Generac Power Systems 4000XL 9777-2 Manuel utilisateur

Owner’s Manual

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Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT

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Model No. 9777-4 (4,000 Watt AC Generator) Manual No. 193524GS Revision 0 (08/04/2003)

Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page

• Generator

• Wheel kit

• Storage Cover

• Battery charge cables

• Spare Spark Plug,Air Filter, and Oil Filter

• Spark Plug Wrench

• Locking 20 Amp plug

• Locking 30 Amp plug

• Engine oil

• Owner's manual

• Engine manual

*If any parts are missing or damaged, call 1-800-270-1408.

Parts Included*Table of Contents

4000XL Extended Life Generator

EQUIPMENT

DESCRIPTION

Read this manual carefully and become

familiar with your generator. Know its

applications, its limitations and any hazards

involved.

The generators are an engine–driven, revolving field,

alternating current (AC) generator. It was designed to supply

electrical power for operating compatible electrical lighting,

appliances, tools and motor loads.The generator’s revolving

field is driven at about 3,600 rpm by a single-cylinder engine.

CAUTION! DO NOT exceed the generator’s

wattage/amperage capacity. See “Don’t Overload

Generator” on page 12.

Every effort has been made to ensure that information in this

manual is accurate 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 Control System for this generator is warranted

for standards set by the Environmental Protection Agency. For

warranty information refer to the engine owner’s manual.

SAFETY RULES

This is the safety alert symbol. It is used to

alert you to potential personal injury hazards.

Obey all safety messages that follow this

symbol to avoid possible injury or death.

The safety alert symbol ( ) is used with a signal word

(DANGER, CAUTION,WARNING), a pictorial and/or a

safety message to alert you to hazards. DANGER indicates

a hazard which, if not avoided, will result in death or serious

injury. WARNING indicates a hazard which, if not avoided,

could result in death or serious injury. CAUTION

indicates a hazard which, if not avoided, might result in

minor or moderate injury. CAUTION, when used

without the alert symbol, indicates a situation that could

result in equipment damage. Follow safety messages to

avoid or reduce the risk of injury or death.

Hazard Symbols and Meanings

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

WARNING

In the State of California a spark arrester is required by law

(Section 4442 of the California Public Resources Code).

Other states may have similar laws. Federal laws apply on

federal lands. If you equip the muffler with a spark arrester,

it must be maintained in effective working order.

Fire

Explosion

Toxic Fumes

Hot Surface

Electrical Shock

Electrocution Electrical Shock

Explosive Pressure Chemical Burn

4000XL Extended Life Generator

• DO NOT allow any open flame, spark, heat, or lit cigarette

during and for several minutes after charging a battery.

• Wear protective goggles, rubber apron, and rubber gloves.

Storage batteries give off explosive hydrogen gas

during recharging.

Hydrogen gas stays around battery for a long

time after battery has been charged.

Slightest spark will ignite hydrogen and cause

explosion.

You can be blinded or severely injured.

Battery electrolyte fluid contains acid and is

extremely caustic.

Contact with battery fluid will cause severe

chemical burns.

DANGER

• Operate generator ONLY outdoors.

• Keep at least 2 feet of clearance on all sides of generator for

adequate ventilation.

• DO NOT operate generator inside any building or enclosure,

including the generator compartment of a recreational vehicle (RV).

Running generator gives off carbon monoxide,

an odorless, colorless, poison gas.

Breathing carbon monoxide will cause nausea,

fainting or death.

DANGER

• When using generator for backup power, notify utility

company. Use approved transfer equipment to isolate

generator from electric utility.

• Use a ground circuit fault interrupter (GFCI) in any damp or

highly conductive area, such as metal decking or steel work.

• DO NOT touch bare wires or receptacles.

• DO NOT use generator with electrical cords which are worn,

frayed, bare or otherwise damaged.

• DO NOT 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.

Generator produces powerful voltage.

Failure to isolate generator from power utility

can result in death or injury to electric utility

workers due to backfeed of electrical energy.

DANGER

WHEN ADDING FUEL

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

removing gas cap. Loosen cap slowly to relieve pressure in tank.

• Fill fuel tank outdoors.

• DO NOT overfill tank.Allow 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.

WHEN OPERATING EQUIPMENT

• 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.

WHEN TRANSPORTING OR REPAIRING EQUIPMENT

• Transport/repair with fuel tank EMPTY or with fuel shutoff

valve OFF.

• Disconnect spark plug wire.

WHEN STORING FUEL OR EQUIPMENT WITH FUEL

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.

Fuel and its vapors are extremely flammable and

explosive.

Fire or explosion can cause severe burns or

death.

WARNING

• 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

4000XL Extended Life Generator

• DO NOT touch hot surfaces.

• Allow equipment to cool before touching.

Running engines produce heat.Temperature of

muffler and nearby areas can reach or exceed

150°F (65°C).

Severe burns can occur on contact.

WARNING

• DO NOT tamper with governed speed. Generator supplies

correct rated frequency and voltage when running at governed

speed.

• DO NOT modify generator in any way.

