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16

4000EXL Extended Life Generator

3.

Wash sediment cup, o-ring, retaining ring, and screen in
a nonflammable solvent. Dry them thoroughly.

4.

Place screen, retaining ring, and o-ring into fuel valve.
Install sediment cup and tighten securely.

5.

Move fuel valve to “On” position, and check for leaks.
Replace o-ring if there is any leakage.

Battery Maintenance

Other than float charging, described elsewhere, no
maintenance is required for the battery. Keep the battery
and terminals clean and dry.

IMPORTANT: Battery charging should be performed in a
dry location, such as inside a garage.

Generator Cleaning

• Use a damp cloth to wipe exterior surfaces clean.

• Use a soft bristle brush to loosen caked on dirt or oil.
• Use a vacuum cleaner to pick up loose dirt and debris.
• Use low pressure air (not to exceed 25 psi) to blow

away dirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.

STORAGE

The generator should be started at least once every seven
days and allowed to run at least 30 minutes. If this cannot
be done and you must store the unit for more than 30 days,
use the following guidelines to prepare it for storage.

Generator Storage

• Clean the generator as outlined in “Generator Cleaning”.

• Check that cooling air slots and openings on generator

are open and unobstructed.

Engine Storage

See engine owner’s manual for instructions.

Other Storage Tips

• To prevent gum from forming in fuel system or on

essential carburetor parts, empty all two supplied fuel
stabilizer containers into fuel tank and fill with fresh
gasoline. Run the unit for several minutes to circulate the
additive through the carburetor.The unit and fuel can
then be stored for up to 24 months. Additional fuel
stabilizer can be purchased locally.

• DO NOT store gasoline from one season to another

unless it has been treated as described above.

• Replace fuel container if it starts to rust. Rust and/or dirt

in fuel can cause problems if it's used with this unit.

• Store in clean and dry area.

• DO NOT expose generator to excessive moisture, dust, dirt,

or corrosive vapors.

• DO NOT insert any objects through cooling slots.

Improper treatment of generator can damage it and
shorten its life.

CAUTION

• DO NOT place a storage cover over a hot generator.

• Let equipment cool for a sufficient time before placing the

cover on the equipment.

Storage covers can be flammable.

WARNING

Summary of Contents for 4000EXL

Page 1: ... 000 Watt AC Generator Manual No 189189GS Revision 11 03 01 2005 BRIGGS STRATTON POWER PRODUCTS GROUP LLC JEFFERSON WISCONSIN U S A Generac Portable Products is a licensed trademark of Briggs Stratton Power Products Before using this product read this manual and follow all Safety Rules and Operating Instructions CAUTION ...

Page 2: ... the engine owner s manual SAFETY RULES This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death The safety alert symbol is used with a signal word DANGER CAUTION WARNING a pictorial and or a safety message to alert you to hazards DANGER indicates a hazard which if not avoided wil...

Page 3: ...fluid contains acid and is extremely caustic Contact with battery fluid will cause severe chemical burns DANGER Operate generator ONLY outdoors Keep exhaust gas from entering a confined area through windows doors ventilation intakes or other openings DO NOT operate generator inside any building or enclosure including the generator compartment of a recreational vehicle RV Running generator gives of...

Page 4: ...arting engine pull cord slowly until resistance is felt and then pull rapidly to avoid kickback NEVER start or stop engine with electrical devices plugged in and turned on Rapid retraction of starter cord kickback will pull hand and arm toward engine faster than you can let go Broken bones fractures bruises or sprains could result WARNING WHEN ADJUSTING OR MAKING REPAIRS TOYOUR GENERATOR Disconnec...

Page 5: ...motor loads 120 240 Volt AC 20 Amp Receptacle May be used to supply electrical power for the operation of 120 and or 240 Volt AC 20 Amp single phase 60 Hz electrical lighting appliance tool and motor loads Air Cleaner Protects engine by filtering dust and debris out of intake air Choke Lever Used when starting a cold engine Circuit Breakers AC Each receptacle is provided with a push to reset circu...

Page 6: ...negative black battery cable To install 1 Cut off tie wrap securing loose end of negative black cable 2 Connect negative black battery cable to negative terminal on battery Figure 1 3 Verify that connections to battery and generator are correct and secure Install Handle To install the handle you need the following tools 2 13 mm 1 2 box open end or socket wrenches Install handle as follows 1 Remove...

