Generac Portable Products 10000EXL User manual

10000EXL
Model No. 9801–6 (10,000 Watt AC Generator) Manual No. 186686 Revision 1 (4/6/2001)
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Problems?
Questions?
Before taking your unit
back to the store,
call the generator
helpline at
1-800-270-1408
M–F 8–5 CT
Portable Generator Owner’s Manual
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.

Generac Portable Products 10,000EXL Generator
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EQUIPMENT
DESCRIPTION
This generator is an engine–driven, revolving field,
alternating current (AC) generator. It was designed to
supply electrical power for operating compatible electrical
lighting, appliance, tool and motor loads. This manual
contains information for a generator that operates
120 and/or 240 Volt, single phase, 60Hz devices that
require up to 10,000 watts (10 kW) of power that pull up
to 83.3 Amps at 120 Volts or 41.7 Amps at 240 Volts.
CAUTION! Do Not exceed the generator’s
wattage/amperage capacity. Add up the rated watts of all
devices you are connecting to generator receptacles at one
time. This total should not be greater than 10,000 watts
for this generator. In most cases rated watts of the
electrical device can be found on the device nameplate. If
the device nameplate gives only volts and amps, multiply
volts times amps to obtain watts (volts x amps = watts).
The generator’s revolving field is driven at about 3,600 rpm
by a twin–cylinder engine.
Every effort has been expended to make sure that the
information in this manual is both accurate and current.
However, Generac reserves the right to change, alter or
otherwise improve the product at any time without prior
notice.
CAUTION! Do Not tamper with engine
governed speed. High operating speeds are
dangerous and increase the risk of personal injury
or damage to equipment. The generator supplies
correctly rated frequency and voltage only when
running at proper governed speed. Incorrect
frequency and/or voltage can damage some
connected electrical loads. Operating at excessively
low speeds imposes a heavy load and, when
adequate engine power is not available, may shorten
engine life.
SAFETY RULES
This generator set was designed and manufactured for
specific applications. Do Not attempt to modify the unit
or use it for any application it was not designed for. If you
have any questions about your generator’s application, ask
your dealer/distributor or consult the factory.
The manufacturer could not possibly anticipate every
circumstance that might involve a hazard. For that reason
warnings in the manual and warnings on tags or decals
affixed to the unit are not all–inclusive. If you intend to
handle, operate or service the unit by a procedure or
method not specifically recommended by the manufacturer,
first make sure that such a procedure or method will not
render this equipment unsafe or pose a threat to you and
others.
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
WARNING! You must isolate the generator
from the electric utility by opening the electrical
system’s main circuit breaker or main switch if this
unit is used for backup power. Failure to isolate
the generator from the power utility may
result in injury or death to electric utility
workers and damage to the generator due to
a backfeed of electrical energy. Whenever unit is
providing backup power, the electric utility must be
notified.
DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. Carbon
monoxide, if breathed in sufficient
concentrations, can cause unconsciousness or
death. Operate this equipment outdoors where
adequate ventilation is available.
The Emission Control System for this generator is
warranted for standards set by theEnvironmental
Protection Agency. For warranty information refer to the
engine owner’s manual.
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other
reproductive harm.
WARNING:

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• The generator produces a very powerful voltage that can
cause serious injury or death by electrocution. Never
touch bare wires or receptacles. Never permit a child
or any unqualified person to operate the generator.
•Never handle any kind of electrical cord or device while
standing in water, while barefoot or while hands or feet
are wet. Death or serious injury from electrocution may
result.
• Use a ground fault circuit interrupter (GFCI) in any damp
or highly conductive area (such as metal decking or steel
work).
•Never use worn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damage from electrical shock may result.
•Gasoline is highly FLAMMABLE and its vapors are
EXPLOSIVE. Never allow smoking, open flames,
sparks or heat in the vicinity while handling
gasoline. Avoid spilling gasoline on a hot engine.
Comply with all laws regulating storage and handling of
gasoline.
•Do Not overfill the fuel tank. Always allow room for
fuel expansion. If tank is overfilled, fuel can overflow
onto a hot engine and cause a FIRE or an
EXPLOSION.
•Never store a generator with fuel in the tank where
gasoline vapors might reach an open flame, spark or pilot
light (as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.
• The unit requires an adequate flow of cooling air for its
continued proper operation. Never operate the unit
inside any room or enclosure where the free flow of
cooling air into and out of the unit might be obstructed.
Allow at least 2 feet of clearance on all sides of generator,
even while operating unit outdoors, or you could damage
the unit.
•Never start, or stop the unit with electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting any electrical loads. Disconnect all electrical
loads before shutting down the generator.
•Do Not insert any object through cooling slots of the
engine. You could damage the unit or injure yourself.
•Never operate the generator:
in rain; in any enclosed compartment; when connected
electrical devices overheat; if electrical output is lost; if
engine or generator sparks; if flame or smoke is
observed while unit is running; if unit vibrates excessively.
GROUNDING THE
GENERATOR
The National Electric Code requires the frame and
external electrically conductive parts of the generator be
properly connected to approved earth ground. Local
electrical codes may also require proper grounding of the
unit. For this purpose, a ground lug (Figure 1) is provided
on the cradle.
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the ground lug screw and
to an earth–driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. However, local codes may vary widely. Consult with
a local electrician for grounding requirements in your area.
Be sure to keep the ground wire attached while you
connect the electrode.
Properly grounding the generator helps prevent electrical
shock if ground fault conditions exists in the generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
Ground Lug
Figure 1 — Location of Ground Lug

