Generac 1019-1 Owner’s Manual
The Reliable Ones
7500
Portable Generator Owner's Manual
DANGER[ This generator is designed for outdoor use only. Never use this generator inside any building
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or enclosure including the generator compartment of a recreational vehicle (RV). Carbon monoxide
poisoning, fire and/or an explosion may result. No user performed modifications, including venting of
exhaust and/or cooling ventilation, will eliminate the danger. Always have at least two feet of clearance on
all sides of the generator even while operating the unit outdoors.
DANGER! You must isolate the generator from the electric utility by opening the electrical system's main
circuit breaker or main switch if this unit is used for backup power, Failure to isolate the generator from
the power utility may result in injury or death to electric utility workers and damage to the
generator due to a backfeed of electrical energy,
The Emission Control System for this generator is warranted for standards set by the
Environmental Protection Agency, For warranty information refer to the Engine Owner's manual.
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Model No. 1019-1 (7500 Watt AC Generator) Manual No B4594 Revision 0 (11/1/1999)
Visit our Generac website: www.generac-portables.com
,_ This is the safety alert symbol. It is used to alert you to potential personal injury hazards.Obey all safety messages that follow this symbol to avoid possible injury or death.
GeneracPortableProducts7500EXLExtendedLifeGenerator
EQUIPMENT DESCRIPTION
This generator is an engine-driven, revolving field,
alternating current (AC) generator. It was designed to
supply electrical power for operating compatible
electrical lighting, appliance, tool and motor loads.
This manual contains information for a generator that
operates 120 and/or 240 Volts, single phase, 60Hz
devices that require up to 7500 watts (7.5 kW) of
power that pull up to 62.5 Amps at 120 Volts or
31.2 Amps at 240 Volts.
A CAUTION: Do Not exceed the generator's
The generator's revolving field is driven at about
3600 rpm by a single cylinder engine.
Every effort has been expended to make sure that the
information in this manual is both accurate and
current. However, Generac reserves the right to
change, alter or otherwise improve the product at any
time without prior notice.
A
wattage/amperage capacity Add up the rated
watts of all devices you are connecting to
generator receptacles at one time. This total
should not be greater than 7,500 watts for this
generator. In most cases rated watts of the
electrical device can be found on the device
nameplate. If the device nameplate gives only
volts and amps, multiply volts times amps to
obtain watts (volts x amps = watts).
DANGER: Do Not tamper with engine
governed speed. High operating speeds are
dangerous and increase risk of personal injury
or damage to equipment The generator
supplies correctly rated frequency and voltage
only when running at proper governed speed.
Incorrect frequency and/or voltage can damage
some connected electrical loads Operating at
excessively low speeds imposes a heavy load
at such reduced speeds, when adequate
engine power is not available, and may shorten
engine life
SAFETY RULES
This generator set was designed and manufactured
for specific applications. Do Not attempt to modify the
unit or use it for any application it was not designed
for. If you have any questions about your generator's
application, ask your dealer or consult the factory.
The manufacturer could not possibly anticipate every
circumstance that might involve a hazard. For that
reason, warnings in the manual and warnings on tags
or decals affixed to the unit are not all-inclusive. If you
intend to handle, operate or service the unit by a
procedure or method not specifically recommended by
the manufacturer, first make sure that such a
procedure or method will not render this equipment
unsafe or pose a threat to you and others.
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
• The generator produces a very powerful voltage that
can cause extremely dangerous electrical shock.
Avoid contact with bare wires, terminals, etc. Never
permit any unqualified person to operate or service
the generator.
• Never handle any kind of electrical cord or device
while standing in water, while barefoot or while
hands or feet are wet.
• The National Electric Code requires the frame and
external electrically conductive parts of generator be
properly connected to an approved earth ground.
Local electrical codes may also require proper
grounding of the generator. Consult with a local
electrician for grounding requirements in your area.
• Use a ground fault circuit interrupter in any damp or
highly conductive area (such as metal decking or
steel work).
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GeneracPortableProducts7500EXLExtendedLifeGenerator
• DoNotuseworn,bare,frayedorotherwise
damagedelectricalcordsetswiththegenerator.
