Generac Power Systems 9801-7 User manual

Owner’s Manual
Questions? Help is just a moment away!
Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-portables.com or www.briggsandstratton.com
Model No. 9801-7 (10,000 Watt AC Generator) Manual No. 189484GS Revision 2 (09/24/2002)
Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-23
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page
• Generator
• Wheel kit
• Storage Cover
• Battery
• Battery Float Charger
• Battery Charge Cables
• Spare Air Filter and Pre-cleaner
• Spare Oil Filter
• (2) Spare Spark Plugs
• Spark Plug Wrench
• (2) Locking 30 Amp Plugs
• Locking 20 Amp Plug
• (2) Engine Oil
• Owner's Manual
• Engine Manual
*If any parts are missing or damaged, call 1-800-270-1408.
Parts Included*Table of Contents

10000EXL Extended Life Generator
2
EQUIPMENT
DESCRIPTION
Read this manual carefully and become familiar
with your generator. Know its applications, its
limitations and any hazards involved.
This generator is an engine–driven, revolving field, alternating
current (AC) generator. It was designed to supply electrical
power for operating compatible electrical lighting, appliances,
tools and motor loads.The generator’s revolving field is
driven at about 3,600 rpm by a twin-cylinder engine.
CAUTION! DO NOT exceed the generator’s
wattage/amperage capacity. See “Don’t Overload the
Generator” on page 12.
Every effort has been made to ensure that information in
this manual is accurate and current. However, Generac
reserves the right to change, alter or otherwise improve the
product and this document at any time without prior notice.
The Emission Control System for this generator is warranted
for standards set by the Environmental Protection Agency. For
warranty information refer to the engine owner’s manual.
SAFETY RULES
The safety alert symbol ( ) is used with a signal word
(DANGER, CAUTION,WARNING), a pictorial and/or a
safety message to alert you to hazards. DANGER indicates
a hazard which, if not avoided, will result in death or
serious injury. WARNING indicates a hazard which, if not
avoided, could result in death or serious injury.
CAUTION indicates a hazard which, if not avoided, might
result in minor or moderate injury. CAUTION, when used
without the alert symbol, indicates a situation that could
result in equipment damage. Follow safety messages to
avoid or reduce the risk of injury or death.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
• Operate generator ONLY outdoors.
• Keep at least 2 feet of clearance on all sides of generator for
adaquate ventilation.
• DO NOT operate generator inside any building or enclosure,
including the generator compartment of a recreational vehicle (RV).
Running generator gives off carbon monoxide,
an ordorless, colorless, poison gas.
Breathing carbon monoxide will cause nausea,
fainting or death.
DANGER
• When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
• Use a ground fault circuit interrupter (GFCI) in any damp or
highly conductive area, such as metal decking or steel work.
• DO NOT touch bare wires or receptacles.
• DO NOT use generator with electrical cords which are worn,
frayed, bare or otherwise damaged.
• DO NOT operate generator in the rain.
• DO NOT handle generator or electrical cords while standing
in water, while barefoot, or while hands or feet are wet.
• DO NOT allow unqualified persons or children to operate or
service generator.
Generator produces powerful voltage.
Failure to isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
DANGER
• National Electric Code requires generator to be properly
grounded to an approved earth ground. Call an electrician for
local grounding requirements.
Failure to properly ground generator can result
in electrocution, especially if the generator is
equipped with a wheel kit.
DANGER
In the State of California a spark arrester is required by law
(Section 4442 of the California Public Resources Code).
Other states may have similar laws. Federal laws apply on
federal lands. If you equip the muffler with a spark arrester,
it must be maintained in effective working order.
WHEN ADJUSTING OR MAKING REPAIRS TOYOUR
GENERATOR
• Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.
Unintentional sparking can result in fire or
electric shock.
WARNING

