Generac 4000EXL Owner's Manual

Before usingthis produce,read [hismanuaHand foHHowaHH

Safety RuHesand Operating Instructions,

Questions_ Help is iust a moment away!

Vous avez des questions_Vous n'avez pas besoin d'aller loin pour trouver de I'aide!

CaHH:Generac C;enerator Hempmine/ Appemez mamigned'assistance de C;enerac Motor ° m°so@°27o°m4@8 H-F 8-5 CT

Oenerac Portable Products is a licensed trademark of Briggs & Stratton Power Products,

Generac Portable Products est une marque d6pos6ee autoris_e de Briggs & Stratton Power Products,

BRJGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WiSCONSiN, LLSoAo

Avant d'utiHiser ce produi[, veuiHHezHireHemanueHe[ suivre routes Hesdirectives rehcives _ Has6curit6 et _ H'utiHisation.

TABLE OF CONTENTS

Safety RuHes .................................. 2:4

Know Your Generator ........................... S

AssembHy .................................... 6-7

Operation .................................. 8- H4

Product Specifications ........................... H5

Maintenance ................................ HS-H6

Storage ...................................... H6

Troubleshooting ............................... H7

Notes ....................................... H8

V_/arranty ..................................... H9

EQUmPNENT

Read this manuam carefummyand become famimiar

....... with your generator. Know its appmications, its

mimitations _d any h_ds invomved°

This generator is an engine-driven, revoHving fieHd, alternating current (AC) generator. It was designed to

suppHy eHectricaH power for operating compatibHe eHectricaH Highting, appHiances, tooHs and motor Hoads.The generator's

revolving fieHd is driven at about 3_600 rpm by a singHe- cyHinder engine.

CAUTION! DO NOT exceed the generator's wattage/amperage capacity. See "Don't Overload

Generator*'.

Every effort has been made to ensure that information in

this manuaHisaccurate 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 ControH System for this generator is

warranted for standards set by the Environmental

Protection Agency. For warranty information refer to the

engine owner's manuaH.

SAFETY RULES

This is the safety amert symbom, mtis used to amert you to potentiam personam iniuryhazards. Obey atomsafety messages that fommowthis symbol to avoid possible injuryor death.

The safety aHert symboH (_k) is used with a signaHword

(DANGER, CAUTION,WARNING), a pictoriaH and/or a safety message to aHert you to hazards. DANGER indicates

a hazard which, if not avoided, will resuHtin death or

serious injury. WARNmNG indicates a hazard which, if not

avoided, could resuHt in death or serious injury.

CAUTmON indicates a hazard which, if not avoided, might resuHt in minor or moderate injury. CAUTmON, when used

without the aHert symboH, indicates a situation that couHd

resuHt in equipment damage. FoHHowsafety messages to

avoid or reduce the risk of injury or death.

Hazard Symbols and Meanings

EHectrocution EHectricaHShock EHectricaHShock

Toxic Fumes ExpHosion Fire

Copyright © 2005 Bri&_s & Stratton Power Products Group, LLC. AHHrights reserved. No part of this materiaH may be reproduced or transmitted in any form by any means without the express written permission of Bri&!_s& Stratton Power Products Group, LLC.

ExpHosive Pressure ChemicaH Burn

Hot Surface Kickback

DANGER

DO NOT aiIow any open flame, spark, heat, or lit cigarette during and for several minutes after charging a battery.

Wear protective go_ies, rubber apron, and rubber gloves.

WHEN ADDING OR DRAINING FUEL

Turn generator OFF and let it cool at least 2 minutes before

removing fuel cap. Loosen cap slowly to relieve pressure in

tank.

Fill or drain fuel tank outdoors. DO NOT overfill tank.AIIow 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.

_fHEN STARTING EQUIPHENT

WANNING

Operate generator ONLY outdoors. Keep exhaust gas fl'om entering a confined area through

windows, doors, ventilation intakes or other openings.

DO NOT operate generator inside an}, building or enclosure, including the generator compartment of a recreational vehicle (RV).

WARNING

When using generator for backup pow,en 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 NC)T touch bare wires or receptacles. DO NOT use generator with electrical cords which are worn,

frayed, bare or otherwise damaged.

DO NC)T 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:

Ensure spark phJg, muffier_ fuel cap and air cleaner are in place.

• DO NOT crank engine with spark plug removed. If fuel spills, wait until it evaporates before starting engine.

WHEN OPERATING EQUIPNENT

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.

9'HEN TRANSPORTING OR REPAIRING

EQUIPNENT

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.

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

When starting engine, pull cord slowly until resistance is felt

and then pull rapidly to avoid kickback. NEVER start or stop engine with electrical devices plugged in

and mr'ned on.

