Generac 1019-3 User Manual
ATED WATT
LIFE GENERATOR
Owner's Manual
Parts Included*
• Generator
• Wheel kit
• Storage Cover
• 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
• Oviiner's Manual
• Engine Manual
*lf any parts are missing or damaged, call 1-800-270-1408.
Questions? Help is just a moment away!
CalLGenerac 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. I897I3GS Revision 5 (12/18/2003)
Table of Contents
Safety Rules
Knov^ Your Generator
Assembly............................................................................6-7
Operation..........................................................................8-13
Product Specifications.......................................................14
Maintenance........................................................................14
Storage.................................................................................15
Troubleshooting..................................................................15
Schematic............................................................................16
Wiring Diagram....................................................................17
Replacement Parts
Notes....................................................................................23
Warranty
.......................................................................
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0"«24847"05311
2-4
18-22
Last Page
5
EQUIPMENT
SAFETY RULES
DESCRIPTION
Read this: manual carefully and become
familiar with your ^^nerator. Know its
applications, its limitations and any hazards
involved.
The generators are an engine-driven, revolving field,
altsrnating current (AC) generator. It was designed to
supp y electrical power for operating compatible electrical
lighting, appliances, tools and motor oads.The generator’s
revo ving field is driven at about 3,600 rpm by a single-
cy inder engine.
CAUTION! DO NOT exceed the generator’s
wattage/amperage capaci^. See "Don’t Overload
Generator” on pa;^ 13,
Every effort has been made tx> ensure that information in
this manual is accurats and current. However, we reserve
the right to change, altsr or otherwise improve the product
and this document at any time without prior notice.
The Emission Contro System for this generator is
warranted for standards set by the Environmental
Protection A;^ncy, For warranty information refer to the
engine owner’s manual.
In the:State:ofGaiifOrhla: a spare arrester is :reqUlred: :by :laW:
(Section 4442
Other states wlay have similar laws. Federal law^ apply on
federai iandsulf you ecuic the muffler with a: spark arrester, :
itimust ibeimaintainedi in effecti\eiv«5rdng order
of the GàiifOriiia-Public- Riésourcés -Godè).
.............
A
The safe^ alert symbol (A) is used with a signal word
(DANGER, CAUTION,WARNING), a pictorial and/or a
safety messa;^ 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, m/g/it 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.
Hazard Symbols and Meanings
...........
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.
^WARNING
^ >
Electrocution Electrical Shock Electrical Shock.
M
Toxic Fumes
Explosive Pressure Chemica Burn Hot Surface
Explosion
Fire
7500EXL Extended Life Generator
Id=lw^l=l=F±T-y
Parta DU rrodncti
^DANGER
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing cai'bon monoxide will cause nausea,
fainting or deacii.
Qfxsratcl^nbrator ONJ' outdoors.
<ccp :àt: least :2| feet: of clearance ori all I sides of Igtìhbràtor for 11
adequate :ycntilation,
DO NOT operate: generator inside:an>' :building or:encbsurc,
includitig thci^ncratpr: TOmparoiiicnt of a: тсспж^рп^ lydiblq
WHEN ADDING FUEL
• Turn generator OFF and lot ic cool at least 2 minutes before
::: removing @»s| Cap. -oosen cap ;sloy^tp rdieTC|pressurc in rank.!
.
»:: Fill :fijel|tank outdoors. 11111111111111111111111111111111111111111111111111
• DO NOT overfill tank,Allow space for fuel expansion,
DANGER
Generator produces powerful voltage.
Failure to Isolate generator from power utility
can result In deatli or injury to electric utility
workers due to backfeed of electrical energy.
•;; vyhonl using gohej^r lfer backup pcwen lnotify utility 11111111111
::: Company,;Usc approved: transfer;equipment to isolate ;;;;;;;;;;;
;;; generator from electric uti)!^. II
•I I Use a groundl circuit fault interrupter l(GFCI)l in lany damp lor 11
highly conductive area, such as metal decking or steel work.
•I I DO F40~ touch bare Wirtsl Or receptacles.
• DO NOT use gonerabar with electrical cords which are worn,
111 fti^cd, bare or otherwise dama^d.l I
» DO NOT operate generator in the rain, u y
•I I DO NOT I handtel generator or electrical cor ds while Sttinding |
in water, while barefoot or while hands or feet are wet,
i>:: DO NO”a|tow lunqualifled;persons or children to operate or
111 service generator,! 11111111111111111111111111111111111111111111111111111111
*■; Keep fuel I awayi from; sparks, open ;flamts.| pilot lights, hear, and ;
other ignition sources.
• DO NOT light a ciprette or smoke.
WHEN OF>ERATING EQUIPMENT
•I I DO NOT Itiplengine orlixjurpment at angle which causes fuel
I to spill................................
