Generac Portable Products 4000XL 9777-2 User manual

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 isusedto alert you to potential personal injuryhazards.
Obey all safety messagesthat follow this symbol to avoidpossible injuryor death.

GeneracPortableProducts4,000XLGenerator
EQUIPMENT
DESCRIPTION
This generator isan engine-driven, revolving field,
alternating current (AC) generator. It was designedto
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, singlephase,60 Hz devicesthat
require up to 4,000 watts (4.0 kW) of power that pull up
to 33.3 Amps at 120Volts or 16.7Amps at 240 Volts.
_hL CAUTION! Do Not exceed the generator's
wattage/amperage capacity.Add up the rated watts
of all devicesyou 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 canbe 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 hasthe following features:
•120/240Volt, 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 Systems7.8 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 candamagesome
connected electrical loads.Operating at excessively
low speedsimposesa heavyload.When adequate
engine power isnot availableengine life may be
shortened.
SAFETY RULES
This generator set was designedand manufactured for
specific applications. Do Not attempt to modify the unit
or use it for anyapplication it was not designedfor. 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 manualand warnings on tagsor decals
affixed to the unit are not all-inclusive. Ifyou intend to
handle,operate or service the unit by a procedure or
method not specificallyrecommended 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
usedfor 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 isproviding
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
adequateventilation is available.
The EmissionControl 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 injuryor death by electrocution. Never
touch bare wires or receptacles. Never permit a child
or anyunqualified 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 injuryfrom electrocution may
result.
• Use a ground fault circuit interrupter (GFCI) in anydamp
or highly conductive area (such as metal decking or steel
work).
•Never useworn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damagefrom 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 spillinggasoline 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
gasolinevaporsmight reach an open flame, spark or pilot
light(as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.
• The unitrequires an adequateflow of cooling air for its
continued proper operation. Never operate the unit
insideanyroom or enclosure where the free flow of
cooling air intoand out of the unit might be obstructed.
Allow at least2 feet of clearanceon all sides of generator,
evenwhile operating unitoutdoors, or you could damage
the unit See"Cold Weather Operation" on page 10.
•Never start or stop the unitwith electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting anyelectrical loads.Disconnect all electrical
loadsbefore shutting down the generator.
•Do Not insertanyobject through cooling slots of the
engine.You could damagethe unit or injureyourself.
•Never operate the generator:
in rain; in any enclosedcompartment;when connected
electricaldevicesoverheat; if electrical output islost;if
engine or generator sparks; ifflame or smoke is
observed while unit isrunning; ifunit 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 keepthe 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 ifa 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
120/240Volt AC,
20 Amp Receptacle
12Volt DC, 10Amp
Receptacle
120Volt AC, 15Amp, IdleControl Switch
Duplex Receptacle Grounding Wing Nut
12 Volt DC, I0 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, singlephase,60 Hz electrical
lighting, appliance,tool and motor loads.
120 Volt AC, 30 Amp Receptacle -- May be usedto
supply electrical power for the operation of 120Volt AC,
30 Amp, singlephase,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, singlephase,60 Hz electrical lighting,
appliance,tool and motor loads.
Circuit Breakers (AC) -- Eachreceptacle isprovided
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
loadisnot 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. Ifany parts are missingor 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 hasbeen properly filledwith the
recommended oil mayresult in an enginefailure.
To fill your engine with oil:
•PJace generator on aJevel surface.
• Clean area around oil filland remove oil fillcap.
• 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 sealedball 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 areaaround fuel fillcap, remove cap.
• Slowly add unleaded regular gasolineto 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 isimportantto prevent gum deposits
from forming in essentialfuel system parts such asthe
carburetor, fuel filter, fuel hose or tank during storage.
Also, experience indicatesthat alcohol-blended fuels (called
gasohol, ethanol or methanol) canattract moisture, which
leadsto separation and formation of acids during storage.
Acidic gascan damagethe 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 aspermanent 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 isin "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
(Figure5).
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 step6.
6. Move the chokelever to "Half' chokeposition, and
pull recoil handletwice.
• If enginefailsto start, repeat steps4 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,
singlephase, 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 loadsto 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 II.
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 IdleControl switch in the "Oft"' position.
• Let engine run at no-load for 30 secondsto 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 isdesignedto greatly improvefuel economy.
When this switch is turned ON, the engine will only
run at itsnormal high governed engine speed when an
electrical loadisconnected. 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
canignite the hydrogen and causean explosion. Such
anexplosion canshatter the battery and cause
blindnessor other serious injury.
ADANGER! Oo Not permit smoking, open flame,
sparksor anyother 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 cancausesevere 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 havinga discharged battery.
To recharge 12 Volt batteries, proceed as follows:
• Check fluid levelin all battery cells. If necessary,add
ONLY distilled water to cover separators in battery
cells. Do Not use tap water.
• If the battery isequipped with vent caps,make sure they
are installedand are tight.
•If necessary,clean battery terminals.
• Connect battery charge cableconnector plug to panel
receptacle identifiedbythe words "12-VOLT D.C."
• Connect battery charge cableclamp with red handle to
the positive (+) battery terminal (Figure6).
12 VOLT D.C.
RECEPTACLE
+
POS NEG
12 VOLT BATTERY
• Connect battery charge cableclamp with black handle
to the negative (-) battery terminal (Figure6).
• Start engine. Let the engine run while battery recharges.
• When battery hascharged, 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 chargewhen specific
gravity of its fluid (as measured by hydrometer) is 1.260or
higher.
,mmm7

