The Reliable Ones
7500
Portable Generator Owner's Manual
L
A
A
DANGER[ This generator is designed for outdoor use only. Never use this generator inside any building
or enclosure including 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 (7500 Watt AC Generator) Manual No B4594 Revision 0 (11/1/1999)
Visit our Generac website: www.generac-portables.com
,_ 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.
GeneracPortableProducts7500EXLExtendedLifeGenerator
EQUIPMENT DESCRIPTION
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.
A CAUTION: Do Not exceed the generator's
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).
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 otherwise improve the product at any
time without prior notice.
A
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
SAFETY RULES
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.
• 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).
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GeneracPortableProducts7500EXLExtendedLifeGenerator
• DoNotuseworn,bare,frayedorotherwise
damagedelectricalcordsetswiththegenerator.
• Operategeneratoronlyonlevelsurfacesandwhere
itwillnotbeexposedtoexcessivemoisture,dirt,
dustorcorrosivevapors.
• GasolineishighlyFLAMMABLEanditsvaporsare
EXPLOSIVE.DoNotpermitsmoking,openflames,
sparksorheatinthevicinitywhilehandlinggasoline.
Avoidspillinggasolineonahotengine.Complywith
allregulationsrequiringstorageandhandlingof
gasoline.
• DoNotoverfillthefueltank.Alwaysallowroomfor
fuelexpansion.Iftankisoverfitled,fuelcanoverflow
ontoahotengineandcauseFIREoran
EXPLOSION.
• Neverstoregeneratorwithfuelintankwhere
gasolinevaporsmightreachanopenflame,sparkor
pilotlight(asonafurnace,waterheaterorclothes
dryer).FIREoranEXPLOSIONmightresult.
• GeneratorexhaustgasescontainDEADLYcarbon
monoxidegas.Thisdangerousgas,ifbreathedin
sufficientconcentrations,cancause
unconsciousnessorevendeath.Operatethis
equipmentonlyintheopenairwhereadequate
ventilationisavailable.
• Theunitrequiresanadequateflowofcoolingairfor
itscontinuedproperoperation.Neveroperatethe
unitinsideanyroomorenclosurewherethefree
flowofcoolingairintoandoutoftheunitmightbe
obstructed.Withoutsufficientcoolingairflow,the
unitquicklyoverheats,damagingthegeneratoror
nearbyproperty.
• Allowatleast2feetofclearanceonallsidesof
generator,evenwhileoperatingunitoutdoors,or
youcoulddamagetheunit.ReviewColdWeather
Operationonpage9.
• Neverstartorstoptheunitwithelectricalloads
connectedtoreceptaclesANDwiththeconnected
devicesturnedON.Starttheengineandletit
stabilizebeforeconnectingelectricalloads.
Disconnectallelectricalloadsbeforeshuttingdown
thegenerator.
• Never operate generator:
in rain; in any enclosed compartment; if engine
speed changes; if connected electrical devices
overheat; 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
electrical codes may also require proper grounding of
the unit. For that purpose, a GROUNDING WING NUT
(Figure 1) is provided on the cradle frame.
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.
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GeneracPortableProducts7500EXLExtendedLifeGenerator
KNOW YOUR GENERATOR
Read this owner's manual and safety rules before operating your generator.
Compare the illustrationswith your generator to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference
Circuit Breakers (AC)
12 Volt DC
Receptacle
Idle Control Switch
Electric Start Button
Recoil Starter
Choke Lever
120 Volt AC,
30 Amp Locking
Receptacle
/
120/240 Volt AC, 30 Amp /
Locking Receptacle
/
120 Volt AC, 20 Amp
Receptacles
Grounding Wing Nut
Run/Stop Switch
Spark Arrestor Muffler
240 Volt AC, 50 Amp
Receptacle
12 Volt DC Receptacle i Use this receptacle with
battery charge cables to charge a 12 Volt battery.
120 Volt AC, 20 Amp Receptacles i 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 i 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.
240 Volt AC, 50 Amp Receptacle i May be used to
supply electrical power for the operation of 240 Volt
AC, 50 Amp, single phase, 60 Hz electrical loads.
Choke Lever i 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 Muffler-- Exhaust muffler lowers
engine noise and is equipped with a spark arrestor
screen.
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GeneracPortableProducts7500EXLExtendedLifeGenerator
Yourgeneratorrequiressomeassemblyandis ready
foruseafterithasbeenproperlyservicedwiththe
recommendedoilandfuel.
