Generac Power Systems 4000EXL Manuale utente

Owner’s Manual

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

Model No. 1645-0 (4,000 Watt AC Generator) Manual No. 189189GS Revision 11 (03/01/2005)

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WISCONSIN, U.S.A.

Generac Portable Products is a licensed trademark of Briggs & Stratton Power Products.

Before using this product, read

this manual and follow all Safety

Rules and Operating Instructions.

CAUTION

4000EXL Extended Life Generator

TABLE OF CONTENTS

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

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

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19

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

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”.

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

Fire

Explosion

Toxic Fumes

Kickback

Electrical Shock

Electrocution Electrical Shock

Explosive Pressure Chemical Burn

Hot Surface

may be reproduced or transmitted in any form by any

means without the express written permission of Briggs &

Stratton Power Products Group, LLC.

4000EXL Extended Life Generator

• 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.

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

• 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

• Operate generator ONLY outdoors.

• Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings.

• 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.

WARNING

WHEN ADDING OR DRAINING FUEL

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

removing fuel cap. Loosen cap slowly to relieve pressure in

tank.

• Fill or drain 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 STARTING EQUIPMENT

• Ensure spark plug, muffler, fuel cap and air cleaner are in place.

• DO NOT crank engine with spark plug removed.

• If fuel spills, wait until it evaporates before starting engine.

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

4000EXL Extended Life Generator

• 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”.

• 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 starting engine, pull cord slowly until resistance is felt

and then pull rapidly to avoid kickback.

• NEVER start or stop engine with electrical devices plugged in

and turned on.

Rapid retraction of starter cord (kickback) will

pull hand and arm toward engine faster than

you can let go.

Broken bones, fractures, bruises or sprains could

result.

WARNING

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.

WHEN TESTING FOR ENGINE SPARK

• Use approved spark plug tester.

• DO NOT check for spark with spark plug removed.

Unintentional sparking can result in fire or

electric shock.

WARNING

• DO NOT touch hot surfaces.

• Allow equipment to cool before touching.

• The generator must be at least 5 feet from structures having

combustible walls and/or other combustible materials.

• Keep at least 3 feet of clearance on all sides of generator for

adequate cooling, maintenance and servicing.

• 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.

Running engines produce heat.Temperature of

muffler and nearby areas can reach or exceed

150°F (65°C).

Severe burns can occur on contact.

Combustible debris, such as leaves, grass, brush,

ect. can catch fire.

WARNING

4000EXL 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

Start Button

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 — Protects engine by filtering dust and

debris out of intake air.

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 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.

Start Button — When pressed, cranks engine to start.

Oil Fill Cap

4000EXL Extended Life Generator

ASSEMBLY

IMPORTANT: Read entire owner’s manual before you

attempt to assemble or operate your new generator.

Carton Contents

Parts included:

• Generator

• Wheel kit

• Battery

• Battery charge cables

• Battery float charger

• Locking 20 Amp plug

• Locking 30 Amp plug

• Engine oil

• Two packets of fuel stabilizer

• Owner's manual

• Engine manual

If any of the above parts are missing or damaged, call the

pressure washer helpline at 1–800–270–1408.

Attach Negative Battery Wire

The sealed battery on the generator is fully charged and

pre–installed except for the negative (black) battery cable.

To install:

1. Cut off tie wrap securing loose end of negative (black)

cable.

2. Connect negative (black) battery cable to negative (–)

terminal on battery (Figure 1).

3. Verify that connections to battery and generator are

correct and secure.

Install Handle

To install the handle you need the following tools:

• 2 - 13 mm (1/2”) box, open end, or socket wrenches

Install handle as follows:

1. Remove hardware from bracket on handle.

2. Place lifting handle on alternator end of cradle so that

handle falls between the two twistlock receptacles as

shown in Figure 2.Attach handle with provided cap

screws and hex nuts.Tighten with 13mm wrenches.

Figure 1 — Negative Battery Connection

Positive

battery cable

Negative

battery cable

Figure 2 — Install Handle

Capscrew

Handle

Hex

Nut

4000EXL Extended Life Generator

Add Engine Oil

• Place generator on a level surface.

