Generac 005788-0 XG4000 Owner's manual

Brand: Generac

Model: 005788-0 XG4000

Category: Power generators

Type: Owner's manual

This manual is also suitable for

MODEL: 005778-0 ×G4000

GENERAC _

wner'sIVlanual

XGSeriesPortableGenerator

Owner'sManual

introduction..............................................................................1

Readthis ManualThorougNy..................................................1

Safety Rules............................................................................1

Standardstndex.......................................................................3

Generalinformation.................................................................4

1.1 Unpacking................................................................................4

1.2 Assembly.................................................................................4

Operation.................................................................................5

2.1 Knowthe Generator................................................................. 5

2.2 Hourmeter............................................................................... 6

2.3 CordSets andConnectionPlugs.............................................. 6

2.4 Howto UsetheGenerator........................................................6

2.5 Don'tOverloadthe Generator...................................................7

2.6 WattageReferenceGuide......................................................... 8

2.7 BeforeStartingthe Generator...................................................8

2.8 ToStartthe Engine................................................................... 9

2.9 Stoppingthe Engine............................................................... 10

2.10 Low OilPressureShutdownSystem....................................... 10

Maintenance..........................................................................10

3.1 MaintenanceSchedule........................................................... 10

3.2 ProductSpecifications........................................................... 10

3.3 GeneralRecommendations.................................................... 10

3.4 ServiceAir Cleaner................................................................ 12

3.5 CleanSparkArrestor Screen.................................................. 12

3.6 General.................................................................................. 12

3.7 LongTermStorage................................................................. 12

3.8 OtherStorageTips................................................................. 13

Troubleshooting.....................................................................14

4.1 TroubleshootingGuide............................................................14

Notes.....................................................................................15

Warranty................................................................................16

Manualdelpropietario.............................19

Introduccion...........................................................................21

Leaeste manualcompletamente...........................................21

Reglasde seguridad..............................................................21

[ndicedeestandares..............................................................23

InformaciGnGeneral..............................................................24

1.1 Desempaque..........................................................................24

1.2 Ensamble...............................................................................24

OperaciGn..............................................................................25

2.1 Conozcael generador............................................................25

2.2 Medidorde horas................................................................... 26

2.3 Juegode cables y conectores................................................26

2.4 Comousar estegenerador.....................................................26

2.5 Nosobrecargueel generador.................................................27

2.6 Guiade refrenciade potencias...............................................28

2.7 Antesde arrancarel generador..............................................28

2.8 Arranquedelmotor................................................................29

2.9 Detenerel Motor.................................................................... 30

2.10 Sistemade apagadoporbaja presion de aceite......................30

Mantenimiento.......................................................................30

3.1 Programademantenimiento...................................................30

3.2 Especificacionesdelproducto................................................30

3.3 Recomendacionesgenerales..................................................30

3.4 Darservicioallimpiadordeaire.............................................32

3.5 Limpiezadelapantalladelsupresor.......................................32

3.6 General..................................................................................33

3.7 AImacenamientopotlargoplazo............................................33

3.8 Otrosconsejosparaalmacenamiento.....................................33

DetecciGnde problemas........................................................34

4.1 Guiadedeteccbndeproblemas............................................34

Notas.....................................................................................35

Garantia.................................................................................35

Manueld'entretien....................................39

Introduction............................................................................41

Life attentivement ce manuel................................................41

Regies de securit6.................................................................41

Indexdesnormes..................................................................43

InformationsgenGrales..........................................................44

1.1 Deballage..............................................................................44

1.2 Montage................................................................................44

Fonctionnement.....................................................................45

2.1 Bienconnaitrele generateur...................................................45

2.2 Horometre..............................................................................46

2.3 Cordonsetconnecteurs.........................................................46

2.4 Utilisationdugenerateur.........................................................46

2.5 Nepassurchargerlegenerateur.............................................47

2.6 Guidedereferencedewattage...............................................48

2.7 Avantledemarragedugenerateur..........................................48

2.8 Demarragedumoteur............................................................49

2.9 Arretdumoteur......................................................................50

2.10 Systemed'arretdebassepressiond'huile..............................50

Maintenance..........................................................................50

3.1 Programmedemaintenance...................................................50

3.2 Caractefistiquestechniquesdesproduits................................51

3.3 Recommandationsgenerales.................................................51

3.4 Filtrea_air...............................................................................52

3.5 NettoyagedeI'ecranpare-etincelles........................................53

3.6 Generalites.............................................................................53

3.7 Stockage;_longterme...........................................................53

3.8 Autresconseilsdestockage...................................................54

Depannage.............................................................................55

4.1 Guidededepannage..............................................................55

Garantie.................................................................................55

iNTRODUCTiON

Thankyou for purchasingthis modelby GeneracPowerSystems,

Inc. This model is a compact, high performance, air-cooled,

engine driven generatordesigned to supply electrical power to

operateelectrical loads where no utility power is availableor in

placeof utility dueto a poweroutage.

BEADTHiSMANUALTHOROUGHLY

If any portion of this manual is not understood, contact the

nearest Authorized Dealerfor starting, operating and servicing

procedures.

The operator is responsible for proper and safe use of the

equipment.We strongly recommendthat the operator readthis

manualandthoroughlyunderstandall instructionsbeforeusingthe

equipment.Wealsostronglyrecommendinstructingotherusersto

properlystart andoperatethe unit.This preparesthem ifthey need

to operatetheequipmentin an emergency.

Thegeneratorcan operatesafely,efficiently and reliablyonly if it

is properlylocated,operatedand maintained.Beforeoperatingor

servicingthe generator:

• Becomefamiliar with and strictly adhereto all local, stateand

nationalcodes and regulations.

• Study all safety warnings in this manual and on the product

carefully.

• Becomefamiliar with thismanualandthe unit beforeuse.

Themanufacturercannot anticipateevery possible circumstance

that might involvea hazard.Thewarnings in this manual,and on

tags and decals affixedto the unit are,therefore,not all inclusive.

If usinga procedure,work method or operatingtechniquethat the

manufacturerdoes not specifically recommend,ensurethat it is

safe for others. Also make sure the procedure,work method or

operatingtechnique utilizeddoes not renderthe generatorunsafe.

THE INFORMATIONCONTAINEDHEREIN WAS BASED ON

MACHINESIN PRODUCTIONAT THE TIME OF PUBLICATION.

GENERACRESERVESTHERIGHTTOMODIFYTHISMANUALAT

ANYTIME.

SAFETYRULES

Throughoutthis publication,and on tags and decals affixedto the

generator,DANGER,WARNING,CAUTIONand NOTEblocks are

usedto alert personnelto special instructionsabout a particular

operation that may be hazardous if performed incorrectly or

carelessly. Observe them carefully. Their definitions are as

follows:

iNDICATESA HAZARDOUSSiTUATiONORACTIONWHICH,IF

NOTAVOIDED,WiLLRESULTiN DEATHORSERIOUSiNJURY.

Indicatesa hazardoussituationor actionwhich,if not

avoided, couldresultindeathorseriousinjury.

,ACAUTION!

Indicatesa hazardoussituationor action which,if not

avoided, couldresultinminoror moderateinjury.

NOTE:

Notescontainadditionalinformation importanttoa procedure

and will be found within the regular text bodyof this manual.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliancewith the special

instructionswhileperforming theaction or serviceareessentialto

preventingaccidents.

Four commonly used safety symbols accompanythe DANGER,

WARNINGand CAUTIONblocks. The type of information each

indicatesis asfollows:

,_This symbol points out important safety

information that, if not followed, could

endanger personal safety and/or property of

others.

This symbol points out potential explosion

hazard.

i/_This symbol points out potential fire hazard.

i/_This symbol points out potential electrical

shock hazard.

GENERAL HAZARDS

• Neveroperatein an enclosedareaor indoors.

