Generac Portable Products 9777-3 User manual

Owner's Manual
". | =*=
Generator
Wheel kit
Storage Cover
Batter)" charge cables
Spare Spark Plug,Air Filter, and Oil Filter
Spark PlugWrench
Locking20 Amp plug
Locking30 Amp plug
Engineoil
Owner's manual
Enginemanual
If any parts are missing or damaged, call 1-800-270-1408.
SafetyRules.................................... 2-3
Assembly...................................... 4-5
Know Your Generator ............................. 6
Operation .................................... 7-I I
Product Specifications............................. 12
Maintenance.................................... 12
Storage........................................ 12
Troubleshooting ................................. 13
Schematic...................................... 14
Wiring Diagram ................................. 15
Replacement Parts............................. {6-19
Warranty ................................. Last Page
Questions? Help is just a moment away!
Call:Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-portables.com or www.briggsandstratton.com

EQUIPMENT
DESCRIPTION
Read this manual carefully and become familiar
with your generator. Know its applications, its
limitations and any hazards involved.
Thisgenerator isan engine-driven, revolving field, alternating
current (AC) generator. It was designedto supply electrical
power for operating compatible electrical lighting,appliances,
tools and motor loads.Thegenerator's revolvingfield is
driven at about 3,600rpm by a single-cylinderengine.
CAUTION! Do Not exceed the generator's
wattage/amperage capacity.See"Don't Overload the
Generator" on page I I.
Everyeffort hasbeenmadeto ensurethat information inthis
manualisaccurateand current However,Generacreserves
the right to change,alter or otherwise improvethe product
and this document at anytime without prior notice.
The EmissionControl Systemfor this generator iswarranted
for standardsset by the EnvironmentalProtection Agency.For
warranty informationrefer to the engineowner's manual.
SAFETY RULES
The safety alert symbol (_k) isusedwith a signalword
(DANGER, CAUTION,WARNING), a pictorial and/or a
safety messageto alert you to hazards.DANGER indicates
a hazardwhich, ifnot avoided,will result in death or serious
injury. WARNING indicatesa hazardwhich, if not avoided,
couldresult in death or serious injury.CAUTION
indicatesa hazardwhich, ifnot 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 messagesto
avoid or reduce the risk of injuryor death.
WARNING
The engine exhaust from this product contains I
chemicals known to the State of California to cause
cancer, b rth defects, or other reproduct ve harm.
DANGER
Operate generator ONLY outdoors.
Keep at least 2 feet of clearance on all sidesof generator for
adequateventilation.
Do not operate generator insideany building or enclosure,
includingthe generator compartment of a recreational vehicle
(RV).
DANGER
National ElectricCode requires generator to be properly
grounded to an approved earth ground. Call an electrician for
local grounding requirements.
DANGER
When usinggenerator for backup power, notify utility
company.Useapproved transfer equipment to isolate
generator from electric utility.
Use aground fault circuit interrupter (GFCI) in any damp or
highly conductive area,such asmetal decking or steel work.
Do not touch bare wires or receptacles.
Do not usegenerator 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 handsor feet are wet.
Do not allow unqualified persons or children to operate or
service generator.

, WARNING
WHEN ADDING FUEL
Turn generator OFF and let it cool at least2 minutes before
removing gascap.Loosen cap slowly to relievepressure in tank_
Fill fuel tank outdoors.
Do not overfill tank.Allow spacefor fuel expansion.
Keepgasoline awayfrom sparks,open flames,pilot lights, heat,
and other ignition sources.
Do not light a cigarette or smoke.
NHEN OPERATING EQUIPMENT
Do not tip engine or equipment at anglewhich causes
gasoline to spill.
tHEN TRANSPORTING OR REPAIRING EQUIPMENT
Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFE
Disconnect spark plug wire.
NHEN STORING GASOLINE OR EQUIPMENT WITH
FUEL IN TANK
Store awayfrom furnaces,stoves,water heaters, clothes
dryers or other appliancesthat havepilot light or other
ignition source becausethey can ignite gasoline vapors.
DANGER
Do not allow any openflame, spark, heat,or lit cigarette
during andfor several minutes after charging a battery.
Wear protective goggles,rubber apron, and rubber gloves.
, WARNING
Do not touch hot surfaces.
Allow equipment to cool before touching.
CAUTION
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.
CAUTION
See"Don't Overload Your Generator" on page I h
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.
CAUTION
Use generator only for intended uses.
tf you have questions about intended use,ask dealeror
contact Generac.
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.
tf connected devices overheat, turn them off and disconnect
them from generaton
Shut off generator if.'
-electrical output is lost;
-equipment sparks,smokes,or emits flames;
-unit vibrates excessively.

