Generac 9801-7 Portable Generator User Manual
Contents
1. by Briggs amp Stratton POWER PRODUCTS 108 44A 44A CB tA AUTN RESET 45A 45A 30A 30A 20A 80A 20A CB CB CB CB CB CB CB CB Ht 0 s 18 13 44A 44 na 1A 50V S0A MB 22 120 240V START STOP oO O O 30A 120V 30A 120V 20A 44C 120V 20A AC 15 SWITCH 44 Sy T CAUTINN A TUTLET TAB 84 1 1 MUST BE m R BRTKEN NFF IF UTLET IS 83 s Yes REPLACED n5 ON OFF IDLE CINTRTL YA 18 SWITCH 2 am 1 n 22 O m 83 0 GRN 44 THROTTLE SR CONTROL 13 Ja 55 STEPPER i ae MOTOR 55 J3 STEPPER I 55 22 155 MnTIR 0 GRN 156 8 chm RESISTIR O O C555 13 ry E ri 55 8s VATI 18V 10A D C 11 55 BARD J 84 84 v 4 D P 156 4 r83 83 15 Ry L 15s LS Je u D Bu 13 28 E Fs uc 18 55 BATTERY 18 ee pe rut CHARGE es TIME m 7 RECTIFIER L S mess a DELAY OO UH 66 RELAY 55 TERMINAL BLOCK Q 25 ohm RESISTOR CHNTRTL PANEL 22 25 WATT eH ea aal 13 13 ss 18 0 13 GRN VU samp LOW HIL 800v SWITCH DINDE x LS D IGNITINN SYSTEM DINDE 9 10 AMP ISD 13 x zal2. 10A CB O 904 OUS 15 6E a 13 1 55 13 13 13 kH 66 BRIDGE 1 RECTIFIER 55 77 FULL WAVE F sanp 55 RECTIFIER ANANA n amp DINDE FIELD FIELD EY sue EE RESISTOR a Fall 55 t p PH 77 OTT TN 13 55 EXCITATINN CHIL i 12VDC FLOAT RESISTOR T CHARGER 13 INPUT CAPACITIR 6A A SS ifr 13 13A 13 I 2 2 Ene POWER POWER BATTERY WINDING WINDING 13 55 WHT BRN BLK BLU 22 e ee Q o 11 44 13 ON OFF IDLE CONTROL da SWITCH ig TDR LL pe 2 LJ 44 22 L 55 42 STEPPER aa Ba 44 11 T MTIR IDLE 4 X emri 84 83 EE BrARD J7 155 ollelelealo 156 155 156 Js J6 156 l 22 155 a HIL ee 193 al ES RREssure e SWITCH 156 TSD i 18A SPARK 18A PLUG 2 ENG IGNITINN 304 CB SPARK PLUG dL 81 ENG IGNITIHN 11A i 30A 224 CB L WeZAewea4ov ius 30 oy HA 5sV T 44A 10000EXL Extended Life Generator GENERAC Portable Products
3. ENGINE SHIELD Heat SUPPORT Engine SHIELD Heat VALVE Fuel Shut Off BUSHING Fuel Valve CAP Fuel Tank MOUNTS Vibration SCREW ASSY Tank Fuel Includes Items 5 amp 6 CRADLE GROMMET Fuel Tank Mounting SCREW Wing SCREW WASHER Lock NUT DECAL Caution Hot Muffler WASHER SHIELD Heat ASSY Control Panel see pages 20 21 ASSY Wire Ground SCREW SCREW WASHER WASHER DECAL 1 800 DECAL Ground DECAL Danger DECAL Unit NUT Lock PLUG Dome DECAL Start Instructions SCREW SCREW DECAL Fuel Shut Off ALTERNATOR see page 23 U CHANNEL ASSY Stepper Motor BATTERY SCREW WASHER Lock BRACKET Battery Tie Down J BOLT CABLE Battery Positive CABLE Battery Negative WASHER WASHER Lock NUT Lock NUT Nylok SCREW NUT WASHER SCREW WASHER Item Part 106 107 55934TGS 55934GGS 22511GS 96832GS 52618GS B4794GS 33141GS 30340GS 48031CGS 62265GS 95349GS 96717GS 95921GS 75477GS 96716GS 95348GS 96378GS 51713GS 49226GS 95920GS 22287GS 188987GS 23762GS 77282GS 189302AGS 22097GS 22127GS 186102GS 188989GS 189198GS 58359GS 189484GS 191460GS B4605GS BB5586GS 187104GS B4135GS 39287GS B4177GS 49820GS 43438GS 93568GS 37806GS 189505GS B4767GS 65787GS 189482GS 189481 GS 189506GS B3518GS BB3061GS 10000EXL Extended Life Generator GENER AC by Briggs amp Stratton POWER PRODUCTS Qty Descript
4. 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 and install the wheel kit as follows 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 amp 5 Remove the wooden blocks Support Leg ____ Flat Washer 1 Lock Washer 20mm Cap Screw 30mm Cap Screw Washer E Ring 10000EXL Extended Life Generator GENERAC 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
5. 13 SPARK STATHR EUG at GRN DC FLOAT CHARGER a GRLUND TII REAR v SPARK BEARING CARRIER PLUG 2 134 9 B OC 0 1 STARTER 13 ELECTRIC UA START SWITCH 4 mi 55 p cu Tn FRAME suPPLIEp GRTUND BATTERY ortable Products by Briggs amp Stratton POWER PRODUCTS EXPLODED VIEW MAIN UNIT DETAIL OF JACK ASSEMBLY COAXIAL DC To Stepper Motor 10000EXL Extended Life Generator DETAIL OF ELECTRIC START SWITCH TO STARTER Ta RBC TO TERMINAL ON BATTERY muc gem T 5 PARTS LIST MAIN UNIT Item Part NSP JB4509AGS A77304GS JB5567GS 80270GS 78299GS B4325GS 38353GS 7883 I BGS 10 BI997GS ll AI89487GS 12 83465GS 13 87680GS 14 23152GS 15 22237GS 16 22241GS 17 77816GS I8 22131GS 19 J93074GS 20 186076GS 2 19553621GS 22 45757GS 23 75246GS 24 22145GS 25 26850GS 26 20566GS 27 B4986GS 28 92982GS 29 189409GS 3 52857GS 32 187049GS 33 93826GS 34 76040GS 35 B2153GS 36 73054GS 37 B4268GS 38 A5850GS 39 96867GS 40 B4489GS 4 39253GS 42 22129GS 43 A96925GS 44 96924GS 45 89302DGS 46 19753621GS 47 23897GS 48 49226GS 49 52856GS 50 49820GS 5 42907GS 52 49813GS 54 27482GS 55 47411GS 56 22473GS Qty Description 2 6 4 4 6 o