Ifyouhave 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 flat 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.
CARTON CONTENTS
Check alt 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
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 7" 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).
I
J
J
• Set battery onto tray and attach bracket, J-bolts, lock
washers, flat washers, and hex nuts (Figure 3).
Tighten hardware with 3/8" wrench.
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GeneracPortableProducts7500EXLExtendedLifeGenerator
,_. CAUTION: Be sure the black cable is
connected to the engine mount and not the
frame. You could damage the ground wire.
• Connect the red battery cable from the engine
starter switch to positive (+) battery terminal
(Figure 4)
• 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.
Select the oil's viscosity grade according to your
expected operating temperature:
I colder _ 32°F -_,_warmer
!
5W-30 10W-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°E 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.
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.
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.
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.
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GeneracPortableProducts7500EXLExtendedLifeGenerator
Toavoidengineproblems,thefuelsystemshouldbe
emptiedbeforestorageof30daysorlonger.Drainthe
gastank,starttheengineandletit rununtilthefuel
linesandcarburetorareempty.Usefreshfuelnext
season.See"Storage"onpage12foradditional
information.
Neveruseengineorcarburetorcleanerproductsinthe
fueltankor permanentdamagemayoccur.
Toadd fuel:
• Clean area around fuel fitl 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.
.1/2" Air Space
• Install fuel cap and wipe up any spilled gasoline.
OPERATING THE
GENERATOR
,_. CAUTION! Never start, or stop, the generatorwith electrical loads connected to the unit AND
with the connected devices turned ON.
Starting the Engine
• Disconnect all electrical loads from the generator
• Open the fuel shut-off valve, as shown in Figure 6.
For Electric Start:
• 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.
• Pull slowly on recoil handle until you feel some
resistance. Then pull rapidly to start engine. Return
recoil slowly, Do Not let it "snap back".
Refer to the engine owner's manual for complete
starting instructions.
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 all 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-load 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
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GeneracPortableProducts7500EXLExtendedLifeGenerator
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 wilt 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
A
DANGER: Storage batteries give off explosive
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.
,_ll 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 bums. 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).
Red
\
12 VOLT D.C.
RECEPTACLE
Black
+
POS NEG
• 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.
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GeneracPortableProducts7500EXLExtendedLifeGenerator
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 all 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.
IMPORTANT!: 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
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
)ush-to-reset circuit breaker.
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).
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3-WireCordSet
Generac Portable Products 7500EXL Extended Life Generator
NEMA L5-30
r7_7 Ground
(Green)
Neutral
120V
Hot
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.
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 Volt load (Figure 11)
4-Wire Cord Set
Y (Hot) X (Hot)
Ground
NEMA L14-30 (Green)
This receptacle 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).
_=========240 VoltsA¢ ===========_
NEMA ]4-50
Use this receptacle to operate 240 Volt AC, 60 Hz,
single phase loads requiring up to 7,500 watts
(7.5 kW) of power.
A
CAUTION! Although this outlet states it has a
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.
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GeneracPortableProducts7500EXLExtendedLifeGenerator
DON'T 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 overloading 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.
• 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
*Air Conditioner (12,000 Btu) .................... 1700
*Air Conditioner (24,000 Btu) .................... 3800
*Air Conditioner (40,000 Btu) .................... 6000
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) ........................... 2000
*Compressor (3/4 HP) .......................... 1800
*Compressor (1/2 HP) .......................... 1400
Cuding Iron ................................... 700
*Freezer ...................................... 700
*Dehumidifier .................................. 650
Disc Sander (9") .............................. 1200
Edge Trimmer ................................. 500
Electric Blanket ................................ 400
Electric Nail Gun .............................. 1200
Electric Range (per element) ..................... 1500
Electric Skillet ................................ 1250
*Furnace Fan (3/5 HP) .......................... 875
*Garage Door Opener ..................... 500 to 750
Hair Dryer ................................... 1200
Hand Drill .............................. 250 to 1100
Device .............. Running Watts
Hedge Trimmer ................................ 450
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, Airless (1/3 HP) ................... 600
Paint Sprayer, Airless (handheld) .................. 150
Radio ................................... 50 to 200
*Refrigerator .................................. 700
Slow Cooker .................................. 200
*Submersible Pump (1-1/2 HP) ................... 2800
*Submersible Pump (1 HP) ...................... 2000
*Submersible Pump (1/2 HP) .................... 1500
*Sump Pump ........................... 800 to 1050
*Table Saw (10") ........................ 1750 to 2000
Television ............................... 200 to 500
Toaster ............................... 1000 to 1650
Weed Trimmer ................................. 500
* Allow 3 times the listed watts for starting these devices.