• For safety reasons, the manufacturer recommends that the

maintenanceof this equipmentis carried out by an Authorized

Dealer.Inspectthe generatorregularly,and contactthe nearest

AuthorizedDealerfor partsneedingrepairorreplacement.

• Operategeneratoronly on levelsurfacesandwhereit will notbe

exposedto excessivemoisture,dirt, dust or corrosivevapors.

• Keep hands, feet, clothing, etc., away from drive belts, fans,

and othermoving parts. Neverremoveany fan guardor shield

whilethe unit isoperating.

• Certain parts of the generator get extremely hot during

operation. Keep clear of the generator until it has cooled to

avoidsevereburns.

• Do NOToperategeneratorinthe rain.

• Do not alter the construction of the generator or change

controlswhich might createan unsafeoperatingcondition.

• Never start or stop the unit with electrical loads connected

to receptaclesAND with connecteddevicesturned ON. Start

the engine and let it stabilize before connecting electrical

loads. Disconnectall electricalloads beforeshutting downthe

generator.

• Do notinsert objectsthrough unit's cooling slots.

• When working on this equipment, remain alert at all times.

Never work on the equipment when physically or mentally

fatigued.

• Neverusethe generatoror anyof its parts as a step. Stepping

on the unit can stress and break parts, and may result in

dangerousoperating conditions from leakingexhaust gases,

fuel leakage,oil leakage,etc.

NOTE:

Thisgeneratoris equipped with a spark arrestor muffler. The

spark arrestor must be maintained in effectiveworking order

by the owner/operator. In the State of California, a spark

arrestoris requiredby law (Section 4442 of theCalifornia

PublicResourcesCode).Otherstatesmay havesimilar laws.

Federal lawsapply on federallands.

EXHAUST & LOCATIONHAZARDS

• Never operate in an enclosed areaor indoors!NEVERuse in

the home,or in partlyenclosedareassuchas garages, even

if doors and windowsare open! ONLYuse outdoors and far

from openwindows,doors, vents,andin anareathatwill not

accumulatedeadly exhaust.

Using a generator indoors CAN KILL YOU IN MINUTES,

Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell,

NEVER use insidea home

or garage, EVEN iF doors

and windows are open.

Only use OUTSIDE and

far away from windows,

doors,and vents.

• The engine exhaustfumes contain carbon monoxide, which

can you cannot see or smell. This poisonous gas, if breathed

in sufficient concentrations, can cause unconsciousness or

evendeath.

• Adequate, unobstructed flow of cooling and ventilating air

is critical to correct generator operation. Do not alter the

installation or permit even partial blockage of ventilation

provisions, as this can seriously affect safe operationof the

generator.ThegeneratorMUSTbeoperatedoutdoors.

• This exhaustsystemmust be properlymaintained.Do nothing

that mightrendertheexhaustsystemunsafeorinnoncompliance

with any localcodes and/orstandards.

• Alwaysusea batteryoperatedcarbonmonoxidealarmindoors,

installedaccordingto themanufacturersinstructions.

• If you start to feet sick, dizzy,or weak after the generatorhas

beenrunning,moveto fresh air IMMEDIATELYSeeadoctor,as

you couldhavecarbonmonoxidepoisoning.

ELECTRICALHAZARDS

• The generator produces dangerously high voltage when in

operation.Avoidcontactwith barewires,terminals,connections,

etc., while the unit is running,even on equipmentconnected

to the generator. Ensureall appropriate covers, guards and

barriersarein placebeforeoperatingthegenerator.

• Never handle any kind of electrical cord or device while

standinginwater,while barefootorwhile handsor feet arewet.

DANGEROUSELECTRICALSHOCKMAYRESULT.

• TheNationalElectricCode(NEC)requirestheframe andexternal

electrically conductive parts of the generator be properly

connectedto an approvedearthground.Local electricalcodes

may also require proper grounding of the generator.Consult

with a localelectricianfor groundingrequirementsin thearea.

• Use a ground fault circuit interrupter in any damp or highly

conductivearea(such as metaldecking or steelwork).

• Do not useworn, bare,frayed or otherwisedamagedelectrical

cord setswith the generator.

• Beforeperforminganymaintenanceonthegenerator,disconnect

the enginestarting battery (if equipped)to prevent accidental

start up. Disconnectthe cablefrom the batterypost indicated

by a NEGATIVE,NEGor (-) first. Reconnectthatcable last.

• In caseof accidentcausedby electricshock, immediatelyshut

down the source of electrical power. If this is not possible,

attempt to free the victim from the live conductor. AVOID

DIRECTCONTACTWITH THEVICTIM, Use a non-conducting

implement,such asa rope or board,to freethevictim from the

live conductor.If the victim is unconscious,applyfirst aidand

getimmediatemedical help.

FIREHAZARDS

• GasolineishighlyFLAMMABLEand itsvaporsare EXPLOSIVE.

Do not permitsmoking,open flames, sparksor heat in the

vicinitywhilehandlinggasoline.

• Neveraddfuel whileunit isrunning or hot. Allow engineto cool

completelybeforeaddingfuel.

• Never fill fuel tank indoors. Comply with all laws regulating

storageand handlingof gasoline.

• Do not overfill the fuel tank. Always allow roomfor fuel

expansion. If tank is over=filled,fuel can overflow onto a hot

engineandcauseFIREor an EXPLOSION.Neverstoregenerator

with fuel in tank where gasolinevapors might reach an open

flame, spark or pilot light (as on a furnace, water heateror

clothes dryer). FIREor EXPLOSIONmay result. Allow unit to

cool entirelybeforestorage.

• Wipe up any fuel or oil spills immediately.Ensure that no

combustiblematerialsareleft on or nearthegenerator.Keepthe

areasurroundingthe generatorcleanandfree from debrisand

keepa clearanceof five (5) feet on all side to allow for proper

ventilationofthe generator.

• Do notinsert objectsthrough unit's cooling slots.

• Do not operatethe generator if connected electrical devices

overheat,if electricaloutputislost,if engineor generatorsparks

or ifflames or smokeare observedwhileunit is running.

• Keepafire extinguishernearthe generatoratall times.

ST4ND4RDS/tYDEX

Intheabsenceof pertinentstandards,codes,regulationsandtaws,

the publishedinformationlistedbelow may be usedas a guideline

foroperationofthis equipment.Alwaysreferencethelatestrevision

availablefor the standardslisted.

1. NFPANo. 70, NFPAHANDBOOKOF NATIONALELECTRIC

CODE.

2. Article X, NATIONALBUILDINGCODE,available from the

American InsuranceAssociation, 85 John Street, New York,

N.Y 10038.

3. AGRICULTURALWIRINGHANDBOOK,availablefrom the Food

and EnergyCouncil, 909 UniversityAvenue, Columbia, MO

65201.

4. ASAE EP-3634, INSTALLATIONAND MAINTENANCEOF

FARMSTANDBYELECTRICALSYSTEMS,availablefrom the

AmericanSocietyof AgriculturalEngineers,2950 NilesRoad,

St. Joseph,MI 49085.

MODELNO:

SERIALNO:

CALIFORNIAPROPOSITION55 WARNING

Engineexhaustand someof itsconstituentsareknown

to theStateof Californiato causecancer,birth defects

and otherreproductiveharm.

CALIFORNIAPROPOSITION55 WARNING

This productcontainsor emitschemicalsknown tothe

Stateof Californiato causecancer,birthdefects and

otherreproductiveharm.

1.1 UNPACKING

• Removeall packagingmaterial.

• Removeseparateaccessory box.

• Removecarton off the generator.

1.1.1 ACCESSORYBOX

Checkall contents(Figure1). If anyparts aremissingor damaged

locatean authorizeddealerat1-888-436-3722.

