retaining ring and screen from the fuel valve
(Figure 15).
• Wash the sediment cup, o-ring, retaining ring, and screen
in a nonflammable solvent. Dry them thoroughly.
• Place the screen, retaining ring, and o-ring into the fuel
valve. Install the sediment cup and tighten securely.
• Move the fuel valve to the “On” position, and check for
leaks. Replace the o-ring if there is any leakage.
Battery Maintenance
Other than float charging, described elsewhere, no
maintenance is required for the battery. Keep the battery
and terminals clean and dry.
IMPORTANT: Battery charging should be performed in a
dry location, such as inside a garage.
Figure 15 — FuelValve Maintenance
Sediment Cup
O-ring
Retaining Ring
Screen

12
4000EXL Extended Life Generator
To Clean the Generator
• Use a damp cloth to wipe exterior surfaces clean.
• A soft bristle brush may be used to loosen caked on dirt
or oil.
• A vacuum cleaner may be used to pick up loose dirt.
• 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.
STORAGE
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.
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.
CAUTION! Storage covers can be flammable.
Do Not place a storage cover over a hot
generator. Let the unit cool for a sufficient time
before placing the cover on the unit.
Engine Storage
See engine owner’s manual for instructions.
Other Storage Tips
• To prevent gum from forming in fuel system or on
essential carburetor parts, empty all two supplied fuel
stabilizer containers into fuel tank and fill with fresh
gasoline. Run the unit for several minutes to circulate the
additive through the carburetor.The unit and fuel can
then be stored for up to 24 months.Additional fuel
stabilizer can be purchased locally.
•Do Not store gasoline from one season to another
unless it has been treated as described above.
• Replace gasoline can if it starts to rust. Rust and/or dirt
in gasoline can cause problems when that fuel is used
with this unit.
• Store in clean and dry area.

4000EXL Extended Life Generator
13
TROUBLESHOOTING
Problem
Cause
Correction
Engine is running, but no
AC output is available.
1. One of the circuit breakers is open.
2. Fault in generator.
3. Poor connection or defective cord set.
4. Connected device is bad.
1. Reset circuit breaker.
2. Contact Generac Portable Products
service facility.
3. Check and repair.
4. Connect another device that is in
good condition.
Engine runs good at no-
load but “bogs” down"
when loads are connected.
1. Short circuit in a connected load.
2. Engine speed is too slow.
3. Generator is overloaded.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. Contact Generac Power Systems
service facility.
3. See “Don't Overload the Generator”
on page 10.
4. Contact Generac Portable Products
service facility.
Engine will not start; or
starts and runs rough.
1. Run/Stop Switch set to “Stop”.
2. Fuel Valve is in the “Off” position.
3. Dirty air cleaner.
4. Out of gasoline.
5. Stale gasoline.
6. Spark plug wire not connected to
spark plug.
7. Bad spark plug.
8. Water in gasoline.
9. Overchoking.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
13. Failed battery.
1. Set switch to “Run”.
2. Turn the fuel valve to the “On”
position.
3. Clean or replace air cleaner.
4. Fill fuel tank.
5. Drain gas tank; fill with fresh fuel.
6. Connect wire to spark plug.
7. Replace spark plug.
8. Drain gas tank; fill with fresh fuel.
9. Open choke fully and crank engine.
10. Contact Generac Power Systems
service facility.
11. Contact Generac Power Systems
service facility.
12. Contact Generac Power Systems
service facility.
13. Replace battery.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
1. Fill fuel tank.
2. Fill crankcase to proper level.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
1. See “Don't Overload the Generator”
on page 10.
2. Replace air filter.
Engine “hunts” or falters.
1. Choke is opened too soon.
2. Carburetor is running too rich or too
lean.
1. Move choke to halfway position until
engine runs smoothly.
2. Contact Generac Power Systems
service facility.

