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10

4000EXL Extended Life Generator

DON'T OVERLOAD YOUR

GENERATOR

Capacity

You must make sure your generator can supply enough
rated (running) and surge (starting) watts for the items you
will power at the same time. Follow these simple steps:
1.

Select the items you will power at the same time.

2.

Total the rated (running) watts of these items.This is
the amount of power your generator must produce to
keep your items running. See Figure 15.

3.

Estimate how many surge (starting) watts you will
need. Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliances such as a circular saw or refrigerator.
Because not all motors start at the same time, total
surge watts can be estimated by adding only the
item(s) with the highest additional surge watts to the
total rated watts from step 2.

Example:

Total Rated (Running) Watts

= 3075

Highest Additional  Surge Watts

=  1800

Total Generator Output Required = 4875

Power Management

To prolong the life of your generator and attached devices,
it is important to take care when adding electrical loads to
your generator.There should be nothing connected to the
generator outlets before starting it's engine.The correct
and safe way to manage generator power is to sequentially
add loads as follows:
1.

With nothing connected to the generator, start the
engine as described in this manual.

2.

Plug in and turn on the first load, preferably the largest
load you have.

3.

Permit the generator 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
appliance for actual wattage.

Tool or Appliance

Rated (Running)

Watts

Additional Surge

(Starting) Watts

Window Air
Conditioner

1200

1800

Refrigerator

800

1600

Deep Freezer

500

500

Television

500

-

Light (75 Watts)

75

-

3075 Total

Running Watts

1800 Highest

Surge Watts

Tool or Appliance 

Rated* 

(Running) 

Watts 

Additional 

Surge 

(Starting) 

Watts 

Essentials 

 

 

Light Bulb - 75 watt 

75 

Deep Freezer 

500 

500 

Sump Pump 

800 

1200 

Refrigerator/Freezer - 18 Cu. Ft. 

800 

1600 

Water Well Pump - 1/3 HP 

1000 

2000 

Heating/Cooling 

 

 

Window AC - 10,000 BTU 

1200 

1800 

Window Fan 

300 

600 

Furnace Fan Blower - 1/2 HP 

800 

1300 

Kitchen 

 

 

Microwave Oven - 1000 Watt 

1000 

Coffee Maker 

1500 

Electric Stove - Single Element 

1500 

Hot Plate 

2500 

Family Room 

 

 

DVD/CD Player 

100 

VCR 

100 

Stereo Receiver 

450 

Color Television - 27” 

500 

Personal Computer w/17” monitor 

800 

Other 

 

 

Security System 

180 

AM/FM Clock Radio 

300 

Garage Door Opener - 1/2 HP 

480 

520 

Electric Water Heater - 40 Gallon 

4000 

DIY/Job Site 

 

 

Quartz Halogen Work Light 

1000 

Airless Sprayer - 1/3 HP 

600 

1200 

Reciprocating Saw 

960 

960 

Electric Drill - 1/2 HP 

1000 

1000 

Circular Saw - 7 1/4” 

1500 

1500 

Miter Saw - 10” 

1800 

1800 

Table Planer - 6” 

1800 

1800 

Table Saw/Radial Arm Saw - 10” 

2000 

2000 

Air Compressor - 1-1/2 HP 

2500 

2500 

Figure 15 - Wattage Reference Chart

Summary of Contents for 1645-0

Page 1: ...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 Warranty Last Page 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 missi...

Page 2: ...en used without the alert symbol indicates a situation that could result in equipment damage Follow safety messages to avoid or reduce the risk of injury or death The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING Operate generator ONLY outdoors Keep at least 2 feet of clearance on all sides of g...

Page 3: ...tor can result in electrocution Failure to isolate generator from power utility can result in death or injury to electric utility workers due to backfeed of electrical energy WARNING Do not touch hot surfaces Allow equipment to cool before touching Running engines produce heat Temperature of muffler and nearby areas can reach or exceed 150 F 65 C Severe burns can occur on contact WARNING Do not ta...

Page 4: ... unit to cool for two minutes before refueling Do Not light a cigarette or smoke when filling the fuel tank WARNING Do Not overfill the fuel tank Always allow room for fuel expansion Use regular UNLEADED gasoline with the generator engine Do Not use premium gasoline Do Not mix oil with gasoline Clean area around fuel fill cap remove cap Slowly add unleaded regular gasoline to fuel tank Be careful ...

Page 5: ...ce tool and 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 Uses a dry type filter element and foam pre cleaner to limit the amount of dirt and dust sucked into the engine Choke Lever Used when starting a cold engine Circuit Break...

