Generac XG4000-5778-2 Owner's manual

GENERAC

Owner'sIVlanual

SeriesPortabJeGenerator

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

Readthis IVlanualThoroughly..................................................1

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

StandardsIndex.......................................................................3

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

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

1.1.1 AccessoryBox............................................................4

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

1.2.1 AssemblingtheWheelKitandFrameFoot...................4

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

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

2.2 Hourmeter- No Reset.............................................................. 6

2.3 Hourmeter- With Reset............................................................6

2.4 CordSets andConnectionPlugs.............................................. 6

2.4.1 120VAC,20Amp, GFCIDuplexReceptacle..................6

2.4.2 120/240 VAC,20 Amp Receptacle..............................7

2.5 Howto Usethe Generator........................................................7

2.5.1 Groundingthe GeneratorWhenUsedasa Portable......7

2.5.2 Connecting the Generatorto a Building's

ElectricalSystem......................................................... 8

2.5.3 Neutralto FrameGrounding......................................... 8

2.5.4 ConnectingElectricalloads..........................................8

2.6 Don'tOverloadthe Generator...................................................8

2.7 WattageReferenceGuide......................................................... 9

2.8 BeforeStartingthe Generator...................................................9

2.8.1 Adding EngineOil........................................................ 9

2.8.2 Adding Gasoline........................................................ 10

2.9 ToStartthe Engine................................................................. 10

2.10 Stoppingthe Engine............................................................... 11

2.11 Low OilPressureShutdownSystem....................................... 11

2.11.1 Restarting.................................................................. 11

Maintenance.......................................................................... 11

3.1 Performing ScheduledMaintenance....................................... 11

3.2 MaintenanceSchedule........................................................... 11

3.3 ProductSpecifications........................................................... 11

3.3.1 GeneratorSpecifications............................................. 11

3.3.2 EngineSpecifications ................................................. 11

3.3.3 EmissionsInformation................................................ 12

3.4 GeneralRecommendations.................................................... 12

3.4.1 GeneratorMaintenance............................................... 12

3.4.2 ToCleanthe Generator............................................... 12

3.4.3 EngineMaintenance................................................... 12

3.4.4 CheckingOil Level...................................................... 12

3.4.5 Changingthe Oiland OilFilter.....................................12

3.4.6 Replacingthe SparkPlug............................................ 13

3.5 ServiceAir Filter..................................................................... 13

3.6 CleanSparkArrestorScreen.................................................. 13

3.7 General.................................................................................. 14

3.8 Long TermStorage................................................................. 14

3.9 OtherStorageTips................................................................. 14

Troubleshooting.....................................................................1,5

4.1 TroubleshootingGuide............................................................15

Notes.....................................................................................16

Warranty................................................................................18

MANUALDELUSUARIO....................................23

MANUELDEL'UTILISATEUR.............................45

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.

READTHiSMANUALTHOROUGHLY

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 read this

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.

• Becomefamiliarwith this manualandthe 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 hazardousif performed incorrectly or

carelessly. Observe them carefully. Their definitions are as

follows:

iNDICATESA HAZARDOUSSiTUATiONORACTIONWHICH,IF

NOTAVOIDED,WiLLRESULTiN DEATHORSERIOUSiNJURY.

Indicatesa hazardoussituationor actionwhich,ifnot

avoided, couldresultindeathorseriousinjury.

,ACAUTION!

Indicatesa hazardoussituationor action which,if not

avoided, couldresultinminoror moderateinjury.

NOTE:

Notescontainadditionalinformationimportanttoa procedure

and will be foundwithin theregulartextbodyof thismanual.

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 accompany the 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 enclosed area, in a vehicle, or indoors

EVENIFdoorsand windows areopen.

• For safety reasons, the manufacturer recommends that the

maintenanceof this equipmentis carried out by an Authorized

Dealer.Inspectthe generatorregularly,and contactthe nearest

AuthorizedDealerfor parts needingrepairor replacement.

• Operategeneratoronly on levelsurfacesandwhereit will notbe

exposedto excessivemoisture,dirt, dust or corrosivevapors.

• Keephands,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.

• Neverstart 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:

This generatoris equipped with a spark arrestormuffler. The

spark arrestor must bemaintained in effective working order

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

arrestor is requiredbylaw (Section4442 ofthe California

PublicResourcesCode).Otherstates may havesimilarlaws.

Federal lawsapply on federallands.

EXHAUST & LOCATIONHAZARDS

• Never operate in an enclosed area or indoors!NEVERuse

in the home,in a vehicle,or in partlyenclosedareassuch

as garages, evenif doors and windowsare open! ONLYuse

outdoors and far from open windows,doors,vents,andinan

areathatwill notaccumulatedeadly exhaust.

Using a generator indoors CAN KiLL YOU JNMINUTES.

Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell.

NEVER use insidea home

or garage, EVEN JFdoors

and windows are open.

Only use OUTSIDE and

far away from windows,

doors, and vents.

* The engine exhaustfumes contain carbon monoxide, which

you cannot see or smell. This poisonous gas, if breathedin

sufficientconcentrations,can causeunconsciousnessor even

death.

* 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 themanufacturer'sinstructions.

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

beenrunning,moveto fresh air IMMEDIATELYSeea doctor,as

you couldhavecarbonmonoxidepoisoning.

ELECTRICALHAZARDS

* The generator produces dangerouslyhigh 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. Reconnectthat cable 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 aid and

getimmediatemedical help.

FiREHAZARDS

• GasolineishighlyFLAMMABLEand itsvaporsare EXPLOSIVE.

Do not permitsmoking,open flames, sparksor heat in the

vicinitywhilehandlinggasoline.

• Never add fuel while unitis runningor hot.Allow engineto

cool completelybeforeaddingfuel.

• Never fill fuel tankindoors, 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 reachan 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.

STANDARDS/#DEX

Intheabsenceof pertinentstandards,codes,regulationsandtaws,

the publishedinformationlistedbelowmay be usedas a guideline

foroperationofthis equipment.Alwaysreferencethelatestrevision

availablefor the standardslisted.

