Generac Power Systems 9801-7 Bedienungsanleitung

Owner’s Manual

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)

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

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 TOYOUR

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

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

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.

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

KNOWYOUR 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 12Volt 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

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-offValve

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

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 120Volt 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 12Volt 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

10000EXL Extended Life Generator

• 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 100% 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 battery 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 120Volt AC wall receptacle.

• 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.

RECEPTACLES

240 Volt AC, 50 Amp Receptacle

Use a NEMA 14–50 plug with this receptacle (Figure 11).

Connect a 4-wire cord set rated for 250 Volt AC loads at

50 Amps to the plug.

Use this receptacle to operate 240Volt 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.

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. 240 Volt loads powered through this outlet

should not exceed 41.7 Amps of current draw.

Figure 10 — Battery Charger Jack

Figure 11 — 240Volt AC, 50 Amp Receptacle

120 Volts

AC 120 Volts

X (Hot)

Y (Hot)

240 Volts AC

Frame Ground

NEMA 14-50

W (Neutral)

10000EXL Extended Life Generator

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 120Volt load.

This receptacle powers 120/240 Volt AC, 60 Hz, single

phase loads requiring up to 3,600 watts of power at

30 Amps for 120Volts; 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.

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).

Use this receptacle to operate 120Volt 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.

Figure 13 — 120 Volt AC, 30 Amp, Locking Receptacle

3-Wire Cord Set

Neutral

120V

Hot

Ground (Green)

NEMA L5-30

Figure 12 — 120/240 Volt AC, 30 Amp Receptacle

4-Wire Cord Set

240V

120V 120V W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-30 Ground (Green)

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