Generac Power Systems GP7500E Series Owner's Manual
000365
Owner’s Manual
GP7500E Series Portable Generator
Model Number
Serial Number
Reference all appropriate documentation.
This manual should remain with the unit.
www.generac.com or 1-888-436-3722
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NOT INTENDED FOR USE IN CRITICAL
LIFE SUPPORT APPLICATIONS.
DEADLY EXHAUST FUMES! USE
OUTSIDE, ONLY, FAR AWAY FROM
WINDOWS, DOORS AND VENTS!
SAVE THIS MANUAL. Provide this
manual to any operator of the generator.
WARNING
California Proposition 65. Engine exhaust and some of
its constituents are known to the state of California to
cause cancer, birth defects, and other reproductive
harm.
(000004)
WARNING
California Proposition 65. This product contains or
emits chemicals known to the state of California to
cause cancer, birth defects, and other reproductive
harm.
(000005)
Table of Contents
Table of Contents
Section 1 Safety
1.1 Introduction ....................................................1
1.2 Read This Manual Thoroughly .....................1
1.3 Safety Rules ...................................................1
1.4 General Hazards ............................................2
1.5 Exhaust and Location Hazards ....................2
1.6 Electrical Hazards ..........................................3
1.7 Fire Hazards ...................................................3
1.8 Unit Identification Label ................................3
Section 2 Assembly
2.1 Unpacking ......................................................5
2.1.1 Accessory Kits ....................................................5
2.2 Assembly ........................................................5
2.2.1 Required Tools ................. ... ... .... ... ... ... .... ... ........5
2.2.2 Installing Wheels ................................................ 5
2.2.3 Installing Frame Feet ........ ... ... .... ... ... ... .... ... ... ... ..5
2.2.4 Installing Handle .................................................6
2.2.5 Battery Cables ............................................... .....6
2.3 Emission Information ....................................6
Section 4 Maintenance
4.1 Maintenance Schedule ................................13
4.2 Product Specifications ................................13
4.2.1 Generator Specifications......... ... .... ... ... ... .... ... ...13
4.2.2 Engine Specifications..... ... ... ... ... .... ... ... ... .... ... ...13
4.3 Clean Exterior Surfaces ..............................13
4.3.1 General ...................................... .... ... ... ... .... ... ...13
4.3.2 Cleaning ........................ ... ... ... ... .... ...................14
4.4 Check Engine Oil Level ...............................14
4.5 Change Engine Oil ......................................14
4.6 Clean/Replace Air Filter ..............................15
4.7 Fuel Filter Replacement ..............................15
4.8 Clean/Gap/Replace Spark Plug ..................15
4.9 Battery Replacement (if applicable) ..........16
4.10 Check/Adjust Valve Clearance .................16
4.10.1 Check Valve Clearance ..................................16
4.10.2 Adjust Valve Clearance .................................. 16
4.11 Storage .......................................................17
4.11.1 General ...........................................................17
4.11.2 Long Term Storage ........................................17
4.11.3 Additional Storage Tips ..................................18
Section 3 Operation
3.1 Know the Generator ......................................7
3.1.1 Connection Plugs ...............................................7
3.2 Hour Meter ......................................................8
3.3 How to Use the Generator .............................9
3.3.1 Grounding Generator if Used as Portab le ..........9
3.3.2 Connecting to Building Electrical System ...........9
3.4 Do Not Overload Generator ........................10
3.5 Wattage Reference Guide ...........................10
3.6 Before Starting Generator ...........................10
3.6.1 Add Engine Oil .................................................10
3.6.2 Add Gasoline .......... ....................................... ...11
3.7 Starting Electric Start Engine .....................12
3.7.1 Manual Start .................. ... ... ... .... ... ... ... .... .........12
3.8 Stopping Engine ..........................................12
3.9 Low Oil Level Shutdown .............................12
Section 5 Troubleshooting
5.1 Troubleshooting ..........................................19
5.1.1 Troubleshooting Guide ........... ... .... ... ... ... .... ... ...19
5.2 Replacement Service Parts ........................ 20
Owner’s Manual for Portable Generator i
Table of Contents
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ii Owner’s Manual for Portable Generator
Section 1 Safety
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000001)
DANGER
Indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
(000002)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
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1.1 — Introduction
Thank you for purchasing a Generac Power Systems Inc.
product. This unit has been designed to provide high -performance, efficient operation, and years of use when
maintained properly. This unit is designed to operate
electrical loads where no utility power is available, or in
place of utility power due to a power outage.