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Your generator requires some assembly and is ready for
use after it has been properly serviced with the
recommended oil and fuel.
IMPORTANT: Any attempt to run the engine before it
has been serviced with the recommended oil will result in
an engine failure.
TO REMOVE GENERATOR
FROM CARTON
• Set the palleted carton on a rigid flat surface.
• Carefully cut bands around the shipping carton.
• Lift carton off the generator.
• Remove all packing material, carton fillers, etc.
• Remove the generator from the shipping pallet.
CARTON CONTENTS
Check all contents. If any parts are missing or damaged, call
the generator helpline at 1–800–270–1408. Contents
include:
• The main unit
• Owner’s and engine manuals
• 2 bottles engine oil
• 125 Volt, 30 Amp plug
• 125 Volt, 20 Amp plug
• 120/240 Volt, 30 Amp plug
• Battery charge cable
• Wheel kit
ASSEMBLE WHEEL KIT
If you have any problems with the assembly of your
generator, please call the generator helpline at
1–800–270–1408.
IMPORTANT: This wheel kit is not intended for
over–the–road use.
To install your wheel kit you need the following tool:
• 13 mm box, open end, or socket wrench
Install Wheel Kit as follows:
1. Place temporary blocks on a flat, even surface and
place the bottom of the generator cradle on the
blocks.
2. Slide axle through both axle mounting brackets on
cradle frame, as shown in Figure 2.
3. Slide a wheel spacer over each end of the axle.
4. Install a wheel on an axle and slide a flat washer over
the axle. Secure the wheel with retaining pin.
NOTE:Be sure to install each wheel with the air
pressure valve on the outboard side.
5. Install the other wheel in the same manner.
6. Secure the vibration mount to the support leg with a
lock nut, a flat washer and a 30 mm long capscrew.
7. Secure the support leg assembly to the cradle with
20 mm long capscrews, flat washers, and lock washers.
8 Position the handle on the cradle end opposite the
control panel. Secure the handle with 45 mm long
capscrews and lock nuts.
9. Tighten all lock nuts with the 13 mm wrench to ensure
all components are secure.

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CHECK BATTERY / ATTACH
NEGATIVE BATTERY
WIRE
The battery on the generator is fully charged, sealed and
pre–installed except for the negative (black) battery cable.
To install:
• Cut off tie wrap on negative (black) cable attached to the
battery hold down.
• Remove nut on the negative battery terminal.
• Slide the negative battery cable over the screw on the
negative terminal (Figure 3).
• Reattach nut and tighten.
• Verify that the connections to the battery and generator
are tight and secure.
Figure 2 — Assemble Wheel Kit
Figure 3 — Negative Battery Connection
Handle
30 mm
Capscrew
Vibration
Mount
Locknut
Flat washer
Wheel
Spacer
Wheel Retaining Pin
20 mm Capscrew
Lock washer
Flat washer
Support Leg
Locknut
45 mm Capscrew
Axle Flat
washer