• This generator is not for use in mobile equipment or marine
111 applications. 111111111111111111111111111111
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
.
rl I Store:aw!y:fromlfu:maces,:stoves,vmtor heaters, clothes
111 dryers or other applimctalthai lhave pilot light or other 11111111
111 ighMph source | tecause they can ignite fuel vapors. |
Fuel and its vapors are extremely flammable and
explosive.
Fire or explosion can cause sevei e bui iis or
deatli.
^V^RNING
* •
...
;;
.........................
..
Ш Ш Ш
Storage batteries give off explosive hydrogen gas
dui'ing rechai'ging,
Hydi’ogen gas stays around battery for a long
time after battery has been charged.
Slightest spai'k will Ignite hydrogen and cause
explosion.
You can be blinded or severely injured.
Battery electrolyte fluid contains acid and is
extremely caustic.
Contact with battei'y fluid will cause sevei'e
chemical burns.
1 • DO NOT allow any open flame, spaHc, heat, or lit cigarcctc I
during and for several m
• Wear protective gosgli^
inutts after charging: a battery.:
, rubber apron, and rubber gloves.
~his generator docs not moot U. S. Coast Guard Regulatibnl
I SSGFR“ jSj and I should; not be used on marine applications.
I Failure to use the appropriate! U. S. Coast Guard lappnovedl 11
Igéhératór could result in bodily injury and/or property 111111
I damage.; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
.........
шштшшт
forbibk Prodicti
7500EXL Extended Life Generator
A WARNING
Exceeding generators wattage/amperage capacity can
Unintentional spai'king can result in fire oi'
electric shock.
WHEN
gene
i>:: OisGonnpct |tho Spark :pl pg wire; from: thpi spark; pi ug; and pjaco;
::: the WirC:WhCTC:lt :Cahhbt: COntaCC spark plug.:::::::::::::::::::::::
ADJUSTING OR MAKING REPAIRS TO YOUR
RA
iTOR
Щ Щ Ш Ш Ш
Running engines produce heat.Temperature of
muffler and neai'by areas can reach oi' exceed
I50T f65X),
Severe burns can occur on contact.
: DO h40~ touch hot sur&ces.: i i i i i i i i i i i i i i i
; ^ low equipment; № gqqI; bqfp touehihg.
Ж CAUTION
Excessively higli opeivating speeds increase risk of injury
and damage to geneivatot:
Excessively low speeds impose a heavy load.
DO NOT tamper with governed speed. Generator supplies
correct rated frequency and voltage when running at governed
speed, ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
DO NOTImbdii^ gohoratdrfnlahylmy.: 11111111111111111111111111111
damage generator and/or electrical devices connected
*;; See “Opn'tiOyerlpad ;Gensratpri*; on page 13.
•:: Start gcheratbrand: let engine stahilrzel before connecting: 11
;;; eliectriiat ibadsi 1111111111111111111111111111111111111111111 k
•:: Connect:electrical: loads:in: OFF :pos№on.then turn GN for
::: bfXSI^oh.::::::::::::::::::::::::::::::::::::::::::::::::: k
Turn;dectrical; loads ;OPF; and disconnect fram; generator;;;
before Upping generator. ;;;
Improper treatment of generator can damage it and
shoi'ten its life.
•;; Use; generator brily for intended; uses.
• If you have questions about intondtsd use, ask dealer or call
I -8Da-2H)-IdOS.
• Operate gonorator only on level surfaces.
• DO NOT expose generator to excessive moisture, dust, dirt,
;;; br:C0rri3S)¥C:VapbrSi::::::::::::::::::::
•:: DO NOT Insertjany:objects;through cooling slots,
•; ; If ebnnectod dbviciS QVcrhbat. turn them off and disconnect
them from generator,
•:: Shut off generator if:
;;;;;;;;; -electrical output is lost:
;;;;;;;;; -equipment ;spark3,;siT1bkbs,; or ;emte flarnes;;;;;;;;;;;;;;;;;
......... vibrates excessively.
CAUTION
.......
CAUTION
...............................
KNOWYOUR GENERATOR
Read this owners manual and safety rules before operating your generator.
Compare the illustrations with your generator, to femiliarize yourself with the locations of wirious controls and
adjustments. Save this manual for future reference.
; 12 Volt pc ; Receptacle 1^ Use this I receptacle w’tfi
battery charge I cables l&i Ichairge I a 112Vólt baittèry. Il II II II II II II II
Il2blVdltACfl2ÒAmp Duplex Rècéptacléli-I-I- May be
lùislédltbl isltij3j2lyl electrical Ipc^er fori the operaio ' of
|j2QYoItlAGilsihj^e phase.60 I Izlélectlriléallllightingi.làpplliahce.-
Itpoli and; motor iloadis.i 1111111111111111111111111111111111111
i j 20iVbjt ACti30 Amp iLocking iRecejAaclei i— May be
used|toi supplyelectrical ip^erifòrithe lopertópn ;pf...........
