4000XL Portable Generator Owner’s Manual

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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 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.

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 Generac Portable Products 4,000XL Generator

EQUIPMENT SAFETY RULES

DESCRIPTION This generator set was designed and manufactured for
specific applications. Do Not attempt to modify the unit
This generator is an engine-driven, revolving field, or use it for any application it was not designed for. If you
alternating current (AC) generator. It was designed to have any questions about your generator’s application, ask
supply electrical power for operating compatible electrical your dealer/distributor or consult the factory.
lighting, appliance, tool, and motor loads. This manual
The manufacturer could not possibly anticipate every
contains information for a generator that operates
circumstance that might involve a hazard. For that reason
120 and/or 240 Volt AC, single phase, 60 Hz devices that
warnings in the manual and warnings on tags or decals
require up to 4,000 watts (4.0 kW) of power that pull up
affixed to the unit are not all–inclusive. If you intend to
to 33.3 Amps at 120 Volts or 16.7 Amps at 240 Volts.
handle, operate or service the unit by a procedure or
CAUTION! Do Not exceed the generator’s method not specifically recommended by the manufacturer,
wattage/amperage capacity. Add up the rated watts first make sure that such a procedure or method will not
of all devices you are connecting to generator render this equipment unsafe or pose a threat to you and
receptacles at one time. This total should not be others.
greater than 4,000 watts. In most cases rated watts Read this manual carefully and become familiar
of the electrical device can be found on the device with your generator set. Know its applications, its
nameplate. If the device nameplate gives only volts limitations and any hazards involved.
and amps, multiply volts times amps to obtain watts
(volts X amps = watts). WARNING:
The 4,000 watt generator has the following features: The engine exhaust from this product
contains chemicals known to the State
• 120/240 Volt, 20 Amp locking receptacle and a 120 Volt, of California to cause cancer, birth
30 Amp locking receptacle. defects, or other reproductive harm.
• 120 Volt, 15 Amp receptacles.
DANGER! You must isolate the generator from
• 12 Volt DC, 10 Amp receptacle.
the electric utility by opening the electrical system’s
• Low Oil Shutdown: Automatically shuts down the engine main circuit breaker or main switch if this unit is
if oil drops below safe operation level. used for backup power. Failure to isolate the
• Four gallon overhead fuel tank with fuel gauge. generator from the power utility may result
in injury or death to electric utility workers
• The generator’s revolving field is driven at about
and damage to the generator due to a backfeed
3,600 rpm by a Generac Power Systems 7.8 h.p. engine.
of electrical energy. Whenever unit is providing
WARNING! Do Not tamper with engine backup power, the electric utility must be notified.
governed speed. High operating speeds are
dangerous and increase risk of personal injury or DANGER! Generator exhaust gases contain
damage to equipment. The generator supplies DEADLY carbon monoxide gas. Carbon
correct rated frequency and voltage only when monoxide, if breathed in sufficient
running at proper governed speed. Incorrect concentrations, can cause unconsciousness or
frequency and/or voltage can damage some death. Operate this equipment outdoors where
connected electrical loads. Operating at excessively adequate ventilation is available.
low speeds imposes a heavy load. When adequate The Emission Control System for this generator is
engine power is not available engine life may be warranted for standards set by the Environmental
shortened. 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 • Never operate the generator:
cause serious injury or death by electrocution. Never in rain; in any enclosed compartment; when connected
touch bare wires or receptacles. Never permit a child electrical devices overheat; if electrical output is lost; if
or any unqualified person to operate the generator. engine or generator sparks; if flame or smoke is
• Never handle any kind of electrical cord or device while observed while unit is running; if unit vibrates
standing in water, while barefoot or while hands or feet excessively.
are wet. Death or serious injury from electrocution may
result. GROUNDING THE
• Use a ground fault circuit interrupter (GFCI) in any damp
or highly conductive area (such as metal decking or steel
GENERATOR
work). The National Electrical Code requires that the frame and
• Never use worn, bare, frayed or otherwise damaged external electrically conductive parts of this generator be
electrical cords with the generator. Death, serious injury properly connected to an approved earth ground. Local
and property damage from electrical shock may result. electrical codes may also require proper grounding of the
• Gasoline is highly FLAMMABLE and its vapors unit. For that purpose, a GROUNDING WING NUT is
are EXPLOSIVE. Never allow smoking, open provided on the generator end (Figure 1).
flames, sparks or heat in the vicinity while Figure 1 — Grounding Wing Nut
handling gasoline. Avoid spilling gasoline on a hot
engine. Comply with all laws regulating storage and
handling of gasoline.
• Do Not overfill 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
Grounding
gasoline vapors might reach an open flame, spark or pilot Wing Nut
light (as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.
• The unit requires an adequate flow of cooling air for its Generally, connecting a No. 12 AWG (American Wire
continued proper operation. Never operate the unit Gauge) stranded copper wire to the grounding wing nut
inside any room or enclosure where the free flow of and to an earth-driven copper or brass grounding rod
cooling air into and out of the unit might be obstructed. (electrode) provides adequate protection against electrical
Allow at least 2 feet of clearance on all sides of generator, shock. Be careful to keep the grounding wire attached after
even while operating unit outdoors, or you could damage connecting the stranded copper wire. However, local codes
the unit. See “Cold Weather Operation” on page 10. may vary widely. Consult with a local electrician for
• Never start or stop the unit with electrical loads grounding requirements in your area.
connected to receptacles with the connected devices Properly grounding the generator helps prevent electrical
turned ON. Start the engine and let it stabilize before shock if a ground fault condition exists in the generator or
connecting any electrical loads. Disconnect all electrical in connected electrical devices. Proper grounding also helps
loads before shutting down the generator. dissipate static electricity, which often builds up in
• Do Not insert any object through cooling slots of the ungrounded devices.
engine. You could damage the unit or injure yourself.