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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.
12 Volt DC Receptacle — Use this receptacle with
battery charge cables to charge a 12 Volt battery.
120 Volt AC, 20 Amp Duplex Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, single phase, 60 Hz, AC electrical lighting,
appliance, tool and motor loads.
120 Volt AC, 20 Amp Locking Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120 Volt AC, 30 Amp Locking Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120/240 Volt AC, 30 Amp Locking Receptacle —
May be used to supply electrical power for the operation
of 120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz
electrical lighting, appliance, tool and motor loads.
120/240 Volt AC, 50 Amp Receptacle — May be used
to supply electrical power for the operation of
120/240 Volt AC, 50 Amp, single phase, 60 Hz electrical
loads.
Air Cleaner — Used to limit the amount of dirt and dust
that gets in the engine.
Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — Each receptacle is provided
with a push to reset circuit breaker to protect the
generator against electrical overload.
Grounding Lug — Use this connection to properly
ground the generator. See “Grounding the Generator” on
page 3.
Idle Control Switch — The idle control runs the engine
at normal (high) speeds when there is a load present and
runs the engine at idle (low) speeds when a load is not
present. This feature greatly improves fuel economy,
extends the life of the engine, and reduces engine noise.
Ignition Switch — Must be set to the On (–) position to
start generator. To turn off generator, set switch to the
Stop (o) position.
Spark Arrestor Muffler — Exhaust muffler lowers
engine noise and is equipped with a spark arrestor screen.
Start Button — When pressed, cranks engine to start.
120 Volt AC, 20 Amp
Duplex Receptacle
Idle Control Switch
Ignition Switch Choke Lever
120 Volt AC, 30 Amp
Locking Receptacle
120 Volt AC, 20 Amp
Locking Receptacle 120/240 Volt AC,
50 Amp Receptacle
Circuit Breakers (AC)
120/240 Volt AC, 30 Amp
Locking Receptacle
12 Volt DC Receptacle
Air Cleaner
Start Button
Grounding Lug
Spark Arrestor
Muffler

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BEFORE STARTING THE
ENGINE
Add Engine Oil
CAUTION! Any attempt to crank or start the engine
before it has been properly serviced with the
recommended oil results in an engine failure.
• Make sure unit is on a level surface.
• Follow the oil recommendations and oil fill instructions
given in the engine owner’s manual.
NOTE: The generator’s revolving field rides on a
pre–lubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
Add Gasoline
WARNING! Never fill fuel tank indoors. Never
fill fuel tank when engine is running or hot. Do Not
light a cigarette or smoke when filling the fuel tank.
WARNING! Do Not overfill the fuel tank.
Always leave room for expansion.
• Use regular UNLEADED gasoline in the generator.
Do Not use premium gasoline. Do Not mix oil with
gasoline. Do Not overfill the gas tank.
• Clean area around fuel fill cap; remove cap.
• Fill fuel tank with clean, fresh, unleaded gasoline. Be
careful not to overfill. Allow 1/2" of tank space for fuel
expansion, as shown in Figure 4.
• Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in essential fuel system parts such as the
carburetor, fuel filter, fuel hose or tank during storage.
Also, experience indicates that alcohol–blended fuels
(called gasohol, ethanol or methanol) can attract moisture,
which leads to separation and formation of acids during
storage. Acidic gas can damage the fuel system of an engine
while in storage. To avoid engine problems, the fuel system
should be emptied before storage of 30 days or longer. See
“Storage”. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
IMPORTANT: When running your unit in cold weather
be sure to shelter the unit from the wind.
OPERATING THE
GENERATOR
CAUTION! Never start or stop the unit with
electrical loads connected AND with the connected
devices turned on.
Starting the Engine
• Disconnect all electrical loads from the generator.
• Make sure the Idle Control switch is turned OFF.
• Open the fuel shut–off valve.
• Set the Ignition switch to the On (–) position.
• Pull choke control out to close choke.
NOTE: If engine is warm, you may not need as much
choke.
For Electric Start:
• Press the Run/Stop switch to the “RUN” position, Press
the electric start button, located on the generator cradle
opposite the control panel, until engine cranks.
• Use short starting cycles (15 sec. per min.) to prolong
starter life. Extended cranking can damage starter motor.
CAUTION! If starting the engine with the electric
starter, always operate the engine with the battery
connected. This ensures that the battery will be recharged.
Figure 4 — Fuel Level

