Generac 101 9-3 User Manual
Operator’s Manual
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Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-portables.com
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
2
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
3
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
4
• 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
5
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
6
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
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