Contentsinclude:

• 2-Axle Pins • OilFilter

• 2- WheelSpacers • Air Filter

• 2- HairPins • SparkPlug

• 2- Wheels • SparkPlugWrench

• 1 - FrameFoot • ShopTowel

• 1 - FootBolt • 1 QuartSAE30 Oil Bottle

• 1 - FootFlatWasher • OilFunnel

• 3 - FlangedNuts • 2 - VibrationMounts

Figure 1 - Accessory Box

Refer to Figure 2 and

follows:

install the wheel kit and frame foot as

Slidethe Axle Pin throughthe Wheel,WheelSpacer(Washer)

and the Frame.

Installthe HairPinto the AxlePin to securethe wheel. Repeat

for the oppositeside.

SecuretheVibrationMountsto theFrameFootwiththe included

lockingnuts.

ToinstalltheFrameFoot,removethelock nutfrom theVibration

Mountstud.

PlacetheFrameFooton theVibrationMount stud andre-install

the lock nut.Tightenthe nutcompletely.

Install the Frame Bolt though the FrameWasher,Frame and

Framefoot. Securewitha locking nut.

Figure 2 - Wheel and Foot Assembly

ASSEMBLE

FRAME

FOOT

SECUREWHEEL

ANDAXLEWITH

HAIRPIN

1.2 ASSEMBLY

ReadentireOwner's Manual beforeattemptingto assemble or

operatethe generator. The generatorrequires some assembly

priorto usingit. Ifproblemsarisewhenassemblingthe generator,

pleasecallthe GeneratorHelplineat 1-888-436-3722.

1.2.1 ASSEMBLINGTHEWHEELKITANDFRAMEFOOT

Thewheel kit is designedto greatlyimprovethe portability of the

generator.You will need the following tools to install the wheel

kit: Pliers, 1/2" (13mm) wrench and a socket wrench with a 1/2"

(13mm) socket.

NOTE:

Thewheel kit isnotintendedfor over-the-roaduse.

RE-USETHIS

NUTFROM

VIBRATION--¢

MOUNT

WHEELSPACER

FRAME

WASHER

FLANGE

NUT

FRAME

BOLT

SLIDEAXLE

THROUGHWHEEL

ANDWHEEL

SPACER

2.1 KNOWTHEGENERATOR

Read the Owner'sManual and Safety Rules before operating

thisgenerator.

Comparethegeneratorto Figure3 to becomefamiliarizedwith the

locations of various controls and adjustments.Savethis manual

for future reference.

1. Run/StopSwitch - Controlsthe operationof the generator.

2. FuelShut Off - Valvebetweenfueltank and carburetor.Turn

off and run carburetoroutof fuelfor extendedstorage.

3. Panel LED's- Provideilluminationof the control panelwhile

thegeneratoris operating.

4. 120/240 Volt AC, 20 Amp LockingReceptacle- Supplies

electricalpowerfor the operationof 120 and/or240 VoltAC,

20 Amp, single-phase,60 Hz, electrical lighting, appliance,

tool andmotor loads.

5. 120 Volt AC,20 Amp,GFCiDuplexReceptacle - Supplies

electrical power for the operationof 120 Volt AC, 20 Amp,

single-phase, 60 Hz electrical lighting, appliance,tool and

motor loads. It also provides protection with an Integral

Ground Fault Circuit Interrupter, complete with a press to

"Test"and "Reset"button.

5. CircuitBreakers(AC) - Eachpush button circuit breakeris

ratedat20 Amps;this protectsthegeneratoragainstelectrical

overload.

7. Hourmeter- Providesoperatinghoursfor Service Intervals.

8. PowerBar- Indicatesthe amountof power beingusedfrom

thegenerator;each sectionis approximately25%

g. FuelTank- Tankholds4.5 U.S.gallonsof fuel.

10, FuelGauge- Showsfuel levelin tank.

11, Handles - Pivot and retractfor storage. Press the spring-

loadedbuttonto move handles.

12. Oil Fill- Checkoil levelandadd oil here.

13. GroundingLug - Groundthe generatorto an approvedearth

groundhere.See"GroundingtheGenerator"for details.

14. Muffler - Includesthe sparkarrestor andquietsthe engine.

15, Spark Plug - Ignites Air/Fuel Mixture (Side panel must be

removed).

15. EngineOil Filter- Filtersengineoil; seeSection 3.1 for the

properservice intervals.

17. Choke- Usedwhenstarting a cold engine.

18, AirCleaner- Filtersintakeair as it is drawn intothe engine.

19. Oil Drain- Drain valveto remove used oil from the engine

crankcase.

20, Recoil Starter- Useto start enginemanually.

Figure3 - GeneratorLocationsand Controls

1 4

I \ /

/ }

3 6 7

2.2 HOURMETER

The Hourmeter tracks hours of operation for scheduled

maintenance:

Therewill bea"CHGOIL"messageevery100 hours.Themessage

will flash one hour before and one hour after each 100 hour

interval,providinga two hourwindow to perform service.

Every 200 hours the "SVC" icon on the lower left hand corner

of the display will flash. The messagewill flash one hourbefore

and one hour after each 200 hour interval,providing a two hour

window to perform service.

Whenthe hour meter is inthe FlashAlert mode, the maintenance

message will always alternate with elapsedtime in hours and

tenths. The hours will flash four times, then alternate with the

maintenancemessagefourtimes untilthemeter resetsitself.

* 100 hours- CHGOIL-- OilChangeInterval(Every100 hrs)

* 200 hours- SVC-- Air FilterInterval(Every200 hrs)

2.3 CORDSETSANDCONNECTIONPLUGS

2.3.1 120VAC,20AMP,GFC/DUPLEXRECEPTACLE

This is a 120 Volt outletprotectedagainstoverloadby a 20 Amp

push-to-resetcircuitbreaker(Figure4). Useeachsocketto power

120 VoltAC, singlephase,60 Hzelectricalloadsrequiringup to a

combined 2400 watts (2.4 kW) or 20 Amps of current.Useonly

high quality,well-insulated, 3-wire groundedcord sets ratedfor

125 Volts at 20 Amps (or greater).

Keepextensioncords as short as possibleto preventvoltagedrop

and possibleoverheatingof wires.

Figure 4 - 120 Ve/t AC, 20 Amp, GFC/ Duplex Receptac/e

Figure 5 - 120/240 Vo/t AC, 20 Amp Receptac/e

Use this receptacleto operate120 Volt AC, 60 Hz, singlephase

loads requiringup to 2400 watts (2.4 kW) of powerat 20 Amps

or 240 Volt AC, 60 Hz,single phase loadsrequiring up to 4000

watts (4.0 kW) of power at16.6 Amps. Theoutletis protectedby

a circuit breaker.

2.4 HOWTOUSETHEGENERATOR

If thereare any problems operatingthe generator,pleasecall the

generatorhetplineat 1-888-436-3722.

Never operate in an enclosed area or indoors!

NEVER use in the home, or in partly enclosed

areas such as garages, even if doors and

windows are open! ONLY use outdoors and far

from open windows, doors, vents, and in an

area that will not accumulate deadly exhaust.

2.3.2 120/240VAC,20 AMP,RECEPTACLE

Use a NEMA L14-20 plug with this receptacle (rotate to lock!

unlock). Connecta suitable4-wire groundedcord set to the plug

andto thedesiredtoad.Thecordset shouldbe ratedfor 250 Volts

ACat 20 Amps (or greater)(Figure5).

Using a generator indoors CAN KILL

YOU IN MINUTES.

Generator exhaust contains carbon

monoxide. This is a poison you

cannot see or smell.

Si usa un generador en interiores,

MORIRA EN POCOS MINUTOS.

El escape del generador contiene

monoxido de carbono. Es un veneno

que no tiene olor ni se puede ver.

NEVER use inside a home or garage, EVEN IF doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and vents.

NUNCA Io use dentro de una casa o garaje, AUN si las puertas y ventanas

estan abiertas, $61o uselo EN EXTERIORES y lejos de ventanas, puertas y

ductos de ventilacion.

