GENERAC 10000EXL User manual
10000EXL
GENERAC
Model No. 98014 (10,000 Watt AC Generator) Manual No. B4428 Revision 2 (8/11/1999)
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The Reliable Ones
Portable Generator Owner’s Manual
DANGER! This generator is designed for outdoor use only. Never use this generator inside any building
or enclosure including the generator compartment of a recreational vehicle (RV). Carbon monoxide
poisoning, fire and/or an explosion may result. No user performed modifications, including venting of
exhaust and/or cooling ventilation, will eliminate the danger. Always have at least two feet of clearance on
all sides of the generator even while operating the unit outdoors.
DANGER! You must isolate the generator from the electric utility by opening the electrical systems
main circuit breaker or main switch if this unit is used for backup power. Failure to isolate the generator
from the power utility may result in injury or death to electric utility workers and damage to the
generator due to a backfeed of electrical energy.
The Emission Control System for this generator is warranted for standards set by the
Environmental Protection Agency. For warranty information refer to the Engine Owners manual.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury or death.
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EQUIPMENT DESCRIPTION
This generator is an enginedriven, revolving field,
alternating current (AC) generator. It was designed to
supply electrical power for operating compatible
electrical lighting, appliance, tool and motor loads.
This manual contains information for a generator that
operates 120 and/or 240 Volt, single phase, 60Hz
devices that require up to 10,000 watts (10 kW) of
power that pull up to 83.3 Amps at 120 Volts or
41.7 Amps at 240 Volts.
CAUTION! Do not exceed the generators
wattage/amperage capacity. Add up the rated
watts of all devices you are connecting to
generator receptacles at one time. This total
should not be greater than 10,000 watts for this
generator. In most cases rated watts of the
electrical device can be found on the device
nameplate. If the device nameplate gives only
Volts and Amps, multiply Volts times Amps to
obtain watts (Volts x Amps = watts).
The generators revolving field is driven at about
3600 rpm by a twincylinder engine.
Every effort has been expended to make sure that the
information in this manual is both accurate and
current. However, Generac reserves the right to
change, alter or otherwise improve the product at any
time without prior notice.
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 frequency and/or voltage can damage
some connected electrical loads. Operating at
excessively low speeds imposes a heavy load
and, when adequate engine power is not
available, may shorten engine life.
SAFETY RULES
This generator set was designed and manufactured
for specific applications. Do not attempt to modify the
unit or use it for any application it was not designed
for. If you have any questions about your generators
application, ask your Dealer/Distributor or consult the
factory.
The manufacturer could not possibly anticipate every
circumstance that might involve a hazard. For that
reason warnings in the Manual and warnings on tags
or decals affixed to the unit are not allinclusive. If you
intend to handle, operate or service the unit by a
procedure or method not specifically recommended by
the manufacturer, first make sure that such a
procedure or method will not render this equipment
unsafe or pose a threat to you and others.
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
DANGER! You must isolate the generator
from the electric utility by opening the electrical
systems main circuit breaker or main switch if
this unit is used for backup power. Failure to
isolate the generator from the power utility
may result in injury or death to electric
utility workers and damage to the generator
due to a backfeed of electrical energy.
DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. Carbon
monoxide, if breathed in sufficient
concentrations, can cause
unconsciousness or death. Operate this
equipment outdoors where adequate
ventilation is available.
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other
reproductive harm.
WARNING:
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The generator produces a very powerful voltage that
can cause serious injury or death by electrocution.
Never touch bare wires or receptacles. Never permit
a child or any unqualified person to operate the
generator.
Never handle any kind of electrical cord or device
while standing in water, while barefoot or while
hands or feet are wet. Death or serious injury from
electrocution may result.
Use a ground fault circuit interrupter (GFCI) in any
damp or highly conductive area (such as metal
decking or steel work).
Never use worn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious
injury and property damage from electrical shock
may result.
Gasoline is highly FLAMMABLE and its vapors
are EXPLOSIVE. Never allow smoking, open
flames, sparks or heat in the vicinity while
handling gasoline. Avoid spilling gasoline on a hot
engine. Comply with all laws regulating storage and
handling of gasoline.
Do not overfill the fuel tank. Always allow room for
fuel expansion. If tank is overfilled, fuel can
overflow onto a hot engine and cause a FIRE or
an EXPLOSION.
Never store a generator with fuel in the tank where
gasoline vapors might reach an open flame, spark
or pilot light (as on a furnace, water heater, clothes
dryer). FIRE or an EXPLOSION may result.
The enginegenerator requires an adequate flow of
cooling air for its continued proper operation. Never
operate the unit inside any room or enclosure where
the free flow of cooling air into and out of the unit
might be obstructed. Allow at least 2 feet of clearance
on all sides of generator, even while operating unit
outdoors, or you could damage the unit.
Never start, or stop, the enginegenerator with
electrical loads connected to receptacles with the
connected devices turned ON. Start the engine and
let it stabilize before connecting any electrical loads.