Page 6: ...a Properly grounding the generator helps prevent electrical shock if a ground fault condition exists in the generator or in connected electrical devices Proper grounding also helps dissipate static electricity which often builds up in ungrounded devices OPERATING THE GENERATOR CAUTION Never start or stop unit with electrical loads connected AND with the connected devices turned ON IMPORTANT Always...

Page 7: ...the fuel shut off valve Operating Automatic Idle Control This switch is designed to greatly improve fuel economy When this switch is turned ON the engine will only run at its normal high governed engine speed when an electrical load is connected When an electrical load is removed the engine will run at a reduced speed With the switch off the engine will run at the normal high engine speed Always h...

Page 8: ... end away from wind and elements Enclosure should hold enough heat created by the generator to prevent problems CAUTION Never run unit indoors Do Not enclose generator any more than shown Remove generator from shelter when temperature is above 40 F 4 C How to Use the Battery Charger Use battery float charger jack to keep the starting battery charged and ready for use Battery charging should be don...

Page 9: ...atts Powering loads that exceed the wattage amperage capacity of the generator can damage it or cause serious injuries 240 Volt loads powered through this outlet should not exceed 16 7 Amps of current draw 120 Volt AC 30 Amp Locking Receptacle Use a NEMA L5 30 plug with this receptacle Connect a 3 wire cord set rated for 125 Volts AC at 30 Amps to the plug Figure 13 Use this receptacle to operate ...

Page 10: ...nerator 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 appl...

Page 11: ...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 and dirt buildup on the...

Page 12: ...ling air slots and openings on generator are open and unobstructed CAUTION Storage covers can be flammable Do Not place a storage cover over a hot generator Let the unit cool for a sufficient time before placing the cover on the unit 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...

Page 13: ... Stale gasoline 6 Spark plug wire not connected to spark plug 7 Bad spark plug 8 Water in gasoline 9 Overchoking 10 Excessively rich fuel mixture 11 Intake valve stuck open or closed 12 Engine has lost compression 13 Failed battery 1 Set switch to Run 2 Turn the fuel valve to the On position 3 Clean or replace air cleaner 4 Fill fuel tank 5 Drain gas tank fill with fresh fuel 6 Connect wire to spa...

Page 14: ...14 4000EXL Extended Life Generator SCHEMATIC ...

Page 15: ...4000EXL Extended Life Generator 15 WIRING DIAGRAM ...

Page 16: ...16 4000EXL Extended Life Generator EXPLODED VIEW MAIN UNIT ...

Page 17: ...Red 42 77395GS 4 NUT M6 Flange Lock 43 J189312GS 1 SHIELD Heat 44 188989GS 1 ASM Jack DC 45 189198GS 1 DECAL Instructions ES 46 58359GS 1 LUG 5 16 22 18 I S Item Part Qty Description 47 78549GS 1 DECAL Electric Start 48 187079GS 1 BATTERY 12V 10A 49 J188988GS 1 TRAY Battery 50 189740GS 1 HARNESS Wire Starter 51 52858GS 4 NUT M8 Flange Lock 52 185939FGS 1 ASSY Wire 16 Red 53 22127GS 5 NUT 1 4 20 He...

Page 18: ...KER 18 Amp 9 82538GS 1 SWITCH On Off Rocker 10 84134GS 1 GROMMET Rubber 11 83514GS 1 CIRCUIT BREAKER 10 Amp 12 83970GS 1 CONTROL BOARD System Item Part Qty Description 13 84028GS 1 TRANSFORMER Idle Control 14 67022GS 1 GROMMET Rubber 15 85584GS 1 BAR Bus 16 84543AGS 2 SCREW 3 0 x 12mm 17 84543CGS 9 SCREW 3 5 x 18mm 18 84198GS 3 SHIELD Circuit Breaker 19 84197GS 1 BAR Circuit Breaker Retaining 21 7...

Page 19: ... LIST WHEEL KIT Item Part Qty Description 1 B4217GS 1 ASSEMBLY Handle 2 B1764GS 1 LEG Mounting 3 52858GS 2 NUT Locking Hex M8 1 25 4 39287GS 2 HHCS M8 1 25 x 45 5 93693FGS 1 AXLE 6 B4966GS 2 WHEEL 10 Diameter 7 87005AGS 2 PIN Retaining 8 22247GS 2 WASHER Flat ...

Page 20: ...een subjected to improper or unauthorized installation or alteration misuse negligence accident overloading overspeeding improper maintenance repair or storage so as in Generac Portable Products judgment 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 lim...

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