2.4.1 SYSTEMGROUNO

The generatorhas a system groundthat connectsthe generator

frame components to the ground terminals on the AC output

receptacles. Thesystem groundis bondedto the ACneutralwire

in the generatorcontrol panelvia ajumper wire.

+ 2.4.1.1 SpecialRequirements

There may be Federalor State OccupationalSafety and Health

Administration(OSHA)regulations,localcodes,or ordinancesthat

applyto the intendeduse ofthe generator.

Pleaseconsult a qualified electrician,electrical inspector, or the

local agencyhavingjurisdiction:

* In some areas, generators are requiredto be registeredwith

local utilitycompanies.

* If the generatoris used at a construction site, there may be

additionalregulationswhich must be observed.

+ 2.4.1.2 Connectingtoa Building'sElectricalSystem

Connectionsfor standby power to a building's electricalsystem

must be made by a qualified electrician. The connection must

isolatethe generatorpower from utility poweror otheralternative

powersourcesand must complywith all relatedlaws andcodes.

2.4.2 GROUND/NGTHEGENERATOR

The National Electrical Code requires that the frame and

external electrically conductiveparts of this generator be

properlyconnectedto an approvedearth ground(Figure 6).

Local electrical codes may also requireproper grounding of the

unit. Forthat purpose,connectinga No. 10 AWG(AmericanWire

Gauge) stranded copper wire to the grounding lug and to an

earth-driven copper or brass grounding rod (electrode)provides

adequateprotectionagainstelectricalshock. However,localcodes

may vary widely. Consultwith a localelectricianfor grounding

requirementsin the area.

Proper groundingof the generatorwill help preventelectrical

shockin the event of a ground fault condition in the generator

or in connectedelectrical devices. Proper grounding also helps

dissipate static electricity, which often builds up in ungrounded

devices.

Figure6 - Groundingthe Generator

CONNECTGENERATORGROUNDHERE

2.4.3 NEUTRALTOFRAMEGROUNDING

If service work is performed on the alternator,DO NOTdiscard

the white jumper wires from the terminal blockto the alternator

ground, locatedon the rearbearingcarrier.Alway makesurethe

wires are properly connected before using the generator after

alternatorservicework is done (Figure7).

Figure7 - Neutra/to FrameGroundWires

DONOTDISCARD

Failure to reconnect these wires may create a

potential shock hazard when the generator is

running!

2.4.4 CONNECT/NGELECTR/CALLOADS

DONOTconnect240 Volt loadsto 120Volt receptacles.DONOT

connect 3-phaseloads to the generator.DONOTconnect 50 Hz

loadsto the generator.

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

starting.

* Plug in and turn on the desired 120 or 240 Volt AC, single

phase,60 Hzelectricalloads.

* Add up the ratedwatts (or amps) of all loadsto beconnected

at onetime. This total should not be greaterthan (a) the rated

wattage/amperagecapacity of the generator or (b) circuit

breakerratingof thereceptaclesupplyingthe power.See"Don't

OverloadtheGenerator".

2.5 DON'TOVERLOADTHEGENERATOR

Overloadinga generatorin excess of its ratedwattage capacity

can result in damageto the generatorandto connectedelectrical

devices.Observethefollowing to preventoverloadingthe unit:

* Addupthetotal wattageofall electricaldevicesto be connected

at one time. This total should NOT be greater than the

generator'swattagecapacity.

* The ratedwattageof lights can betaken from light bulbs. The

ratedwattageof tools, appliancesand motors can usually be

foundon a datalabelor decalaffixedto the device.

* If the appliance,toot or motor does not givewattage, multiply

voltstimes ampereratingto determinewatts (voltsx amps =

watts).

* Some electric motors, such as inductiontypes, require about

threetimes morewatts of powerfor startingthan for running.

This surge of power lasts only a few seconds when starting

such motors.Makesureto allowfor high startingwattagewhen

selectingelectricaldevicesto connectto the generator:

1. Figurethe watts neededto start the largestmotor.

2. Add to that figure the running watts of all other connected

loads.

TheWattageReferenceGuideis providedto assist in determining

how many itemsthe generatorcan operateatonetime.

2.6 WATTAGEREFERENCEGUIDE

NOTE:

Allfiguresare approximate. See datalabelonappliancefor

wattagerequirements.

Device.......................................... Running Watts

*Air Conditioner(12,000 Btu)................................. 1700

*Air Conditioner(24,000 Btu)................................. 3800

*Air Conditioner(40,000 Btu)................................. 6000

Battery Charger(20 Amp) .................................... 500

Belt Sander(3") ........................................... 1000

ChainSaw ............................................... 1200

Circular Saw(6-1/2") ................................. 800 to 1000

*Clothes Dryer (Electric) .................................... 5750

*Clothes Dryer (Gas) ........................................ 700

*Clothes Washer .......................................... 1150

CoffeeMaker............................................. 1750

*Compressor (1 HP) ....................................... 2000

*Compressor (3/4 HP)...................................... 1800

*Compressor (1/2 HP)...................................... 1400

CurlingIron ............................................... 700

*Dehumidifier.............................................. 650

Disc Sander(9")........................................... 1200

EdgeTrimmer.............................................. 500

ElectricBlanket............................................. 400

ElectricNail Gun........................................... 1200

ElectricRange(per element).................................. 1500

ElectricSkillet............................................. 1250

*Freezer.................................................. 700

*FurnaceFan(3/5 HP)....................................... 875

*Garage Door Opener.................................. 500to750

HairDryer ............................................... 1200

HandDrill.......................................... 250to11O0

HedgeTrimmer............................................. 450

Impact Wrench............................................. 500

Iron.................................................... 1200

*JetPump ................................................ 800

LawnMower............................................. 1200

Light Bulb................................................. 100

MicrowaveOven..................................... 700to1000

*MilkCooler.............................................. 1100

OilBurneronFurnace........................................ 300

OilFiredSpaceHeater(140,000 Btu) ............................ 400

OilFiredSpaceHeater(85,000 Btu) ............................. 225

OilFiredSpaceHeater(30,000 Btu) ............................. 150

*Paint Sprayer,Airless (1/3 HP)................................ 600

PaintSprayer,Airless (handheld) ............................... 150

Radio............................................... 50 to 200

*Refrigerator .............................................. 700

Slow Cooker............................................... 200

*Submersible Pump (1-1/2 HP) ............................... 2800

*Submersible Pump (1 HP) .................................. 2000

*Submersible Pump (1/2 HP)................................. 1500

*Sump Pump....................................... 800 to 1050

*Table Saw(10") ................................... 1750 to 2000

Television........................................... 200 to 500

Toaster........................................... 1000 to 1650

WeedTrimmer ............................................. 500

* Allow 3 times thelisted watts for starting these devices.

2.7 BEFORESTARTINGTHEGENERATOR

Priorto operatingthe generator,engineoil andgasolinewill need

to be added,asfollows:

2.7.1 AL}D/NGENG/NEO/L

All oil should meet minimum American PetroleumInstitute (API)

Service Class SJ, SL or better.Use no special additives. Select

the oil's viscosity grade according to the expected operating

temperature(also seechart).

* Above40° F,useSAE30

* Below40° Fand downto 10° F,use10W-30

* Below10° F,use synthetic5W-30

mEm

°F =20 =10 0 10 20 32 40 60 80 100

°c_'0 -_o Jg ; 1; 2; _o 4;

Temperature Range of Expected Use

,&CAUTION!

_t ny attempt to crank or start the engine

before it has been properly serviced with the

recommended oil may result in an engine

failure.

* Placegeneratoron a levelsurface.

* Cleanareaaroundoil fill andremoveoil fill cap.

* Slowly fill enginewith oil through the oil fill opening until it

reaches the full mark. Stop filling occasionally to check oil

level.Engineoil is full when levelis up to thethreads ofthe oil

fill plug (Figure8).

