Generac Power Systems 1470-0, 7000EXL Owner's Manual

Owner’s Manual

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Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT

Web: www.generac-portables.com or www.briggsandstratton.com

Model No. 1470-0 (7,000 Watt AC Generator) Manual No. 186744GS Revision 6 (07/08/2003)

Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page

• Generator

• Wheel kit

• Battery

• Battery charge cables

• Battery float charger

• Extenda Panel™ cord

• Locking 30 Amp plug

• Two Bottles of engine oil

• Three packets of fuel stabilizer

• Owner's manual

• Engine manual
*If any parts are missing or damaged, call 1-800-270-1408.

Parts Included*

Table of Contents

2

7000EXL Extended Life Generator

EQUIPMENT

DESCRIPTION

Read this manual carefully and become
familiar with your generator. Know its
applications, its limitations and any hazards
involved.

The generators are an engine–driven, revolving field,
alternating current (AC) generator.It was designed to supply
electrical power for operating compatible electrical lighting,
appliances, tools and motor loads.The generator’s revolving
field is driven at about 3,600 rpm by a single-cylinder engine.

CAUTION! DO NOT exceed the generator’s

wattage/amperage capacity. See “Don’t Overload
Generator” on page 12.

Every effort has been made to ensure that information in this
manual is accurate and current. However, we reserve the
right to change, alter or otherwise improve the product and
this document at any time without prior notice.

The Emission Control System for this generator is warranted
for standards set by the Environmental Protection Agency. For
warranty information refer to the engine owner’s manual.

SAFETY RULES

This is the safety alert symbol. It is used to
alert you to potential personal injury hazards.
Obey all safety messages that follow this
symbol to avoid possible injury or death.

The safety alert symbol ( ) is used with a signal word
(DANGER, CAUTION,WARNING), a pictorial and/or a
safety message to alert you to hazards. DANGER indicates
a hazard which, if not avoided, will result in death or serious
injury. WARNING indicates a hazard which, if not avoided,
could result in death or serious injury. CAUTION
indicates a hazard which, if not avoided, might result in
minor or moderate injury. CAUTION, when used
without the alert symbol, indicates a situation that could
result in equipment damage. Follow safety messages to
avoid or reduce the risk of injury or death.

Hazard Symbols and Meanings

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

WARNING

In the State of California a spark arrester is required by law
(Section 4442 of the California Public Resources Code).
Other states may have similar laws. Federal laws apply on
federal lands. If you equip the muffler with a spark arrester,
it must be maintained in effective working order.

Fire

Explosion

Toxic Fumes

Hot Surface

Electrical Shock

Electrocution

Electrical Shock

Explosive Pressure

Chemical Burn

7000EXL Extended Life Generator

3

• Operate generator ONLY outdoors.

• Keep at least 2 feet of clearance on all sides of generator for
adequate ventilation.

• DO NOT operate generator inside any building or enclosure,
including the generator compartment of a recreational vehicle (RV).

Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.

Breathing carbon monoxide will cause nausea,
fainting or death.

DANGER

• When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.

• Use a ground circuit fault interrupter (GFCI) in any damp or
highly conductive area, such as metal decking or steel work.

• DO NOT touch bare wires or receptacles.

• DO NOT use generator with electrical cords which are worn,
frayed, bare or otherwise damaged.

• DO NOT operate generator in the rain.

• DO NOT handle generator or electrical cords while standing
in water, while barefoot, or while hands or feet are wet.

• DO NOT allow unqualified persons or children to operate or
service generator.

Generator produces powerful voltage.
Failure to isolate generator from power utility

can result in death or injury to electric utility
workers due to backfeed of electrical energy.

DANGER

• National Electric Code requires generator to be properly
grounded to an approved earth ground. Call an electrician for
local grounding requirements.

Failure to properly ground generator can result
in electrocution, especially if the generator is
equipped with a wheel kit.

DANGER

• This generator does not meet U. S. Coast Guard Regulation
33CFR-183 and should not be used on marine applications.

• Failure to use the appropriate U. S. Coast Guard approved
generator could result in bodily injury and/or property
damage.

WARNING

• DO NOT allow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a battery.

• Wear protective goggles, rubber apron, and rubber gloves.

Storage batteries give off explosive hydrogen gas
during recharging.

Hydrogen gas stays around battery for a long
time after battery has been charged.

Slightest spark will ignite hydrogen and cause
explosion.

You can be blinded or severely injured.
Battery electrolyte fluid contains acid and is

extremely caustic.
Contact with battery fluid will cause severe

chemical burns.