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• When the engine starts, open the choke gradually as
engine warms up up by pushing in on the choke handle.
• Set the Idle Control On/Off switch to the “On”
position.
For Manual Start:
• Grasp starter grip handle and pull slowly until you feel
some resistance. Then pull cord out with rapid full arm
stroke. Let rope return slowly. Do Not let rope “snap
back” against starter. Repeat, if necessary, with choke
opened slightly.
• When engine starts, open the choke gradually as the
engine warms up by pushing in on the choke handle.
• Set the Idle Control On/Off switch to the “On”
position.
Applying Electrical Loads
• Let engine stabilize and warm up for about three minutes
after starting.
• Plug in the desired 120 or 240 Volt AC, single phase,
60 Hertz electrical loads.
DO NOT OVERLOAD THE GENERATOR. Add up
the rated watts (or Amps) of all loads to be connected
at one time. This total should not be greater than the
rated wattage/amperage capacity of the generator. See
“Don’t Overload the Generator” on page 12 for details.
Stopping the Engine
• Disconnect all electrical loads.
• Turn “Off” Idle Control switch.
• Run engine at no–load for three minutes.
• Set the Ignition switch to the “Stop” position.
• Close 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. The engine will run at a reduced speed
when no load is present. With the switch OFF, the engine
will run constantly at the normal high engine speed.
Always have the switch OFF when starting and
stopping the engine.
Charging a Battery
Your generator has the capability of recharging a discharged
12 Volt automotive or utility style storage battery. Do Not
use the unit to charge any 6 Volt batteries. Do Not use
the unit to crank an engine having a discharged battery.
WARNING! Storage batteries give off explosive
hydrogen gas while recharging. An explosive mixture
will remain around the battery for a long time after
it has been charged. The slightest spark can ignite
the hydrogen and cause an explosion. Such an
explosion can shatter the battery and cause
blindness or other serious injury.
WARNING! Do Not permit smoking, open
flame, sparks or any other source of heat around a
battery. Wear protective goggles, rubber apron and
rubber gloves when working around a battery.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe burns. If
spill occurs, flush area with clear water immediately.
To recharge 12 Volt batteries, proceed as follows:
• Check fluid level in all battery cells. If necessary, add
ONLY distilled water to cover separators in battery
cells. Do Not use tap water.
• If the battery is equipped with vent caps, make sure they
are installed and are tight.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to panel
receptacle identified by the words “12–VOLTS D.C.”.
• Connect battery charge cable clamp with red handle to
the positive (+) battery terminal (Figure 5).

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• Connect battery charge cable clamp attached to the
black lead to the negative (–) battery terminal
(Figure 5).
• Start engine. Let the engine run while battery recharges.
• When battery has charged, shut down engine.
NOTE: Use an automotive hydrometer to test battery
state of charge and condition. Follow the hydrometer
manufacturer’s instructions carefully. Generally, a battery is
considered to be at 100% state of charge when specific
gravity of its fluid (as measured by hydrometer) is 1.260 or
higher.
RECEPTACLES
This generator is equipped with the following receptacles:
120 Volt, 20 Amp, Duplex
Receptacle
Each of these outlets is protected against overload by
20 Amp push–to–reset circuit breakers. Use each outlet to
operate 120 Volt, 60 Hz, single phase loads requiring
2,400 (2.4 kW) watts at 20 Amps of current (Figure 6).
Figure 5 — Connect Battery Charge Cables
Black lead
Figure 6 — 120 Volt, 20 Amp Duplex Receptacle

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120 Volt, 20 Amp Locking Type
Receptacle
Use a NEMA L5–20 plug with this receptacle. Connect a
3–wire cord set rated for 125 Volt AC loads at 20 Amps to
the plug (Figure 7).
Use this receptacle to operate 120 Volt AC, 60 Hz, single
phase loads requiring up to 2,400 watts (2.4 kW) of power
at 20 Amps. The outlet is protected by a 20 Amp
push–to–reset circuit breaker.
120 Volt, 30 Amp Locking Type
Receptacle
Use a NEMA L5–30 plug with this receptacle. Connect a
3–wire cord set rated for 125 Volt AC loads at 30 Amps to
the plug (Figure 8).
Use this receptacle to operate 120 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts (3.6 kW) of power
at 30 Amps. The outlet is protected by a 30 Amp
push–to–reset circuit breaker.
Figure 8 — 120 Volt, 30 Amp, Locking Receptacle
Figure 7 — 120 Volt, 20 Amp, Locking Receptacle