3
10000EXL Extended Life Generator
WHEN ADDING FUEL
• Turn generator OFF and let it cool at least 2 minutes before
removing gas cap. Loosen cap slowly to relieve pressure in tank.
• Fill fuel tank outdoors.
• DO NOT overfill tank.Allow space for fuel expansion.
• Keep gasoline away from sparks, open flames, pilot lights, heat,
and other ignition sources.
• DO NOT light a cigarette or smoke.
WHEN OPERATING EQUIPMENT
• DO NOT tip engine or equipment at angle which causes
gasoline to spill.
WHEN TRANSPORTING OR REPAIRING EQUIPMENT
• Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFF.
• Disconnect spark plug wire.
WHEN STORING GASOLINE OR EQUIPMENT WITH
FUEL IN TANK
• Store away from furnaces, stoves, water heaters, clothes
dryers or other appliances that have pilot light or other
ignition source because they can ignite gasoline vapors.
Gasoline and its vapors are extremely flammable
and explosive.
Fire or explosion can cause severe burns or
death.
WARNING
• DO NOT allow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a battery.
• Wear protective goggles, rubber apron, and rubber gloves.
Storage batteries give off explosive hydrogen gas
during recharging.
Hydrogen gas stays near battery for a long time
after battery has been charged.
Slightest spark will ignite hydrogen and cause
explosion.
You can be blinded or severely injured.
Battery electrolyte fluid contains acid and is
extremely caustic.
Contact with battery fluid will cause severe
chemical burns.
DANGER
• DO NOT touch hot surfaces.
• Allow equipment to cool before touching.
Running engines produce heat.Temperature of
muffler and nearby areas can reach or exceed
150°F (65°C).
Severe burns can occur on contact.
WARNING
• DO NOT tamper with governed speed. Generator supplies
correct rated frequency and voltage when running at governed
speed.
• DO NOT modify generator in any way.
Excessively high operating speeds increase risk of injury
and damage to generator.
Excessively low speeds impose a heavy load.
CAUTION
• See “Don’t Overload Your Generator” on page 12.
• Start generator and let engine stabilize before connecting
electrical loads.
• Connect electrical loads in OFF position, then turn ON for
operation.
• Turn electrical loads OFF and disconnect from generator
before stopping generator.
Exceeding generators wattage/amperage cappacity can
damage generator and/or electrical devices connected
to it.
CAUTION
• Use generator only for intended uses.
• If you have questions about intended use, ask dealer or
contact Generac.
• Operate generator only on level surfaces.
• DO NOT expose generator to excessive moisture, dust, dirt,
or corrosive vapors.
• DO NOT insert any objects through cooling slots.
• If connected devices overheat, turn them off and disconnect
them from generator.
• Shut off generator if:
-electrical output is lost;
-equipment sparks, smokes, or emits flames;
-unit vibrates excessively.
Improper treatment of generator can damage it and
shorten its life.
CAUTION

10000EXL Extended Life Generator
4
Your generator requires some assembly and is ready for
use after it has been properly serviced with the
recommended oil and fuel.
If you have any problems with the assembly of your
generator, please call the generator helpline at
1-800-270-1408.
IMPORTANT: Any attempt to run the unit before it has
been serviced with the recommended oil will result in an
engine failure.
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.
INSTALL WHEEL KIT
The wheel kit is designed to greatly improve the portability
of your generator.
NOTE: Wheel kit is not intended for over-the-road use.
You will need a socket wrench with 1/2" or 13mm sockets
and a needle-nose plier to install this kit.
Refer to Figure 1 and install the wheel kit as follows:
1. Place the generator on a hard flat surface.
2. Stand at the control panel end of the generator and
gently tilt the generator up, high enough to place
wooden blocks beneath the cradle.This will allow you
to add the wheels.
3. Slide the axle through the holes in the brackets
provided on the generator cradle.
4. Slide a wheel spacer, wheel and flat washer on one end
of the axle. Make sure the air inflation valve is outward.
Place the e-ring onto the groove in the axle.
5. Place one end of the needle nose pliers on the bottom
of the axle and the other end of the pliers on top of
the e-ring. Seat the e-ring by pressing the pliers closed.
6. Slide the axle through until wheel is tight against bracket.
7. Install the e-ring on the other side in the same manner
as steps 4 & 5. Remove the wooden blocks.
Support Leg
Flat Washer
Axle
20mm Cap Screw
Hex Nut
Wheel E-Ring
Figure 1 — Install Wheel Kit
30mm
Cap
Screw
Flat
Washer
Vibration
Mount Lock Washer
Wheel Spacers

