Generac Power Systems 10000EXL User manual

The Reliable Ones -
IOOOOexl
Portable Generator
Owner’s Manual
A Danger: This generator is designed for outdoor use only. Do not use this generator inside any building or enclo¬
sure including the generator compartment of a recreational vehicle (RV). Fire or an explosion may result. No
user performed modifications, including venting of exhaust and/or cooling ventilation, will eliminate the
danger. Also, allow at least two feet of clearance on all sides of the generator even while operating the unit out¬
doors.
A Danger: If this unit is used for backup power in the event of a utility power failure, the following step must be
taken: Before connecting the generator to an electrical system, open the main circuit breaker or main switch
serving the system, to isolate the generator system from the electric utility. Failure to isolate the generator and
utility systems may result in damage to the generator and may also result in injury or death to electric utility
workers, due to a backfeed of electrical energy.
The Emission Control System for this generator is warranted for standards set by the Environmental Protection
Agency.
Model No. 9801-1 (10000 Watt AC Generator) Manual No. 96023 Revision 3 (7/30/98)
A This symbol points out important safety instructions, which, if not followed, could endanger the personal
safety and/or property of yourself and others. Read and follow all instructions in the manual before
attempting to operate this unit.

Generac 10000EXL Extended Life Generator
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 volts, single phase,
60Hz devices that require up to 10000 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 connect¬
ing to generator receptacles at one time.
This total should not be greater than 10000
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
3600 rpm by a twin-cylinder engine.
Every effort has been expended to make sure that
the information in this manual is both accurate and cur¬
rent. However, Generac reserves the right to change,
alter or otherwise improve the product at
any time without prior notice.
DANGER: 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 fre¬
quency 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.
□ WARNING:
Model & Serial Numbers
In the spaces provided below, insert the Model
and Serial numbers of your generator. Retain
these numbers for future reference. You can find
Model and Serial numbers on the generator data
plate, along with other important information.
Model Number_
Serial Number _
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
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 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 manu¬
facturer, 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 limita¬
tions and any hazards involved.
• The generator produces a very powerful voltage
that can cause extremely dangerous electrical
shock. Avoid contact with bare wires, terminals, etc.
Never permit any unqualified person to operate or
service the generator.
• Never handle any kind of electrical cord or device
while standing in water, while barefoot or while
hands or feet are wet.
• The National Electric Code requires the frame and
external electrically conductive parts of generator
be properly connected to an approved earth
ground. Local electrical codes may also require
proper grounding of the generator. Consult with a
local electrician for grounding requirements in your
area.
• Use a ground fault circuit interrupter in any damp
or highly conductive area (such as metal decking
or steel work).
• Do not use any worn, bare, frayed or otherwise
damaged electrical cord sets with the generator.
• Operate generator only on level surfaces and where
it will not be exposed to excessive moisture, dirt,
dust or corrosive vapors.
Extended Life Generator
2

Generac 10000EXL Extended Life Generator
• Gasoline is highly FLAMMABLE and its vapors are
EXPLOSIVE. Do not permit smoking, open flames,
sparks or heat in the vicinity while handling gaso¬
line. Avoid spilling gasoline on a hot engine.
Comply with all regulations requiring storage and
handling of gasoline.
• Do not overfill the fuel tank. Always allow room for
fuel expansion. If tank is overfilled, fuel can over¬
flow onto a hot engine and cause FIRE or an
EXPLOSION.
• Never store the generator with fuel in the tank
where gasoline vapors might reach an open flame,
spark or pilot light (as on a furnace, water heater or
clothes dryer). FIRE or an EXPLOSION might
result.
• Generator exhaust gases contain DEADLY carbon
monoxide gas. Operate this equipment only in the
open air where adequate ventilation is available.
• The engine-generator 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..
• Never start, or stop, the engine-generator with elec¬
trical loads connected to receptacles with the
connected devices turned ON. Start the engine
and let it stabilize before connecting electrical
loads. Disconnect all electrical loads before shut¬
ting down the generator.
• Do not insert any object through cooling slots of the
engine-generator. You could damage the unit or
injure yourself.
• Never operate the generator: (a) in rain; (b) in any
enclosed compartment; (c) if engine speed
changes; (d) if connected electrical devices over¬
heat; (e) if electrical output is lost; (f) if engine or
generator sparks; (g) if flame or smoke is observed
while unit is running; (h) 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.
Figure 1 — Location of Ground Lug
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 elec¬
trical shock. However, local codes may vary widely.
Consult with a local electrician for grounding require¬
ments in your area. Be sure to keep the ground wire
attached while you connect the electrode.
Properly grounding the generator helps prevent elec¬
trical 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.
Extended Lite Generator