* Installoil fill capandfingertighten securely.

* Checkengineoil levelbeforestarting eachtimethereafter.

Figure 8 - Oil/_eve/

FILLCRANKCASETO

THEBOTTOMOFTHESE

---- THREADSWITHTHE

RECOMMENDED

ENGINEOIL

2.7.2 ADD/NGGASOLINE

Never fill fuel tank indoors. Never fill fuel tank

when engine is running or hot. Avoid spilling

gasoline on a hot engine. Allow engine to cool

entirely before filling fuel tank.

z_Do not overfill the fuel tank. Always leave room

for fuel expansion. If the fuel tank is overfiJJed,

fuel can overflow onto a hot engine and cause

FiRE or EXPLOSION. Wipe up any spilled fuel

immediately.

Do not light a cigarette or smoke when filling

the fuel tank. Gasoline is highly FLAMMABLE

and its vapors are EXPLOSIVE.

* Use regularUNLEADEDgasolinewith the generatorengine.Do

not usepremium gasoline.Donotmix oil with gasoline.

* Do not use gasolinewith morethan 10%alcohol such as E85

or Methanol.

* Cleanareaaroundfuelfill cap, removecap.

* Slowly add unleadedregulargasolineto fueltank. Fillto bottom

of screenfilter.Becarefulnott0 overfill(Figure9).

* Installfuel capand wipe upany spilledgasoline.

Figure9 - FuelFill !,eve/

IMPORTANT:It is importantto preventgumdepositsfrom forming

in fuel system parts such as the carburetor,fuel hose or tank

during storage. Alcohol-blended fuels (called gasohol, ethanol

or methanol) can attractmoisture, which leadsto separationand

formationof acids during storage.Acidic gascan damagethefuel

system of an enginewhile in storage.Toavoid engineproblems,

the fuel system shouldbe emptied beforestorage of 30 days or

longer.Seethe "Storage"section. Neveruseengine or carburetor

cleaner products in the fuel tank as permanent damage may

occur.

2.8 TOSTARTTHEENGINE

Never start or stop engine with electrical

devices plugged into the receptacles AND

devices turned on.

* Unplug all electrical loads from the unit's receptacles before

startingthe engine.

* Make surethe unit is in a levelposition.

* Openthefuel shut-off valve(Figure10).

Figure 10 - Fuel Shut-Off Valve

Slide engine CHOKEknob outward to "Full Choke"position

(Figure11).

Figure 11- Choke Operation

DONOTFiLL

ABOVELIP!

NOTE:

The switchmustbe in theRUNposition.

Tostart manually,firmly grasptherecoil handleand pull slowly

until increasedresistance is felt. Pull rapidly up and awayto

start engine. Then follow the same choke sequence listed

above.

When the engine starts, slide choke knob to "1/2 Choke"

position untilthe engine runssmoothly andthenfully in to the

"Run" position. If enginefalters, slide chokeknob backout to

"1/2 Choke"position until the engine runs smoothly and then

to "Run" position.

NOTE:

If engine fires,but does not continueto run,pullchokeknob to

"Full Choke"and repeatstartinginstructions.

iMPORTANT:Donotoverloadthe generator.Also, do not overload

individual panel receptacles.These outlets are protectedagainst

overload with push-to-reset-type circuit breakers. If amperage

rating of any circuit breakeris exceeded,that breakeropensand

electricaloutputtothat receptacleislost. Read"Don't Overloadthe

Generator"carefully.

2.9 STOPPINGTHEENGINE

• Shutoff all loads,thenunplugtheelectricalloadsfrom generator

panelreceptacles.Neverstart or stop theenginewith electrical

devicespluggedin andturnedon.

• Let engine run at no-load for several minutes to stabilizethe

internaltemperaturesof engineandgenerator.

• MoveRun/Stopswitch to "Off" position.

• Closefuelvalve.

2.10LOW OILPRESSURESHUTDOWNSYSTEM

Theengineis equippedwith a low oil pressuresensor that shuts

downthe engineautomaticallywhentheoil pressuredrops below

5 psi. If the engine shuts down by itself and the fuel tank has

enoughgasoline,checkengineoil level.

2.10.1INITIALSTART-UP

A delaybuilt intothe low oil shutdownsystemallows oil pressure

to build during starting. The delay allows the engine to run for

about10 secondsbeforesensing oil pressure.

2.10.2SENSINGLOWOiLPRESSURE

If the systemsenseslow oil pressureduringoperation,the engine

shutsdown.

2.10.3RESTARtiNG

Iftrying to restartthe enginewithin 10secondsafterit shutsdown,

the enginemay NOTstart. Thesystem needs5 to 10 secondsto

reset.

If the engineis restartedafter such a shutdown andthe low oil

pressurehas not beencorrected,the enginewill run for about10

secondsas describedaboveandthen stop.

3.1 MAINTENANCESCHEDULE

Follow the calendar intervals. More frequent service is required

whenoperatingin adverseconditionsnotedbelow.

CheckOil Level

ChangeOil and OilFilter:!:

CleanSparkArrestor Screen

ServiceAir Cleaner

ReplaceSparkPlug

At EachUse

*Every Season/Every100 Hours

EverySeason

**Every Season/Every200 Hours

EverySeason

:i: Changeoil after first 30 hours of operationthen every season.

* Changeoiland oilfilter every monthwhen operatingunderheavyload or inhigh

temperatures.

** Cleanmoreoften underdirty or dusty operatingconditions. Replaceair cleaner

parts if very dirty.

3.2 PRODUCTSPECIFICATIONS

3.2.1 GENERATORSPEC/F/CATiONS

Model # ................................................................................. 005778-0

RatedMax. Power................................................................... 4.0 kW**

SurgePower............................................................................... 5.0 kW

RatedACVoltage...................................................................... 120/240

RatedMax AC Load

Current@ 240V............................................................. 16.6 Amps**

Current@ 120V............................................................. 33.3 Amps**

RatedFrequency.................................................... 60 Hz@ 3600 RPM

Phase................................................................................ SinglePhase

** Maximumwattageandcurrentaresubjectto,andlimitedby,suchfactors

asfuelBtucontent,ambienttemperature,altitude,enginecondition,etc..

Maximumpowerdecreasesabout3.5%for each1,000feetabovesealevel;

andwillalsodecreaseabout1%for each6° C(10°F)above16°C(60°F)

ambienttemperature.

3.2.2 ENG/NESPEC/F/CATIONS

RatedHorsepower@ 3600 RPM......................................................... 6

Displacement............................................................................ 216.5cc

SparkPlugType................................... ChampionRC14YCor Equivalent

SparkPlug Gap............................................... 0.030 inch or (0.76 mm)

GasolineCapacity......................................................... 4.5 U.S.gallons

OilType.................................... SeeChart in "AddingEngineOil"Section

OilCapacity................................................ w/Filter Change= 0.8 Qts.

RunTime/FuelConsumption-l/2 Load

4 kW................................................. 14 Hours/ .35 gallonsper hour

ClassI1EmissionCertified

3.3 GENERALRECOMMENDATIONS

Thewarrantyofthe generatordoesnotcover itemsthathavebeen

subjectedto operatorabuse or negligence.To receivefull value

from the warranty,the operatormust maintain the generatoras

instructed inthis manual.

Some adjustmentswill needto be made periodicallyto properly

maintainthegenerator.

All adjustmentsin the Maintenancesection of this manualshould

be madeatleastonceeachseason.Followthe requirementsin the

"MaintenanceSchedule".

NOTE:

Oncea year replace the sparkplugandreplace the air filter.

A newsparkplugand cleanair filter assureproperfuel-air

mixtureandhelpthe enginerun betterandlastlonger.