1.2 — Read This Manual Thoroughly
If any portion of this manual is not understood, contact
the nearest Authorized Dealer for starting, operating and
servicing procedures.
The operator is responsible for proper and safe use of
the equipment. We strongly recommend that the ope rator
read this manual and thoroughly understand all instructions before using the equipment. We also strongly recommend instructing other users to properly start and
operate the unit. This prepares them if they need to operate the equipment in an emergency.
The generator can operate safely, efficiently and reliably
only if it is properly located, operated and maintained.
Before operating or servicing the generator:
• Become familiar with and strictly adhere to all local,
state and national codes and regulations.
• S tudy all safety warnings in this manual and on the
product carefully.
• Become familiar with this manual and the unit
before use.
The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in
this manual, and on tags and decals affixed to the unit
are, therefore, not all inclusive.
If using a procedure, work method or operating techn ique
that the manufacturer does not specifically recommend,
ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized does
not render the generator unsafe.
THE INFORMATION CONTAINED HEREIN WAS
BASED ON UNITS IN PRODUCTION AT THE TIME OF
PUBLICA TION. GENERAC RESERVES THE RIGHT TO
MODIFY THIS MANUAL AT ANY TIME.
Owner’s Manual for Portable Generator 1
1.3 — Safety Rules
Throughout this publication, and on tags and decals
affixed to the generator , DANGER, W ARNING , CAUTION
and NOTE blocks are used to alert personnel to special
instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe
them carefully. Their definitions are as follows:
NOTE: Notes contain additional information important to a procedure and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that
they indicate. Common sense and strict compliance with
the special instructions while performing the action or
service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type of
information each indicates is as follows:
This symbol points out important safety
information that, if not followed, could
endanger personal safety and/or property.
This symbol points out potential explosion
hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical
shock hazard.
Safety
(000103)
DANGER
Asphyxiation. Running engines produce carbon
monoxide, a colorless, odorless, poisonous gas.
Carbon monoxide, if not avoided,
will result in death or serious injury.
(000108)
WARNING
Hot Surfaces. When operting machine, do not
touch hot surfaces. Keep machine away from
combustables during use. Hot surfaces
could result in severe burns or fire.
(000103)
DANGER
Asphyxiation. Running engines produce carbon
monoxide, a colorless, odorless, poisonous gas.
Carbon monoxide, if not avoided,
will result in death or serious injury.
Figure 1-1. Exhaust Hazard
1.4 — General Hazards
• Always wear approved hearing pr otection where
necessary. See Figure 1-2.
• For safety reasons, it is recommended that the
maintenance of this equipment be performed by an
Authorized Dealer . In sp ect the genera to r regu lar ly,
and contact the nearest Authorized Dealer for p arts
needing repair or replacement.
• Operate generator only on level surfaces and
where it will not be exposed to excessive moisture,
dirt, dust or corrosive vapors.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving parts. Never remove
any fan guard or shield while the unit is operating.
• Do not insert objects through unit’s cooling slots.
• When working on this equipment, remain alert at all
times.
• Never work on the equipment when physically or
mentally fatigued.
• Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
1.5 — Exhaust and Location Hazards
• Adequate, unobstructed flow of cooling and venti-
lating air is critical to correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect safe operation of the generator. The
generator MUST be operated outdoors.
• This exhaust system must be properly maintained.
Do nothing that might render the exhaust system
unsafe or in noncompliance with any local codes
and/or standards.
• Always use a battery operated carbon monoxide
alarm indoors, installed according to the manufacturers instructions.
• If you sta rt to feel sick, dizzy, or weak after the gen-
erator has been running, move to fresh air IMMEDIATELY. See a doctor, as you could have carbon
monoxide poisoning.
• Do NOT operate generator in the rain.
• Do not alter the construction of the generator or
change controls which might create an unsafe
operating condition.
• Never start or stop the unit with electrical loads
connected to receptacles AND with connected
devices turned ON. S tart the engine and let it stabilize before connecting electrical loads. Disconnect
all electrical loads before shutting down the generator.
2 Owner’s Manual for Portable Generator
Figure 1-2. Hearing Hazard
Safety
(000104)
DANGER
Electrocution. Water contact with a power source,
if not avoided, will result in death or serious injury.
(000105)
DANGER
Explosion and Fire. Fuel and vapors are extremely
flammable and explosive. Add fuel in a well
ventilated area. Keep fire and spark away. Failure to
do so will result in death or serious injury.
