Generac 9777-1 Owner’s Manual

GEN ERAC 4000XL

Extended Life Generator

Owner's Manual

Operating and Maintenance Instructions

Danger:thisgeneratorisdesignedforoutdooruseonly.Donotusethisgeneratorinsideanybuildingorenclosure includingthegeneratorcompadmentofa recreationalvehicle(RV).Fireoranexplosionmayresult. Nouserperformed

modifications, includingventingofexhaustand/orcoolingventilation,willeliminatethedanger.Also,allowat least

twofeetof clearanceonallsidesofthegeneratorevenwhileoperatingthe unitoutdoors.

Danger:ifthis unitis usedfor backuppowerintheeventof autilitypowerfailure,thefollowingstepmusthetaken: Beforeconnectingthe generatorto anelectricalsystem,openthe maincircuitbreakeror mainswitchserving the

system,to isolatethegeneratorsystemfromtheelectricutility,Failureto isolatethegeneratorand utilitysystems mayresultindamageto thegeneratorandmayalsoresultininjuryordeathtoelectricutilityworkers,dueto aback- feedof electricalenergy.

The Emission Control System for this generator is war-

ranted for standards set by the California Air Resources Board (CARB). For warranty information refer to the Engine

Owner's manual.

ModelNo.9777-1 (4000WattAC Generator)PartNo. 99022 (Revision1 11/15/96)

Generac4000XL ExtendedLifeGenerator

EQUIPMENTDESCRIPTION

This generator is an engine-driven, revolving field, alternat- ingcurrent(AC)generator, ttwas designedtosupplyelectrical powerfor operating compatible electrical lighting, appliance,

tooland motor loads. Thismanual contains information fora generatorthat operates 120 and/or 240 volts, single phase,

60Hzdevicesthat require upto 4000 watts (4.0 kW)of power

that pullupto 33.3amps at 120volts or16.7ampsat 240volts.

wattage/amperagecapacity.Add upthe rated

_ CAUTION: Do notexceedthe generator's

wattsofall devices you are_tit_ toget_ra-

tor receptaclesat onetime. Thistotal shouldnot

begreaterthan 4000watts for thisgenerator. In mostcasesrated watts ofthe electricaldevicecan

befoundon thedevice nameplate. If thedevice nameplategivesonly voltsand amps,multiply

voltstimesampsto obtainwatts (voltsx amps= watts).

Thegenerator's revolvingfield is drivenat about3600 rpm by a singfe-cytinderengine.

Everyeffort has been expended to make surethat theinfor-

mation inthis manualis bothaccurate and current. However, Generac reserves the right to change, alter or otherwise improvethe product at any time without prior notice.

_ DANGER: Do nottamper withenginegoverned

speed, Highoperatingspeedsaredangerousand increaserisk ofpersonal injuryordamageto

equipment. The generatorsuppliescorrectrated frequencyand voltageonlywhenrunningat

propergovernedspeed. Incorrectfrequency andforvoltagecan damagesomeconnectedelec-

tricalloads. Operatingat excessivelylow speeds imposesa heavyload at suchreduced speeds,

whenadequate enginepoweris not available,and may shortenginelife.

MODEL & SERIALNUMBERS

In the spaces provided below, insertthe Model and

Serial numbers of your generator. Re_in these num- bersfor future reference. Youcan find Model and Serial

numbers on the generator data plate, along with other important information.

ModelNumber Serial Number

SAFETYRULES

This generator set was designed and manufacturedfor spe- chic applications. Do not attempt to modifythe unit or use it for any application it was not designed for. Ifyou have any

questions about your generator's application, ask your Oeater!Oisfributoror consutt the factory.

The manufacturer could not possiblyanticipate every cir-

cumstance that might involve a hazard. For that reason warningsinthe Manualand warningson tags or decals affixed

tothe unit are not all-inclusive. Ifyou intendto handle, oper- ateorservicethe unitbyaprocedureor methodnotspecifically

recommendedby the manufacturer,first make sure that such

a procedure or methodwill not render this equipment unsafe

or posea threatto you and others. Read this manual carefullyand become familiar with your

generator set. Know its applications, its limitations and any hazards involved.

. The generator producesavery powerful voltagethat can

cause extremelydangerouselectricalshock. Avoidcontact

with bare wires, terminals, etc. Neverpermitany unquali- fied personto 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 ElectricCode requires the frame and exter- nal electrically conductive parts of generator be properly

connected to an approved earth ground. Local electrical

codes may alsorequire proper grounding ofthe generator. Consult with a localelectricianfor grounding requirements

in your area.

• Use a ground fault circuit interrupter in any damp or highly

conductive area (such as metal decking or steel work).

• Donot use any worn, bare, frayed or otherwise _ma_ed

electricalcord sets with the generator. Using any defective cord set may result in electrical shock or damage to equip-

ment and/or property

• Operategenerator only on level surfaces and where it will not be exposed to excessive moisture, dirt, dust or corro-

sive vapors.