: 120 Volt AG, 130: Amp,l single | phase, 601 Hz I electrical llìghtìng,
lajjpliahceljltoòll land Imbiioir I Heads; 11111111111111111111111
Il 20/240 yoltlAC,l30 lArnpl ILockingl Receptacle — May
Iblei usèdi Ito Isupp y lelèctricàJl power fòr thel opèratiort cf
I j 20 and/or 24Ól¥óllt AC. |3Q Amipj islh^él phase, 60 Hz
iejectrical; iightjng,appliance;,itooi land ; motor; loads,; ; ;;;;;;;;
120/240 VoltAdC^ 50 Amp i^ceptade ™ May be used
to supply eiectrical povrer for the operation of 240 Vo t AC.
50 ;Amp,;slngle Iphase, 60 ;Hz leiectrlcal; loads. ;;;;;;;;;;;;;;;;;;
Air iCleaner l-^l Uses; a dry ^pe filter; element and foam
Ipire^leanerltol mit thel amount I of dirt and I dust i sucked I
intol the lengine. 1111111111111111111111111111111111111111111111111111111111
' Choke Lever Used whehlstariilng a cold; e-gi-e.
.......
i iCii-cuitiBreatere pC) Each receptaclei isi provided i i i i i
: :with: al "pUSh: iiXJ: itieset'' :circuit :brea!cer 'to. :p:ratect: the
I generator lapinlstl eleittrical loverioad, 11111111111111111111111111111111
I iFuel Tank ~l Cajsadtyl of seven I (7) I U.S. gallons. 111111111111111
; ;E jectric; S^rt ;Switch Press ;to ;start the; engine,;;;;;;;;;
: :G№und|ng; Fastener—;|f;required,; please ;consu ;;;;;;;
cual;ifjed;eleGtricia"*, electrical inspector, or ccal agency ;
'•avlhg jurisdictio", ; ;
Idle iGlOntrall iSwitch — Tre id e control runs the engine
at ;nprhial; ;(h!gh); ;speeds;when ;there; is; a; load; present ;and
r'un;s;the ;engine ;at idle ilpy/j ;speeds: when a load is not
..
I Ipriesentt: 111111111111111111111111111111111111111111111111111111111111111111111111
Oil Fill Cap — Add oil to engi ne here.
Recoil Starter — Used to start the engine manually,
Run/Stop Switch — Must be in “Run” position to start
ertgine. Set to “Stop” to stop a running engine.
SparkArresteriMuffler-^:Exhaust muffler lowers engine
; ;noise; and; is equipped; with a;spar4arrester screen.
..........
............
..............
;
.....
ASSEMBLY
Your generator requires some assemb y and is ready for
use after it has been praper y serviced with the
recommended oil and fuel.
If you have any problems: with the assembly of your
generator, please call the generator helpline at
1-800-270-1406.
IMPORTANT: Any attempt to run the unit before it has
been serviced with the recommended oi will result in an
engine ^ilure.
Remove Generator From Carton
1. Set carton on a rigid flat surface with “This Side Up”
arrows pointing upvrard.
2. Carefully open top flaps of shipping carton. Review
"Cold Weather Operation” on page 10,
3. Cut down corners at one end of carton from top tx>
bottom and lay that side of carton down flat
4. Remove all packing materia, carton fillers, etc,
5. Remove the generator from the shipping carron.
Install Wheel Kit
The wheel kit is designed to greaty improve the portability
of your generator.
NOTE; Whee kit is not intended for over-the-road use.
You will need a socket wrench with 1/2” or 13mm sockets
and a need e-nose p ier to install this kit.
Refer to Figure I and install the wheel kit as follows:
I.
Place the bottom of the generator cradle on a flat,
even surfice.Temporarily place unit on blocks to ease
assembly.
2.
Slide axle through both axle mounting bracl@ts on
cradle frame, as shown in Figure I,
3.
Slide a whee over the axle.
NOTE; Be sure to install both whee s with the air
pressure valve on the outboard side.
4. Place the e-ring onto the groove in the axle,You may
add the flat washer if desired.
NOTE; Use retaining pins instead of e-clip, if app icab e,
5. Place one end of the needle nose p iers on the bottom
of the ax e and the other end of the pliers on top of
the e-ring. Seat the e-ring by pressing the p iers closed.
6. Repeat step 3 through 5 to secure second wheel.
Figure I —liistallWhccI Kit
7500EXL Extended Life Generator
Id=lw^l=l=F±T-y
Farta DU rrodncti
7. Remove the temporary blocks.
8. Ata,di the vibration mounts to the support eg with
30mm capscrews, vrashers and lock nuts,
9. With the wheels on, you can now lift up the handle
end and attach the support leg with 20mm cap screws
and lock nuts.
