Generac 101 9-3 User Manual

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Operator’s Manual

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Model No. 1019-3 (7,500 Watt AC Generator) Manual No. 189713GS Revision 11 (12/15/2005)

Before using this product, read

this manual and follow all Safety

Rules and Operating Instructions.

WARNING

7500EXL Extended Life Generator

TABLE OF CONTENTS

Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Know Your Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

EQUIPMENT

DESCRIPTION

Read this manual carefully and become familiar with your generator. Know its applications, its limitations and any hazards involved.

The generators are 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 singlecylinder engine.

CAUTION! DO NOT exceed the generator’s

wattage/amperage capacity. See “Don’t Overload Generator”.

Every effort has been made to ensure that information in this manual is accurate and current. However, we reserve 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 and the California Air Resources Board. For warranty information refer to the engine operator’s manual.

SAFETY RULES

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.

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.

Hazard Symbols and Meanings

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING

Fire

Explosion

Toxic Fumes

Kickback

Operator’s Manual

Electrical Shock

Explosive Pressure

Chemical Burn

Hot Surface

Copyright © 2005 Briggs & Stratton Power Products Group, LLC. All rights reserved. No part of this material may be reproduced or transmitted in any form by any means without the express written permission of Briggs & Stratton Power Products Group, LLC.

SAVE THESE INSTRUCTIONS

7500EXL Extended Life Generator

• This generator does not meet U. S. Coast Guard Regulation 33CFR-183 and should not be used on marine applications.

• Failure to use the appropriate U. S.Coast Guard approved generator could result in bodily injury and/or property damage.

WARNING

WHEN ADDING OR DRAINING FUEL

• Turn generator OFF and let it cool at least 2 minutes before removing fuel cap.Loosen cap slowly to relieve pressure in tank.

• Fill or drain fuel tank outdoors.

• DO NOT overfill tank.Allow space for fuel expansion.

• Keep fuel away from sparks, open flames,pilot lights, heat, and other ignition sources.

• DO NOT light a cigarette or smoke.

WHEN STARTING EQUIPMENT

• Ensure spark plug, muffler, fuel cap and air cleaner are in place.

• DO NOT crank engine with spark plug removed.

• If fuel spills, wait until it evaporates before starting engine.

WHEN OPERATING EQUIPMENT

• DO NOT tip engine or equipment at angle which causes fuel to spill.

• This generator is not for use in mobile equipment or marine applications.

WHEN TRANSPORTING OR REPAIRING EQUIPMENT

• Transport/repair with fuel tank EMPTY or with fuel shutoff valve OFF.

• Disconnect spark plug wire.

WHEN STORING FUEL 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 fuel vapors.

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WARNING

• When using generator for backup power, notify utility company. Use approved transfer equipment to isolate generator from electric utility.

• Use a ground circuit fault 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 or wet weather.

• 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.

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

• Operate generator ONLY outdoors.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings.

• DO NOT operate generator inside any building or enclosure (even if doors or windows are open),including the generator compartment of a recreational vehicle (RV).

Running generator gives off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause nausea, fainting or death.

WARNING

7500EXL Extended Life Generator

• Use generator only for intended uses.

• If you have questions about intended use, ask dealer or call 1-800-270-1408.

• 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

• When starting engine, pull cord slowly until resistance is felt and then pull rapidly to avoid kickback.

• NEVER start or stop engine with electrical devices plugged in and turned on.

Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises or sprains could result.

WARNING

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.

WHEN TESTING FOR ENGINE SPARK

• Use approved spark plug tester.

• DO NOT check for spark with spark plug removed.

Unintentional sparking can result in fire or electric shock.

WARNING

• DO NOT touch hot surfaces and avoid hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 ft. (152 cm) clearance on all sides of generator including overhead.

• Code of Federal Regulation (CFR) Title 36 Parks, Forests, and Public Property require equipment powered by an internal combustion engine to have a spark arrester,maintained in effective working order, complying to USDA Forest service standard 5100-1C or later revision. In the State of California a spark arrester is required under section 4442 of the California Public resources code. Other states may have similar laws.