DANGER

WHEN ADDING FUEL

• Turn generator OFF and let it cool at least 2 minutes before
removing gas cap.Loosen cap slowly to relieve pressure in tank.

• Fill fuel tank outdoors.

• DO NOT overfill tank.Allow space for fuel expansion.

• Keep fuel away from sparks, open flames, pilot lights, heat, and
other ignition sources.

• DO NOT light a cigarette or smoke.

WHEN OPERATING EQUIPMENT

• DO NOT tip engine or equipment at angle which causes fuel
to spill.

• This generator is not for use in mobile equipment or marine
applications.

WHEN TRANSPORTING OR REPAIRING EQUIPMENT

• Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFF.

• Disconnect spark plug wire.

WHEN STORING FUEL OR EQUIPMENT WITH FUEL
IN TANK

• Store away from furnaces, stoves, water heaters, clothes
dryers or other appliances that have pilot light or other
ignition source because they can ignite fuel vapors.

Fuel and its vapors are extremely flammable and
explosive.

Fire or explosion can cause severe burns or
death.

WARNING

4

7000EXL Extended Life Generator

• DO NOT touch hot surfaces.

• Allow equipment to cool before touching.

Running engines produce heat.Temperature of
muffler and nearby areas can reach or exceed
150°F (65°C).

Severe burns can occur on contact.

WARNING

• DO NOT tamper with governed speed.Generator supplies
correct rated frequency and voltage when running at governed
speed.

• DO NOT modify generator in any way.

Excessively high operating speeds increase risk of injury
and damage to generator.

Excessively low speeds impose a heavy load.

CAUTION

• See “Don’t Overload Generator” on page 12.

• Start generator and let engine stabilize before connecting
electrical loads.

• Connect electrical loads in OFF position, then turn ON for
operation.

• Turn electrical loads OFF and disconnect from generator
before stopping generator.

Exceeding generators wattage/amperage capacity can
damage generator and/or electrical devices connected
to it.

CAUTION

WHEN ADJUSTING OR MAKING REPAIRS TO YOUR
GENERATOR

• Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.

Unintentional sparking can result in fire or
electric shock.

WARNING

• Use generator only for intended uses.

• If you have questions about intended use, ask dealer or call
the Generac generator helpline at 1-800-270-1408.

• Operate generator only on level surfaces.

• DO NOT expose generator to excessive moisture, dust, dirt,
or corrosive vapors.

• DO NOT insert any objects through cooling slots.

• If connected devices overheat, turn them off and disconnect
them from generator.

• Shut off generator if:

-electrical output is lost;

-equipment sparks, smokes, or emits flames;

-unit vibrates excessively.

Improper treatment of generator can damage it and
shorten its life.

CAUTION

7000EXL Extended Life Generator

5

KNOW YOUR GENERATOR

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

Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.

120 Volt AC, 20 Amp
Duplex Receptacle

Fuel Tank

Idle Control Switch

Choke Lever

Start Button

12 Volt DC, 10 Amp
Receptacle

Run/Stop Switch

120 Volt AC, 30 Amp
Receptacle

Circuit Breakers (AC)

120/240 Volt AC,
30 Amp Receptacle

Spark Arrester Muffler

Air Cleaner

Grounding Fastener

12 Volt DC,10 Amp Receptacle — Recharge a
discharged 12 Volt automotive type battery through this
receptacle.

120 Volt AC, 20 Amp, Duplex Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.

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

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

Air Cleaner — Uses a dry type filter element and foam
pre–cleaner to limit the amount of dirt and dust sucked
into the engine.

Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — Each receptacle is provided

with a "push to reset" circuit breaker to protect the
generator against electrical overload.

Fuel Tank — Capacity of seven (7) U.S. gallons.
Grounding Fastener — Used for proper grounding of

unit.
Idle Control Switch — With this switch set to ON,

generator automatically reduces engine speed when no
load is connected and increases engine to proper speed
when load is applied. However, be sure switch is OFF when
starting engine.

Run/Stop Switch — Set this switch to "Run" before
starting engine. Set switch to "Stop" to switch OFF engine.

Spark Arrester Muffler — Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.

Start Button — When pressed, cranks engine to start.

6

7000EXL Extended Life Generator

ASSEMBLY

Your generator requires attachment of the negative battery
cable and is ready for use after it has been properly
serviced with the recommended oil and fuel.

