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. 9777-4 (4,000 Watt AC Generator) Manual No. 193524GS Revision 0 (08/04/2003)
Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23
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.
The generators are 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
Generator” on page 12.
Every effort has been made to ensure that information in this
manual is accurate and current. However, we reserve 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
This is the safety alert symbol. It is used to
alert you to potential personal injury hazards.
Obey all safety messages that follow this
symbol to avoid possible injury or death.
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.
Hazard Symbols and Meanings
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
In the State of California a spark arrester is required by law
(Section 4442 of the California Public Resources Code).
Other states may have similar laws. Federal laws apply on
federal lands. If you equip the muffler with a spark arrester,
it must be maintained in effective working order.
Fire
Explosion
Toxic Fumes
Hot Surface
Electrical Shock
Electrocution Electrical Shock
Explosive Pressure Chemical Burn

4000XL 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
• 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 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 isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
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 fuel 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 fuel
to spill.
• This generator is not for use in mobile equipment or marine
applications.
WHEN TRANSPORTING OR REPAIRING EQUIPMENT
• Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFF.
• Disconnect spark plug wire.
WHEN STORING FUEL 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 fuel vapors.
Fuel and its vapors are extremely flammable and
explosive.
Fire or explosion can cause severe burns or
death.
WARNING
• This generator does not meet U. S. Coast Guard Regulation
33CFR-183 and should not be used on marine applications.
• Failure to use the appropriate U. S. Coast Guard approved
generator could result in bodily injury and/or property
damage.
WARNING

4
4000XL Extended Life Generator
• 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 Generator” on page 12.
• 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 call
1-800-270-1408.
• 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
WHEN ADJUSTING OR MAKING REPAIRS TOYOUR
GENERATOR
• Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.
Unintentional sparking can result in fire or
electric shock.
WARNING

4000XL 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 Fastener
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 Fastener — If required, please consult a
qualified electrician, electrical inspector, or the local agency
having jurisdiction.
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.
Oil Fill Cap

6
4000XL Extended Life Generator
ASSEMBLY
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.
Remove Generator From Carton
1. Set carton on a rigid flat surface with “This Side Up”
arrows pointing upward.
2. Carefully open top flaps of shipping carton. Review
“Cold Weather Operation” on page 10.
3. Cut down corners at one end of carton from top to
bottom and lay that side of carton down flat.
4. Remove all packing material, carton fillers, etc.
5. Remove generator from shipping carton.
Install Wheel Kit
To install the wheel kit, the following tools are required:
• Socket wrench with 1/2" or 13mm sockets
• Needle-nose pliers
Install Wheel Kit as follows: (See Figure 1)
1. Place bottom of the generator cradle on a flat, even
surface.Temporarily place unit on blocks to ease assembly.
2. Slide axle through both axle mounting brackets on
cradle frame, as shown.
3. Slide wheel over axle.
NOTE: Be sure to install both wheels with air pressure
valve on outboard side.
4. Retain wheel on axle with e-ring using a needle-nose
pliers.You may add the flat washer if desired.
5. Repeat step 3 and 4 to secure second wheel.
Mounting Leg
Use Existing Fasteners
Axle
Flat Washer
Cap Screw
Handle
Hex
nut
Wheel E-Ring
Figure 1 — Install Wheel Kit

4000XL Extended Life Generator
7
6. Remove existing hardware from vibration mounts with
13mm wrench. Use same hardware to attach mounting leg.
7. Remove temporary blocks.
8. Center handle bracket on generator frame at control
panel end of cradle.
9. Attach handle bracket with two cap screws and two hex
nuts. Use two 13 mm wrenches to tighten hardware.
10. Check that all fasteners are tight and tires are inflated
between 15-40 PSI.
BEFORE STARTING
ENGINE
Add Engine Oil and Fuel
• Place generator on a level surface.
• Refer to engine owner’s manual and follow oil and fuel
recommendations and instructions.
NOTE: Check oil often during engine break–in. Refer to
engine owner’s manual for recommendations.
NOTE: The generator assembly rotates on a prelubricated
and sealed ball bearing that requires no additional
lubrication for the life of the bearing.
CAUTION
• Refer to engine manual for oil and fuel fill information.
• Damage to equipment resulting from failure to follow this
instruction will void warranty.
Any attempt to crank or start the engine before it has
been properly filled with the recommended oil will result
in equipment failure.