Running engines produce heat.Temperature of muffler and nearby areas can reach or exceed 150°F (65°C).

Severe burns can occur on contact. Exhaust heat/gases can ignite combustibles,

structures or damage fuel tank causing a fire.

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 Generator”.

• 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 capacity can damage generator and/or electrical devices connected to it.

CAUTION

7500EXL Extended Life Generator

KNOW YOUR GENERATOR

Read this Operator’s Manual and safety rules before operating your generator.

Compare this illustration 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 Receptacle — 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 — May be used to supply electrical power for the operation of 120 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle — May be used to supply electrical power for the operation of 120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

120/240 Volt AC, 50 Amp Receptacle — May be used to supply electrical power for the operation of 240 Volt AC, 50 Amp, single phase, 60 Hz electrical loads.

Air Cleaner — Protects engine by filtering dust and debris out of intake air.

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 seven (7) U.S. gallons. Electric Start Switch — Press to start the engine.

Grounding Fastener — Consult your local agency having

jurisdiction for grounding requirements in your area. 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.

Run/Stop Switch — Must be in “Run” position to start engine. Set to “Stop” 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 Receptacle

Idle Control Switch

Recoil Starter

Run/Stop Switch

Choke Lever

120/240 Volt AC, 30 Amp Locking Receptacle

120/240 Volt AC, 50 Amp Receptacle

Circuit Breakers (AC)

120 Volt AC, 30 Amp Locking Receptacle

12 Volt DC Receptacle

Spark Arrester Muffler

Electric Start Button

Grounding Fastener

Air Cleaner

Fuel Tank

Oil Fill Cap

7500EXL Extended Life Generator

ASSEMBLY

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.

Unpack the Generator

1. Set the carton on a rigid flat surface.

2. Open carton completely by cutting each corner from top to bottom.

3. Remove everything from carton except generator.

4. Leave generator on carton to install wheel kit.

Carton Contents

Check all contents against those listed below:

• Generator

• Wheel kit

• Storage Cover

• Adapter Cord Set

• Battery

• Battery Float Charger

• Battery Charge Cables

• Spare Spark Plug,Air Filter, and Oil Filter

• Spark Plug Wrench

• (2) Locking 30 Amp Plugs

• Engine Oil

• Operator's Manual

• Engine Manual If any parts are missing or damaged, call the generator helpline at 1-800-270-1408.

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 the following tools to install this wheel kit:

• 1/2" or 13mm socket wrench

• 1/2" or 13mm open end wrench

• 7/16" socket wrench

• 7/16" open end wrench

• Pliers

• Safety glasses

Refer to Figure 1 and install the wheel kit as follows:

1. Tip generator so that engine end is up.

Support Leg

M8 Lock Nut

Axle

Flat Washer

M8x20mm Capscrew

1/4x20 Lock Nut

Wheel

E-Ring

Figure 1 — Install Wheel Kit

1/4-20x1” Capscrew

Vibration Mount

7500EXL Extended Life Generator

2. Slide axle through both mounting brackets.

3. Slide a wheel over the axle.

NOTE: Be sure to install both wheels with the air pressure valve on the outboard side.

4. Place a washer on axle and then place an e-ring in axle groove.

5. Install e-ring with pliers, squeezing from top of e-ring to bottom of axle.

6. Repeat step 3 thru 5 to secure second wheel.

7. Tip generator so that engine side is down.

8. Attach the vibration mounts to the support leg with 1/4-20 x 1” capscrews and 1/4-20 lock nuts.

9. Line up holes in support leg with holes in generator frame.

10. Attach support leg using 2 capscrews (M8 x 20 mm) and 2 hex nuts (M8).Tighten with a 1/2” or 13mm socket wrench and 1/2” or 13mm wrench.

