Generac XG4000-5778-0 Owner's manual

Category
Power generators
Type
Owner's manual

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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:
e
e
e
e
e
e
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
t
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
J
WHEELSPACER
h
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
@
@
/
2
I \ /
/ }
J
3 6 7
\
3
@
@
9
10
11
12
13
14
15
16
17
19
18
2O
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.
B
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.
A
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
_L
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
8
*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/
i
i
i
i
FILLCRANKCASETO
THEBOTTOMOFTHESE
---- THREADSWITHTHE
RECOMMENDED
ENGINEOIL
n
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
I
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".
1o
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
11
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.
12
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.
13
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.
14
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
16
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
4)
5)
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.
* 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.
23
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Generac XG4000-5778-0 Owner's manual

Category
Power generators
Type
Owner's manual
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