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 Generac Portable Products 4,000XL 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.

Fuel Tank
Circuit Breakers (AC)

Fuel Shut Off Valve

120 Volt AC, 30 Amp
Receptacle
Run/Stop Switch

120/240 Volt AC,

20 Amp Receptacle

12 Volt DC, 10 Amp

Receptacle

120 Volt AC, 15 Amp,

Duplex Receptacle Idle Control Switch
Grounding Wing Nut

12 Volt DC, 10 Amp Receptacle — Use this receptacle Circuit Breakers (AC) — Each receptacle is provided
with battery charge cables to charge a 12 Volt battery. with a circuit breaker to protect the generator against
120 Volt AC, 15 Amp Duplex Receptacle — May be electrical overload. Breakers are "push to reset" type.
used to supply electrical power for the operation of Fuel Shut Off Valve — Controls fuel supply to engine.
120 Volt AC, 15 Amp, single phase, 60 Hz electrical Fuel Tank — Capacity of 4 U.S. gallons (15 liters).
lighting, appliance, tool and motor loads.
Grounding Wing Nut — Provides a tie-point for
120 Volt AC, 30 Amp Receptacle — May be used to connecting the generator frame to earth ground.
supply electrical power for the operation of 120 Volt AC,
30 Amp, single phase, 60 Hz electrical lighting, appliance, Idle Control Switch — The idle control runs the engine
tool and motor loads. at normal (high) speeds when there is an electrical load
present and runs the engine at idle (low) speeds when a
120/240 Volt AC, 20 Amp Receptacle — May be used load is not present. This feature greatly improves fuel
to supply electrical power for the operation of 120 and/or economy, extends the life of the engine, and reduces engine
240 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting, noise.
appliance, tool and motor loads.
Run/Stop Switch — Must be in “Run” position to start
engine. Set to “Stop” to stop a running engine.

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 Generac Portable Products 4,000XL Generator

CONTENTS Add Gasoline

Check all contents. If any parts are missing or damaged, call DANGER! Explosion Hazard! Never fill fuel tank
the generator helpline at 1-800-270-1408. Review “Cold indoors. Never fill fuel tank when engine is running
Weather Operation” on page 8. Shipped with your or hot. Do Not light a cigarette or smoke when
generator is: filling the fuel tank.
• Main unit
WARNING! Do Not overfill the fuel tank.
• 20 Amp and 30 Amp locking plugs Always allow room for fuel expansion.
• Spare spark plug and air filter
• Use regular UNLEADED gasoline with the generator
• Spark plug wrench engine. Do Not use premium gasoline. Do Not mix oil
• Video tape with gasoline.
• Oil • Clean area around fuel fill cap, remove cap.
• Engine and unit owner’s manual • Slowly add unleaded regular gasoline to fuel tank. Be
• Battery charge cables careful not to overfill. Allow about 1/2" of tank space for
fuel expansion (Figure 2).
Figure 2 — Typical Fuel Expansion Space
BEFORE STARTING ENGINE
Add Oil
WARNING! Any attempt to crank or start the
engine before it has been properly filled with the
recommended oil may result in an engine failure.

