Generac 9777-2 Owner’s Manual

GEN RAC°I

Portable Products

Portable Generator Owner's Manual

Model No. 9777-2 (4000 Watt AC Generator) Manual No. B4400 Revision 4 (9/20/2000)

Visit our Generac website: www.generac-portables.com

This isthe safety alert symbol. It isusedto alert you to potential personal injuryhazards.

Obey all safety messagesthat follow this symbol to avoidpossible injuryor death.

GeneracPortableProducts4,000XLGenerator

EQUIPMENT

DESCRIPTION

This generator is an engine-driven,revolving field,
alternating current (AC) generator. It was designedto
supply electrical power for operating compatible electrical
lighting, appliance,tool, and motor loads.This manual
contains informationfor a generator that operates

120and/or 240 Volt AC, singlephase,60 Hz devices that
require up to 4,000 watts (4.0 kW) of power that pull up
to 33.3 Amps at 120Volts or 16.7 Amps at 240 Volts.

_hL CAUTION! Do Not exceed the generator's

wattage/amperage capacity.Add up the rated watts
of all devicesyou are connecting to generator

receptacles at one time. This total should not be

greater than 4,000 watts. In most casesrated watts
of the electrical device canbe found on the device

nameplate.If the device nameplategives only volts

and amps,multiply volts times amps to obtain watts

(volts X amps= watts).

The 4,000 watt generator hasthe following features:

• 120/240Volt, 20 Amp locking receptacle and a 120Volt,

30 Amp locking receptacle.

• 120Volt, 15Amp receptacles.

• 12Volt DC, l0 Amp receptacle.

• Low Oil Shutdown: Automatically shuts down the engine

if oil drops below safeoperation level.

• Four gallon overhead fuel tank with fuel gauge.

• The generator's revolving field is driven at about

3,600 rpm by a Generac Power Systems 7.8 h.p. engine.

_hL WARNING! Do Not tamper with engine

governed speed.High operating speedsare
dangerous and increaserisk of personal injuryor

damageto equipment The generator supplies
correct rated frequency and voltage only when

running at proper governed speed. Incorrect

frequency and/or voltage candamagesome
connected electrical loads.Operating at excessively

low speedsimposesaheavyload.When adequate

engine power isnot availableengine life may be
shortened.

SAFETY RULES

This generator set was designedand manufactured for
specific applications. Do Not attempt to modify the unit

or use it for anyapplication it was not designedfor. If you

haveany questions about your generator's application, ask

your dealer/distributor or consult the factory.
The manufacturer could not possibly anticipate every

circumstance that might involvea hazard. For that reason
warnings in the manual and warnings on tagsor decals
affixed to the unit are not all-inclusive. If you intend to

handle,operate or service the unit by a procedure or
method not specificallyrecommended by the manufacturer,

first make sure that such a procedure or method will not

render this equipment unsafeor pose a threat to you and

others.

Read this manual carefully and become familiar

with your generator set. Know its applications, its

limitations and any hazards involved.

_hL DANGER! You must isolatethe generator from

the electric utility by opening the electrical system's
main circuit breaker or main switch if this unit is

usedfor backup power. Failure to isolate the

generator from the power utility may result
in injury or death to electric utility workers
and damage to the generator due to a backfeed

of electrical energy.Whenever unit is providing
backup power, the electric utility must be notified.

_ ANGER! Generator exhaust gases contain

DEADLY carbon monoxide gas. Carbon
monoxide, if breathed in sufficient

concentrations, can cause unconsciousness or

death. Operate this equipment outdoors where

adequateventilation is available.

The EmissionControl Systemfor this generator is
warranted for standards set by the Environmental

Protection Agency. For warranty information refer to the

engine owner's manual.

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2

Generac Portable Products 4,000XL Generator

• The generator produces a very powerful voltage that can

causeserious injury or death by electrocution. Never
touch bare wires or receptacles. Never permit a child
or anyunqualified person to operate the generator.

• Never handle any kind of electrical cord or device while

standing in water, while barefoot or while hands or feet
are wet Death or serious injuryfrom electrocution may

result.

• Use a ground fault circuit interrupter (GFCI) in anydamp

or highly conductive area (such as metal decking or steel

work).

• Never useworn, bare, frayed or otherwise damaged

electrical cords with the generator. Death, serious injury
and property damagefrom electrical shock may result.