Disconnect all electrical loads before shutting down
the generator.
Do not insert any object through cooling slots of the
engine. You could damage the unit or injure yourself.
Never operate the generator:
(a) in rain;
(b) in any enclosed compartment;
(c) if connected electrical devices overheat;
(d) if electrical output is lost;
(e) if engine or generator sparks;
(f) if flame or smoke is observed while unit is
running;
(g) if unit vibrates excessively.
GROUNDING THE
GENERATOR
The National Electric Code requires the frame and
external electrically conductive parts of the generator
be properly connected to approved earth ground.
Local electrical codes may also require proper
grounding of the unit. For this purpose, a ground lug
(Figure 1) is provided on the cradle.
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the ground lug screw
and to an earthdriven copper or brass grounding rod
(electrode) provides adequate protection against
electrical shock. However, local codes may vary
widely. Consult with a local electrician for grounding
requirements in your area. Be sure to keep the ground
wire attached while you connect the electrode.
Properly grounding the generator helps prevent
electrical shock if ground fault conditions exists in the
generator or in connected electrical devices. Proper
grounding also helps dissipate static electricity, which
often builds up in ungrounded devices.
Figure 1 Location of Ground Lug
Ground Lug
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Your generator requires some assembly and is ready
for use after it has been properly serviced with the
recommended oil and fuel.
If you have any problems with the assembly of your
generator, please call the Generator Helpline at
18002701408
IMPORTANT: Any attempt to run the engine before it
has been serviced with the recommended oil will
result in an engine failure.
TO REMOVE GENERATOR
FROM CARTON
Set the palleted carton on a rigid flat surface.
Carefully cut bands around the shipping carton.
Lift carton off the generator. Review Cold Weather
Operation on page 8.
Remove all packing material, carton fillers, etc.
Remove the generator from the shipping pallet.
CARTON CONTENTS
Check all contents. If any parts are missing or
damaged, call the Generator Helpline at
18002701408. Contents include:
10,000 Watt Generator
Owners Manual
Engine Manual
Owners Registration Card
2 Bottles of Engine Oil (28 oz.)
125 Volt, 30 Amp Plug
125 Volt, 20 Amp Plug
240 Volt, 30 Amp Plug
Battery Charge Cable
Oil Fill Funnel
Wheel Kit
ASSEMBLE WHEEL KIT
IMPORTANT: This wheel kit is not intended for
overtheroad use.
To install your wheel kit you need the following tool:
13 mm box, open end, or socket wrench
Install Wheel Kit as follows:
1. Place the bottom of the generator cradle on a flat,
even surface. It may help assembly if you
temporarily raise cradle on blocks.
2. Slide axle (Item 9) through both axle mounting
brackets on cradle frame, as shown in Figure 2.
3. Slide a wheel spacer (Item 10) over each end of
the axle.
4. Install the wheel (Item 11) as shown. Slide a flat
washer (Item 12) over the axle, then secure the
wheel with a retaining pin (Item 13).
NOTE: Be sure to install each wheel with the air
pressure valve on the outboard side.
5. Install the other wheel in the same manner.
6. Secure the vibration mount (Item 5) to the support
leg (Item 4) with a lock nut (Item 3), a flat washer
(Item 6) and a 30 mm long cap screw (Item 7).
7. Secure the support leg assembly to the cradle
with 20 mm long capscrews (Item 8) and lock nuts
(Item 3). If your unit has weldnuts assembled to
the cradle, assemble with 20 mm cap screws, lock
washers, and flat washers.
8 Position the handle (Item 1) on the cradle end
opposite the control panel, as shown. Attach the
handle with the cap screws (Item 2) and lock nuts
(Item 3).
9. Tighten all lock nuts with the 13 mm wrench.
Make sure all components are secure.
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CHECK BATTERY / ATTACH
NEGATIVE BATTERY WIRE
The battery on the generator is fully charged, sealed
and preinstalled except for the negative (black)
battery cable.
To install:
Cut off tie wrap on negative (black) cable attached
to the battery hold down.
Remove nut on the negative battery terminal.
Slide the negative battery cable over the screw on
the negative terminal (Figure 3).
Reattach nut and tighten.
Ensure the connections to the battery and generator
and tight and secure.
Figure 2 Assemble Wheel Kit
Figure 3 Negative Battery Connection
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KNOW YOUR GENERATOR
Read this owners manual and safety rules before operating your generator.
Compare the illustrations with your generator to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.
12 Volt DC Receptacle Use this receptacle with
battery charge cables to charge a 12 Volt battery.
120 Volt AC, 20 Amp Duplex Receptacle May be
used to supply electrical power for the operation of
120 Volt AC, single phase, 60 Hz, AC electrical
lighting, appliance, tool and motor loads.
