Generac Power Systems XP4000 Professional User manual

Owner’s
Manual
• SAFETY
• ASSEMBLY
• OPERATION
• TROUBLESHOOTING
• WARRANTY
www.generac.com
or
1-888-GENERAC
XP Professional Series
Portable Generator
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
MODELS: 005604-0 XP4000
4,000 Watt Portable Generator
AUTHORIZED DEALER SUPPORT:

Table of Contents
Portable Generator System
Owner's Manual
Introduction..............................................................................1
Read this Manual Thoroughly..................................................1
Safety Rules ............................................................................2
Standards Index.......................................................................3
Section 1 – General Information..............................................4
1.1 Unpacking................................................................................4
1.2 Assembly.................................................................................4
Section 2 – Operation..............................................................4
2.1 Know the Generator .................................................................4
2.2 Hourmeter ...............................................................................5
2.3 Cord Sets and Connection Plugs..............................................5
2.4 How to Use the Generator........................................................6
2.5 Don’t Overload the Generator ...................................................6
2.6 Wattage Reference Guide .........................................................7
2.7 Before Starting the Generator...................................................7
2.8 To Start the Engine...................................................................8
2.9 Stopping the Engine.................................................................9
2.10 Low Oil Pressure Shutdown System.........................................9
Section 3 – Maintenance.........................................................9
3.1 Maintenance Schedule .............................................................9
3.2 Product Specifications .............................................................9
3.3 General Recommendations ......................................................9
3.4 Service Air Cleaner ................................................................11
3.5 Clean Spark Arrestor Screen ..................................................11
3.6 Adjusting Valve Clearance ......................................................11
3.7 General..................................................................................12
3.8 Long Term Storage.................................................................12
3.9 Other Storage Tips.................................................................12
Section 4 – Troubleshooting ..................................................13
4.1 Troubleshooting Guide............................................................13
Section 5 – Notes ..................................................................14
Section 6 – Warranty.............................................................16
Manual del propietario ............................. 19
Introducción...........................................................................21
Lea este manual completamente...........................................21
Reglas de seguridad..............................................................22
Índice de estándares..............................................................23
Sección 1 – Información General........................................24
1.1 Desempaque..........................................................................24
1.2 Ensamble...............................................................................24
Sección 2 – Operación .......................................................24
2.1 Conozca el generador ............................................................24
2.2 Medidor de horas...................................................................25
2.3 Juego de cables y conectores................................................25
2.4 Cómo usar el generador.........................................................26
2.5 No sobrecargue el generador .................................................26
2.6 Guía de refrencia de potencias ...............................................27
2.7 Antes de arrancar el generador ..............................................27
2.8 Arranque del motor ................................................................28
2.9 Detener el Motor ....................................................................29
2.10 Sistema de apagado por baja presión de aceite......................29
Section 3 – Mantenimiento.................................................29
3.1 Programa de mantenimiento...................................................29
3.2 Especificaciones del producto................................................29
3.3 Recomendaciones generales..................................................29
3.4 Dar servicio al limpiador de aire.............................................31
3.5 Limpiar de la pantalla de supresíon de chispa ........................31
3.6 Ajuste de la claridad de la válvula...........................................31
3.7 General..................................................................................32
3.8 Almacenamiento por largo plazo ............................................32
3.9 Otros consejos para almacenamiento.....................................32
Sección 4 – Detección de problemas.................................33
4.1 Guía de detección de problemas ............................................33
Sección 5 – Garantía..........................................................34
Manuel d'entretien.................................... 37
Introduction............................................................................39
Lire attentivement ce manuel................................................39
Règles de sécurité.................................................................40
Index des normes ..................................................................41
Section 1 – Informations générales.......................................42
1.1 Déballage ..............................................................................42
1.2 Montage ................................................................................42
Section 2 – Fonctionnement..................................................42
2.1 Bien connaître le générateur...................................................42
2.2 Horomètre..............................................................................43
2.3 Cordons et connecteurs.........................................................43
2.4 Utilisation du générateur.........................................................44
2.5 Ne pas surcharger le générateur.............................................44
2.6 Guide de référence de wattage...............................................45
2.7 Avant le démarrage du générateur..........................................45
2.8 Démarrage du moteur ............................................................46
2.9 Arrêt du moteur......................................................................47
2.10 Système d'arrêt de basse pression d'huile ..............................47
Section 3 – Maintenance.......................................................47
3.1 Programme de maintenance...................................................47
3.2 Caractéristiques techniques des produits................................47
3.3 Recommandations générales .................................................47
3.4 Entretien du filtre à air ............................................................49
3.5 Nettoyage de l'écran pare-étincelles........................................49
3.6 Réglage du jeu des soupapes.................................................49
3.7 Généralités.............................................................................50
3.8 Stockage à long terme ...........................................................50
3.9 Autres conseils de stockage...................................................50
Section 4 – Dépannage..........................................................51
4.1 Guide de dépannage ..............................................................51
Section 5 – Garantie..............................................................52