• Gasoline is highly FLAMMABLE and its vapors

are EXPLOSIVE. Never allow 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 overfitl the fuel tank. Always allow room for

fuel expansion. If tank is overfilled, fuel can overflow
onto a hot engine and cause a FIRE or an

EXPLOSION.

• Never store a generator with fuel in the tank where

gasolinevaporsmight reach an open flame, spark or pilot
light(as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.

• The unit requires an adequateflow of cooling air for its

continued proper operation. Never operate the unit
insideanyroom or enclosure where the free flow of

cooling air intoandout of the unit might be obstructed.
Allow at least2 feet of clearanceon all sides of generator,

evenwhile operating unitoutdoors, or you could damage
the unit See"Cold Weather Operation" on page 10.

• Never start or stop the unit with electrical loads

connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before

connecting anyelectrical loads.Disconnect all electrical
loadsbefore shutting down the generator.

• Do Not insertanyobject through cooling slots of the

engine.You could damagethe unit or injureyourself.

• Never operate the generator:

in rain; in any enclosedcompartment;when connected
electricaldevicesoverheat; if electrical output islost;if

engine or generator sparks; ifflame or smoke is
observed while unit isrunning; if unit vibrates
excessively.

GROUNDING THE

G EN ERATO R

The National ElectricalCode requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of the
unit For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure I).

Generally, connecting a No. 12AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut

and to an earth-driven copper or brass grounding rod
(electrode) provides adequate protection against electrical

shock. Be careful to keepthe grounding wire attached after
connecting the stranded copper wire. However, localcodes

may vary widely. Consult with a localelectrician for
grounding requirements in your area.

Properly grounding the generator helps prevent electrical
shock ifa ground fault condition exists inthe generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.

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3

GeneracPortableProducts4,000XLGenerator

KNOW YOUR GENERATOR

Read this owner's manual and safety rules before operating your generator.

Compare the illustrations with your generator to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.

FuelTank

Circuit Breakers (AC)

Fuel Shut Off Valve

120 Volt AC, 30 Am

Receptacle

120/240Volt AC,

20 Amp Receptacle

Run/Stop Switch

12Volt DC, 10Amp

Receptacle

120Volt AC, 15Amp, IdleControl Switch

Duplex Receptacle Grounding Wing Nut

12 Volt DC, I0 Amp Receptacle -- Use this receptacle

with battery chargecablesto chargea 12Volt battery.

120 Volt AC, I 5 Amp Duplex Receptacle -- May be

used to supply electrical power for the operation of

120Volt AC, 15Amp, single phase,60 Hz electrical

lighting, appliance,tool andmotor loads.

120 Volt AC, 30 Amp Receptacle -- May be usedto

supply electrical power for the operation of 120Volt AC,
30 Amp, singlephase,60 Hz electrical lighting,appliance,

tool and motor loads.

120/240 Volt AC, 20 Amp Receptacle -- May be used
to supply electrical power for the operation of 120and/or
240 Volt AC, 20 Amp, single phase,60 Hz electrical lighting,
appliance,tool and motor loads.

Circuit Breakers (AC) -- Each receptacle is provided
with a circuit breaker to protect the generator against
electrical overload. Breakers are "push to reset" type.

Fuel Shut Off Valve -- Controls fuel supply to engine.
Fuel Tank -- Capacity of 4 U.S.gallons (15 liters).

Grounding Wing Nut -- Provides a tie-point for
connecting the generator frame to earth ground.

Idle Control Switch -- The idle control runs the engine
at normal (high) speeds when there isan electrical toad

present and runs the engine at idle (tow) speedswhen a
loadis not present. This feature greatly improvesfuel

economy, extends the life of the engine, and reduces engine
noise.

RunlStop Switch -- Must be in "Run" position to start
engine. Set to "Stop" to stop a running engine.

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4

GeneracPortableProducts4,000XLGenerator

CONTENTS

Check all contents. If any parts are missing or damaged,call
the generator helpline at 1-800-270-1408. Review "Cold

Weather Operation" on page8. Shippedwith your
generator is:

Main unit
20 Amp and 30 Amp locking plugs

Spare spark plug and air filter
Spark plug wrench
Video tape

Oil
Engineand unit owner's manual

Battery charge cables

BEFORE STARTING ENGINE

Add Oil

_hL WARNING! Any attempt to crank or start the

engine before it hasbeenproperly filledwith the

recommended oil mayresult in an enginefailure.