Check Battery / Attach Negative

Battery Wire

The sealed battery on the generator is fully charged and
pre–installed except for the negative (black) battery cable.

To install:

1. Cut off tie wrap securing loose end of negative (black)
cable.

2. Remove nut and washer on negative battery terminal.

3. Slide negative battery cable over screw on negative
terminal (Figure 1).

4. Reattach washer and nut and tighten.

5. Verify that connections to battery and generator are
tight and secure.

BEFORE STARTING THE

ENGINE

Add Engine Oil and Fuel

• Place generator on a level surface.

• Refer to engine owner’s manual and follow oil and fuel
recommendations and instructions.

NOTE: Check oil often during engine break–in. Refer to
engine owner’s manual for recommendations.

NOTE:The generator assembly rotates on a prelubricated
and sealed ball bearing that requires no additional
lubrication for the life of the bearing.

Figure 1 — Negative Battery Connection

Positive battery cable

Screw

Negative
battery
cable

Washer

Nut

CAUTION

• Refer to engine manual for oil and fuel fill information.

• Damage to equipment resulting from failure to follow this
instruction will void warranty.

Any attempt to crank or start the engine before it has
been properly filled with the recommended oil will result
in equipment failure.

7000EXL Extended Life Generator

7

GROUNDING THE

GENERATOR

The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of the
unit. For that purpose, a GROUNDING FASTENER is
provided on the generator end (Figure 2).

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. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, local codes
may vary widely. Consult with a local electrician for
grounding requirements in your area.

Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices, especially when the unit is
equipped with a wheel kit. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.

OPERATING THE

GENERATOR

IMPORTANT: Always unplug the battery float charger

before starting the generator.

Starting the Engine

Disconnect all electrical loads from the generator. Follow
these start instruction steps in numerical order:

1. Turn fuel valve to “On” position (Figure 3).The fuel

valve handle should be vertical (pointing toward
ground) for fuel to flow.

2. Make sure Idle Control switch is in “Off” position

(Figure 4).

3. Start engine according to instructions given in engine
owner’s manual.

Figure 2 — Grounding Fastener

Grounding
Fastener

Figure 3 — Fuel Valve

Fuel Valve is shown
in the On position

Figure 4 — Idle Control Switch

• See “Don’t Overload Generator” on page 12.

• Start generator and let engine stabilize before connecting
electrical loads.

• Connect electrical loads in OFF position, then turn ON for
operation.

• Turn electrical loads OFF and disconnect from generator
before stopping generator.

Exceeding generators wattage/amperage capacity can
damage generator and/or electrical devices connected
to it.

CAUTION

8

7000EXL Extended Life Generator

Connecting Electrical Loads

• Let engine stabilize and warm up for a few minutes after
starting.

• Plug in and turn on the desired 120 and/or 240 Volt AC,
single phase, 60 Hz electrical loads.

• DO NOT connect 240 Volt loads to the 120 Volt
receptacles.

• DO NOT connect 3–phase loads to the generator.

• DO NOT connect 50 Hz loads to the generator.

• DO NOT OVERLOAD GENERATOR. See “Don’t
Overload Generator” on page 12.

Stopping the Engine

1. Unplug all electrical loads from generator panel

receptacles. NEVER start or stop engine with electrical
devices plugged in and turned on.

2. Put idle control switch in “Off” position.

3. Let engine run at no–load for 30 seconds to stabilize

internal temperatures of engine and generator.

4. Turn engine off according to instructions given in

engine owner’s manual.

5. Move fuel valve to “Off” position.

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 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.

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:

1. Check fluid level in all battery cells. If necessary, add
ONLY distilled water to cover separators in battery
cells. DO NOT use tap water.

2. If battery is equipped with vent caps, make sure they
are installed and are tight.

3. If necessary, clean battery terminals.

4. Connect battery charge cable connector plug to panel
receptacle identified by the words “12-VOLTS D.C.”.

5. Connect battery charge cable clamp with red handle
to the positive (+) battery terminal (Figure 5).

• DO NOT allow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a battery.

• Wear protective goggles, rubber apron, and rubber gloves.

Storage batteries give off explosive hydrogen gas
during recharging.

Hydrogen gas stays near battery for a long time
after battery has been charged.

Slightest spark will ignite hydrogen and cause
explosion.

You can be blinded or severely injured.
Battery electrolyte fluid contains acid and is

extremely caustic.
Contact with battery fluid will cause severe

chemical burns.

DANGER

Figure 5 — Battery Connections

7000EXL Extended Life Generator

9

6. Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 5).