To fill your engine with oil:

• Place generator on a level surface.
• Clean area around oil fill and remove oil fill cap.
• Select the oil's viscosity grade and fill engine with oil
following the instructions given in the engine owner’s • Install fuel cap and wipe up any spilled gasoline.
manual. Do Not overfill! IMPORTANT: It is important to prevent gum deposits
• Install oil fill cap. from forming in essential fuel system parts such as the
carburetor, fuel filter, fuel hose or tank during storage.
NOTE: The generator’s revolving field rides on a pre- Also, experience indicates that alcohol-blended fuels (called
lubricated and sealed ball bearing that requires no gasohol, ethanol or methanol) can attract moisture, which
additional lubrication for the life of the bearing. leads to separation and formation of acids during storage.
Acidic gas can damage the fuel system of an engine while in
storage.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See “Storage”
on page 11. Never use engine or carburetor cleaner
products in the fuel tank as permanent damage may occur.

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 Generac Portable Products 4,000XL Generator

OPERATING THE 5. Grasp the recoil handle and pull slowly until slight
resistance is felt. Then pull rapidly one time only to
GENERATOR start engine.
• If engine starts, proceed to step 7.
CAUTION! Never start or stop the engine with
electrical loads connected to the unit and with the • If engine fails to start, proceed to step 6.
connected devices turned ON. 6. Move the choke lever to “Half” choke position, and
pull recoil handle twice.
Starting the Engine • If engine fails to start, repeat steps 4 thru 6.
Disconnect all electrical loads from the generator. Use the 7. Move choke lever to “Run” position. If engine falters,
following start instruction steps by numerical order: move choke lever to “Half” choke position until the
1. Make sure the Idle Control switch is in “Off” position. engine runs smoothly, and then to “Run” position.
2. Turn the fuel valve to the “On” position (Figure 3). NOTE: If engine still fails to start after 3 pulls, check for
proper oil level in crankcase. This unit is equipped with a
Figure 3 — Fuel Valve in Open Position. 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 Hertz electrical loads.
3. Set the Run/Stop switch to “Run” position (Figure 4).
• Do Not connect 240 Volt loads to 120 Volt receptacles.
Figure 4 — Run/Stop Switch
• Do Not connect 3–phase loads to the generator.
• Do Not connect 50Hz loads to the generator.
• DO NOT OVERLOAD THE GENERATOR. Add up
the rated watts (or amps) of all loads to 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 11.

Stopping the Engine

4. Place the choke lever in the “Full” choke position • Unplug all electrical loads from generator panel
(Figure 5). receptacles. Never start or stop engine with electrical
devices plugged in and turned on.
Figure 5 — Choke Lever
• Put the Idle Control switch in the “Off” position.
“Full” choke • Let engine run at no–load for 30 seconds to stabilize the
Position internal temperatures of engine and generator.
• Move Run/Stop switch to “Stop”.
• Close the fuel shut–off valve.

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 Generac Portable Products 4,000XL Generator

Operating Automatic Idle Control To recharge 12 Volt batteries, proceed as follows:

This switch is designed to greatly improve fuel economy. • Check fluid level in all battery cells. If necessary, add
When this switch is turned ON, the engine will only ONLY distilled water to cover separators in battery
run at its normal high governed engine speed when an cells. Do Not use tap water.
electrical load is connected. When the load is removed, • If the battery is equipped with vent caps, make sure they
the engine will run at a reduced speed. With the switch are installed and are tight.
OFF, the engine will run at the normal high engine speed. • If necessary, clean battery terminals.
Always have the switch off when starting and
stopping the engine. • Connect battery charge cable connector plug to panel
receptacle identified by the words “12-VOLT D.C.”
Charging a Battery • Connect battery charge cable clamp with red handle to
the positive (+) battery terminal (Figure 6).
DANGER! Storage batteries give off explosive Figure 6 — Battery Connections
hydrogen gas while recharging. This explosive
mixture will remain around the battery for a long
time after it has been charged. The slightest spark
can ignite the hydrogen and cause an explosion. Such
an explosion can shatter the battery and cause
blindness or other serious injury.

