Sportsman GEN7500DF Instruction Manual

GEN7500DF

Visit our website for Frequently Asked Questions http://sports m anseriesbrand.com

7500 SURGE WATTS / 6000 RUNNING WATTS

DUAL FUEL LPG LIQUID PROPANE & GASOLINE

PORTABLE GENERATOR

INSTRUCTION MANUAL

READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS PRODUCT.

This manual provides important information on proper operation & maintenance. Every effort has been
made to ensure the accuracy of this manual. These instructions are not meant to cover every possible
condition and situation that may occur. We reserve the right to change this product at any time without
prior notice.

IF THERE IS ANY QUESTION ABOUT A CONDITION BEING SAFE OR UNSAFE,
DO NOT OPERATE THIS PRODUCT!

DO NOT RETURN THIS GENERATOR TO THE RETAILER!

If you experience a problem, have questions or need parts for this product, call Customer Service at
1-866-460-9436, Monday-Friday, 8 AM - 4 PM Central Time. A copy of the sales receipt is required.

FOR CONSUMER USE ONLY – NOT FOR PROFESSIONAL USE.

KEEP THIS MANUAL, SALES RECEIPT & APPLICA BLE WARRANTY FOR FUTURE
REFERENCE.

SEEK THE ADVISE OF A LICENSED ELECTRICIAN FOR 120V / 240V WIRING

2

Model GEN7500DF 7500 Surge Watts / 6000 Running Watts

This unit is a Dual Fuel LPG or Gasoline Fuel powered generator.

FEATURES:

• 7500 Surge Output / 6000 Running Watts

• 120/240 Volt Operation

• 13 HP Engine, 4 Stroke

• Displacement (CC): 389cc

• AVR Automatic Voltage Regulation

• Low Oil Shut Off

• Spark Arrestor

• UL Listed Electrical Components

• Engine Shut Off Switch

• Circuit Breaker & Power Outlets

• Spark Plug Model F6RTC.

• 1-12V DC Outlet

• 4-120V Outlets

• 1-120/240V Outlet

• 1-120V RV Outlet

• 6.2 Gallons Max Capacity Gasoline Fuel Tank

• Complies with EPA / CARB emissions

• Decibel Rating < 80 db

• Mobility Kit: Included

• Run time = 9 hrs @ 50% load

• Battery Not Included (see page 9 for additional details)
(Use a 12 Volt motorcycle battery no larger than 6" L x 4.5" H x 4" W (151 mm x 99 mm x 98 mm).
CCA (Cold Cranking Amps): 130 Min CCA. Comparable model: 12 Volt 12 Ah Sealed Lead Acid
Model # UB12120 requires nut/bolt adaptor or Model # CYLAZ10SXTA (or XTAZ10S)

• Fuel type - Liquid Propane Gas (also commonly referred to as LP, LPG and Propane) Or Unleaded Gasoline

• If you are using a generator above sea level, the generator may not function properly because of air flow getting through the mixer.

• Propane Tank Not Included

• If you want to use a propane tank larger than 20 lbs, call Customer Service for details at 866-460-9436.

THIS ENGINE MEETS U.S. EPA EMISSION STANDARDS UNDER 40 CFR 1054.625 .

The emission-related warranty is valid for two (2) years. Keep the purchase receipt and mail in the product registration card for proof of purchase.
Buffalo Corp limits emission-related warranty repairs to authorized service centers for owners located within 100 miles of an authorized service
center. For owners located more than 100 miles from an authorized service center, Buffalo Corp will, in its sole discretion, either pay for shipping
costs to and from an authorized service center, provide for a service technician to come to the owner to make the warranty repair, or pay for the
repair to be made at a local non-authorized service center. The provisions of this paragraph apply only for the contiguous states, excluding the states
with high-altitude areas identified in 40 CFR part 1068, Appendix III.

To exercise this warranty, DO NOT RETURN TO RETAILER. Instead, call Customer Service toll free at 1-866-460-9436 (email address
[e-mail]) and you will be instructed on where to take the engine for warranty service. Take the generator and proof of
purchase (your receipt) to the repair facility recommended by the Customer Service Representative. The warranty does not extend to generators
damaged or affected by fuel contamination, accidents, neglect, misuse, unauthorized alterations, use in an application for which the product was not
designed and any other modifications or abuse.