Your generator requires some assemblyand isready for
use after it hasbeen properly serviced with the
recommended oil and fuel.
If you have any problems with the assembly of your
generator, please call the generator helpline at
1-800-270-1408.
IMPORTANT: Any attempt to run the unit before it has
been serviced with the recommended oil wilt result in an
engine failure.
REMOVE G EN ERATOR
FROM CARTON
• Set the carton on a rigid flat surface with "This Side Up"
arrows pointing upward.
• Carefully open the top flaps of the shippingcarton.
Review"Cold Weather Operation" on page9.
• Cut down corners at one end of carton from top to
bottom and laythat side of carton down flat.
• Removeall packing material, carton fillers, etc.
• Removethe generator from the shipping carton.
INSTALL WHEEL KIT
To installthe wheel kit, the following tool isrequired:
• Socket wrench with I/2" or 13mmsockets.
• Needle-nose pliers.
Install Wheel Kit as follows: (SeeFigure I)
• Placethe bottom of the generator cradle on a flat, even
surface.Temporarily place unit on blocks to ease
assembly.
• Slideaxle through both axle mounting brackets on cradle
frame, asshown.
• Slide a wheel over the axle.
NOTE: Be sure to installboth wheels with the air
pressure valve on the outboard side.
• Retain wheel on axle with the e-ring usinga needle-nose
pliers.You may add the fiat washer ifdesired.
• Repeat step 3 and 4 to secure second wheel.
• Remove the existing hardware from the vibration
mounts with 13mmwrench. Use the same hardware to
attach the mounting leg.
Cap Screw
Handle Assembly
\\\
Mounting Leg
Use Existing Fasteners
/
Axle
FlatWasher
/
E-Ring

•Removethe temporary blocks.
•Center the handle bracket on generator frame at control
panel end of cradle.
• Attach handle bracket with two capscrews and two hex
nuts. Use two 13mm wrenches to tighten hardware.
• Check that all fasteners are tight and the tires are
inflated between 15-40 PSI.
BEFORE STARTING THE
ENGINE
Add Oil
CAUTION! Any attempt to crank or start the engine
before it hasbeen 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 inthe engine owner's manual.
NOTE: The generator's revolving field rides on a
prelubricated and sealedball bearing that requires no
additional lubrication for the life of the bearing.
Add Gasoline
_ARNING! 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 gasolinewith the generator
engine.Do Not use premium gasoline. Do Not mix oil
with gasoline.
• Clean areaaround fuel fill cap,remove cap.
• Slowly add unleaded regular gasoline to fuel tank. Be
careful not to overfill.Allow about I/2" of tank spacefor
fuel expansion (Figure 2).
112" Air
Install fuel capand 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 fuel can damagethe fuel system of an enginewhile
in storage.
To avoid engine problems, the fuel system should be
emptied before storage of 30 daysor longer.See"Storage"
on page 12.Never useengine or carburetor cleaner
products in the fuel tank or permanent damagemay occur.

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.
Oil Fill Cap
Circuit Breakers (AC) _ _-
1201240Volt AC,
20 Amp Receptacle
Recoil Starter
FuelTank
Fuel Shut Off Valve
120Volt AC, 30 Amp
Receptacle
Run/Stop Switch
12Volt DC, 10Amp
Receptacle
120Volt AC, 15Amp,
Duplex Receptacle GroundingWing Nut
12Volt OC, 10Amp Receptacle- Use this receptacle
with battery charge cables to chargea 12Volt battery.
120Volt AC, 15Amp Duplex Receptacle -- May be
usedto supply electrical power for the operation of
120Volt AC, 15Amp, single phase,60 Hz electrical lighting,
appliance,tool and motor loads.
120Volt AC, 30 Amp Receptacle -- Maybe used to
supply electrical power for the operation of 120Volt AC,
30 Amp, singlephase,60 Hz electrical lighting,appliance,
tool and motor loads.
12012.40Volt 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,toot 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.
SparkArrester Muffler
Idle Control Switch
Fuel Shut OffValve -- Controls fuel supply to engine.
Fuel Tank -- Capacity of 4 U.S.gallons (15 liters).
GroundingWing Nut -- Provides a tie-point for
connecting the generator frame to earth ground.
Idle Control Switch --The idlecontrol runs the engine
at normal (high) speeds when there isan electrical load
present and runs the engine at idle (low) speedswhen a
load is not present.This feature greatly improves fuel
economy,extends the life of the engine,and reduces engine
noise.
Oil Fill Cap --Add oil to engine here.
Recoil starter -- Used to start the engine.
Run/Stop Switch -- Must be in "Run" position to start
engine. Set to "Stop" to stop arunning engine.
Spare Arrester Muffler -- Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.

