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.
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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
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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.
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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

Generac 10000EXL Extended Life Generator
llllill
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
■ Replace Spark Plugs _
Remove and replace spark plugs (Champion
RC12YC) every 100 operating hours or once
annually, whichever comes first. See ENGINE
SPECIFICATIONS for recommended sparkplugs.
Set gap on plugs to 0.76mm.
A CAUTION! DO NOT blast dean spark plugs.
Clean with pen knife or wire brush and sol¬
vent.
■ Check Engine Oil Level _
Check engine crankcase oil level frequently (prior to
each use or at least every eight hours of operation).
See Page 5 for recommended oils. Rest unit on a
level surface and remove dipstick from extended oil fill
tube. Wipe dipstick dry and reinstall all the way into
the oil fill tube. Again remove dipstick. Oil should be at
dipstick FULL mark. Add oil as necessary. DO NOT
OVERFILL ABOVE “FULL" MARK.
■ Changing Oil and Oil Filter _
Change oil after the first eight hours of operation.
Thereafter, change oil every 50 operating hours under
normal conditions. If engine is operated under heavy
load or in high ambient temperatures, change oil
every 25 hours of operation. Drain oil from oil drain
plug while engine is still warm from running.
Change engine oil filter every 100 hours of operation
(every second oil change). Before installing new filter,
lightly lubricate filter gasket with fresh, clean engine
oil. Screw new filter on by hand until gasket contacts
the filter adapter. Then tighten about 3/4 turn further.
Start and run engine for about 30 seconds, then shut
down. Recheck oil level and add oil as necessary.
Finally, start engine and check for leaks. See figure
12 below for location of oil filter and oil drain plug.
Figure 12 — Oil Drain Plug and Oil Filter
■ Service Engine Air Cleaner _
Your engine will not run properly and may be dam¬
aged if you run it using a dirty air cleaner. Clean or
replace foam pre-cleaner every 25 hours of operation.
Service cartridge every 100 operating hours or once
annually, whichever comes first. Clean or replace
more often if operating under dusty or dirty condi¬
tions.
To service foam pre-cleaner (Figure 13), proceed as
follows:
Figure 13 — Replacing Air Cleaner
Components
• The cover is attached to the air cleaner housing by
two latches. Lift up on the latches to unlock them,
then remove the cover.
• Carefully remove foam pre-cleaner from around the
cartridge.
• Replace pre-cleaner or wash in liquid detergent and
water.
• Squeeze (don't twist) pre-cleaner in a clean, dry
cloth.
• Saturate pre-cleaner in engine oil. Squeeze in a
clean absorbent cloth to remove excess oil.
Extended Life Generator
11

Generac 10000EXL Extended Life Generator
NOTE: if you are going to clean the PAPER
CARTRIDGE do not install the foam pre-cleaner.
Proceed to the instructions for servicing the cartridge.
• Carefully install the foam pre-cleaner around the
cartridge.
To service the paper cartridge, proceed as follows:
• Clean cartridge by tapping gently on a flat surface.
If cartridge is very dirty, replace or wash in a low or
non-sudsing detergent and warm water solution.
• Rinse thoroughly with flowing water from mesh side
until water runs clear.
• Let cartridge dry thoroughly before using.
A CAUTION! DO NOT use petroleum solvents
such as kerosene to clean the element.
Such solvents will cause deterioration of
the element. DO NOT oil the element.
DO NOT use pressure air to clean or dry
the element.
• Reinstall paper cartridge, retain with cartridge
retainer and knob.
• Carefully install foam pre-cleaner.
• Install cover assembly and latch onto air cleaner
body.
Engine Governed Speed
Engine speed was properly adjusted at factory and
should require no additional adjustment. DO NOT
attempt to change engine speed.
Excessively high speeds are dangerous and increase
risk of personal injury. Excessively low speeds impose
a heavy load on the engine when sufficient power is
not available, which may shorten engine life.
Operating the engine at incorrect speed settings
affects electrical generator operation as follows:
• Operating engine at high speeds results in an
over-frequency and over-voltage condition.
• Operating engine at low speeds causes an
under-frequency and under-voltage condition.
IMPORTANT: Incorrect frequency and/or voltage
may damage some connected electrical loads.
If you suspect engine speed is incorrect, take your
generator to an authorized service facility for repair
and adjustment.
Clean Spark Arrestor Muffler
The engine exhaust muffler has a spark arrester
screen. The screen should be inspected every
100 operating hours, or once each year, whichever
comes first.
A DANGER! Let muffler cool before working
on it. Contact with a hot muffler or engine
can cause severe burns.
NOTE: If you use your generator on any forested,
brush or grass-covered unimproved land, it must have
a spark arrester. The spark arrestor must be cleaned
and maintained in good condition by the owner or
operator.
The preceding is required by law in the State of
California. Other states may have similar laws.
Federal laws apply on federal lands.
Clean and inspect the spark arrestor as follows:
• Remove four screws that attach the spark arrestor
screen.
• Inspect the screen and replace if torn, perforated
or otherwise damaged. DO NOT USE a defective
screen. If the screen is not damaged, clean it with
a commercial solvent.
• Reattach the screen and the heat shield.
Extended Life Generator