7. Start engine. Let engine run while battery recharges.

8. 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.

COLD WEATHER

OPERATION

Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icing of the carburetor and/or the crankcase
breather system.

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 6.

• 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.

Figure 6 — Permanent Cold Weather Shelter

Wind

• Operate generator ONLY outdoors.

• Keep at least 2 feet of clearance on all sides of generator for
adequate ventilation.

• DO NOT operate generator inside any building or enclosure,
including the generator compartment of a recreational vehicle (RV).

• Remove generator from shelter when temperature is above
40°F [4°C].

Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.

Breathing carbon monoxide will cause nausea,
fainting or death.

DANGER

10

7000EXL Extended Life Generator

How to Use the Battery Charger

Use battery float charger jack to keep the starting battery
charged and ready for use. Battery charging should be done
in a dry location, such as inside a garage.

1. Plug charger into unit’s “Battery Float Charger” jack,
which is located on starter switch (Figure 7). Plug
battery charger into a 120 Volt AC wall receptacle.

2. Unplug charger from unit and wall outlet when
generator is being started and while it is in operation.

3. Keep this charger plugged in when generator is not in
use to prolong battery life.The charger has a built in
float equalizer and will not overcharge battery, even
when plugged in for an extended period of time.

IMPORTANT: See “Battery Maintenance” on page 13 for
additional information.

EXTENDA PANEL™

The generator is equipped with a 25’ Extenda Panel™
device designed for a 240 Volt, 30 Amp grounded neutral
circuit (Figure 8).The Extenda Panel™ provides a
convenient supply of emergency power into your dwelling
so that your generator can be operated safely outside.

The maximum load on each outlet is 20 Amps.The
maximum total load on both yellow wire outlets or black
wire outlets is 30 Amps.

NOTE: Follow all safety precautions when connecting any
extension cord or device to the generator.

RECEPTACLES

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) (Figure 9).You can use the same 4-wire cord if you
plan to run a 120 Volt load.

Figure 7 — Battery Charger Jack

Figure 8 — Extenda Panel™

Figure 9 — 120/240 Volt AC, 30 Amp Receptacle

4-Wire Cord Set

240V

120V

120V

W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-30

Ground (Green)

• NEVER attempt to power a device requiring more
amperage than generator or receptacle can supply.

• DO NOT overload the generator. See “Don’t Overload
Generator”.

Receptacles may be marked with rating value greater
than generator output capacity.

CAUTION

7000EXL Extended Life Generator

11

This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts of power (3.6 kW)
at 30 Amps for 120 Volts OR 7,000 watts of power
(7.0 kW) at 29.2 Amps for 240 Volts.The outlet is
protected by a 30 Amp push-to-reset circuit breaker.

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).

Use this receptacle to operate 120 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts (3.6 kW) of power
at 30 Amps.The outlet is protected by a 30 Amp
push–to–reset circuit breaker.

120 Volt AC, 20 Amp, Duplex

Receptacle

Each receptacle (Figure 11) is protected against overload by
a 20 Amp push–to–reset circuit breaker.

Use each receptacle to operate 120 Volt AC, single–phase,
60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)
at 20 Amps of current. Use cord sets that are rated for
125 Volt AC loads at 20 Amps (or greater).

12 Volt DC, 10 Amp Receptacle

This receptacle allows you to recharge a 12 Volt
automotive or utility style storage battery with the battery
charge cables provided (Figure 12).

This receptacle can not recharge 6 Volt batteries and can
not be used to crank an engine having a discharged battery.
See the section “Charging a Battery” (page 8) before
attempting to recharge a battery.

Figure 10 — 120 Volt AC, 30 Amp, Locking Receptacle

3-Wire Cord Set

Neutral

120V

Hot

Ground (Green)

NEMA L5-30

Figure 11 — 120 Volt AC, 20 Amp Receptacles

Figure 12 — 12 Volt DC, 10 Amp Receptacle

12

7000EXL Extended Life Generator

DON'T OVERLOAD

GENERATOR

Capacity

You must make sure your generator can supply enough
rated (running) and surge (starting) watts for the items you
will power at the same time. Follow these simple steps:

1. Select the items you will power at the same time.

2. Total the rated (running) watts of these items.This is
the amount of power your generator must produce to
keep your items running. See Figure 13.

3. Estimate how many surge (starting) watts you will
need. Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliances such as a circular saw or refrigerator.
Because not all motors start at the same time, total
surge watts can be estimated by adding only the
item(s) with the highest additional surge watts to the
total rated watts from step 2.