• Operategeneratoronlyonlevelsurfacesandwhere
itwillnotbeexposedtoexcessivemoisture,dirt,
dustorcorrosivevapors.
• GasolineishighlyFLAMMABLEanditsvaporsare
EXPLOSIVE.DoNotpermitsmoking,openflames,
sparksorheatinthevicinitywhilehandlinggasoline.
Avoidspillinggasolineonahotengine.Complywith
allregulationsrequiringstorageandhandlingof
gasoline.
• DoNotoverfillthefueltank.Alwaysallowroomfor
fuelexpansion.Iftankisoverfitled,fuelcanoverflow
ontoahotengineandcauseFIREoran
EXPLOSION.
• Neverstoregeneratorwithfuelintankwhere
gasolinevaporsmightreachanopenflame,sparkor
pilotlight(asonafurnace,waterheaterorclothes
dryer).FIREoranEXPLOSIONmightresult.
• GeneratorexhaustgasescontainDEADLYcarbon
monoxidegas.Thisdangerousgas,ifbreathedin
sufficientconcentrations,cancause
unconsciousnessorevendeath.Operatethis
equipmentonlyintheopenairwhereadequate
ventilationisavailable.
• Theunitrequiresanadequateflowofcoolingairfor
itscontinuedproperoperation.Neveroperatethe
unitinsideanyroomorenclosurewherethefree
flowofcoolingairintoandoutoftheunitmightbe
obstructed.Withoutsufficientcoolingairflow,the
unitquicklyoverheats,damagingthegeneratoror
nearbyproperty.
• Allowatleast2feetofclearanceonallsidesof
generator,evenwhileoperatingunitoutdoors,or
youcoulddamagetheunit.ReviewColdWeather
Operationonpage9.
• Neverstartorstoptheunitwithelectricalloads
connectedtoreceptaclesANDwiththeconnected
devicesturnedON.Starttheengineandletit
stabilizebeforeconnectingelectricalloads.
Disconnectallelectricalloadsbeforeshuttingdown
thegenerator.
• Never operate generator:
in rain; in any enclosed compartment; if engine
speed changes; if connected electrical devices
overheat; if electrical output is lost; if engine or
generator sparks; if flame or smoke is observed
while unit is running; if unit vibrates excessively.
GROUNDING THE
GENERATOR
The National Electric Code requires the frame and
external electrically conductive parts of generator be
properly connected to approved earth ground. Local
electrical codes may also require proper grounding of
the unit. For that purpose, a GROUNDING WING NUT
(Figure 1) is provided on the cradle frame.
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. However, local codes may vary
widely. Consult with a local electrician for grounding
requirements in your area. Be sure to keep the
grounding wire secure while you connect to the
grounding rod.
Properly grounding the generator helps prevent
electrical shock if a ground fault condition exists in the
generator or in connected electrical devices. Proper
grounding also helps dissipate static electricity, which
often builds up in ungrounded devices.
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GeneracPortableProducts7500EXLExtendedLifeGenerator
KNOW YOUR GENERATOR
Read this owner's manual and safety rules before operating your generator.
Compare the illustrationswith your generator to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference
Circuit Breakers (AC)
12 Volt DC
Receptacle
Idle Control Switch
120 Volt AC,
30 Amp Locking
Receptacle
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120/240 Volt AC, 30 Amp /
Locking Receptacle
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120 Volt AC, 20 Amp
Receptacles
12 Volt DC Receptacle i Use this receptacle with
battery charge cables to charge a 12 Volt battery.
120 Volt AC, 20 Amp Receptacles i May be used to
supply electrical power for the operation of 120 Volt
AC, single phase, 60 Hz electrical lighting, appliance,
tool and motor loads.
120 Volt AC, 30 Amp Locking Receptacle i 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 i May be used to
supply electrical power for the operation of 240 Volt
AC, 50 Amp, single phase, 60 Hz electrical loads.
Grounding Wing Nut
Electric Start Button
Recoil Starter
Choke Lever
Run/Stop Switch
Spark Arrestor Muffler
240 Volt AC, 50 Amp
Receptacle
Choke Lever i 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.