8
4000XL Extended Life Generator
USING THE GENERATOR
System Ground
The generator has a system ground that connects the
generator frame components to the ground terminals on
the AC output receptacles.The system ground is connected
to the AC neutral wire (the neutral is bonded to the
generator frame).
Special Requirements
There may be Federal or State Occupational Safety and
Health Administration (OSHA) regulations, local codes, or
ordinances that apply to the intended use of the generator.
Please consult a qualified electrician, electrical inspector, or
the local agency having jurisdiction.
• In some areas, generators are required to be registered
with local utility companies.
• If the generator is used at a construction site, there may
be additional regulations which must be observed.
Connecting to a Building’s Electrical
System
Connections for standby power to a building’s electrical
system must be made by a qualified electrician.The
connection must isolate the generator power from utility
power, and must comply with all applicable laws and
electrical codes.
OPERATING THE
GENERATOR
Starting the Engine
Disconnect all electrical loads from the generator. Follow
these start instruction steps in numerical order:
1. Make sure unit is on a level surface.
IMPORTANT: Failure to start and operate unit on a level
surface will cause the unit not to start or shut down
during operation.
2. Turn fuel valve to “On” position (Figure 2).
3. Make sure Idle Control switch is in “Off” position
(Figure 3).
3. Start engine according to instructions given in engine
owner’s manual.
• 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
• See “Don’t Overload Generator” on page 12.
• 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
Figure 3 — Idle Control Switch
Figure 2 — Fuel Shut-offValve

4000XL Extended Life Generator
9
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.
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 Generator” on page 12.
Stopping the Engine
1. Unplug ALL electrical loads from generator panel
receptacles. NEVER start or stop engine with electrical
devices plugged in and turned ON.
2. Move idle control switch to “Off” position.
3. Let engine run at no-load for several minutes to
stabilize internal temperatures of engine and generator.
4. Turn engine off according to instructions given in the
engine owner’s manual.
5. Move fuel valve to “Off” position.
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
electrical loads are 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
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 6 Volt batteries. DO NOT
use the unit to crank an engine having a discharged battery.
To recharge 12Volt batteries, proceed as follows:
1. Check fluid level in all battery cells. If necessary, add
ONLY distilled water to cover separators in battery
cells. DO NOT use tap water.
2. If battery is equipped with vent caps, make sure they
are installed and are tight.
3. If necessary, clean battery terminals.
4. Connect battery charge cable connector plug to panel
receptacle identified by the words “12-VOLTS D.C.”.
5. Connect battery charge cable clamp with red handle
to the positive (+) battery terminal (Figure 4).
• 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 near 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
Figure 4 — Battery Connections

10
4000XL Extended Life Generator
6. Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 4).
7. Start engine. Let engine run while battery recharges.
8. 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:
1. Make sure entire muffler-side of generator is exposed.
Note that your generator may appear different from
that shown in Figure 5.
2. Ensure a minimum of two feet clearance between
open side of box and nearest object.
3. Face exposed end away from wind and elements.
4. Enclosure should hold enough heat created by
generator to prevent problems.
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 6).
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 5 — Temporary Cold Weather Shelter
Wind
• 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).
• Remove generator from shelter when temperature is above
40°F [4°C].
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide will cause nausea,
fainting or death.
DANGER
• NEVER attempt to power a device requiring more
amperage than generator or receptacle can supply.
• DO NOT overload the generator. See “Don’t Overload
Generator”.
Receptacles may be marked with rating value greater
than generator output capacity.
CAUTION
Figure 6 — 120Volt AC, 15 Amp Duplex Receptacle

4000XL Extended Life Generator
11
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 7).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.
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 8).
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 receptacle (Figure 9) allows you to recharge a 12 Volt
automotive or utility style storage battery with the battery
charge cables provided.
This receptacle can not recharge 6 Volt batteries and can
not be used to crank an engine having a discharged battery.
See “Charging a Battery” on page 9 before attempting to
recharge a battery.This outlet is protected by a 10 Amp
self resetting circuit breaker.
Figure 7 — 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 8 — 120 Volt AC, 30 Amp, Locking Receptacle
3-Wire Cord Set
Neutral
120V
Hot
Ground (Green)
NEMA L5-30
Figure 9 — 12Volt DC, 10 Amp Receptacle

