Generac 1019-3 Portable Generator User Manual
Contents
1. BLU 11 114 BLU 444 11B 11 114 104 354 354 15 80A 304 44 C B EA E C B C B AUTO RESET j 14 11 11A 44 44C 448 15 j l 2 55 1e0v 204 120 240v 120 240V 504 304 18Y 104 IC ps t 55 GREEN m D D WHITE 13 ee 114 444 n 1HLE 55 CONTROL 55 22 SWITCH O e o IH BLU WHT ee CI 55 ge 11 GRN GRN ERNZYEL 22 55 22 13 156 156 155 155 PRN 155 13 o e SYSTEM 55 2 CONTROL ill a BOARD GRN YEL I m IDLE CONTROL il ET TRANSFORMER il 2 PIN 1 on CONNECTOR o G 44 E BATTERY H ON IDLE il CONTROL L 6 CHARGE Ht T 56 RECTIFIER m is 66 1 1 IDLE BLU WHT iji CONTROL YEL 77 il YEL il WHT LOW DIL GRN YEL HH 3 PIN PRESSURE DC FLOAT STATUR P CONNECTOR SWITCH CHARGER DN ENGINE F zz d 0 1 D n SHROUD m GRN YEL I AMDDE Low mL L POS BRUSH BLK PRESSURE CLOSEST TD il RIE LED ia BEARING p CATHODE 4 WHT n ELECTRIC 1 BLK UEM A BEARING CARRIER ENGINE SWITCH BOTTOM il SEU 6 1 6 POWER n 134 10 7 01718 135 9 Lj REGULATOR HW BDARD HE TF It SPARK IH rj r12. POWER REGULATOR BOARD T f 1 2 6 4 S N TY 77 DPE B 2 Je R FIELD POWER 2 POWER p H E p E ae AL p D 11 ee 44 A A E K 1 IDLE E CONTROL TRANSFORMER p TE aJ Lo G N A fe re pu C B a 123 of ee 44 IDLE cnNrgnL PLK SVST R 2 PER CONTROL ug BOARD ai HGRN 0 354 B ay LOP 114 ji AIN LED BLU A o d F RED n RED BLU WHT 88 OFF cu LP 11 t SWITCH SWITCH 22 18 re QW 11A 44A 4 RUN 180 840V SP o 504 304 ENS GRN 30 22 C Bis SPARK SWITCH 9 uro 22 PLUG 120V 20A 44B P adis ENG 22 He O 4 IGNITION da e eve 12VDC ee FLOAT Xf e 11C CHARGER 44B BATTERY CHARGE INPUT 118 CAE 6A LORA A Dr 66A 774 DIODE 55 66 77 134 11 bred 20A 44B 13A 1344 11B CB yaqvaany ELECTRIC tev 304 START _BATTERY AN 22 4 SWITCH Ke SS 13 55 STARTER 22 AUTO Q T 371 11B 120V RESET 99 a 304 104 C E No 2 YE COl amp EXA2V 104 DU Lis 11B 7500EXL Extended Life Generator WIRING DIAGRAM
3. Hot Plate o 250 po qu DVDICD Player IO EN s us Stereo Receiver d se Color Television 27 500 Personal Computer w I 7 monitor 800 Other c o 1 Security System 180 AM FM Clock Radio 300 Electric Water Heater 40 Gallon 4000 Di ijobSite Jo o Quartz Halogen Work Light 1000 Reciprocating Saw 960 960 Circular Saw 7 14 1500 1500 Wattages listed are approximate only Check tool or appliance for actual wattage GENERAC 7500EXL Extended Life Generator SPECIFICATIONS Maximum Surge Watts 13 500 watts Continuous Wattage Capacity 7 500 watts Power Factor io i ANETES 1 0 Rated Maximum Continuous AC Load Current At 120 VO SLI 62 5 Amps At 240 Volts ici vou i AER ES 31 2 Amps Phase lv e e X ottawa NR I phase Rated Frequency 1 60 Hertz Fuel Tank Capacity 7 U S galloris 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 defectiv
4. Exceeding generators wattage amperage capacity can damage generator and or electrical devices connected EG it Sec Don t Overload Generator on page 13 Start generator and let engine stabilize before connecting electrical loads Connect electrical loads in OFF position then tarn ON for operation Turn electrical loads OFF and disconnect from generator before stopping generator OPERATION Starting the Engine Disconnect all electrical loads from the generator Use the following start instruction steps by numerical order I Make sure unit is on a level surface IMPORTANT Failure to start and operate unit on a level surface will cause the unit not to start or shut down during operation 2 Turn the fuel valve to the On position Figure 4 The fuel valve handle should be vertical pointing toward the ground for fuel to flow Figure 4 Fuel Valve Fuel Valve is shown in the On position 3 Make sure the Idle Control switch is in Off position Figure 5 Figure 5 Idle Control Switch 4 Start the engine according to instructions given in the engine owner s manual NOT E If engine starts after 3 pulls but fails to run or if unit shuts down during operation make sure unit is on a level surface and check for proper oil level in crankcase This unit may be equipped with a low oil protection device See engine manual Connecting Electrical Loads Let engine stabilize and war
