Generac Power Systems 4000XL 9777-2 User manual

Owner’s Manual
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
Model No. 9777-3 (4,000 Watt AC Generator) Manual No. 189393GS Revision 1 (09/11/2002)
Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page
• Generator
• Wheel kit
• Storage Cover
• Battery charge cables
• Spare Spark Plug,Air Filter, and Oil Filter
• Spark Plug Wrench
• Locking 20 Amp plug
• Locking 30 Amp plug
• Engine oil
• Owner's manual
• Engine manual
*If any parts are missing or damaged, call 1-800-270-1408.
Parts Included*Table of Contents

2
4000XL 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 11.
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.
• 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 using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
• Use a ground fault circuit 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 isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
DANGER
• National Electric Code requires generator to be properly
grounded to an approved earth ground. Call an electrician for
local grounding requirements.
Failure to properly ground generator can result
in electrocution, especially if the generator is
equipped with a wheel kit.
DANGER
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING

4000XL Extended Life Generator
3
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
• 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
• 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 11.
• 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 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.
• 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
4000XL Extended Life Generator
Your generator requires some assembly and is ready for
use after it has been 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 will result in an
engine failure.
REMOVE GENERATOR
FROM CARTON
• Set the carton on a rigid flat surface with “This Side Up”
arrows pointing upward.
• Carefully open the top flaps of the shipping carton.
Review “Cold Weather Operation” on page 9.
• Cut down corners at one end of carton from top to
bottom and lay that side of carton down flat.
• Remove all packing material, carton fillers, etc.
• Remove the generator from the shipping carton.
INSTALL WHEEL KIT
To install the wheel kit, the following tool is required:
• Socket wrench with 1/2" or 13mm sockets.
• Needle-nose pliers.
Install Wheel Kit as follows: (See Figure 1)
• Place the bottom of the generator cradle on a flat, even
surface.Temporarily place unit on blocks to ease
assembly.
• Slide axle through both axle mounting brackets on cradle
frame, as shown.
• Slide a wheel over the axle.
NOTE: Be sure to install both wheels with the air
pressure valve on the outboard side.
• Retain wheel on axle with the e-ring using a needle-nose
pliers.You may add the flat washer if desired.
• Repeat step 3 and 4 to secure second wheel.
• Remove the existing hardware from the vibration
mounts with 13mm wrench. Use the same hardware to
attach the mounting leg.
Mounting Leg
Use Existing Fasteners
Axle
Flat Washer
Cap Screw
Handle Assembly
Hex nut
Wheel E-Ring
Figure 1 — Install Wheel Kit

4000XL Extended Life Generator
5
• Remove the temporary blocks.
• Center the handle bracket on generator frame at control
panel end of cradle.
• Attach handle bracket with two cap screws and two hex
nuts. Use two 13 mm 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 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 overfill.Allow about 1/2" of tank 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.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See “Storage”
on page 12. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
Figure 2 — Typical Fuel Expansion Space
1/2” Air
Space
Tank
Fuel

6
4000XL Extended Life Generator
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.
12 Volt DC, 10 Amp Receptacle — Use this receptacle
with battery charge cables to charge a 12 Volt battery.
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.
Circuit Breakers (AC) — Each receptacle is provided
with a circuit breaker to protect the generator against
electrical overload. Breakers are "push to reset" type.
Fuel Shut Off Valve — Controls fuel supply to engine.
Fuel Tank — Capacity of 4 U.S. gallons (15 liters).
Grounding Wing Nut — Provides a tie-point for
connecting the generator frame to earth ground.
Idle Control Switch — The idle control runs the engine
at normal (high) speeds when there is an electrical load
present and runs the engine at idle (low) speeds when 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 a running engine.
Spark Arrester Muffler — Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.
Circuit Breakers (AC)
Idle Control Switch
Run/Stop Switch
Fuel Shut Off Valve
Fuel Tank
120 Volt AC, 30 Amp
Receptacle
120/240 Volt AC,
20 Amp Receptacle
12 Volt DC, 10 Amp
Receptacle
120 Volt AC, 15 Amp,
Duplex Receptacle Grounding Wing Nut
Oil Fill Cap
Spark Arrester Muffler
Recoil Starter

4000XL Extended Life Generator
7
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, especially when 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 with
electrical loads connected AND with the connected
devices turned ON.
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
Fuel Valve is shown in
the “On” position
Figure 3 — Grounding Wing Nut
Grounding
Wing Nut

8
4000XL Extended Life Generator
5. 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
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 11.
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 alternator.
• 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).
Figure 8 — Battery Connections

4000XL Extended Life Generator
9
• Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 8).
• 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.
In an emergency, use the original shipping box as a
temporary shelter:
• Cut off all flaps.
• Cut out one of the long sides of the box to expose
exhaust side of unit. Ensure a minimum of two feet
clearance between open side of box and nearest object.
• Cut appropriate slots to access receptacles of unit.
• Start unit, then place box over it.
IMPORTANT: Remove shelter when temperature is
above 40°F [4°C].
For a more permanent shelter, build a structure that will
enclose three sides and the top of the generator:
• Make sure entire muffler-side of generator 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.
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 10).
Use each outlet to operate 120 Volt, 60 Hz, single phase
loads requiring 1,800 (1.8 kW) watts at 15 Amps of current.
Figure 10 — 120Volt AC, 15 Amp Duplex Receptacle
Figure 9 — Temporary Cold Weather Shelter
Wind

10
4000XL Extended Life Generator
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 11).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 12).
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 13). See
“Charging a Battery” on page 8.
Figure 11 — 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 12 — 120 Volt AC, 30 Amp, Locking Receptacle
3-Wire Cord Set
Neutral
120V
Hot
Ground (Green)
NEMA L5-30
Figure 13 — 12Volt DC, 10 Amp Receptacle