Generac Power Systems 4000XL Owner's Manual
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Generac Power Systems 4000XL Owner's Manual

Extended life generator
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Parts Included*
• 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.
Model No. 9777-4 (4,000 Watt AC Generator) Manual No. 193524GS Revision 0 (08/04/2003)
Owner's Manual
Questions? Help is just a moment away!
Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-portables.com or www.briggsandstratton.com

Table of Contents

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

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Summary of Contents for Generac Power Systems 4000XL

  • Page 1: Table Of Contents

    *If any parts are missing or damaged, call 1-800-270-1408. Questions? Help is just a moment away! Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT Web: www.generac-portables.com or www.briggsandstratton.com Model No. 9777-4 (4,000 Watt AC Generator) Manual No. 193524GS Revision 0 (08/04/2003)

  • Page 2: Safety Rules

    4000XL Extended Life Generator EQUIPMENT SAFETY RULES DESCRIPTION This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Read this manual carefully and become Obey all safety messages that follow this familiar with your generator. Know its symbol to avoid possible injury or death.
  • Page 3 4000XL Extended Life Generator DANGER WARNING Running generator gives off carbon monoxide, Fuel and its vapors are extremely flammable and an odorless, colorless, poison gas. explosive. Breathing carbon monoxide will cause nausea, Fire or explosion can cause severe burns or fainting or death.
  • Page 4 4000XL Extended Life Generator CAUTION WARNING Exceeding generators wattage/amperage capacity can damage generator and/or electrical devices connected Unintentional sparking can result in fire or to it. electric shock. • See “Don’t Overload Generator” on page 12. • Start generator and let engine stabilize before connecting WHEN ADJUSTING OR MAKING REPAIRS TO YOUR electrical loads.

  • Page 5: Know Your Generator

    4000XL Extended Life Generator 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.

  • Page 6: Assembly

    4000XL Extended Life Generator ASSEMBLY Install Wheel Kit To install the wheel kit, the following tools are required: Your generator requires some assembly and is ready for use after it has been properly serviced with the • Socket wrench with 1/2" or 13mm sockets recommended oil and fuel.
  • Page 7 4000XL Extended Life Generator Remove existing hardware from vibration mounts with BEFORE STARTING 13mm wrench. Use same hardware to attach mounting leg. ENGINE Remove temporary blocks. Center handle bracket on generator frame at control panel end of cradle. Add Engine Oil and Fuel Attach handle bracket with two cap screws and two hex •...

  • Page 8: Operation

    4000XL Extended Life Generator USING THE GENERATOR OPERATING THE GENERATOR System Ground CAUTION The generator has a system ground that connects the Exceeding generators wattage/amperage capacity can generator frame components to the ground terminals on damage generator and/or electrical devices connected the AC output receptacles.The system ground is connected...

  • Page 9: Charging A Battery

    4000XL Extended Life Generator NOTE: If engine still fails to start after 3 pulls, check for Charging a Battery proper oil level in crankcase.This unit is equipped with a Your generator has the capability of recharging a discharged Low Oil Shutdown System. See engine manual.

  • Page 10: Operation

    4000XL Extended Life Generator Connect battery charge cable clamp with black handle DANGER to the negative (–) battery terminal (Figure 4). Running generator gives off carbon monoxide, Start engine. Let engine run while battery recharges. an odorless, colorless, poison gas.
  • Page 11 4000XL Extended Life Generator 120/240 Volt AC, 20 Amp Locking Figure 8 — 120 Volt AC, 30 Amp, Locking Receptacle Receptacle 3-Wire Cord Set NEMA L5-30 Use a NEMA L14-20 plug with this receptacle. Connect a 4-wire cord set rated for 250 Volts at 20 Amps (or greater) (Figure 7).You can use the same 4-wire cord if you plan to...

  • Page 12: Power Management

    4000XL Extended Life Generator DON'T OVERLOAD YOUR Plug in and turn on the next load. Again, permit the generator to stabilize. GENERATOR Repeat steps 4 and 5 for each additional load. NEVER add more loads than the generator capacity.Take special care to consider surge loads in generator capacity, Capacity as described above.

  • Page 13: Product Specifications

    4000XL Extended Life Generator SPECIFICATIONS NOTE: DO NOT use a garden hose to clean generator. Water can enter engine fuel system and cause problems. In Maximum Surge Watts ....6,600 watts addition, if water enters generator through cooling air slots, Continuous Wattage Capacity .

  • Page 14: Storage

    4000XL Extended Life Generator Move fuel valve to “On” position, and check for leaks. Generator Storage Replace o-ring if there is any leakage. • Clean the generator as outlined in “Generator Cleaning”. Generator Cleaning • Check that cooling air slots and openings on generator are open and unobstructed.

  • Page 15: Notes

    4000XL Extended Life Generator NOTES...
  • Page 16 4000XL Extended Life Generator NOTES...

  • Page 17: Troubleshooting

    4000XL Extended Life Generator TROUBLESHOOTING Problem Cause Correction One of the circuit breakers is Reset circuit breaker. open. Fault in generator. Contact Authorized service facility. No AC output is available, but Poor connection or defective Check and repair. generator is running.

  • Page 18: Schematic

    4000XL Extended Life Generator SCHEMATIC...

  • Page 19: Wiring Diagram

    4000XL Extended Life Generator WIRING DIAGRAM...

  • Page 20: Replacement Parts

    4000XL Extended Life Generator EXPLODED VIEW – MAIN UNIT...
  • Page 21 4000XL Extended Life Generator PARTS LIST – MAIN UNIT Item Part # Description Item Part # Description M189159GS CRADLE 40 22145GS WASHER M84021GS SUPPORT, Engine, Red 41 86494GS SCREW,Wing ENGINE 42 86292GS SCREW 66365GS HOUSING, Engine Adapter 43 52858GS NUT, Lock...
  • Page 22 4000XL Extended Life Generator EXPLODED VIEW AND PARTS LIST – CONTROL PANEL Item Part # Description Item Part # Description 83976GS PANEL, Control 13 84028GS TRANSFORMER, Idle Control 83975GS BOX, Control 14 67022GS GROMMET, Rubber 66818GS OUTLET, 120 V AC, 15 A Duplex...
  • Page 23 4000XL Extended Life Generator EXPLODED VIEW AND PARTS LIST – WHEEL KIT Item Part # Description 189715GS ASSY, Handle B1764GS LEG, Mounting 52858GS NUT, Locking 39287GS SCREW 191267FGS AXLE B4966GS WHEEL 191265GS E-RING 22247GS WASHER...

  • Page 24: Warranty

    LIMITED WARRANTY "Generac Portable Products is a licensed trademark of Briggs & Stratton Power Products. Briggs & Stratton Power Products will repair or replace, free of charge, any part, or parts of the equipment** that are defective in material or workmanship or both.

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