Generac Portable Products 4000 EXL - User Manual

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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

Model No. 1645-0 (4,000 Watt AC Generator) Manual No. 189189GS Revision 1 (01/03/2002)

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

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 missing or damaged, call 1-800-270-1408.

Parts Included*

Table of Contents

Questions and Answers

M
Michael CarterAug 5, 2025
What to do if my Generac Portable Products Portable Generator engine is running, but there is no AC output?
- R
  Rachel PruittAug 5, 2025
  If your generator's engine is running but there's no AC output, here's what you can check: * One of the circuit breakers might be open. Reset the circuit breaker. * There might be a poor connection or a defective cord set. Check and repair the connection or cord set. * The connected device might be faulty. Connect another device that is in good condition.
A
Anna HuntAug 10, 2025
What to do if my Generac Portable Products Portable Generator engine shuts down during operation?
- J
  jchenAug 10, 2025
  If your generator's engine shuts down during operation, it could be due to the following reasons: * The generator is out of gasoline. Refill the fuel tank. * The oil level is low. Fill the crankcase to the proper level.
B
Brian LawsonAug 15, 2025
Why does my Generac Portable Products Portable Generator engine run good at no-load but bogs down when loads are connected?
- R
  robertlopezAug 15, 2025
  If your Generac Portable Products Portable Generator runs well without a load but bogs down when you connect devices, it could be due to: * A short circuit in a connected load. Disconnect the shorted electrical load. * The generator is overloaded. See “Don't Overload the Generator”.
W
william16Aug 20, 2025
Why does my Generac Portable Products 4000 EXL engine lack power?
- J
  james94Aug 20, 2025
  If your Generac Portable Products Portable Generator engine lacks power, consider these potential causes: * The load is too high. See “Don't Overload the Generator”. * The air filter is dirty. Replace the air filter.
S
Scott CastroAug 26, 2025
Why does my Generac Portable Products Portable Generator engine hunt or falter?
- Z
  zdavisAug 26, 2025
  If your Generac Portable Products Portable Generator engine hunts or falters, it might be because: * The choke is opened too soon. Move the choke to the halfway position until the engine runs smoothly.
J
Jenna MartinezOct 30, 2025
Why won't my Generac Portable Products 4000 EXL start or starts and runs rough?
- S
  Stephanie AndrewsOct 31, 2025
  There are several reasons why your generator might not start or runs rough: * The Run/Stop Switch might be set to “Stop”. If so, set the switch to “Run”. * The fuel valve may be in the “Off” position. Turn the fuel valve to the “On” position. * The air cleaner might be dirty. Clean or replace the air cleaner. * You might be out of gasoline. Fill the fuel tank. * The gasoline might be stale. Drain the gas tank and fill it with fresh fuel. * The spark plug wire may not be connected to the spark plug. Connect the wire to the spark plug. * The spark plug might be bad. Replace the spark plug. * There might be water in the gasoline. Drain the gas tank and fill it with fresh fuel. * You might be overchoking. Open the choke fully and crank the engine. * The battery might have ...

Summary

Safety Rules

Dangers and Warnings

Critical safety alerts on carbon monoxide, fuel, and electrical hazards.

Electrical Safety Precautions

Warnings about voltage, grounding, and wet conditions.

Operation Hazards

Cautions related to heat, speed, load, and battery handling.

Assembly

Fueling and Oil Preparation

Operation

Grounding the Generator

Requirements and methods for grounding the generator.

Starting the Engine

Step-by-step guide for starting the generator.

Automatic Idle Control and Battery Charging

Receptacles

Dont Overload Your Generator

Capacity Calculation

Guide to calculating required running and surge watts.

Power Management

Maintenance

Storage

Troubleshooting

Generac Portable Products 4000 EXL Specifications

General

Brand	Generac Portable Products
Model	4000 EXL
Category	Portable Generator
Language	English

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