3.3.1 GENERATORMA/NTENANCE

Operateand storethe unitin a cleandry environmentwhere itwill

not be exposedto excessivedust, dirt, moistureor any corrosive

vapors.Coolingairslots inthegeneratormustnotbecomeclogged

with snow, leaves,or any otherforeign material.

Checkthe cleanlinessof the generatorfrequentlyandcleanwhen

dust, dirt, oil, moistureor otherforeignsubstancesarevisible on

its exteriorsurface.

,_ CAUTION!

,_ Never insert any object or tool through the air

cooling slots, even if the engine is not running.

NOTE:

DONOTusea gardenhoseto cleangenerator.Water can

enterthe enginefuel systemand causeproblems,inaddition,

if waterentersthe generatorthroughcoolingair slots,some

water will be retainedin voidsand crevicesof therotor

and starerwindinginsulation.Water and dirt builduponthe

generatorinternalwindingswill eventually decrease the

insulationresistanceof thesewindings.

3.3.2 TOCLEANTHEGENERATOR

• Usea damp cloth to wipe exteriorsurfaces clean.

• A soft, bristlebrush may beusedto loosencaked on dirt, oil,

etc.

• A vacuum cleaner may be used to pick up loose dirt and

debris.

• Low pressure air (not to exceed 25 psi) may be used to

blow away dirt. Inspect cooling air slots and openings

on the generator.These openings must be kept clean and

unobstructed.

3.3.3 ENG/NEMA/NTENANCE

/_When working on the generator, always

disconnect spark plug wire from spark plug and

keep the wire away from the spark plug.

3.3.4 CHECKINGO/LLEVEL

See the "BEFORESTARTINGTHE GENERATOR"section for

information on checking the oil level. The oil level should be

checkedbeforeeachuse,or atleasteveryeighthoursofoperation.

Keepthe oil levelmaintained.

3.3.5 CNANG/NGTIlE O/LANOOILFILTER

Changethe oil and filter after the first 30 hours of operation.

Changethe oil every 100 hours or every season thereafter.If

running this unit under dirty or dusty conditions, or in extremely

hotweather,changethe oil moreoften.

,ACAUTION!

,_Hot oil may cause burns. Allow engine to

cool before draining oil. Avoid prolonged

or repeated skin exposure with used oil.

Thoroughly wash exposed areas with soap.

Usethe following instructionsto changetheoil while theengine

is still warm:

• Cleanareaaroundoil drainplug.

• Removeoil drain plug from engineand oil fill plug to drain oil

completelyinto a suitablecontainer.

• When oil has completely drained, install oil drain plug and

tightensecurely.

• Place a suitable container beneath the oil filter and turn

filter counterclockwiseto remove.Discard according to local

regulations.

• Coat gasket of new filter with clean engine oil. Turn filter

clockwise until gasketcontacts lightly with filter adapter.Then

tightenan additional3/4 turn.

• Fill engine with recommendedoil. (See "Before Starting the

Generator"for oil recommendations).

• Wipeup anyspilledoil.

• Disposeof usedoil at a propercollectioncenter.

3.3.6 REPLACINGTIlESPARKPLUG

Use Champion RC14YCspark plug or equivalent.Replace the

plug once eachyear. This will help the enginestart easierand

run better.

1. Stopthe engine and pull the spark plug wire off of the spark

plug.

2. Togain access, removethe four (4) screws and removethe

side panel.

3. Cleanthe areaaroundthe spark plugand removeit from the

cylinder head.

4. Set the spark plug's gap to .76 mm (0.030 in.). Install the

correctly gapped spark plug into the cylinder head (Figure

12).

5. Pushthe bootfirmly on the sparkplug and install sidepanel.

Figure 12 - Spark Plug Gap

'1 'i

3.4 SERVICEAiRCLEANER

Theenginewill not run properlyand may bedamagedif usinga

dirty air cleaner.Cleanor replacethe aircleanerpaperfilter every

200 hoursor oncea year (Figure13). Cleanor replacemore often

if operatingunderdustyconditions.

Tocleanor replacepaperair filter:

* Removeair cleanercover;then removethe paperfilter.

* Cleanpaperfilter bytapping it gentlyon a solid surface. If the

filter istoo dirty, replaceit with a new one. Disposeof the old

filter properly.

* Cleanaircleanercover,then insertnew paperfilter intothebase

of theair cleaner.Re-installair cleanercover.

Figure 13- Air Fi/ter

Filter

Base

Cover

NOTE:

Toordera newair filter,pleasecontactthenearestauthorized

servicecenterat 1-888-435-3722.

3.5 CLEANSPARKARRESTORSCREEN

Theengineexhaustmufflerhasa sparkarrestorscreen.Inspectand

cleanthescreenevery1O0hoursor atleastonceeachyear(Figure

14). If unit is usedregularly,inspectandcleanmore often.

NOTE:

If usingthegeneratoron any forest-covered,brush-covered

or grass-coveredunimproved land,it mustequipped with a

sparkarrestor.The sparkarrestormustbe maintained in good

conditionby theowner/operator.

Cleanandinspectthe sparkarrestorwhentheengineisat ambient

temperatureasfollows:

Insert a flat blade screwdriverthrough the slot on the side of

the muffler heat shield to access the spark arrestor clamp.

Loosenthe clamp andremovethe spark arrestorscreen from

the muffler.

* Inspect screen and replace if torn, perforated or otherwise

damaged. DO NOT USEa defective screen. If screen is not

damaged,cleanit with commercialsolvent.

* Replacethe sparkarrestorandtightenthe clamp.

Figure 14= SparkArrestor Screen

ARRESTOR

SCREENCLAMP INSERTSCREWDRIVER

THROUGH SLOT INHEAT

SPARK SHIELDTO ACCESS

ARRESTOR ARRESTOR SCREENCLAMP

SCREEN

3.6 GENERAL

Thegeneratorshouldbe startedat leastonceeverysevendaysand

be allowedto run at least30 minutes. If this cannotbe done and

the unit must be stored for morethan 30 days, use thefollowing

informationas a guideto prepareitfor storage.

NEVER store engine with fuel in tank indoors

or in enclosed, poorly ventilated areas where

fumes may reach an open flame, spark or pilot

light as on a furnace, water heater, clothes dryer

or other gas appliance.

,_AIIow unit to cool entirely before storage.

3.7 LONGTERMSTORAGE

It is importantto preventgum depositsfrom forming in essential

fuel systemparts such asthe carburetor,fuel hoseor tank during

storage. Also, experience indicates that alcohol-blended fuels

(called gasohol,ethanolor methanol)can attract moisture,which

leadsto separationandformation of acids during storage.Acidic

gascan damagethefuel systemof an enginewhile in storage.

To avoid engine problems, the fuel system should be emptied

beforestorageof 30 daysor longer,asfollows:

• Removeall gasolinefrom the fueltank.

Drain fuel into approved container outdoors,

away from open flame. Be sure engine is cool.

Do not smoke in the vicinity or light a cigarette.

• Start and run engineuntilenginestopsfrom lackof fuel

• Allowtheengineto coolto thetouch andthendrainthe oil from

thecrankcase.Refillwith the recommendedgrade.

• Removespark plugandpour about1/2 ounce(15 ml) of engine

oil into the cylinder.Cover sparkplug hole with rag. Pull the

recoil starter a couple times to lubricatethe piston rings and

cylinder bore.

,_ CAUTION!

Avoid spray from the spark plug hole when

cranking engine.

* Installandtightenthe sparkplug.Do notconnectthe sparkplug

wire.

* Cleanthe generatoroutersurfaces.Checkthat cooling air slots

and openingson generatorareopen andunobstructed.

* Storethe unit in a clean, dry place.

3.8 OTHERSTORAGETiPS

* Do notstore gasolinefrom oneseasonto another.

* Replacethe gasolinecan if it startsto rust. Rustand/ordirt in

the gasolinewill cause problems with the carburetorand fuel

system.