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 asa
temporary shelter:
•Cut off all flaps.
• Cut out one of the long sides of the box to expose
exhaust side of unit Ensurea minimum of two feet
clearance between open side of box and nearest object.
• Cut appropriate slots to accessreceptacles of unit
• Start unit, then placebox over it.
IMPORTANT: Remove shelter when temperature is
above40°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 NEMA 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 usethe 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 120/240Volt AC, 60 Hz, single
phaseloads 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 isprotected 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-WireCordSet
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 itsrated 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 devicesto 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.
•Ifthe 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
devicesto connect to your generator. Firstestimate 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
*1V2hp 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
II0

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
FuelTank 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 manualfor 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 usedto 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 openingsmust be kept cleanand
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,usethe following guidelines to prepare it for storage.
Generator Storage
•Cleanthe generator asoutlined in "To Clean the
Generator"
• Check that cooling air slots and openingson generator
are open and unobstructed.
_DANGER! Storagecovers can be flammable. Do
Not placea storage cover over a hot generator. Let
the unit cool for asufficient time before placingthe
cover on the unit.
Engine Storage
Seeengine owner's manualfor 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.
III

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 isopen.
2. Poor connection or defective cord set.
3. Connected device isbad.
4. Fault in generator.
I. Short circuit in a connected load.
2. Generator is overloaded.
3. Enginespeed istoo slow.
4. Shortedgeneratorcircuit.
I. Run/Stopswitch set to "Stop".
2. Dirty air cleaner.
3. Out of gasoline.
4. Stalegasoline.
5. Sparkplug 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 servicefacility.
I I. Contact Generac servicefacility.
12. Contact Generac servicefacility.
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 isrunning 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
L]OJ
F H
E
D•
D
G
A
E
2
G
N
A
_Y_TEM
CONTROL
GRH
SLU z _ /
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
I15

I
?//_ J
Generac Portable Products 4,000XL Generator
EXPLODED VIEW - HAIN UNIT
52
65
5O
f-_ 48
\47
lO
DETAIL " X "
SEE
DETAIL " Y "
1 f 56
S5
\\\
52
27_
62 8\
J
SEE
DETAIL
-X,,
26
65
15
11
/
2O
q
22
12
I
14
16
/16

Generac Portabte Products 4,000XL Generator l/! yG_
I
J/_ Ii
m
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 1.25x 20
PPHMS,M8 x 35
SHCS,M8 1.25x 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 -1.0x 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
I
I
2
I
I
I
I
I
4
I
Description
HHMS, M6 1.0x 60
VALVE,Tank
BUSHING, PlasticTank
GAUGE, Fuel
TANK, Fuel
SHIELD, Heat
INSULATION, #2- I/4" Thick
CLIP,Insulation
WIRE, Ground
WASHER, Shakeproof # I0
WASHER, M6 Shakeproof
DECAL, Control Panel
DECAL, Danger
DECAL, Heat Shield
DECAL, Operating Instructions
DECAL, FuelShut Off
DECAL, Generac 1-800
DECAL, Caution Hot Muffler
ASSY.,Control Panel
HHCS, 12 - 14 x 7/8 SelfDrill
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
120/240Volt 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
/17

I
//_ I
Generac Portable Products 4,000XL Generator
EXPLODED VIEW AND PARTS LIST - CONTROL PANEL
14
88/
\\\ I F
18
7 17
11
15
24
'\
1
'\\\
17 17
26
\3
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 120/240Volts, 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
/18

Generac Portable Products 4,000XL Generator
NOTES
/19

LIMITED WARRANTY
FOR "GN" ENGINE DRIVEN PORTABLE GENERATORS
GENERAC PORTABLEPRODUCTS (hereafter referred to asthe COMPANY) warrants to the original purchaser that the
alternator and control panel for itsportable 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 isnot transferable and appliesonly to portable
generators driven by a GN-Series engine.
Consumer* Commercial*
Alternator 2 years (2ridyear parts only) I year
Engine Warranted solely by the engine manufacturer
With the exception of European Community Countries, all unitsbound for export shall be warranted for One (I)
Yearin Consumer applications, end 90 daysin 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 saidwarranty period, the COMPANY wilt, at isoption, repair or replace anypart which, upon examination bythe
COMPANY, isfound to be defective under normal useand service**. Starting batteries are not warranted by the
COMPANY. All transportation costs under warranty, includingreturn to the factory ifnecessary,are to be borne bythe
purchaser and prepaid by the purchaser.This warranty does not cover normal maintenanceand service anddoes not apply
to a generator set,alternator, or parts which havebeen 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 adverselyaffect 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.
THEREIS 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 ISLIMITED TO THE TIME PERIODAS
SPECIFIEDIN THE EXPRESSWARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL
DAMAGES UNDER ANY AND ALL WARRANTIES ISEXCLUDED. THE COMPANY ALSO DISCLAIMS
ANY RESPONSIBILITYFOR INCIDENTAL OR CONSEQUENTIAL DAMAGES,SUCH AS THE LOSSOF
TIME OR THE USEOF 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,sothe abovelimitationsor exclusions may not applyto you. This warranty givesyou specific legal
rights andyou may also haveother rights, which vary from state to state.
For service, seeyour 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