Installation
m
Generac 10000EXL Extended Life Generator
Installing Battery
You must purchase and install You must purchase and install a 12 volt DC battery
(Y50-N18L-A3 Motorcycle Battery). The battery
should be serviced with electrolyte fluid and fully
charged prior to installation. Install the battery as fol¬
lows:
• Locate the battery fasteners and wires shipped
loose in the carton. You should have 2-7" bolts, 2-
lock washers, 2-washers, 1 -battery bracket and
2-hex nuts. In addition you should have one M8 x
1.25 inch bolt to attach the black battery cable to
the engine.
• Set battery onto tray.
• Secure battery with the 2-7” bolts, 2-lock washers,
2-washers, 1-battery bracket and 2-hex nuts. See
figure 2 below.
A CAUTION: Be sure the black cable is con¬
nected to the engine mount and not the
frame. You could damage the ground wire.
• Connect the other end of the black battery cable to
the negative (-) battery post.
• Connect the red battery cable to the engine starter
switch. See figure 4 below.
Figure 4 — Connect Red Battery Cable to
Engine Starter Switch
Connect the back battery cable to the engine using
the M8 x 1.25 inch bolt. See location in figure 3
below.
Connect the
red battery
cable to this
connection on
the electric
starter switch.
Connect the red battery cable from the electric starter
switch to positive (+) post on the battery.
Figure 5 — Overview of Battery
Connections
Extended Life Generator

Generac 10000EXL Extended Life Generator
mmm
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.
Circuit Breakers (AC)
Ignition Switch
Idle Control Switch .
120-Volt AC, 20 Amp
Duplex Receptacle
12 Volt DC Receptacle
120-Volt AC,
20 AMP Locking
Receptacle
120-Volt AC,
30 AMP Locking
Receptacle
Recoil Starter
240-Volt AC, 50 AMP
Locking Receptacle
120/240-Volt AC, 30 AMP
Locking Receptacle
Grounding Lug
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 light¬
ing, appliance, tool and motor loads.
120-Volt AC, 20 AMP Locking Receptacle — May
be used to supply electrical power for the operation of
120 volts at 20 amps AC, single phase, 60 Hz, AC
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 volts at 30 amps AC, single phase, 60 Hz, AC
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 volts at 30 amps AC,
single phase, 60 Hz, AC electrical lighting, appliance,
tool and motor loads.
240-Volt AC, 50 AMP Locking Receptacle — May
be used to supply electrical power for the operation of
240 volts at 41.7 amps AC, single phase, 60 Hz, AC
electrical loads.
Choke lever — Used when starting a cold engine.
Circuit Breakers (AC) — Each receptacle except the
50 amp receptacle is provided with a circuit breaker
to protect the generator against electrical overload.
Breakers are "push to reset” type.
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 On (—) position to
start generator. To turn off generator, set switch to the
Stop (o) position.
Recoil starter — Used for starting the engine.
Spark Arrestor Muffler (not shown) — Exhaust
muffler lowers engine noise and is equipped with a
spark arrestor screen.
Air Cleaner — Uses a dry type filter element and
foam pre-cleaner to limit the amount of dirt and dust
that gets in the engine.
Extended Life Generator
5

Operation
Generac 10000EXL Extended Life Generator
BEFORE STARTING THE ENGINE
Perform the following tasks before starting the
generator:
■ Add Engine Oil _
Note: When adding oil to the engine crankcase in the
future, use only high quality detergent oil rated with
API service classification SF and SG rated SAE 30
weight. Use no special additives. DO NOT USE SAE
10W-40.
Select the oil’s viscosity grade according to your
expected operating temperature.
colder
- 32°F -
■ . - -
—» warmer
5W-30
i
SAE 30
Although multi-viscosity oils (5W30, 10W30, etc.)
improve starting in cold weather, these multi-viscosity
oils will result in increased oil consumption when used
above 32°F. Check your engine oil level more fre¬
quently to avoid possible damage from running low on
oil.
To add oil to the generator:
The oil fill on your engine is partially blocked by the
fuel tank. Please use the oil fill nozzle provided and
follow the instructions below to properly add oil to the
engine.
1. ) Remove paper seal on the oil fill nozzle (P/N
B3518).
2. ) Remove red cap on the oil fill nozzle.
3. ) Using a scissors, cut the tip off the oil fill nozzle.
Note: Cut no more than 1/4" from the tip.
4. ) Place oil fill nozzle on oil bottle.
5. ) Clean around oil fill cap and remove it.
6. ) Remove oil dipstick, wipe clean and reinsert in
engine.
7. ) Fill engine with oil till it reaches the full mark on
the dipstick. Stop occasionally to check oil level.
Do not overfill.
8. ) Install oil dipstick.
9. ) Install oil fill cap. Hand tighten securely.
A CAUTION: Any attempt to crank or start
the engine before it has been properly ser¬
viced with the recommended oil results in
an engine failure.
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 Fuel
A DANGER: 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.
A CAUTION: Do not overfill the fuel tank.
Always allow room (about 1/2”) for fuel expan¬
sion.
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 stor¬
age. 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. Drain the
gas tank, start the engine and let it run until the fuel
lines and carburetor are empty. Use fresh fuel next
season. See "Storage” Instructions on page 13 for
additional information.
Never use engine or carburetor cleaner products in
the fuel tank or permanent damage may occur.
To add fuel:
• Clean area around fuel fill cap, remove cap.
• Add “UNLEADED” regular gasoline, slowly, to fuel
tank. Leave about a 1/2” space in the fuel tank for fuel
expansion. Do not overfill fuel tank.
• Install fuel cap and wipe up any spilled gasoline.
Extended Ule Generator
6