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11
Generac Portable Products 7500EXL Extended Life Generator
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.
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 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.
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
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.
,_ll DANGER: Storage covers can be flammable.
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.
Engine Storage
See engine owner's manual for instructions on how to
properly 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
and/or dirt in a gasoline can cause problems when
you use that fuel with this unit.
• Store unit in clean and dry area.
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
i
12
GeneracPortableProducts7500EXLExtendedLifeGenerator
TROUBLESHOOTING
Problem
Engine is running, but
no AC output is
available.
Engine runs good but
bogs down when
loads are connected.
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
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 GeneratoY'
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.
Engine will not start;
or starts and runs
rough,
spark plug.
6. Bad spark plug.
7. Water in gasoline.
8. Overchoking.
9. Low oil level.
10.
11.
12.
Excessively rich fuel mixture.
Intake valve stuck open or closed.
Engine has lost compression.
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,
Engine shuts down
during operation.
Engine lacks power.
Engine "hunts" or
falters.
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.
Carburetor is running too rich or too
lean.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Generac service facility,
1. See"Don't Overload the GeneratoP
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
GeneracPortableProducts7500EXLExtendedLifeGenerator
ID]_LF_i_]_
SCHEMATIC DIAGRAM
18
35_
L0P
155 156 2@ 44
SYSTEH
CONTROL
s BOARD
I BLU/_HT 2_
IDLE
G
L
0 B
I
14
Generac Portable Products 7500EXL Extended Life Generator
ID_'! _
WIRING DIAGRAM
J •
120V/20A 120/240v
GRN/YEL /x
IDLE ¢DNTRDL
TRAN_FDRHER
¢
10A
C_B_
AUTD RESET
IDLE
CONTROL
SWITCH
RUN
_N
NUT ON
ENGINE BLOCK
I
15
I
_j/- I
Generac Portable Products 7500EXL Extended Life Generator
MAIN UNIT EXPLODED VIEW
51
1/
65\
51
\
\
26 33 13--
62
38
10
\\
<
16-
58
57
\
\,
21
17
\
37
\65
DETAIL OF
ELECTRIC START
SWITCH
57
66 67 68
/ /
65 TO STARTER
_9
55
/
16
Generac Portable Products 7500EXL Extended Life Generator
I
Ill
m
MAIN UNIT PARTS LIST
Item Part # Qty. Description
1 A92432 1 CRADLE
2 A92531 1 SUPPORT, Engine
3 A92731 1 SUPPORT, Engine & Muffler
4 92247 1 HOUSING, Engine Adapter
5 B1342G 1 ASSEMBLY, Rotor
6 B1897G 1 ASSEMBLY, Stator
7 65791 1 BEARING
8 67451 1 WASHER, Special Flat - M8
9 22129 12 WASHER, Lock- M8
10 86307 4 HHMS, 5/16-24 x 3/4 SEMS
11 47481 1 HHCS, 5/16-24 x 10.625
12 92609 2 MOUNT, Vibration
13 82857 4 MOUNT, Vibration
14 40976 2 SCREW, M8 - 1.25 x 20
15 66476 2 CAPSCREW, M6 - 1.0 x
12mm
16 92532 1 BRACKET, Muffler
17 22142 2 SCREW, 5/16 - 18 x 3/4
18 91153 1 MUFFLER
19 90239 1 GASKET, Muffler
20 81917 1 PIN, Roll 4mm x 10
21 B4986 1 DECAL, Ground
25 66825C 1 CARRIER, Rear Bearing
26 74908 4 TAPTITE, M5-0.8 x 10
27 66449L 4 BOLT, Stator M6-1 x 190mm
28 65795 2 RECTIFIER, Battery Charge
29 66849C 1 TAPTITE, M5-0.8 x 30
30 67022 1 GROMMET, Rubber
31 84132 1 ASSEMBLY, Power Regulator
32 66386 1 ASSEMBLY, Brush Holder
33 66849 2 TAPTITE, M5-0.8 x 16
34 B78388 1 COVER, Bearing Carrier
35 22769 1 WASHER, Shakeproof Int.