11. Return generator to normal operating position (resting on wheels and support leg).

12. Check each fastener to ensure it is secure.

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:

1. Cut off tie wrap securing loose end of negative (black) cable.

2. Remove screw, lock washer and flat washer on negative battery terminal.

3. Slide lock washer, flat washer and negative battery cable over screw (Figure 2).

4. Reattach screw to negative battery terminal and tighten.

5. Verify that connections to battery and generator are tight and secure.

Figure 2 — Negative Battery Connection

Negative

Battery Cable

Screw

Flat Washer

Lock Washer

Positive

Battery Cable

• Always wear eye protection when installing/removing e-rings.

E-rings can cause eye injury. E-rings can spring back and become airborne

when installing or removing.

CAUTION

7500EXL Extended Life Generator

BEFORE STARTING THE

ENGINE

Add Engine Oil

• Place generator on a level surface.

• Refer to engine operator’s manual and follow oil recommendations and instructions.

NOTE: Check oil often during engine break–in. Refer to engine operator’s manual for recommendations.

NOTE:The generator assembly rotates on a prelubricated and sealed ball bearing that requires no additional lubrication for the life of the bearing.

Add Fuel

NOTE:This gasoline engine is certified to operate on

gasoline. Exhaust Emission Control System: EM (Engine Modifications).

1. Use clean, fresh, regular UNLEADED fuel with a minimum of 85 octane. DO NOT use fuel which contains Methanol. DO NOT mix oil with fuel.

2. Clean area around fuel fill cap, remove cap.

3. Slowly add regular unleaded fuel to fuel tank. Be careful not to overfill.Allow at least 1.5" of tank space for fuel expansion (Figure 3).

4. Install fuel cap and wipe up any spilled fuel.

Fuel

Tank

1.5” Air Space

Figure 3 - Fuel Expansion

CAUTION

• Refer to engine manual for oil fill information.

• Damage to equipment resulting from failure to follow this instruction will void warranty.

Any attempt to crank or start the engine before it has been properly filled with the recommended oil will result in equipment failure.

WHEN ADDING FUEL

• Turn generator OFF and let it cool at least 2 minutes before removing fuel cap.Loosen cap slowly to relieve pressure in tank.

• Fill fuel tank outdoors.

• DO NOT overfill tank.Allow space for fuel expansion.

• Keep fuel away from sparks, open flames,pilot lights, heat, and other ignition sources.

• DO NOT light a cigarette or smoke.

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WARNING

7500EXL Extended Life Generator

USING THE GENERATOR

System Ground

The generator has a system ground that connects the generator frame components to the ground terminals on the AC output receptacles.The system ground is connected to the AC neutral wire (see “Equipment Description”, earlier in this manual).

Special Requirements

There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction.

• In some areas, generators are required to be registered with local utility companies.

• If the generator is used at a construction site, there may be additional regulations which must be observed.

Connecting to a Building’s Electrical

System

Connections for standby power to a building’s electrical system must be made by a qualified electrician.The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes.

Generator Location

Generator Clearance

Place generator in a well ventilated area, which will allow for removal of deadly exhaust gas. DO NOT place generator where exhaust gas could accumulate and enter inside or be drawn into a potentially occupied building. Ensure exhaust gas is kept away from any windows, doors, ventilation intakes or other openings that can allow exhaust gas to collect in a confined area (Figure 4). Prevailing winds and air currents should be taken into consideration when positioning generator.

Figure 4 — Generator Clearance

Exhaust Port

Typical Generator Shown

• 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.

WARNING

• Operate generator ONLY outdoors.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings.

• DO NOT operate generator inside any building or enclosure (even if doors or windows are open),including the generator compartment of a recreational vehicle (RV).

Running generator gives off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause nausea, fainting or death.