INTRODUCTION
Thank you for purchasing this model by Generac Power Systems,
Inc. This model is a compact, high performance, air-cooled,
engine driven generator designed to supply electrical power to
operate electrical loads where no utility power is available or in
place of utility due to a power outage.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the
nearest Authorized Dealer for starting, operating and servicing
procedures.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
operation that may be hazardous if performed incorrectly or
carelessly. Observe them carefully. Their definitions are as
follows:
DANGER
After this heading, read instructions that, if
not strictly complied with, will result in serious
personal injury, including death and/or property
damage.
After this heading, read instructions that, if not
strictly complied with, may result in serious
personal injury and/or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements that require
special emphasis.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the service are essential to preventing
accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
This symbol points out important safety
information that, if not followed, could endanger
personal safety and/or property of others.
This symbol points out potential explosion
hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use of the
equipment. We strongly recommend that the operator read this
manual and thoroughly understand all instructions before using
the equipment.
We also strongly recommend instructing other users to properly
start and operate the unit. This prepares them if they need to
operate the equipment in an emergency.
DANGER
Using a generator indoors WILL KILL YOU IN
MINUTES. Exhaust contains carbon monoxide, a
poison gas you cannot see or smell.
NEVER use in the home, or in partly enclosed
areas such as garages. ONLY use outdoors and
far from open windows, doors, vents, and in an
area that will not accumulate deadly exhaust.
Using a generator indoors WILL KILLYOU IN MINUTES. Exhaust contains
carbon monoxide, a poison gas you cannot see or smell.
NEVER use in the home or in partly enclosed areas such as garages.
ONLY use outdoors and far from open windows, doors and vents.
DANGER
Always disconnect the spark plug wire and
place the wire where they cannot contact the
spark plug to prevent accidental starting when
setting up, transporting, adjusting or making
repairs to the generator.
The generator produces dangerously high voltage that can•
cause extremely hazardous electrical shock. Avoid contact with
bare wires, terminals, etc. Never permit any unqualified person
to operate or service the generator.
Never handle any kind of electrical cord or device while•
standing in water, while barefoot or while hands or feet are wet.
Dangerous electrical shock will result.
The National Electric Code requires the frame and external•
electrically conductive parts of the generator be properly
connected to an approved earth ground. Local electrical codes
may also require proper grounding of the generator. Consult
with a local electrician for grounding requirements in the area.
Use a ground fault circuit interrupter in any damp or highly•
conductive area (such as metal decking or steel work).
Do not use worn, bare, frayed or otherwise damaged electrical•
cord sets with the generator.
Operate generator only on level surfaces and where it will not be•
exposed to excessive moisture, dirt, dust or corrosive vapors.
Gasoline is highly• FLAMMABLE and its vapors are EXPLOSIVE.
Do not permit smoking, open flames, sparks or heat in the
vicinity while handling gasoline. Avoid spilling gasoline on
a hot engine. Comply with all laws regulating storage and
handling of gasoline.
Do not overfill the fuel tank. Always allow room
for fuel expansion. If tank is over-filled, fuel can
overflow onto a hot engine and cause FIRE or
an EXPLOSION. Never add fuel while unit is
running or hot. Allow engine to cool entirely
before adding fuel.
1

2
DANGER
Never store generator with fuel in tank where
gasoline vapors might reach an open flame,
spark or pilot light (as on a furnace, water
heater or clothes dryer). FIRE or EXPLOSION
may result. Allow unit to cool entirely before
storage.
Generator exhaust gases contain DEADLY
carbon monoxide gas. This dangerous gas,
if breathed, can cause headaches, fatigue,
diziness, vomiting, confusion, siezures, nausea,
fainting, unconsciousness or even death.
Operate this equipment only in the open air
where adequate ventilation is available.
NEVER operate the generator indoors, in a
garage, near an open window, door, ventilated
intake, crawl space, other opening, or in an area
that could accumulate exhaust gas.
Allow at least five (5) feet, or greater, of
clearance on all sides of generator to allow
for proper ventilation for personal safety and
prevent damage to the unit. Never operate the
unit inside any room or enclosure.
Never start or stop the unit with electrical loads connected• to receptacles AND with connected devices turned ON. Start
the engine and let it stabilize before connecting electrical
loads. Disconnect all electrical loads before shutting down the
generator.
Do not insert objects through unit's cooling slots.•
Never operate generator:• in rain; indoors or in any enclosed
compartment; if connected electrical devices overheat; if
electrical output is lost; if engine or generator sparks; if flames
or smoke are observed while unit is running; if unit vibrates
excessively.
Install a battery operated carbon monoxide alarm indoors,•
according to manufacturer’s instructions/recommendations.
NOTE:
This generator is equipped with a spark arrestor muffler. The
spark arrestor must be maintained in effective working order by
the owner/ operator. In the State of California, a spark arrestor
is required by law (Section 4442 of the California Public
Resources Code). Other states may have similar laws. Federal
laws apply on federal lands.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this manual
and with the unit. The generator can operate safely, efficiently and
reliably only if it is properly installed, operated and maintained.
Many accidents are caused by failing to follow simple and
fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all inclusive.
If using a procedure, work method or operating technique that the
manufacturer does not specifically recommend, ensure that it is
safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently,
neglecting its maintenance or being careless
can cause possible injury or death. Permit only
responsible and capable persons to operate or
maintain this equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators. Do not touch hot surfaces such as
the muffler. Severe burns can occur on contact.
Allow generator to cool before touching.
GENERAL HAZARDS 
Never operate in an enclosed area or indoors.•
For safety reasons, the manufacturer recommends that the• maintenance of this equipment is carried out by an Authorized
Dealer.
The engine exhaust fumes contain carbon monoxide, which• can be DEADLY. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even death. This
exhaust system must be properly maintained. Do nothing that
might render the exhaust system unsafe or in noncompliance
with any local codes and/or standards.
IMPORTANT SAFETY INSTRUCTIONS
Portable Generator System
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit's
installation site. Safety should be stressed to all operators and potential operators of this equipment.
The engine exhaust from this product contains
chemicals known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:

This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:


Keep hands, feet, clothing, etc., away from drive belts, fans, and• other moving or hot parts. Never remove any fan guard while
the unit is operating.
Adequate, unobstructed flow of cooling and ventilating air• is critical to correct generator operation. Do not alter the
installation or permit even partial blockage of ventilation
provisions, as this can seriously affect safe operation of the
generator. The generator MUST be operated outdoors.
When working on this equipment, remain alert at all times. Never• work on the equipment when physically or mentally fatigued.
Inspect the generator regularly, and contact the nearest• Authorized Dealer for parts needing repair or replacement.
Before performing any maintenance on the generator, disconnect• its battery cables to prevent accidental start up. Disconnect the
cable from the battery post indicated by a NEGATIVE, NEG or
(–) first. Reconnect that cable last.
Never use the generator or any of its parts as a step. Stepping• on the unit can stress and break parts, and may result in
dangerous operating conditions from leaking exhaust gases,
fuel leakage, oil leakage, etc.
Do NOT operate generator in the rain.•
ELECTRICAL HAZARDS 
All generators covered by this manual produce dangerous•
electrical voltages and can cause fatal electrical shock. Utility
power delivers extremely high and dangerous voltages as does
the generator when it is in operation. Avoid contact with bare
wires, terminals, connections, etc., while the unit is running.
Ensure all appropriate covers, guards and barriers are in place
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
Do not handle any kind of electrical device while standing•
in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
The National Electrical Code (NEC) requires the frame and•
external electrically conductive parts of the generator to be
connected to an approved earth ground. Local electrical codes
also may require proper grounding of the generator electrical
system.
In case of accident caused by electric shock, immediately shut•
down the source of electrical power. If this is not possible,
attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a non-conducting
implement, such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply first aid and
get immediate medical help.
Never wear jewelry when working on this equipment. Jewelry•
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
FIRE HAZARDS 
For fire safety, the generator must be operated and maintained•
properly. Operation must always comply with applicable codes,
standards, laws and regulations. Adhere strictly to local,
state and national electrical and building codes. Comply with
regulations the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the generator is
operated in accordance with the manufacturer’s instructions
and recommendations. Do not alter the construction of the
generator or change controls which might create an unsafe
operating condition.
Keep a fire extinguisher near the generator at all times.•
Extinguishers rated “ABC” by the National Fire Protection
Association are appropriate for use on the standby electric
system. Keep the extinguisher properly charged and be familiar
with its use. If there are any questions pertaining to fire
extinguishers, consult the local fire department.
Gasoline is extremely FLAMMABLE. Never add fuel while unit is•
running or hot. Avoid spilling gasoline on a hot engine. Allow
engine/unit to cool entirely before adding fuel. Do not over fill
fuel tank. Allow room for fuel expansion. Wipe up fuel spills
immediately. If tank is overfilled, fuel can overflow onto a hot
engine and cause FIRE. Never fill fuel tank indoors.
EXPLOSION HAZARDS 
Do not smoke around the generator. Wipe up any fuel or oil spills•
immediately. Ensure that no combustible materials are left on or
near the generator, as FIRE or EXPLOSION may result. Keep the
area surrounding the generator clean and free from debris.
Gasoline is extremely FLAMABLE and EXPLOSIVE.•
STANDARDS INDEX
In the absence of pertinent standards, codes, regulations and laws,
the published information listed below may be used as a guideline
for operation of this equipment. Always reference the latest revision
available for the standards listed.
1. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC
CODE.
2. Article X, NATIONAL BUILDING CODE, available from the
American Insurance Association, 85 John Street, New York,
N.Y. 10038.
3. AGRICULTURAL WIRING HANDBOOK, available from the Food
and Energy Council, 909 University Avenue, Columbia, MO
65201.
4. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF
FARM STANDBY ELECTRICAL SYSTEMS, available from the
American Society of Agricultural Engineers, 2950 Niles Road,
St. Joseph, MI 49085.
5. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS
CODE.
3
IMPORTANT SAFETY INSTRUCTIONS
Portable Generator System

4
1.1 UNPACKING
Remove all packaging material.•
Remove separate accessory box.•
Remove carton off the generator.•
1.1.1 ACCESSORY BOX
Check all contents (Figure 1). If any parts are missing or damaged
locate an authorized dealer at 1-888-436-3722.
Contents include:
2 – Axle Pins • Oil Funnel•
6 – Washers • 2 – Wheels•
2 – Cotter Pins • Extension Cord•
Spark Plug •• Spark Plug Wrench
Air Filter • Shop Towel•
Oil Filter • 1 Quart SAE 30 Oil Bottle•
Figure 1 – Accessory Boxes
1.2 ASSEMBLY
Read entire Owner's Manual before attempting to assemble or
operate the generator. The generator requires some assembly
prior to using it. If problems arise when assembling the generator,
please call the Generator Helpline at 1-888-436-3722.
1.2.1 ASSEMBLING THE WHEEL KIT
The wheel kit is designed to greatly improve the portability of the
generator. A pair of pliers is needed for assembling the wheel kit.
NOTE:
The wheel kit is not intended for over-the-road use.
Refer to Figure 2 and install the wheel kit as follows:•
Generator will be resting on an accessory box after box is cut•
back.
Open end of accessory box to remove contents.•
Slide the axle through the holes on the axle brackets.•
Slide one wheel with flat washer to the outside.•
Insert retaining pin and using pliers, bend out the ends to•
prevent the pins from falling out of the axle. Repeat for other
side.
Lift the engine side of the generator to pull out the insert.•
Figure 2 – Wheel Assembly
Flat Washer
Cotter Pin
Wheel
Axle
2.1 KNOW THE GENERATOR
Read the Owner’s Manual and Safety Rules before operating
this generator.
Compare the generator to Figures 3 through 5 to become
familiarized with the locations of various controls and adjustments.
Save this manual for future reference.
1. 120 Volt AC, 20 Amp, GFCI Duplex Receptacle – Supplies
electrical power for the operation of 120 Volt AC, 20 Amp,
single-phase, 60 Hz electrical lighting, appliance, tool and
motor loads. It also provides protection with an Integral
Ground Fault Circuit Interrupter, complete with a press to
"Test" and "Reset" button.
2. 120/240 Volt AC, 20 Amp Locking Receptacle – Supplies
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.
Figure 3 - Control Panel
12
3
4
5
7
Section 1 – General Information
Portable Generator System

55
3. Circuit Breakers (AC) – Each 20 Amp GFCI receptacle and
the 20 Amp Twistlock receptacle, is protected by a 2-pole
lever circuit breaker rated at 20 Amps to protect the generator
against electrical overload.
4. Hourmeter – Provides operating hours for Service Intervals.
5. Fuel Shut Off – Valve between fuel tank and carburetor. Turn
off and run carburetor out of fuel for extended storage.
6. Choke – Used when starting a cold engine.
7. Run/Stop Switch – Controls the operation of the generator.
8. Air Cleaner – Filters intake air as it is drawn into the engine.
9. Fuel Tank – Tank holds 5 U.S. gallons of fuel.
10. Grounding Lug – Ground the generator to an approved earth
ground here. See "Grounding the Generator" for details.
11. Muffler – Includes the spark arrestor and quiets the engine.
12. Handles – Pivot and retract for storage. Press the spring-
loaded button to move handles.
13. Gas Cap – Fuel fill location.
14. Fuel Gauge – Shows fuel level in tank.
15. Oil Fill – Check oil level and add oil here.
Figure 4 - Generator Controls
10
11
17
Figure 5 - Generator Controls
8
9
12
13
14
16
6
15
16. Recoil Starter – Use to start engine manually.
17. Spark Plug – Ignites Air/Fuel Mixture (Side panel removed - 4
Torx Screws "T27").
2.2 HOURMETER
The Hourmeter tracks hours of operation for scheduled
maintenance:
There will be a subsequent "CHG OIL" message every 100 hours.
The message will flash one hour before and one hour after each
100 hour interval, again providing a two hour window to perform
service.
Every 200 hours the "SVC" icon on the lower left hand corner of
the display will flash. The message will flash one hour before and
one hour after each 200 hour interval providing a two hour window
to perform service.
When the hour meter is in the Flash Alert mode, the maintenance
message will always alternate with elapsed time in hours and
tenths. The hours will flash four times, then alternate with the
maintenance message four times until the meter resets itself.
100 hours - CHG OIL — Oil Change Interval (Every 100 hrs)•
200 hours - SVC — Air Filter Interval (Every 200 hrs)•
2.3 CORD SETS AND CONNECTION PLUGS
2.3.1 120 VAC, 20 AMP, GFCI DUPLEX RECEPTACLE
This is a 120 Volt outlet protected against overload by a 20 Amp
push-to-reset circuit breaker (Figure 6). Use each socket to power
120 Volt AC, single phase, 60 Hz electrical loads requiring up to a
combined 2400 watts (2.4 kW) or 20 Amps of current. Use only
high quality, well-insulated, 3-wire grounded cord sets rated for
125 Volts at 20 Amps (or greater).
Keep extension cords as short as possible to prevent voltage drop
and possible overheating of wires.
Figure 6 - 120 Volt AC, 20 Amp, GFCI Duplex Receptacle
Section 2 – Operation
Portable Generator System