Example:

Total Rated (Running) Watts = 3075
Highest Additional Surge Watts = 1800
Total Generator Output Required = 4875

Power Management

To prolong the life of your generator and attached devices,
it is important to take care when adding electrical loads to
your generator.There should be nothing connected to the
generator outlets before starting it's engine.The correct
and safe way to manage generator power is to sequentially
add loads as follows:

1. With nothing connected to the generator, start the
engine as described in this manual.

2. Plug in and turn on the first load, preferably the largest
load you have.

3. Permit the generator output to stabilize (engine runs
smoothly and attached device operates properly.

4. Plug in and turn on the next load.

5. Again, permit the generator to stabilize.

6. Repeat steps 4 and 5 for each additional load.
NEVER add more loads than the generator capacity.Take

special care to consider surge loads in generator capacity,
as described above.

*Wattages listed are approximate only. Check tool or
appliance for actual wattage.

Tool or Appliance

Rated (Running)

Watts

Additional Surge

(Starting) Watts
Window Air
Conditioner

1200 1800

Refrigerator 800 1600
Deep Freezer 500 500
Television 500 ­Light (75 Watts) 75 -

3075 Total

Running Watts

1800 Highest

Surge Watts

Tool or Appliance

Rated*

(Running)

Watts

Additional

Surge

(Starting)

Watts

Essentials

Light Bulb - 75 watt

75

-

Deep Freezer

500

500

Sump Pump

800

1200

Refrigerator/Freezer - 18 Cu. Ft.

800

1600

Water Well Pump - 1/3 HP

1000

2000

Heating/Cooling

Window AC - 10,000 BTU

1200

1800

Window Fan

300

600

Furnace Fan Blower - 1/2 HP

800

1300

Kitchen

Microwave Oven - 1000 Watt

1000

-

Coffee Maker

1500

-

Electric Stove - Single Element

1500

-

Hot Plate

2500

-

Family Room

DVD/CD Player

100

-

VCR

100

-

Stereo Receiver

450

-

Color Television - 27”

500

-

Personal Computer w/17” monitor

800

-

Other

Security System

180

-

AM/FM Clock Radio

300

-

Garage Door Opener - 1/2 HP

480

520

Electric Water Heater - 40 Gallon

4000

-

DIY/Job Site

Quartz Halogen Work Light

1000

-

Airless Sprayer - 1/3 HP

600

1200

Reciprocating Saw

960

960

Electric Drill - 1/2 HP

1000

1000

Circular Saw - 7 1/4”

1500

1500

Miter Saw - 10”

1800

1800

Table Planer - 6”

1800

1800

Table Saw/Radial Arm Saw - 10”

2000

2000

Air Compressor - 1-1/2 HP

2500

2500

Figure 13 - Wattage Reference Chart

7000EXL Extended Life Generator

13

SPECIFICATIONS

Maximum Surge Watts . . . . . . . . . . . . . . 12,250 Watts

Continuous Wattage Capacity . . . . . . . . . . 7,000 Watts

Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0

Rated Maximum Continuous Load Current

At 120 Volts . . . . . . . . . . . . . . . . . . . . . . 58.3 Amps

At 240 Volts . . . . . . . . . . . . . . . . . . . . . . 29.2 Amps

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-phase

Rated Frequency . . . . . . . . . . . . . . . . . . . . . . 60 Hertz

Fuel Tank Capacity . . . . . . . . . . . . . . . . . . 7 U.S. gallons

Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . 240 lbs.

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.
NOTE: If equipped with inflatable tires,keep the air pressure

at the value marked on the tire or within 15 and 40 psi.

Engine Maintenance

See engine owner’s manual for instructions.

KEEP OUT OF REACH OF CHILDREN. DON'T
POLLUTE. CONSERVE RESOURCES. RETURN
USED OIL TO COLLECTION CENTERS.

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 snow,
leaves or any other foreign material.

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.

Battery Maintenance

Other than float charging, described elsewhere, no
maintenance is required for the battery. Keep the battery
and terminals clean and dry.

IMPORTANT: Battery charging should be performed in a
dry location, such as inside a garage.

Generator Cleaning

• Use a damp cloth to wipe exterior surfaces clean.

• Use a soft bristle brush to loosen caked on dirt or oil.

• Use a vacuum cleaner to pick up loose dirt.

• Use low pressure air (not to exceed 25 psi) to blow
away dirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.