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120/240 Volt, 30 Amp Locking Type
Receptacle
Use a NEMA L14–30 plug with this receptacle. Connect a
4–wire cord set rated for 250 Volt AC loads at 30 Amps
(or greater) (Figure 9). 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 3,600 watts of power (3.6 kW)
at 30 Amps for 120 Volts AC; 7,200 watts of power
(7.2 kW) at 30 Amps for 240 Volts AC. The outlet is
protected by a 30 Amp push–to–reset circuit breaker.
240 Volt, 50 Amp Receptacle
Use a NEMA 14–50 plug with this receptacle. Connect a
4–wire cord set rated for 250 Volt AC loads at 50 Amps to
the plug (Figure 10).
Use this receptacle to operate 240 Volt AC, 60 Hz, single
phase loads requiring up to 10,000 watts (10.0 kW) of
power.
CAUTION! Although this outlet states it has a
240 Volt 50 Amp rating (up to 12,500 watts), the
generator is only rated for 10,000 watts. Powering
loads that exceed the wattage/ amperage capacity of
the generator can damage it or cause serious
injuries.
Figure 9 — 120/240 Volt, 30 Amp, Locking Receptacle
Figure 10 — 120/240 Volt, 50 Amp, Receptacle

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DON’T OVERLOAD THE
GENERATOR
Overloading a generator in excess of its rated wattage
capacity can result in damage to generator and to
connected electrical devices. Observe the following, to
prevent overloading the unit:
• Add up the total wattage of all electrical devices to be
connected at one time. This total should NOT be
greater than the generator’s wattage capacity.
• The rated wattage of lights can be taken from light bulbs.
The rated wattage of tools, appliances and motors can
usually be found on a data plate or decal affixed to the
device.
• If the appliance, tool or motor does not give wattage,
multiply Volts times ampere rating to determine watts
(volts x amps = watts).
• Some electric motors, such as induction types, require
about three times more watts of power for starting than
for running. This surge of power lasts for only a few
seconds when starting such motors. Be sure you allow
for this high starting wattage when selecting electrical
devices to connect to your generator. First figure the
watts needed to start the largest motor. Add to that
figure the running watts of all other connected loads.
• Items in Figure 11 below are provided to help you to
determine how many items the generator can operate at
one time.
Recreational/Home Uses
Tool/Appliance..................................................Watts
AM/FM clock radio ..................................................................50
Light bulb .................................................................................100
Fan .............................................................................................200
20" color TV............................................................................400
*Deep freezer .........................................................................500
Personal computer and 15" monitor.................................800
*1/3 hp furnace fan blower ..................................................800
Microwave oven......................................................................800
*18 cu ft refrigerator.............................................................800
Sump pump ...........................................................................1000
Electric skillet........................................................................1250
*½ hp water well pump .....................................................1400
*12,000 Btu window air conditioner...............................1400
Space heater..........................................................................1800
Electric water heater ..........................................................4000
Professional/Contractor Uses
Tool/Appliance..................................................Watts
*1/3 hp airless sprayer ..........................................................600
3/8" hammer drill ...................................................................600
Variable speed Sawzall® .......................................................960
½" power drill ......................................................................1000
Quartz-halogen work light ................................................1000
Belt sander ............................................................................1200
7 ¼" circular saw .................................................................1500
7 ¼" worm drive saw .........................................................1600
*1½ hp air compressor......................................................1800
*10" power miter saw.........................................................1800
6" bench grinder ..................................................................1800
*6" table planer.....................................................................1800
*10" table/radial arm saw...................................................2000
Wire feed welder.................................................................2400
*=allow 3 times listed watts for starting surge
Figure 11 — Wattage Reference Guide