Excessively high operating speeds increase risk of injury

and damage to generator.

Excessively low speeds impose a heavy load.

CAUTION

• See “Don’t Overload Generator” on page 12.

• Start generator and let engine stabilize before connecting

electrical loads.

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

operation.

• Turn electrical loads OFF and disconnect from generator

before stopping generator.

Exceeding generators wattage/amperage capacity can

damage generator and/or electrical devices connected

to it.

CAUTION

• 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 objects 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.

Improper treatment of generator can damage it and

shorten its life.

CAUTION

WHEN ADJUSTING OR MAKING REPAIRS TOYOUR

GENERATOR

• Disconnect the spark plug wire from the spark plug and place

the wire where it cannot contact spark plug.

Unintentional sparking can result in fire or

electric shock.

WARNING

4000XL Extended Life Generator

KNOWYOUR 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.

120 Volt AC, 15 Amp

Duplex Receptacle

Fuel Tank

Idle Control Switch

Choke Lever

Recoil Starter

12 Volt DC, 10 Amp

Receptacle

Run/Stop Switch

120 Volt AC, 30 Amp

Receptacle

Circuit Breakers (AC)

120/240 Volt AC,

20 Amp Receptacle

Spark Arrester Muffler

Air Cleaner

Grounding Fastener

12 Volt DC,10 Amp Receptacle — Recharge a

discharged 12 Volt automotive type battery through this

receptacle.

120 Volt AC, 15 Amp Duplex Receptacle — May be

used to supply electrical power for the operation of

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

appliance, tool and motor loads.

120 Volt AC, 30 Amp Receptacle — May be used to

supply electrical power for the operation of 120 Volt AC,

30 Amp, single phase, 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 120 and/or

240 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting,

appliance, tool and motor loads.

Air Cleaner — Uses a dry type filter element and foam

pre–cleaner to limit the amount of dirt and dust sucked

into the engine.

Choke Lever — Used when starting a cold engine.

Circuit Breakers (AC) — Each receptacle is provided

with a "push to reset" circuit breaker to protect the

generator against electrical overload.

Fuel Tank — Capacity of 4.5 U.S. gallons.

Grounding Fastener — If required, please consult a

qualified electrician, electrical inspector, or the local agency

having jurisdiction.

Idle 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

sure switch is OFF when starting engine.

Oil Fill Cap — Add oil to engine here.

Recoil starter — Used to start the engine manually.

Run/Stop Switch — Set this switch to "Run" before

using recoil starter. Set switch to "Stop" to switch OFF

engine.

Spark Arrester Muffler — Exhaust muffler lowers

engine noise and is equipped with a spark arrester screen.

Oil Fill Cap

4000XL Extended Life Generator

ASSEMBLY

Your generator requires some assembly and is ready for

use after it has been properly serviced with the

recommended oil and fuel.

If you have any problems with the assembly of your

generator, please call the generator helpline at

1-800-270-1408.

Remove Generator From Carton

1. Set carton on a rigid flat surface with “This Side Up”

arrows pointing upward.

2. Carefully open top flaps of shipping carton. Review

“Cold Weather Operation” on page 10.

3. Cut down corners at one end of carton from top to

bottom and lay that side of carton down flat.

4. Remove all packing material, carton fillers, etc.

5. Remove generator from shipping carton.

Install Wheel Kit

To install the wheel kit, the following tools are required:

• Socket wrench with 1/2" or 13mm sockets

• Needle-nose pliers

Install Wheel Kit as follows: (See Figure 1)

1. Place bottom of the generator cradle on a flat, even

surface.Temporarily place unit on blocks to ease assembly.

2. Slide axle through both axle mounting brackets on

cradle frame, as shown.

3. Slide wheel over axle.

NOTE: Be sure to install both wheels with air pressure

valve on outboard side.

4. Retain wheel on axle with e-ring using a needle-nose

pliers.You may add the flat washer if desired.

5. Repeat step 3 and 4 to secure second wheel.

Mounting Leg

Use Existing Fasteners

Axle

Flat Washer

Cap Screw

Handle

Hex

nut

Wheel E-Ring

Figure 1 — Install Wheel Kit

4000XL Extended Life Generator

6. Remove existing hardware from vibration mounts with

13mm wrench. Use same hardware to attach mounting leg.

7. Remove temporary blocks.

8. Center handle bracket on generator frame at control

panel end of cradle.

9. Attach handle bracket with two cap screws and two hex

nuts. Use two 13 mm wrenches to tighten hardware.

10. Check that all fasteners are tight and tires are inflated

between 15-40 PSI.

BEFORE STARTING

ENGINE

Add Engine Oil and Fuel

• Place generator on a level surface.

• Refer to engine owner’s manual and follow oil and fuel

recommendations and instructions.

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

engine owner’s manual for recommendations.

NOTE: The generator assembly rotates on a prelubricated

and sealed ball bearing that requires no additional

lubrication for the life of the bearing.

CAUTION

• Refer to engine manual for oil and fuel fill information.

• Damage to equipment resulting from failure to follow this

instruction will void warranty.