* If possible,storethe unitindoors, ina garageor shed,andcover

it to give protectionfrom dust anddirt. BESURETO EMPTY

TIlE FUELTANK.

. If it is not practicalto emptythe fuel tank and the unit is to be

storedfor sometime, useacommerciallyavailablefuelstabilizer

addedto the gasolineto increasethe lifeof thegasoline.

* Cover the unit with a suitable protectivecover that does not

retainmoisture.

_t EVER cover the generator while engine and

exhaust area are warm. Allow unit to cool

entirely.

4.1 TBOUBLESHOOTINGGUIDE

Engineisrunning,but noAC output

is available.

1. Circuit breakeris open.

2. Poorconnectionor defectivecord set.

3. Connecteddevice is bad.

4. Faultin generator.

5. GFCItrips the20 Amp outlets.

1. Resetcircuit breaker.

2. Checkand repair.

3. Connectanotherdevicethat is ingood condition.

4. ContactAuthorizedServiceFacility.

5. Repairthe"short" andresetthe GFCI.

! I

Engine runs good but bogs down 1. Short circuit in a connectedload. 1. Disconnectshortedelectricalload.

when loadsare connected. 2. Generatoris overloaded. 2. See"Don't Overloadthe Generator".

3. Enginespeedistoo slow. 3. ContactAuthorizedServiceFacility.

4. Shorted generatorcircuit. 4. ContactAuthorizedServiceFacility.

Enginewill not start; or starts and 1. Fuelshut-off is OFF. 1. TurnFuelshut-off ON.

runs rough. 2. Dirty air cleaner. 2. Cleanor replaceair cleaner.

3. Out of gasoline. 3. Fillfuel tank.

4. Stalegasoline. 4. Drainfuel tank andfill with fresh fuel.

5. Sparkplug wire not connectedto spark plug. 5. Connectwire to spark plug.

6. Badsparkplug.

7. Waterin gasoline.

8. Over-choking.

9. Low oil level.

10. Excessiverich fuel mixture.

11. Intakevalvestuck open or closed.

12. Enginehas lost compression.

6. Replacesparkplug.

7. Drainfuel tank;fill with fresh fuel.

8. Put choke knobto No Chokeposition.

9. Fillcrankcaseto proper level.

10. ContactAuthorizedServiceFacility.

11. ContactAuthorizedServiceFacility.

12. ContactAuthorizedServiceFacility.

Engineshuts downduring 1. Out of gasoline. 1. Fillfuel tank.

operation. 2. Low oil level. 2. Fillcrankcaseto proper level.

3. Faultin engine. 3. ContactAuthorizedServiceFacility.

Engine lackspower. 1. Load is too high. 1. See"Don't Overloadthe Generator".

2. Dirty air filter. 2. Replaceairfilter.

3. Engineneedsto beserviced. 3. ContactAuthorizedServiceFacility.

Engine "hunts" or falters. 1. Chokeis openedtoo soon. 1. Movechoke to halfway positionuntil engineruns

2. Carburetoris runningtoo rich or too lean. smoothly.

2. ContactAuthorizedServiceFacility.

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FEDERAL EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The United States Environmental Protection Agency (EPA) and Generac Power Systems, Inc. (Generac) are pleased to explain the

Emission Control System warranty on your new 2008 and later equipment. New equipment that use small spark-ignited engines

must be designed, built, and equipped to meet stringent anti-smog standards for the federal government. Generac will warrant

the emission control system on your generator for the period of time listed below provided there has been no abuse, neglect,

unapproved modification or improper maintenance of your equipment.

Your emission control system may include parts such as the: carburetor, ignition system, fuel system, catalytic converter, and other

associated emission-related components (if equipped).

MANUFACTURER'S WARRANTY COVERAGE:

This emission control system is warranted for two years. If, during such warranty period, any emission-related part on your

equipment is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac

Authorized Warranty Service Dealer.

OWNER'S WARRANTY RESPONSIBILITIES:

As the generator owner, you are responsible for the completion of all required maintenance as listed in your factory supplied

Owner's Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your

generator, but Generac cannot deny warranty solely due to the lack of receipts.

As the generator owner, you should be aware that Generac may deny any and/or all warranty coverage or responsibility if your

generator, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or

the use of counterfeit and/or "grey market" parts not made, supplied or approved by Generac.

You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs, The warranty

repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer. To

locate the Generac Authorized Warranty Service Dealer nearest you, call our toll free number:

1 =800=333= 1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty

(ECS Warranty), which is provided to you by Generac pursuant to federal law. See also the "Generac Limited Warranties for

Generac Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by Generac. Note that this

warranty shall not apply to any incidental, consequential or indirect damages caused by defects in materials or workmanship or

any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties, expressed or implied.

Specifically, Generac makes no other warranties as to the merchantability or fitness for a particular purpose. Some states do not

allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

The ECS Warranty applies only to the emission control system of your new equipment. If there is any conflict in terms between the

ECS Warranty and the Generac Warranty, the Generac Warranty shall apply. Both the ECS Warranty and the Generac Warranty

describe important rights and obligations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service,

evidence must be presented showing the date of the sate to the original purchaser/owner.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following

address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 " WHITEWATER, Wl 53190

Part 1

Part No.0H1911 Rev.A 01/09

EMiSSiON CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS warranty) for equipment using small spark-ignited engines:

(a) Applicability: This warranty shall apply to equipment that uses small off-road engines. The ECS Warranty period shall begin

on the date the new equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24

consecutive months thereafter.

(b)

(c)

General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or

equipment and to each subsequent purchaser/owner that the ECS when installed was:

(1) Designed, built and equipped so as to conform with all applicable regulations; and

(2) Free from defects in materials and workmanship which cause the failure of a warranted part at any time during the ECS

Warranty Period.

The warranty on emissions-related parts wilt be interpreted as follows:

(1) Any warranted part that is not scheduled for replacement as required maintenance in the Owner's Manual shall be

warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or

replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall

be warranted for the remainder of the ECS Warranty Period.

(2) Any warranted part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted

for the ECS Warranty Period. A statement in the Owner's Manual to the effect of "repair or replace as necessary" shall not

reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the

remainder of the ECS Warranty Period.

(3) Any warranted part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted

for the period of time prior to first scheduled replacement point for that part. Ifthe part fails prior to the first scheduled

replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-

related part repaired or replaced under the ECS warranty shall be warranted for the remainder of the period prior to the

first scheduled replacement point for that part.

(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge

to the owner at a Generac Authorized Warranty Service Facility.

(5) Notwithstanding the provisions of subsection (4) above, warranty services or repairs must be provided at Generac

Authorized Service Facilities.

(6) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held

responsible for diagnostic costs if the repair is deemed warrantable.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to

meet the expected demand for such parts.

(8) Any Generac authorized and approved emission-related replacement parts may be used in the performance of any ECS

warranty maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce

Generac ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or "grey market" parts may not be used to modify or repair a Generac

engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac

shall not be held liable hereunder for failures of any warranted parts of Generac equipment caused by the use of such an

unapproved, add-on, modified, counterfeit and/or "grey market" part.

