Table of Contents
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Parts Included*
• Generator
• Wheel kit
• Battery
• Battery charge cables
• Battery float charger
• Locking 20 Amp plug
• Locking 30 Amp plug
• Engine oil
• Two packets of fuel stabilizer
• Owner's manual
• Engine manual
*If any parts are missing or damaged, call 1-800-270-1408.
Model No. 1645-0 (4,000 Watt AC Generator) Manual No. 189189GS Revision 1 (01/03/2002)
Owner's Manual
Questions? Help is just a moment away!
Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-portables.com or www.briggsandstratton.com
Table of Contents
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
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Table of Contents
Related Manuals for Generac Portable Products 4000 EXL
Summary of Contents for Generac Portable Products 4000 EXL
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Page 1: Table Of Contents
Owner’s Manual Parts Included* Table of Contents • Generator Safety Rules ........2-3 Assembly . -
Page 2: Safety Rules
4000EXL Extended Life Generator EQUIPMENT DANGER DESCRIPTION Running generator gives off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide will cause nausea, Read this manual carefully and become familiar fainting or death. with your generator. Know its applications, its limitations and any hazards involved. - Page 3 4000EXL Extended Life Generator WARNING WARNING Generator produces powerful voltage. Running engines produce heat.Temperature of muffler and nearby areas can reach or exceed Failure to properly ground generator can result 150°F (65°C). in electrocution. Severe burns can occur on contact. Failure to isolate generator from power utility can result in death or injury to electric utility •...
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Page 4: Assembly
4000EXL Extended Life Generator CHECK BATTERY / ATTACH Add Gasoline NEGATIVE BATTERY WARNING! Never fill fuel tank indoors. Never fill fuel tank when engine is running or hot. Allow WIRE unit to cool for two minutes before refueling. Do Not light a cigarette or smoke when filling the fuel The sealed battery on the generator is fully charged and tank. -
Page 5: Know Your Generator
4000EXL Extended Life Generator KNOW YOUR GENERATOR Read this owner’s manual and safety rules before operating your generator. Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference. Start Button Recoil Starter Fuel Tank... -
Page 6: Starting The Engine
4000EXL Extended Life Generator GROUNDING THE Starting the Engine Disconnect all electrical loads from the generator. Follow GENERATOR these start instruction steps in numerical order: Turn the fuel valve to the “On” position (Figure 4). The National Electrical Code requires that the frame and external electrically conductive parts of this generator be Figure 4 —... -
Page 7: Operating Automatic Idle Control
4000EXL Extended Life Generator 5A. For electric starting, press start switch on Operating Automatic Idle Control generator cradle.To prolong the life of the starter This switch is designed to greatly improve fuel economy. components, press the starter button for no more When this switch is turned ON, the engine will only than 15 seconds, and pause for 30 seconds. -
Page 8: Operation
4000EXL Extended Life Generator • Ensure a minimum of two feet clearance between open Figure 8 — Battery Connections side of box and nearest object. • Face exposed end away from wind and elements. • Enclosure should hold enough heat created by the generator to prevent problems. - Page 9 4000EXL Extended Life Generator RECEPTACLES CAUTION! Although this outlet is rated for 240 Volt 20 Amp (up to 4,800 watts), the generator is only rated for 4,000 watts. Powering loads that 120 Volt AC, 15 Amp Receptacles exceed the wattage/amperage capacity of the Each of these outlets is protected against overload by generator can damage it or cause serious injuries.
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Page 10: Power Management
4000EXL Extended Life Generator DON'T OVERLOAD YOUR Plug in and turn on the next load. Again, permit the generator to stabilize. GENERATOR 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, Capacity as described above. -
Page 11: Product Specifications
4000EXL Extended Life Generator SPECIFICATIONS slots, some of the water will be retained in voids and cracks of the rotor and stator winding insulation.Water Maximum Surge Watts ....6,600 Watts and dirt buildup on the generator internal windings will Continuous Wattage Capacity . -
Page 12: Storage
4000EXL Extended Life Generator To Clean the Generator Engine Storage • Use a damp cloth to wipe exterior surfaces clean. See engine owner’s manual for instructions. • A soft bristle brush may be used to loosen caked on dirt Other Storage Tips or oil. -
Page 13: Troubleshooting
Drain gas tank; fill with fresh fuel. Overchoking. Open choke fully and crank engine. 10. Excessively rich fuel mixture. 10. Contact Generac Power Systems service facility. 11. Intake valve stuck open or closed. 11. Contact Generac Power Systems service facility. -
Page 14: Schematic
4000EXL Extended Life Generator SCHEMATIC... -
Page 15: Wiring Diagram
4000EXL Extended Life Generator WIRING DIAGRAM... -
Page 16: Replacement Parts
4000EXL Extended Life Generator EXPLODED VIEW – MAIN UNIT... - Page 17 4000EXL Extended Life Generator PARTS LIST – MAIN UNIT Item Part # Qty Description Item Part # Qty Description A189159GS 1 CRADLE, 4000EXL 47 78549GS 1 DECAL, Electric Start A84021GS 1 SUPPORT, Engine 48 187079GS 1 BATTERY, 12V, 10A 189517GS 1 DECAL, Recoil 49 J188988GS 1 TRAY, Battery...
- Page 18 4000EXL Extended Life Generator EXPLODED VIEW AND PARTS LIST – CONTROL PANEL Item Part # Qty Description Item Part # Qty Description 83976GS 1 PANEL, Control 13 84028GS 1 TRANSFORMER, Idle Control 83975GS 1 BOX, Control 14 67022GS 1 GROMMET, Rubber 66818GS 2 OUTLET, 120 Volts AC 15 85584GS...
- Page 19 4000EXL Extended Life Generator EXPLODED VIEW AND PARTS LIST – WHEEL KIT Item Part # Qty Description B4217GS 1 ASSEMBLY, Handle B1764GS 1 LEG, Mounting 52858GS 2 NUT, Locking Hex M8 - 1.25 39287GS 2 HHCS, M8 - 1.25 x 45 93693FGS 1 AXLE B4966GS...
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Page 20: Limited Warranty
LIMITED WARRANTY GENERAC PORTABLE PRODUCTS OWNER WARRANTY POLICY Effective October 1, 2001 LIMITED WARRANTY "Generac Portable Products, LLC will repair or replace, free of charge, any part, or parts of the equipment that are defective in material or workmanship or both.Transportation charges on parts submitted for repair or replacement under this Warranty must be borne by purchaser. This warranty is effective for the time periods and subject to the conditions provided for in this policy.