5. 5 PLUG il ON TO ile 1 ENGINE BLOCK FRAME zi 18 VOLT GROUND BATTERY GENERAC 7500EXL Extended Life Generator Portable Products jah 24 EXPLODED VIEW ALTERNATOR O0 CA C S DIRES Ne m 1 a w 3 a rao 4 zd AN B 4 iK 1 f AN e ie EXPLODED VIEW FRAME n fi DETAIL OF BATTERY TRAY o Aa o DETAIL OF ELECTRIC START SWITCH TO STARTER TO RBC DETAIL OF JACK TO TERMINAL ASSEMBLY COAX ON BATTERY GENERAC Portable Produ 7500EXL Extended Life Generator jeh PARTS LIST ALTERNATOR amp FRAME Item Part OO X O L0 hh a hy 10 12 14 15 17 18 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 39 40 41 43 44 45 46 48 43 3l 52 53 54 56 BI87024GS 194389GS 92982GS 92665GS 193823GS B4363GS 85000GS 93826GS 78831BGS 83465GS 77395GS 192980GS B2153GS 43116GS 73054GS 22127GS 77816GS 83083GS 86307GS 92247GS M925
6. Figure 10 120 Volt AC 30 Amp Locking Receptacle 3 Wire Cord Set NEMA L5 30 Neutral F N 120V N f wea 3 Hot l Ground Green 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 GENERAC Portable Produ 120 240 Volt AC 30 Amp Locking Receptacle Use a NEMA LI 4 30 plug with this receptacle Connect a 4 wire cord set rated for 250 Volt AC loads at 30 Amps or greater Figure 1 You can use the same 4 wire cord Tf you plan to run a 120 Volt load Figure 120 240 Volt AC 30 Amp Receptacle n 4 Wire Cord Set 240V 120V 120Y Neutral AN he Y Hot X Hoo NEMA L14 30 7777 Ground Green This receptacle powers 120 240 Volt AC 60 Hz single phase loads requiring up to 3 600 watts of power at 30 Amps for 120 Volts 7 200 watts of power 7 2 kW at 30 Amps for 240 Volts The outlet is protected by a 30 Amp push to reset circuit breaker 7500EXL Extended Life Generator 120 240 Volt AC 50 Amp Receptacle Use a NEMA 14 50 plug with this receptacle Figure 123 Connect a 4 wire cord set rated for 250 Volt AC loads at 50 Amps to the plug Figure 12 120 240 Volt AC 50 Amp Receptacle 4 240 Volts AC Eu
7. Frame Ground X Hot 120 Volts 20 Volts AC piq AC W Neutral NEMA 14 50 Use this receptacle to operate 20 240 Volt AC 60 Hz single phase loads requiring up to 7 500 watts 7 5 kVV of power The outlet is protected by a 33 Amp push to reset circuit breaker DON T OVERLOAD GENERATOR Capaci 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 l Select the items you will power at the same time 2 Total the rated running watts of these items This fs 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 Rated Running Watts Additional Surge Starting VVatts Tool or Appliance Window Air Conditioner 1800 Highest 3075 Total Running Watts Surge Watts Total Rated Running Watts 3075 Highest Additional Surge Watts 1800 Total Generator Output Required 4875 Power Management Te prolong the life of your generator and attached d
8. Use a ground fault circuit interrupter GFC in any damp or highly conductive area such as metal decking or steel work DO NOT touch bare wires or receptacles DO NOT us generator with electrical cords which arc worn frayed bare or otherwise damaged DO NOT operate goncrator in the rain DO NOT handle generator or clectrical cords while standing in water while barefoot or while hands or fect arc wet DO NOT allow unqualified persons or children to operate or service generator 7500EXL 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 Plug the charger into the units Battery Float Charger jack which is located on the starter switch Figure 3 Plug battery charger into a 120 Volt AC wall receptacle Unplug the charger from the unit and the wall outlet when generator is being started and while it is in operation 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 the battery even when plugged in for an extended period of time IMPORTANT See Battery Maintenance on page 4 for additional information OPERATING THE GENERATOR IMPORTANT Always unplug the battery float charger before starting the generator CAUTION
