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10000EXL
GENERAC
Model No. 98014 (10,000 Watt AC Generator) Manual No. B4428 Revision 2 (8/11/1999)
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Problems?
Questions?
Before taking your unit
back to the store,
call the generator
helpline at
1-800-270-1408
MF 85 CT
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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Generac Portable Products 10000EXL Generator
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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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Generac Portable Products 10000EXL Generator
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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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Charging a Battery
Your generator has the capability of recharging a
discharged 12 Volt automotive or utility style storage
battery. Do not use the unit to charge any 6 Volt
batteries. Do not use the unit to crank an engine
having a discharged battery.
DANGER! Storage batteries give off explosive
hydrogen gas while recharging. An explosive
mixture will remain around the battery for a
long time after it has been charged. The
slightest spark can ignite the hydrogen and
cause an explosion. Such an explosion can
shatter the battery and cause blindness or
other serious injury.
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 electrolyte fluid is an
extremely caustic sulfuric acid solution that can
cause severe burns. If spill occurs flush area
with clear water immediately.
To recharge 12 Volt batteries, proceed as follows:
Check fluid level in all battery cells. If necessary,
add ONLY distilled water to cover separators in
battery cells. Do not use tap water.
If the battery is equipped with vent caps, make sure
they are installed and are tight.
If necessary, clean battery terminals.
Connect battery charge cable connector plug to
panel receptacle identified by the words
12VOLT 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
manufacturers instructions carefully. Generally, a
battery is considered to be at 100% state of charge
when specific gravity of its fluid (as measured by
hydrometer) is 1.260 or higher.
RECEPTACLES
This generator is equipped with the following
receptacles:
120 Volt, 20 Amp, Duplex
Receptacle
Each of these outlets is protected against overload by
20 Amp pushtoreset type circuit breakers. Use each
outlet to operate 120 Volt, 60 Hz, single phase loads
requiring 2400 (2.4 kW) watts at 20 Amps of current
(Figure 6).
Figure 6 120 Volt, 20 Amp Duplex Receptacle
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120 Volt, 20 Amp Locking Type
Receptacle
Use a NEMA L520 plug with this receptacle.
Connect a 3wire cord set rated 125 Volts at 20 AC
Amps to the plug (Figure 7).
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 pushtoreset circuit breaker.
120 Volt, 30 Amp Locking Type
Receptacle
Use a NEMA L530 plug with this receptacle.
Connect a 3wire cord set rated for 125 Volts at 30
AC Amps to the plug (Figure 8).
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 pushtoreset circuit breaker.
Figure 7 120 Volt, 20 Amp, Locking Receptacle
Figure 8 120 Volt, 30 Amp, Locking Receptacle
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Generac Portable Products 10000EXL Generator
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120/240 Volt, 30 Amp Locking Type
Receptacle
Use a NEMA L1430 plug with this receptacle.
Connect a 4wire cord set rated 250 Volt at 30 AC
Amps (or greater) (Figure 9). You can use the same
4wire cord if 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 pushtoreset
circuit breaker.
240 Volt, 50 Amp Receptacle
Use a NEMA 1450 plug with this receptacle.
Connect a 4wire cord set rated for 250 Volts at 50
AC Amps to the plug (Figure 10).
Use this receptacle to operate 240 Volts AC, 60 Hz,
single phase loads requiring up to 10,000 watts
(10.0 kW) of power.
CAUTION! Although this outlet states it has a
240 Volt 50 Amp rating (up to 12,500 watts),
the generator is only rated for 10,000 watts.
Powering loads that exceed the wattage/
Amperage capacity of the generator can
damage it or cause serious injuries.
Figure 9 120/240 Volt, 30 Amp, Locking Receptacle
Figure 10 120/240 Volt, 50 Amp, Receptacle
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DONT OVERLOAD THE
GENERATOR
Overloading a generator in excess of its rated wattage
capacity can result in damage to generator and to
connected electrical devices. Observe the following, to
prevent overloading the unit:
Add up the total wattage of all electrical devices to
be connected at one time. This total should NOT be
greater than the generators wattage capacity.