DANGER! Do Not permit smoking, open flame,

sparks or any other 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 can cause severe burns. If spill occurs,
flush area with clear water immediately.
Your generator has the capability of recharging a discharged
12 Volt automotive or utility style storage battery. Do Not • Connect battery charge cable clamp with black handle
use the unit to charge any 6 Volt batteries. Do Not use to the negative (–) battery terminal (Figure 6).
the unit to crank an engine having a discharged battery. • Start engine. Let the engine run while battery recharges.
• 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.

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 Generac Portable Products 4,000XL Generator

Cold Weather Operation • Ensure a minimum of two feet clearance between open
side of box and nearest object.
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your Generac generator • Face exposed end away from wind and elements.
may experience icing of the carburetor and/or the • Enclosure should hold enough heat created by the
crankcase breather system. generator to prevent problems.
In an emergency, use the original shipping box as a
temporary shelter:
CAUTION! NEVER run unit indoors; Do Not
enclose generator any more than shown. Remove
• Cut off all flaps. shelter when temperatures are above 40°F [4°C].
• Cut out one of the long sides of the box to expose
exhaust side of unit. Ensure a minimum of two feet
clearance between open side of box and nearest object.
RECEPTACLES
• Cut appropriate slots to access receptacles of unit.
120 Volt AC, 15 Amp Receptacles
• Start unit, then place box over it.
Each of these outlets is protected against overload by
IMPORTANT: Remove shelter when temperature is 15 Amp push-to-reset type circuit breakers (Figure 8).
above 40°F [4°C].
Figure 8 — 120 Volt AC, 15 Amp Duplex Receptacle
For a more permanent shelter, build a structure that will
enclose three sides and the top of the generator:
• Make sure entire muffler-side of generator is exposed
(Figure 7).
Figure 7 — Temporary Cold Weather Shelter

Wind

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

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

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 Generac Portable Products 4,000XL Generator

120/240 Volt AC, 20 Amp Locking 120 Volt AC, 30 Amp Locking
Receptacle Receptacle
Use a NEMA L14-20 plug with this receptacle. Connect a Use a NEMA L5-30 plug with this receptacle. Connect a
4-wire cord set rated for 250 Volts at 20 Amps (or greater) 3-wire cord set rated for 125 Volts AC at 30 Amps to the
(Figure 9). You can use the same 4-wire cord if you plan to plug (Figure 10).
run a 120 Volt load.
Figure 10 — 120 Volt AC, 30 Amp Locking Receptacle
Figure 9 — 120/240 Volt AC, 20 Amp Receptacle

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 120/240 Volt AC, 60 Hz, single 12 Volt DC, 10 Amp Receptacle
phase loads requiring up to 2,400 watts of power at
This connector (identified by the legend “12-VOLT D.C.”)
20 Amps for 120 Volts; 4,000 watts of power (4.0 kW) at
supplies 12 Volts DC at 10 Amps through battery charging
16.7 Amps for 240 Volts. The outlet is protected by a
cables for recharging 12 Volt batteries (Figure 11). See
20 Amp push-to-reset circuit breaker.
“Charging a Battery” on page 7.
Figure 11 — 12 Volt DC, 10 Amp Receptacle

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 Generac Portable Products 4,000XL Generator

DON’T OVERLOAD THE • If the appliance, tool or motor does not give wattage,
multiply 120 Volts times ampere rating to determine
GENERATOR watts (volts x amps = watts).
• Some electric motors, such as induction types, require
Overloading a generator in excess of its rated wattage about three times more watts of power for starting than
capacity can result in damage to the generator and/or for running. This surge of power lasts for only a few
connected electrical devices. Observe the following, to seconds when starting such motors. Be sure you allow
prevent overloading the unit: for this high starting wattage when selecting electrical
• Add up the total wattage of all electrical devices to be devices to connect to your generator. First estimate the
connected at one time. This total should NOT be watts needed to start the largest motor. Add to that
greater than the generator’s wattage capacity. figure the running watts of all other connected loads.
• The rated wattage of lights can be taken from light bulbs. • The wattage reference guide (Figure 11) is provided to
The rated wattage of tools, appliances and motors can help you to determine how many items the generator
usually be found on a data plate or decal affixed to the can operate at one time.
device.