8. Attach the vibration mounts to the support leg with a
30mm capscrew and lock nut.
9. With the wheels on, secure the support leg assembly
to the cradle with 20 mm long capscrews, flat washers,
and lock washers.
10. Check each fastener to ensure it is secure and the
tires are inflated between 15-40 PSI.
CHECK BATTERY / ATTACH
NEGATIVE BATTERY
WIRE
The sealed battery on the generator is fully charged and
pre–installed except for the negative (black) battery cable.
To install:
• Cut off tie wrap securing loose end of negative (black)
cable.
• Remove nut and washer on the negative battery terminal.
• Slide the negative battery cable over the screw on the
negative terminal (Figure 2).
• Reattach washer and nut and tighten.
• Verify that the connections to the battery and generator
are tight and secure.
BEFORE STARTING THE
ENGINE
Add Oil
CAUTION! Any attempt to crank or start the engine
before it has been properly filled with the recommended
oil may result in an engine failure.
To fill your engine with oil:
• Place generator on a level surface.
• Follow the oil grade recommendations and oil fill
instructions given in the engine owner’s manual.
NOTE: The generator assembly rotates on a prelubricated
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.Allow unit
to cool for two minutes before refueling. DO NOT
light a cigarette or smoke when filling the fuel tank.
WARNING! DO NOT overfill the fuel tank.
Always allow room for fuel expansion.
• Use regular UNLEADED gasoline with the generator
engine. DO NOT use premium gasoline. DO NOT mix
oil with gasoline.
• Clean area around fuel fill cap, remove cap.
• Slowly add unleaded regular gasoline to fuel tank. Be
careful not to overfill.Allow about 1.5" of tank space for
fuel expansion (Figure 3).
• Install fuel cap and permit any spilled gasoline to evaporate.
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”
on page 14. NEVER use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
5
10000EXL Extended Life Generator
Figure 2 — Negative Battery Connection
Negative
Battery Cable
Figure 3 — Typical Fuel Expansion Space
Fuel
Tank
1.5” Air Space

10000EXL Extended Life Generator
6
KNOWYOUR 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 12Volt battery.
120 Volt AC, 20 Amp Duplex Receptacles — 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, 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.
240 Volt AC, 50 Amp Receptacle — May be used to
supply electrical power for the operation of 240 Volt AC,
50 Amp, single phase, 60 Hz electrical loads.
Air Cleaner — Uses a dry type filter element and foam
pre–cleaner to limit the amount of dirt and dust sucked
into the engine.
Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — Each receptacle is provided
with a "push to reset" circuit breaker to protect the
generator against electrical overload.
Fuel Tank — Capacity of eight (8) U.S. gallons.
Electric Start Switch — Press to start the engine.
Grounding Wing Nut — Use this connection to
properly ground the generator.
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.
Oil Fill Cap — Add oil to engine here.
Recoil Starter — Used to start the engine manually.
Ignition Switch — Must be in “On” (–) position to start
engine. Set to “Off” (o) to stop a running engine.
Spark Arrester Muffler — Exhaust muffler lowers engine
noise and is equipped with a spark arrester screen.
120 Volt AC, 20 Amp
Duplex Receptacles
Idle Control Switch
Recoil Starter
Ignition Switch
Choke Lever
120 Volt AC, 30 Amp
Locking Receptacle 240 Volt AC, 50 Amp
Receptacle
Circuit Breakers (AC)
120/240 Volt AC, 30 Amp
Locking Receptacle
12 Volt DC
Receptacle
Spark Arrester Muffler
Electric Start Button
Grounding Wing Nut
Air Cleaner
Fuel Tank
Oil Fill Cap
120 Volt AC, 20 Amp
Locking Receptacle