6. GENERAC EI M RAC by Briggs amp Stratton 0 0 6 Portable Products POWER PRODUCTS EXE Parts Included 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 RATED WATT EXTENDED LIFE GENERATOR Owner s Manual Troubleshooting Schematic f any parts are missing or damaged call 1 800 270 1408 Questions Help is just a moment away Call Generac Generator Helpline 1 800 270 1408 M F 8 5 CT Web www generac portables com or www briggsandstratton com Model No 9801 7 10 000 Watt AC Generator Manual No 189484GS Revision 2 09 24 2002 GENERAC Portable Products by Briggs amp Stratton POWER PRODUCTS 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 Generato
7. 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 Figure 3 Typical Fuel Expansion Space 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 GENERAC Portable Products by Briggs amp Stratton POWER PRODUCTS KNOW YOUR GENERATOR 10000EXL Extended Life Generator Read this owner s manual and safety rules before operating your generator Compare
8. loads OFF and disconnect from generator before stopping generator CAUTION Improper treatment of generator can damage it and shorten its life 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 GENERAC 10000EXL Extended Life Generator by Briggs amp Stratton POWER PRODUCTS 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 Figure Install Wheel Kit Wheel
9. 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 Figure 2 Negative Battery Connection L D Negative Battery Cable 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 by Briggs amp Stratton POWER PRODUCTS To fill your engine with oil e 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
10. 0A Locking 4 68759GS 1 OUTLET 120V 20A Duplex 5 68868GS 1 OUTLET 120V 30A Locking 6 B5II2GS 1 ASSY Diode 7 186102GS 1 ASSY Engine Harness 8 90576GS 1 GROMMET Rubber 9 B4262GS 1 OUTLET 120 240V 50A 10 87962GS BREAKER Circuit I1 93929GS 4 STAND OFF 12 51715GS 12 NUT 13 22264GS 16 WASHER Lock 14 43181GS 10 SCREW 16 38150GS 20 WASHER 17 23365GS 12 WASHER 18 90418GS OUTLET I2V DC 19 43182GS 10 WASHER Lock 20 75207AGS 2 BREAKER Circuit 30A 2 78653GS SWITCH Run Stop 22 93986GS 8 SCREW 23 91526GS 4 SCREW 24 49226GS 5 WASHER Lock 25 23897GS 5 WASHER 26 75207GS 3 BREAKER Circuit 20A 27 74190GS 1 OUTLET 120V 20A 28 92953GS BLOCK 50 Amp 3 Terminal 29 80077GS 4 SCREW 30 94117GS BOARD Idle Control 3 84028GS TRANSFORMER Idle Control 32 65795GS RECTIFIER Battery Charge 33 84135GS GROMMET Rubber 34 79224GS 1 SCREW 35 186200GS RESISTOR 36 B4893GS 4 STAND OFF 37 82538GS SWITCH On Off 38 51714GS 4 NUT 39 51716GS NUT 40 B4445GS 2 BREAKER Circuit 45A 4 B4894GS RECTIFIER Battery Charge 42 77314GS RELAY 3A Thermal 43 B4892GS RESISTOR 44 27565GS TAPE Glass Insulation GENERAC 10000EXL Extended Life Generator d by Briggs amp Stratton Item Part Qty Description BB5586GS 2 HANDLE Includes Item 2 2 B4605GS 2 GRIP 3 39287GS 2 SCREW 4 22145GS 6 WASHER 5 49820GS 2 NUT Nylok 6 187104GS 4 WASHER Nylon 7 B4135GS 2 PIN with Lanyar