6
Section 2 – Operation
Portable Generator System
2.3.2 120/240 VAC, 20 AMP RECEPTACLE
Use a NEMA L14-20 plug with this receptacle (rotate to lock/
unlock). Connect a suitable 4-wire grounded cord set to the plug
and to the desired load. The cord set should be rated for 250 Volts
AC at 20 Amps (or greater) (Figure 7).
Figure 7 - 120/240 VAC, 20 Amp Receptacle
Use this receptacle to operate 120 Volt AC, 60 Hz, single phase
loads requiring up to 2400 watts (2.4 kW) of power at 20 Amps
or 240 Volt AC, 60 Hz, single phase loads requiring up to 4000
watts (4.0 kW) of power at 16.6 Amps. The outlet is protected by
a circuit breaker.
2.4 HOW TO USE THE GENERATOR
If there are any problems operating the generator, please call the
generator helpline at 1-888-436-3722.
2.4.1 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 bonded to the AC neutral wire
in the generator control panel via a jumper wire.
2.4.1.1 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.
2.4.1.2 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 or other alternative
power sources and must comply with all applicable laws and
electrical codes.
2.4.2 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 (Figure 9).
Local electrical codes may also require proper grounding of the
unit. For that purpose, connecting a No. 10 AWG (American Wire
Gauge) stranded copper wire to the grounding lug and to an
earth-driven copper or brass grounding rod (electrode) provides
adequate protection against electrical shock. However, local codes
may vary widely. Consult with a local electrician for grounding
requirements in the area.
Figure 9 - Grounding the Generator
Proper grounding of the generator will help prevent electrical
shock in the event of a ground fault condition in the generator
or in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in ungrounded
devices.
2.4.3 CONNECTING ELECTRICAL LOADS
DO NOT connect 240 Volt loads to 120 Volt receptacles. DO NOT
connect 3-phase loads to the generator. DO NOT connect 50 Hz
loads to the generator.
Let engine stabilize and warm up for a few minutes after•
starting.
Plug in and turn on the desired 120 or 240 Volt AC, single•
phase, 60 Hz electrical loads.
Add up the rated watts (or amps) of all loads to be connected•
at one time. This total should not be greater than (a) the rated
wattage/amperage capacity of the generator or (b) circuit
breaker rating of the receptacle supplying the power. See "Don't
Overload the Generator".
2.5 DON’T OVERLOAD THE GENERATOR
Overloading a generator in excess of its rated wattage capacity
can result in damage to the generator and to connected electrical
devices. Observe the following to prevent overloading the unit:
Add up the total wattage of all electrical devices to be connected•
at one time. This total should NOT be greater than the
generator's wattage capacity.

7
The rated wattage of lights can be taken from light bulbs. The•
rated wattage of tools, appliances and motors can usually be
found on a data label or decal affixed to the device.
If the appliance, tool or motor does not give wattage, multiply•
volts 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 only a few seconds when starting
such motors. Make sure to allow for high starting wattage when
selecting electrical devices to connect to the generator:
1. Figure the watts needed to start the largest motor.
2. Add to that figure the running watts of all other connected
loads.
The Wattage Reference Guide is provided to assist in determining
how many items the generator can operate at one time.
NOTE:
All figures are approximate. See data label on appliance for
wattage requirements.
2.6 WATTAGE REFERENCE GUIDE
Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Running Watts
*Air Conditioner (12,000 Btu) . . . . . . . . . . . . . . . . . . . . . . . . . . 1700
*Air Conditioner (24,000 Btu) . . . . . . . . . . . . . . . . . . . . . . . . . . 3800
*Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . . . . . . . . . . . 6000
Battery Charger (20 Amp). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Chain Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Circular Saw (6-1/2") . . . . . . . . . . . . . . . . . . . . . . . . . . .800 to 1000
*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5750
*Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1150
Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750
*Compressor (1 HP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400
Curling Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
*Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650
Disc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Electric Range (per element). . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250
*Freezer . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..700
*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875
*Garage Door Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 to 750
Hair Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 1100
Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800
Lawn Mower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Microwave Oven. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 to 1000
*Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100
Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . . . . . . . . . . . . 400
Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . . . . . . . . . . . . 225
Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . . . . . . . . . . . . 150
*Paint Sprayer, Airless (1/3 HP) . . . . . . . . . . . . . . . . . . . . . . . . . 600
Paint Sprayer, Airless (handheld). . . . . . . . . . . . . . . . . . . . . . . . . 150
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 200
*Refrigerator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
Slow Cooker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
*Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . 2800
*Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
*Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
*Sump Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 to 1050
*Table Saw (10") . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1750 to 2000
Television . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 to 500
Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 to 1650
Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
* Allow 3 times the listed watts for starting these devices.
2.7 BEFORE STARTING THE GENERATOR
Prior to operating the generator, engine oil and gasoline will need
to be added, as follows:
2.7.1 ADDING ENGINE OIL
All oil should meet minimum American Petroleum Institute (API)
Service Class SJ, SL or better. Use no special additives. Select
the oil's viscosity grade according to the expected operating
temperature (also see chart).
Above 40° F, use SAE 30•
Below 40° F and down to 10° F, use 10W-30•
Below 10° F, use synthetic 5W-30•
Any attempt to crank or start the engine before
it has been properly serviced with the
recommended oil may result in an engine
failure.
10W-30
10W-30
SAE 30
SA E 30
Synthetic 5W-30
Synthetic 5W-30
Place generator on a level surface.•
Clean area around oil fill and remove oil fill cap.•
Section 2 – Operation
Portable Generator System