1. NationalFireProtectionAssociation(NFPA)70:TheNATIONAL

ELECTRICCODE(NEC)availablefrom www.nfpa.org

2. NationalFire ProtectionAssociation (NFPA)5000: BUILDING

CONSTRUCTIONAND SAFETYCODEavailablefrom www.

nfpa.org

3. InternationalBuildingCodeavailablefrom www.iccsafe.org

4. Agricultural Wiring Handbookavailablefrom www.rerc.org ,

Rural ElectricityResourceCouncil P.O.Box 309 Wilmington,

OH45177-0309

5. ASAEEP-364.2Installationand Maintenanceof FarmStandby

Electric Power available from www.asabe.org, American

Society of Agricultural & Biological Engineers2950 Niles

Road,St. Joseph,MI 49085

This list is not all inclusive.Checkwith theAuthority HavingLocal

Jurisdiction (AHJ)for any localcodes or standardswhich may be

applicableto yourjurisdiction.

MODELNO:

SERIALNO:

CALIFORNIAPROPOSITION55 WARNING

Engineexhaustand someof its constituentsareknown

to theStateof Californiato causecancer,birth defects

and otherreproductiveharm.

CALIFORNIAPROPOSITION55 WARNING

This productcontainsor emitschemicalsknown tothe

Stateof Californiato causecancer,birthdefects and

otherreproductiveharm.

UnitID

Locations

1.1 UNPACKING

• Removeallpackagingmaterial.

• Removeseparateaccessory box.

• Removecartonoffthe 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- FrameBolt • 1 QuartSAE30 Oil Bottle

• 1- FrameFlatWasher • OilFunnel

• 3- FlangeNuts • 2 - VibrationMounts

Figure 1 - Accessory Box

Referto Figure2 andinstallthe wheelkit andframefoot asfollows:

1. Slidethe AxlePinthroughtheWheel,WheelSpacer(Washer)

andthe Frame.

2. Installthe HairPintothe AxlePinto securethewheel. Repeat

for the oppositeside.

3. Secure the Vibration Mounts to the Frame Foot with the

includedlocking nuts.

4. To install the Frame Foot, remove the lock nut from the

VibrationMount stud.

5. Place the Frame Foot on the Vibration Mount stud and

re-installthelock nut.Tightenthe nutcompletely.

6. Installthe FrameBolt throughthe FrameWasher,Frameand

Framefoot. Securewith a flangenut.

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. If problems arisewhenassemblingthe generator,

pleasecallthe GeneratorHelplineat 1-888-436-3722.

1.2.1 ASSEMBLINGTHEWHEELKITANBFRAMEFOOT

Thewheel kit is designedto greatly improvethe portability of the

generator.Youwilt needthefollowing tools to installthewheelkit:

• Pliers

• 1/2" (13mm) Wrench

• SocketWrenchwith a 1/2" (13mm) socket.

NOTE:

The wheelsare notintendedfor over-the-roaduse.

RE-USETHIS

NUTFROM

VIBRATION--_

MOUNT

WHEELSPACER

FRAME

WASHER

FLANGE

NUT

INSTALLFRAMEFOOT

FRAME

BOLT

SLIDEAXLE

THROUGHWHEEL

ANDWHEEL

SPACER

2.1 KNOWTHEGENERATOR

Read the Owner'sIVlanualand 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.

6. CircuitBreakers(AC) - The push-to-reset circuit breakers

(49 state model) or the 2-pole circuit breaker (CSA/CARB

models) are rated at 20 Amps; this protects the generator

againstelectricaloverload.

7. Hourmeter- Providesoperatinghoursfor Service Intervals.

8. PowerBar- Indicatesthe amountof power beingusedfrom

thegenerator;each sectionis approximately20%.

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. Grounding Lug- 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. RecoilStarter - Useto start enginemanually.

"21. CarbonCanister- Absorbs fueltank vapors.

22. Roll OverValve - Passesfuel vaporsto the carboncanister.

23. Recovery Hose- Installedbetweenthe engineair intake,the

carboncanisterandthe RollOverValve.

* Californiamodelonly,

Figure 3 - Generator Locations and Controls

49 State

1 4 5 8

@ @

2 3 6 7 3

CSA/CARB

1 4 5 8

2 3 6 7 3

11

12

13

23

22

21

15

16 20

17

18

2.2 HOURMETER=NORESET

The Hourmeter tracks hours of operation

maintenance:

for scheduled

Therewill be a onetime breakin "CHGOIL"messagethat flashes

with the elapsedtime in hoursand tenths after thefirst 30 hours

of operation.

This messagewill actuallybeginflashing at 29 hoursand disable

itself at 31 hours providing a two hour window to perform the

service.

Therewill be a subsequent"CHGOIL"messageevery 100 hours.

Themessagewilt flash one hour beforeand one hour after each

100 hour interval,again providinga two hour window to perform

service.

Every200 hoursthe "SVC"icon on the lower left hand corner of

the display will flash. Themessagewill flash one hourbeforeand

onehourafter each200 hourintervalprovidingatwo hourwindow

to perform service.

Whenthe hour meter is inthe FlashAlert mode, the maintenance

message will always alternate with elapsedtime in hours and

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

maintenancemessagefour times untilthemeter resetsitself.

,, 100 hours- CHGOIL-- Oil ChangeInterval(Every100 hrs)

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

2.3 HOURMETEB=WITHRESET

TheHourmetertrackshoursofoperationforscheduledmaintenance

(seechart).

Operation: Pushand releasethe reset button to toggle between

screens. The hours count backwards from the set interval as

shown in the chart.

Whenthe meter reaches5 hours,thetext"CHGOIL"(or "SVCAIR

FILTER"or "CHGPLUG")will flash continuallyfor two minutes.

Afterthis time,the meterwill go backto displayingthetotal hours

of the unit (for 2 minutes). This cyle will repeatfor the entire 5

hours.

When the service interval reaches zero hours, the text "NOW"

replacesthe hours remaining.

Fora newgeneratorfor instance,the messagewill say "CHGOIL"

thenflash "in30". This meansthat in 30 hours, theoil wilt needto

be changed. Pressingthe buttonafew moretimes will bring the

meter backto the screenthat shows thetotal hoursrun.