WARNING

• Keep at least 5 ft. (152 cm) clearance on all sides of generator including overhead.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

WARNING

7500EXL Extended Life Generator

OPERATING THE

GENERATOR

Starting the Engine

IMPORTANT: Always unplug the battery float charger

before starting the generator. Disconnect all electrical loads from the generator. Use the

following start instruction steps by numerical order:

1. Make sure unit is on a level surface. IMPORTANT: Failure to start and operate unit on a level

surface will cause the unit not to start or shut down during operation.

2. Turn the fuel valve to the “On” position (Figure 5).The

fuel valve handle should be vertical (pointing toward the ground) for fuel to flow.

3. Make sure the Idle Control switch is in “Off” position

(Figure 6).

4. Start the engine according to instructions given in the engine operator’s manual.

NOTE:If engine starts after 3 pulls but fails to run, or if unit shuts down during operation, make sure unit is on a level surface and check for proper oil level in crankcase. This unit may be equipped with a low oil protection device. See engine manual.

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 Generator”.

Fuel Valve is shown in the On position

Figure 5 — Fuel Valve

Figure 6 — Idle Control Switch

• See “Don’t Overload Generator”.

• 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 capacity can damage generator and/or electrical devices connected to it.

CAUTION

• When starting engine, pull cord slowly until resistance is felt and then pull rapidly to avoid kickback.

• NEVER start or stop engine with electrical devices plugged in and turned on.

Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises or sprains could result.

WARNING

• DO NOT touch hot surfaces and avoid hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 ft. (152 cm) clearance on all sides of generator including overhead.

Running engines produce heat.Temperature of muffler and nearby areas can reach or exceed 150°F (65°C).

Severe burns can occur on contact. Exhaust heat/gases can ignite combustibles,

structures or damage fuel tank causing a fire.

WARNING

7500EXL Extended Life Generator

Stopping the Engine

1. Turn off and unplug all electrical loads from generator

panel receptacles. NEVER start or stop engine with electrical devices plugged in and turned on.

2. Put idle control switch in “Off” position.

3. Let engine run at no–load for 30 seconds to stabilize internal temperatures of engine and generator.

4. Turn engine off according to instructions given in engine operator’s manual.

5. Move fuel valve to “Off” position.

Operating Automatic Idle Control

This switch is designed to greatly improve fuel economy. When this switch is turned ON, the engine will only run at its normal high governed engine speed when an electrical load is connected.When an electrical load is removed, the engine will run at a reduced speed. With the switch off, the engine will run at the normal high engine speed. Always have the switch off when starting and

stopping the engine.

Charging a Battery

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:

1. Check fluid level in all battery cells. If necessary, add

ONLY distilled water to cover separators in battery cells. DO NOT use tap water.

2. If battery is equipped with vent caps, make sure they are installed and are tight.

3. If necessary, clean battery terminals.

4. Connect battery charge cable connector plug to panel receptacle identified by the words “12-VOLTS D.C.”

5. Connect battery charge cable clamp with red handle to the positive (+) battery terminal (Figure 7).

6. Connect battery charge cable clamp with black handle to the negative (–) battery terminal (Figure 7).

7. Start engine. Let engine run while battery recharges.

8. 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.

Figure 7 — Battery Connections

• 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

7500EXL Extended Life Generator

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 8). Plug battery charger into a 120 Volt 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 17 for additional information.

COLD WEATHER

OPERATION

Under certain weather conditions (temperatures below 40°F [4°C] combined with high humidity), your generator may experience icing of the carburetor and/or the crankcase breather system.To reduce this problem, you need to perform the following:

1. Make sure generator has clean, fresh fuel.

2. Open fuel valve (turn valve to open position).

3. Use SAE 5W-30 oil (synthetic preferred, see engine operator’s manual).

4. Check oil level daily or after every eight (8) hours of operation.

5. Maintain generator following “Maintenance Schedule” in engine operator’s manual.

6. Shelter unit from elements.

Figure 8 — Battery Charger Jack

7500EXL Extended Life Generator

Creating a Temporary Shelter

1. In an emergency, use the original shipping carton.

2. Cut off top carton flaps and one long side of carton to expose muffler side of unit. If required, tape up other sides of carton to fit over generator as shown in Figure 9.