The rated wattage of lights can be taken from light
bulbs. The rated wattage of tools, appliances and
motors can usually be found on a data plate or
decal affixed to the device.
If the appliance, tool or motor does not give
wattage, multiply Volts times ampere rating to
determine watts (volts x amps = watts).
Some electric motors, such as induction types,
require about three times more watts of power for
starting than for running. This surge of power lasts
for only a few seconds when starting such motors.
Be sure you allow for this high starting wattage
when selecting electrical devices to connect to your
generator. First figure the watts needed to start the
largest motor. Add to that figure the running watts of
all other connected loads.
Items in Figure 11 below are provided to help you to
determine how many items the generator can
operate at one time.
Device .............................................Running Watts
*Air Conditioner (12,000 Btu)..........................1700
*Air Conditioner (24,000 Btu)..........................3800
*Air Conditioner (40,000 Btu)..........................6000
Battery Charger (20 Amp) ................................500
Belt Sander (3") ..............................................1000
Chain Saw ......................................................1200
Circular Saw (61/2")...........................800 to 1000
*Clothes Dryer (Electric) .................................5750
*Clothes Dryer (Gas) ........................................700
*Clothes Washer.............................................1150
Coffee Maker ..................................................1750
*Compressor (1 HP) .......................................2000
*Compressor (3/4 HP) ....................................1800
*Compressor (1/2 HP) ....................................1400
Curling Iron .......................................................700
*Freezer............................................................700
*Dehumidifier ....................................................650
Disc Sander (9") .............................................1200
Edge Trimmer...................................................500
Electric Blanket.................................................400
Electric Nail Gun.............................................1200
Electric Range (per element)..........................1500
Electric Skillet .................................................1250
*Furnace Fan (3/5 HP) .....................................875
*Garage Door Opener ...........................500 to 750
Hair Dryer .......................................................1200
Hand Drill .............................................250 to 1100
Device .............................................Running Watts
Hedge Trimmer.................................................450
Impact Wrench..................................................500
Iron .................................................................1200
*Jet Pump .........................................................800
Lawn Mower ...................................................1200
Light Bulb..........................................................100
Microwave Oven..................................700 to 1000
*Milk Cooler ....................................................1100
Oil Burner on Furnace ......................................300
Oil Fired Space Heater (140,000 Btu) ..............400
Oil Fired Space Heater (85,000 Btu) ................225
Oil Fired Space Heater (30,000 Btu) ................150
*Paint Sprayer, Airless (1/3 HP)........................600
Paint Sprayer, Airless (handheld) .....................150
Radio .......................................................50 to 200
*Refrigerator .....................................................700
Slow Cooker .....................................................200
*Submersible Pump (11/2 HP) .....................2800
*Submersible Pump (1 HP) ............................2000
*Submersible Pump (1/2 HP) .........................1500
*Sump Pump .......................................800 to 1050
*Table Saw (10") ................................1750 to 2000
Television...............................................200 to 500
Toaster...............................................1000 to 1650
Weed Trimmer..................................................500
* Allow 3 times the listed watts for starting these devices.
Figure 11 Wattage Reference Guide
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GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure
that all periodic maintenance tasks are completed on
a timely basis; that all discrepancies are corrected;
and that the unit is kept clean and properly stored.
Never operate a damaged or defective generator.
Engine Maintenance
See your engine owners manual for information
needed to maintain and service the engine.
Generator Maintenance
Generator maintenance consists of keeping the unit
clean and dry. Operate and store the unit in a clean
dry environment where it will not be exposed to
excessive dust, dirt, moisture or any corrosive vapors.
Make sure the cooling air slots in the generator do not
become clogged with snow, leaves or other foreign
material.
Check cleanliness of the generator frequently and
clean when dust, dirt, oil, moisture or other foreign
substances are visible on its exterior surface.