1 YEAR LIMITED WARRANTY (30 Day Limited Warranty for Commercial and Rental Purpose)

Generators are warranted to be free from defects in materials and workmanship for a period of 1 year from date of original purchase. Buffalo Corp.
is not liable for any indirect, incidental or consequential damages from the sale or use of this product. Any implied warranties are limited to 1 year
as stated, or as otherwise stated, in this written limited warranty. Some states do not allow the exclusion or limitation of incidental or consequential
damages. Some states do not allow limitation on the length of an implied warranty. Buffalo Corp will repair or replace, at its discretion, any part that
is proven to be defective in materials or workmanship under normal use during the 1 year warranty period. Warranty repairs or replacements will be
made without charge for parts or labor. Parts replaced during warranty repairs will be considered as part of the original product and will have the
same warranty period as the original product. This warranty gives you specific legal rights, and you may have other rights that vary from state to
state.

This warranty gives you specific legal rights, and you may have other rights that vary from state to state.

GEN7500DF 7500 Surge Watt / 6000 Running Watt Portable Dual Fuel LPG Liquid Propane Gas & Gasoline Electric Start Generator Manual

3

TABLE OF CONTENTS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS .............................................................................................. 4

PACKAGE CONTENTS

PACKAGE CONTENTS .......................................................................................................................................... 9

COMPONENTS .................................................................................................................................................... 10

PREPARING THE GENERATOR FOR USE ................................................................................................................... 11

Using This Generator For The First Time ............................................................................................................. 11

Step 1 – Add Oil ........................................................................................................................................... 11

Step 2 – Connect Fuel ................................................................................................................................. 12

Step 3 – Ground The Generator ................................................................................................................... 13

Subsequent Use Of This Generator ...................................................................................................................... 13

Step 1 – Verify Oil Level ............................................................................................................................... 13

Step 3 – Ground The Generator ................................................................................................................... 14

STARTING THE GENERATOR ....................................................................................................................................... 14

USING THE GENERATOR ............................................................................................................................................. 15

AC Usage ............................................................................................................................................................. 15

DC Usage ............................................................................................................................................................. 17

STOPPING THE GENERATOR ...................................................................................................................................... 17

MAINTENANCE/CARE .................................................................................................................................................... 18

Recommended Maintenance Schedule ................................................................................................................ 18

Cleaning The Generator ....................................................................................................................................... 18

Checking The Oil Level ......................................................................................................................................... 18

Changing/Adding Oil ............................................................................................................................................. 19

Air Filter Maintenance ........................................................................................................................................... 20

Spark Plug Maintenance ....................................................................................................................................... 20

STORAGE/TRANSPORT PROCEDURES ...................................................................................................................... 21

TROUBLESHOOTING ..................................................................................................................................................... 21

SPECIFICATIONS ........................................................................................................................................................... 22

PARTS DIAGRAM .......................................................................................................................................................... 23

PORTABILITY KIT INSTALLATION ................................................................................................................................ 33

GEN7500DF 7500 Surge Watt / 6000 Running Watt Portable Dual Fuel LPG Liquid Propane Gas & Gasoline Electric Start Generator Manual

4

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

This is the safety alert symbol. It is used to alert you to potential
DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which,
if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a
result in property damage.

High Altitude Use:

What You Need to Know About Safety Instructions

Warning and Important Safety Instructions appearing in this manual are not meant to cover all possible conditions and
situations that may occur. Common sense, caution and care must be exercised when operating or cleaning tools and
equipment.

Always contact your dealer, distributor, service agent or manufacturer about problems or conditions you do not understand.

personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

potentially hazardous situation which, if not avoided, may

SEEK THE ADVISE OF A LICENSED ELECTRICIAN FOR 120V / 240V WIRING

Legal Requirements:

Federal and/or State Occupational Safety and Health Administration (OSHA) regulations, local codes, and/or ordinances may apply to the intended
use of this generator. Consult a qualified electrician, electrical inspector, and/or the local agency having jurisdiction. Some areas require generators
to be registered with local utility companies. Additional regulations may apply if this generator will be used at a construction site.

This generator is not recommended for high altitude
use above 3,000 feet.

GEN7500DF 7500 Surge Watt / 6000 Running Watt Portable Dual Fuel LPG Liquid Propane Gas & Gasoline Electric Start Generator Manual

5

• Keep at least several feet of clearance on all sides to allow proper ventilation for this generator.

defects, or other reproductive harm.

• Before transporting, turn the fuel valve to the "off" position and disconnect the spark plug.

• Do not allow children or non-qualified persons to operate this generator.

• Keep at least several feet of clearance on all sides of this generator during operation. Do not enclose this generator in any structure.

electricity. An undersized cord can overheat, short out and cause a fire.

IMPORTANT SAFETY INSTRUCTIONS

STOP!

Before using this generator and if you have any questions regarding the hazard and safety notices listed in this manual and/or on
this generator, call 1-866-460-9436, Monday - Friday, 8 AM - 4 PM Central Time.