NOTE: If required, remove wheel kit to fit carton over generator as shown in Figure 9.

3. Cut appropriate slots to access receptacles of unit.

4. Face exposed end away from wind and elements.

5. Locate generator as described in the section “Generator Location”. Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings.

6. Start generator as described in the section “Starting the Engine”, then place carton over generator. Keep at least 5 ft. (152 cm) clearance on all sides of generator including overhead with shelter in place.

7. Remove shelter when temperatures are above 40°F [4°C].

8. Turn engine OFF and let cool two (2) minutes before refueling.Wipe up any spilled fuel.

Creating a Permanent Shelter

1. Build a structure that will enclose three sides and the top of the generator, making sure muffler side of generator is exposed.

NOTE: Structure should hold enough heat created by the generator to prevent icing problem.

2. DO NOT enclose generator any more than shown in Figure 9.

NOTE: If a wheel kit is installed on the generator, enlarge shelter accordingly.

3. Follow steps 3 through 8 as described previously in “Creating a Temporary Shelter”.

Figure 9 — Permanent Cold Weather Shelter

Wind

• Operate generator ONLY outdoors.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings.

• DO NOT operate generator inside any building or enclosure (even if doors or windows are open),including the generator compartment of a recreational vehicle (RV).

Running generator gives off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause nausea, fainting or death.

WARNING

• DO NOT touch hot surfaces and avoid hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 ft. (152 cm) clearance on all sides of generator including overhead.

• Remove shelter when temperatures are above 40°F [4°C].

Running engines produce heat.Temperature of muffler and nearby areas can reach or exceed 150°F (65°C).

Severe burns can occur on contact. Exhaust heat/gases can ignite combustibles,

structures or damage fuel tank causing a fire.

WARNING

7500EXL Extended Life Generator

GENERATOR ADAPTER

CORD SET

The generator is equipped with a 25’ generator adapter cord set designed for a 240 Volt,30 Amp grounded neutral circuit (Figure 10).The generator adapter cord set provides a convenient supply of emergency power into your dwelling so that your generator can be operated safely outside.

The maximum load on each outlet is 20 Amps.The maximum total load on both yellow wire outlets or both black wire outlets is 30 Amps.

NOTE: Follow all safety precautions when connecting any extension cord or device to the generator.

RECEPTACLES

12 Volt DC, 10 Amp Receptacle

This receptacle allows you to recharge a 12 Volt automotive or utility style storage battery with the battery charge cables provided (Figure 11).

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 11) before attempting to recharge a battery.

120 Volt AC, 20 Amp, Duplex

Receptacle

Each receptacle (Figure 12) is protected against overload by a 20 Amp push–to–reset circuit breaker.

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).

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 12 — 120 Volt AC, 20 Amp,Duplex Receptacle

• NEVER attempt to power a device requiring more amperage than generator or receptacle can supply.

• DO NOT overload the generator. See “Don’t Overload Generator”.

Receptacles may be marked with rating value greater than generator output capacity.

CAUTION

Figure 10 — Generator Adapter Cord Set

Figure 11 — 12 Volt DC, 10 Amp Receptacle

7500EXL Extended Life Generator

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.

120/240 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 14).You can use the same 4–wire cord if you plan to run a 120 Volt 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 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.

120/240 Volt AC, 50 Amp Receptacle

Use a NEMA 14–50 plug with this receptacle (Figure 15). Connect a 4-wire cord set rated for 250 Volt AC loads at 50 Amps to the plug.

Use this receptacle to operate 120/240 Volt AC, 60 Hz, single phase loads requiring up to 7,500 watts (7.5 kW) of power.The outlet is protected by a 35 Amp push–to–reset circuit breaker.

