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)
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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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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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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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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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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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