• Used motor oil has been shown to cause skin cancer in
certain laboratory animals.

• Thoroughly wash exposed areas with soap and water.

Avoid prolonged or repeated skin contact with used
motor oil.

CAUTION

• DO NOT expose generator to excessive moisture, dust, dirt,
or corrosive vapors.

• DO NOT insert any objects through cooling slots.

Improper treatment of generator can damage it and
shorten its life.

CAUTION

WHEN ADJUSTING OR MAKING REPAIRS TO YOUR
GENERATOR

• Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.

Unintentional sparking can result in fire or
electric shock.

WARNING

14

7000EXL Extended Life Generator

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.

Generator Storage

• Clean the generator as outlined in “Generator Cleaning”.

• Check that cooling air slots and openings on generator
are open and unobstructed.

Engine Storage

See engine owner’s manual for instructions.

Other Storage Tips

• To prevent gum from forming in fuel system or on
essential carburetor parts, empty all three supplied fuel
stabilizer containers into fuel tank and fill with fresh
gasoline. Run the unit for several minutes to circulate the
additive through the carburetor.The unit and fuel can
then be stored for up to 24 months.Additional fuel
stabilizer can be purchased locally.

• DO NOT store gasoline from one season to another
unless it has been treated as described above.

• Replace fuel container if it starts to rust. Rust and/or dirt
in fuel can cause problems if it's used with this unit.

• Store in clean and dry area.

• DO NOT place a storage cover over a hot generator.

• Let equipment cool for a sufficient time before placing the
cover on the equipment.

Storage covers can be flammable.

WARNING

7000EXL Extended Life Generator

15

TROUBLESHOOTING

Problem

Cause

Correction

Engine is running, but no
AC output is available.

1. One of the circuit breakers is open.

2. Fault in generator.

3. Poor connection or defective cord set.

4. Connected device is bad.

1. Reset circuit breaker.

2. Contact local service facility.

3. Check and repair.

4. Connect another device that is in
good condition.

Engine runs good at no­load but “bogs” down"
when loads are connected.

1. Short circuit in a connected load.

2. Generator is overloaded.

3. Shorted generator circuit.

1. Disconnect shorted electrical load.

2. See “Don't Overload Generator”.

3. Contact local service facility.

Engine will not start; or
starts and runs rough.

1. Fuel Valve is in the “Off” position.

2. Failed battery.

1. Turn the fuel valve to the “On”
position.

2. Replace battery.

Engine shuts down during
operation.

Out of gasoline.

Fill fuel tank.

Engine lacks power.

Load is too high.

See “Don't Overload Generator”.

16

7000EXL Extended Life Generator

NOTES

7000EXL Extended Life Generator

17

NOTES

18

7000EXL Extended Life Generator

SCHEMATIC

7000EXL Extended Life Generator

19

WIRING DIAGRAM

20

7000EXL Extended Life Generator

EXPLODED VIEW - ALTERNATOR

7000EXL Extended Life Generator

21

EXPLODED VIEW - FRAME

12

22

7000EXL Extended Life Generator

PARTS LIST - ALTERNATOR & FRAME

Item Part # Qty Description

1 M187024GS 1 CRADLE
2 192982GS 1 SHIELD, Heat
3 92982GS 1 DECAL, Danger
4 92665GS 1 INSULATION
5 B1998GS 1 ASSY,Tank, Fuel (Includes Item 12)
6 B4363GS 1 CAP, with Gauge, Fuel
7 85000GS 1 CLIP, Insulation
8 93826GS 1 DECAL, Start Instructions