Extended Life Gensrator

Generac4000XL ExtendedLifeGenerator

• GasolineishighlyFLAMMABLEand its vaporsara EXPLO- SIVE. Do not permit smoking, openflames, sparks or heat

in the vicinity while handling gasoline. Avoidspilling gaso- lineon a hot engine. Complywithalllawsregulatingstorage

and handling of gasoline.

• Donotoverfillthefueltank. Alwaysallowroomforfuelexpan- sion, Iftankis overfitled,fuelcanoverflowontoa hotengine

and cause FIRE or an EXPLOSION,

• Never store generator with fuel in tank where gasoline

vapors might reach anopen flame or spark or pilotlight(as on a furnace, water heater or clothes dryer). FIRE or an

EXPLOSIONmight result.

• GeneratorexhaustgasescontainDEADLYcarbonmonoxidegas.

Thisdangerousgas,if breathedinsufficientconcentrations,can causeunconsciousnessorevendeath. Operatethisequipment

onlyin theopenairwhereadequateventilationis available,

• Theengine.generatorrequiresanadequateflowofcoolingairfor

itscontinuedproperoperation.Neveroperatetheunitinsideany

roomorenclosurewherethefreeflowofcoolingairintoandout ofthe unitmightbeobstructed.Withoutsufficientcoolingairflow,

the unitquicklyoverheats,damagingthe generatoror nearby property,

• Allowat least2feetof clearanceonalIsidesofgenerator,even

whileoperatingunitoutdoors,or youcoulddamagetheunit.

• Neverstart,orstop,theengine-generatorwithelectricalloadscon-

nectedto receptacleswiththe connecteddevicesturnedON. Starttheengineand letit stabilizebeforeconnectingelectrical loads. Disconnectall electricalloadsbeforeshuttingdownthe generator.

• Donotinsertanyobjectthroughcoolingslotsoftheengine-gen- erator, Youcoulddamagetheunitor injureyourself.

• Neveroperategenerator(a) inrain;(b) in any enclosedcom-

partment;(c)itenginespeedchanges;(d)ifconnectedelectrica!

devicesoverheat;(e)ifelectricaloutputislost;(f)ifengineorgen- eratorsparks;(g) if flameor smokeisobservedwhileunit is

running;(h)if unitvibratesexcessively.

Generally,connectinga No. 12AWG(American Wire Gauge) stranded copper wire to the grounding wing screw and to an earth-driven copper or brass grounding rod (electrode) pro-

vides adequateprotection againstelectrical shock. However, local codes may vary widely. Consult with a local electrician

for grounding requirements in your area. Besure to keep the

ground wireattached while you connect the electrode. Properly grounding the generator helps prevent electrical

shock ifa ground fault conditions exists in the generator or in connectedelectricaldevices, Propergroundingalso helpsdis-

sipate static electricity, which often builds up in ungrounded

devices.

BEFORESTARTINGTHE ENGINE

Perform the following tasks beforetrying to start the genera- tor engine:

• ADD ENGINEOIL BEFOREINITIAL START

Removeone ofthe yellow Oil Fill Caps (Figure 2 on page 4) andadd engineoiluntiloillevelis atpointofoverflowing,Check

engine oillevelbeforestarting each time thereafter. Ifoil level is belowpoint of overflowing, fill to proper level.

GROUNDINGTHE GENERATOR

The National Electric Code requires the frame and external

electrically conductive parts of generator be properly con- nectedtoapproved earth ground. Localelectrical codes may

also require proper grounding of the unit. Forthat purpose, a GROUNDINGWINGSCREW (Figure 1) isprovided onthe

cradleframe.

Extended Life Generator

Generac4000XL ExtendedLifeGenerator

[_ AUTION: Any attemptto crankor startthe

engine beforeithas been properlyservicedwith therecommendedoil resultsinan enginefailure.

The recommendedoilsinclude the following:

• Duringsummer months: SAE 10W-30

• Duringwintermonths: SAE 5W-20or 5W-30. DONOTUSE SAE 10W-40.

Crankcaseoil capacityisabout 620mlor about21 fluidounces with the oil filter. Without the filter to capacity is870ml (29.5

oz.). Use no special additives. NOTE: The generator's revolving field rides on a pre-lubri-

cared and sealed ball bearing that requires no additional lubrication forthe life of the bearing.

• APPLYINGELECTRICALLOADS

• Letenginestabilizeand warm upforaboutfive minutesafter starting.

• Plug in and turn on the desired 120 or 240 volts, single phase,60 Hertz,AC electricalloads.DO NOTOVERLOAD THE GENERATOR. Add up the rated watts (or amps)of all loadsto be connectedat one time. This total should not

begreaterthan the ratedwattage/amperagecapacity of the generator.