Generac 10000EXL Extended Life Generator
Operation
OPERATING THE GENERATOR
CAUTION! Never start, or stop, the genera¬
tor with electrical loads connected to the
receptacles.
■ Starting the Engine _
• Disconnect all electrical loads from the generator.
• Make sure the idle control 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
choking.
Note: Make sure the idle control switch is “Off”
before starting the engine.
For Electric Start:
• Press electric starter switch until engine cranks and
starts.
For Manual Start:
• Pull slowly on recoil handle until you feel some
resistance. Then pull rapidly to start engine. Return
recoil slowly, do not let it “snap back.”
■ Applying Electrical Loads _
• Let engine stabilize and warm up for about five min¬
utes after starting.
• Plug in and turn on the desired 120 or 240 volt,
single phase, 60 Hertz, AC 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 genera¬
tor. See page 10 “Don’t Overload the Generator for
details
■ Stopping the Engine _
• Disconnect all electrical loads
• Turn OFF idle control.
• Run engine at no-load for a few minutes.
° Set the Ignition Switch to the Stop (o) position
• Close the fuel shut-off valve.
M Operating Automatic idle Control
This switch is designed to greatly improve fuel econ¬
omy. 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 elec¬
trical 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 have
the switch OFF when starting and stopping the
engine.
M Charging a Battery _
A DANGER: Storage batteries give off explo¬
sive 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.
A DANGER: 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 elec¬
trolyte fluid is an extremely caustic sulfuric
acid solution that can cause severe bums.
If spill occurs flush area with clear water
immediately.
Your generator has the capability of recharging a dis¬
charged 12-volt automotive or utility style storage
battery. Do not use the unit to charge any 6-volt bat¬
teries. Do not use the unit to crank an engine having
a discharged battery.
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 bat¬
tery 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.
Extended Life Generator

Generac 10000EXL Extended Life Generator
• Connect battery charge cable connector plug to
panel receptacle identified by the words “12-VOLT
D.C.”
• Connect battery charge cable clamp with red
handle to the positive (+) battery terminal
• Connect battery charge cable clamp with black
handle to the negative (-) battery terminal.
• 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 bat¬
tery is considered to be at 100% state of charge when
specific gravity of its fluid (as measured by hydrome¬
ter) is 1.260 or higher.
CORD SETS FOR RECEPTACLES
This generator is equipped with the following recepta¬
cles:
■ Two 120-Volt, 20 Amp Receptacles
These receptacles are protected against overload by
a 20-amp push-to-reset circuit breaker. Use each
receptacle to operate 120 volt, single phase 60 Hz,
AC electrical loads requiring up to 2400 watts (2.4
kW) at 20 amps of current. Use cord sets that are
rated 125 volts at 20 amps (or greater).
■ 120-Volt, 20 Amp Locking Type
Receptacle _
Use NEMA L5-20P type plug with this receptacle.
Generac provides a plug as part of the optional
accessories that go with the generator (Part # 37806).
Connect a 3-wire cord set rated 125 volts at 20 AC
amps to the plug (Figure 8). Use this receptacle to
operate 120 volt AC, 60 Hz, single phase loads
requiring up to 2400 watts (2.4 kW) of power at 20 AC
amps. The outlet is protected by a 20 amp push-to-
reset circuit breaker.
Figure 8 — 120 Volt, 20 Amp Receptacle
■ 120-Volt, 30 Amp Locking Type
Receptacle _
Use NEMA L5-30P type plug with this receptacle.
Generac provides a plug as part of the optional
accessories that go with the generator (Part # 37806).
Connect a 3-wire cord set rated 125 volts at 30 AC
amps to the plug (Figure 9). Use this receptacle to
operate 120 volt AC, 60 Hz, single phase loads
requiring up to 3600 watts (3.6 kW) of power at 30 AC
amps. The outlet is protected by a 30 amp push-to-
reset circuit breaker.
Figure 9 — 120 Volt, 30 Amp Receptacle
PURCHASED
3-WIRE CORD
Extended Life Generator