Any attempt to crank or start the engine before it has

been properly filled with the recommended oil will result

in equipment failure.

4000XL Extended Life Generator

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 neutral wire (the neutral 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 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.

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, and must comply with all applicable laws and

electrical codes.

OPERATING THE

GENERATOR

Starting the Engine

Disconnect all electrical loads from the generator. Follow

these start instruction steps in numerical order:

1. Make sure unit is on a level surface.

IMPORTANT: Failure to start and operate unit on a level

surface will cause the unit not to start or shut down

during operation.

2. Turn fuel valve to “On” position (Figure 2).

3. Make sure Idle Control switch is in “Off” position

(Figure 3).

3. Start engine according to instructions given in engine

owner’s manual.

• When using generator for backup power, 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 NOT touch bare wires or receptacles.

• DO NOT use generator with electrical cords which are worn,

frayed, bare or otherwise damaged.

• DO NOT 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.

Generator produces powerful voltage.

Failure to isolate generator from power utility

can result in death or injury to electric utility

workers due to backfeed of electrical energy.

DANGER

• See “Don’t Overload Generator” on page 12.

• Start generator and let engine stabilize before connecting

electrical loads.

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

operation.

• Turn electrical loads OFF and disconnect from generator

before stopping generator.

Exceeding generators wattage/amperage capacity can

damage generator and/or electrical devices connected

to it.

CAUTION

Figure 3 — Idle Control Switch

Figure 2 — Fuel Shut-offValve

4000XL Extended Life Generator

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.

Connecting Electrical Loads

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

starting.

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

single phase, 60 Hz electrical loads.

• DO NOT connect 240 Volt loads to the 120 Volt

receptacles.

• DO NOT connect 3–phase loads to the generator.

• DO NOT connect 50 Hz loads to the generator.

•DO NOT OVERLOAD THE GENERATOR. See

“Don’t Overload Generator” on page 12.

Stopping the Engine

1. Unplug ALL electrical loads from generator panel

receptacles. NEVER start or stop engine with electrical

devices plugged in and turned ON.

2. Move idle control switch to “Off” position.

3. Let engine run at no-load for several minutes to

stabilize internal temperatures of engine and generator.

4. Turn engine off according to instructions given in the

engine owner’s manual.

5. Move fuel valve to “Off” position.

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.When an electrical load is

removed, 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

starting and stopping the engine.

Charging a Battery

Your generator has the capability of recharging a discharged

12 Volt 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 having a discharged battery.

To recharge 12Volt batteries, proceed as follows:

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

ONLY distilled water to cover separators in battery

cells. DO NOT use tap water.

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 “12-VOLTS D.C.”.

5. Connect battery charge cable clamp with red handle

to the positive (+) battery terminal (Figure 4).

• DO NOT allow any open flame, spark, heat, or lit cigarette

during and for several minutes after charging a battery.

• Wear protective goggles, rubber apron, and rubber gloves.

Storage batteries give off explosive hydrogen gas

during recharging.

Hydrogen gas stays near battery for a long time

after battery has been charged.

Slightest spark will ignite hydrogen and cause

explosion.

You can be blinded or severely injured.

Battery electrolyte fluid contains acid and is

extremely caustic.

Contact with battery fluid will cause severe

chemical burns.

DANGER

Figure 4 — Battery Connections

4000XL Extended Life Generator

6. Connect battery charge cable clamp with black handle

to the negative (–) battery terminal (Figure 4).

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] and a high dew point), your generator may

experience icing of the carburetor and/or the crankcase

breather system.

Build a structure that will enclose three sides and the top

of the generator:

1. Make sure entire muffler-side of generator is exposed.

Note that your generator may appear different from

that shown in Figure 5.

2. Ensure a minimum of two feet clearance between

open side of box and nearest object.

3. Face exposed end away from wind and elements.

4. Enclosure should hold enough heat created by

generator to prevent problems.

RECEPTACLES

120 Volt AC, 15 Amp Receptacles

Each of these outlets is protected against overload by

15 Amp push-to-reset type circuit breakers (Figure 6).

Use each outlet to operate 120 Volt, 60 Hz, single phase

loads requiring 1,800 (1.8 kW) watts at 15 Amps of current.

Figure 5 — Temporary Cold Weather Shelter

Wind

• Operate generator ONLY outdoors.

• Keep at least 2 feet of clearance on all sides of generator for

adequate ventilation.

• DO NOT operate generator inside any building or enclosure,

including the generator compartment of a recreational vehicle (RV).

• Remove generator from shelter when temperature is above

40°F [4°C].

Running generator gives off carbon monoxide,

an odorless, colorless, poison gas.

Breathing carbon monoxide will cause nausea,

fainting or death.

DANGER

• NEVER attempt to power a device requiring more

amperage than generator or receptacle can supply.

• DO NOT overload the generator. See “Don’t Overload

Generator”.

Receptacles may be marked with rating value greater

than generator output capacity.

CAUTION

Figure 6 — 120Volt AC, 15 Amp Duplex Receptacle

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