NOTE: DO NOT use a garden hose to clean
generator. Water can enter the engine fuel system
and cause problems. In addition, if water enters the
generator through the cooling air slots, some water
will be retained in the voids and cracks of the rotor
and stator winding insulation. Water and dirt buildup
on the generator internal windings will eventually
decrease the insulation resistance of these windings.
To Clean the Generator
Use a damp cloth to wipe exterior surfaces clean.
Soft, bristle brush may be used to loosen caked on
dirt or oil.
A vacuum cleaner may be used to pick up loose dirt
and debris.
Low pressure air (not to exceed 25 psi) may be
used to blow away dirt. Inspect cooling air slots and
opening on generator. These openings must be kept
clean and unobstructed.
STORAGE INSTRUCTIONS
The generator should be started at least once every
seven days and allowed to run at least 30 minutes. If
this cannot be done and you must store the unit for
more than 30 days, use the following guidelines to
prepare it for storage.
Generator Storage
Clean the generator as outlined in To Clean the
Generator.
Check that the cooling air slots and openings on the
generator are open and unobstructed.
Remove the negative battery cable from the battery
to prevent the battery from being depleted.
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.
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.
SPECIFICATIONS
Rated Maximum Continuous
AC Power Output.......................... 10,000 watts
(10 kW)
Rated Voltage .................................. 120/240 Volts
Rated Maximum Current
at 240 Volts................................... 41.7 AC Amperes
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 ..................................... Y50N18LA3
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Generac Portable Products 10000EXL Generator
14
Problem Cause Correction
Engine is running, but no 1. One of the circuit breakers is open. 1. Reset circuit breaker.
AC output is available. 2. Fault in generator. 2. Contact Generac service facility.
3. Poor connection or defective 3. Check and repair.
cord set.
4. Connected device is bad. 4. Connect another device that
is in good condition.
Engine runs good at no-load but bogs 1. Short circuit in a connected load. 1. Disconnect shorted electrical
down" when loads are connected. load.
2. Engine speed is too slow. 2. Contact Generac service facility.
3. Generator is overloaded. 3. See Don't Overload the
Generator, page 12.
4. Shorted generator circuit. 4. Contact Generac service facility.
Engine will not start; or starts 1. Run/Stop Switch set to STOP. 1. Set switch to RUN.
and runs rough. 2. Dirty air cleaner. 2. Clean or replace air cleaner.
3. Out of gasoline. 3. Fill fuel tank.
4. Stale gasoline. 4. Drain gas tank; fill with fresh fuel.
5. Spark plug wire not connected 5. Connect wire to spark plug.
to spark plug.
6. Bad spark plug. 6. Replace spark plug.
7. Water in gasoline. 7. Drain gas tank; fill with fresh fuel.
8. Overchoking. 8. Open choke fully and crank engine.
9. Excessively rich fuel mixture. 9. Contact Generac service facility.
10.Intake valve stuck open or closed. 10. Contact Generac service facility.
11.Engine compression lost. 11. Contact Generac service facility.
12.Failed battery. 12. Replace battery.
Engine shuts down during operation. 1. Out of gasoline. 1. Fill fuel tank.
2. Low oil level. 2. Fill crankcase to proper level.
Engine lacks power. 1. Load is too high. 1. See Don't Overload the
Generator, page 12.
2. Dirty air filter. 2. Replace air filter.
Engine hunts or falters. 1. Choke is opened too soon. 1. Move choke to halfway position until
engine runs smoothly.
2. Carburetor is running too rich 2. Contact Generac service facility.
or too lean.