Generac 10000EXL Extended Life Generator
Operation
■ 120/240 Volt, 30 Amp Locking
Type Receptacle _
Use NEMA L14-30P type plug with this receptacle.
You can order one from Generac (Part # 43438). Con¬
nect a 4-wire cord set rated 250 volt at 30 AC amps
(or greater) (Figure 10). You can use the same 4-wire
cord if the you plan only to run a 120 volt load. This
receptacle powers 120/240 volt AC, 60 Hz, single
phase loads requiring up to 3600 watts of power (3.6
kW) at 30 AC Amps for 120 volts; 7200 watts of power
(7.2 kW) at 30 AC amps for 240 volts. The outlet is
protected by a 30 amp push-to-reset circuit breaker.
Figure 10 — 120/240 VOLT, 30 AMP
Receptacle
■ 240 Volt, 50 amp Receptacles
Use a compatible 3 prong plug with this receptacle
(Figure 11). Connect a 3-wire cord set rated 250 volts
at 50 AC amps to the plug. Use this receptacle to
operate 240 volts AC, 50 Hz, single phase loads
requiring up to 10000 watts (10 kW) of power.
CAUTION! Although this outlet states it
has a 240 volts 50-amp rating (up to 12,500
watts), the generator is only rated for 10000
WATTS. Powering loads that exceed the
wattage/ amperage capacity of the genera¬
tor can damage it or cause serious injuries.
Loads with 240 volts powered through this
outlet should not exceed 41.7 amps of
current.
Figure 11 — 240 VOLT, 50 AMP Receptacle
Extended Life Generator

OPl-RATinN
Generac 10000EXL Extended Life Generator
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 fol¬
lowing, 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 deter¬
mine watts (volts x amps = watts).
• Some electric motors, such as induction types,
require about two-and-a-half 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 con¬
nect 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 the guide below are provided to help you to
determine how many items the generator can oper¬
ate at one time
ENGINE PROTECTIVE DEVICES
M Low Oil Pressure Shutdown System
The engine is equipped with a low oil pressure sensor
that shuts down the engine automatically when the oil
pressure drops below 6 psi. If the engine shuts down
by itself and the fuel tank has enough gasoline, check
engine oil level.
1. Initial Start-up: A delay built in the shutdown
system allows oil pressure to build during starting.
The delay allows the engine to run for about 10 sec¬
onds before sensing oil pressure.
2. Sensing Low Pressure: If the system senses low
oil pressure during operation, the engine shuts
down.
3. Restarting: If you try to restart the engine within 5
to 10 seconds after it shuts down, the engine may
NOT start. The system needs 5 to 10 seconds to
reset.
IMPORTANT: If you do restart the engine after such a
shutdown and not corrected the low oil pressure, the
engine runs for about 10 seconds as described above
and then stops.
'Air Conditioner (12,000 Btu)
Battery Charger (20 amp).
Belt Sander (3”).
Chain Saw.
Circular Saw (6-12/”).
Coffee Maker.
'Compressor (1 HP).
'Compressor (3/4 HP).
'Compressor (1/2 HP).
'Freezer.
Disc Sander (9").
Edge Trimmer.
Electric Nail Gun.
Electric Range (one element)
Electric Skillet.
'Furnace Fan (1/3 HP).
Hair Dryer.
Hand Drill (1”).
Hand Drill (1/2”).
Hand Drill (3/8”).
Hand Drill (1/4”).
Hedge Trimmer.
WATTAGE REFERENCE GUIDE
RUNNING WATTS RUNNING WATTS
.1700 Impact Wrench.500
.500 'Jet Pump.800
.1000 Lawn Mower.1200
.1200 Light Bulb.100
.800 to 1000 Microwave Oven.700
.1000 'Milk Cooler.1100
.2000 Oil Burner on Furnace.300
.1800 Oil Fired Space Heater (140,000 Btu).400
.1400 Oil Fired Space Heater (85,000 Btu).225
.500 Oil Fired Space Heater (30,000 Btu).150
.1200 'Paint Sprayer, Airless (1/3 HP).600
.500 Paint Sprayer, Airless (handheld).150
.1200 Radio.50 to 200
.1500 'Refrigerator.600
.1250 Slow Cooker.200
.1200 'Submersible Pump (1-1/2 HP).2800
.1200 "Submersible Pump (1 HP).2000
.1100 'Submersible Pump (1/2 HP).1500
.750 to 1000 Sump Pump.600
.500 'Table Saw (10”).1750 to 2000
.250 Television.200 to 500
.450 * Allow 2-1/2 times the listed watts for starting these devices.
Extended Life Generator
10