120 Volt AC, 20 Amp Locking Receptacle May
be used to supply electrical power for the operation
of 120 Volt AC, 20 Amp, single phase, 60 Hz
electrical lighting, appliance, tool and motor loads.
120 Volt AC, 30 Amp Locking Receptacle May
be used to supply electrical power for the operation
of 120 Volt AC, 30 Amp, single phase, 60 Hz
electrical lighting, appliance, tool and motor loads.
120/240 Volt AC, 30 Amp Locking Receptacle
May be used to supply electrical power for the
operation of 120 and/or 240 Volt AC, 30 Amp, single
phase, 60 Hz electrical lighting, appliance, tool and
motor loads.
120/240 Volt AC, 50 Amp Receptacle May be
used to supply electrical power for the operation of
120/240 Volt AC, 50 Amp, single phase, 60 Hz
electrical loads.
Air Cleaner Used to limit the amount of dirt and
dust that gets in the engine.
Choke Lever Used when starting a cold engine.
Circuit Breakers (AC) Each receptacle is
provided with a 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.
Spark Arrestor Muffler (not shown) Exhaust
muffler lowers engine noise and is equipped with a
spark arrestor screen.
Start Button When pressed, cranks engine to start.
120 Volt AC, 20 Amp
Duplex Receptacle
Idle Control Switch
Ignition Switch
Choke Lever
120 Volt AC, 30 Amp
Locking Receptacle
120 Volt AC, 20 Amp
Locking Receptacle
120/240 Volt AC,
50 Amp Receptacle
Circuit Breakers (AC)
120/240 Volt AC, 30 Amp
Locking Receptacle
12 Volt DC Receptacle
Air Cleaner
Start Button
Grounding Lug
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BEFORE STARTING THE
ENGINE
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 10W40.
Select the oils viscosity grade according to your
expected operating temperature:
Above 40°F, use SAE 10W30 or SAE 30.
Below 40°F, use synthetic 5W20 or 5W30.
To add oil to the generator:
Make sure unit is on a level surface.
Clean around oil fill cap and remove it.
Remove oil dipstick, wipe clean and reinsert in
engine.
Fill engine with oil till it reaches the full mark on the
dipstick. Stop occasionally to check oil level. Do not
overfill.
Install oil dipstick.
Install oil fill cap. Hand tighten securely.
CAUTION! Any attempt to crank or start the
engine before it has been properly serviced
with the recommended oil results in an engine
failure.
NOTE: The generators revolving field rides on a
prelubricated and sealed ball bearing that requires
no additional lubrication for the life of the bearing.
Add Gasoline
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.
DANGER! Do not overfill the fuel tank.
Always leave room for expansion.
Use regular UNLEADED gasoline in the generator.
DO NOT use premium gasoline. DO NOT mix oil
with gasoline. DO NOT overfill the gas tank.
Clean area around fuel fill cap; remove cap.
Fill fuel tank with clean, fresh, unleaded gasoline.
Be careful not to overfill. Allow 1/2" of tank space for
fuel expansion (Figure 4).
Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in essential fuel system parts such as
the carburetor, fuel filter, fuel hose or tank during
storage. Also, experience indicates that
alcoholblended 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 13. Never use
engine or carburetor cleaner products in the fuel tank
or permanent damage may occur.
10W30, SAE 30
Synthetic 5W20, 5W30
Figure 4 Fuel Level
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OPERATING THE
GENERATOR
CAUTION! Never start, or stop, the generator
with electrical loads connected to the
receptacles.
Starting the Engine
Disconnect all electrical loads from the generator.
Make sure the Idle Control Switch is turned OFF.
Open the fuel shutoff 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 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 two
minutes after starting.
Plug in and turn on the desired 120 or 240 Volt AC,
single phase, 60 Hertz electrical loads. DO NOT
OVERLOAD THE GENERATOR. Add up the rated
watts (or Amps) of all loads to be connected at one
time. This total should not be greater than the rated
wattage/amperage capacity of the generator. See
page 12, Dont Overload the Generator for details.
Stopping the Engine
Disconnect all electrical loads.
Turn OFF idle control.
Run engine at noload for a few minutes.
Set the Ignition Switch to the Stop (o) position.
Close the fuel shutoff valve.
Operating Automatic Idle Control
This switch is designed to greatly improve fuel
economy. When this switch is turned ON, the engine
will only run at its normal high governed engine speed
when an electrical load is connected. When an
electrical 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.
Cold Weather Operation
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your Generac
generator may experience icing of the carburetor
and/or the crankcase breather system.
In an emergency, use the original shipping box as a
temporary shelter:
Cut off all flaps
Cut out one of the long sides of the box to expose
exhaust side of unit. Ensure a minimum of two feet
clearance between open side of box and nearest
object.
Cut appropriate slots to access receptacles of unit.
Start unit, then place box over it, as shown in
Figure 5.
IMPORTANT!: Remove shelter when temperature is
above 40°F [4°C].
Figure 5 Typical Temporary Shelter (Unit may vary)
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