Generac 7500 User Manual

The Reliable Ones

7500EXL

Portable Generator Owner *s Manual

DANGER! This generator is designed for outdoor use only. Never use this generator inside any buiiding

or enciosure inciuding 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.

Model No. 1019-1 ^500 Watt AC Generator) Manual No. B4594 Revision 0 (11/1/1999)

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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.

www.generac-portables.com

Generac Portable Products 7500EXL Extended Life Generator

EQUIPMENT DESCRIPTION SAFETY RULES

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.

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 othenwise improve the product at any time without prior notice.

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.

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.

WARNING: 0

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects, or other reproductive harm.

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).

Generac Portable Products 7500EXL Extended Life Generator

Do Not use worn, bare, frayed or otherwise

damaged eiectricai cord sets with the generator. Operate generator only on level surfaces and where

it will not be exposed to excessive moisture, dirt, dust or corrosive vapors.

Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE. Do Not permit smoking, open flames,

sparks or heat in the vicinity while handling gasoline. Avoid spilling gasoline on a hot engine. Comply with all regulations requiring storage and handling of gasoline.

Do Not overfill the fuel tank. Always allow room for

fuel expansion. If tank is overfilled, fuel can overflow onto a hot engine and cause FIRE or an

EXPLOSION.

Never store generator with fuel in tank where gasoline vapors might reach an open flame, spark or pilot light (as on a furnace, water heater or clothes dryer). FIRE or an EXPLOSION might result.

Generator exhaust gases contain DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Operate this equipment only in the open air where adequate ventilation is available.

The unit requires an adequate flow of cooling air for its continued proper operation. Never operate the unit inside any room or enclosure where the free flow of cooling air into and out of the unit might be obstructed. Without sufficient cooling air flow, the unit quickly overheats, damaging the generator or nearby property.

Allow at least 2 feet of clearance on ail sides of generator, even while operating unit outdoors, or you could damage the unit. Review Cold Weather Operation on page 9.

Never start or stop the unit with electrical loads connected to receptacles AND with the connected devices turned ON. Start the engine and let it stabilize before connecting electrical loads.

Disconnect ail electrical loads before shutting down the generator.

• Never operate generator;

in rain; in any enclosed compartment; if engine speed changes; if connected electrical devices overtieat; 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 eiectricai codes may also require proper grounding of the unit. For that purpose, a GROUNDING WING NUT (Figure 1) Is provided on the cradle frame.

Figure 1 — 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.

Know Your

Generac Portable Products 7500EXL Extended Life Generator

G f f l E E A T O R

KNOW YOUR GENERATOR

Read this owner’s manual and safety rules before operating your generator.

Compare the ilfustrations with your generator to familiarize yourself with the iocations 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 Receptacles — 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 Receptacie —

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

240 Volt AC, 50 Amp Receptacle — May be used to

supply electrical power for the operation of 240 Volt AC, 50 Amp, single phase, 60 Hz electrical loads.

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.

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 Muffier — Exhaust muffler lowers

engine noise and is equipped with a spark arrestor screen.

Generac Portable Products 7500EXL Extended Life Generator

Your generator requires some assembly and is ready for use after it has been properly serviced with the recommended oil and fuel.

If you have any problems with the assembly of your generator, please call the generator helpline at 1-800-270-1408.

IMPORTANT: Any attempt to run the unit before it has

been serviced with the recommended oil will result in an engine failure.

REMOVE GENERATOR FROM CARTON

• Set the carton on a rigid fiat 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 1" 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).

Figure 2 — Installing Battery Tray

CARTON CONTENTS

Check all 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.

Figure 3 — Installing Battery

Generac Portable Products 7500EXL Extended Life Generator

CAUTION: Be sure the black cable is

• Connect the red battery cable from the engine

connected to the engine mount and not the frame. You could damage the ground wire.

starter switch to positive {+) battery terminal {Figure 4).

Figure 4 — Battery Starting Cable Connections

Select the oil’s viscosity grade according to your

expected operating temperature:

colder

5W-30

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°F. 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

engine before it has been properly serviced with the recommended oil will result in an engine failure.

32° F

—I-

' warmer

10W-30

• 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.

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.

Add Fuel

DANGER: NEVER fill fuel tank indoors.

A A

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.

NEVER fill fuel tank when engine is running or hot. Do Not light a cigarette or smoke when

filling the fuel tank.

CAUTION: Do Not overfill the fuel tank.

Always allow room for fuel expansion.

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