WARNING

WHEN ADJUSTING OR MAKING REPAiRSTOYOUR GENERATOR

Disconnect the spark plug wh'e from the spark plug and place the wire where it cannot contact spark plug.

WHENTESTING FOR ENGINE SPARK

Use approved spark plug tester DO NOT check for spark with spark plug removed.

DO NOT tamper with governed speed. Generator supplies correct rated frequency and voltage when running at governed

speed.

DO NOT modify generator in any WaT:

See "Don't Overload Generator". Start generator and let engine stabilize before connecting

electrical loads. Connect electrical loads in OFF position, then turn ON for

operatiom

Turn electricaI loads OFF and disconnect from generator

before stopping generator.

CAUTION

WARNING

DO NOT touch hot surfaces. Allow equipment to cool before touching.

The generator must be at least S feet from structures having combustible wails and/or other combustible materials.

Keep at least 3 feet of clearance on all sides of generator for adequate cooling, maintenance and servicing.

In the State of California a spark arrester is required by law (Section 4442 of the California PuNic Resources Code). Other states may have similar laws. Federal laws apply on federal lands. If you equip the muffler with a spark arresten it must be

maintained in effective working order:

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 obiects 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.

KNOWYOU P,GENERATOR

Read this owner's manuam and safety fumes before operating your generator,

Compare the illustrations with ),our generator, to familiarize yourseff with the locations of various controls and adjustments. Save ths manuaHfor future reference.

FueHTank

OH FHHCap

Circot Breaker (AC)

DoubHe Porte Circot Breaker (AC)

[dHeCon[roll Switch

H2VoHtDC, HOAmp

Receptacle

H20/240 Vok AC,

20 Amp Receptacle

H20 VoHtAC, 30 Amp

Receptacle

H20 Vok AC, 20 Amp

Duplex Receptacle

[ 2 Vomt DC, I 0 Amp Receptacle -- Recharge a discharged [ 2 Volt automotive type battery through this receptacle.

[ 20 Vo[t AC, 20 Amp Duplex Receptacle -- Hay be used to

supply electrical power for the operation of H20Volt AC, 20Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor

loads.

[ 20 Vomt AC_ 30 Amp Receptacle -- Hay be used to supply

electrical power for the operation of [20 Vok AC, 30 Amp, single phase, 60 Hz electrical lighting, appliance, too[ and motor loads.

1201240 Volt AC, 20 Amp Receptacle- Hay be used to

supply electrical power for the operation of H20 and/or 240Vok AC, 20 Am D single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

Air CJeaner -- Protects engine by filtering dust and debris out of intake air:

Choke Lever -- Used when starting a cold engine. Circuit Breaker (AC) --The H20VoltAC, 30 Amp receptacle is

provided with a "push to reset" circuit breaker to protect the generator" against electrical overload.

Recoil Starter

Run/Stop Switch

Lever

Air Cleaner

Spark Attester Huffler

Grounding Fastener

Double Pole Circuit Breaker (AC) --A double pole circuit

breaker is provided to protect all the receptacles and generator

against electrical overload.

Fuem Tank -- Capacity of 4.5 U.S. gallons. (3rounding Fastener -- Used for proper grounding of unit.

[die 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 stare switch is OFF when

starting engine.

Oil Fill Cap --Add oil to engine here.

Recoil starter -- Used to start the engine manually.

Run/gtop Switch -- Set this switch to "Run" before using

recoil starter: Set switch to "Stop" to switch OFF engine.

Spark Attester Muffler- Exhaust muffler lowers engine noise and is equipped with a spark attester screen.

Start Button --When pressed, cranks engine to start.

ASSEMBLY

[MPORTANT: Read entireowner'smanuai beforeyou

attempt to assembie or operate your new generator.

2. Connect negative (black) battery cable to negative (-) terminal on battery (Figure I).

Carton Contents

Parts incmuded:

Generator Wheei kit

Battery Battery charge cabies Battery float charger Locking 20 Amp piug Locking 30 Amp piug

Engine oii

Two packets of fuei stabilizer

Owner's manuaH Engine manuaH

ff any of the above parts are missing or damaged_ cali the

generator heipiine at 1-800-270-m 408.

Attach Negative Battery Wire

The sealed battery on the generator is fuliy charged and pre-installed except for the negative (biack) battery cabie.

To instamm:

I. Cut off tie wrap securing Hoose end of negative (bHack)

cable.

Negative battery cable

Positive

battery cable

3. Verify that connections to battery and generator are

correct and secure.