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10000EXL Extended Life Generator
GROUNDING THE
GENERATOR
The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require additional grounding of
the unit. For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure 4).
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth–driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, local codes
may vary widely. Consult with a local electrician for
grounding requirements in your area.
Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices, especially when the unit is
equipped with a wheel kit. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
OPERATING THE
GENERATOR
CAUTION! NEVER start or stop unit with
electrical loads connected AND with the connected
devices turned ON.
IMPORTANT: Always unplug the battery float charger
before starting the generator.
Starting the Engine
Disconnect all electrical loads from the generator. Follow
start instruction steps in numerical order:
1. Turn the fuel valve to the “On” position (Figure 5).
2. Make sure the Idle Control switch is in “Off” position
(Figure 6).
3. Set the Ignition switch to “On” (–) position (Figure 7).
4. Pull choke control out to close choke (Figure 8).
Figure 5 — Fuel Shut-offValve
Figure 7 — Ignition Switch
Figure 8 — Choke Lever
Figure 6 — Idle Control Switch
Figure 4 — Grounding Wing Nut
Grounding
Wing Nut
Fuel Valve is shown
in “On” position

10000EXL Extended Life Generator
8
5A. For electric starting, press start switch on generator
cradle.To prolong the life of the starter components,
press the starter button for no more than 15 seconds,
and pause for 30 seconds.
5B. For manual starting, grasp the recoil handle and pull
slowly until slight resistance is felt.Then pull rapidly
one time only to start engine.
6. When engine starts, open the choke gradually as the
engine warms up by pushing in on the choke handle.
NOTE: If engine still fails to start after 3 pulls, check for
proper oil level in crankcase.This unit is equipped with an
Oil Pressure Switch. See engine manual.
Refer to the engine owner’s manual for complete
starting instructions.
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes after
starting.
• Plug in and turn on the desired 120 and/or 240 Volt AC,
single phase, 60 Hz electrical loads.
• DO NOT connect 240 Volt loads to the 120Volt receptacles.
• DO NOT connect 3–phase loads to the generator.
• DO NOT connect 50 Hz loads to the generator.
•DO NOT OVERLOAD THE GENERATOR. See
“Don’t Overload the Generator” on page 12.
Stopping the Engine
• Unplug all electrical loads from generator panel
receptacles. NEVER start or stop engine with electrical
devices plugged in and turned on.
• Put the idle control switch in the “Off” position.
• Let engine run at no–load for 30 seconds to stabilize the
internal temperatures of engine and generator.
• Move Ignition switch to “Off” (o) position.
• Close the fuel shut–off valve.
Operating Automatic Idle Control
This feature is designed to greatly improve fuel economy.
When this switch is turned ON, the engine will only run
at its normal high governed engine speed when an electrical
load is connected.When electrical loads are 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.
Charging a 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, resulting in
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 dangerous
sulfuric acid solution that can cause severe burns. If
spill occurs flush area with clear water immediately.
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.
To recharge 12Volt 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 9).
• Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 9).
Figure 9 — Battery Connections