Figure 15 — 120/240 Volt AC, 50 Amp Receptacle

NEMA 14-50

120 Volts

W (Neutral)

Frame Ground

X (Hot)

Y (Hot)

240 Volts AC

Figure 14 — 120/240 Volt AC, 30 Amp Receptacle

4-Wire Cord Set

240V

120V

W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-30

Ground (Green)

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

3-Wire Cord Set

Neutral

120V

Hot

Ground (Green)

NEMA L5-30

7500EXL Extended Life Generator

DON'T OVERLOAD

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:

1. 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 16.

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:

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 it's engine.The correct and safe way to manage generator power is to sequentially add loads as follows:

1. 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.

*Wattages listed are approximate only. Check tool or appliance for actual wattage.

Tool or Appliance

Rated (Running)

Watts

Additional Surge

(Starting) Watts Window Air Conditioner

1200 1800

Refrigerator 800 1600 Deep Freezer 500 500 Television 500 Light (75 Watts) 75 -

3075 Total

Running Watts

1800 Highest

Surge Watts

Tool or Appliance

Rated*

(Running)

Watts

Additional

Surge

(Starting)

Watts

Essentials

Light Bulb - 75 watt 75 Deep Freezer 500 500 Sump Pump 800 1200 Refrigerator/Freezer - 18 Cu. Ft. 800 1600 Water Well Pump - 1/3 HP 1000 2000

Heating/Cooling

Window AC - 10,000 BTU 1200 1800 Window Fan 300 600 Furnace Fan Blower - 1/2 HP 800 1300

Kitchen

Microwave Oven - 1000 Watt 1000 Coffee Maker 1500 Electric Stove - Single Element 1500 Hot Plate 2500 -

Family Room

DVD/CD Player 100 VCR 100 Stereo Receiver 450 Color Television - 27” 500 Personal Computer w/17” monitor 800 -

Other

Security System 180 AM/FM Clock Radio 300 Garage Door Opener - 1/2 HP 480 520 Electric Water Heater - 40 Gallon 4000 -

DIY/Job Site

Quartz Halogen Work Light 1000 Airless Sprayer - 1/3 HP 600 1200 Reciprocating Saw 960 960 Electric Drill - 1/2 HP 1000 1000 Circular Saw - 7 1/4” 1500 1500 Miter Saw - 10” 1800 1800 Planer/Jointer - 6” 1800 1800 Table Saw/Radial Arm Saw - 10” 2000 2000 Air Compressor - 1-1/2 HP 2500 2500

Figure 16 - Wattage Reference Chart

7500EXL Extended Life Generator

SPECIFICATIONS

Starting Wattage . . . . . . . . . . . . . . . . . . . . . .13,500 watts

Wattage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,500 watts

AC Load Current:

At 120 Volts . . . . . . . . . . . . . . . . . . . . . . . . .62.5 Amps

At 240 Volts . . . . . . . . . . . . . . . . . . . . . . . . .31.2 Amps

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase

Rated Frequency . . . . . . . . . . . . . . . . . . . . . . . . .60 Hertz

Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . 7 U.S. gallons

Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . .240 lbs.

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 defective generator. NOTE: Should you have questions about replacing

components on your Generac Portable Products generator, please call 1-800-270-1408 for assistance.

Engine Maintenance

See engine operator’s manual for instructions.

KEEP OUT OF REACH OF CHILDREN. DON'T POLLUTE. CONSERVE RESOURCES. RETURN USED OIL TO COLLECTION CENTERS.

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 in a dry location, such as inside a garage.

To Clean the Generator

• Use a damp cloth to wipe exterior surfaces clean.

• Use a soft bristle brush to loosen caked on dirt or oil.

• Use a vacuum cleaner to pick up loose dirt.

• Use low pressure air (not to exceed 25 psi) to blow away dirt. Inspect cooling air slots and opening on generator.These openings must be kept clean and unobstructed.

• Used motor oil has been shown to cause skin cancer in certain laboratory animals.

• Thoroughly wash exposed areas with soap and water.

Avoid prolonged or repeated skin contact with used motor oil.