9. fer the life of the bearing GENERAC Portable Products USING THE GENERATOR System Ground The generator has a system ground that connects the generator frame components to the ground terminals on the AC output receptacles The system ground is connected to the AC neutral wire see Equipment Description earlier in this manual Special Requirements There may be Federal or State Occupational Safety and Health Administration OSHA regulations local codes or ordinances that apply to the intended use of the generator Please consult a qualified electrician electrical inspector or the local agency having jurisdiction n some areas generators are required to be registered with local utility companies f the generator is used at a construction site there may be additional regulations which must be observed Connecting to a Building s Electrical System Connections for standby power to a building s electrical system must be made by a qualified electrician The connection must isolate the generator power from utility power and must comply with all applicable laws and electrical codes e Generator produces powerful voltage Failure to isolare generator from power utility can result in death or injury to electric utility workers due to backfeed of electrical energy When using generator for backup power notify utility company Use approved transfer equipment to isolate generator from electric utility
10. or starts and runs rough 2 Failed battery Engine shuts down during operation Engine lacks power Load is too high TSOGEXL Extended Life Generator 3 Poor connection or defective cord set Short circuit in a connected load 3 Shorted generator circuit Fuel Valve is in the Off position Q t of gasoline GENERAC 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 add fuel stabilizer into fuel tank and fill with fresh fuel 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 Fuel stabilizer can be purchased locally DO NOT store fuel 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 unit in a clean and dry area Correction Reset circuit breaker Contact Generac service facility Check and repair Connect another device that is in good condition Disconnect shorted electrical load See Don t Overload Generator Contact Generac service facility Turn fuel valve to On position 2 Replace battery Fill fuel tarik See Don t Gverload Generator GENERAC 7500EXL Extended Life Generator Portable Products SCHEMATIC
11. to charge any 6 Volt batteries DO NOT use the unit to crank an engirie having a discharged battery f age batteries give off explosive hydrogen gas during recharging Hydrogen gas stays near batrery 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 extreniely caustic Contact with bareery fluid will cause severe chemical burns 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 To recharge 12 Volt batteries proceed as follows Check fluid level in all battery celis If necessary add ONLY distilled water to cover separators in battery cells DO NOT use tap water GENERAC Portable Produ 2 If battery is equipped with vent caps make sure they are installed and are tight 3 lf necessary clean battery terminals Connect battery charge cable connector plug to panel receptacle identified by the words I12 VGLTS D C 5 Connect battery charge cable clamp with red handle to the positive battery terminal Figure 6 Figure 6 Battery Connections A 12 VOLT D C RECEPTACLE 6 Connect battery charge cable clamp with black handle to the negative battery terminal Figure 6 7 Start engine Let engine run while battery
12. 23 8433565 ASSY Wire Harness 10 75207AGS BREAKER Circuit 24 84134GS GROMMET Rubber Connector 11 75207GS BREAKER Circuit 25 B92069GS BOX Control Panel 12 23365GS WASHER 26 84028GS TRANSFORMER Idle Control 13 68868GS OUTLET 30A 120V Locking 27 43181GS SCREW 14 43437GS OUTLET 30A 120V 240V Locking 28 4318265 WASHER Lock GENERAC Portable Produ 8 ltem Part B19320065 B4966GS 191267GGS 191265GS 39287GS B186927GS 191413GS 22413GS 52858GS 22247GS 39253GS 22145GS 49820GS 187104GS 189718GS B4135GS 192432GS 7500EXL Extended Life Generator a Description HANDLE Includes Item 15 WHEEL AXLE E RING SCREW LEG Support VIBE MOUNT with Washer SCREW NUT Lock WASHER SCREW WASHER NUT Nylok WASHER Nylon GRIP PIN with Lanyard NUT Lock ie utt NOTES 7500EXL Extended Life Generator GENERAC NOTES GENERAC PORTABLE PRODUCTS OWNER WARRANTY POLICY Effective January 2003 LIMITED WARRANTY Generac Portable Products is a licensed trademark of Briggs amp Stratton Power Products Briggs amp Stratton Power Products will repair or replace free of charge any part or parts of the equipment that are defective iri 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 Iri this policy For w