9
10000EXL Extended Life Generator
• 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.
How to Use the Battery Charger
Use battery float charger jack to keep the starting battery
charged and ready for use. Battery charging should be done
in a dry location, such as inside a garage.
• Plug the charger into the unit’s “Battery Float Charger”
jack, which is located on the starter switch (Figure 10).
Plug battery charger into a 120Volt AC wall receptacle.
• Unplug the charger from the unit and the wall outlet when
generator is being started and while it is in operation.
• Keep this charger plugged in when generator is not in
use to prolong battery life.The charger has a built in float
equalizer and will not overcharge the battery, even when
plugged in for an extended period of time.
IMPORTANT: See “Battery Maintenance” on page 13 for
additional information.
RECEPTACLES
240 Volt AC, 50 Amp Receptacle
Use a NEMA 14–50 plug with this receptacle (Figure 11).
Connect a 4-wire cord set rated for 250 Volt AC loads at
50 Amps to the plug.
Use this receptacle to operate 240Volt AC, 50 Amp, 60 Hz,
single phase loads requiring up to 10,000 watts (10.0 kW)
of power.The outlet is protected by a 45 Amp
push–to–reset circuit breaker.
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. 240 Volt loads powered through this outlet
should not exceed 41.7 Amps of current draw.
Figure 10 — Battery Charger Jack
Figure 11 — 240Volt AC, 50 Amp Receptacle
120 Volts
AC 120 Volts
AC
X (Hot)
Y (Hot)
240 Volts AC
Frame Ground
NEMA 14-50
W (Neutral)

10000EXL Extended Life Generator
10
120/240 Volt AC, 30 Amp, Locking
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 12).You can use the same 4–wire cord if
you plan to run a 120Volt load.
This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts of power at
30 Amps for 120Volts; 7,200 watts of power (7.2 kW) at
30 Amps for 240 Volts.The outlet is protected by a 30 Amp
push–to–reset circuit breaker.
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L5–30 plug with this receptacle. Connect a
3–wire cord set rated for 125 Volt AC loads at 30 Amps to
the plug (Figure 13).
Use this receptacle to operate 120Volt 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 13 — 120 Volt AC, 30 Amp, Locking Receptacle
3-Wire Cord Set
Neutral
120V
Hot
Ground (Green)
NEMA L5-30
Figure 12 — 120/240 Volt AC, 30 Amp Receptacle
4-Wire Cord Set
240V
120V 120V W (Neutral)
X (Hot)
Y (Hot)
NEMA L14-30 Ground (Green)

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10000EXL Extended Life Generator
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 14).
Use this receptacle to operate 120Volt 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 AC, 20 Amp, Duplex
Receptacle
Each receptacle (Figure 15) is protected against overload by
a 20 Amp push–to–reset circuit breaker.
Use each receptacle to operate 120Volt AC, single–phase,
60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)
at 20 Amps of current. Use cord sets that are rated for
125 Volt AC loads at 20 Amps (or greater).
12 Volt DC, 10 Amp Receptacle
This receptacle allows you to recharge a 12Volt
automotive or utility style storage battery with the battery
charge cables provided (Figure 16).
This receptacle can not recharge 6 Volt batteries and can
not be used to crank an engine having a discharged battery.
See the section “Charging a Battery” (page 8) before
attempting to recharge a battery.
Figure 15 — 120 Volt AC, 20 Amp, Duplex Receptacle
Figure 16 — 12Volt DC, 10 Amp Receptacle
Figure 14 — 120 Volt AC, 20 Amp, Locking Receptacle
3-Wire Cord Set
Neutral
120V
Hot
Ground (Green)
NEMA L5-20

