Owner’s Manual
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Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
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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 TO YOUR
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
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.
12 Volt DC Receptacle — Use this receptacle with
battery charge cables to charge a 12 Volt 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
7
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-off Valve
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 120 Volt 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 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 “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
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