Figure 11 — Wattage Reference Guide

Recreational/Home Uses Professional/Contractor Uses
Tool/Appliance....................................................Watts Tool/Appliance....................................................Watts
AM/FM clock radio.....................................................................50 *1/3 hp airless sprayer.............................................................600
Light bulb....................................................................................100 3/8" hammer drill .....................................................................600
Fan................................................................................................200 Variable speed Sawzall®..........................................................960
20" color TV..............................................................................400 ½" power drill.........................................................................1000
*Deep freezer............................................................................500 Quartz-halogen work light...................................................1000
Personal computer and 15" monitor ...................................800 Belt sander...............................................................................1200
*1/3 hp furnace fan blower.....................................................800 7 ¼" circular saw ...................................................................1500
Microwave oven........................................................................800 7 ¼" worm drive saw............................................................1600
*18 cu ft refrigerator ...............................................................800 *1½ hp air compressor ........................................................1800
Sump pump..............................................................................1000 *10" power miter saw...........................................................1800
Electric skillet..........................................................................1250 6" bench grinder.....................................................................1800
*½ hp water well pump........................................................1400 *6" table planer.......................................................................1800
*12,000 Btu window air conditioner .................................1400 *10" table/radial arm saw .....................................................2000
Space heater............................................................................1800 Wire feed welder...................................................................2400
Electric water heater.............................................................4000 * allow 3 times listed watts for starting this device

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 Generac Portable Products 4,000XL Generator

SPECIFICATIONS To Clean the Generator

Maximum Surge Watts . . . . . . . . . . . . . . . 5,000 Watts • Use a damp cloth to wipe exterior surfaces clean.
Continuous Wattage Capacity . . . . . . . . . 4,000 Watts • Soft, bristle brush may be used to loosen caked on dirt
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 or oil.
Rated Maximum Continuous Load Current • A vacuum cleaner may be used to pick up loose dirt and
At 120 Volts . . . . . . . . . . . . . . . . . . . . . . 33.3 Amps debris.
At 240 Volts . . . . . . . . . . . . . . . . . . . . . . 16.7 Amps • Low pressure air (not to exceed 25 psi) may be used to
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-phase blow away dirt. Inspect cooling air slots and opening on
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . 60 Hertz generator. These openings must be kept clean and
Fuel Tank Capacity . . . . . . . . . . . . . . . . . 4 U.S. gallons unobstructed.

GENERAL MAINTENANCE STORAGE INSTRUCTIONS

RECOMMENDATIONS The generator should be started at least once every seven
days and allowed to run at least 30 minutes. If this cannot
The Owner/Operator is responsible for making sure that
be done and you must store the unit for more than 30
all periodic maintenance tasks are completed on a timely
days, use the following guidelines to prepare it for storage.
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. Never operate a
damaged or defective generator. Generator Storage
• Clean the generator as outlined in “To Clean the
Engine Maintenance Generator.”
See engine manual for instructions. • Check that cooling air slots and openings on generator
are open and unobstructed.
Generator Maintenance DANGER! Storage covers can be flammable. Do
Generator maintenance consists of keeping the unit clean Not place a storage cover over a hot generator. Let
and dry. Operate and store the unit in a clean dry the unit cool for a sufficient time before placing the
environment where it will not be exposed to excessive cover on the unit.
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.
Engine Storage
See engine owner’s manual for instructions.
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 Other Storage Tips
slots, some of the water will be retained in voids and • Do Not store gasoline from one season to another.
cracks of the rotor and stator winding insulation. Water • Replace your gasoline can if it starts to rust. Rust and/or
and dirt buildup on the generator internal windings will dirt in a gasoline can cause problems when you use
eventually decrease the insulation resistance of these contaminated fuel with this unit.
windings.
• Store in clean and dry area.

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 Generac Portable Products 4,000XL Generator