Reset: Toggleto the alert that you wish to reset then hold the

buttondownfor 9 seconds.Themaintenancehoursareresetwhen

thedisplay shows "0000.0".

NOTE:

Thehourglass graphic willflashon and off whenthe engine

is running.Thissignifiesthatthe meteristrackinghours of

operation.

Figure 4 - Hourmeter

OOOO'O

HOUR GLASS RESET BUTTON

GRAPHIC (IF EQUIPPED)

2.4 CORDSETSANDCONNECTIONPLUGS

2.4.1 120VAC,20AMP,GFC/DUPLEXRECEPTACLE

This is a 120 Volt outlet protectedagainst overloadby a 20 Amp

push-to-resetcircuitbreaker(Figure5). Useeachsocketto power

120 VoltAC, singlephase,60 Hzelectricalloadsrequiringup to a

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

high quality,welt-insulated,3-wire grounded cord sets ratedfor

125 Volts at 20 Amps (or greater).A cord set 15 feet or shorter

is preferred.

Keepextensioncords as short as possibleto preventvoltagedrop

and possibleoverheatingof wires.

Nourmeter(With Reset) Chart

Message Frequencyof Message Interval Duration of message

CHGOIL Initialbreak-inperiod First30 Hours

CHGOIL Re-occuring 100 hours ON/OFFfor 2 minutes in a 5

SVCAIR FILTER Re-occuring 200 hours hour period

CHGPLUG Re-occuring 200 hours

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

2.4.2 120/240VAC,20 AMPRECEPTACLE

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

ACat20 Amps (or greater)(Figure6).

Figure 6 - 120/240 VoRAC, 20 Amp Receptac/e

_t he engine exhaust fumes contain carbon

monoxide, which can you cannot see or smell.

This poisonous gas, if breathed in sufficient

concentrations, can cause unconsciousness or

even death.

_t 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 operation

of the generator. The generator MUST be

operated outdoors.

_t This exhaust system must be properly

maintained. Do nothing that might render the

exhaust system unsafe or in noncompliance

with any local codes and/or standards.

AIways use a battery operated carbon

monoxide alarm indoors, installed according to

the manufacturers instructions.

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 inside a home

or garage, EVEN iF doors

and windows are open.

Only use OUTSIDE and

far away from windows,

doors, and vents.

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 powerat 16.6 Amps. Theoutletis protectedby

a circuit breaker.

2,5 HOWTOUSETHEGENERATOR

Seethe "ToStart the Engine"sectionfor howto safelystart and

stop the generatorand how to connect anddisconnect loads. If

there are any problems operatingthe generator,pleasecall the

generatorhelplineat 1-888-436-3722.

Never operate in an encJosed area or indoors!

NEVER use in the home, in a vehicJe, or in

partly encJosed 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.

2.5.1 GROUNDINGTHEGENERATORWHENUSEDASA

PORTABLE

This generator has an equipment ground that connects the

generatorframe componentsto the ground terminals on the AC

output receptacles (see NEC 250.34 (A) for explanation).This

allows the generatorto be used as a portablewithout grounding

theframe ofthe generatoras specifiedin NEC250.34.

SpecialRequirements

There may be Federalor State OccupationalSafety and Health

Administration(OSHA)regulations,localcodes,or ordinancesthat

applyto the intendeduse ofthe generator.

Pleaseconsult a qualified electrician, electricalinspector, or the

local agencyhavingjurisdiction:

* Insomeareas,generatorsarerequiredto beregisteredwith local

utilitycompanies.

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

additionalregulationswhich mustbe observed.

2.5.2 CONNECTINGTHEGENERATORTOA BU/LD/NG'S

ELECTRICALSYSTEM

Connectionsfor standby power to a building's electricalsystem

must be made by a qualifiedelectricianand in strict compliance

with all national and local electrical codes and laws. The

connectionmust isolatethegeneratorpowerfrom utility poweror

otheralternativepowersources.

NOTE:

Becausethe generatorequipment groundis bondedto the AC

neutral wires in thegenerator(see Figure8), either a 3-pole

transferswitchor a 2 poletransferswitchwith a switching

neutralkit isrequiredto connectthisgenerator to a building

load. Inthis application thegenerator becomes a separately

derived system(seeNEC250.20 (D)), and mustbe grounded

in accordancewith thenationalor localelectrical code

requirements.

GroundingtheGeneratorina BuildingStandbyApplication

The National Electrical Code requires that the frame and

external electrically conductiveparts of this generator be

properlyconnectedto an approvedearth ground (Figure 7).

Local electrical codes also require grounding of the unit. For

that purpose,connecting a No. 10 AWG (AmericanWire Gauge)

strandedcopperwire to the groundinglug and to an earth-driven

copper or brass grounding rod (electrode) provides adequate

protection against electrical shock. However,local codes may

vary widely. Consultwith a local electrician for grounding

requirementsin the area.

Proper grounding of the generator will 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.

Figure7 - Groundingthe Generator

CONNECTGENERATORGROUNDHERE

2.5.3 NEUTRALTOFRAMEGROUNDING

If service work is performed on the alternator,DO NOTdiscard

the white jumper wires from the terminal block to the alternator

ground, located on the rear bearing carrier. Always make sure

the wires are properlyconnectedbeforeusingthe generatorafter

alternatorservicework is done (Figure8).

Figure8 - Neutral to FrameGroundWires

DONOTDISCARD

THESEWIRES!

NEUTRALTO

FRAMEGROUND

//_Failure to reconnect these wires may create a

potential shock hazard when the generator is

running!

2.5.4 CONNECtiNGELECTR/CALLOADS

DONOTconnect240 Volt loadsto 120 Voltreceptacles.

DONOTconnect3 phaseloadsto the generator.

DONOTconnect50 Hzloadsto 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 be connected

at one time. This total should no be greaterthan (a) the rated

wattage/amperagecapacity of the generator or (b) circuit

breakerratingofthereceptaclesupplyingthepower.See"Don't

OverloadtheGenerator

2.6 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,tool or motor does not give wattage,multiply

voltstimes ampereratingto determinewatts (voltsx amps =

watts).

• Some electric motors, such as inductiontypes, requireabout

threetimes more watts of powerfor starting thanfor running.