11. 4 Fill fuel tank 5 Stale gasoline 5 Drain gas tank fill with fresh fuel 6 Spark plug wire not connected to 6 Connect wire to spark plug spark plug Engine will not start or 7 Bad spark plug 7 Replace spark plug l starts and runs rough 8 Water in gasoline 8 Drain gas tank fill with fresh fuel 9 Overchoking 9 Open choke fully and crank engine 10 Excessively rich fuel mixture 10 Contact Briggs and Stratton service facility l Intake valve stuck open or closed Il Contact Briggs and Stratton service facility 12 Engine has lost compression 12 Contact Briggs and Stratton service facility 13 Failed battery 13 Replace battery Engine shuts down during Out of gasoline 1 Fill fuel tank operation 2 Low oil level 2 Fill crankcase to proper level I Load is too high See Don t Overload the Generator Engine lacks power on page 12 2 Dirty air filter 2 Replace air filter Choke is opened too soon I Move choke to halfway position until NT 35 engine runs smoothly Engine hunte or falters 2 Carburetor is running too rich or too 2 uid Briggs and Sdn service lean facility GENERAC 10000EXL Extended Life Generator by Briggs amp Stratton POWER PRODUCTS SCHEMATICS SCHEMATIC
12. Neutral 120V Hot Ground Green Use this receptacle to operate 120 Volt AC 60 Hz single phase loads requiring up to 3 600 watts 3 6 kW of power at 30 Amps The outlet is protected by a 30 Amp push to reset circuit breaker 120 Volt 20 Amp Locking Type Receptacle Use a NEMA L5 20 plug with this receptacle Connect a 3 wire cord set rated for 125 Volt AC loads at 20 Amps to the plug Figure 14 Figure 14 120 Volt AC 20 Amp Locking Receptacle 3 Wire Cord Set E NEMA L5 20 Neutral o a Ground Green Use this receptacle to operate 120 Volt AC 60 Hz single phase loads requiring up to 2 400 watts 2 4 kVV of power at 20 Amps The outlet is protected by a 20 Amp push to reset circuit breaker 120 Volt AC 20 Amp Duplex Receptacle Each receptacle Figure 15 is protected against overload by a 20 Amp push to reset circuit breaker 10000EXL Extended Life Generator GENERAC Portable Products by Briggs amp Stratton POWER PRODUCTS Figure 15 120 Volt AC 20 Amp Duplex Receptacle Use each receptacle to operate 120 Volt AC single phase 60 Hz electrical loads requiring up to 2 400 watts 2 4 kW at 20 Amps of current Use cord sets that are rated for 125 Volt AC loads at 20 Amps or greater 12 Volt DC 10 Amp Receptacle This receptacle allows you to recharge a 12 Volt automotive or utility
13. TION Although this outlet states it has a A 240 Volt 50 Amp rating up to 12 500 watts the generator is only rated for 10 000 watts Powering loads that exceed the wattage amperage capacity of the generator can damage it or cause serious injuries 240 Volt loads powered through this outlet should not exceed 41 7 Amps of current draw GENERAC Portable Products by Briggs amp Stratton POWER PRODUCTS 120 240 Volt AC 30 Amp Locking Receptacle Use a NEMA L14 30 plug with this receptacle Connect a 4 wire cord set rated for 250 Volt AC loads at 30 Amps or greater Figure 12 You can use the same 4 wire cord if you plan to run a 120 Volt load Figure 12 120 240 Volt AC 30 Amp Receptacle 4 Wire Cord Set 240V 20V e l 20V W Neutral M Y Hot X Hot NEMA LI4 30 L Ground Green This receptacle powers 120 240 Volt AC 60 Hz single phase loads requiring up to 3 600 watts of power at 30 Amps for 120 Volts 7 200 watts of power 7 2 kW at 30 Amps for 240 Volts The outlet is protected by a 30 Amp push to reset circuit breaker 10000EXL Extended Life Generator 120 Volt AC 30 Amp Locking Receptacle Use a NEMA L5 30 plug with this receptacle Connect a 3 wire cord set rated for 125 Volt AC loads at 30 Amps to the plug Figure 13 Figure 13 120 Volt AC 30 Amp Locking Receptacle 3 Wire Cord Set e NEMA L5 30
14. charging 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 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 10000EXL Extended Life Generator GENERAC by Briggs amp Stratton POWER PRODUCTS Running engines produce heat Temperature of muffler and nearby areas can reach or exceed 150 F 65 C oss Severe burns can occur on contact DO NOT touch hot surfaces Allow equipment to cool before touching Excessively high operating speeds increase risk of injury and damage to generator Excessively low speeds impose a heavy load 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 CAUTION Exceeding generators wattage amperage cappacity can damage generator and or electrical devices connected to it 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