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 mayalso require proper grounding of the
unit. For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure 3).
I_I_'_L:I_ [eL_l _"_a
Wing Nut
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. Becareful to keepthe 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 aground fault condition exists in the generator or
in connected electrical devices,especiallywhen the unit is
equipped with a wheel kit. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
OPERATING THE
GENERATOR
_CAUTION! Never start or stop unit withelectrical loads connected AND with the connected
devicesturned ON.
Starting the Engine
Disconnect all electrical loadsfrom the generator. Follow
these start instruction steps in numerical order:
I. Turn the fuel valve to the "On" position (Figure 4).
2.
.
4.
FuelValve is shown in
the "On" position
Make sure the Idle Control switch is in"Off" position
(Figure 5).
IDLE
Setthe Run/Stop switch to "Run" position (Figure6).
Placethe choke lever in the "Full" choke position
(Figure7).
"Full" choke
Position

S.
6.
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.
Move the choke lever to "Half" choke position, and
pull recoil handle twice.
• If engine fails to start, repeat steps4 thru 6.
7. Move choke leverto "Run" position. If engine falters,
move choke leverto "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 oll level in crankcase.This unit is equipped with a
Low Oit Shutdown System.Seeengine 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.
• Plugin and turn on the desired 120and/or 240 VottAC,
single phase,60 Hz electrical loads.
• Do Not connect 240Volt loads to the 120Volt
receptacles.
• Do Not connect 3_hase loadsto the generator.
• Do Not connect 50 Hz loads to the generator.
•DO NOT OVERLOADTHE 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 plugged in and turned on.
• Put the idle control switch in the "Off" position.
• Let engine run at no-load for 30 secondsto stabilize the
internal temperatures of engine and alternator.
• Move run/stop switch to "Stop".
• Close the fuel shut-off valve.
Operating Automatic Idle Control
This switch isdesignedto 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 enginewill 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
AARNING! Storagebatteries giveoff explosive
hydrogengaswhile recharging.An explosive mixture
will remain around the battery for a long time after
it hasbeen charged.The slightest spark can ignite
the hydrogen and causean explosion, resulting in
blindnessor other serious injury.
AWARNING! Do Not permit smoking, open
flame,sparksor anyothersourceofheatarounda
battery.Wear protective goggles,rubber apron and
rubber gloves when working around a battery.
Battery electrolyte fluidisan extremely caustic
sulfuric acid solution that can causesevere burns. If
spill occurs flush areawith clear water immediately.
Your generator hasthe capability of recharging adischarged
12Volt automotive or utility style storage battery. Do Not
usethe unit to charge any6Volt batteries. Do Not use the
unit to crank an engine havinga discharged battery.
To recharge 12Volt batteries, proceed as follows:
• Check fluidlevel in 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 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 (Figure8).
12VOLT D.C.
RECEPTACLE
+
POS NEG
12VOLTBAl-I'ERY
I:|

•Connect battery chargecableclamp with black handle
to the negative (-) battery terminal (Figure8).
• 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 instructions carefully.Generally,a battery is
considered to be at 100%state of chargewhen specific
gravity of its fluid (asmeasured by hydrometer) is 1.260or
higher.
COLD WEATH ER
OPERATION
Under certain weather conditions (temperaturesbelow
40°F [4°C] and a high dew point),your generator may
experience icingof the carburetor and/or the crankcase
breather system.
In an emergency,usethe original shipping box asa
temporary shelter:
• Cut off all flaps.
• Cut out one of the longsides of the box to expose
exhaust sideof 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 place box over it.
IMPORTANT: Removeshelter 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 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.
ACAUTION! Never run unit indoors.Do Not
enclose generator any more than shown.
RECEPTACLES
120 Volt AC, 15 Amp Receptacles
Eachof these outlets is protected againstoverload by
15Amp push-to-reset type circuit breakers (Figure 10).
Use each outlet to operate 120Volt, 60 Hz,single phase
loads requiring 1,800(I.8 kW) watts at 15Amps of current.

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 250Volts at 20 Amps (or greater)
(Figure I I).You canuse the same4-wire cord ifyou plan to
run a 120Volt load. pa_ Ip,(*]kv_aJr.,T *" . * :" ._ m
4-Wire Cord Set
I
' (Neutral)
Y(Hot) X (Hot)
NEMA L14-20 Ground (Green)
This receptacle powers 120/240Volt AC, 60 Hz,single
phaseloadsrequiring up to 2,400 watts of power at
20 Amps for 120Volts;4,000 watts of power (4.0 kW) at
16.7Amps for 240Volts.The outlet isprotected by a
20 Amp push-to-reset circuit breaker.
_L CAUTION! Although this outlet israted for
240Volt 20Amp (up to 4,800 watts), the generator
is only rated for 4,000 watts. Powering loadsthat
exceed the wattage/amperagecapacity of the
generator candamageit or causeserious injuries.
240 Volt loads powered through this outlet should
not exceed 16.7Amps 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 125Volts AC at 30 Amps to the
plug (Figure 12).
3-Wire Cord Set
iNEMA L5-30
Neutral
120V
Hot
Ground (Green)
Use this receptacle to operate 120Volt AC, 60 Hz, single
phaseloadsrequiring up to 3,600 watts (3.6 kW) of power
at 30Amps.The outlet isprotected by a 30Amp
push-to-reset circuit breaker.
12 Volt DC, I 0 Amp Receptacle
This connector (identified by the legend"I2-VOLT D.C")
supplies 12Volts DC at I0Amps through battery charging
cablesfor recharging 12Volt batteries (Figure 13).See
"Charging a Battery" on page 8.
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