Carbon Monoxide Gas: When in operation, the exhaust from this generator contains poisonous carbon monoxide gas. Carbon

monoxide gas is both odorless and colorless AND may be present even if you do not see or smell gas. Breathing this poison gas can
lead to headaches, dizziness, drowsiness, loss of consciousness and eventually death.

• Use this generator ONLY outdoors in non-confined areas.

Chemicals: According to the State of California, the exhaust from this generator contains chemicals known to cause cancer, birth

Propane (LPG): This generator may emit highly flammable and explosive vapors, which can cause severe burns or even death. A

nearby open flame can lead to an explosion even if not directly in contact the fuel.

• Do not operate this generator near open flame.

• Always operate this generator on a firm, level surface.
This fuel is highly flammable and explosive. Handling fuel can result in serious injury or burns.

• Before starting the generator, inspect your LPG tank valve for damage or leaks, attach only approved tanks that have been properly filled by
an approved station. DO NOT light or smoke cigarettes.
Replace the hose at the first sign of a leak or if age-cracking becomes apparent.

• Always handle propane fuel and generator outdoors.

Powerful Voltage: This generator produces powerful voltage, which can result in electrocution.

• ALWAYS ground this generator before using it. (See “Ground the Generator” section in this manual).

• Only electrical devices should be plugged into this generator, either directly or with an extension cord. NEVER connect a building electrical
system to this generator without a qualified electrician. Doing so voids your warranty. Such connections must isolate generator power from
utility power and comply with local electrical laws and codes. Failure to comply can create a back feed into utility lines creating an electrocution
hazard, which may result in serious injury or death to utility workers. Such a back feed may cause this generator to explode, burn and create
fires when utility power is restored.

• Do not use this generator in wet conditions (rain, snow, active sprinkler system, wet hands, etc.). Always keep this generator dry and operate it
with dry hands.

• Do not touch bare wires or outlets (receptacles).

High Temperatures: This generator produces heat when in operation. Temperatures near the exhaust can exceed 150 Degrees

Fahrenheit (65 Degrees Celsius).

• Do not touch hot surfaces. Observe all warning placards on this generator denoting hot surfaces.

• Allow this generator to cool for several minutes after use before touching the engine, muffler or other areas that are hot during operation and
before storing indoors.

• Hot exhaust may ignite some materials. Keep flammable materials away from this generator.

Usage: Avoid the use of extension cords if possible. If you choose to use them, be sure they are sized adequately to handle the flow of

GEN7500DF 7500 Surge Watt / 6000 Running Watt Portable Dual Fuel LPG Liquid Propane Gas & Gasoline Electric Start Generator Manual

6

• Turn off all connected electrical devices before stopping this generator.

meet national electric codes for class 1 hazardous areas.

and your propane equipment.

pacemaker could cause a pacemaker to malfunction or fail. Caution is necessary when near the engine’s recoil starter.

operating or working around the generator when it is running.

information consult the devices operation manual or call customer service at 1-866-460-9436 Monday - Friday, 8 AM - 4 PM Central Time.

Usage: Misuse of this generator can damage it or shorten its life.

• Use this generator only for its intended purpose.

• Operate this generator only on a dry, level surface.

• Allow this generator to run for several minutes before connecting any electrical devices.

• Promptly turn off any malfunctioning devices and disconnect them.

• Do not operate an excessive number of electrical devices in excess of the wattage capacity of this generator.

• Do not turn on electrical devices until after they are connected to this generator.

Flammable liquid gas under pressure. Can form explosive mixtures with air. May cause frostbite. In Case Of Inhalation: Persons suffering from
lack of oxygen should be removed to fresh air. If victim is not breathing, administer artificial respiration. If breathing is difficult, administer
oxygen. Obtain prompt medical attention. In Case Of Eye Contact: Contact with liquid or cold vapor can cause freezing of tissue. Gently flush
eyes with lukewarm water. Obtain medical attention immediately. In Case Of Skin Contact: Contact with liquid or cold vapor can cause
frostbite. Immediately warm affected area with lukewarm water not to exceed 105°F (40°C). Fire And Explosion Hazards: Propane is easily
ignited. It is heavier than air, therefore, it may collect in low areas or travel along the ground where an ignition source may be present. Pressure
in a container can build up due to heat, and it may rupture if pressure relief devices should fail to function. Storage: Cylinders should be stored
upright with valve protection cap in place and firmly secured to prevent falling or being knocked over. Protect cylinders from physical damage;
do not drag, roll, slide or drop. Use a suitable hand truck for cylinder movement. Post "No Smoking or Open Flames" signs in the storage areas.
There should be no sources of ignition. All electrical equipment should be explosion proof in the storage and use areas. Storage areas must

Propane smells like rotten eggs, a skunk’s spray, or a dead animal. IF YOU SMELL GAS- NO FLAMES OR SPARKS! Immediately put out all
smoking materials and other open flames. Do not operate lights, appliances, telephones, or cell phones. - Flames or sparks from these
sources can trigger an explosion or a fire.