Generac 10000EXL Extended Life Generator
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: We DO NOT recommend using 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.
M 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.
M 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. Extended
• Store the unit in a clean dry place.
DANGER: 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
M Other Storage Tips _
• Do not store gasoline from one season to another.
• Replace your gasoline can if it starts to rust. Rust
and/or dirt in a gasoline can cause problems when
you use that fuel with this unit
• Store in clean and dry area.
SPECIFICATIONS
M Generator _
Rated Maximum Continuous
AC Power Output.J 0000 watts (10 kW)
Rated Voltage.120/240 Volts
Rated Maximum Current at 240 Volts..41.7 AC amperes
Rated Maximum Current at 120 Volts.83.3 AC amperes
Phase.1
Rated AC Frequency.60 Hertz
Number of Rotor Poles.2
Driven Speed of Rotor.3600 rpm
Battery Size.Y50-N182-A3
■ Engine
Type. .Air-Cooled V-Twin
Displacement. .570cc
Valve Arrangement.
.Overhead Valves
Setting at no load. .3600 rpm
Lubrication System...
Oil Capacity
With Oil Filter Change.
.3.5 U.S. Pints
Without Oil Filter Change.
.3 U.S. Pints
Recommended Spark Plugs
Champion.
.RC12YC
Autolite. .3924
Spark Plug Gap.
.0.030 inch (0.76mm)
Spark Plug Torque.
.200 inch-pounds
(22.5 N-m)
Rated Horsepower. .19 at 3600 RPM
Fuel Canacitv. ....5 IJ.S. Gallons
(19 Liters)
Generator
13

Generac 10000EXL Extended Life Generator
TROUBLESHOOTING POINTS
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 Generac Service Facility.
3. See “Don't Overload the
Generator".
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 Generac Service Facility.
10. Contact Generac Service Facility.
11. Contact Generac 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”
2. Replace air filter.
Engine “hunts” or falters.
1. Choke is opened too soon.
2. Carburetor is running too rich
or too lean.
1. Move choke to halfway position until
engine runs smoothly.
2. Contact Generac Service Facility.
Extended Lite
Generator

Generac 10000EXL Extended Life Generator

Generac 10000EXL Extended Lite Generator
CONTROL PANEL EXPLODED VIEW AND PARTS LIST
item
Part#
Qty.
Description
Item
Part#
Qtv.
Description
i
A95909 1
PANEL, Control
20
75207-A
2 CIRCUIT
BREAKER, 30 Amp
2
B95906 1 BOX, Control
21 78653 1 SWITCH, Run - Stop
3 43437 1 OUTLET, 120/240V, 30 Amp
22 93986
4
SCREW, M3 - 0.5 x 20mm
Locking Type
23 91526
4
SCREW, M5 - .08 x 12mm
4
68759 1
OUTLET 120V, 20 Amp
24 49226
5 LOCK WASHER, M5
Duplex GFCI
25
23897
5 FLAT WASHER, M5
5
68868
1
OUTLET 120V, 30 Amp
26 75207 3 CIRCUIT
BREAKER, 20 Amp
Locking Type
27
74190
1
OUTLET, 120V/20A Locking
6
96476
1 BOARD, System Control
28
92953
1
BLOCK, 50 Amp, 3 - Terminal
7 96067 1
ASSEMBLY, Engine Harness
29
80077 4
SCREW, M4 x 20mm
8 90576 1
GROMMET, Rubber
30
94117 1
BOARD, Idle Control
9
74191 1
OUTLET 50 Amp 240V 31 84028
1
TRANSFORMER, Idle Control
10 87962 1 CIRCUIT
BREAKER
32 65795 2
RECTIFIER, Battery Charge
11
93929 4
STAND OFF, 1/2" Hex
33 84135 1
GROMMET Rubber
12
51715 12
NUT, M4 - 0.7 Hex
34
79224 1
SCREW, M5-0.8 x 30mm
13
22264
16 LOCK WASHER, #8 M4
35 64525
4
STAND OFF, 3/4“ Hex
14 43181 4
SCREW, M3 - .05 x 10mm
36 64526 8
SCREW, #6-32 x 3/8“ Tap
16
38150
12 FLAT WASHER, #8
37 82538 1
SWITCH, On - Off
17 23365 12
WASHER, #8 Shakeproof
38 96471 1
ASSEMBLY, Extension Cord
18
90418 1
OUTLET, 12V DC Snap 39 51716
1
HEXNUT, M5-0.8
19 43182 4
LOCK WASHER, M3
Drawing No. 96025
Extended Life Generator
17