Electric Start Switch -- Pressed 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.
Recoil Starter = Used as an alternate means of
starting the engine.
Run/Stop Switch -- Must be in "Run" position to start
engine. Set to "Stop" to stop a running engine.
Spark Arrestor Muffler-- Exhaust muffler lowers
engine noise and is equipped with a spark arrestor
screen.
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GeneracPortableProducts7500EXLExtendedLifeGenerator
Yourgeneratorrequiressomeassemblyandis ready
foruseafterit hasbeenproperlyservicedwiththe
recommendedoilandfuel.
Ifyouhave 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 carton on a rigid flat surface with "This Side
Up" arrows pointing upward.
• Carefully open the top flaps of the shipping carton.
Review "Cold Weather Operation" on page 9.
• Cut down corners at one end of carton from top to
bottom and lay that side of carton down flat.
• Remove all packing material, carton fillers, etc.
• Remove the generator from the shipping carton.
INSTALLING TRAY AND
BATTERY
You must purchase and install a 12 Volt DC battery
(Series U1-109). The battery should be serviced with
electrolyte fluid and fully charged prior to installation.
Install the battery as follows:
• Find the battery tray and fasteners shipped loose in
the carton. The battery bracket, two 7" J-bolts, two
lock washers and two hex nuts are included.
• Remove the four battery tray screws from base.
• Position the battery tray and install (Figure 2).
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CARTON CONTENTS
Check alt contents If any parts are missing or
damaged, call the generator helpline at
1-800-270-1408.
• The generator
Electric start battery cables
Generator and engine owner's manuals
Locking 20 Amp and 30 Amp plugs
Battery charge cables
Battery tray mounting bracket/hardware
Spare spark plug and air filter element
Spark plug wrench
• Set battery onto tray and attach bracket, J-bolts, lock
washers, flat washers, and hex nuts (Figure 3).
Tighten hardware with 3/8" wrench.
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GeneracPortableProducts7500EXLExtendedLifeGenerator
,_. CAUTION: Be sure the black cable is
connected to the engine mount and not the
frame. You could damage the ground wire.
Select the oil's viscosity grade according to your
expected operating temperature:
• Connect the red battery cable from the engine
starter switch to positive (+) battery terminal
(Figure 4)
I colder _ 32°F -_,_warmer
Although multi-viscosity oils (5W30, 10W30, etc.)
improve starting in cold weather, these multi-viscosity
oils will result in increased oil consumption when used
above 32°E Check your engine oil level frequently to
avoid possible damage from running low on oil. See
the engine owner's manual for further information.
To add oil to the engine:
• Place generator on a level surface.
• Clean area around oil fill and remove oil cap.
• Slowly add oil through the oil fill opening until it
reaches the top. DO NOT OVERFILL.
• Install oil cap, hand tighten securely.
,_ CAUTION: Any attempt to crank or start the
NOTE: The generator's revolving field rides on a pre-
lubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
5W-30 10W-30
engine before it has been properly serviced
with the recommended oil will result in an
engine failure.
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• Connect the black battery cable to the negative (-)
battery terminal (Figure 4).
• Connect the other end of the black cable to the
engine, not the frame.
BEFORE STARTING THE
ENGINE
Perform the following tasks before trying to start the
generator engine:
Add Engine Oil
NOTE: In the future, When adding oil to the engine
crankcase use only high quality detergent oil rated
with API service classification SF and SG. Use no
special additives DO NOT USE SAE 10W-40.
Add Fuel
,_ DANGER: NEVER fill fuel tank indoors.
,_. CAUTION: Do Not overfill the fuel tank
Use only regular UNLEADED gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in essential fuel system parts such as the
carburetor, fuel filter, fuel hose or tank during storage.
Also, experience indicates that alcohol-blended fuels
(called gasohol, ethanol or methanol) can attract
moisture, which leads to separation and formation of
acids during storage. Acidic gas can damage the fuel
system of an engine while in storage.
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NEVER fill fuel tank when engine is running or
hot. Do Not light a cigarette or smoke when
filling the fuel tank
Always allow room for fuel expansion.
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