15. d 8 B9I3394GS LEG Mounting Support 9 191413GS 1 VIBE MOUNT with Washer 10 52858GS NUT Lock I1 22129GS 2 WASHER Lock 12 39253GS 2 SCREW 13 42909GS SCREW 14 191267BGS AXLE 15 B89635GS 2 SPACER Wheel 16 89742GS 2 WHEEL 17 22247GS 2 WASHER Wheel 18 191265GS 2 E RING 10000EXL Extended Life Generator ortable Products by Briggs amp Stratton POWER PRODUCTS Item Part Qty Description B4906GS SHIELD Front 2 B4907GS 2 GRID Front 3 B4908GS BOLT Shaft Stay 4 B4909GS 4 BOLT Stay 5 B4910GS 1 ASSY Housing 6 B491IIGS 1 CAP 7 B4912GS 1 COVER Blind End 8 B4913GS COVER Top Black 9 B4914GS 2 CAPACITOR I B4916GS CAPACITOR Diode Varistor EMC I2 191297GS ASSY Rotor Includes Item 11 14 B4919GS 2 SCREW 15 B4920GS 8 SCREW 16 49820GS NUT Lock 17 188928GS CONNECTOR 6 Pin 18 22473GS 6 WASHER 19 49813GS 6 NUT LIMITED VARRANTY GENERAC PORTABLE PRODUCTS OWNER WARRANTY POLICY Effective October 2001 LIMITED WARRANTY Generac Portable Products LLC will repair or replace free of charge any part or parts of the equipment that are defective in material or workmanship or both Transportation charges on parts submitted for repair or replacement under this Warranty must be borne by purchaser This warranty is effective for the time periods and subject to the conditions provided for in this policy For warranty service find the nearest Authorized Service Dealer in our d
16. e 4 Figure 4 Grounding Wing Nut Grounding Wing Nut 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 10000EXL Extended Life Generator GENERAC Portable Products by Briggs amp Stratton POWER PRODUCTS Starting the Engine Disconnect all electrical loads from the generator Follow start instruction steps in numerical order Turn the fuel valve to the On position Figure 5 Figure 5 Fuel Shut off Valve FUEL TANK Fuel Valve is shown in On position 2 Make sure the Idle Control switch is in Off positi
17. e unit and fuel can then be stored for up to 24 months Fuel stabilizer can be purchased locally DO NOT store gasoline from one season to another unless it has been treated as described above Replace fuel container if it starts to rust Rust and or dirt in fuel can cause problems if it s used with this unit Store unit in a clean and dry area TROUBLE SHOOTING TROUBLESHOOTING Problem Cause One of the circuit breakers is open 10000EXL Extended Life Generator GENER AC by Briggs amp Stratton POWER PRODUCTS Correction Reset circuit breaker Engine i 2 Fault in generator 2 Contact Generac service facility ngine is running but no 3 P defect d Check and AC output is available Poor connection or defective cord set 3 eck and repair B 4 Connected device is bad 4 Connect another device that is in good condition l Short circuit in a connected load l Disconnect shorted electrical load Engine runs good at no 2 Engine speed is too slow 2 Contact Generac service facility load but bogs down 3 Generator is overloaded 3 See Don t Overload the Generator when loads are connected on page 12 4 Shorted generator circuit 4 Contact Generac service facility I Ignition Switch set to Stop l Setswitch to On 2 Fuel Valve is in the Off position 2 Turn fuel valve to the On position 3 Dirty air cleaner 3 Clean or replace air cleaner 4 Out of gasoline
18. ealer locator map at www generac portables com or call 1 877 544 0982 THERE IS NO OTHER EXPRESS WARRANTY IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE TIME PERIOD SPECIFIED OR TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW Some states do not allow limitations on how long an implied warranty lasts and some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation and exclusion 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 and country to country WARRANTY PERIOD PRODUCTS CONSUMER USE COMMERCIAL USE Portable Generator year 90 days Side Valve Engine Powered Portable Generator 2 years year Overhead Valve Engine Powered 2nd year parts only Electric Powered Pressure Washer year None Gasoline Powered Pressure Washer year 90 days The warranty period begins on the date of purchase by the first retail consumer or commercial end user and continues for the period of time stated in the table above Consumer use means personal residential household use by a retail consumer Commercial use means all other uses including use for commercial income pr