Add Gasoline

_hL ANGER! Explosion Hazard! Never fillfuel tank

indoors. Never fill fuel tank when engine is running

or hot. Do Not light a cigarette or smoke when
filling the fuel tank.

_lk WARNING! Do Not overfill the fuel tank.

Always allow room for fuel expansion.

• Use regular UNLEADED gasoline with the generator
engine. Do Not use premium gasoline. Do Not mix oil
with gasoline.

• Clean area around fuel fillcap, remove cap.

• Slowly add unleaded regular gasoline to fuel tank. Be
careful not to overfill. Allow about I/2" of tank space for
fuel expansion (Figure 2).

1/2" Air Space Tank

To fill your engine with oil:

• PJace generator on a Jevel surface.

• Clean area around oil fill and remove oil fillcap.

• Selectthe oil's viscosity grade and fill engine with oil
following the instructions given in the engine owner's

manual. Do Not overfil!!

• Install oil fill cap.

NOTE: The generator's revolving field rides on a pre-
lubricated and sealedball bearing that requires no
additional lubrication for the life of the bearing.

• Installfuel cap and wipe up any spilled gasoline.
IMPORTANT: It isimportantto prevent gum deposits

from forming in essential fuel system parts such asthe
carburetor, fuel filter, fuel hose or tank during storage.
Also, experience indicatesthat alcohol-blended fuels (called
gasohol, ethanol or methanol) can attract moisture, which
leadsto separation and formation of acids during storage.
Acidic gascan damage the fuel system of an engine while in

storage.
To avoid engine problems, the fuel system should be

emptied before storage of 30 daysor longer.See "Storage"
on page I I. Never use engine or carburetor cleaner
products inthe fuel tank aspermanent damagemayoccur.

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5

GeneracPortableProducts4,000XLGenerator

OPERATING THE

GENERATOR

_k AUTION! Never start or stop the engine withelectrical loads connected to the unit and with the

connected devices turned ON.

Starting the Engine

Disconnect all electrical loadsfrom the generator. Use the
following start instructionsteps by numerical order:

I. Make sure the Idle Control switch isin "Off" position.

2. Turn the fuel valve to the "On" position (Figure 3).

3. Set the Run/Stop switch to "Run" position (Figure 4).

5. Grasp the recoil handle and pull slowly until slight

resistance is felt. Then pull rapidly one time only to

start engine.

• If enginestarts,proceed to step7.

• If engine fails to start, proceed to step6.

6. Move the chokelever to "Half' chokeposition, and

pull recoil handletwice.

• If engine fails to start, repeat steps4 thru 6.

7. Move choke leverto "Run" position. If engine falters,

move choke lever to "Half" choke position until the
engine runs smoothly, and then to "Run" position.

NOTE: If engine still fails to start after 3 pulls, check for
proper oil levelin crankcase.This unit is equipped with a
Low Oil Shutdown System. Seeengine manual.

Connecting Electrical Loads

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

starting.

• Plugin and turn on the desired 120and/or 240Volt AC,

singlephase, 60 Hertz electrical loads.

• Do Not connect 240 Volt loadsto 120Volt receptacles.

• Do Not connect 3-phase loadsto the generator.

• Do Not connect 50Hz loadsto the generator.

• DO NOT OVERLOAD THE GENERATOR. Add up

the rated watts (or amps) of all loadsto be connected at
one time. This total should not be greater than the rated
wattage/amperage capacity of the generator. See"Don't
Overload the Generator" on page I I.

4. Placethe choke lever in the "Full" choke position
(Figure5).

Position

Stopping the Engine

• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with electrical

devices pluggedin and turned on.

• Put the Idle Control switch in the "Oft"' position.

• Let engine run at no-load for 30 secondsto stabilize the
internal temperatures of engine and generator.

• Move Run/Stop switch to "Stop".

• Close the fuel shut-off valve.

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6

GeneracPortableProducts4,000XLGenerator

Operating Automatic Idle Control

This switch isdesigned to greatly improvefuel economy.
When this switch is turned ON, the engine will only
run at its normal high governed engine speed when an

electrical loadisconnected. When the load is removed,
the engine will run at a reduced speed.With the switch

OFF, the enginewill run at the normal high engine speed.