8
Slowly fill engine with oil through the oil fill opening until it•
reaches the full mark. Stop filling occasionally to check oil
level. (Engine oil is full when level is up to the threads of the
oil fill plug.)
Install oil fill cap and finger tighten securely.•
Check engine oil level before starting each time thereafter.•
2.7.2 ADDING GASOLINE
DANGER
Never fill fuel tank indoors. Never fill fuel tank
when engine is running or hot. Avoid spilling
gasoline on a hot engine. Allow engine to cool
entirely before filling fuel tank. DO NOT light a
cigarette or smoke when filling the fuel tank.
Do not overfill the fuel tank. Always leave room
for fuel expansion. If the fuel tank is overfilled,
fuel can overflow onto a hot engine and cause
FIRE or EXPLOSION. Wipe up any spilled fuel
immediately.
Do not light a cigarette ro smoke whin filling the
fuel tank. Gasoline is highly FLAMMABLE and
its vapors are EXPLOSIVE.
Use regular UNLEADED gasoline with the generator engine. Do•
not use premium gasoline. Do not mix oil with gasoline.
Do not use gasoline with more than 10% alcohol such as E85•
or Methanol.
Clean area around fuel fill cap, remove cap.•
Slowly add unleaded regular gasoline to fuel tank. Fill to bottom•
of screen filter. Be careful not to overfill (Figure 9).
Install fuel cap and wipe up any spilled gasoline.•
Figure 9 - Fuel Tank
DO NOT Fill Above Lip
Fuel
Fuel Tank
IMPORTANT: It is important to prevent gum deposits from forming
in fuel system parts such as the carburetor, fuel hose or tank
during storage. Alcohol-blended fuels (called gasohol, ethanol
or methanol) can attract moisture, which leads to separation and
formation of acids during storage. Acidic gas 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 the "Storage" section. Never use engine or carburetor
cleaner products in the fuel tank as permanent damage may
occur.
2.8 TO START THE ENGINE
Never start or stop engine with electrical
devices plugged into the receptacles AND
devices turned on.
Unplug all electrical loads from the unit's receptacles before•
starting the engine.
Make sure the unit is in a level position.•
Open the fuel shut-off valve (Figure 10).•
Figure 10 - Fuel Shut-off Valve
Slide engine CHOKE knob outward to• “Full Choke” position
(Figure 11).
Figure 11 - Choke Position
NOTE:
The switch must be in the RUN position.
To start manually, firmly grasp the recoil handle and pull slowly•
until increased resistance is felt. Pull rapidly up and away to
start engine. Then follow the same choke sequence listed
above.
When the engine starts, slide choke knob to “1/2 Choke”•
position until the engine runs smoothly and then fully in to the
“Run” position. If engine falters, slide choke knob back out to
“1/2 Choke” position until the engine runs smoothly and then
to “Run” position.
Section 2 – Operation
Portable Generator System

9
NOTE:
If engine fires, but does not continue to run, pull choke knob to
“Full Choke” and repeat starting instructions.
IMPORTANT: Do not overload the generator. Also, do not overload
individual panel receptacles. These outlets are protected against
overload with push-to-reset-type circuit breakers. If amperage
rating of any circuit breaker is exceeded, that breaker opens and
electrical output to that receptacle is lost. Read “Don’t Overload the
Generator” carefully.
2.9 STOPPING THE ENGINE
Shut off all loads, then unplug the electrical loads from generator•
panel receptacles. Never start or stop the engine with electrical
devices plugged in and turned on.
Let engine run at no-load for several minutes to stabilize the•
internal temperatures of engine and generator.
MoveRun/Stop switch to “Off” position.•
Close fuel valve.•
2.10 LOW OIL PRESSURE SHUTDOWN SYSTEM
The engine is equipped with a low oil pressure sensor that shuts
down the engine automatically when the oil pressure drops below
5 psi. If the engine shuts down by itself and the fuel tank has
enough gasoline, check engine oil level.
2.10.1 INITIAL START-UP
A delay built into the low oil shutdown system allows oil pressure
to build during starting. The delay allows the engine to run for
about 10 seconds before sensing oil pressure.
2.10.2 SENSING LOW OIL PRESSURE
If the system senses low oil pressure during operation, the engine
shuts down.
2.10.3 RESTARTING
If trying to restart the engine within 10 seconds after it shuts down,
the engine may NOT start. The system needs 5 to 10 seconds to
reset.
If the engine is restarted after such a shutdown and the low oil
pressure has not been corrected, the engine will run for about 10
seconds as described above and then stop.
3.1 MAINTENANCE SCHEDULE
Follow the calendar intervals. More frequent service is required
when operating in adverse conditions noted below.
Check Oil Level At Each Use
Change Oil and Oil Filter‡ *Every Season/Every 100 Hours
Clean Spark Arrestor Screen Every Season
Check Valve Clearance ***Every Season/Every 100 Hours
Service Air Cleaner **Every Season/Every 200 Hours
Replace Spark Plug Every Season
‡ Change oil after first 30 hours of operation then every season.
* Change oil and oil filter every month when operating under heavy load or in high
temperatures.
** Clean more often under dirty or dusty operating conditions. Replace air cleaner
parts if very dirty.
*** Check valve clearance and adjust if necessary after first 50 hours of
operation and every 100 hours thereafter.
3.2 PRODUCT SPECIFICATIONS
3.2.1 GENERATOR SPECIFICATIONS
Model #.................................................................................005604-0
Rated Max. Power...................................................................4.0 kW**
Surge Power...............................................................................5.0 kW
Rated AC Voltage ......................................................................120/240
Rated Max AC Load
Current @ 240V.............................................................16.6 Amps**
Current @ 120V.............................................................33.3 Amps**
Rated Frequency .................................................... 60 Hz @ 3600 RPM
Phase ................................................................................Single Phase
** Maximum wattage and current are subject to, and limited by, such factors
as fuel Btu content, ambient temperature, altitude, engine condition, etc..
Maximum power decreases about 3.5% for each 1,000 feet above sea level;
and will also decrease about 1% for each 6° C (10° F) above 16° C (60° F)
ambient temperature.
3.2.2 ENGINE SPECIFICATIONS
Rated Horsepower @ 3600 RPM.........................................................6
Displacement............................................................................216.5cc
Spark Plug Type...................................Champion RC14YC or Equivalent
Spark Plug Gap............................................... 0.030 inch or (0.76 mm)
Gasoline Capacity ............................................................ 5 U.S. gallons
Oil Type....................................See Chart in "Adding Engine Oil" Section
Oil Capacity ................................................ w/ Filter Change = 0.8 Qts.
Run Time/Fuel Consumption-1/2 Load
4 kW ................................................. 14 Hours / .35 gallons per hour
Class II Emission Certified
3.3 GENERAL RECOMMENDATIONS
The warranty of the generator does not cover items that have been
subjected to operator abuse or negligence. To receive full value
from the warranty, the operator must maintain the generator as
instructed in this manual.
Some adjustments will need to be made periodically to properly
maintain the generator.
All adjustments in the Maintenance section of this manual should
be made at least once each season. Follow the requirements in the
"Maintenance Schedule".
NOTE:
Once a year replace the spark plug and replace the air filter.
A new spark plug and clean air filter assure proper fuel-air
mixture and help the engine run better and last longer.
9
Section 3 — Maintenance
Portable Generator System