10000EXL Extended Life Generator
12
DON'T OVERLOADYOUR
GENERATOR
Capacity
You must make sure your generator can supply enough
rated (running) and surge (starting) watts for the items you
will power at the same time. Follow these simple steps:
1. Select the items you will power at the same time.
2. Total the rated (running) watts of these items.This is
the amount of power your generator must produce to
keep your items running. See Figure 17.
3. Estimate how many surge (starting) watts you will
need. Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliances such as a circular saw or refrigerator.
Because not all motors start at the same time, total
surge watts can be estimated by adding only the
item(s) with the highest additional surge watts to the
total rated watts from step 2.
Example:
Total Rated (Running) Watts = 3075
Highest Additional Surge Watts = 1800
Total Generator Output Required = 4875
Power Management
To prolong the life of your generator and attached devices,
it is important to take care when adding electrical loads to
your generator.There should be nothing connected to the
generator outlets before starting its engine.The correct
and safe way to manage generator power is to sequentially
add loads as follows:
1. With nothing connected to the generator, start the
engine as described in this manual.
2. Plug in and turn on the first load, preferably the largest
load you have.
3. Permit the generator output to stabilize (engine runs
smoothly and attached device operates properly.
4. Plug in and turn on the next load.
5. Again, permit the generator to stabilize.
6. Repeat steps 4 and 5 for each additional load.
NEVER add more loads than the generator capacity.Take
special care to consider surge loads in generator capacity,
as described above.
*Wattages listed are approximate only. Check tool or
appliance for actual wattage.
Tool or Appliance Rated (Running)
Watts Additional Surge (Starting) Watts
Window Air
Conditioner 1200 1800
Refrigerator 800 1600
Deep Freezer 500 500
Television 500 -
Light (75 Watts) 75 -
3075 Total
Running Watts 1800 Highest Surge Watts
Tool or Appliance
Rated*
(Running)
Watts
Additional
Surge
(Starting)
Watts
Essentials
Light Bulb -75 watt
75
-
Deep Freezer
500
500
Sump Pump
800
1200
Refrigerator/Freezer -18 Cu. Ft.
800
1600
Water Well Pump -1/3 HP
1000
2000
Heating/Cooling
Window AC -10,000 BTU
1200
1800
Window Fan
300
600
Furnace Fan Blower -1/2 HP
800
1300
Kitchen
Microwave Oven -1000 Watt
1000
-
Coffee Maker
1500
-
Electric Stove -Single Element
1500
-
Hot Plate
2500
-
Family Room
DVD/CD Player
100
-
VCR
100
-
Stereo Receiver
450
-
Color Television -27”
500
-
Personal Computer w/17” monitor
800
-
Other
Security System
180
-
AM/FM Clock Radio
300
-
Garage Door Opener -1/2 HP
480
520
Electric Water Heater -40 Gallon
4000
-
DIY/Job Site
Quartz Halogen Work Light
1000
-
Airless Sprayer -1/3 HP
600
1200
Reciprocating Saw
960
960
Electric Drill -1/2 HP
1000
1000
Circular Saw -7 1/4”
1500
1500
Miter Saw -10”
1800
1800
Table Planer -6”
1800
1800
Table Saw/Radial Arm Saw -10”
2000
2000
Air Compressor -1-1/2 HP
2500
2500
Figure 17 - Wattage Reference Chart

13
10000EXL Extended Life Generator
SPECIFICATIONS
Maximum Surge Watts . . . . . . . . . . . . . . . .12,500 watts
Continuous Wattage Capacity . . . . . . . . . .10,000 watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0
Rated Maximum Continuous AC Load Current:
At 120 Volts . . . . . . . . . . . . . . . . . . . . . . .83.3 Amps
At 240 Volts . . . . . . . . . . . . . . . . . . . . . . .41.7 Amps
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . .60 Hertz
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . 8 U.S. gallons
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . .300 lbs.
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 engine owner’s manual for instructions.
CAUTION! Avoid prolonged or repeated skin
contact with used motor oil. Used motor oil has
been shown to cause skin cancer in certain
laboratory animals.Thoroughly wash exposed areas
with soap and water.
KEEP OUT OF REACH OF CHILDREN. DON'T
POLLUTE. CONSERVE RESOURCES. RETURN
USED OIL TO COLLECTION CENTERS.
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. Cooling air
slots in the generator must not become clogged with snow,
leaves or any other foreign material.
NOTE: DO NOT use a garden hose to clean generator.
Water can enter engine fuel system and cause problems. In
addition, if water enters generator through cooling air slots,
some of the water will be retained in voids and cracks of
the rotor and stator winding insulation.Water and dirt
buildup on the generator internal windings will eventually
decrease the insulation resistance of these windings.
Battery Maintenance
Other than float charging, described elsewhere, no
maintenance is required for the battery. Keep the battery
and terminals clean and dry.
IMPORTANT: Battery charging should be performed in a
dry location, such as inside a garage.
To Clean the Generator
• Use a damp cloth to wipe exterior surfaces clean.
• A soft bristle brush may be used to loosen caked on dirt
or oil.
• A vacuum cleaner may be used to pick up loose dirt.
• 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.