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GENERAL MAINTENANCE
RECOMMENDATIONS
The owner/operator is responsible for making sure that all
periodic maintenance tasks are completed on a timely
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. Never operate a
damaged or defective generator.
Engine Maintenance
See your engine owner’s manual for information needed to
maintain and service the engine.
Generator Maintenance
Generator maintenance consists of keeping the unit clean
and dry. Operate and store the unit in a clean dry
environment where it will not be exposed to excessive
dust, dirt, moisture or any corrosive vapors. Make sure the
cooling air slots in the generator do not become clogged
with snow, leaves or other foreign material.
Check cleanliness of the generator frequently and clean
when dust, dirt, oil, moisture or other foreign substances
are visible on its exterior surface.
NOTE: Do Not use a garden hose to clean generator.
Water can enter the engine fuel system and cause
problems. In addition, if water enters the generator
through the cooling air slots, some water will be retained
in the voids and cracks of the rotor and stator winding
insulation. Water and dirt buildup on the generator internal
windings will eventually decrease the insulation resistance
of these windings.
To Clean the Generator
• Use a damp cloth to wipe exterior surfaces clean.
• Soft, bristle brush may be used to loosen caked on dirt
or oil.
• A vacuum cleaner may be used to pick up loose dirt and
debris.
• Low pressure air (not to exceed 25 psi) may be used to
blow away dirt. Inspect cooling air slots and opening on
generator. These openings must be kept clean and
unobstructed.
STORAGE INSTRUCTIONS
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 “To Clean the
Generator.”
• Check that the cooling air slots and openings on the
generator are open and unobstructed.
• Change engine oil.
• Drain fuel and run engine until the fuel system is empty.
• Remove spark plugs and pour about 1 ounce of clean
engine oil into spark plug holes. Crank engine over
slowly several times, to distribute oil. Install and tighten
spark plugs.
• Remove the negative battery cable from the battery to
prevent the battery from being depleted.
• Store the unit in a clean dry place.
CAUTION! Storage covers can be flammable.
Do Not place a storage cover over a hot
generator. Let the unit cool for 5 minutes before
placing cover on the unit.
SPECIFICATIONS
Rated Maximum Continuous
AC Power Output .................................. 10,000 watts
(10 kW)
Rated Maximum Surge
AC Power Output .................................. 12,000 watts
(12 kW)
Rated Voltage............................................... 120/240 Volts
Rated Maximum AC Current
at 240 Volts .............................................. 41.7 Amperes
at 120 Volts .............................................. 83.3 Amperes
Phase.............................................................. 1
Rated AC Frequency.................................. 60 Hertz
Number of Rotor Poles............................ 2

Generac Portable Products 10,000EXL Generator
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NOTES

Generac Portable Products 10,000EXL Generator
15
TROUBLESHOOTING
Problem Cause Correction
Engine is running, but no
AC output is available.
1. One of the circuit breakers is open.
2. Fault in generator.
3. Poor connection or defective cord set.
4. Connected device is bad.
1. Reset circuit breaker.
2. Contact Generac service facility.
3. Check and repair.
4. Connect another device that is in good
condition.
Engine runs good at no-
load but “bogs down"
when loads are
connected.
1. Short circuit in a connected load.
2. Engine speed is too slow.
3. Generator is overloaded.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. Contact Briggs & Stratton service
facility.
3. See “Don't Overload the Generator”
on page 12.
4. Contact Generac service facility.
Engine will not start; or
starts and runs rough.
1. Run/Stop Switch set to “STOP”.
2. Dirty air cleaner.
3. Out of gasoline.
4. Stale gasoline.
5. Spark plug wire not connected to
spark plug.
6. Bad spark plug.
7. Water in gasoline.
8. Overchoking.
9. Excessively rich fuel mixture.
10 Intake valve stuck open or closed.
11 Engine compression lost.
12 Failed battery.
1. Set switch to “RUN”.
2. Clean or replace air cleaner.
3. Fill fuel tank.
4. Drain gas tank; fill with fresh fuel.
5. Connect wire to spark plug.
6. Replace spark plug.
7. Drain gas tank; fill with fresh fuel.
8. Open choke fully and crank engine.
9. Contact Briggs & Stratton service
facility.
10 Contact Briggs & Stratton service
facility.
11 Contact Briggs & Stratton service
facility.
12 Replace battery.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level. 1. Fill fuel tank. 2. Fill crankcase to proper level.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
1. See “Don't Overload the Generator”
on page 12.
2. Replace air filter.