10
3.3.1 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.
Check the cleanliness of the generator frequently and clean when
dust, dirt, oil, moisture or other foreign substances are visible on
its exterior surface.
Never insert any object or tool through the air
cooling slots, even if the engine is not running.
NOTE:
DO NOT use a garden hose to clean generator. Water can enter
the engine fuel system and cause problems. In addition, if water
enters the generator through cooling air slots, some water will
be retained in voids and crevices 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.
3.3.2 TO CLEAN THE GENERATOR
Use a damp cloth to wipe exterior surfaces clean.•
A soft, bristle brush may be used to loosen caked on dirt, oil,• etc.
A vacuum cleaner may be used to pick up loose dirt and• debris.
Low pressure air (not to exceed 25 psi) may be used to• blow away dirt. Inspect cooling air slots and openings
on the generator. These openings must be kept clean and
unobstructed.
3.3.3 ENGINE MAINTENANCE
DANGER
When working on the generator, always
disconnect negative cable from battery. Also
disconnect spark plug wires from spark plug
and keep wire away from spark plug.
3.3.4 CHECKING OIL LEVEL
See the “BEFORE STARTING THE GENERATOR” section for
information on checking the oil level. The oil level should be
checked before each use, or at least every eight hours of operation.
Keep the oil level maintained.
3.3.5 CHANGING THE OIL AND OIL FILTER
Change the oil and filter after the first 30 hours of operation.
Change the oil every 100 hours or every season thereafter. If
running this unit under dirty or dusty conditions, or in extremely
hot weather, change the oil more often.
Hot oil may cause burns. Allow engine to cool
before draining oil. Avoid prolonged or repeated
skin exposure with used oil. Thoroughly wash
exposed areas with soap.
NOTE:
Whenever possible, run engine for approximately 5 minutes to
get the engine oil hot. This will aid in draining the oil.
Use the following instructions to change the oil while the engine
is still warm:
Clean area around oil drain plug.•
Remove oil drain plug from engine and oil fill plug to drain oil• completely into a suitable container.
When oil has completely drained, install oil drain plug and• tighten securely.
Place a suitable container beneath the oil filter and turn• filter counterclockwise to remove. Discard according to local
regulations.
Coat gasket of new filter with clean engine oil. Turn filter• clockwise until gasket contacts lightly with filter adapter. Then
tighten an additional 3/4 turn.
Fill oil sump with recommended oil. (See “Before Starting the• Generator” for oil recommendations).
Wipe up any spilled oil.•
Dispose of used oil at a proper collection center.•
3.3.6 REPLACING THE SPARK PLUG
Use Champion RC14YC spark plug or equivalent. Replace the
plug once each year. This will help the engine start easier and
run better.
1. Stop the engine and pull the spark plug wire off of the spark
plug.
2. To gain access, remove the four (4) Torx screws "T27" and
take off side panel.
3. Clean the area around the spark plug and remove it from the
cylinder head.
4. Set the spark plug's gap to .76 mm (0.030 in.). Install the
correctly gapped spark plug into the cylinder head (Figure
12).
5. Push the boot firmly on the spark plug and install side panel.
Figure 12 - Spark Plug Gap
Section 3 — Maintenance
Portable Generator System

11
3.4 SERVICE AIR CLEANER
The engine will not run properly and may be damaged if using a
dirty air cleaner. Clean or replace the air cleaner paper filter every
200 hours or once a year (Figure 13). Clean or replace more often
if operating under dusty conditions.
To clean or replace paper air filter:
Remove air cleaner cover; then remove foam pre-filter (service•
if necessary) and remove paper filter.
Clean paper filter by tapping it gently on a solid surface. If the•
filter is too dirty, replace it with a new one. Dispose of the old
filter properly.
Clean air cleaner cover then slip pre-cleaner over filter. Next•
insert new paper filter into the base of the air cleaner. Re-install
air cleaner cover.
Figure 13 - Air Cleaner
Base
Cover
Filter
NOTE:
To order a new air filter, please contact the nearest authorized
service center at 1-888-436-3722.
3.5 CLEAN SPARK ARRESTOR SCREEN
The engine exhaust muffler has a spark arrestor screen. Inspect
and clean the screen at least once each year (Figure 14). If unit is
used regularly, inspect and clean more often.
NOTE:
If using the generator on any forest-covered, brush-covered
or grass-covered unimproved land, it must equipped with a
spark arrestor. The spark arrestor must be maintained in good
condition by the owner/operator.
Clean and inspect the spark arrestor when the engine is at
ambient temperature as follows:
Remove muffler heat shield from muffler by removing the four•
screws.
Remove spark arrestor from muffler by removing the four•
screws.
Inspect screen and replace if torn, perforated or otherwise•
damaged. DO NOT USE a defective screen. If screen is not
damaged, clean it with commercial solvent.
Replace the spark arrestor and muffler heat shield.•
Figure 14 - Spark Arrestor
Heat Shield
Spark Arrestor
3.6 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, adjust the valve clearance in
the engine.
When adjusting valve clearance, the engine should be at room
temperature and the piston should be at Top Dead Center (TDC)
of its compression stroke (both valves closed). Correct clearance
is 0.001-0.003 inch (0.03-0.07mm). Adjust valve clearance as
follows:
1. Loosen the rocker arm jam nut. Use an allen wrench to turn
the pivot ball stud while checking clearance between the
rocker arm and the valve stem with a feeler gauge (Figure
15).
Figure 15 — Adjusting Valve Clearance
FEELER GAUGE
ALLEN WRENCH
Section 3 — Maintenance
Portable Generator System