000366
1.6 — Electrical Hazards
• The generator produces dang erously high voltage
when in operation. Avoid contact with bare wires,
terminals, connections, etc., while the unit is running, even on equipment connected to the generator. Ensure all appropriate covers, guards and
barriers are in place before operating the generator.
• The National Electric Code (NEC) requires the
frame and external electrically conductive parts of
the 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 the area.
• Use a ground fault circuit interrupter in any damp
or highly conductive area (such as metal decking
or steel work).
• Do not use worn, bare, frayed or otherwise dam-
aged electrical cord sets with the generator.
• Before performing any main tenance on the ge nera-
tor, disconnect the engine starting battery (if
equipped) to prevent accidental start up. Disconnect the cable from the battery post indicated by a
NEGATIVE, NEG or (–) first. Reconnect that cable
last.
• In case of accident caused by electric shock,
immediately shut down the source of electrical
power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CON-
TACT WITH THE VICTIM. Use a non-conducting
implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical
help.
• Never fill fuel tank indoors. Comply with all laws
regulating storage and handling of gasoline.
• Do not overfill the fuel tank. Always allow room for
fuel expansion. If tank is over-filled, 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 EXPLOSION may
result. Allow unit to cool entirely before storage.
• Wipe up any fuel or oil spills immediately. Ensure
that no combustible materials are left on or near
the generator. Keep the area surrounding the generator clean and free from debris and keep a clearance of five (5) feet on all sides to allow for proper
ventilation of the generator.
• Do not insert objects through unit’s cooling slots.
• Do not operate the generator if connected electri-
cal devices overheat, if electrical output is lost, if
engine or generator sparks or if flames or smoke
are observed while unit is running.
• Keep a fire extinguisher near the generator at all
times.
1.8 — Unit Identification Label
See Figure 1-3. Information from the Unit Identification
Label is required when requesting information or ordering
service parts. For quick and easy reference, record the
Serial and Model numbers printed on the label in the
space provided on the front cover.
1.7 — Fire Hazards
• Gasoline is highly FLAMMABLE and its vap ors are
EXPLOSIVE. Do not permit smoking, open flames,
sparks or heat in the vicinity while handling gasoline.
Owner’s Manual for Portable Generator 3
Figure 1-3. Unit Identification Label
Safety
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4 Owner’s Manual for Portable Generator
A
B C
D
Section 2 General Information
2.1 — Unpacking
• Remove all packaging material.
• Remove separate accessory kit box.
• Remove generator from carton.
2.1.1— Accessory Kits
Check contents against the list in Table 2-1. If any parts
are missing or damaged, or if any problems occur during
assembly , call the Ge nerator Helplin e at 1-888-436- 3722.
Table 2-1. Contents
Parts Description Quantity
General
Generator 1
Owner’s Manual 1
Product Registration Card
(English, Spanish, and French)
Warranty and Emission Sheets 1
Bottle of SAE 30 Oil 1
Frame Foot (L) 2
Handle Assembly 1
Battery Charger 1
Hardware Bag
Cotter Pin (A) 2
1/2” Flat Washer (B) 2
9-1/2” Wheel (C) 2
Axle Pin (D) 2
M8 Hex Bolt (F) 5
M8 Hex Flange Nut (H) 5
1
2.2 — Assembly
The generator requires some assembly prior to usage. If
problems arise when assembling the generator, call 1888--436-3722.
2.2.2 — Installing Wheels
NOTE: The wheels are not intended for over-the-road
use.
1. Install the Wheels as follows (Figure 2-1):
— Slide the Axle Pin (D) through the Wheel (C),
Wheel Bracket on the frame and a 5/8" Flat
Washer (B).
— Insert the Cotter Pin (A) through the Axle Pin (D).
Use the needle nosed pliers to bend open to lock
in place.
Figure 2-1. Wheel Assembly
2.2.3 — Installing Frame Feet
1. Install the Frame Foot Assemblies as shown (Figure
2-2).
— Slide the M8 Hex Bolts (F) through the holes in the
Frame Rail.
— Slide the Frame Foot (L) onto the Hex Head Bolts
(F). Then install the Locking Flange Nuts (H).
Tighten securely using a 12 mm and 13 mm
wrench.
2. Repeat the Step 1 to install the other Frame Foot
Assembly.
2.2.1 — Required Tools
• Wrenches: 13 mm (2 ea), 8 mm (2)
• Needle nosed pliers
Owner’s Manual for Portable Generator 5
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