14
4000EXL Extended Life Generator
SCHEMATIC

4000EXL Extended Life Generator
15
WIRING DIAGRAM

16
4000EXL Extended Life Generator
EXPLODED VIEW – MAIN UNIT

4000EXL Extended Life Generator
17
Item Part # Qty Description
1 A189159GS 1 CRADLE, 4000EXL
2 A84021GS 1 SUPPORT, Engine
3 189517GS 1 DECAL, Recoil
4 66365GS 1 HOUSING, Engine Adapter
5 67989GS 11 NUT, M8 Flanged Serrated
6 86307GS 4 HHMS, 5/16-24 x 3/4
7 84141JGS 1 ASSEMBLY, Rotor (Inclds Item 8)
8 65791GS 1 BEARING
9 96796GS 1 WASHER, M8 Flat
10 47480GS 1 HHCS, 5/16-24 x 7"
11 187105AGS 1 ASSEMBLY, Stator
12 81917GS 1 PIN, Roll M4 x 10
13 86308GS 4 BOLT, M6 - 1.0 x 115
14 84132GS 1 ASSMBLY, Drive Module Pwr
Reg.
15 67022GS 1 GROMMET, Rubber
16 74908GS 4 TAPTITE, M5-0.8 x 10
17 B4871GS 1 COVER, Bearing Carrier
18 185931HGS 1 ASM WIRE, #55, Black
19 66386GS 1 ASSEMBLY, Brush Holder
20 66849GS 2 TAPTITE, M5 0.8 x 16
21 SRV66825DGS 1 CARRIER, Rear Bearing
22 20566GS 1 DECAL, Generac 1-800
23 86494GS 1 SCREW, M6 -1.0 x 16 Wing
24 26850GS 2 WASHER, M6 Shakeproof
25 14353621GS 1 WIRE, Ground
26 85652GS 2 MOUNT,Vibration
27 86292GS 1 HHCS, 10 - 16 x 3/4" Self Driller
28 23762GS 2 WASHER, Shakeproof #10
29 B4986GS 1 DECAL, Ground
30 84346GS 3 PPHMS, M8 x 35
31 40976GS 2 SHCS, M8 1.25 x 20
32 89476GS 1 GASKET, Exhaust
33 65795GS 2 RECTIFIER, Battery Charge
34 66849CGS 1 TAPTITE, M5 0.8 x 30
35 83208GS 1 BRACKET, Muffler
36 66476GS 2 HHMS, LW M6 1.00 x 12
37 83071GS 1 MUFFLER
38 83083GS 1 SCREEN, Spark Arrest
39 70644GS 1 PPHMS, M8 1.25 x 20
40 84508GS 2 MOUNT,Vibration 45°
41 185931GGS 1 ASM WIRE, #13, Red
42 77395GS 4 NUT, M6 Flange Lock
43 J189312GS 1 SHIELD, Heat
44 188989GS 1 ASM, Jack, DC
45 189198GS 1 DECAL, Instructions, ES
46 58359GS 1 LUG, 5/16 #22/18 I-S
Item Part # Qty Description
47 78549GS 1 DECAL, Electric Start
48 187079GS 1 BATTERY, 12V, 10A
49 J188988GS 1 TRAY, Battery
50 189740GS 1 HARNESS,Wire, Starter
51 52858GS 4 NUT, M8 Flange Lock
52 185939FGS 1 ASSY.,Wire, #16, Red
53 22127GS 5 NUT, 1/4" - 20 Hex
54 22097GS 5 WASHER, M6 Lock
55 77282GS 1 SWITCH, Starter
56 B2153GS 6 HHCS, 12 - 14 x 7/8 Self Driller
57 188987GS 1 BRACKET, Starter Switch
58 22287GS 2 SCREW, 1/4" - 20 x 3/4"
59 B1797GS 4 CLIP,Tree
60 93826GS 1 DECAL, Operating Instructions
61 39414GS 1 HHCS, M8 - 1.25 x 35
62 77816GS 1 DECAL, Caution Hot Muffler
63 189219GS 1 DECAL, Control Panel
64 87116GS 1 ASSY., Control Panel
65 73054AGS 1 DECAL, Fuel Shut Off
66 189218GS 2 DECAL, Heat Shield
67 J189130GS 1 SHIELD, Heat
68 84687GS 1 INSULATION, #2-1/4" Thick
69 85000GS 1 CLIP, Insulation
70 92982GS 1 DECAL, Danger
71 189568GS 1 CLAMP, Hose
72 189133GS 1 VALVE,Tank
73 96796GS 4 WASHER
74 189134GS 4 GROMMET, Rubber
75 51731GS 4 HHCS, M8 - 1.25 x 50
76 189137GS 4 SPACER
77 189135GS 1 CAP, Fuel
78 189131GS 1 ASSY, Fuel Tank
79 A8926GS 1 MANUAL, Engine
80 189208GS 2 STABILIZER, 1oz Tube
81 65787GS 1 CABLE, Battery Charge
82 B4177GS 1 CHARGER, Batter
83 37806GS 1 PLUG, 125V, 30A
84 43483GS 1 PLUG, 250V, 20A
85 BB3061GS 1 BOTTLE, Oil, 28oz Generac
86 189189GS 1 MANUAL, 4000, Generac
87 D1456GS 1 MANUAL, Engine Parts
88 189759GS 1 KIT, Fuel Valve Repair
900 NSP 1 ENGINE
Optional Accessories Not Included:
84883GS Cord Wrap
PARTS LIST – MAIN UNIT