Always have the switch oft when starting and
stopping the engine.

Charging a Battery

A ANGER! Storage batteries give off explosive

hydrogen gaswhile recharging.This explosive
mixture will remain around the battery for a long
time after it has been charged.The slightest spark
canignite the hydrogen and causean explosion. Such
anexplosion canshatter the battery and cause
blindnessor other serious injury.

A DANGER! Oo Not permit smoking, open flame,

sparksor anyother source of heat around a battery.
Wear protective goggles,rubber apron and rubber

gloves when working around a battery. Battery

electrolyte fluid is an extremely caustic sulfuric acid
solution that cancausesevereburns. If spill occurs,
flush area with clear water immediately.

Your generator hasthe capability of recharging a discharged

12Volt automotive or utility style storage battery. Do Not
use the unit to charge any 6 Volt batteries. Do Not use
the unit to crank an engine havingadischargedbattery.

To recharge 12 Volt batteries, proceed as follows:

• Check fluid levelin all battery cells. If necessary,add
ONLY distilled water to cover separators in battery
cells. Do Not use tap water.

• Ifthe battery is equipped with vent caps,makesure they
are installedandare tight.

• If necessary,clean battery terminals.

• Connect battery charge cableconnector plug to panel

receptacle identifiedby the words "12-VOLT D.C."

• Connect battery charge cableclamp with red handle to
the positive (+) battery terminal (Figure6).

12 VOLT D.C.

RECEPTACLE

+

POS NEG

12 VOLT BATTERY

• Connect battery charge cableclamp with black handle
to the negative (-) battery terminal (Figure6).

• Start engine. Let the engine run while battery recharges.

• When battery hascharged,shut down engine

NOTE: Use an automotive hydrometer to test battery

state of charge and condition. Follow the hydrometer

manufacturer's instructionscarefully. 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.

,mmm

7

Generac Portable Products 4,000XL Generator

Cold Weather Operation

Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your Generac generator
max experience icing of the carburetor and/or the
crankcase breather system.

In an emergency,use the original shipping box asa
temporary shelter:

• Cut off all flaps.

• Cut out one of the long sides of the box to expose
exhaust side of unit Ensurea minimum of two feet

clearance between open side of box and nearest object.

• Cut appropriate slots to accessreceptacles of unit

• Start unit, then placebox over it.

IMPORTANT: Remove shelter when temperature is
above40°F [4°C].

For a more permanent shelter, build a structure that will
enclose three sides and the top of the generator:

• Makesure entire muffler-side of generator isexposed
(Figure 7).

Wind

• Ensure a minimum of two feet clearance between open
side of box and nearest object.

• Face exposed end away from wind and elements.

• Enclosure should hold enough heat created by the
generator to prevent problems.

_ AUTION! NEVER run unit indoors; Do Not

enclose generator any more than shown. Remove
shelter when temperatures are above 40°F [4°C].

RECEPTACLES

120 Volt AC, 15 Amp Receptacles

Eachof these outlets is protected againstoverload by

15Amp push-to-reset type circuit breakers (Figure 8).

II

I

II

i

Use each outlet to operate 120 Volt, 60 Hz, single phase
loads requiring 1,800 (I.8 kW) watts at 15 Amps of

current.

I

8

GeneracPortableProducts4,000XLGenerator

120/240 Volt AC, 20 Amp Locking

Receptacle

Use a N EMA LI4-20 plug with this receptacle. Connect a
4-wire cord set rated for 250 Volts at 20 Amps (or greater)
(Figure 9). You can usethe same4-wire cord if you plan to

run a 120Volt load.

4-Wire Cord Set

Y(Hot) x (Hot)

Ground

NEMA L14-20 (Green)

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5-30 plug with this receptacle. Connect a
3*wire cord set rated for 125Volts AC at 30 Amps to the
plug (Figure 10).

I[e_ IP,Te]kV_mF.'T__ _m

3-WireCord Set

r-- Neutml

120V

Hot

NEMA L5-30

Use this receptacle to operate 120 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts (3.6 kW) of power

at 30 Amps. The outlet is protected by a 30 Amp
push-to-reset circuit breaker.