TROUBLESHOOTING

Problem Cause Solution

1. Circuit breaker is open. 1. Reset circuit breaker.
Engine is running, but 2. Poor connection or defective cord set. 2. Check and repair.
no AC output is 3. Connected device is bad. 3. Connect another device that is in good
available. condition.
4. Fault in generator. 4. Contact Generac service facility.
1. Short circuit in a connected load. 1. Disconnect shorted electrical load.
Engine runs good but 2. Generator is overloaded. 2. See “Don’t Overload the Generator”
bogs down when loads on page 10.
are connected. 3. Engine speed is too slow. 3. Contact Generac service facility.
4. Shorted generator circuit. 4. Contact Generac service facility.
1. Run/Stop switch set to “Stop”. 1. Set switch to “Run”.
2. Dirty air cleaner. 2. Clean or replace air cleaner.
3. Out of gasoline. 3. Fill fuel tank.
4. Stale gasoline. 4. Drain gas tank and fill with fresh fuel.
5. Spark plug wire not connected to spark 5. Connect wire to spark plug.
plug.
Engine will not start; or 6. Bad spark plug. 6. Replace spark plug.
starts and runs rough. 7. Water in gasoline. 7. Drain gas tank; fill with fresh fuel.
8. Overchoking. 8. Put choke lever to “No Choke”
position.
9. Low oil level. 9. Fill crankcase to proper level.
10. Excessively rich fuel mixture. 10. Contact Generac service facility.
11. Intake valve stuck open or closed. 11. Contact Generac service facility.
12. Engine has lost compression. 12. Contact Generac service facility.
1. Out of gasoline. 1. Fill fuel tank.
Engine shuts down
2. Low oil level. 2. Fill crankcase to proper level.
during operation.
3. Fault in engine. 3. Contact Generac service facility.
1. Load is too high. 1. See “Don’t Overload the Generator”
on page 10.
Engine lacks power.
2. Dirty air filter. 2. Replace air filter.
3. Engine needs to be serviced. 3. Contact Generac service facility.
1. Choke is opened too soon. 1. Move choke to halfway position till
Engine “hunts” or engine runs smoothly.
falters. 2. Carburetor is running too rich or too 2. Contact Generac service facility.
lean.

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 Generac Portable Products 4,000XL Generator

NOTES

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 Generac Portable Products 4,000XL Generator

ELECTRICAL SCHEMATIC

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 Generac Portable Products 4,000XL Generator

WIRING DIAGRAM

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 Generac Portable Products 4,000XL Generator

EXPLODED VIEW – MAIN UNIT

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 Generac Portable Products 4,000XL Generator

PARTS LIST – MAIN UNIT

Item Part # Qty Description Item Part # Qty Description
1 A93199 1 CRADLE, XL 46 78831B 4 HHMS, M6 1.0 x 60
2 A84021 1 SUPPORT, Engine 47 80270 1 VALVE, Tank
3 NSP 1 ENGINE 48 78299 1 BUSHING, Plastic Tank
4 66365 1 HOUSING, Engine Adapter 49 85134 1 GAUGE, Fuel
5 84141J 1 ASSEMBLY, Rotor 50 88325 1 TANK, Fuel
6 83540J 1 ASSEMBLY, Stator 51 B84042 1 SHIELD, Heat
7 65791 1 BEARING 52 84687 1 INSULATION, #2-1/4" Thick
8 96796 1 WASHER, M8 Flat 53 85000 1 CLIP, Insulation
10 86307 4 HHMS, 5/16-24 x 3/4 54 14353621 1 WIRE, Ground
11 47480 1 HHCS, 5/16-24 x 7" 55 23762 1 WASHER, Shakeproof #10
12 84508 2 MOUNT, Vibration 45° 56 26850 2 WASHER, M6 Shakeproof
13 52858 8 NUT, M8 Locking 60 B4399 1 DECAL, Control Panel
14 83208 1 BRACKET, Muffler 61 92982 1 DECAL, Danger
15 B4986 1 DECAL, Ground 62 B4398 2 DECAL, Heat Shield
16 66476 2 HHMS, LW M6 1.00 x 12 63 93826 1 DECAL, Operating Instructions
17 89476 1 GASKET, Exhaust 64 73054 1 DECAL, Fuel Shut Off
18 70644 1 PPHMS, M8 1.25 x 20 65 20566 1 DECAL, Generac 1-800
19 84346 3 PPHMS, M8 x 35 66 77816 1 DECAL, Caution Hot Muffler
20 40976 2 SHCS, M8 1.25 x 20 67 87116 1 ASSY., Control Panel
21 83083 1 SCREEN, Spark Arrest 68 B2153 4 HHCS, 12 - 14 x 7/8 Self Drill
22 83071 1 MUFFLER 69 84409 1 SLEEVING, Flexo, HW 1/2" x
23 81917 1 PIN, Roll M4 x 10 .83 ft.
25 66825-B 1 CARRIER, Rear Bearing
26 85652 2 MOUNT, Vibration
27 67989 2 NUT, M8 Flanged Serrated Parts Not Illustrated:
30 74908 4 TAPTITE, M5-0.8 x 10 37806 120 Volt AC 30 Amp Plug
32 86308 4 BOLT, M6 - 1.0 x 115 43483 120/240 Volt AC 20 Amp Plug
33 65795 1 RECTIFIER, Battery Charge 65787 Battery Charge Cable
34 66849A 1 TAPTITE, M5 0.8 x 20 72347 Spark Plug
35 67022 1 GROMMET, Rubber 78601 Air Filter
36 84132 1 ASSEMBLY, Drive Module Pwr 84882 Spark Plug Wrench
Reg. B4400 Owner’s Manual
37 66386 1 ASSEMBLY, Brush Holder B4572 Video
38 66849 2 TAPTITE, M5 0.8 x 16 BB3061 Oil, 28 oz.
39 B4871 1 COVER, Bearing Carrier NSP Engine Owner’s Manual
41 86494 1 SCREW, M6 -1.0 x 16 Wing
42 86292 1 HHCS, 10 - 16 x 3/4" Self Optional Accessories Not Included:
Driller 84883 Cord Wrap
43 77395 4 NUT, M6 Flange Lock 84895 Storage Cover
44 83465 4 GROMMET, Tank