This surge of power lasts only a few seconds when starting

such motors. Makesureto allowfor highstartingwattagewhen

selectingelectricaldevicesto connectto the generator:

1. Figurethewatts neededto start thelargest motor.

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

loads.

TheWattageReferenceGuideis providedto assist in determining

howmany itemsthe generatorcan operateat onetime.

2.7 WATTAGEREFERENCEGUIDE

NOTE:

Allfigures are approximate. See data labelon appliancefor

wattage requirements.

Device.......................................... RunningWatts

*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

Chain Saw............................................... 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

OurlingIron ............................................... 700

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

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

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

Electric Blanket............................................. 400

Electric NailGun........................................... 1200

Electric Range(per element).................................. 1500

Electric Skillet............................................. 1250

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

*Furnace Fan(3/5 HP)....................................... 875

*Garage Door Opener.................................. 500 to 750

Hair Dryer ............................................... 1200

HandDrill .......................................... 250to 1100

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

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

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

*Jet Pump ................................................ 800

Lawn Mower ............................................. 1200

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

Microwave Oven..................................... 700 to 1000

*Milk Cooler.............................................. 1100

OilBurner on Furnace........................................ 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....................................... 800to 1050

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

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

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

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

* Allow 3 times the listed watts for starting these devices.

2.8 BEFORESTARTINGTHEGENERATOR

Prior to operatingthe generator,engineoil and gasolinewill need

to beadded,asfollows:

2.8.1 ADD/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(alsoseechart).

• Above40° F,useSAE30

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

• Below 10° F,usesynthetic5W-30

mEm

7I

°F -20 -!0 O 10 20 32 40 60 80 leo

oc-3'o -_o -;o ; 1'0 2'0 3'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.

• Place generatoron a level surface (not to exceed15° in any

direction).

• Cleanareaaroundoil fill andremoveoil fill cap.

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

reaches the full mark. Stop filling occasionallyto check oil

level. Engineoil isfull when levelis up to thethreads of the oil

fill plug (Figure9).

• Installoil fill cap andfingertightensecurely.

• Checkengineoil levelbeforestarting eachtime thereafter.

Figure g - Oil Level

m

FILLCRANKCASETO

THEBOTTOMOFTHESE

- -- THREADSWITHTHE

RECOMMENDED

ENGINEOIL

V ,

2.8,2 ADD/fiGGASOLINE

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 overfilled,

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 regularUNLEADEDgasofinewith the generatorengine.Do

not usepremiumgasoline.Do notmix oil with gasoline.

• Do not usegasolinewith morethan 10% alcohol such as E85

or Methanol.

• Cleanareaaroundfuelfill cap, removecap.

• Slowly addunleadedregulargasolineto fueltank. Fillto bottom

of screenfilter.Be carefulnottooverfill (Figure10).

• Installfuel cap andwipe up any spilledgasoline.

Figure 10 - Fuel Fill Level

DONOTFILL

ABOVELIP!

IMPORTANT:Itis importantto preventgum depositsfrom forming

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

during storage. Alcohol-blendedfuels (called gasohol, ethanol

or methanol)can attract moisture, which leadsto separationand

formationof acids duringstorage.Acidic gascandamagethefuel

system of an enginewhile in storage.Toavoid engineproblems,

the fuel system should be emptiedbefore storage of 30 days or

longer.Seethe "Storage"section. Neveruseengineor carburetor

cleanerproductsinthefueltank aspermanentdamagemay occur.

2.9 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 receptaclesbefore

startingthe engine.

• Place generatoron a levelsurface (not to exceed15° in any

direction).

• Openthefuel shut-off valve (Figure11).

Figure 11 - Fuel Shut-Off Valve

Slide engine CHOKEknob outward to "FullChoke"position

(Figure12).

Figure 12- Choke Operation

\

1o

NOTE:

The engine switchmustbe in theONposition.

* Tostart manually,firmly grasptherecoil handleand pull slowly

until increasedresistance is felt. Pull rapidly up and away to

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 doesnot continuetorun,pull chokeknobto

"Full Choke"and repeatstartinginstructions.

A, CAUTION!

,_Do not overload the generator. Also, do

not overload individual panel receptacles.

These outlets are protected against overload

with push=to=reset=type circuit breakers, if

amperage rating of any circuit breaker is

exceeded, that breaker opens and electrical

output to that receptacle is lost. Read "Don't

Overload the Generator" carefully.

2.10STOPPINGTHEENGINE

1. Shut off all loads, then unplug the electrical loads from

generatorpanel receptacles.Never start or stop the engine

with electricaldevicespluggedin andturnedon.

2. Let enginerun at no-load for severalminutesto stabilizethe

internaltemperaturesof engineand generator.

3. Move Run/Stopswitch to "Off" position.

4. Closefuelvalve.

2.11LOW01LPRESSURESHUTDOWNSYSTEM

Theengineis equippedwith a low oil pressuresensor that shuts

downthe engineautomaticallywhentheoil pressuredropsbelow

5 psi. A delay built into the low oil shutdown system allows oil

pressureto build during starting. The delayallows the engineto

run for about10 secondsbeforesensingoil pressure.If theengine

shutsdown by itselfandthe fueltank hasenoughgasoline,check

engineoil level.

2.1I.IRESTARTING

If trying to restart the engine within 10 seconds after a low oil

pressureshut down, theenginemay NOTstart. Thesystemneeds

5 to 10 secondsto reset.

If the engine is restartedafter such a shutdown and the low oil

pressure has not been corrected (i.e. adding oil), the enginewill

run for about10 secondsas describedaboveandthen stop.

3.1 PEBFOBIVlINGSCHEDULEDMAINTENANCE

It is importantto perform serviceas specifiedin the Maintenance

Schedulefor proper generatoroperation, and to ensurethat the

generatorcomplieswith theapplicableemissionstandardsfor the

durationof its usefullife. Serviceand repairsmaybe performedby

anycapablepersonor repairshop. Additionally,emissionscritical

maintenancemust be performed as scheduledin orderfor the

Emissions Warrantyto be valid. Emissions critical maintenance

consists of servicingthe air filter and spark plugs in accordance

with the MaintenanceSchedule.

3.2 MAINTENANCESCHEDULE

Follow the calendar intervals. More frequent service is required

whenoperatingin adverseconditionsnotedbelow.

CheckOilLevel AtEachUse

ChangeOilandOilFilters *EverySeason/Every100Hours

CleanSparkArrestorScreen EverySeason/Every100Hours

ServiceAirFilter **EverySeason/Every200Hours

ReplaceSparkPlug EverySeason/Every200Hours

:i: Changeoil after first 30 hours of operationthenevery season.

* Changeoiland oilfilter every monthwhen operatingunderheavyload or in high

temperatures.

** Clean more often under dirty or dusty operating conditions. Replaceairfilter

parts if very dirty.

3.3 PBODUCTSPECIFICATIONS

3.3.1GENERATOR SPEC/F/CAT/ON$

RatedMax. Power................................................................... 3.6 kW**

SurgePower............................................................................... 4.5 kW

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

RatedMax ACLoad

Current@ 240V............................................................. 15.0 Amps**

Current@ 120V............................................................. 30.0 Amps**

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

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

** Maximumwattageandcurrentaresubjectto,andlimitedby,suchfactors

asfuelBtucontent,ambienttemperature,altitude,enginecondition,etc..

Maximumpowerdecreasesabout3.5%foreach1,000feetabovesealevel;

andwillalsodecreaseabout1%foreach6°C(10° F)above16° C(60° F)

ambienttemperature.

3.3.2 ENG/NESPECIFICATIONS

RatedHorsepower@ 3600 RPIVl......................................................... 6

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

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

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

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

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

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

RunTime/FuelConsumption-l/2 Load

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

ClassI EmissionCertified

11

3.3.3 EMISSIONSINFORMATION

TheEnvironmentalProtectionAgency(and CaliforniaAir Resource

Board for generators certified to CA standards) require(s)that

this generator comply with exhaust and evaporative emission

standards.Locate the emissions compliancedecalon the engine

to determinewhat standardsthe generatormeets. This generator

is certified to operateon gasoline.The emission control system

consists ofthe following:

* Air InductionSystem

- IntakePipe/Manifold

- AirCleaner

, FuelSystem

- Carburetor

- FuelTanWCap

- FuelLines

- EvaporativeVentLines

- CarbonCanister(forCAenginesonly)

, IgnitionSystem

- SparkPlug

- IgnitionModule

, ExhaustSystem

- ExhaustManifold/Muffler

3.4 GENERALRECOMMENDATIONS

Thewarrantyof thegeneratordoes notcover itemsthat havebeen

subjectedto operator abuseor negligence.To receivefull value

from the warranty, the operator must maintain the generatoras

instructed inthis manual.

Some adjustmentswilt need to be made periodically to properly

maintainthegenerator.

All adjustmentsin the Maintenancesectionof this manualshould

be madeat leastonceeachseason.Followthe requirementsinthe

"MaintenanceSchedule".

NOTE:

Oncea year replacethe spark plugand replace the air filter.

A new sparkplugand cleanair filter assure properfuel-air

mixture andhelpthe engine run better andlast longer.

3.4.1 GENERATORMAINTENANCE

Operateand storethe unit in a cleandry environmentwhereit will

not be exposedto excessivedust,dirt, moistureor any corrosive

vapors.Coolingair slotsin thegeneratormustnot becomeclogged

with snow, leaves,or anyotherforeign material.

Checkthe cleanlinessof the generatorfrequentlyand cleanwhen

dust, dirt, oil, moistureor otherforeign substancesarevisible on

its exteriorsurface.

,_ CAUTION!

,l_ Never insert any object or tool through the air

cooling slots, even if the engine is not running.

NOTE:

DONOTuse a garden hoseto cleangenerator.Water can

enter the engine fuel system andcauseproblems.In addition,

if water entersthe generatorthrough coolingair slots,some

waterwill be retained in voidsand crevicesof the rotor

and stator windinginsulation.Water anddirtbuildup on the

generatorinternalwindingswill eventually decreasethe

insulationresistanceof these windings.

3.4.2 TOCLEANTHEGENERATOR

* Usea dampcloth to wipe exteriorsurfaces clean.

* A soft, bristlebrushmaybe usedto loosencakedon dirt, oil,etc.

* A vacuumcleanermay be usedto pick up loosedirt anddebris.

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

blow away dirt. Inspect cooling air slots and openingson the

generator.Theseopeningsmustbekeptcleanandunobstructed.

3.4.3 ENGINEMAINTENANCE

When working on the generator, always

disconnect spark plug wire from spark plug and

keep the wire away from the spark plug.

3.4.4 CHECKINGOILLEVEL

See the "BEFORESTARTINGTHE GENERATOR"section for

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

checkedbeforeeachuse,or at leasteveryeighthoursof operation.

Keepthe oil levelmaintained.

3.4.5 CHANGINGTHEOILANDOILFILTER

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

Changethe oil every 100 hours or every seasonthereafter.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.

Usethefollowinginstructionsto changethe oil afterthe engine

coolsdown:

1. Cleanareaaroundoil drainplug.

2. Removeoil drain plugfrom engineand oil fill plug to drainoil

completelyinto a suitablecontainer.

3. When oil has completely drained, install oil drain plug and

tightensecurely.

4. Placea suitable containerbeneaththe oil filter and turn filter

counterclockwise to remove. Discard according to local

regulations.

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

clockwise untilgasketcontacts lightlywith filter adapter.Then

tightenan additional3/4 turn.

12

6. Fill engine with recommendedoil. (See "Before Startingthe

Generator"for oil recommendations).

7. Wipeup anyspilledoil.

8. Disposeof usedoil at a propercollectioncenter.

3.4.6 REPLACINGTHESPARKPLUG

Use Champion RC14YCspark plug or equivalent.Replace the

plugevery 200 hours.This wilt help the engine start easierand

run better.

1. Stopthe engineand pull the sparkplugwire off of the spark

plug.

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

side panel.

3. Cleanthe area aroundthe spark plug and remove it from the

cylinder head.

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

correctly gappedsparkplug intothe cylinderhead(Figure13).

5. Pushthe bootfirmly onthe sparkplug and install sidepanel.

Figure 13 - Spark Plug Gap

3.5 SERVICEAIRFILTER

Theenginewilt not run properlyand may be damagedif usinga

dirty air filter. Cleanor replacethe air filter paperfilter every 200

hours or once a year (Figure14). Cleanor replacemore often if

operatingunderdusty conditions.

Tocleanor replacepaperair filter:

1. Removeairfilter cover;then removethe paperfilter.

2. Cleanpaperfilter bytappingit gentlyon a solid surface. If the

filter is too dirty, replaceit with a newone. Disposeof theold

filter properly.

3. Cleanair filter cover,then insert new paperfilter intothe base

of the airfilter.Re-installair filter cover.

NOTE:

Toorder a new air filter, pleasecontactthe nearestauthorized

servicecenterat 1-888-436-3722.

Figure 14- Air Filter

Filter

Base

Covel

3.6 CLEANSPARKARRESTORSCREEN

The engineexhaustmuffler has a spark arrestor screen. Inspect

and cleanthe screen every 100 hours or at least onceeachyear

(Figure15). If unit is usedregularly,inspectand cleanmoreoften.

i_lf using the generator on any forest=covered,

brush=covered or grass=covered unimproved

land, it must be equipped with a spark arrestor.

The spark arrestor must be maintained in good

condition by the owner/operator.

Cleanandinspectthe sparkarrestorwhentheengineisat ambient

temperatureasfollows:

1. Insert a flat blade screwdriverthrough the slot on the side of

the muffler heat shieldto access the spark arrestor clamp.

Loosenthe clamp and removethe spark arrestorscreenfrom

themuffler.

2. Inspect screen and replace if torn, perforated or otherwise

damaged. DONOT USEa defective screen. If screen is not

damaged,cleanit with commercialsolvent.

3. Replacethe spark arrestorandtightenthe clamp.

13

Figure 15 -- Spark Arrestor Screen

SPARK

ARRESTOR

SCREEN

ARRESTOR

SCREENCLAMP

INSERTSCREWDRIVER

THROUGHSLOT INHEAT

SHIELDTO ACCESS

ARRESTORSCREENCLAMP

3.7 GENERAL

Thegeneratorshould be started at leastonce every 30 days and

be allowedto run at least30 minutes. If this cannot be done and

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

informationas a guideto prepareit for 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.

_t Allow unit to cool entirely before storage.

3.8 LONGTERMSTORAGE

It is importantto preventgum depositsfrom forming in essential

fuel systemparts such asthe carburetor,fuel hoseor tank during

storage. Also, experience indicates that alcohol-blendedfuels

(calledgasohol,ethanolor methanol)can attract moisture,which

leadsto separationand formation of acids during storage.Acidic

gas candamagethefuel systemof an enginewhile in storage.

To avoid engine problems, the fuel system should be emptied

beforestorageof 30 days or longer,asfollows:

1. Removeall gasolinefrom thefueltank.

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.

2. Start and run engineuntilenginestopsfrom lack of fuel

3. Allow the engineto cool to the touch and then drain the oil

from the crankcase.Refillwith the recommendedgrade.

4. Removespark plug and pour about 1/2 ounce (15 mt) of

engineoil intothecylinder.Coversparkplug holewith rag.Putt

the recoil starter a couple times to lubricatethe piston rings

and cylinderbore.

CAUTION!

_t void spray from the spark plug hole when

cranking engine.

5. Install and tighten the spark plug. Do not connect the spark

plug wire.

6. Cleanthe generatorouter surfaces. Check that cooling air

slots andopeningson generatorareopen andunobstructed.

7. Storethe unit in a clean, dry place.

3.9 OTHERSTORAGETiPS

* Donot store gasolinefrom oneseasonto another.

* Replacethe gasolinecan if it starts to rust. Rustand/or dirt in

the gasolinewill cause problems with the carburetorand fuel

system.

* If possible, store the unit indoors, in a garage or shed, and

cover it to give protectionfrom dust and dirt. BESURETO

EMPTYTHEFUELTANK.

* If it is not practical to emptythe fuel tank and the unit is to

be stored for some time, use a commercially availablefuel

stabilizer added to the gasoline to increase the life of the

gasoline.

* Coverthe unit with a suitable protective cover that does not

retainmoisture.

i_NEVER cover the generator while engine and

exhaust area are warm. Allow unit to cool

entirely.

14

4.1 TBOUBLESHOOTINGGUIDE

Engineisrunning,but noAC output

is available.

1. Circuit breakeris open.

2. Poor connectionor defectivecord set.

3. Connecteddevice is bad.

4. Faultin generator.

5. GFCItrips the20 Amp outlets.

1. Resetcircuit breaker.

2. Checkand repair.

3. Connectanotherdevicethatis in good condition.

4. ContactAuthorizedServiceFacility.

5. Repairthe"short" and resetthe 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.

runsrough. 2. Dirtyair filter. 2. Cleanor replaceairfilter.

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 chokeknobto 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.

15

Page is loading ...

EM/$$/ONWARRANTYFOREPACERTIFIEDEQUIPMENT

U,S, EPA EMiSSiON CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLiGATiONS

TheUnited StatesEnvironmentalProtectionAgency (EPA)andGeneracPowerSystems,Inc. (Generac)arepleasedto explainthe Emission Control

SystemWarranty(ECSWarranty) on yournew 2011 and laterequipment.New equipmentthat use smallspark-ignitedenginesmust bedesigned,built,

andequippedto meetstringentanti-smog standardsfor the federalgovernment.Generacwill warrantthe emission control systemon your equipment

for the periodof time listed belowprovidedthere has beenno abuse, neglect,unapprovedmodificationor impropermaintenanceofyour equipment.

Theemission control systemon this equipmentincludesall componentswhose failurewould increasethe emissionsof anyregulatedpollutant.These

componentsarelisted in the Emissions Information sectionofthis manual.

MANUFACTURER'S WARRANTY COVERAGE:

This ECSWarranty is validfor two years,or for the sameperiod as specifiedin the GeneracLimitedWarranty,whicheveris longer.Forequipmentwith

hourmeters,the warranty periodis a number of hours equalto halfthe UsefulLifeto which the equipmentis certified, or the warrantyperiod specified

abovein years,whicheveris less.TheUsefulLife can befound on the EmissionControlLabelon the engine.If, during suchwarranty period,any

emission-relatedpart on yourequipment isfound to be defectivein materialsor workmanship, repairsor replacementwill be performedby a Generac

AuthorizedWarrantyServiceDealer.

OWNER'S WARRANTY RESPONSiBiLiTiES:

Asthe equipmentowner,you areresponsiblefor the completion of all requiredmaintenanceas listed in your factory suppliedOwner'sManual.For

warranty purposes,Generacrecommendsthat you retainall receiptscoveringmaintenanceon your generator,but Generaccannotdeny warranty

solelydueto the lack of receipts.

Youshould beawarethat Generacmay deny anyand/or all warrantycoverageor responsibilityif your equipment,or apart!componentthereof,has

failed due to abuse,neglect, impropermaintenance,or unapprovedmodifications.

Youare responsible for contactingaGeoeracAuthorized Warranty Dealeras soonas a problemoccurs.Thewarranty repairsshouldbe

completed in a reasonableamount oftime, not to exceed 30 days.

Warrantyservice can bearrangedby contactingeitheryour sellingdealeror a GeneracAuthorizedWarrantyServiceDealer.Tolocatethe Generac

AuthorizedWarrantyServiceDealernearestyou, call ourtoll free numberbelow, or email[email protected].

1-800-333-1322

IMPORTANTNOTE:This warranty statementexplainsyour rights andobligationsunderthe Emission ControlSystemWarranty,which is providedto

you by Generacpursuantto federallaw. Seealsothe "GeneracLimitedWarrantiesfor GeneracPowerSystems,Inc.," which is enclosedherewith on a

separatesheet,also providedto you byGenerac.Notethat this warranty shall not apply to any incidental,consequentialor indirect damagescaused

bydefects in materialsor workmanshipor any delayin repairor replacementof the defectivepart(s). This warranty is in place of all otherwarranties,

expressedor implied.Specifically,Generacmakesno other warrantiesasto the merchantabilityor fitness for aparticular purpose.Any implied

warrantieswhich areallowed by law, shallbe limited in durationto the terms of the expresswarranty providedherein.Somestatesdo not allow

limitationson how long an implied warrantylasts, sothe abovelimitation may not applyto you.

TheECSWarrantyappliesonly to the emissioncontrol system of your newequipment.Boththe ECSWarrantyandthe GeneracWarranty describe

importantrights and obligationswith respectto your new engine.

Warrantyservice can beperformed onlyby a GeneracAuthorizedWarrantyServiceFacility.When requestingwarranty service,evidencemust be

presentedshowingthe dateofthe saleto the originalpurchaser/owner.

Ifyou haveany questionsregardingyour warranty rightsandresponsibilities,you shouldcontact Generacatthe following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 * WHITEWATER, Wi 53190

PartI of 2

18

PartNo. 0J3335ARev.A 11/11

EM/SS/ONWARRANTYFOREPACERTIFIEDEQUIPMENT

EMiSSiON CONTROL SYSTEM WARRANTY

EmissionControlSystemWarranty (ECSWarranty)for equipmentusing small spark-ignitedengines:

(a) Applicability: This warrantyshall applyto equipmentthat usessmall off-road engines.The ECSWarranty periodshall beginon the datethe new

equipmentis purchasedby/deliveredto its original, end-usepurchaser/ownerandshallcontinue for the lesserof:

(1) Theperiodof time specifiedin the GeneracLimitedWarrantyenclosedherewith,but not lessthan24 months, or

(2) Forenginesequippedwith hour meters,a numberof operating hoursequalto half of the engine'suseful life.The useful life is specifiedon the

EmissionsControl Labelon the engine.

(b) GeneralEmissionsWarrantyCoverage:Generacwarrantsto the original,end-usepurchaser/ownerof the newengineor equipmentandto each

subsequentpurchaser/ownerthatthe ECSwhen installedwas:

(1) Designed,built and equippedsoas to conform with all applicableregulations;and

(2) Freefrom defectsin materialsandworkmanship which causethe failure of awarrantedpart at anytime duringthe ECSWarrantyPeriod.

(c) Thewarranty on emissions-relatedparts will be interpretedasfollows:

(1) Anywarrantedpart that is not scheduledfor replacementas requiredmaintenancein the Owner'sManual shall bewarrantedfor the ECS

WarrantyPeriod.If any such partfails during the ECSWarrantyPeriod,it shallbe repairedor replacedby Generacaccordingto Subsection

(4) below.Any such part repairedor replacedunderthe ECSWarranty shallbewarrantedfor the remainderofthe ECSWarranty Period.

(2) Anywarrantedpart that is scheduledonlyfor regularinspection asspecifiedin the Owner'sManualshallbe warrantedfor the ECSWarranty

Period.A statementin the Owner's Manualto the effect of "repairorreplace as necessary"shall not reducethe ECSWarranty Period.Any

such part repairedor replacedunderthe ECSWarranty shallbe warrantedfor the remainderofthe ECSWarrantyPeriod.

(3) Anywarrantedpart that is scheduledfor replacementas required maintenancein the Owner'sManualshallbe warrantedfor the periodof time

priorto first scheduledreplacementpoint for that part. If the part fails prior to the first scheduledreplacement,the part shall be repairedor

replacedby Generacaccordingto Subsection(4) below.Any such emissions-relatedpart repairedor replacedunderthe ECSwarranty shall

bewarrantedfor the remainderof the period prior to the first scheduledreplacementpointfor thatpart.

(4) Repairor replacementof anywarranted,emissions-relatedpart underthis ECSWarranty shall beperformed atno chargeto the owner ata

GeneracAuthorizedWarrantyServiceFacility.

(5) Notwithstandingthe provisions of subsection (4) above,warranty servicesor repairsmust be providedat GeneracAuthorizedService

Facilities.

(6) Whenthe engineis inspectedby a GeneracAuthorizedWarrantyServiceFacility,the purchaser/ownershall not be heldresponsiblefor

diagnosticcosts if the repairis deemedwarrantable.

(7) Throughoutthe ECSWarrantyPeriod,Generacshall maintainasupply of warrantedemission-relatedparts sufficient to meetthe expected

demandfor such parts.

(8) AnyGeneracauthorizedand approvedemission-relatedreplacementparts may beusedin the performanceof any ECSWarrantymaintenance

or repairs and will beprovidedwithout chargeto the purchaser/owner.Suchuseshall not reduce Generac'sECSWarrantyobligations.

(9) No modifications,other thanthose explicitlyapprovedbyGenerac,may be madeto the generator.Unapprovedmodificationsvoid this ECS

Warrantyand shall be sufficientgroundfor disallowingan ECSWarrantyclaim.

(10) Generacshall not be heldliablehereunderfor failures of any non-authorizedreplacementparts, or failures of anyauthorizedparts causedby

the useof non-authorizedreplacementparts.

EMISSION RELATED PARTS MAY iNCLUDE THE FOLLOWING (IF EQUIPPED):

1) FUELMETERINGSYSTEM 3) IGNITIONSYSTEM

A. CARBURETORANDINTERNALPARTS A. SPARKPLUGS

B. FUELTANK!CAP B. IGNITtONCOILS/MODULE

C. FUELLINES 4) AIRINJECTIONSYSTEM

D. EVAPORATIVEVENTLINES A. PULSEAIRVALVE

E. REGULATOR(GASEOUSFUELS) 5) EXHAUSTSYSTEM

2) AIRINDUCTIONSYSTEM A. CATALYST

A. INTAKEMANIFOLD B. EXHAUSTMANIFOLD

B. AIRFILTER

Part 2of 2

PartNo. OJ3335ARev.A 11/11

19

EM/$$/ONWARRANTYFORCARBCERT/F/EDEOU/PMENT

CALiFORNiA AND U.S, EPA EMiSSiON CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLiGATiONS

The CaliforniaAir Resource Board (CARB)and the UnitedStates EnvironmentalProtectionAgency (EPA),together with GeneracPower Systems, Inc.

(Generac)arepleasedto explainthe EmissionControlSystemWarranty(ECSWarranty)onyour new2012 equipment.Newequipmentthat usesmallspark-

ignitedenginesmustbe designed,built, and equippedto meetstringentanti-smogstandardsfor the stateof Californiaandthe federal government.Generac

will warrantthe emission control system on your equipment for the periodof time listed below providedthere has been no abuse, neglect, unapproved

modificationor impropermaintenanceof your equipment.

The emissioncontrol system on this equipment includes all components whose failure would increasethe emissions of any regulatedpollutant.These

componentsarelistedin the EmissionsInformation sectionof this manual.

MANUFACTURER'S WARRANTY COVERAGE:

This ECSWarrantyis validfor two years, orfor the sameperiod as specifiedinthe GeneracLimitedWarranty,whicheveris longer.Forequipmentwithhour

meters,the warranty periodis a numberof hoursequalto halfthe Useful Lifeto whichthe equipmentis certified, or thewarrantyperiod specifiedabovein

years,whicheveris less.TheUseful Life canbe found on the EmissionControl Labelon the engine. If, during such warrantyperiod, any emission-related

part on your equipmentis found to be defectivein materialsor workmanship,repairsor replacementwill be performedby a GeneracAuthorizedWarranty

ServiceDealer.

OWNER'S WARRANTY RESPONSiBiLiTiES:

Asthe equipmentowner,you areresponsiblefor the completionofall requiredmaintenanceaslistedin your factory suppliedOwner'sManual.Forwarranty

purposes,Generacrecommendsthat you retain all receipts coveringmaintenanceon your generator,but Generaccannot denywarranty solely due to the

lack of receipts.

You shouldbe awarethat Generacmay denyany and/or all warranty coverageor responsibilityif your equipment,or apart!componentthereof, hasfailed

dueto abuse,neglect,impropermaintenance,or unapprovedmodifications.

Youare responsiblefor contacting a Genera¢AuthorizedWarranty Dealer as soon as a problemoccurs.The warranty repairsshould be completed

in a reasonable amount oftime, not to exceed30 days.

Warrantyservicecan bearrangedbycontactingeitheryoursellingdealeror a GeneracAuthorizedWarrantyServiceDealer.TolocatetheGeneracAuthorized

WarrantyServiceDealernearestyou, call ourtoll free numberbelow, or email [email protected].

1-800-333-1322

IMPORTANTNOTE:This warrantystatement explainsyour rights and obligations underthe EmissionControlSystemWarranty,which is providedto you

by Generacpursuantto federallaw.Seealsothe "GeneracLimitedWarrantiesfor GeneracPowerSystems, Inc.,"which is enclosedherewithon a separate

sheet,also providedto you by Generac.Notethat this warranty shallnot apply to any incidental,consequentialorindirect damagescausedby defects in

materialsor workmanshipor anydelayinrepairorreplacementofthe defectivepart(s). This warrantyisin placeof allotherwarranties,expressedor implied.

Specifically,Generacmakesno other warrantiesas to the merchantabilityor fitness for a particular purpose.Any impliedwarranties allowed by law shall

be limited in durationto theterms ofthe expresswarranty providedherein.Somestatesdo not allow limitationson how long an impliedwarranty lasts, so

the abovelimitationmay not apply to you.

TheECSWarrantyappliesonlytothe emissioncontrol systemofyour newequipment.Boththe ECSWarrantyand the GeneracWarrantydescribeimportant

rightsand obligations with respectto your new engine.

Warrantyservice canbe performedonlyby aGeneracAuthorizedWarrantyServiceFacility.Whenrequestingwarrantyservice,evidencemust bepresented

showingthe dateof the saleto the originalpurchaser/owner.

Ifyou haveany questionsregardingyourwarranty rights andresponsibilities,you shouldcontact Generacatthe following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 * WHITEWATER, WI 53190

Part 1of 2

2O

PartNo. 0J8147CRev.A 01/12

Page is loading ...

Generac XG4000-5778-2 Owner's manual

This manual is also suitable for

Generac XG4000-5778-2 Owner's manual

in other languages

Related papers

Other documents