EMISSION RELATED PARTS MAY INCLUDE THE FOLLOWING (IF EQUIPPED)"

1) FUEL METERING SYSTEM

A. CARBURETOR AND INTERNAL PARTS

B. PRESSURE REGULATOR

2) AIR INDUCTION SYSTEM

A. INTAKE MANIFOLD

B. AIR FILTER

8) IGNITION SYSTEM

A. SPARK PLUGS

B. IGNITION COILS / MODULE

AIR INJECTION SYSTEM

A. PULSE AIR VALVE

EXHAUST SYSTEM

A. CATALYST

B. THERMAL REACTOR

C. EXHAUST MANIFOLD

Part 2

PartNo.0H1911 Rev.A 01/09

1"7

GENERAC POWER SYSTEMS "TWO YEAR" LiMiTED WARRANTY FOR

XG SERIES PORTABLE GENERATORS

For a period of two years from the dateof original sale, GeneracPower Systems, Inc. (Generac)warrants its XG Series generators will befree from defects in materials

andworkmanship for the items and period set forth below. Generacwill, at its option, repair or replace any part which, upon examination, inspection and testing by

Generacor a GeneracAuthorized Warranty Service Dealer, is found to be defective. Any equipmentthat the purchaser/owner claims to be defective must be returned to

and examined by the nearest GeneracAuthorized Warranty Service Dealer.All transportation costs under the warranty, including return to the factory, areto be borne and

prepaid by the purchaser/owner. This warranty applies only to GeneracXG Series portable generators and is nottransferable from original purchaser.Save your proof-of-

_urchasereceipt. Ifyou do not provide proof of the initial purchase date,the manufacturer's shipping date of the product will be used to determinethe warranty period.

WARRANTY SCHEDULE

3onsumerapplicationsarewarrantedfor two(2) years.CommercialandRentalapplicationsarewarrantedfor one(1)yearor 1000hoursmaximum,whichevercomes

first.

CONSUMER APPLICATION

YEARONE- 100%(onehundredpercent)coverageonLaborandPart(s)(proofofpurchaseandmaintenanceis required):

, AllComponents

YEARTWO-100%(onehundredpercent)coverageonPart(s)(proofof purchaseandmaintenanceisrequired):

, AllComponents

COMMERCiAL/RENTAL APPLICATION

YEARONE- 100%(onehundredpercent)coverageonLaborandPart(s)(proofofpurchaseandmaintenanceis required):

,AllComponents

NOTE: Forthe purpose ofthis warranty "consumer use" means personal residential household or recreational use by original purchaser. This warranty does not apply

to units usedfor Prime Power in place of utility where utility power service is present or where utility power service does not normally exist. Once a generator

has experienced commercial or rentaluse, it shall thereafter beconsidered a non-consumer use generatorfor the purpose of this warranty.

All warranty expense allowances are subject to the conditions definedin Generac's Warranty Policies, Procedures and Flat RateManual.

THiS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

, Generacportable generators that utilizenon-Generac replacement parts.

, Costs of normal maintenance and adjustments.

, Failurescaused by any contaminatedfuels, oils or lack of proper oil levels.

, Repairs or diagnostics performed by individuals otherthan Guardian/Generacauthorized dealersnot authorizedin writing by GeneracPowerSystems.

, Failuresdue, but not limited, to normal wear and tear,accident, misuse, abuse, negligence or improper use. As with all mechanical devices, the Generacengines need

periodic part(s) service and replacementto perform as designed.This warranty will not cover repairwhen normal use has exhaustedthe life of a part(s) or engine.

, Failurescaused by any act of God and otherforce majeure eventsbeyond the manufactures control.

, Damage related to rodent and/or insect infestation.

, Productsthat aremodified or altered ina manner not authorizedby Generacin writing.

, Any incidental, consequential or indirect damagescaused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).

, Failuredue to misapplication.

, Telephone,cellular phone, facsimile, internet access or other communication expenses.

, Living ortravel expensesof person(s) performing service, except as specifically included within theterms of a specific unit warranty period.

, Expensesrelatedto "customer instruction" or troubleshooting where no manufacturing defect is found.

, Rentalequipment used while warranty repairs arebeing performed.

, Overnight freight or special shipping costs for replacement part(s).

, Overtime, holiday or emergency labor.

, Starting batteries,fuses, filters, light bulbs andengine fluids.

THISWARRANTYISINPLACEOFALLOTHERWARRANTIES,EXPRESSEDORIMPLIED,SPECIFICALLY,GENERACPOWERSYSTEMSMAKESNOOTHERWARRANTIES

ASTOTHEMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSE.Anyimpliedwarrantieswhichareallowedby law,shallbelimitedin durationtotheterms

oftheexpresswarrantyprovidedherein.Somestatesdonot allowlimitationson howlonganimpliedwarrantylasts,so theabovelimitationmaynotapplyto purchaser/

owner.

GENERACPOWERSYSTEMSONLYLIABILITYSHALLBETHEREPAIRORREPLACEMENTOFPART(S)ASSTATEDABOVE.INNOEVENTSHALLGENERACPOWER

SYSTEMSBELIABLEFORANYINCIDENTAL,ORCONSEQUENTIALDAMAGES,EVENIFSUCHDAMAGESAREA DIRECTRESULTOFGENERACPOWERSYSTEMS,

INC.NEGLIGENCE.Somestatesdonotallowtheexclusionorlimitationofincidentalor consequentialdamages,sotheabovelimitationsmaynotapplytopurchaser/

owner.Purchaser/owneragreesto makenoclaimsagainstGeneracPowerSystems,Inc.basedonnegligence.Thiswarrantygivespurchaser/ownerspecificlegalrights.

Purchaser/owneralsomayhaveotherrightsthatvaryfromstateto state.

GENERAC POWER SYSTEMS, INC,

P,O, BOX 8 " Waukesha, Wl 53187

Ph: (888) GENERAC (438-3722) • Fax: (262) 544-4851

To locate the nearest Authorized Dealer visit our website www.generac.com

PartNo.0H5472 RevisionB (10/20/09) PrintedinU.S.A.

ManualPartNo.0H2004 RevisionD (10/11/10) PrintedinU.S.A.

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* Limpiecualquier derramedecombustible inmediatamente.Asegurese

de queno se hayadejadomaterialescombustiblessobre o cercadel

generador.Mantengaela.reacircundantedel generadorlimpia y libre

deresiduosy conserveun espaciodecinco (5) piesatodos los lados

parapermitir una ventilacionapropiadadelgenerador.

* No opere el generador si los dispositivos electricos conectados

se sobrecalientan,si la salida electrica se pierde,si el motor o el

generadorechanchispas osi se observahumo cuandola unidadesta.

funcionando.

* Tengaunextinguidorcerca al generadorentodo momento.

#NB/CEBEESTANBARES

Enausenciadelos estandares,codigos, regulacioneso leyespertinentes,

la informacion publicada listada abajo puede usarse como guia para

la operacion de esteequipo. Siempre consulte la revision mas reciente

aplicableparael estandarlistado.

1. NFPANo.70, NFPAHANDBOOKOFNATIONALELECTRICCODE.

2. Article X, NATIONALBUILDINGCODE,disponible en la American

InsuranceAssociation,85 JohnStreet,NewYork,N.Y.10038.

3. AGRICULTURALWIRING HANDBOOK,disponible en la Food and

EnergyCouncil,909 UniversityAvenue,Columbia,MO65201.

4. ASAE EP-3634, INSTALLATIONAND MAINTENANCEOF FARM

STANDBY ELECTRICALSYSTEMS, disponible en la American

Society of Agricultural Engineers,2950 Niles Road,St. Joseph, MI

49085.

5. NFPANo.30, FLAMMABLEANDCOMBUSTIBLELIQUIDSCODE.

ADVERTENCIA DE LA PROPOSICION65 DECALIFORNIA

ElEstad{)deCalif{)rniasabeque el escapedel m{)t{)ry

algun{)sdesusc{)mp{)nentescausancancer,defect{)sde

nacimient{)y {)tr{)sda_{)srepr{)ductiv{)s.

ADVERTENCIA DE LA PROPOSICION65 DECALIFORNIA

Esteproduct{)c{)ntiene{)emite quimic{)sque el Estad{)de

Calif{)rnia sabeque causancancer,defect{)sde nacimient{)u

{)tr{)sdafi{)srepr{)ductiv{)s.

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Generac 005788-0 XG4000 Owner's manual

Brand: Generac

Model: 005788-0 XG4000

Category: Power generators

Type: Owner's manual

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