Install Handle

To instali the handie you need the following tools:

o 2 o H3 mm (i/2") box, open end, or socket wrenches Install handle as follows:

i. Remove hardware from bracket on handie.

2. Piace iifqng handie on aiternator end of cradie so that

handle fails between the two twistiock receptacles as

shown in Figure 2.Attach handle with provided cap screws and hex nuts.Tighten with 13mm wrenches.

Capscrew

Hex

Nut

Handle

BEFORE STARTING THE

ENGINE

Add Engine 0il

° Place generator on a level surface.

, Refer to engine manual for oil tiff information. . Damage to equipment resulting from failure to follow this

instruction will void warranty.

° Refer m engine owner's manual and follow oil

recommendations and ins[rucdons.

NOTE: Check oil often during engine break-in. Refer to

engine owner's manual for recommendations.

NOTE: The generator assembly rotates on a prehbricated

and sealed ball bearing that requires no additional lubrication for the life of the bearing,

Add Fuel

NOTE: This gasoline engine is certified to operate on

gasoline. Exhaust Emission Control System:EH (Engine

Hodifications).

WARNING

WHEN ADDING FUEL

Turn generator OFF and let it cool at least 2 minutes before

removing fuel cap. Loosen cap slowly to relieve pressure in tank. Fill fuel tank outdoors,

DO NOT overfill tank.Allow space for fuet expansion. Keep fuel away from sparks, open flames, pilot lights, heat, and

other ignition sources. DO NOT light a cigarette or smoke.

Use clean, fresh, regular UNLEADED fuel with a minimum of 85 octane with equipment. DO NOT use

fuel which contains Hethanol. DO NOT mix oil with fuel.

2. Clean area around fuel fill cap, remove cap.

3. Slowly add regular unleaded fuel to fuel tank. Be careful

not to fill above the baffle.This allows adequate space

for fuel expansion (Figure 3),

TANK

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 neutra[ wire (the neutra[ 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 eIectriciam electrical inspector, or the local agency having jurisdiction.

o In some areas_generators are required to be registered

with local utility companies.

o If the generator is used at a construction site, there may

be additional regulations which must be observed.

Connecting to a guild[rig's Electrical

Connections forstandby 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.

Operate generator ONLY outdoors. Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings_

DO NOT operate generator inside any building or enclosure_ including the generator comparnnent of a recreationa[ vehicle (RV).

The generator must be at least 5 ft. (I 52 cm) from

structures having combustible walls and/or other combustible materials. Leave at least 3 ft. (92 cm) all around

generator including overhead, for adequate cooling,

maintenance and servicing.

Place generator in a well ventilated arem which will allow for removal of deadly exhaust gas. DO NOT place generator where exhaust gas could accumulate and enter

inside or be drawn into a potentially occupied building.

Ensure exhaust gas is kept away from any windows_ doors_ ventilation intakes or other openings that can allow

exhaust gas to collect in a confined area (Figure 4).

Prevailing winds and air currents should be taken into

consideration when positioning generator.

WARNING

When using generator for backup power, notify utility

company. Use approved transfer equipment to isolate

generator from electric utilit>;

Use a ground fault circuit interrupter (GFC[) in any damp or highly conductive arem such as metal decking or steel work.

DO NOT touch bare wires or receptacles. DO NOT use generator with eJectricaI cords which are worn,

frayed, bare or otherwise damaged.

DO NOT operate generator in the rain. DO NOT handle generator or electrical cords whiIe standing

in waten while barefoot, or while hands or feet are wet. DO NOT allow unqualified persons or children to operate or

service generatoK

Typical Generator Shown

Exhaust Port

OPERATmNG THE

G EN E RATO R

See"Don't Overload Generator". Start generator and let engine stabilize before connecting

electrical loads. Connect electrical loads in OFF position, then turn ON for

operation. "Furn electrical loads OFF and disconnect from generator

before stopping generator:

iMPORTANT: AHways unpHugthe battery float charger

before starting the generator.

Stardng the Engine

Disconnect all electrical loads from the generator. Follow

these start instruction steps in numerical order:

I. Turn fuel valve to"On" position (Figure 5).

WARNING

When starting engine, pull cord sJow.ly until resistance is feJt and then pull rapidly to avoid kickback.

NEVER start or stop engine with electrical devices plugged in

and turned on.

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.

WANNING

DO NOT touch hot surfaces. Allow equipment to cool before touching.

The generator must be at least 5 feet from structures having

combustible walls and/or other combustible materials. Keep at least 3 feet of clearance on all sides of generator for

adequate cooJing, maintenance and servicing.