12
4000XL 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 10.
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
Planer/Jointer - 6” 1800 1800
Table Saw/Radial Arm Saw - 10” 2000 2000
Air Compressor - 1-1/2 HP 2500 2500
Figure 10 - Wattage Reference Chart

4000XL Extended Life Generator
13
SPECIFICATIONS
Maximum Surge Watts . . . . . . . . . . . . . . . . .6,600 watts
Continuous Wattage Capacity . . . . . . . . . . .4,000 watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0
Rated Maximum Continuous AC 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 U.S. gallons
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . 134 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.
Engine Maintenance
See engine owner’s manual for instructions.
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).
1. Move fuel valve to “Off” position.
2. Remove sediment cup from fuel valve. Remove o-ring,
retaining ring and screen from fuel valve (Figure 11).
3. Wash sediment cup, o-ring, retaining ring, and screen in
a nonflammable solvent. Dry them thoroughly.
4. Place screen, retaining ring, and o-ring into fuel valve.
Install sediment cup and tighten securely.
• Used motor oil has been shown to cause skin cancer in
certain laboratory animals.
• Thoroughly wash exposed areas with soap and water.
Avoid prolonged or repeated skin contact with used
motor oil.
CAUTION
WHEN ADJUSTING OR MAKING REPAIRS TOYOUR
GENERATOR
• Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.
Unintentional sparking can result in fire or
electric shock.
WARNING
Figure 11 — FuelValve Maintenance
Sediment Cup
O-ring
Retaining Ring
Screen

14
4000XL Extended Life Generator
5. Move fuel valve to “On” position, and check for leaks.
Replace o-ring if there is any leakage.
Generator Cleaning
• Use a damp cloth to wipe exterior surfaces clean.
• Use a soft bristle brush to loosen caked on dirt or oil.
• Use a vacuum cleaner to pick up loose dirt and debris.
• Use low pressure air (not to exceed 25 psi) 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 “Generator Cleaning”.
• Check that cooling air slots and openings on generator
are open and unobstructed.
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, add fuel stabilizer 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. Fuel stabilizer can be purchased locally.
• DO NOT store gasoline from one season to another
unless it has been treated as described above.
• Replace fuel container if it starts to rust. Rust and/or dirt
in fuel can cause problems if it's used with this unit.
• Store in clean and dry area.
• DO NOT expose generator to excessive moisture, dust, dirt,
or corrosive vapors.
• DO NOT insert any objects through cooling slots.
Improper treatment of generator can damage it and
shorten its life.
CAUTION
• DO NOT place a storage cover over a hot generator.
• Let equipment cool for a sufficient time before placing the
cover on the equipment.
Storage covers can be flammable.
WARNING

4000XL Extended Life Generator
15
NOTES

16
4000XL Extended Life Generator
NOTES

4000XL Extended Life Generator
17
TROUBLESHOOTING
Problem
No AC output is available, but
generator is running.
Generator runs good at no-load
but "bogs" down" when loads are
connected.
Generator will not start; or starts
and runs rough.
Generator shuts down during
operation.
Generator lacks power.
Cause
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. Short circuit in a connected load.
2. Generator is overloaded.
3. Shorted generator circuit.
Low oil level.
1. Out of gasoline.
2. Low oil level.
Load is too high.
Correction
1. Reset circuit breaker.
2. Contact Authorized service
facility.
3. Check and repair.
4. Connect another device that is in
good condition.
1. Disconnect shorted electrical
load.
2. See "Don't Overload Generator".
3. Contact Authorized service
facility.
Fill crankcase to proper level or place
generator on level surface.
1. Fill fuel tank.
2. Fill crankcase to proper level or
place generator on level surface.
See "Don't Overload Generator".

18
4000XL Extended Life Generator
SCHEMATIC

4000XL Extended Life Generator
19
WIRING DIAGRAM

20
4000XL Extended Life Generator
EXPLODED VIEW – MAIN UNIT