GENERAC
The Reliable Ones
10000EXL
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 system’s 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 Owner’s manual.
|
|
|
|
Problems? |
|||
|
|
Questions? |
|||||
|
Before |
|
|
|
|||
|
|
back taking |
|||||
|
|
call the the your unit |
|||||
|
|
|
|
to |
|
|
store, |
1 |
|
|
|
|
|
|
|
- |
helplinegenerator |
||||||
|
800 |
|
|
|
at |
||
M |
|
- |
|
|
|
||
–F |
|
270 |
|
|
|||
|
|
|
8–5 |
- |
|
||
|
|
|
|
|
1408 |
||
|
|
|
|
|
|
CT |
|
Model No. 9801–4 (10,000 Watt AC Generator) Manual No. B4428 Revision 2 (8/11/1999) Visit our Generac website: www.generac–portables.com
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.
Generac Portable Products 10000EXL Generator
EQUIPMENT DESCRIPTION
This generator is an engine–driven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, appliance, tool and motor loads. This manual contains information for a generator that operates 120 and/or 240 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 generator’s 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 generator’s revolving field is driven at about 3600 rpm by a twin–cylinder engine.
Every effort has been expended to make sure that the information in this manual is both accurate and 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 generator’s application, ask your Dealer/Distributor or consult the factory.
The manufacturer could not possibly anticipate every circumstance that might involve a hazard. For that reason warnings in the Manual and warnings on tags or decals affixed to the unit are not all–inclusive. If you intend to handle, operate or service the unit by a procedure or method not specifically recommended by the 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.
WARNING:
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
DANGER! You must isolate the generator from the electric utility by opening the electrical system’s 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.
2
Generac Portable Products 10000EXL Generator
•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 engine–generator requires an adequate flow of cooling air for its continued proper operation. Never operate the unit inside any room or enclosure where the free flow of cooling air into and out of the unit might be obstructed. Allow at least 2 feet of clearance on all sides of generator, even while operating unit outdoors, or you could damage the unit.
•Never start, or stop, the engine–generator 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.
Figure 1 — Location of Ground Lug
Ground Lug
Generally, connecting a No. 12 AWG (American Wire Gauge) stranded copper wire to the ground lug screw and to an earth–driven copper or brass grounding rod (electrode) provides adequate protection against 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.
3
Generac Portable Products 10000EXL Generator
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 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 1–800–270–1408. Contents include:
•10,000 Watt Generator
•Owner’s Manual
•Engine Manual
•Owner’s 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 over–the–road 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.
8Position 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.
4
Generac Portable Products 10000EXL Generator
Figure 2 — Assemble Wheel Kit
CHECK BATTERY / ATTACH Figure 3 — Negative Battery Connection
NEGATIVE BATTERY WIRE
The battery on the generator is fully charged, sealed and pre–installed 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.
5
Generac Portable Products 10000EXL Generator
KNOW YOUR GENERATOR
Read this owner’s manual and safety rules before operating your generator.
Compare the illustrations with your generator to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.
Circuit Breakers (AC)
Ignition Switch
Idle Control Switch
120 Volt AC, 20 Amp
Duplex Receptacle
12 Volt DC Receptacle
120 Volt AC, 20 Amp
Locking Receptacle
120 Volt AC, 30 Amp
Locking Receptacle
120/240 Volt AC, 30 Amp
Locking Receptacle
Start Button
Air Cleaner
Choke Lever
120/240 Volt AC,
50 Amp Receptacle
Grounding Lug
12 Volt DC Receptacle — Use this receptacle with battery charge cables to charge a 12 Volt battery.
120 Volt AC, 20 Amp Duplex Receptacle — May be used to supply electrical power for the operation of 120 Volt AC, single phase, 60 Hz, AC electrical 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.
6
Generac Portable Products 10000EXL Generator
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 10W–40.
Select the oil’s viscosity grade according to your expected operating temperature:
10W–30, SAE 30
Synthetic 5W–20, 5W–30
•Above 40°F, use SAE 10W–30 or SAE 30.
•Below 40°F, use synthetic 5W–20 or 5W–30.
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 generator’s revolving field rides on a pre–lubricated and sealed ball bearing that requires no additional lubrication for the life of the bearing.
Add 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).
Figure 4 — Fuel Level
• 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 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 13. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur.
7
Generac Portable Products 10000EXL Generator
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 shut–off valve.
•Set the Ignition Switch to the On (–) position.
•Pull choke control out to close choke. Note: If engine is warm, you may not need as much choking.
Note: Make sure the idle control switch is “Off” before starting the engine.
For Electric Start:
•Press electric starter switch until engine 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, “Don’t Overload the Generator” for details.
Stopping the Engine
•Disconnect all electrical loads.
•Turn OFF idle control.
•Run engine at no–load for a few minutes.
•Set the Ignition Switch to the Stop (o) position.
•Close the fuel shut–off valve.
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)
8
Loading...