WHAT IS CARBON MONOXIDE (CO)?
You can’t taste or smell CO, but it is a very dangerous gas. High levels of CO can come from appliances that are not operating correctly, or from
a venting system or chimney that becomes blocked. CO CAN BE DEADLY! High levels of CO can make you dizzy or sick. In extreme cases,
CO can cause brain damage or death.
Symptoms of CO poisoning include: headache, dizziness, fatigue, shortness of breath,
and nausea.

IF YOU SUSPEC T CO IS PRESENT, ACT IMMED IATELY!

1. If you or a family member shows physical symptoms of CO poisoning, get everyone out of the building and call 911 or your local fire
department.

2. If it is safe to do so, open windows to allow entry of fresh air, and turn off any appliances you suspect may be releasing CO.

3. If no one has symptoms, but you suspect that CO is present, call your propane retailer or a qualified service technician to check CO levels

Usage: Consult a physician(s) before using this generator if using a pacemaker. Electromagnetic fields in close proximity to a heart

Usage: Prolonged exposure to high noise levels can be hazardous to hearing. Always wear ANSI-approved hearing protection when

Usage: This generator is not intended to power sensitive electronic equipment such as TVs, DVD players, stereos, desktop

computers or laptop computers without the use of an appropriate line conditioner and/or surge protector (both not included).

Sensitive electronic equipment should be operated on approved inverter type generators or pure sine wave generators. For additional

GEN7500DF 7500 Surge Watt / 6000 Running Watt Portable Dual Fuel LPG Liquid Propane Gas & Gasoline Electric Start Generator Manual

7

GEN7500DF 7500 Surge Watt / 6000 Running Watt Portable Dual Fuel LPG Liquid Propane Gas & Gasoline Electric Start Generator Manual

8

In addition to the previously described safety information, familiarize yourself with all safety and hazard notices on this generator.

GEN7500DF 7500 Surge Watt / 6000 Running Watt Portable Dual Fuel LPG Liquid Propane Gas & Gasoline Electric Start Generator Manual

9

PACKAGE CONTENTS

Item List:

Battery Requirements

The following items are supplied with this Model GEN7500DF Portable LP & Gasoline Generator. Verify that all items are included.

STOP!

If there are missing items, call 1-866-460-9436, Monday - Friday, 8 AM - 4 PM Central Time for customer service. DO NOT RETURN THIS
GENERATOR TO THE RETAILER.

Set of 2 DC connector wires for connecting 12 Volt automotive-type batteries

Spark plug wrench

You may choose to purchase our battery
GEN7500DFB (sold separately)
Call 866-460-9436 for details and pricing
This battery is designed specifically for
the Sportsman Dual Fuel generator GEN7500DF.

Other batteries are available online or at your
local dealer. See below requirements:
(Use a 12 Volt motorcycle battery no larger than
6" L x 4.5" H x 4" W (151 mm x 99 mm x 98 mm).
CCA (Cold Cranking Amps): 130 Min CCA.
Comparable model: 12 Volt 12 Ah Sealed Lead Acid (Model # UB12120)
(Model UB12120 requires a Nut & Bolt adaptor)

5 Ft. Regulator Hose Kit

(YOU MUST USE THE SUPPLIED REGULATOR FOR SAFE OP E RAT IO N)

GEN7500DF 7500 Surge Watt / 6000 Running Watt Portable Dual Fuel LPG Liquid Propane Gas & Gasoline Electric Start Generator Manual

10

ATTENTION:

To prevent electrical shock from faulty appliances,

GENERATOR COMPONENTS

Observe the locations and functions of the various components and controls of this generator.

WARNING:
YOU MUST USE
THE SUPPLIED
REGULATOR FOR
SAF E OPERATION

the generator should be grounded. Connect a
length of heavy wire between the ground terminal
and the ground source.

Consult with a qualified electrician to ensure
compliance with local electrical codes.

The Air-fuel Mixer is not adjustable. Tampering with the governor can damage your generator and electrical devices, and will void your warranty.

GEN7500DF 7500 Surge Watt / 6000 Running Watt Portable Dual Fuel LPG Liquid Propane Gas & Gasoline Electric Start Generator Manual