18
4000EXL Extended Life Generator
EXPLODED VIEW AND PARTS LIST – CONTROL PANEL
Item Part # Qty Description
1 83976GS 1 PANEL, Control
2 83975GS 1 BOX, Control
3 66818GS 2 OUTLET, 120 Volts AC
4 66821GS 1 OUTLET, 12 Volts DC
5 68867CGS 1 OUTLET, 120/240 volts, 20 Amp
Locking
6 68868CGS 1 OUTLET, 120 volts, 30 Amp
Locking
7 75207AGS 1 CIRCUIT BREAKER, 30 Amp
8 75207GGS 2 CIRCUIT BREAKER, 18 Amp
9 82538GS 1 SWITCH, On/Off Rocker
10 84134GS 1 GROMMET, Rubber
11 83514GS 1 CIRCUIT BREAKER, 10 Amp
12 83970GS 1 CONTROL BOARD, System
Item Part # Qty Description
13 84028GS 1 TRANSFORMER, Idle Control
14 67022GS 1 GROMMET, Rubber
15 85584GS 1 BAR, Bus
16 84543AGS 2 SCREW, 3.0 x 12mm
17 84543CGS 9 SCREW, 3.5 x 18mm
18 84198GS 3 SHIELD, Circuit Breaker
19 84197GS 1 BAR, Circuit Breaker Retaining
21 75476GS 2 SCREW, 4.15 x 16mm
22 22264GS 4 WASHER, M4 Lock
23 51715GS 4 NUT, M3 Hex
24 84543BGS 10 SCREW, 3.5 x 12mm
25 84335GS 1 WIRE HARNESS
26 82542GS 1 BAR, DC Outlet Retaining

4000EXL Extended Life Generator
19
EXPLODED VIEW AND PARTS LIST – WHEEL KIT
Item Part # Qty Description
1 B4217GS 1 ASSEMBLY, Handle
2 B1764GS 1 LEG, Mounting
3 52858GS 2 NUT, Locking Hex M8 - 1.25
4 39287GS 2 HHCS, M8 - 1.25 x 45
5 93693FGS 1 AXLE
6 B4966GS 2 WHEEL, 10" Diameter
7 87005AGS 2 PIN, Retaining
8 22247GS 2 WASHER, Flat