TROUBLESHOOTING
Page 15
Generac Portable Products 10000EXL Generator
15
NOTES
Page 16
Generac Portable Products 10000EXL Generator
16
SCHEMATIC
Page 17
Generac Portable Products 10000EXL Generator
17
WIRING DIAGRAM
Page 18
Generac Portable Products 10000EXL Generator
18
GENERATOR EXPLODED VIEW
Page 19
Generac Portable Products 10000EXL Generator
19
Item Part # Qty Description
1 NSP 1 ENGINE, Generac Power
Systems
2 B93074 1 SHIELD, Heat
3 A77304 2 SUPPORT, Engine
4 B90916 1 STATOR, Heat Shield
5 80270 1 VALVE, Fuel Shut-Off
6 78299 1 BUSHING, Fuel Valve
7 B4325 1 CAP, Fuel Gauge
8 38353 8 MOUNTS, Vibration
9 78831B 4 CAPSCREW, M6-1.0 x 60mm
10 B1696 1 TANK, Fuel
11 AB4137 1 CRADLE
12 83465 4 GROMMET, Fuel Tank
Mounting
13 56892 3 CRIMPTITE, 10-24 x 3/8"
14 23152 8 CAPSCREW, 3/8-16 x 3/4"
Lg.
15 22237 16 WASHER, 3/8" Lock
16 22241 8 NUT, 3/8-16 Hex
17 75246 4 SELF-TAPPING, 3/8-16 x 1-
1/4" Lg.
18 22129 2 WASHER, M8-Lock
19 39253 2 CAPSCREW, M8-1.25 x 16
20 B4433 1 ASSEMBLY, Control Panel
21 96867 1 ASSEMBLY, Stepper Motor
22 B4489 1 BATTERY
23 185-53621 1 ASSEMBLY, Ground Wire
24 86292 11 CAPSCREW, #10 Self Driller
25 23762 1 WASHER, #10 Shakeproof
26 79661P 1 DECAL, Engine
28 92982 1 DECAL, Danger
29 B4478 1 DECAL, Control Panel
30 B4479 1 DECAL, Side Panel
31 78817 1 DECAL, Data Plate
32 77816 1 DECAL, Caution Hot Muffler
33 95349 1 PLATE, Adjust
34 95348 1 BELL, Crank
35 20566 1 DECAL, 1-800
36 B4986 1 DECAL, Ground
37 93826 1 DECAL, Start Instruction
38 75477 2 SCRW, M5-0.8 x 20Lg.
Phillips Hd.
39 96716 3 WASHER, Nylon
40 95921 1 LINKAGE, Bell Crank to
Throttle
41 95920 1 LINKAGE, Stepper Motor to
Bell Crank
Item Part # Qty Description
42 33141 1 CAPSCREW, #10-32 x 3/4"
Hex Hd.
43 51713 1 WASHER, M5 Flat
44 49226 1 WASHER, M5 Lock
45 62265 2 GROMMET, Rubber
46 A84650 1 TRAY, Battery
47 A44951 1 BAR, Battery Hold-Down
48 B4832 2 SCREW, 1/4-20" NC x 7.5"
Hx Hd. Mach.
49 22097 7 WASHER, 1/4" Lock
50 22127 4 NUT, ¼ "-20 Hex
51 22261 1 SHAKEPROOF, 3/8" Internal
52 77282 1 SWITCH, Starter
53 78289 1 BRACKET, Starter Switch
54 22287 2 CAPSCREW, 1/4"-20 x 3/4"
55 90914 1 ADAPTER, Oil Filter
56 70185 1 FILTER, Oil
57 60108 1 SWITCH, Low Oil Pressure
58 40945 3 CAPSCREW, M6-1.0 x 20
Socket Hd
59 68548 1 GASKET, Oil Filter Adapter
60 73054 1 DECAL, Fuel Shut Off
61 B93841 1 SHIELD, Oil Sensor Heat
62 46852 2 TAPTITE, #10-32 x 1/4"
63 22473 2 WASHER, 1/4" Flat
64 182-53621 1 WIRE ASSEMBLY,Starter
65 196-53621 1 WIRE ASSEMBLY, Battery
66 197-53621 1 WIRE ASSEMBLY, Ground
67 96378 1 SPACER
68 96717 1 SPRING
69 52618 2 HHCS, M5 - 0.8 x 12 Lg.