12
2. When valve clearance is correct, hold the pivot ball stud with
the allen wrench and tighten the rocker arm jam nut with a
crows foot. Tighten the jam nut to 65-85 inch-pounds torque.
After tightening the jam nut, recheck valve clearance to make
sure it did not change (Figure 16).
Figure 16 — Tightening Jam Nut
CROW'S
FOOT
3.7 GENERAL
The generator should be started at least once every seven days and
be allowed to run at least 30 minutes. If this cannot be done and
the unit must be stored for more than 30 days, use the following
information as a guide to prepare it for storage.
DANGER
NEVER store engine with fuel in tank indoors
or in enclosed, poorly ventilated areas where
fumes may reach an open flame, spark or pilot
light as on a furnace, water heater, clothes dryer
or other gas appliance.
Allow unit to cool entirely before storage.
3.8 LONG TERM STORAGE
It is important to prevent gum deposits from forming in essential
fuel system parts such as the carburetor, 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
gas 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, as follows:
Remove all gasoline from the fuel tank.•
DANGER
Drain fuel into approved container outdoors,
away from open flame. Be sure engine is cool.
Do not smoke in the vicinity or light a cigarette.
Start and run engine until engine stops from lack of fuel.•
While engine is still warm, drain oil from crankcase. Refill with•
recommended grade.
Remove spark plugs and pour about 1/2 ounce (15 ml) of•
engine oil into the cylinders. Cover spark plug hole with rag.
Pull the recoil starter a couple times to lubricate the piston rings
and cylinder bore.
Avoid spray from spark plug holes when
cranking engine.
Install and tighten spark plugs. Do not connect spark plug•
wires.
Clean the generator outer surfaces. Check that cooling air slots•
and openings on generator are open and unobstructed.
Store the unit in a clean, dry place.•
3.9 OTHER STORAGE TIPS
Do not store gasoline from one season to another.•
Replace the gasoline can if it starts to rust. Rust and/or dirt in•
the gasoline will cause problems with the carburetor and fuel
system.
If possible, store the unit indoors and cover it to give protection•
from dust and dirt. BE SURE TO EMPTY THE FUEL TANK.
If it is not practical to empty the fuel tank and the unit is to be•
stored for some time, use a commercially available fuel stabilizer
added to the gasoline to increase the life of the gasoline.
Cover the unit with a suitable protective cover that does not•
retain moisture.
DANGER
NEVER cover the generator while engine and
exhaust area are warm. Allow unit to cool
entirely.
Section 3 — Maintenance
Portable Generator System

13
4.1 TROUBLESHOOTING GUIDE
PROBLEM CAUSE CORRECTION
Engine is running, but no AC output
is available.
1. Circuit breaker is open.
2. Poor connection or defective cord set.
3. Connected device is bad.
4. Fault in generator.
5. GFCI trips the 20 Amp outlets.
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in good condition.
4. Contact Authorized Service Facility.
5. Repair the "short" and reset the GFCI.
Engine runs good but bogs down
when loads are connected.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator” .
3. Contact Authorized Service Facility.
4. Contact Authorized Service Facility.
Engine will not start; or starts and
runs rough.
1. Fuel shut-off is OFF.
2. Dirty air cleaner.
3. Out of gasoline.
4. Stale gasoline.
5. Spark plug wire not connected to spark plug.
6. Bad spark plug.
7. Water in gasoline.
8. Over-choking.
9. Low oil level.
10. Excessive rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
1. Turn Fuel shut-off ON.
2. Clean or replace air cleaner.
3. Fill fuel tank.
4. Drain fuel tank and fill with fresh fuel.
5. Connect wire to spark plug.
6. Replace spark plug.
7. Drain fuel tank; fill with fresh fuel.
8. Put choke knob to No Choke position.
9. Fill crankcase to proper level.
10. Contact Authorized Service Facility.
11. Contact Authorized Service Facility.
12. Contact Authorized Service Facility.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Authorized Service Facility.
Engine lacks power. 1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. See “Don’t Overload the Generator”.
2. Replace air filter.
3. Contact Authorized Service Facility.
Engine “hunts” or falters. 1. Choke is opened too soon.
2. Carburetor is running too rich or too lean.
1. Move choke to halfway position until engine runs
smoothly.
2. Contact Authorized Service Facility.
Section 4 — Troubleshooting
Portable Generator System

14
Section 5 — Notes
Portable Generator System

15
Section 5 — Notes
Portable Generator System

16
Section 6 – Warranty
Portable Generator System
FEDERAL EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the
Emission Control System warranty on your new 2008 and later equipment. New equipment that use small spark-ignited engines
must be designed, built, and equipped to meet stringent anti-smog standards for the federal government. Generac will warrant
the emission control system on your generator for the period of time listed below provided there has been no abuse, neglect,
unapproved modification or improper maintenance of your equipment.
Your emission control system may include parts such as the: carburetor, ignition system, fuel system, catalytic converter, and other
associated emission-related components (if equipped).
MANUFACTURER’S WARRANTY COVERAGE:
This emission control system is warranted for two years. If, during such warranty period, any emission-related part on your
equipment is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac
Authorized Warranty Service Dealer.
OWNER'S WARRANTY RESPONSIBILITIES:
As the generator owner, you are responsible for the completion of all required maintenance as listed in your factory supplied
Owner's Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your
generator, but Generac cannot deny warranty solely due to the lack of receipts.
As the generator owner, you should be aware that Generac may deny any and/or all warranty coverage or responsibility if your
generator, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or
the use of counterfeit and/or "grey market" parts not made, supplied or approved by Generac.
You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs. The warranty
repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer. To
locate the Generac Authorized Warranty Service Dealer nearest you, call our toll free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty
(ECS Warranty), which is provided to you by Generac pursuant to federal law. See also the "Generac Limited Warranties for
Generac Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by Generac. Note that this
warranty shall not apply to any incidental, consequential or indirect damages caused by defects in materials or workmanship or
any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties, expressed or implied.
Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Some states do not
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
The ECS Warranty applies only to the emission control system of your new equipment. If there is any conflict in terms between the
ECS Warranty and the Generac Warranty, the Generac Warranty shall apply. Both the ECS Warranty and the Generac Warranty
describe important rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service,
evidence must be presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following
address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Part 1
Part No. 0H1911 Rev. A 01/09