LIMITED WARRANTY
GENERAC PORTABLE PRODUCTS OWNER WARRANTY POLICY Effective October 1, 2001
WARRANTY PERIOD*
* The warranty period begins on the date of purchase by the first retail consumer or commercial end user, and continues for the period of time
stated in the table above. "Consumer use" means personal residential household use by a retail consumer. "Commercial use" means all other uses,
including use for commercial, income producing or rental purposes. Once equipment has been used commercially, it shall thereafter be considered
to be in commercial use for purposes of this warranty. Used equipment, demonstration equipment and equipment used for prime power in place
of a utility are not warranted.Accessory parts such as guns, hoses, wands and nozzles are excluded from the product warranty.
** The gasoline engine and starting batteries are warranted solely by the manufacturers of those products.
WARRANTY REGISTRATION IS NOT NECESSARYTO OBTAIN WARRANTY ON GENERAC PORTABLE PRODUCTS
EQUIPMENT. SAVEYOUR PROOF OF PURCHASE RECEIPT. IFYOU DO NOT PROVIDE PROOF OF THE INITIAL
PURCHASE DATE AT THE TIME WARRANTY SERVICE IS REQUESTED,THE MANUFACTURING DATE OF THE
EQUIPMENT WILL BE USED TO DETERMINE THE WARRANTY PERIOD.
About your equipment warranty:
Generac Portable Products welcomes warranty repair and apologizes to you for being inconvenienced.Any Authorized Service Dealer may perform
warranty repairs. Most warranty repairs are handled routinely, but sometimes requests for warranty service may not be appropriate. For example,
warranty would not apply if equipment damage occurred because of misuse, lack of routine maintenance, shipping, handling, warehousing or improper
installation. Similarly, warranty is void if the serial number of the equipment has been removed or the equipment has been altered or modified.
If a customer differs with the decision of the Service Dealer, an investigation will be made to determine whether the warranty applies.Ask the
Service Dealer to submit all supporting facts to its Distributor for review. If the Distributor decides that the claim is justified, the customer will be
fully reimbursed for those items that are defective.To avoid misunderstandings that might occur between the customer and the Dealer, listed
below are some of the causes of equipment failure that the warranty does not cover:
Normal wear:
Outdoor Power Equipment, like all mechanical devices, needs periodic parts, service and replacement to perform well.This warranty
does not cover repair when normal use has exhausted the life of a part or the equipment.
Installation and Maintenance:
This warranty does not apply to equipment or parts that have been subjected to improper or unauthorized installation or alteration,
misuse, negligence, accident, overloading, overspeeding, improper maintenance, repair or storage so as, in Generac Portable Products'
judgment, to adversely affect its performance and reliability.This warranty also does not cover normal maintenance such as adjustments,
fuel system cleaning and obstruction (due to chemical, dirt, carbon or lime, etc.).
Other Exclusions:
Also excluded from this warranty are wear items such as quick couplers, oil gauges, belts, o-rings, filters, pump packing, etc., pumps
which have been run without water supplied or damage or malfunctions resulting from accidents, abuse, modifications, alterations, or
improper servicing or freezing or chemical deterioration.
Warranty is available only through service dealers authorized by Generac Portable Products.This warranty does not apply to
service by any other entity.
You may locate your nearest Authorized Generac Portable Product Service Dealer in our dealer locator map at
www.generac-portables.com or call 1-877-544-0982.
Generac Portable Products, LLC
Jefferson,Wisconsin U.S.A.
LIMITED WARRANTY
"Generac Portable Products, LLC will repair or replace, free of charge, any part, or parts of the equipment that are defective in material or
workmanship or both.Transportation charges on parts submitted for repair or replacement under this Warranty must be borne by purchaser.
This warranty is effective for the time periods and subject to the conditions provided for in this policy. For warranty service, find the nearest
Authorized Service Dealer in our dealer locator map at www.generac-portables.com or call 1-877-544-0982.THERE IS NO OTHER EXPRESS
WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,ARE
LIMITED TO THE TIME PERIOD SPECIFIED, OR TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE
EXCLUDED. LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT
EXCLUSION IS PERMITTED BY LAW. Some states do not allow limitations on how long an implied warranty lasts, and some states do not
allow the exclusion or limitation of incidental or consequential damages, so the above limitation and exclusion may not apply to you.This
warranty gives you specific legal rights and you may also have other rights which vary from state to state and country to country."
PRODUCTS** CONSUMER USE COMMERCIAL USE FACTORY RECONDITIONED UNITS
Portable Generator 1 year 90 days 90 days
(Side Valve Engine Powered)
Portable Generator 2 years 1 year 90 days
(OverheadValve Engine Powered) (2nd year parts only)
Electric Powered Pressure Washer 1 year None None
Gasoline Powered Pressure Washer 1 year 90 days 90 days
Generac Portable Products Are Made Under One Or More Of The Following Patents: (Other Patents Pending)
5902094 5823752 5718255 5890413