#10
36 86494 1 SCREW, M6-1.0 x 16 Wing
37 B2153 9 HHCS, - #10 Self Driller
38 77395 4 NUT, Flange Lock - M6
39 83465 4 GROMMET, Tank
40 57058 4 HHMS, M6-1.0 x 55
41 80270 1 VALVE, Tank
42 78299 1 BUSHING, Tank
Item Part # Qty. Description
43 B4363 1 CAP, with Gauge, Fuel
44 B1998 1 TANK, Fuel
45 B92039 1 SHIELD, Heat
46 92665 1 INSULATION, #2-1/4" Thick
47 85000 1 CLIP, Insulation
48 14353621 1 WIRE, Ground
49 26850 2 LW, EXT, Shakeproof M6
50 57593 1 MOUNT, Cable Tie
51 92982 1 DECAL, Danger
52 B4569 2 DECAL, Heat Shield
55 25244 12 NUT, 5/16-18 Hex
57 B4569 1 DECAL, Control Panel
58 B4366 1 ASSEMBLY, Control Box
59 NSP 1 ENGINE
60 22531 2 HHCS, 5/16-18 x 1-3/4"
62 93826 1 DECAL, Start Instructions
63 B96068 1 SHIELD, Heat
64 56893 5 CRIMPTITE, 10-24 x 1/2
65 77282 1 SWITCH, Starter
66 22287 2 SCREW, 1/4 - 20 x 3/4
67 22097 2 LOCKWASHER, M6
68 22127 2 NUT, 1/4 - 20 Hex
69 78289 1 BRACKET, Starter Switch
70 22473 4 WASHER, M6 Flat
Parts Not Illustrated
A96923 1 Tray, Battery
96924 2 J-Bolt, M8 - 1.25
22129 2 Lockwasher
45771 2 Hex nut M8
22145 2 Flat Washer
15453621 1 Cable, Positive Battery
15553621 1 Cable, Negative Battery
37806 1 120V 30 A plug
43438 1 120/240V 30 A plug
65787 1 Cable, Battery Charge
A96925 1 Bracket, Tie Down
B4594 1 Manual, owner's
72347 1 Spark Plug
73111 1 Air Cleaner Element
84882 1 Spark Plug Wrench
/
17
I=&'_J-#J"d |
I
? j/_ I
Generac Portable Products 7500EXL Extended Life Generator
CONTROL PANEL EXPLODED VIEW AND PARTS LIST
lO
lO
28
27
19
2C 21
25
26
12
Item Pa_ # Qty.
1 BB4461 1
2 23897 4
3 49226 4
4 91526 4
5 82538 1
6 82881 6
7 B4262 1
8 90418 1
9 75207N 2
10 75207A 2
11 75207 2
12 23365 10
13 68868 1
14 43437 1
13
L$.\
2
\
3
Description
PANEL, Control
WASHER, #10 M5 Flat
WASHER, M5 Lock
SCREW, M5-0.8 x 12 mm
SWITCH, Idle Control
WASHER, 7/16" Int. Lock
OUTLET, 50A, 240V
OUTLET, 10A, 12VDC
CIRCUIT BREAKER, 35 Amp
CIRCUIT BREAKER, 30 Amp
CIRCUIT BREAKER, 20 Amp
WASHER, #8 Shakeproof
OUTLET, 30A, 120V Locking
OUTLET, 30A, 120V/240V
Locking
17 18
7
18
17
>9
12 _
Item Pa_ # Qty.
15 68759 1
16 43180 10
17 22264 10
18 51715 10
19 64526 8
20 83970 1
21 64525 4
22 87962 1
23 84335 1
24 84134 1
25 B92069 1
26 84028 1
27 43181 4
28 43182 4
J24
Description
OUTLET, 20A,120V
WASHER, M4 Flat
WASHER, #8 M4 Lock
NUT, M4 - 0.7 Hex
SCREW, #6-32 x 3/8"
BOARD, System Control
3/4" Hex Standoff
CIRCUIT BREAKER, 10A
(automatic), 12V
ASSEMBLY, Wire Harness
GROMMET, Rubber
BOX, Control Panel
TRANSFORMER, Idle Control
SCREW, M3 - 0.5 x 10 mm
WASHER, M3 Lock
I
18
GeneracPortableProducts7500EXLExtendedLifeGenerator
NOTES
/
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 the 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 wilt, 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 TO THE DURATION 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.
GENERAC PORTABLE PRODUCTS
Jefferson, Wisconsin 53549
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