Q Generac 10000EXL Extended Life Generator

Generac 10000EXL Extended Life Generator
GENERATOR PARTS LIST
Item
Part#
Qtv.
Description
Item Part#
Qiy. Description
1 NSP 1
ENGINE, V-Twin Spec93571
39
96716 3 WASHER, Nylon
2 B93074 1 SHIELD, Heat
40 95920 1
LINKAGE, Stepper Motor to
3
A77304
2
SUPPORT, Engine
Bell Crank
4
B90916
1
STATOR, Heat Shield 41
95921 1
LINKAGE, Bell Crank to
5 80270
1
VALVE, Fuel Shut-Off
Throttle
6 78299
1
BUSHING, Fuel Valve 42 33141
1
CAPSCREW, #10-32 x 3/4"
7
90878
1
CAP, Fuel Tank
Hex Hd.
8 35097 8
MOUNTS, Vibration
43
51713
1
WASHER, M5 Flat
9
78831B
4
CAPSCREW, M6-1.Ox 44
49226
1
WASHER, M5 Lock
60mm
45 62265 2
GROMMET Rubber
10 93615 1 TANK, Fuel
46 A84650 1
TRAY, Battery
11 A92558 1 CRADLE
47
A44951 1
BAR, Battery Hold-Down
12
83465 4 GROMMET, Fuel Tank
48
45000 2
SCREW, 1/4-20” NC x 7” Hx
Mounting
Hd. Mach.
13 56892
3 CRIMPTITE, 10-24x3/8” 49
22097
9 WASHER, 1/4" Lock
14
23152 8
CAPSCREW, 3/8-16 X 3/4"
50 22127
6 NUT, 1/4”-20 Hex
Lg-
51 22261 1
SHAKEPROOF, 3/8" Internal
15
22237
16
WASHER, 3/8” Lock
52
77282
1
SWITCH, Starter
16
22241
8
NUT, 3/8-16 Hex
53
78289
1 BRACKET, Starter Switch
17
75246 4
SELF-TAPPING, 3/8-16x1-
54 22287
2
CAPSCREW. 1/4”-20 x 3/4"
1/4” Lg.
55 90914
1
ADAPTER, Oil Filter
18
22129
2
WASHER, M8-Lock
56
70185 1 FILTER, Oil
19 39253 2
CAPSCREW, M8-1.25x16
57 60108
1
SWITCH, Low Oil Pressure
20
96054
1 ASSEMBLY, Control Panel
58
40945 3
CAPSCREW, M6-1.0 x 20
21 96867 1
ASSEMBLY, Stepper Motor
Socket Hd
23 185-53621 1
ASSEMBLY, Ground Wire
61
A93841
1
SHIELD, Oil Sensor Heat
24
86292 7
CAPSCREW, #10 Self Driller
62 46852
2
TAPTITE, #10-32 x 1/4”
25 23762 1
WASHER, #10 Shakeproof
63 22473
2 WASHER, 1/4” Flat
26
79661P
1
DECAL, Engine #93571
64
182-53621 1
WIRE ASSEMBLY,Starter
28 92982 1
DECAL, Danger 65
183-53621 1
WIRE ASSEMBLY, Battery
29
96056 1
DECAL, Control Panel
66
184-53621
1
WIRE ASSEMBLY, Ground
30 96055
1
DECAL, Side Panel 67
96378 1
SPACER
32 77816 1
DECAL, Caution Hot Muffler
68 96717 1 SPRING
33
95349
1
PLATE, Adjust
70 73054 1
DECAL, Fuel Shut Off
34
95348
1
BELL, Crank
71
68548
1
GASKET, Oil Filter Adapter
37 93826 1
DECAL, Start Instruction
38 75477 2
SCRW, M5-0.8 x 20Lg.
Phillips Hd.
Extended life Generator
Drawing No. 96024

I
Generac 10000EXL Extended Life Generator
ROTOR AND STATOR EXPLODED VIEW