19. er Spark Arrester Muffler 240 Volt AC 50 Amp Receptacle Grounding Wing Nut 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 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 GROUNDING WING NUT is provided on the generator end Figur
20. f 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 Figure 9 Battery Connections 12 VOLT D C RECEPTACLE Connect battery charge cable clamp with black handle to the negative battery terminal Figure 9 Start engine Let the engine run while battery recharges When battery has charged shut down engine NOTE Use an automotive hydrometer to test battery state of charge and condition Follow the hydrometer manufacturer s instructions carefully Generally a battery is considered to be at 10076 state of charge when specific gravity of its fluid as measured by hydrometer is 1 260 or higher How to Use the Battery Charger Use batter
21. ing order 10000EXL Extended Life Generator SAFETY RULES A DANGER Running generator gives off carbon monoxide an ordorless colorless poison gas Breathing carbon monoxide will cause nausea fainting or death 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 A DANGER Failure to properly ground generator can result in electrocution especially if the generator is equipped with a wheel kit National Electric Code requires generator to be properly grounded to an approved earth ground Call an electrician for local grounding requirements A DANGER o 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 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 o
22. ion 2 6 l 3 l l l 2 l l l l 2 3 l l l l l 2 l 2 l l 4 4 l l l l l l 2 2 4 2 2 l 2 l l l l l l l 2 l 2 CLAMP Hose CLAMP Hose SCREW CLAMP Hose SCREW GROMMET Generator Cover SCREW HOSE CLAMP Hose GROMMET Rubber PLATE Adjust SPRING LINKAGE Bell Crank to Throttle SCREW WASHER Nylon BRACKET Bell Crank SPACER WASHER WASHER Lock LINKAGE Stepper Motor to Bell Crank SCREW BRACKET Starter Switch WASHER SWITCH Starter ASSY Wire WASHER Lock NUT WIRE Harness ASSY Jack DC DECAL Instruction ES LUG MANUAL Owners MANUAL Engine GRIP HANDLE Includes Item 90 WASHER Nylon PIN with Lanyard SCREW CHARGE Battery Float NUT Nylok PLUG 120 240V 30A 4 Prong PLUG 125V 20A PLUG 120V 30A 3 Prong FILTER Oil COVER Storage CABLE Battery Charge ELEMENT Air Filter PRE CLEANER Air SPARK PLUG CAP Funnel Oil Bottle BOTTLE Oil Optional Accessories Not Included 84883GS Cord Wrap 6 9 9 9 C 2 9 o x ui X f o e ortable Products by Briggs amp Stratton POWER PRODUCTS EXPLODED VIEW CONTROL PANEL See 10000EXL Extended Life Generator GENERAC by Briggs amp Stratton PARTS LIST CONTROL PANEL Item Part Qty Description AB4432GS PANEL Control 2 B95906GS BOX Control 3 43437GS OUTLET 120 240V 3
23. ion will be made to determine whether the warranty applies Ask the Service Dealer to submit all supporting facts to its Distributor for review If the Distributor decides that the claim is justified the customer will be fully reimbursed for those items that are defective To avoid misunderstandings that might occur between the customer and the Dealer listed below are some of the causes of equipment failure that the warranty does not cover Normal wear Outdoor Power Equipment like all mechanical devices needs periodic parts service and replacement to perform well This warranty does not cover repair when normal use has exhausted the life of a part or the equipment Installation and Maintenance This warranty does not apply to equipment or parts that have been subjected to improper or unauthorized installation or alteration