This receptacle powers 120/240Volt AC, 60 Hz, single
phaseloads requiring up to 2,400 watts of power at

20 Amps for 120Volts; 4,000 watts of power (4.0 kW) at

16.7Amps for 240 Volts. The outlet is protected by a

20 Amp push-to-reset circuit breaker.

12 Volt DC, 10 Amp Receptacle

This connector (identified by the legend"12-VOLT D.C:')
supplies 12Volts DC at 10Amps through battery charging
cablesfor recharging 12Volt batteries (Figure I I). See
"Charging a Battery" on page 7.

iBm

9

Generac Portable Products 4,000XL Generator

DON'T OVERLOAD THE

GENERATOR

Overloading a generator in excess of itsrated wattage
capacity can result in damageto the generator and/or
connected electrical devices. Observe the following, to
prevent overloading the unit:

• Add up the total wattage of all electrical devicesto be
connected at one time. This total should NOT be

greater than the generator's wattage capacity.

• The rated wattage of lightscan be taken from light bulbs.
The rated wattage of tools, appliancesand motors can
usually be found on a data plate or decal affixed to the

device.

Recreational/Home Uses

Tool/Appliance .................................................... Watts

AM/FM clock radio .....................................................................50

Light bulb ....................................................................................100

Fan................................................................................................200

20" color TV ..............................................................................400

*Deep freezer ............................................................................500

Personal computer and 15" monitor ...................................800

*1/3 hp furnace fan blower .....................................................800

Microwave oven ........................................................................800

*18 cuft refrigerator ...............................................................800

Sump pump ..............................................................................1000

Electric skillet ..........................................................................1250

*_/2hp water well pump ........................................................1400

* 12,000 Btu window air conditioner .................................1400

Space heater ............................................................................1800

Electric water heater .............................................................4000

• Ifthe appliance, tool or motor does not give wattage,
multiply 120Volts 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 for only a few
seconds when starting such motors. Be sure you allow
for this high starting wattage when selecting electrical
devicesto connect to your generator. Firstestimate the
watts needed to start the largestmotor. Add to that
figure the running watts of all other connected loads.

• The wattage reference guide (Figure I I) is provided to
help you to determine how many items the generator

can operate at one time.

Professional/C ontractor Uses

Tool/Appliance .................................................... Watts

"1/3 hp airlesssprayer.............................................................600

3/8" hammerdrill .....................................................................600

Variable speedSawzalt®..........................................................960

V2"power drill .........................................................................1000

Quartz-halogen work light...................................................1000

Belt sander...............................................................................1200

7 ¼" circularsaw...................................................................1500

7 ¼" worm drive saw............................................................1600

*1V2hp air compressor ........................................................1800

* I0" power miter saw...........................................................1800

6" bench grinder .....................................................................1800

"6" table planer.......................................................................1800

*10" table/radial arm saw .....................................................2000

Wire feed welder ...................................................................2400

* allow 3 times listed watts for starting this device

I

I0

Generac Portable Products 4,000XL Generator

SPECIFICATIONS

Maximum SurgeWatts ............... 5,000 Watts

Continuous Wattage Capacity ......... 4,000 Watts

Power Factor ............................. 1.0

Rated Maximum Continuous Load Current

At 120Volts ...................... 33.3 Amps

At 240 Volts ...................... 16.7Amps

Phase................................ I-phase

Rated Frequency ...................... 60 Hertz

FuelTank Capacity ................. 4 U.S.gallons

GENERAL MAINTENANCE

RECOMMENDATIONS

The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on atimely
basis;that all discrepancies are corrected; and that the unit
is kept clean andproperly stored. Never operate a

damaged or defective generator.

Engine Maintenance

See engine manualfor instructions.

Generator Maintenance

To Clean the Generator

• Use a damp cloth to wipe exterior surfaces clean.

• Soft, bristle brush may be used to loosen caked on dirt
or oil.

• A vacuum cleaner may be usedto pick up loose dirt and
debris.

• Low pressure air (not to exceed 25 psi) may be used to
blow awaydirt. Inspect cooling air slots and opening on

generator. These openingsmust be kept clean and
unobstructed.

STORAGE INSTRUCTIONS

The generator should be started at least once every seven

daysand allowed to run at least 30 minutes. If this cannot
be done and you must store the unit for more than 30

days,use the following guidelines to prepare it for storage.

Generator Storage

• Cleanthe generator as outlined in "To Clean the
Generator"

• Check that cooling air slots and openingson generator
are open and unobstructed.