CAUTION

• DO NOT expose generator to excessive moisture, dust,dirt, or corrosive vapors.

• DO NOT insert any objects through cooling slots.

Improper treatment of generator can damage it and shorten its life.

CAUTION

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.

WHEN TESTING FOR ENGINE SPARK

• Use approved spark plug tester.

• DO NOT check for spark with spark plug removed.

Unintentional sparking can result in fire or electric shock.

WARNING

7500EXL Extended Life Generator

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.

Engine Storage

See engine operator’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 fuel. Run the unit for several minutes to circulate the additive through the carburetor. The unit and fuel can then be stored for up to 24 months. Fuel stabilizer can be purchased locally.

• DO NOT store fuel 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.

• DO NOT place a storage cover over a hot generator.

• Let equipment cool for a sufficient time before placing the cover on the equipment.

Storage covers can be flammable.

WARNING

7500EXL Extended Life Generator

TROUBLESHOOTING

Problem Cause Correction

No AC output is available, but engine is running.

1. One of the circuit breakers is open.

2. Fault in generator.

3. Poor connection or defective cord set.

4. Connected device is bad.

1. Reset circuit breaker.

2. Contact Generac service facility.

3. Check and repair.

4. Connect another device that is in good condition.

Engine runs good at noload but "bogs" down" when loads are connected.

1. Short circuit in a connected load.

2. Generator is overloaded.

3. Shorted generator circuit.

1. Disconnect shorted electrical load.

2. See "Don't Overload Generator".

3. Contact Generac service facility.

Engine will not start; or starts and runs rough.

1. Fuel valve is in the "Off" position.

2. Failed battery.

1. Turn fuel valve to "On" position.

2. Replace battery.

Engine shuts down during operation.

Out of gasoline. Fill fuel tank.

Engine lacks power. Load is too high. See "Don't Overload Generator".

GENERAC PORTABLE PRODUCTS OWNER EQUIPMENT WARRANTY POLICY

Effective November 1, 2004

WARRANTY PERIOD*

* 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 producing or rental purposes. Once equipment has been used commercially, it shall thereafter be considered to be in commercial use for purposes of this warranty.

** The engine and starting batteries are warranted solely by the manufacturers of those products.

WARRANTY REGISTRATION IS NOT NECESSARY TO OBTAIN WARRANTY ON BRIGGS & STRATTON POWER 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:

We welcome warranty repair and apologize 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 service would not apply if equipment damage occurred because of misuse, lack of routine maintenance, shipping, handling, warehousing or improper installation.Similarly, the warranty is void if the manufacturing date or the serial number on the equipment has been removed or the equipment has been altered or modified. During the warranty period, the Authorized service dealer, at its option, will repair or replace any part that, upon examination, is found to be defective under normal use and service.This warranty will not cover following repairs and equipment:

• 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 and modification, misuse, negligence, accident, overloading,overspeeding, improper maintenance, repair or storage so as, in our 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 improper servicing or freezing or chemical deterioration.Accessory parts such as guns, hoses, wands and nozzles are excluded from the product warranty.This warranty excludes failures due to acts of God and other force majeure events beyond the manufacturers control.Also excluded is used, reconditioned, and demonstration equipment; equipment used for prime power in place of utility power and equipment used in life support applications.

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WISCONSIN, U.S.A.

LIMITED WARRANTY

"Generac Portable Products is a licensed trademark of Briggs & Stratton Power Products. Briggs & Stratton Power Products 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 product 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 your nearest Authorized service dealer by calling 1-800-270-1408.Warranty service may only be performed by a Briggs & Stratton Power Products Authorized service dealer.

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 countries or states do not allow limitations on how long an implied warranty lasts, and some countries or 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 that vary from country to country or state to state.”

PRODUCTS** CONSUMER USE COMMERCIAL USE

Pressure Washer 1 year 90 days Portable Generator 2 years (2nd year parts only) 1 year

Generac 101 9-3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual