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
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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)
Visit our Generac website:
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.
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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
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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.
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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
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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
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• 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
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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.
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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.
Generac Portable Products 7500EXL Extended Life Generator
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. Drain the
gas tank, start the engine and let it am until the fuel
lines and carburetor are empty. Use fresh fuel next
season. See “Storage” on page 12 for additional
information.
Never use engine or carburetor cleaner products in the
fuel tank or permanent damage may occur.
To add fuel:
• Clean area around fuel fill cap, remove cap.
• Slowly add “UNLEADED” regular gasoline, slowly, to
fuel tank. Leave about a 1/2" space in the fuel tank
for fuel expansion (Figure 5). Do Not overfill fuel
tank.
Figure 5 — Typical Fuel Expansion Space
Figure 6 — Fuel Valve Operation
• Prepare engine for starting according to engine
owner’s manual.
• Press starter switch until engine cranks and starts.
For Manual Start:
• Prepare engine for starting according to engine
owner’s manual.
• Puii siowiy on recoil handle until you feel some
resistance. Then pull rapidly to start engine. Return
recoil siowiy. Do Not let it “snap back”.
Refer to the engine owner’s manual for complete
starting instructions.
OPERATING THE GENERATOR
CAUTION! Never start, or stop, the generator
with electrical loads connected to the unit AND
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with the connected devices turned ON.
Starting the Engine
Disconnect all electrical loads from the generator.
Open the fuel shut-off vaive, as shown in Figure 6.
Applying Electrical Loads
• Let engine stabilize and warm up for about five
minutes after starting.
• Plug in and turn on the desired 120 or 240 Volt AC,
single phase, 60 Hz electrical loads. DO NOT
OVERLOAD THE GENERATOR. The total rated
watts (or amps) of aii loads to be connected at one
time should not be greater than the rated
wattage/amperage capacity of the generator. See
“Don’t Overload the Generator” on page 11.
____________
Stopping the Engine
Disconnect all electrical loads.
Run engine at no-ioad for a few minutes to stabilize
unit’s internal temperatures.
Turn off engine according to engine owner’s manual.
Close the fuel shut-off valve.
OPEElAnON
Generac Portable Products 7500EXL Extended Life Generator
Operating Automatic Idle Control
This switch is designed to greatly improve fuel
economy. When this switch is turned ON, the engine
will only am 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.
Battery Safety_____________________
DANGER: Storage batteries give off explosive
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hydrogen gas while recharging. An explosive
mixture will remain around the battery for a
long time after it has been charged. The
slightest spark can ignite the hydrogen and
cause an explosion, which can shatter the
battery and cause blindness or other injury.
DANGER: Do Not permit smoking, open
flame, sparks or any other source of heat
around a battery. Wear protective goggles,
rubber apron and rubber gloves when working
around a battery. Battery electrolyte fluid is an
extremely caustic sulfuric acid solution that can
cause severe burns. If spill occurs flush area
with clear water immediately.
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;
• Check fluid level in all battery cells. If necessary,
add ONLY distilled water to cover separators in
battery cells. Do Not use tap water.
• If the battery is equipped with vent caps, make sure
they are installed and are tight.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to
panel receptacle identified by the words
“12-VOLTS D.C.”.
• Connect battery charge cable clamp with red handle
to the positive (+) battery terminal {Figure 7).
Figure 7 — Battery Charge Cable Connection
• Connect battery charge cable clamp with black
handle to the negative (-) battery terminal,
(Figure 7).
• Start engine. Let the engine run while battery
recharges.
• 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.
Generac Portable Products 7500EXL Extended Life Generator
COLD WEATHER OPERATION
Under certain weather conditions (temperatures below
40"F [4‘'C] and a high dew point), your Generac
generator may experience icing of the carburetor
and/or the crankcase breather system.
In an emergency, use the original shipping box as a
temporary shelter:
• Cut off ail flaps.
• Cut out one of the long sides of the box to expose
exhaust side of unit. Ensure a minimum of two feet
clearance between open side of box and nearest
object.
• Cut appropriate slots to access receptacles and
clear handles.
• Start unit, then place box over it.
IMPORTANTI: Remove shelter when temperature is
above 40°F [4”C].
For a more permanent shelter, build a structure that
will enclose three sides and the top of the generator:
• Make sure entire muffler-side of generator is
exposed. Note that your generator may appear
different from that shown in Figure 8.
Ensure a minimum of two feet clearance between
open side of box and nearest object.
Face exposed end away from wind and elements.
Enclosure should hold enough heat created by the
generator to prevent problems.
CAUTION: NEVER run unit indoors; Do Not
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enclose generator any more than shown.
Remove shelter when temperatures are above
40°F [4°C].
CORD SETS/RECEPTACLES
This generator is equipped with the following
receptacles:
120 Volt AC, 20 Amp Receptacle
This outlet is protected against overload by a 20 Amp
push-to-reset circuit breaker.
Figure 9 — 120 Voit AC, 20 Amp Receptacles
Figure 8 — Temporary Coid Weather Shelter
Use each socket to operate 120 Volt AC, single phase
60 Hz electrical loads requiring up to 2400 watts
(2.4 kW) at 20 Amps (Figure 9). Use cord sets that are
rated for 125 Volt 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 10).
OPEElAnON
Generac Portable Products 7500EXL Extended Life Generator
Figure 10 — 120 Volt AC, 30 Amp Receptacle
3-Wire Cord Set
Neutral
120V
Hot
, Ground
NEMA L5-30
Use this receptacle to operate 120 Volt AC, 60 Hz,
single phase loads requiring up to 3600 watts {3.6 kW)
of power at 30 Amps. The outlet is protected by a 30
Amp push-to-reset circuit breaker.
// / (Green)
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. You can use the same 4-wire
cord if you plan to run a 120 Voit load (Figure 11).
Figure 11 — 120/240 Voit AC, 30 Amp Receptacle
This receptacie powers 120 Volt AC, single phase,
60 Hz loads requiring up to 3,600 watts of power
{3.6 kW). Or it will operate 240 Volt AC, single phase,
60 Hz loads up to 7,200 watts 7.2 kW). The outlet is
protected by a 30 Amp push-to-reset circuit breaker.
240 Volt AC, 50 Amp Receptacle
Use a NEMA 14-50 plug with this receptacle. Connect
a 4-wire cord set rated for 240 Volt AC loads at
50 Amps to the plug {Figure 12).
Figure 12 — 240 Volt, 50 Amp Receptacle
Use this receptacle to operate 240 Volt AC, 60 Hz,
single phase loads requiring up to 7,500 watts
(7.5 kW) of power.
CAUTION! Although this outlet states it has a
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250 Volt 50 Amp rating (up to 12,500 watts),
the generator is only rated for 7,500 Watts.
Powering loads that exceed the wattage/
amperage capacity of the generator can
damage it or cause serious injuries. 240 Volt
loads powered through this outlet should not
exceed 31.2 Amps of current draw.
Generac Portable Products 7500EXL Extended Life Generator
DONT OVERLOAD THE
GENERATOR
Overloading a generator in excess of its rated wattage
capacity can result in damage to generator and to
connected electrical devices. Observe the following, to
prevent overioading the unit:
• Add up the total wattage of all electrical devices to
be connected at one time. This total should NOT be
greater than the generator’s wattage capacity.
• The rated wattage of lights can be taken from light
bulbs. The rated wattage of tools, appliances and
motors can usually be found on a data plate or decal
affixed to the device.
Figure 13 — Wattage Reference Guide
Device ........................ Running Watts
*Air Conditioner (12,000 Btu)
*Air Conditioner (24,000 Btu)
*Air Conditioner (40,000 Btu)
Battery Charger (20 Amp)...........................................................................500
Belt Sander (3")....................................................................................... 1000
Chain Saw..................................................................................................1200
Circular Saw (6-1/2")................................................................. 800 to 1000
‘Clothes Dryer (Electric)............................................................................ 5750
‘Clothes Dryer (Gas)....................................................................................700
‘Clothes Washer.........................................................................................1150
Coffee Maker.............................................................................................1750
‘Compressor (1 HP)
‘Compressor(3/4 HP).................................................................................1800
‘Compressor (1/2 HP)................................................................................1400
Curling Iron...................................................................................................700
‘Freezer........................................................................................................700
‘Dehumidifier................................................................................................650
Disc Sander (9")........................................................................................1200
Edge Trimmer..............................................................................................500
Electric Blanket.......................................................................................... 400
Electric Nail Gun
Electric Range (per element)
Electric Skillet............................................................................................1250
‘Furnace Fan (3/5 HP).................................................................................875
‘Garage Door Opener
Hair Dryer...................................................................................................1200
Hand Drill...................................................................................250 to 1100
...........
.......................................................................................1200
..................................................................
.......................................................
......................................................
.......................................................
......................................................................2000
....................................................................
1700
3800
6000
1500
500 to 750
If the appliance, tool or motor does not give wattage,
multiply volts times ampere rating to determine watts
(volts X amps = watts).
Some electric motors, such as induction types,
require about three times more watts of power for
starting than for running. This surge of power lasts
for only a few seconds when starting such motors.
Be sure you allow for this high starting wattage
when selecting electrical devices to connect to your
generator. First figure the watts needed to start the
largest motor. Add to that figure the running watts of
all other connected loads.
The Wattage Guide shown in Figure 13 is provided
to help you to determine how many items the
generator can operate at one time.
Device ........................ Running Watts
Hedge Trimmer
Impact Wrench.............................................................................................500
Iron.............................................................................................................1200
‘Jet Pump.....................................................................................................800
Lawn Mower........................................................................................... 1200
Light Bulb................................................................................................... 100
Microwave Oven...........................................................................700 to 1000
‘Milk Cooler............................................................................................ 1100
Oil Burner on Furnace.................................................................................300
Oil Fired Space Heater (140,000 Btu).........................................................400
Oil Fired Space H eater (85,000 Btu)..........................................................225
Oil Fired Space Heater (30,000 Btu)...........................................................150
‘Paint Sprayer, Airiess (1/3 HP)
Paint Sprayer, Airless (handheld)...............................................................150
Radio............................................................................................50 to 200
‘Refrigerator.................................................................................................700
Slow Cooker.................................................................................................200
‘Submersible Pump (1-1/2 HP)
‘Submersible Pump (1 HP)..................................................................... 2000
‘Submersible Pump (1/2 HP)
‘Sump Pump
‘Table Saw (10")
Television
Toaster.........................................................................................1000 to 1650
Weed Trimmer......................................................................................... 500
...........................................................................................
..................................................................
................................................................
...................................................................
........
.......................................................................
.......................................................................
.....................................................................................
‘ Allow 3 times the listed watts for starting these devices.
450
600
2800
1500
800 to 1050
1750 to 2000
200 to 500
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/pROl
Generac Portable Products 7500EXL Extended Life Generator
GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure
that ail periodic maintenance tasks are completed on a
timely basis; that ail discrepancies are corrected; and
that the unit is kept clean and properly stored. Never
operate a damaged or defective generator.
Engine Maintenance
See engine manual for instructions.
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 any foreign material.
Check the cleanliness of the generator frequently and
clean when dust, dirt, oil, moisture or other foreign
substances are visible on its exterior surface.
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 siots, 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.
________________
____________ _
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.
• Clean the generator as outlined in “To Clean the
Generator.”
• Check that cooling air slots and openings on
generator are open and unobstructed.
• Disconnect the negative battery cable from the
battery.
DANGER: Storage covers can be flammable.
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Engine Storage
See engine owner’s manual for instructions on how to
property store the engine.
Other Storage Tips
• Do Not store gasoline from one season to the next.
• Replace your gasoline can if it starts to rust. Rust
• Store unit in clean and dry area.
Do Not place a storage cover over a hot
generator. Let the unit cool for a sufficient time
before placing the cover on the unit.
___________________
_________________
and/or dirt in a gasoline can cause problems when
you use that fuel with this unit.
To Clean the Generator
• Use a damp cloth to wipe exterior surfaces clean.
• A soft bristle brush may be used to loosen caked-on
dirt or oil.
• A vacuum cleaner may be used to pick up loose dirt
and debris.
• Low pressure air (not to exceed 25 psi) may be
used to blow away dirt. Inspect cooling air slots and
opening on generator.
______________
SERVICE/ADJUSTMENTS
Refer to engine owner’s manual for information.
SPECIFICATIONS
Rated Maximum Continuous
AC Power Output......................................................7500 watts (7.5 kW)
Rated Voltage...........................................................120/240 Volts
Rated Maximum AC Current
at 120 Volts...........................................................62.5 Amps
at 240 Volts...........................................................31.2 Amps
Phase........................................................................1
Rated AC Frequency................................................60 Hertz
Number of Rotor Poles.............................................2
Driven Speed of Rotor..............................................3600 rpm
12
Generac Portable Products 7500EXL Extended Life Generator
TROUBLESHOOTING
Problem
Engine is running, but
no AC output Is
available.
Engine runs good but
bogs down when
loads are connected.
Engine will not start;
or starts and runs
rough.
Engine shuts down
during operation.
Engine lacks power.
Engine “hunts” or
falters.
Cause
1. Circuit breaker is open.
2. Poor connection or defective cord set.
3. Connected device is bad.
4. Fault in generator.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Run/Stop switch set to “Stop”.
2. Dirty air cleaner.
3. Out of gasoline.
4. Stale gasoline.
5. Spark plug wire not connected to
spark plug.
6. Bad spark plug.
7. Water in gasoline.
8. Overchoking.
9. Low oil level.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
1. Out of gasoline.
2. Low oil level.
3. Fault In engine.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. Choke is opened too soon.
2. CariDuretor is running too rich or too
lean.
Solution
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in
good condition.
4. Contact Generac service facility.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator”
on page 11.
3. Contact Generac service facility.
4. Contact Generac service facility.
1. Set switch to “Run”.
2. Clean or replace air cleaner.
3. Fill fuel tank.
4. Drain gas tank and fill with fresh
fuel.
5. Connect wire to spark plug.
6. Replace spark plug.
7. Drain gas tank; fill with fresh fuel.
8. Put choke lever at “No Choke”
position.
9. Fill crankcase to proper level.
10. Contact Generac service facility.
11. Contact Generac service facility.
12. Contact Generac service facility.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Generac service facility.
1. See “Don’t Overload the Generator”
on page 11.
2. Replace air filter.
3. Contact Generac service facility.
1. Move choke to halfway position till
engine runs smoothly.
2. Contact Generac service facility.
13
Generac Portable Products 7500EXL Extended Life Generator
SCHEMATIC DIAGRAM
14
Generac Portable Products 7500EXL Extended Life Generator
WIRING DIAGRAM
15
Generac Portable Products 7500EXL Extended Life Generator
MAIN UNIT EXPLODED VIEW
16
Generac Portable Products 7500EXL Extended Life Generator
MAIN UNIT PARTS LIST
Item
Part# Qty.
Description Item
1 A92432 1 CRADLE
2
A92531
3 A92731
4 92247 1
5 B1342G
6 B1897G
7
65791
8 67451
9 22129
86307
10
11
47481
12
92609
82857
13
14
40976
15 66476
1
SUPPORT, Engine
1 SUPPORT, Engine & Muffler
HOUSING, Engine Adapter 46 92665
1 ASSEMBLY, Rotor 47
1 ASSEMBLY, Stator
1
BEARING 49 26850
1
WASHER, Special Flat - M8
12 WASHER, Lock - M8
4
HHMS, 5/16-24 X 3/4 SEMS 52
1
HHCS, 5/16-24 X 10.625 55
2 MOUNT, Vibration 57
4
MOUNT Vibration
2
SCREW, M8- 1.25x20
2 CAPSCREW, M6 - 1.0 X
12mm 62
92532 1 BRACKET, Muffler
16
17 22142 2 SCREW, 5/16 -18 X 3/4 64
18 91153
19 90239
81917 1
20
21
B4986
25 66825C
26 74908
1 MUFFLER
1 GASKET. Muffler
PIN, Roll 4mm x 10
1
DECAL, Ground
1 CARRIER, Rear Bearing
4
TAPTITE, M5-0.8 X 10
27 66449L 4 BOLT, Stator M6-1 x 190mm
28 65795
29 66849C
67022 1 GROMMET, Rubber 96924 2
30
84132 1 ASSEMBLY, Power Regulator
31
32
66386
33 66849
34
B78388
35 22769
2 RECTIFIER, Battery Charge
1
TAPTITE, M5-0.8 X 30
1 ASSEMBLY, Brush Holder 45771 2
2
TAPTITE, M5-0.8 X 16
1 COVER, Bearing Camier 15453621 1
1
WASHER, Shakeproof Int.
#10 37806
86494 1 SCREW. M6-1.0X 16 Wing
36
37
B2153 9
38 77395
39 83465
40 57058
41
80270
42
78299
HHCS, - #10 Seif Driller 65787 1
4
NUT, Range Lock - M6
4 GROMMET, Tank B4594 1
4
HHMS, M6-1.0X55
1 VALVE, Tank
1
BUSHING, Tank
Part# Qty.
43 B4363
44
B1998
45 B92039
Description
1
CAP, with Gauge, Fuel
1
TANK, Fuel
1 SHIELD, Heat
1 INSULATION, #2-1/4" Thick
85000
14353621 1
48
50 57593
51
92982 1 DECAL, Danger
B4569
25244 12
B4569
58 B4366
59 NSP
60 22531
93826
63 B96068
56893 5
77282 1 SWITCH, Starter
65
22287 2 SCREW. 1/4 - 20 X 3/4
66
1 CLIP, Insulation
WIRE, Ground
2
LW, EXT, Shakeproof M6
1
MOUNT, Cable Tie
2
DECAL, Heat Shield
NUT, 5/16-18 Hex
1
DECAL, Control Panel
1 ASSEMBLY, Control Box
1 ENGINE
2 HHCS. 5/16-18 X 1-3/4"
1
DECAL, Start Instructions
1
SHIELD, Heat
CRIMPTITE, 10-24 X 1/2
67 22097 2 LOCKWASHER, M6
22127 2 NUT, 1/4 - 20 Hex
68
69 78289
70 22473
Parts Not Illustrated
A96923
1 BRACKET, Starter Switch
4
WASHER, M6 Fiat
1
Tray. Battery
J-Bolt, M8 -1.25
22129
2 Lockwasher
Hex nut M8
2
22145
Flat Washer
Cable, Positive Battery
15553621 1
43438
Cable, Negative Battery
1
120V 30 A plug
1
120/240V30Aplug
Cable, Battery Charge
A96925
1
Bracket. Tie Down
Manual, owner’s
72347 1 Spark Plug
73111
84882 1
1 Air Cleaner Element
Spark Plug Wrench
17
Generac Portable Products 7500EXL Extended Life Generator
CONTROL PANEL EXPLODED VIEW AND PARTS LIST
25
Item Part#
1
BB4461
2 23897 4
3 49226
4
91526
5 82538
6 82881 6
7 B4262 1 OUTLET, 50A, 240V 21
8 90418
75207N 2 CIRCUIT BREAKER, 35 Amp
9
75207A 2 CIRCUIT BREAKER, 30 Amp
10
Description Item
Qty.
1
PANEL, Controi 15 68759
WASHER, #10 M5 Fiat
Part# Qty.
16 43180 10
4 WASHER, M5 Lock 17 22264
4
SCREW, M5-0.8 X 12 mm
1
SWITCH, Idle Controi
WASHER, 7/16" Int. Lock
18 51715 10
19 64526 8
20 83970
64525
1
OUTLET, 10A, 12VDC
22 87962 1 CIRCUIT BREAKER, 10A
23 84335
Description
1 OUTLET, 20A,120V
WASHER, M4 Flat
WASHER, #8 M4 Lock
10
NUT, M4 - 0.7 Hex
SCREW, #6-32 X 3/8"
1
BOARD, System Control
4
3/4" Hex Standoff
(automatic), 12V
1
ASSEMBLY, Wire Harness
11 75207 2 CIRCUIT BREAKER, 20 Amp 24 84134 1 GROMMET, Rubber
12
23365 10
13 68868
WASHER, #8 Shakeproof
1 OUTLET, 30A, 120V Locking
25 B92069
26 84028
14 43437 1 OUTLET, 30A, 120V/240V 27
Locking
28
18
43181
43182 4 WASHER, M3 Lock
1
BOX, Control Panel
1 TRANSFORMER, idle Control
4
SCREW, M3 - 0.5 x 10 mm
NOTES
Generac Portable Products 7500EXL Extended Life Generator
19
LIMITED WARRANTY
for "gn" engine driven portable generators
GENERAC PORTABLE PRODUCTS {hereafter referred to as the COMPANY) warrants to the original purchaser
that the alternator and control panel for its portable generator will be free from defects in materials or
workmanship for the Items and period set forth below from the date of original purchase. This warranty is not
transferable and applies only to portable generators driven by a GN-Series engine. This warranty does not apply
to starting battery, rechargeable flashlight or battery charger.
Consumer* Commercial*
Alternator 2 years {2nd year parts only) 1 year
Engine Warranted solely by the engine manufacturer
With tile exception of European Community Countries, all units bound for export shall be warranted for
One (1) Year in Consumer applications, and 90 days in Commercial applications as defined below.
*NOTE: For the purpose of this warranty "consumer use" means personal residential household use by
original purchaser. This warranty does not apply to units used for Prime Power in place of utility.
"Commercial Use" means all other uses, including rental, construction, commercial and income
producing purposes. Once a generator has experienced commercial use, it shall thereafter be considered
a commercial use generator for the purposes of this warranty.
During said warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination
by the COMPANY, is found to be defective under normal use and service**. Starting batteries are not warranted
by the COMPANY. All transportation costs under warranty, including return to the factory if necessary, are to be
borne by the purchaser and prepaid by the purchaser. This warranty does not cover normal maintenance and
service and does not apply to a generator set, alternator, or parts which have been subjected to improper or
unauthorized installation or alteration, misuse, negligence, accident, overloading, overspeeding, improper
maintenance, repair or storage so as, in the COMPANY’S judgement, to adversely affect its performance and
reliability.
**NORMAL WEAR: As with all mechanical devices, the generator need periodic parts service and
replacement to perform well. This warranty will not cover repair when normal use has exhausted the life
of a part or generator.
THERE IS NO OTHER EXPRESS WARRANTY. THE COMPANY HEREBY DISCLAIMS ANY AND
ALL IMPLIED WARRANTIES. INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE
DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO
THE TIME PERIOD AS SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR
CONSEQUENTIAL. INCIDENTAL OR SPECIAL DAMAGES UNDER ANY AND ALL WARRANTIES
IS EXCLUDED. THE COMPANY ALSO DISCLAIMS ANY RESPONSIBILITY FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SUCH AS THE LOSS OF TIME OR THE USE OF THE POWER
EQUIPMENT. OR ANY COMMERCIAL LOSS DUE TO THE FAILURE OF THE EQUIPMENT: AND
ANY IMPLIED WARRANTIES ARE LIMITED TQ THE DURATIQN OF THIS WRITTEN
WARRANTY.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of
incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty
gives you specific legal rights and you may also have other rights, which vary from state to state.
For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Warranty
service can be performed only by a COMPANY authorized service facility. This warranty will not apply to service
at any other facility. At the time of requesting warranty service, evidence of original purchase date must be
presented.
^2 E M E F*l ^XCÜ# |!3 ^¡3 IB I™ E i cs
Jefferson, Wisconsin 53549
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