Generac Portable Products 10,000EXL Generator
16
SCHEMATIC DIAGRAM

Generac Portable Products 10,000EXL Generator
17
WIRING DIAGRAM

Generac Portable Products 10,000EXL Generator
18
GENERATOR EXPLODED VIEW

Generac Portable Products 10,000EXL Generator
19
Item Part # Qty Description
1 NSP 1 ENGINE
2 BB4509A 1 SHIELD, Heat
3 A77304 2 SUPPORT, Engine
4 BB5567 1 SHIELD, Heat
5 80270 1 VALVE, Fuel Shut-Off
6 78299 1 BUSHING, Fuel Valve
7 B4325 1 CAP, Fuel Tank
8 38353 6 MOUNTS, Vibration
9 78831B 4 CAPSCREW, M6-1.0 x 60mm
10 B1997 1 TANK, Fuel 10 Gal
11 AB4426 1 CRADLE
12 83465 4 GROMMET, Fuel Tank Mounting
13 87680 1 WING NUT, M6 - 1.0
14 23152 6 CAPSCREW, 3/8-16 x 3/4"
15 22237 16 WASHER, 3/8" Lock
16 22241 6 NUT, 3/8"-16 Hex
17 77816 2 DECAL, Caution Hot Muffler
18 22131 2 WASHER, 3/8" Flat
19 B93074 1 SHIELD, Heat
20 186076 1 ASSEMBLY, Control Panel
21 19553621 1 WIRE ASSEMBLY, Ground
22 45757 1 HHCS, M6 - 1.0 x 25
23 75246 4 SELF TAPPING, 3/8"-16 x 1-1/4"
24 22145 2 WASHER, M8 Flat
25 26850 3 WASHER, M6 Shakeproof
26 20566 1 DECAL, 1-800
27 B4986 1 DECAL, Ground
28 92982 1 DECAL, Danger
29 B5021 1 DECAL, Side Panel
30 B5020 1 DECAL, Control Panel
31 52857 1 NUT, Locking M6 - 1.0
32 22287 2 CAPSCREW, 1/4"
33 93826 1 DECAL, Start Instructions
34 78289 1 BRACKET, Starter Switch
35 B2153 19 SCREW, #12 Self Driller
36 73054 1 DECAL, Fuel Shut-Off
37 B4268 1 ALTERNATOR, 10KW
38 77282 1 SWITCH, Starter
39 22097 4 WASHER, 1/4" Lock
40 B4489 1 BATTERY
41 22127 4 NUT, 1/4" - 20 Hex
42 198-53621 1 WIRE ASSEMBLY, Starter
43 A96925 1 BRACKET, Battery Tie Down
44 96924 2 J-BOLT, M8 - 1.25
45 19953621 1 CABLE, Battery Positive
46 19753621 1 CABLE, Battery Negative
47 52618 2 HHCS, M5 - 0.8 x 12
48 49226 1 WASHER, M5 Lock
49 52856 2 NUT, M5 Flange Lock
Item Part # Qty Description
50 49820 2 NUT, Nylok M8 - 1.25
51 42907 1 CAPSCREW, M8 - 1.25 x 20
52 49813 1 NUT, Hex M6 - 1.0
54 27482 1 WASHER, 5/16" Shakeproof
55 47411 4 CAPSCREW, M6 - 1.0 X 16
56 22473 1 WASHER, Flat M6
57 55934T 1 CLAMP, Hose
58 55934G 2 CLAMP, Hose
59 22511 4 CAPSCREW, 3/8 x 1-1/4"
60 96832 1 CLAMP, Hose
61 52618 1 HHCS, M5 - 0.8 x 12
62 B4794 1 GROMMET, Generator Cover
63 23897 2 WASHER, M5 Lock
64 30340 1 HOSE, 1/4" I.D., 21"
65 48031C 2 CLAMP, Hose 1/2"
66 62265 1 GROMMET, Rubber
67 95349 1 PLATE, Adjust
68 96717 1 SPRING
69 95921 1 LINKAGE, Bell Crank to
Throttle
70 75477 2 SCREW, M5-0.8 x 20 Phillips Hd.
71 96716 3 WASHER, Nylon
72 95348 1 BELL, Crank
73 96378 1 SPACER
74 51713 1 WASHER, M5 Flat
75 49226 1 WASHER, M5 Lock
76 95920 1 LINKAGE, Stepper Motor to
Bell Crank
77 33141 1 CAPSCREW, #10-32 x 3/4" Hex
Hd.
78 22129 2 WASHER, M8 - Lock
79 39253 2 CAPSCREW, M8 - 1.25 x 16
80 96867 1 ASSEMBLY, Stepper Motor
81 A5850 1 U-CHANNEL, .09" Groove, 4"
82 76040 1 SCREW, M5-0.8 x 16 Phillips
Head
Items Not Shown
186686 1 Owner’s Manual
37806 1 125V 30A Plug
43438 1 120/240V 30A Plug
65787 1 Battery Charge Cable
93568 1 125V 20A Plug
BB3061 2 Oil Bottle (28oz)
Available Accessories
B4767 Storage Cover
84883 Cord Wrap
GENERATOR PARTS LIST

Generac Portable Products 10,000EXL Generator
20
CONTROL PANEL EXPLODED VIEW