17
17
Section 6 – Warranty
Portable Generator System
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS warranty) for equipment using small spark-ignited engines:
(a) Applicability: This warranty shall apply to equipment that uses small off-road engines. The ECS Warranty period shall begin
on the date the new equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24
consecutive months thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or
equipment and to each subsequent purchaser/owner that the ECS when installed was:
(1) Designed, built and equipped so as to conform with all applicable regulations; and
(2) Free from defects in materials and workmanship which cause the failure of a warranted part at any time during the ECS
Warranty Period.
(c) The warranty on emissions-related parts will be interpreted as follows:
(1) Any warranted part that is not scheduled for replacement as required maintenance in the Owner's Manual shall be
warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or
replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall
be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted
for the ECS Warranty Period. A statement in the Owner’s Manual to the effect of "repair or replace as necessary" shall not
reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the
remainder of the ECS Warranty Period.
(3) Any warranted part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted
for the period of time prior to first scheduled replacement point for that part. If the part fails prior to the first scheduled
replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-
related part repaired or replaced under the ECS warranty shall be warranted for the remainder of the period prior to the
first scheduled replacement point for that part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge
to the owner at a Generac Authorized Warranty Service Facility.
(5) Notwithstanding the provisions of subsection (4) above, warranty services or repairs must be provided at Generac
Authorized Service Facilities.
(6) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held
responsible for diagnostic costs if the repair is deemed warrantable.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to
meet the expected demand for such parts.
(8) Any Generac authorized and approved emission-related replacement parts may be used in the performance of any ECS
warranty maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce
Generac ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or "grey market" parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac
shall not be held liable hereunder for failures of any warranted parts of Generac equipment caused by the use of such an
unapproved, add-on, modified, counterfeit and/or "grey market" part.
EMISSION RELATED PARTS MAY INCLUDE THE FOLLOWING (IF EQUIPPED):
1) FUEL METERING SYSTEM
A. CARBURETOR AND INTERNAL PARTS
B. PRESSURE REGULATOR
2) AIR INDUCTION SYSTEM
A. INTAKE MANIFOLD
B. AIR FILTER
3) IGNITION SYSTEM
A. SPARK PLUGS
B. IGNITION COILS / MODULE
4) AIR INJECTION SYSTEM
A. PULSE AIR VALVE
5) EXHAUST SYSTEM
A. CATALYST
B. THERMAL REACTOR
C. EXHAUST MANIFOLD
Part 2
Part No. 0H1911 Rev. A 01/09

Section 6 – Warranty
Portable Generator System
Manual Part No. 0H0575 Revision C (05/14/09) Printed in U.S.A.
GENERAC POWER SYSTEMS “THREE YEAR” LIMITED WARRANTY FOR
XP SERIES PORTABLE GENERATORS
For a period of three years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its XP Series generators will be free from defects in materials and
workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a
Generac Authorized Warranty Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the
nearest Generac Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/
owner. This warranty applies only to Generac XP Series portable generators and is not transferable from original purchaser. Save your proof-of-purchase receipt. If you do not
provide proof of the initial purchase date, the manufacturer’s shipping date of the product will be used to determine the warranty period.
WARRANTY SCHEDULE
Consumer applications are warranted for three (3) years. Commercial and Rental applications are warranted for two (2) years or 1500 hours maximum, whichever comes first.
CONSUMER APPLICATION
YEARS ONE and TWO - 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):
• Engine- All Components
• Alternator- All Components
YEAR THREE- 100% (one hundred percent) coverage on Part(s) listed (proof of purchase and maintenance is required):
• Engine- All Components
• Alternator- All Components
COMMERCIAL/RENTAL APPLICATION
YEARS ONE and TWO – 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):
• Engine- All Components
• Alternator- All Components
NOTE: For the purpose of this warranty “consumer use” means personal residential household or recreational use by original purchaser. This warranty does not apply to
units used for Prime Power in place of utility where utility power service is present or where utility power service does not normally exist. Once a generator has
experienced commercial or rental use, it shall thereafter be considered a non-consumer use generator for the purpose of this warranty.
All warranty expense allowances are subject to the conditions defined in Generac’s Warranty Policies, Procedures and Flat Rate Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
Generac portable generators that utilize non-Generac replacement parts.•
Costs of normal maintenance and adjustments.•
Failures caused by any contaminated fuels, oils or lack of proper oil levels.•
Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac Power Systems.•
Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper use. As with all mechanical devices, the Generac engines need periodic•
part(s) service and replacement to perform as designed. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.
Failures caused by any act of God and other force majeure events beyond the manufactures control.•
Damage related to rodent and/or insect infestation.•
Products that are modified or altered in a manner not authorized by Generac in writing.•
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).•
Failure due to misapplication.•
Telephone, cellular phone, facsimile, internet access or other communication expenses.•
Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.•
Expenses related to “customer instruction” or troubleshooting where no manufacturing defect is found.•
Rental equipment used while warranty repairs are being performed.•
Overnight freight or special shipping costs for replacement part(s).•
Overtime, holiday or emergency labor.•
Starting batteries, fuses, light bulbs and engine fluids.•
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO
THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties which are allowed by law, shall be limited in duration to the terms of the express
warranty provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to purchaser/owner.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC POWER SYSTEMS
BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply to purchaser/owner. Purchaser/owner
agrees to make no claims against Generac Power Systems, Inc. based on negligence. This warranty gives purchaser/owner specific legal rights. Purchaser/owner also may
have other rights that vary from state to state.
GENERAC POWER SYSTEMS, INC.
P.O. BOX 8 • Waukesha, WI 53187
Ph: (888) GENERAC (436-3722) • Fax: [phone]
To locate the nearest Authorized Dealer visit our website www.generac.com
Part No. 0G9452 Revision B (01/09/09) Printed in U.S.A.