In the State of California a spark attester is required by law (Section 4442 of the California Public Resources Code). Other

states may have similar laws. Federal Iaw.s apply on federal lands. If you equip the muffler with a spark arresten it must be maintained in effective working order.

2. Make sure Idle Control switch is in "Off' position (Figure 6).

IDLE

Start engine according to instructions given in engine owner's manual.

Connectin_ Electrical Loads

o Let engine stabilize and warm up for a few minutes after

starting.

o Plug in and turn on the desired 120 and/or 240VoltAC,

single phase, 60 Hz electrical loads.

o DO NOT connect 240Volt loads to the 120Volt

receptacles.

o DO NOT connect 3-phase loads to the generator.

o DO NOT connect S0 Hz loads to the generator. * DO NOT OVERLOADTNE GENERATOR. See

"Dofft Overload Generator".

H. Turn OFF and unphg ALL eHectricaHHoadsfrom

generator paneHreceptacles. NEVER start or stop engine with eHectricaHdevices plugged in and turned ON.

2. Move idHe control switch to"Off' position.

3. Let engine run at noqoad for severaH minutes to stabilize internaH temperatures of engine and generator.

4. Turn engine off according to instructions given in the

engineowner's manual.

S. Move fuelvalveto"Off' position.

To recharge m2 Vomt batteries, proceed as follows:

I. Check fluid level in all battery cells. If necessary, add

ONLY distilled water to cover separators in battery cells. DO NOT use tap waters

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 "12oVOLTS D.C.".

5. Connect battery charge cable clamp with red handle to the positive (+) battery terminal (Figure 7).

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.VVhen an electrical load is remove& 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

startingand stopping the engine,

Charging a Battery

Your generator has the capability of recharging a discharged 12VoN automotive or utility style storage battery. DO NOT use the unit to charge any 6VoN batteries. DO NOT use the unit to crank an engine having

discharged battery.

DANGER

DO NOT ailow anyopen flame, spark, heat, or lit cigarette during and for several minutes after charginga battery.

Wear protective goggJes, rubber apron, and rubber gloves.

12VOLT DoCo

POS NEG

6. Connect battery charge cable clamp with bmack handle to the negative (-) battery terminal (Figure 7).

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] combined with high humidity), your generator

may experience icing of the carburetor and/or the crankcase breather system.To reduce this problem_ you need to perform the following:

I. Make sure generator has dean_ fresh fuel.

2. Open fuel valve (turn valve to open position).

3. Use SAE SWo30 oil (synthetic preferred, see engine

manual).

4. Check oil level daily or after every eight (8) hours of

operation.

5. Maintain generator following"Maintenance Schedule" in engine manual

6. Sheker unitfrom elements.

Inan emergency, use the oMginaH shipping carton as a

7. Cut off ali carton flaps.

8. Cut out one iong side of carton to expose muffler side of unit as shown in Figure 8.

IMPORTANT: The generator must be at Heast 5 ft.

(152 cm) from structures having combustible wails and/or other combustible materials. Leave at least 3 ft. (92 cm) aiI around generator including overhead_ for adequate cooling_ maintenance and servicing.

WANNING

For a more permanent sheker, build a structure that wii[

enclose three sides and the top of the generator,

7. Make sure entire muffler-side of generator is exposed_ as shown in Figure 8.

IMPORTANT: The generator must be at least 5 ft. (152 cm) from structures having combustibie walis and/or

other combustibie materiais. Leave at [east 3 ft. (92 cm) all[ around generator inciuding overhead, for adequate cooling,

maintenance and servicing.

8. Face exposed end away from wind and elements.

9. Structure shouid hoid enough heat created by the generator to prevent icing probiem.

10. Start and run engine outdoors.

[ 1. Keep exhaust gas from entering a confined area

through windows, doors, ventilation intakes or other

openings.

WANNING

Operate generator ONLY outdoors. Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings.

DO NOT operate generator" inside any building or encIosure, inchding the generator compartment of a recreational vehicle

(w).

DO NOT touch hot surfaces. Allow equipment to cool before touching.

The generator must be st bast 5 feet from structures having combustible waIIsand/or other combustible materiaIs.

Keep at least 3 feet of clearance on aIIsides of generator for adequatecoolin D maintenance and servicing.

Remove shelter when temperatures are above 40°F [4°C].

9. Cut appropriate shots to access receptacies of unit. i0. Start unit, then place carton over it.

IMPORTANT: Remove sheker when temperatures are

above 40°F [4°C].

12. DO NOT enclose generator any more than shown in Figure 8.

13. Remove shelter when temperatures are above 40°F

[4°c1.

14. Turn engine OFF and let cool two (2) minutes before

refueling.

+ 25 hidden pages