13. 31GS 189160GS 22129GS 82857GS 22531GS 92609GS 22142GS A7433GS B92731GS 90239GS BI342GS 96796GS 47481GS BI897A S 40976GS 92532GS 66476GS B4366GS 194390GS 14353621GS 193646GS 81917GS B4986GS 36893GS 84132GS 67022GS SRV66825DGS 23762GS Description CRADLE SHIELD Heat Tank DECAL Danger INSULATION ASSY Tank Fuel CAR with Gauge Fuel CLIP Insulation DECAL Start Instructions SCREW GROMMET Tank NUT Lock KIT Valve Tank SCREW SCREW DECAL Fuel Shut Off NUT DECAL Hot Muffler SCREEN Spark Arrestor SCREW HOUSING Engine Adapter SUPPORT Engine NUT WASHER Lock MOUNT Vibration SCREW MOUNT Vibration SCREW MUFFLER SUPPORT Engine amp Muffler GASKET Muffler ASSY Rotor WASHER SCREW ASSY Stator SCREW BRACKET Muffler SCREW ASSY Control Panel see page 21 SHIELD Heat WIRE Ground KIT Grounding Hardware PIN Roll DECAL Ground SCREW ASSY Power Regulator GROMMET Rubber CARRIER Rear Bearing WASHER Item Part 57 58 59 60 62 63 64 6 74 77 78 79 80 8l 82 83 84 85 86 87 88 90 97 98 99 100 10 102 103 900 66386GS 66849GS B4871GS 74908GS 66849 GS 65795GS 66449L GS 22097GS 194034GS 189302BGS 77282GS 188987GS 188989635 22287GS 22097GS 96113GS 19298565 B4489GS 189302CGS 185939HGS 193347GS 58359GS BI93200GS 189718GS B4135GS 2225965 2212965 49813GS 22125655 NSP Description ASSY Brush Holder SC
14. GENERAC Portable Products Parts Inciuded Table of Contents Generator Safety Rules Wheel kit Know Your Generator Storage Cover Battery Battery Float Charger Product Specifications Battery Charge Cables Maintenance Spare Spark Plug Air Filter and Oil Filter Spark Plug Wrench Troubleshooting 2 Locking 30 Amp Plugs Schematic Engine Oil Wiring Diagram Owner s Manual Replacement Parts Engine Manual If any parts are missing or damaged call 1 800 270 1408 Questions Help is just a moment away Call Generac Generator Helpline 1 800 270 1408 M F 8 5 CT Web www generac portables com 01124847 05311 1 Model No 1019 3 7 500 Watt AC Generator Manual No 189713GS Revision 5 12 18 2003 GENERAC Portable Produ 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 13 Every effort has been made to ensure that information in this manual is accurate and cu
15. REW COVER Bearing Carrier SCREW SCREW RECTIFIER Battery Charge BOLT Stator WASHER Lock KIT Fold Down Handle Hardware ASSY Wire SWITCH Starter BRACKET Switch ASSY Jack DC SCREW WASHER Lock ASSY Wire TRAY Battery BATTERY ASSY Wire ASSY Wire KIT Battery Hardware LUG ASSY Handle with Grip GRIP PIN with Lanyard NUT WASHER Lock NUT WASHER Lock ENGINE Parts Not Illustrated BB3061GS B4767G 72347GS 189713GS 7311165 84882GS 43438GS 70185GS A8927GS B4177G 65787GS 37806GS 194033GS BOTTLE Oil COVER Storage PLUG Spark MANUAL Owner s FILTER Air WRENCH Spark Plug PLUG 120 24 0V 30A 4p FILTER Gil MANUAL Engine CHARGER Battery Float CABLE Battery Charge PLUG 120V 30A KIT Decals Optional Accessories Not Included 84883GS Cord Wrap susc p EXE xtended Life Generator GENERAG iE Portable Products e N aer LI Py Bs e b Co KE Item Part Description ltern Part Description BB446lGS PANEL Control 15 68759GS OUTLET 20A 120V 2 23897GS WASHER 16 43180GS WASHER 3 49226GS WASHER Lock 17 22264GS WASHER Lock 4 391526GS SCREVY 18 5I7156GS NUT 5 82538GS SWITCH Idle Control 19 6452665 SCREW 8288IGS WASHER Lock 20 83970GS BOARD System Control 7 B4262GS OUTLET SOA 240V 2 64525GS STANDGFE Hex 8 90418GS OUTLET 104 I2VDC 22 879625 BREAKER Circuit 10A auto 12V 9 75207NGS BREAKER Circuit