Generator maintenance consists of keeping the unit clean
and dry. Operate and store the unit in a clean dry
environment where it wit{ not be exposed to excessive
dust, dirt, moisture or any corrosive vapors. Cooling air
slots in the generator must not become clogged with snow,

leaves or any other foreign material.

NOTE: Do Not use a garden hose to clean generator.

Water can enter engine fuel system and cause problems. In
addition, if water enters generator through cooling air

slots, some of the water will be retained in voids and
cracks of the rotor and stator winding insulation. Water

and dirt buildup on the generator internal windings wit{
eventually decrease the insulation resistance of these
windings.

I

_ DANGER! Storagecovers can be flammable. Do

Not placeastorage cover over a hot generator. Let
the unit cool for asufficient time before placingthe

cover on the unit.

Engine Storage

Seeengine owner's manualfor instructions.

Other Storage Tips

• Do Not store gasoline from one season to another.

• Replace your gasoline can if it starts to rust. Rust and/or

dirt in a gasoline can cause problems when you use
contaminated fuel with this unit.

• Store in clean and dry area.

II

Generac Portable Products 4,000XL Generator

TROUBLESHOOTING

Problem

Engine is running, but
no AC output is

available.

Engine runs good but
bogs clown when loads

are connected.

Engine will not start; or
starts and runs rough.

Engine shuts down
during operation.

Engine lacks power.

Engine "hunts" or

falters.

Cause

I. Circuit breaker isopen.

2. Poor connection or defective cord set.

3. Connected device is bad.

4. Fault in generator.
I. Short circuit in a connected load.

2. Generator is overloaded.

3. Enginespeed istoo slow.

4. Shortedgeneratorcircuit.
I. Run/Stop switch set to "Stop".

2. Dirty air cleaner.

3. Out of gasoline.

4. Stalegasoline.

5. Sparkplug wire not connected to spark
plug.

6. Badspark plug.

7. Waterin gasoline.

8. Overchoking.

9. Low oil level.

10.

Excessively rich fuel mixture.

II.

Intake valve stuck open or closed.

12.

Engine has lost compression.

I. Out of gasoline.

2. Low oil level

3. Fault in engine.

I. Load is too high.

2. Dirty air filter.

3. Engine needs to be serviced.

I. Choke is opened too soon.

2.

Carburetor is running too rich or too

lean.

Solution

I. Reset circuit breaker.

2. Check and repair.

3. Connect another device that is in good
condition.

4. Contact Generac service facility.
I. Disconnect shorted electricalload.

2. See "Don't Overload the Generator"
on page 10.

3. Contact Generac service facility.

4. Contact Generac service facility.
I. Set switch to "Run".

2. Clean or replace air cleaner.

3. Fill fuel tank.

4. Drain gas tank and fill with fresh fuel.

5. Connect wire to spark plug.

6. Replacespark plug.

7. Drain gastank; fill with fresh fuel.

8. Put choke leverto "No Choke"

position.

9. Fill crankcaseto proper level.

10. Contact Generac servicefacility.
I I. Contact Generac servicefacility.

12. Contact Generac servicefacility.

I. Fill fuel tank.

2. Fill crankcase to proper level.

3. Contact Generac service facility.
I. See "Don't Overload the Generator"

on page 10.

2. Replace air filter.

3. Contact Generac service facility.
I. Move choke to halfway position till

engine runs smoothly.

2. Contact Generac service facility.

/

12

NOTES

Generac Portable Products 4,000XL Generator

/

13

ID3__TI_

GeneracPortableProducts4,000XLGenerator

ELECTRICAL SCHEMATIC

REGULATOR

DPE Uu

POWERBOARD !