misuse negligence accident overloading overspeeding improper maintenance repair or storage so as in Generac Portable Products judgment to adversely affect its performance and reliability This warranty also does not cover normal maintenance such as adjustments fuel system cleaning and obstruction due to chemical dirt carbon or lime etc Other Exclusions Also excluded from this warranty are wear items such as quick couplers oil gauges belts o rings filters pump packing etc pumps which have been run without water supplied or damage or malfunctions resulting from accidents abuse modifications alterations or im
24. levision 500 Light 75 Watts 75 3075 Total 1800 Highest Running Watts Surge Watts Total Rated Running Watts 3075 Highest Additional Surge Watts 1800 Total Generator Output Required 4875 Power Management To prolong the life of your generator and attached devices it is important to take care when adding electrical loads to your generator There should be nothing connected to the generator outlets before starting its engine The correct and safe way to manage generator power is to sequentially add loads as follows l With nothing connected to the generator start the engine as described in this manual 2 Plug in and turn on the first load preferably the largest load you have 3 Permit the generator output to stabilize engine runs smoothly and attached device operates properly 4 Plug in and turn on the next load 5 Again permit the generator to stabilize 6 Repeat steps 4 and 5 for each additional load NEVER add more loads than the generator capacity Take special care to consider surge loads in generator capacity as described above Figure 17 Wattage Reference Chart Additional Surge Starting Watts Rated Running Watts Tool or Appliance Essentials Light Bulb 75 watt 75 Deep Freezer 500 Sump Pump 1200 Refrigerator Freezer 18 Cu Ft 1600 Water Well Pump 1 3 HP 2000 Heating Cooling Window AC 10 000 BTU 1800 Window Fan 600 Furnace Fan Blower 1 2 HP Kitchen Mic
25. n a dry location such as inside a garage To Clean the Generator Use a damp cloth to wipe exterior surfaces clean A soft bristle brush may be used to loosen caked on dirt or oil A vacuum cleaner may be used to pick up loose dirt Low pressure air not to exceed 25 psi may be used to blow away dirt Inspect cooling air slots and opening on generator These openings must be kept clean and unobstructed GENERAC Portable Products by Briggs amp Stratton POWER PRODUCTS STORAGE The generator should be started at least once every seven days and allowed to run at least 30 minutes If this cannot be done and you must store the unit for more than 30 days use the following guidelines to prepare it for storage Generator Storage Clean the generator as outlined in To Clean the Generator Check that cooling air slots and openings on generator are open and unobstructed CAUTION Storage covers can be flammable A DO NOT place a storage cover over a hot generator Let the unit cool for a sufficient time before placing the cover on the unit 10000EXL Extended Life Generator Engine Storage See engine owner s manual for instructions Other Storage Tips To prevent gum from forming in fuel system or on essential carburetor parts add fuel stabilizer into fuel tank and fill with fresh gasoline Run the unit for several minutes to circulate the additive through the carburetor Th
26. nplug 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 VWhen 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 10000EXL Extended Life Generator 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 I