• Refer to engine owner’s manual and follow oil

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.

Add Fuel

NOTE: This gasoline engine is certified to operate on

gasoline. Exhaust Emission Control System: EM (Engine

Modifications).

1. Use clean, fresh, regular UNLEADED fuel with a

minimum of 85 octane with equipment. DO NOT use

fuel which contains Methanol. DO NOT mix oil with

fuel.

2. Clean area around fuel fill cap, remove cap.

3. Slowly add regular unleaded fuel to fuel tank. Be careful

not to fill above the baffle.This allows adequate space

for fuel expansion (Figure 3).

4. Install fuel cap and wipe up any spilled fuel.

CAUTION

• Refer to engine manual for oil 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.

WHEN ADDING FUEL

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

removing fuel 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.

Fuel and its vapors are extremely flammable and

explosive.

Fire or explosion can cause severe burns or

death.

WARNING

FUEL

TANK

Figure 3 — Typical Fuel Expansion Space

Baffle

4000EXL 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.

Generator Location

Generator Clearance

The generator must be at least 5 ft. (152 cm) from

structures having combustible walls and/or other

combustible materials. Leave at least 3 ft. (92 cm) all around

generator including overhead, for adequate cooling,

maintenance and servicing.

Place generator in a well ventilated area, which will allow

for removal of deadly exhaust gas. DO NOT place

generator where exhaust gas could accumulate and enter

inside or be drawn into a potentially occupied building.

Ensure exhaust gas is kept away from any windows, doors,

ventilation intakes or other openings that can allow exhaust

gas to collect in a confined area (Figure 4). Prevailing winds

and air currents should be taken into consideration when

positioning generator.

Figure 4 — Generator Clearance

Exhaust Port

• 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.

WARNING

• Operate generator ONLY outdoors.

• Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings.

• 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.

WARNING

4000EXL Extended Life Generator

OPERATING THE

GENERATOR

IMPORTANT: Always unplug the battery float charger

before starting 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 5).

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

(Figure 6).

4. Start engine according to instructions given in engine

owner’s manual.

NOTE: If engine starts after 3 pulls but fails to run, or if

unit shuts down during operation, make sure unit is on a

level surface and check for proper oil level in crankcase.

This unit may be equipped with a low oil protection device.

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.

• See “Don’t Overload Generator”.

• 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 5 — Fuel Shut-offValve

Figure 6 — Idle Control Switch

• DO NOT touch hot surfaces.

• Allow equipment to cool before touching.

• The generator must be at least 5 feet from structures having

combustible walls and/or other combustible materials.

• Keep at least 3 feet of clearance on all sides of generator for

adequate cooling, maintenance and servicing.

• 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.

Running engines produce heat.Temperature of

muffler and nearby areas can reach or exceed

150°F (65°C).

Severe burns can occur on contact.

Combustible debris, such as leaves, grass, brush,

ect. can catch fire.

WARNING

• When starting engine, pull cord slowly until resistance is felt

and then pull rapidly to avoid kickback.

• NEVER start or stop engine with electrical devices plugged in

and turned on.

Rapid retraction of starter cord (kickback) will

pull hand and arm toward engine faster than

you can let go.

Broken bones, fractures, bruises or sprains could

result.

WARNING

4000EXL Extended Life Generator

•DO NOT OVERLOAD THE GENERATOR. See

“Don’t Overload Generator”.

Stopping the Engine

1. Turn OFF and 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 6Volt batteries. DO NOT use the

unit to crank an engine having a discharged battery.

To recharge 12 Volt 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 7).

6. Connect battery charge cable clamp with black handle

to the negative (–) battery terminal (Figure 7).

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.

How to Use the Battery Charger

Use battery float charger jack to keep the starting battery

charged and ready for use. Battery charging should be done

in a dry location, such as inside a garage.

1. Plug charger into unit’s “Battery Float Charger” jack,

which is located on the starter switch (Figure 8). Plug

battery charger into a 120 Volt AC wall receptacle.

Figure 7 — Battery Connections

• 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 8 — Battery Charger Jack

Indice

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