ID. Check that a I fasteners are tight and the tires are inflated
to the та1ие marl®d on the tire or within 15 and 40 psi.
Check Battery / Attach Negative
Battery Wire
The sealed battery on the generator is fully charged and
pre-installed except for the ne;^tive (blacic) battery cable.
To install:
1. Cut off tie wrap securing oose end of ne;^tive (b ack)
cable.
2. Remove nut and v^isher on neptive battery terminal.
3. S ide negative battery cab e over screw on ne;^tive
terminal (Figure 2),
Figure 2— Negative Battery Connection
____________________
BEFORE STARTING THE
ENGINE
Add Engine Oil and Fuel
• Place generator on a level surface.
• Refer to engine owner’s manual and follow oil and fuel
recommendations and instructions.
CAUTION
Any
attempt to crank or stai't the engine before it has
been propei'ly filled with the recommended oil
in equipment failure.
; Refer to engine manuai for oil; and fuel fill information,
: Damage tol equilpmant resulting from failure to follow this
; instruetioh will void warranty.
NOTE; Check; oil often during engine break—in. Refer to
engine owner’s manual for recommendations,
NOTE: The generator assemb y rotates on a prelubricated
and sealed ball bearing that requires no additiona
lubrication for the life of the bearing.
will
___________
I'esult
.....
4. Reattach washer and nut and tighten.
5. Verify that connections to battery and generatx>r are
tight and secure.
шштшшт
forbibk Prodicti
7500EXL Extended Life Generator
USING THE GENERATOR
System Ground
The generator has a system ground that connects the
generator frame components to the ground tormina s on
the AC output receptacles.The system ground is connected
to the AC neutral wire (see "Equipment Description”,
eariier in this manua).
Special Requirements
There may be Federal or State Occupationa Safety and
Health Administration (OSHA) regu ations, local codes, or
ordinances that app у to the intended use of the generator.
Piease consuita qualified eiectrician, eiectricai inspector, or
the loca agency having jurisdiction,
• In some areas, generators are required to be registered
with bcai utiii^ companies,
• If the generator is used at a construction site, there may
be additionai reguiations which must be observed.
Connecting to a Building’s Electrical
System
Connections for standby power to a building’s e ectrica
system must be made by a qua ifled eiectrician. The
connection must isolate the generator power fram utiiily
power, and must сотр у with a I app icab e aws and
electrical codes.
_____________________
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 bcation, such as inside a ;^rage,
• Plug the charger into the unit’s “Battory Float Char^r”
jack, which is located on the starter switch (Figure 3).
Plug battery charger into a 120 Volt AC wal recepto.de.
Figure 3 — Battery Cliaigcr Jack
■) j''
• Unp ug the char^r 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 ife.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 14 for
additional information,
OPERATING THE
GENERATOR
IMPORTANT; A wa)^ unplug the battery float charger
before starting the generator.
Generatoi' produces powerful voltage.
Failure to Isolate generator from power utility
can result In deatli or injury to electric utility
workers due to backfeed of electi'ical energy.
VyhRh; using generator ifbr backtip powenihotily iutiiity i i 111111111
ccMT|pany.:Use appraved: tranter: qquipmqnc to isolate
gerieiatbr froffi electric Utili^i::::::::::::::::::::::::::
Use a ground: fault idrcult interrupter (C-C) in any idarfip ibr::
highly conductive; areavSUGh as ;metef decking or steel work,
30 NOT touch I bare wlrt»: br rbcoplaclcs.i i k k k k
:DO: NOT use: generator with electrical: cords which are vtrorn,
fti^cd, bare;or:othcrwise damaged.
DO NO~ operate generator in the tain,
DO NOT handle generator or electrical cords while standing
in watenwhiic barefoot or while hands or foot arc wet.
DO NOT al low unqualifled persons or children to operate or
service generator:^
.....
......
.
Exceeding generators watcage/amperage capacity can
damage generator and/or’ electrical devices connected
•:: Sbe ■‘DQfi’tlOveriQad iGchdratbr^ ■ bh ppgcl 13. I
*:: Start gGncf^tqr:an(d: jot onginc 5toi>t|rzc before connecting;;;
::: elCCttiral: llbads;::::::::::::::::::::::::::::::::::::::::::::::: k
*;; Gbririoct electrical loads in OFF positron, then turn ON for
;;; qpet^pn,;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
•:: Turn: cjcctrical: loads :0:FF: affd :disc6hnect from generator
;;; befcre stbpprr|g;generi№brt;;;;;;;;;;;;
eAUTION
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