27. oducing or rental purposes Once equipment has been used commercially it shall thereafter be considered to be in commercial use for purposes of this warranty Used equipment demonstration equipment and equipment used for prime power in place of a utility are not warranted Accessory parts such as guns hoses wands and nozzles are excluded from the product warranty The gasoline engine and starting batteries are warranted solely by the manufacturers of those products WARRANTY REGISTRATION IS NOT NECESSARY TO OBTAIN WARRANTY ON GENERAC PORTABLE PRODUCTS EQUIPMENT SAVE YOUR PROOF OF PURCHASE RECEIPT IF YOU DO NOT PROVIDE PROOF OF THE INITIAL PURCHASE DATE AT THE TIME WARRANTY SERVICE IS REQUESTED THE MANUFACTURING DATE OF THE EQUIPMENT WILL BE USED TO DETERMINE THE WARRANTY PERIOD About your equipment warranty Generac Portable Products welcomes warranty repair and apologizes to you for being inconvenienced Any Authorized Service Dealer may perform warranty repairs Most warranty repairs are handled routinely but sometimes requests for warranty service may not be appropriate For example warranty would not apply if equipment damage occurred because of misuse lack of routine maintenance shipping handling warehousing or improper installation Similarly warranty is void if the serial number of the equipment has been removed or the equipment has been altered or modified If a customer differs with the decision of the Service Dealer an investigat
28. on Figure 6 Figure 6 Idle Control Switch 3 Set the Ignition switch to On position Figure 7 Figure 7 Ignition Switch 4 Pull choke control out to close choke Figure 8 Figure 8 Choke Lever GENERAC Portable Products by Briggs amp Stratton POWER PRODUCTS 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 U
29. proper servicing or freezing or chemical deterioration Warranty is available only through service dealers authorized by Generac Portable Products This warranty does not apply to service by any other entity You may locate your nearest Authorized Generac Portable Product Service Dealer in our dealer locator map at www generac portables com or call 1 877 544 0982 Generac Portable Products Are Made Under One Or More Of The Following Patents Other Patents Pending 5902094 5823752 5718255 5890413 Generac Portable Products LLC Jefferson Wisconsin U S A
30. r 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 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 work
31. r 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 A WARNING Ch Unintentional sparking can result in fire or electric shock 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 SAFETY RULES amp Gasoline and its vapors are extremely flammable and explosive Fire or explosion can cause severe burns or death 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 Storage batteries give off explosive hydrogen gas during re
32. rowave Oven 1000 Watt Coffee Maker Electric Stove Single Element Hot Plate Family Room DVD CD Player VCR Stereo Receiver Color Television 27 Personal Computer w l7 monitor Other Security System AM FM Clock Radio Garage Door Opener 1 2 HP Electric Water Heater 40 Gallon DIY Job Site Quartz Halogen Work Light Airless Sprayer 1 3 HP Reciprocating Saw Electric Drill 1 2 HP Circular Saw 7 1 4 Miter Saw 10 Table Planer 6 Table Saw Radial Arm Saw 10 Air Compressor 1 2 HP Wattages listed are approximate only Check tool or appliance for actual wattage MAINTENANCE SPECIFICATIONS Maximum Surge Watts suus 12 500 watts Continuous Wattage Capacity 10 000 watts Power Factor i ae 1 0 Rated Maximum Continuous AC Load Current AE E20 VolES cut Reese 83 3 Amps At 240 Volts dioses td 41 7 Amps Phase oezsecsem e mm emer Reds phase Rated Frequency 0000s eee 60 Hertz Fuel Tank Capacity 8 US gallons SHIPPING Weight 4 52 xh tirer hein o eia 300 Ibs 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 defecti