Page 7: ...aded fuel to fuel tank Be careful not to fill above the baffle This allows adequate space for fuel expansion Figure 3 4 Install fuel cap and wipe up any spilled fuel CAUTION Refer to engine manual for oil fill information Damage to equipment resulting from failure to follow this instruction will void warranty Any attempt to crank or start the engine before it has been properly filled with the reco...

Page 8: ...NOT place generator where exhaust gas could accumulate and enter inside or be drawn into a potentially occupied building Ensure exhaust gas is kept away from any windows doors ventilation intakes or other openings that can allow exhaust gas to collect in a confined area Figure 4 Prevailing winds and air currents should be taken into consideration when positioning generator Figure 4 Generator Clear...

Page 9: ...ting electrical loads Connect electrical loads in OFF position then turn ON for operation Turn electrical loads OFF and disconnect from generator before stopping generator Exceeding generators wattage amperage capacity can damage generator and or electrical devices connected to it CAUTION Figure 5 Fuel Shut off Valve Figure 6 Idle Control Switch DO NOT touch hot surfaces Allow equipment to cool be...

Page 10: ...e tight 3 If necessary clean battery terminals 4 Connect battery charge cable connector plug to panel receptacle identified by the words 12 VOLTS D C 5 Connect battery charge cable clamp with red handle to the positive battery terminal Figure 7 6 Connect battery charge cable clamp with black handle to the negative battery terminal Figure 7 7 Start engine Let engine run while battery recharges 8 Wh...

Page 11: ...lt AC 20 Amp Locking Receptacle Use a NEMA L14 20 plug with this receptacle Connect a 4 wire cord set rated for 250 Volts at 20 Amps or greater Figure 10 You can use the same 4 wire cord if you plan to run a 120 Volt load This receptacle powers 120 240 Volt AC 60 Hz single phase loads requiring up to 2 000 watts of power at 16 7 Amps for 120 Volts 4 000 watts of power 4 0 kW at 16 7 Amps for 240 V...

Page 12: ...ed battery See Charging a Battery on page 10 before attempting to recharge a battery This outlet is protected by a 10 Amp self resetting circuit breaker COLD WEATHER OPERATION Under certain weather conditions temperatures below 40 F 4 C combined with high humidity your generator may experience icing of the carburetor and or the crankcase breather system To reduce this problem you need to perform t...

Page 13: ... to prevent icing problem 10 Start and run engine outdoors 11 Keep exhaust gas from entering a confined area through windows doors ventilation intakes or other openings 12 DO NOT enclose generator any more than shown in Figure 13 13 Remove shelter when temperatures are above 40 F 4 C 14 Turn engine OFF and let cool two 2 minutes before refueling Figure 13 Permanent Cold Weather Shelter Wind DO NOT...

Page 14: ...rator output to stabilize engine runs smoothly and attached device operates properly 4 Plug in and turn on the next load 5 Again permit the generator to stabilize 6 Repeat steps 4 and 5 for each additional load NEVER add more loads than the generator capacity Take special care to consider surge loads in generator capacity as described above Wattages listed are approximate only Check tool or applia...

Page 15: ...r any corrosive vapors Cooling air slots in the generator must not become clogged with snow leaves or any other foreign material NOTE DO NOT use a garden hose to clean generator Water can enter engine fuel system and cause problems In addition if water enters generator through cooling air slots some of the water will be retained in voids and cracks of the rotor and stator winding insulation Water ...

Page 16: ...more than 30 days use the following guidelines to prepare it for storage Generator Storage Clean the generator as outlined in Generator Cleaning Check that cooling air slots and openings on generator are open and unobstructed Engine Storage See engine owner s manual for instructions Other Storage Tips To prevent gum from forming in fuel system or on essential carburetor parts empty all two supplie...

Page 17: ...1 Short circuit in a connected load 2 Generator is overloaded 3 Shorted generator circuit 1 Disconnect shorted electrical load 2 See Don t Overload Generator 3 Contact Authorized service facility Generator will not start or starts and runs rough 1 Fuel Valve is in Off position 2 Failed battery 3 Low oil level 1 Turn fuel valve to On position 2 Replace battery 3 Fill crankcase to proper level or pl...

Page 18: ...18 4000EXL Extended Life Generator NOTES ...

Page 19: ...4000EXL Extended Life Generator 19 NOTES ...

Page 20: ...udgment to adversely affect its performance and reliability This warranty also does not cover normal maintenance such as adjustments fuel system cleaning and obstruction due to chemical dirt carbon or lime etc Other Exclusions Also excluded from this warranty are wear items such as quick couplers oil gauges belts o rings filters pump packing etc pumps which have been run without water supplied or ...

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