70 52856 2 NUT, M5 Flange Lock
71 23897 2 WASHER, #10 - M5 Flat
Items Not Shown
B4428 1 Generator Owners Manual
B4572 1 Video
37806 1 125V 30A Plug
43438 1 120/240V 30A Plug
65787 1 Battery Charge Cable
93568 1 125V 30A Plug
BB3061 2 Oil Bottle (28oz)
Available Accessories
Storage Cover
Cord Wrap
GENERATOR PARTS LIST
Page 20
Generac Portable Products 10000EXL Generator
20
ROTOR AND STATOR EXPLODED VIEW
Page 21
Generac Portable Products 10000EXL Generator
21
Item Part # Qty Description
1 NSP 1 ENGINE, Generac Power Systems
2 B55277 1 GUARD, Center
3 B71791 1 PLATE, Cover
4 46852 8 SCREW, No. 10-32 x 1/4"
5 22129 11 WASHER, 5/16" Lock
6 86307 2 CAPSCREW, 5/16"-24 x 3/4" Hex Head
7 B55275 3 GUARD, Fan
8 BB2700 1 CASTING, Adapter
9 24114 4 NUT, 5/16-24" Hex
10 22237 4 WASHER, 3/8" Lock
11 23152 4 CAPSCREW, 3/8"-16 x 3/4" Hex Head
12 92381 1 ASSEMBLY, Rotor 10-KW
13 65791 1 BEARING
14 50190 1 WASHER, 5/16" Flat
15 53365 1 CAPSCREW, 5/16"-24 x 10.75" Hex Head
16 B94983 1 ASSEMBLY, Stator 10-KW
17 B49410A 1 CARRIER, Rear Bearing
18 77324 4 CAPSCREW, 5/16"-24 x 12.25 Hex Head
19 B77303 1 SUPPORT, Alternator
20 66849A 2 SCREW, M5-0.8 x 20 Taptite
21 96423 1 SCREEN, Finger Guard
22 92769 1 ASSEMBLY, Power Regulator
ROTOR AND STATOR PARTS LIST
Page 22
Generac Portable Products 10000EXL Generator
22
Item Part # Qty Description
1 95909 1 PANEL, Control
2 95906 1 BOX, Control
3 43437 1 OUTLET, 120/240V, 30 Amp
Locking
4 68759 1 OUTLET, 120V, 20 Amp
Duplex
5 68868 1 OUTLET, 120V, 30 Amp
Locking
6 96476 1 BOARD, System Control
7 96067 1 ASSEMBLY, Engine Harness
8 90576 1 GROMMET, Rubber
9 B4262 1 OUTLET, 120/240V 50 Amp
10 87962 1 CIRCUIT BREAKER
11 93929 4 STAND OFF, 1/2" Hex
12 51715 12 NUT, M4 - 0.7 Hex
13 22264 16 LOCK WASHER, #8 M4
14 43181 4 SCREW, M3 - .05 x 10mm
16 38150 12 FLAT WASHER, #8
17 23365 12 WASHER, #8 Shakeproof
18 90418 1 OUTLET, 12V DC Snap
19 43182 8 LOCK WASHER, M3
Item Part # Qty Description
20 75207-A 2 CIRCUIT BREAKER, 30 Amp
21 78653 1 SWITCH, Run - Stop
22 93986 4 SCREW, M3 - 0.5 x 20mm
23 91526 4 SCREW, M5 - .08 x 12mm
24 49226 5 LOCK WASHER, M5
25 23897 5 FLAT WASHER, M5
26 75207 2 CIRCUIT BREAKER, 20 Amp
27 74190 1 OUTLET, 120V/20A
28 92953 1 BLOCK, 50 Amp, 3 - Terminal
29 80077 4 SCREW, M4 x 20mm
30 94117 1 BOARD, Idle Control
31 84028 1 TRANSFORMER, Idle Control
32 65795 2 RECTIFIER, Battery Charge
33 84135 1 GROMMET, Rubber
34 20911 1 SCREW, M5 - 0.8 x 30mm
35 64525 4 STAND OFF, 3/4" Hex
36 64526 8 SCREW, #6-32 x 3/8" Tap
37 82538 1 SWITCH, On - Off
38 96471 1 ASSEMBLY, Extension Cord
39 51716 1 HEX NUT, M5 - 0.8
40 B4455 2 CIRCUIT BREAKER, 45 Amp
CONTROL PANEL EXPLODED VIEW AND PARTS LIST
Page 23
Generac Portable Products 10000EXL Generator
23
Item Part # Qty Description
1 93393B 1 HANDLE, Wheel Kit
2 39287 4 HHCS, M8 - 1.25 x 45 Lg
3 52858 7 NUT, Locking M8 - 1.25
4 93394 1 LEG, Mounting Support
5 27007 1 MOUNT, Vibration
6 22145 1 FLAT WASHER, 5/16 - M8
7 42909 1 HHCS, M8 - 1.25 x 30 Lg.