L]OJ

F H

D •

E

D

G
A

E

2

G

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ENG,
IGNITION

BATTERY CHARGE

BRN
66

RED

AUTO 13

BLE

55

BLK
55

LOP

SWITCH

BRN
77

_Y_TEM
CONTROL

3

SLU z _ /

GRH

I

14

WIRING DIAGRAM

U(

Generac Portable Products 4,000XL Generator

RED
13

ID_I_I_

GRN

GRY

GRY

GRN

LOW OIL

GATE
EIGNAL

pq

3 PIN SWITCH

ENGINE CATHODE

RUN

SWITCH

NUT ON ENGINE BLOCK

PRESSURE

LOW OIL
PRESSURE

LED

BATTERY

CHARGE
RECTIFIER

I

15

Generac Portable Products 4,000XL Generator

I

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EXPLODED VIEW - HAIN UNIT

65

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16

Generac Portabte Products 4,000XL Generator

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PARTS LIST

Item Part # Qty

1 A93199
2 A84021
3 NSP
4 66365

5 84141J
6 83540J

7 65791
8 96796

Io 86307 4
II 47480 I
12 84508 2
13 52858 8
14 83208 I

15 B4986 I
16 66476 2

17 89476 I
18 70644 I

19 84346 3
20 40976 2
21 83083 I
22 83071 I
23 81917 I

25 66825-B I
26 85652 2

27 67989 2
30 74908 4

32 86308 4
33 65795 I
34 66849A I
35 67022 I
36 84132 I

37 66386 I
38 66849 2

39 B4871 I
41 86494 I
42 86292 I

43 77395 4
44 83465 4

- MAIN UNIT

Description

CRADLE, XL
SUPPORT,Engine

ENGINE
HOUSING, EngineAdapter

ASSEMBLY,Rotor
ASSEMBLY,Stator

BEARING

WASHER, M8 Ftat

HHMS, 5/16-24 x 3/4
HHCS, 5/16-24 x 7"
MOUNT, Vibration 45°

NUT, M8 Locking
BRACKET, Muffler

DECAL, Ground
HHMS, LW M6 1.00x 12
GASKET,Exhaust
PPHMS,M8 1.25x 20
PPHMS,M8 x 35
SHCS,M8 1.25x 20

SCREEN,Spark Arrest
MUFFLER

PIN, Roll M4 x 10
CARRIER, Rear Bearing

MOUNT, Vibration
NUT, M8 FlangedSerrated

TAPTITE, M5-0.8 x 10
BOLT, M6 - 1.0 x 115

RECTIFIER,Battery Charge
TAPTITE, M5 0.8 x 20

GROMMET, Rubber

ASSEMBLY,Drive Module Pwr

Reg.

ASSEMBLY,Brush Holder

TAPTITE, M5 0.8 x 16
COVER, BearingCarrier

SCREW,M6 -I .0 x 16Wing
HHCS, l0 - 16 x 3/4" Setf
Driller

NUT, M6 FlangeLock
GROMMET,Tank

Item

Parts Not Illustrated:

Optional Accessories Not Included:

Part #

46

78831B

47

80270

48

78299

49

85134

50

88325

51

B84042

52

84687

53

85000

54

14353621

55

23762

56

26850

60

B4399

61

92982

62

B4398

63

93826

64

73054

65

20566

66

77816

67

87116

68

B2153

69

84409

37806
43483
65787
72347

78601

84882
B4400

B4572
BB3061

NSP

84883 Cord Wrap
84895 Storage Cover

Qty

4

2

I
I

2

I
I

I
I
I

4

I

Description

HHMS, M6 1.0x 60
VALVE,Tank
BUSHING, PlasticTank
GAUGE, Fuel
TANK, Fuel
SHIELD, Heat
INSULATION, #2- I/4" Thick
CLIP,Insulation
WIRE, Ground

WASHER, Shakeproof # I0
WASHER, M6 Shakeproof

DECAL, Control Panel
DECAL, Danger

DECAL, Heat Shield
DECAL, Operating Instructions

DECAL, FuelShut Off
DECAL, Generac 1-800
DECAL, Caution Hot Muffler
ASSY.,Control Panel
HHCS, 12 - 14 x 7/8 Self Drill
SLEEVING,Flexo, HW I/2" x

.83 ft.

120Volt AC 30 Amp Plug

120/240Volt AC 20 Amp Plug
Battery Charge Cable
Spark Plug

Air Filter
Spark PlugWrench

Owner's Manual
Video

Oil, 28 oz.
EngineOwner's Manual

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17

Generac Portable Products 4,000XL Generator

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EXPLODED VIEW AND PARTS LIST - CONTROL PANEL

14

8 8 /

\\\ I F

18

7 17

11

15

1

'\

\

\

24

'\

Item

I

2

3

4
5

6
7

8
9

10
I1
12

Part #

83976
83975
66818
66821
68867C

68868C

75207A
75207G
82538
84134
83514
83970

\ 3

13

Qty. Description

PANEL, Control
BOX, Control

OUTLET 120Volts AC
OUTLET 12Volts DC

OUTLET 120/240 Volts, 20 Amp
Locking
OUTLET, 120Volts, 30 Amp
Locking
CIRCUIT BREAKER,30 Amp
CIRCUIT BREAKER, 18Amp