9 78831BGS 4 SCREW
10 83465GS 4 GROMMET, Tank
11 77395GS 8 NUT, Lock
12 192980GS 1 KIT,VLV, FUEL, SRV
14 B2153GS 8 SCREW
15 43116GS 4 SCREW
16 39287GS 2 SCREW
17 B4135GS 2 PIN, with Lanyard
18 187104GS 4 WASHER, Nylon
19 49820GS 2 NUT, Nylok
20 83083GS 1 SCREEN, Spark Arrestor
21 86307GS 4 SCREW
22 92247GS 1 HOUSING, Engine Adapter
23 M92531GS 1 SUPPORT, Engine
24 189160GS 12 NUT
25 22129GS 4 WASHER, Lock
26 82857GS 4 MOUNT,Vibration
27 22531GS 2 SCREW
28 92609GS 2 MOUNT,Vibration
29 22142GS 2 SCREW
30 A7433GS 1 MUFFLER
31 M92731GS 1 SUPPORT, Engine & Muffler
32 90239GS 1 GASKET, Muffler
33 B1342GGS 1 ASSY, Rotor
35 96796GS 1 WASHER
36 47481GS 1 SCREW
37 B1897AGS 1 ASSY, Stator
38 20566GS 1 DECAL, 1-800
39 40976GS 2 SCREW
40 92532GS 1 BRACKET, Muffler
41 66476GS 2 SCREW
42 186747GS 1 DECAL, Control Panel
43 92630GS 1 ASSY, Control Panel
44 192983GS 1 SHIELD, Heat
45 14353621GS 1 WIRE, Ground
46 26850GS 2 WASHER
47 BB3061GS 2 BOTTLE,Oil
48 81917GS 1 PIN, Roll
49 B4986GS 1 DECAL, Ground
50 186798GS 2 DECAL, Heat Shield
51 56893GS 5 SCREW
52 84132GS 1 ASSY, Power Regulator
53 67022GS 1 GROMMET, Rubber

Item Part # Qty Description

54 SRV66825DGS 1 CARRIER, Rear Bearing
55 86494GS 1 SCREW,Wing
56 23762GS 3 WASHER
57 66386GS 1 ASSY, Brush Holder
58 66849GS 2 SCREW
59 B4871GS 1 COVER, Bearing Carrier
60 74908GS 4 SCREW
61 B4605GS 2 GRIP
62 66849CGS 1 SCREW
63 65795GS 2 RECTIFIER, Battery Charge
64 66449LGS 4 BOLT, Stator
65 22145GS 4 WASHER
66 22097GS 6 WASHER, Lock
67 186744GS 1 MANUAL, Owners
68 BB5586GS 2 HANDLE (Includes Item 61)
69 52858GS 2 NUT, Lock
73 191267GGS 1 AXLE
74 B4966GS 2 WHEEL
75 22247GS 2 WASHER
76 191265GS 2 E-RING
77 189302BGS 1 ASSY, Wire
78 77282GS 1 SWITCH, Starter
79 188987GS 1 BRACKET, Switch
80 188989GS 1 ASSY, Jack, DC
81 22287GS 2 SCREW
83 22127GS 2 NUT
84 192985GS 1 TRAY, Battery
85 B4489GS 1 BATTERY
86 189302CGS 1 ASSY,Wire
87 185939HGS 1 ASSY,Wire
88 73054GS 1 DECAL, Fuel Shut-Off
89 77816GS 1 DECAL, Hot Muffler
90 39253GS 2 SCREW
91 A8927GS 1 MANUAL, Engine
92 52618GS 2 SCREW
93 23897GS 2 WASHER
94 52856GS 2 NUT
96 191698GS 1 ASSY,Wire
97 58359GS 1 LUG
98 189198GS 1 DECAL, Instruction, ES

99 B4177GS 1 CHARGE, Battery Float
100 189208GS 3 STABILIZER,Fuel
101 65787GS 1 CABLE, Battery Charge
102 37806GS 1 PLUG, 120V/30A
103 188971GS 1 PANEL, Extenda
104 22155GS 1 WASHER, Lock
105 49813GS 1 NUT
106 22259GS 2 NUT
108 189956GS 1 ASSY,Wheel Support
109 86292GS 1 SCREW
900 NSP 1 ENGINE

7000EXL Extended Life Generator

23

EXPLODED VIEW AND PARTS LIST - CONTROL PANEL

Item Part # Qty Description

1 A92070GS 1 PANEL,Control
2 23897GS 4 WASHER
3 49226GS 4 WASHER, Lock
4 91526GS 4 SCREW
5 82538GS 1 SWITCH, Idle Control
6 82881GS 4 WASHER, Lock
7 43181GS 4 SCREW
8 43182GS 4 WASHER, Lock

9 90418GS 1 OUTLET, 12V
10 75207AGS 2 BREAKER, Circuit, 30A
11 75207GS 2 BREAKER, Circuit, 20A
12 23365GS 6 WASHER
13 68868GS 1 OUTLET, 120V, 30A Locking

Item Part # Qty Description

14 43437GS 1 OUTLET, 120V/240V, 30A Locking
15 68759GS 1 OUTLET, 120V, 20A Duplex
16 43180GS 6 WASHER
17 22264GS 6 WASHER, Lock
18 51715GS 6 NUT
19 64526GS 8 SCREW
20 83970GS 1 BOARD, System Control
21 64525GS 4 STAND-OFF
22 87962GS 1 BREAKER, Circuit, 12V, 10A
23 84335GS 1 ASSY,Wire Harness
24 84134GS 1 GROMMET, Rubber Conn.
25 B92069GS 1 BOX, Control Panel
26 84028GS 1 TRANSFORMER, Idle Control