10000EXL Extended Life Generator
14
STORAGE
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 cooling air slots and openings on generator
are open and unobstructed.
CAUTION! Storage covers can be flammable.
DO NOT place a storage cover over a hot
generator. Let the unit cool for a sufficient time
before placing the cover on the unit.
Engine Storage
See engine owner’s manual for instructions.
Other Storage Tips
• To prevent gum from forming in fuel system or on
essential carburetor parts, add fuel stabilizer into fuel
tank and fill with fresh gasoline. Run the unit for several
minutes to circulate the additive through the carburetor.
The unit and fuel can then be stored for up to
24 months. Fuel stabilizer can be purchased locally.
• DO NOT store gasoline from one season to another
unless it has been treated as described above.
• Replace fuel container if it starts to rust. Rust and/or dirt
in fuel can cause problems if it's used with this unit.
• Store unit in a clean and dry area.

15
10000EXL Extended Life Generator
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 Generac 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. Ignition Switch set to “Stop”.
2. Fuel Valve is in the “Off” position.
3. Dirty air cleaner.
4. Out of gasoline.
5. Stale gasoline.
6. Spark plug wire not connected to
spark plug.
7. Bad spark plug.
8. Water in gasoline.
9. Overchoking.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
13. Failed battery.
1. Set switch to “On”.
2. Turn fuel valve to the “On” position.
3. Clean or replace air cleaner.
4. Fill fuel tank.
5. Drain gas tank; fill with fresh fuel.
6. Connect wire to spark plug.
7. Replace spark plug.
8. Drain gas tank; fill with fresh fuel.
9. Open choke fully and crank engine.
10. Contact Briggs and Stratton service
facility.
11. Contact Briggs and Stratton service
facility.
12. Contact Briggs and Stratton service
facility.
13. 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.
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 Briggs and Stratton service
facility.