SWITCH, On/Off Rocker
GROMMET, Rubber

CIRCUIT BREAKER, 10Amp
CONTROL BOARD, System

_9

17 17

26

Item Part #

13 84028
14 67022
15 85584
16 84543A
17 84543C

18 84198

19 84197
21 75476
22 22264
23 51715
24 84543B
25 84335
26 82542

10

Qty. Description

I TRANSFORMER, Idle Control
I GROMMET, Rubber

I BAR, Bus
2 SCREW,3.0 x 12mm
9 SCREW,3.5 x 18mm
3 SHIELD,Circuit Breaker

I BAR, Circuit Breaker Retaining
2 SCREW,4.15 x 16mm

4 WASHER, M4 Lock
4 NUT, M3 Hex

10 SCREW,3.5 x 12mm

I WIRE HARNESS

I BAR, DC Outlet Retaining

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18

NOTES

Generac Portable Products 4,000XL Generator

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19

LIMITED WARRANTY

FOR "GN" ENGINE DRIVEN PORTABLE GENERATORS

GENERAC PORTABLEPRODUCTS (hereafter referred to asthe COMPANY) warrants to the original purchaser that the
alternator and control panel for itsportable generator wilt be free from defects in materials or workmanship for the items

and period set forth below from the date of original purchase.This warranty isnot transferable and applies only to portable
generators driven by a GN-Series engine.

Consumer* Commercial*

Alternator 2 years (2ridyear parts only) I year

Engine Warranted solely by the engine manufacturer

With the exception of European Community Countries, all units bound for export shall be warranted for One (I)
Yearin Consumer applications, end 90 daysin Commercial applications as defined below.

*NOTE: For the purpose of this warranty "consumer use" means personal residential household use by
original purchaser. This warranty does not apply to units used for Prime Power in place of utility.
"Commercial Use" means all other uses, including rental, construction, commercial and income producing
purposes. Once a generator has experienced commercial use, it shall thereafter be considered a
commercial use generator for the purposes of this warranty.

During saidwarranty period, the COMPANY wilt, at isoption, repair or replace anypart which, upon examination bythe
COMPANY, isfound to be defective under normal use and service**. Starting batteries are not warranted by the
COMPANY. All transportation costs under warranty, includingreturn to the factory ifnecessary,are to be borne bythe
purchaser and prepaid by the purchaser.This warranty does not cover normal maintenanceand service anddoes not apply
to a generator set, alternator, or parts which havebeen subjected to improper or unauthorized installation or alteration,
misuse, negligence,accident, overloading, overspeeding,improper maintenance, repair or storage so as,in the COMPANY's
judgement, to adverselyaffect its performance and reliability.

**NORMAL WEAR: As with all mechanical devices, the generator need periodic parts service and
replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of

a part or generator.

THEREIS NO OTHER EXPRESSWARRANTY. THE COMPANY HEREBYDISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND

FITNESSFOR A PARTICULAR PURPOSETO THE EXTENT PERMITTED BY LAW. THE DURATION OF
ANY IMPLIEDWARRANTIES WHICH CANNOT BEDISCLAIMED ISLIMITED TO THE TIME PERIODAS

SPECIFIEDIN THE EXPRESSWARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL
DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS

ANY RESPONSIBILITYFOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, SUCH AS THE LOSSOF
TIME OR THE USEOF THE POWER EQUIPMENT, OR ANY COMMERCIAL LOSS DUE TO THE FAILURE
OF THE EQUIPMENT: AND ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS

WRITTEN WARRANTY.

Some states do not allow limitations on how long an impliedwarranty lasts,or the exclusion or limitation of incidentalor
consequential damages,sothe abovelimitationsor exclusions may not apply to you. This warranty givesyou specific legal

rights andyou may also haveother rights, which vary from state to state.

For service, seeyour nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Warranty service can
be performed only by aCOMPANY authorized service facility. This warranty will not apply to service at any other facility.

At the time of requesting warranty service, evidence of original purchasedate must be presented.

GENERAC PORTABLE PRODUCTS

Jefferson, Wisconsin 53549