• STOPPINGTHE ENGINE

Disconnect all electrical loads and let engine run at no-load forabout five minutes,thenturn off the engine by moving the Run/Stopswitchto STOPposition. Seeengine manual Close

fuel shut-off valve,

OPERATINGAUTOMATICIDLE

CONTROL

An Automatic IdleControl system provides greatly improved fueleconomyb; operatingtheunitat itsnormal high governed

speed only when eiectrical loads are plugged in andturned ON. The systemconsists of (a)an IdleControl Circuit Board,

(b) a Sensing Transformer,(c) an Electromagnet, and (d) an

IdleControl Switch located on the control panel,

• ADD FUEL

Use regular UNLEADED gasolinewith thegenerator engine.

Regularleaded gasoline may also be used if UNLEADED is

not available. Fuel tank capacity is 4 U.S. gallons.

allowroom forfuel expansion.

[_ AUTION: Do notoverfillthe fueltank. Always

OPERATINGTHE GENERATOR

• STARTINGTHE ENGINE

o Disconnectall electrical loads from the generator.

• Openthe fuel shut-off valve.

• Referto the engine manual.

Extended Life Generator

Engine-generatorruns at high governedspeedwith Idle Con-

trol Switch ON(-) only when an electrical load is connected to the generator and turned on. When the electrical load is

disconnected,an Electromagnetisenergized topulltheengine throttle control against its idle stop. Engine then runs at

reduced(idle) speed.

The Electromagnet cannot be energized with Idle Control

Switch OFF,since its power circuit is open. Engine runs at high governed speed (about 3600 rpm) whether load(s) are

connected or not.

• ADJUSTING IDLE CONTROL

Youcan adjust and set the idle Control on the engine-gener- atoras follows:

o With unit running and warmed up, turn the idle control bolt

clockwise(fasterspeed),or counterclockwise(slowerspeed)

until the engine speed is between 40 and 45 Hz. (2400 ~ 2700 rpm). See Figure 3.

Generac4000XL ExtendedLifeGenerator

• LocktheIdleControlJam Nutagainsttheidlecontrolbracket, while making certain the engine speed is still within the

range of 40 to 45 Hz.

NOTE: Engine idlespeeds of less than 40 Hz could cause the engine to stall if you applysudden block loads.

• CHARGING A BATTERY

Yourgenerator hasthe capability of recharging a discharged 12-volt automotive or utility style storage battery. Do not use

the unitto charge any 6-volt batteries. Do not use the unit to crankan engine havinga dischargedbattery. Torecharge 12-

volt batteries, proceed as follows:

• Checkfluid levelinall batterycells. If necessary, add ONLY distilled waterto cover separators in battery cells. DO NOT

USETAP WATER.

• If the battery is equipped withvent caps, make sure they are installed and are tight.

• If necessary, clean battery posts or terminals.

• Connectbatterychargecableconnectorplugtopanel recep- tacle identified bythe words "12-VOLT D.C.(Figure 4).

'I 2 VOLT D.C.

• BATTERYSAFETY

_ ARNING:STORAGEBATTERIESGIVEOFF

EXPLOSIVEHYDROGENGASWHILECHARGING.

AN EXPLOSIVEMIXTUREWILLREMAINAROUND

BATTERYFORA LONGTIME AFTERIT HAS BEEN

CHARGED.THESLIGHTESTSPARKCANIGNITE GASAND CAUSEANEXPLOSION.SUCHAN

EXPLOSIONCAN SHATTERBATTERYANDCAUSE BLINDNESSOROTHERSERIOUSINJURY.

_ WARNING:DONOTPERMITSMOKING,OPEN

FLAME,SPARKSORANY OTHERSOURCEOF HEATAROUNDA BATTERY.DONOTUSE A

LIGHTEROR OTHERFLAMEFORCHECKINGBAT-

TERYFLUIDLEVELS.WEARPROTECTIVE

GOGGLES,RUBBERAPRONANDRUBBER GLOVESWHENWORKINGAROUNDABATTERY. BATTERYELECTROLYTEFLUIDIS AN

EXTREMELYCAUSTICSULFURICACIDSOLUTION

THATCANCAUSESEVEREBURNS.DONOT

PERMITFLUIDCONTACTWITH EYES,SKIN,

CLOTHING,ETC.IFSPILLOCCURS,FLUSHAREA WITHCLEARWATERIMMEDIATELY.

RECEPTACLE

12 VOLTS BATTERY

• Connect batterycharge cable clamp with red handleto bat- tery post or terminal indicatedbya POSITIVE, POS or (+).

• Connect battery chargecable clamp with black handle to battery postor terminal indicated by a NEGATIVE,NEG,or

• Start engine (see"Starting the Engine" on Page4). Letthe engine run while battery recharges.

• When battery has charged, shut down engine (see "Stop- ping the Engine" on Page4).

NOTE: Use an automotive hydrometerto test battery state of charge and condition. Followthe hydrometer manufactur- er'sinstructions carefully. Generally, a battery is considered

to be at 100%state ofcharge when specific gravity of its fluid (as measured by hydrometer) is 1.260.

Extended Life Generator

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