10000EXL Extended Life Generator
16
SCHEMATIC

17
10000EXL Extended Life Generator
WIRING DIAGRAM

10000EXL Extended Life Generator
18
EXPLODED VIEW – MAIN UNIT

19
10000EXL Extended Life Generator
Item Part # Qty Description
1 NSP 1 ENGINE
2 JB4509AGS 1 SHIELD, Heat
3 A77304GS 2 SUPPORT, Engine
4 JB5567GS 1 SHIELD, Heat
5 80270GS 1 VALVE, Fuel Shut-Off
6 78299GS 1 BUSHING, Fuel Valve
7 B4325GS 1 CAP, Fuel Tank
8 38353GS 6 MOUNTS,Vibration
9 78831BGS 4 SCREW
10 B1997GS 1 ASSY,Tank, Fuel (Includes Items 5 & 6)
11 A189487GS 1 CRADLE
12 83465GS 4 GROMMET, Fuel Tank Mounting
13 87680GS 1 SCREW,Wing
14 23152GS 6 SCREW
15 22237GS 16 WASHER, Lock
16 22241GS 6 NUT
17 77816GS 2 DECAL, Caution Hot Muffler
18 22131GS 2 WASHER
19 J93074GS 1 SHIELD, Heat
20 186076GS 1 ASSY, Control Panel (see pages 20-21)
21 19553621GS 1 ASSY,Wire, Ground
22 45757GS 1 SCREW
23 75246GS 4 SCREW
24 22145GS 6 WASHER
25 26850GS 3 WASHER
26 20566GS 1 DECAL, 1-800
27 B4986GS 1 DECAL, Ground
28 92982GS 1 DECAL, Danger
29 189409GS 2 DECAL, Unit
31 52857GS 1 NUT, Lock
32 187049GS 1 PLUG, Dome
33 93826GS 1 DECAL, Start Instructions
34 76040GS 1 SCREW
35 B2153GS 19 SCREW
36 73054GS 1 DECAL, Fuel Shut-Off
37 B4268GS 1 ALTERNATOR (see page 23)
38 A5850GS 1 U-CHANNEL
39 96867GS 1 ASSY, Stepper Motor
40 B4489GS 1 BATTERY
41 39253GS 2 SCREW
42 22129GS 2 WASHER, Lock
43 A96925GS 1 BRACKET, Battery Tie Down
44 96924GS 2 J-BOLT
45 189302DGS 1 CABLE, Battery Positive
46 19753621GS 1 CABLE, Battery Negative
47 23897GS 2 WASHER
48 49226GS 1 WASHER, Lock
49 52856GS 2 NUT, Lock
50 49820GS 2 NUT, Nylok
51 42907GS 1 SCREW
52 49813GS 1 NUT
54 27482GS 1 WASHER
55 47411GS 1 SCREW
56 22473GS 1 WASHER
Item Part # Qty Description
57 55934TGS 1 CLAMP, Hose
58 55934GGS 2 CLAMP, Hose
59 22511GS 6 SCREW
60 96832GS 1 CLAMP, Hose
61 52618GS 3 SCREW
62 B4794GS 1 GROMMET, Generator Cover
63 33141GS 1 SCREW
64 30340GS 1 HOSE
65 48031CGS 2 CLAMP, Hose
66 62265GS 1 GROMMET, Rubber
67 95349GS 1 PLATE,Adjust
68 96717GS 1 SPRING
69 95921GS 1 LINKAGE, Bell Crank to Throttle
70 75477GS 2 SCREW
71 96716GS 3 WASHER, Nylon
72 95348GS 1 BRACKET, Bell Crank
73 96378GS 1 SPACER
74 51713GS 1 WASHER
75 49226GS 1 WASHER, Lock
76 95920GS 1 LINKAGE, Stepper Motor to Bell Crank
77 22287GS 2 SCREW
78 188987GS 1 BRACKET, Starter Switch
79 23762GS 2 WASHER
80 77282GS 1 SWITCH, Starter
81 189302AGS 1 ASSY,Wire
82 22097GS 4 WASHER, Lock
83 22127GS 4 NUT
84 186102GS 1 WIRE, Harness
85 188989GS 1 ASSY, Jack, DC
86 189198GS 1 DECAL, Instruction, ES
87 58359GS 1 LUG
88 189484GS 1 MANUAL, Owners
89 191460GS 1 MANUAL, Engine
90 B4605GS 2 GRIP
91 BB5586GS 2 HANDLE (Includes Item 90)
92 187104GS 4 WASHER, Nylon
93 B4135GS 2 PIN, with Lanyard
94 39287GS 2 SCREW
95 B4177GS 1 CHARGE, Battery Float
96 49820GS 2 NUT, Nylok
97 43438GS 1 PLUG, 120/240V, 30A, 4 Prong
98 93568GS 1 PLUG, 125V, 20A
99 37806GS 1 PLUG, 120V/30A, 3 Prong
100 189505GS 1 FILTER, Oil
101 B4767GS 1 COVER, Storage
102 65787GS 1 CABLE, Battery Charge
103 189482GS 1 ELEMENT,Air Filter
104 189481GS 1 PRE-CLEANER,Air
105 189506GS 2 SPARK PLUG
106 B3518GS 1 CAP, Funnel, Oil Bottle
107 BB3061GS 2 BOTTLE, Oil
Optional Accessories Not Included:
84883GS Cord Wrap
PARTS LIST – MAIN UNIT

10000EXL Extended Life Generator
20
EXPLODED VIEW – CONTROL PANEL