GENERAC PORTABLE PRODUCTS OWNER WARRANTY POLICY Effective January 1, 2003

WARRANTY PERIOD*

* The warranty period begins on the date of purchase by the first retail consumer or commercial end user, and continues for the
period of time stated in the table above. "Consumer use" means personal residential household use by a retail consumer.
"Commercial use" means all other uses, including use for commercial, income producing or rental purposes. Once equipment has
been used commercially, it shall thereafter be considered to be in commercial use for purposes of this warranty.

** The engine and starting batteries are warranted solely by the manufacturers of those products.

WARRANTY REGISTRATION IS NOT NECESSARY TO OBTAIN WARRANTY ON BRIGGS & STRATTON
POWER PRODUCTS EQUIPMENT. SAVE YOUR PROOF OF PURCHASE RECEIPT. IF YOU DO NOT PROVIDE
PROOF OF THE INITIAL PURCHASE DATE AT THE TIME WARRANTY SERVICE IS REQUESTED,THE
MANUFACTURING DATE OF THE EQUIPMENT WILL BE USED TO DETERMINE THE WARRANTY PERIOD.

About your equipment warranty:

We welcome warranty repair and apologize to you for being inconvenienced.Any Authorized service dealer may perform warranty
repairs. Most warranty repairs are handled routinely, but sometimes requests for warranty service may not be appropriate. For
example, warranty service would not apply if equipment damage occurred because of misuse, lack of routine maintenance, shipping,
handling, warehousing or improper installation. Similarly, the warranty is void if the manufacturing date or the serial number on the
equipment has been removed or the equipment has been altered or modified. During the warranty period, the Authorized service
dealer, at its option, will repair or replace any part that, upon examination, is found to be defective under normal use and service.
This warranty will not cover following repairs and equipment:

• Normal Wear: Outdoor power equipment, like all mechanical devices, needs periodic parts, service and replacement to

perform well.This warranty does not cover repair when normal use has exhausted the life of a part or the equipment.

• Installation and Maintenance: This warranty does not apply to equipment or parts that have been subjected to improper or

unauthorized installation or alteration and modification, misuse, negligence, accident, overloading, overspeeding, improper
maintenance, repair or storage so as, in our judgment, to adversely affect its performance and reliability.This warranty also does
not cover normal maintenance such as adjustments, fuel system cleaning and obstruction (due to chemical, dirt, carbon or lime,
etc.).

• Other Exclusions: Also excluded from this warranty are wear items such as quick couplers, oil gauges, belts, o-rings, filters,

pump packing, etc., pumps which have been run without water supplied or damage or malfunctions resulting from accidents,
abuse, modifications, alterations, or improper servicing or freezing or chemical deterioration.Accessory parts such as guns,
hoses, wands and nozzles are excluded from the product warranty.Also excluded is used, reconditioned, and demonstration
equipment; equipment used for prime power in place of utility power and equipment used in life support applications.

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WISCONSIN, U.S.A.

LIMITED WARRANTY

"Generac Portable Products is a licensed trademark of Briggs & Stratton Power Products. Briggs & Stratton Power Products will
repair or replace, free of charge, any part, or parts of the equipment** that are defective in material or workmanship or both.
Transportation charges on parts submitted for repair or replacement under this warranty must be borne by purchaser.This
warranty is effective for the time periods and subject to the conditions provided for in this policy. For warranty service, find your
nearest Authorized service dealer by calling 1-800-270-1408.Warranty service may only be performed by a Briggs & Stratton
Power Products Authorized service dealer.

THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE,ARE LIMITED TO THE TIME PERIOD SPECIFIED, OR TO THE EXTENT PERMITTED
BY LAW.ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED.LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER
ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW. Some countries or
states do not allow limitations on how long an implied warranty lasts, and some countries or states do not allow the exclusion
or limitation of incidental or consequential damages, so the above limitation and exclusion may not apply to you.This warranty
gives you specific legal rights and you may also have other rights that vary from country to country or state to state.”

Equipment ** Consumer Use Commercial Use

Pressure Washer 1 Year 90 Days
Portable Generator 2 Years (2nd year parts only) 1 Year