33. style storage battery with the battery charge cables provided Figure 16 Figure 16 12 Volt DC 10 Amp Receptacle This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery See the section Charging a Battery page 8 before attempting to recharge a battery GENERAC Portable Products by Briggs amp Stratton POWER PRODUCTS DON T OVERLOAD YOUR GENERATOR Capacity You must make sure your generator can supply enough rated running and surge starting watts for the items you will power at the same time Follow these simple steps l Select the items you will power at the same time 2 Total the rated running watts of these items This is the amount of power your generator must produce to keep your items running See Figure 17 3 Estimate how many surge starting watts you will need Surge wattage is the short burst of power needed to start electric motor driven tools or appliances such as a circular saw or refrigerator Because not all motors start at the same time total surge watts can be estimated by adding only the item s with the highest additional surge watts to the total rated watts from step 2 Example Rated Running Additional Surge Tool or Appliance 10000EXL Extended Life Generator Watts Starting Watts Window Air 1200 1800 Conditioner Refrigerator 800 1600 Deep Freezer 500 500 Te
34. the illustrations with your generator to familiarize yourself with the locations of various controls and adjustments Save this manual for future reference Electric Start Button Oil Fill Cap I2 Volt DC Receptacle 120 Volt AC 30 Amp Locking Receptacle 120 240 Volt AC 30 Amp Locking Receptacle 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 Recoil Starter Fuel Tank Choke Lever Air Clean
35. ve generator Engine Maintenance See engine owner s manual for instructions contact with used motor oil Used motor oil has been shown to cause skin cancer in certain laboratory animals Thoroughly wash exposed areas with soap and water KEEP OUT OF REACH OF CHILDREN DON T POLLUTE CONSERVE RESOURCES RETURN USED OIL TO COLLECTION CENTERS T CAUTION Avoid prolonged or repeated skin 10000EXL Extended Life Generator GENERAC Portable Products by Briggs amp Stratton POWER PRODUCTS Generator Maintenance Generator maintenance consists of keeping the unit clean and dry Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust dirt moisture or any corrosive vapors Cooling air slots in the generator must not become clogged with snow leaves or any other foreign material NOTE DO NOT use a garden hose to clean generator Water can enter engine fuel system and cause problems In addition if water enters generator through cooling air slots some of the water will be retained in voids and cracks of the rotor and stator winding insulation Water and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings Battery Maintenance Other than float charging described elsewhere no maintenance is required for the battery Keep the battery and terminals clean and dry IMPORTANT Battery charging should be performed i
36. y float charger jack to keep the starting battery charged and ready for use Battery charging should be done in a dry location such as inside a garage Plug the charger into the unit s Battery Float Charger jack which is located on the starter switch Figure 10 Plug battery charger into a 120 Volt AC wall receptacle Figure 10 Battery Charger Jack Unplug the charger from the unit and the wall outlet when generator is being started and while it is in operation Keep this charger plugged in when generator is not in use to prolong battery life The charger has a built in float equalizer and will not overcharge the battery even when plugged in for an extended period of time IMPORTANT See Battery Maintenance on page 13 for additional information 10000EXL Extended Life Generator GENERAC Portable Products by Briggs amp Stratton POWER PRODUCTS RECEPTACLES 240 Volt AC 50 Amp Receptacle Use a NEMA 14 50 plug with this receptacle Figure 1 Connect a 4 wire cord set rated for 250 Volt AC loads at 50 Amps to the plug Figure 240 Volt AC 50 Amp Receptacle l 240 Volts AC 9 Frame Ground 120 Volts 120 Volts W Neutral NEMA 14 50 Use this receptacle to operate 240 Volt AC 50 Amp 60 Hz single phase loads requiring up to 10 000 watts 10 0 kW of power The outlet is protected by a 45 Amp push to reset circuit breaker CAU
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