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 Generac Portable Products 4,000XL Generator

EXPLODED VIEW AND PARTS LIST – CONTROL PANEL

Item Part # Qty. Description Item Part # Qty. Description

1 83976 1 PANEL, Control 13 84028 1 TRANSFORMER, Idle Control
2 83975 1 BOX, Control 14 67022 1 GROMMET, Rubber
3 66818 2 OUTLET, 120 Volts AC 15 85584 1 BAR, Bus
4 66821 1 OUTLET, 12 Volts DC 16 84543A 2 SCREW, 3.0 x 12mm
5 68867C 1 OUTLET, 120/240 Volts, 20 Amp 17 84543C 9 SCREW, 3.5 x 18mm
Locking 18 84198 3 SHIELD, Circuit Breaker
6 68868C 1 OUTLET, 120 Volts, 30 Amp 19 84197 1 BAR, Circuit Breaker Retaining
Locking 21 75476 2 SCREW, 4.15 x 16mm
7 75207A 1 CIRCUIT BREAKER, 30 Amp 22 22264 4 WASHER, M4 Lock
8 75207G 2 CIRCUIT BREAKER, 18 Amp 23 51715 4 NUT, M3 Hex
9 82538 1 SWITCH, On/Off Rocker 24 84543B 10 SCREW, 3.5 x 12mm
10 84134 1 GROMMET, Rubber 25 84335 1 WIRE HARNESS
11 83514 1 CIRCUIT BREAKER, 10 Amp 26 82542 1 BAR, DC Outlet Retaining
12 83970 1 CONTROL BOARD, System

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 Generac Portable Products 4,000XL Generator

NOTES

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 LIMITED WARRANTY
FOR "GN" ENGINE DRIVEN PORTABLE GENERATORS

GENERAC PORTABLE PRODUCTS (hereafter referred to as the COMPANY) warrants to the original purchaser that the
alternator and control panel for its portable generator will be free from defects in materials or workmanship for the items
and period set forth below from the date of original purchase. This warranty is not transferable and applies only to portable
generators driven by a GN-Series engine.
Consumer* Commercial*
Alternator 2 years (2nd year parts only) 1 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 (1)
Year in Consumer applications, and 90 days in 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 said warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination by the
COMPANY, is found to be defective under normal use and service**. Starting batteries are not warranted by the
COMPANY. All transportation costs under warranty, including return to the factory if necessary, are to be borne by the
purchaser and prepaid by the purchaser. This warranty does not cover normal maintenance and service and does not apply
to a generator set, alternator, or parts which have been 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 adversely affect 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.
THERE IS NO OTHER EXPRESS WARRANTY. THE COMPANY HEREBY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE DURATION OF
ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO THE TIME PERIOD AS
SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL
DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS
ANY RESPONSIBILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, SUCH AS THE LOSS OF
TIME OR THE USE OF 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 implied warranty lasts, or the exclusion or limitation of incidental or
consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal
rights and you may also have other rights, which vary from state to state.
For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Warranty service can
be performed only by a COMPANY authorized service facility. This warranty will not apply to service at any other facility.
At the time of requesting warranty service, evidence of original purchase date must be presented.

GENERAC PORTABLE PRODUCTS

Jefferson, Wisconsin 53549

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