8 39253 2 HHCS, M8 - 1.25 x 20 Lg.
9 93693B 1 AXLE, 5/8 Zinc
10 89635 2 SPACER, Wheel
11 89742 2 WHEEL, Assy 12" Dia.
12 22247 2 WASHER, Flat M8
13 87005 2 PIN, Retaining
WHEEL KIT EXPLODED VIEW AND PARTS LIST
Page 24
LIMITED WARRANTY
FOR OVERHEAD VALVE V-TWIN ENGINE-DRIVEN PORTABLE GENERATORS
GENERAC PORTABLE PRODUCTS (hereafter referred to as the COMPANY) warrants to the original purchaser
that all components originally equipped with the generator, excluding the engine, for its portable generator will be
free from defects in materials or workmanship for the items and period set forth below from the date of original
purchase. This warranty is not transferable and applies only to portable generators driven by an overhead valve
V-Twin engine.
Consumer* Commercial*
Alternator 2 years (2nd year parts only) 1 year
Engine Warranted solely by the engine manufacturer
With the exception of European Community Countries, all units bound for export shall be warranted for
One (1) Year in Consumer applications, and 90 days in Commercial applications as defined below.
*NOTE: For the purpose of this warranty "consumer use" means personal residential household use by
original purchaser. This warranty does not apply to units used for Prime Power in place of utility.
"Commercial Use" means all other uses, including rental, construction, commercial and income
producing purposes. Once a generator has experienced commercial use, it shall thereafter be considered
a commercial use generator for the purposes of this warranty.
During said warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination
by the COMPANY, is found to be defective under normal use and service**. Starting batteries are not warranted
by the COMPANY. All transportation costs under warranty, including return to the factory if necessary, are to be
borne by the purchaser and prepaid by the purchaser. This warranty does not cover normal maintenance and
service and does not apply to a generator set, alternator, or parts which have been subjected to improper or
unauthorized installation or alteration, misuse, negligence, accident, overloading, overspeeding, improper
maintenance, repair or storage so as, in the COMPANYs judgement, to adversely affect its performance and
reliability.
**NORMAL WEAR: As with all mechanical devices, the generator needs periodic parts service and
replacement to perform well. This warranty will not cover repair when normal use has exhausted the life
of a part or generator.
THERE IS NO OTHER EXPRESS WARRANTY. THE COMPANY HEREBY DISCLAIMS ANY AND
ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE
DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO
THE TIME PERIOD AS SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR
CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES UNDER ANY AND ALL WARRANTIES
IS EXCLUDED. THE COMPANY ALSO DISCLAIMS ANY RESPONSIBILITY FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SUCH AS THE LOSS OF TIME OR THE USE OF THE POWER
EQUIPMENT, OR ANY COMMERCIAL LOSS DUE TO THE FAILURE OF THE EQUIPMENT: AND
ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of
incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty
gives you specific legal rights and you may also have other rights, which vary from state to state.
For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Warranty
service can be performed only by a COMPANY authorized service facility. This warranty will not apply to service
at any other facility. At the time of requesting warranty service, evidence of original purchase date must be
presented.
GENERAC PORTABLE PRODUCTS
Jefferson, Wisconsin 53549
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