16. aces clean CAUTION Improper treatment of generator can damage it and shorten its life DO NOT expose gencrator to excessive moisture dust dirt or corrosive vapors DO NOT insert any objects through cooling slats 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 TROUBLE SHOOTING 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 To Clean the Generator Check that cooling air slots and openings on generator are open and unobstructed Storage covers can be flammable DO NOT place a storage caver over a hot generator Let equipment cool for a sufficient time before placing the cover on the equipment TROUBLESHOOTING Problem Cause One of the circuit breakers is open 2 Fault in generator No AC output is available but engine is running 4 Connected device is bad Engine runs good at no load but bogs down when loads are connected 2 Generator is overloaded Engine will not start
17. arranty service find your nearest Authorized service dealer by calling 800 270 1408 Warranty service may only be performed by a Briggs amp Stratton Power Products Authorized service dealer THERE IS NG OTHER EXPRESS WARRANTY IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE TIME PERIOD SPECIFIED GR 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 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 WARRANTY PERIOD Equiprnent Consumer Use Commercial Use Pressure Washer 000 0n yer o ss s 90Dqs os ForabeGemenor Year Grd yar paris en 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 4 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 t
18. asteners are tight and the tires are inflated te the value marked on the tire or within 15 and 40 psi 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 l Cut off tie wrap securing loose end of negative black cable 2 Remove nut and washer on negative battery terminal Slide negative battery cable over screw on negative terminal Figure 2 Figure 2 Negative Battery Connection Washer 7 A gt A Negative 7 battery cable Screw Positive battery cable 4 Reattach washer arid nut and tighten 5 Verify that connectioris 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 recommandations and instructions CAUTION Any attempt to crank or start the engine before it has been properly filled with rhe recommended oil will result in equipment failure Refer to engine manual for oil and fuel fill information Damage to equipment resulting from failure to follow this instruction will void warranty 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
19. e generator Engine Maintenance See engine owner s manual for instructions Avoid prolonged or repeated skin contact with used motor oil Used motor oil has boon shown to cause skin cancer in certain laboratory animals Thoroughly wash exposed arcas with soap and water KEEP OUT OF REACH GF CHILDREN DON T POLLUTE CONSERVE RESOURCES RETURN USED OIL TG 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 Vater 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 To Clean the Generator Use a damp cloth to wipe exterior surf
20. ease consulta qualified electrician electrical inspector or local agency having jurisdiction 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 Oil Fill Cap Add oil to engine here Recoil Starter Used to start the engine manually Run Stop Switch Must be in Run position to start engine Set to Stop to stop a running engine Spark Arrester Muffler Exhaust muffler lowers engine noise and is equipped with a spark arrester screen GENERAC Portable Produ ASSEMBLY Your generator requires some assembly and is ready for use after it has been properly serviced with the recommended oil arid fuel If you have any problems with the assembly of your generator please call the generator helpline ac 1 800 270 1408 IMPORTANT Any attempt to run the unit before it has been serviced with the recommended oil will result in ari engine failure Remove Generator From Carton l Set carton on a rigid flat surface with This Side Up arrows pointing upward 2 Carefully open top flaps of shipping carton Review Cold Weather Operation on page 10 3 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 Figure Install Wheel Ki
21. evices 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 7500EXL Extended Life Generator GENERAC 4 Plug in and turn on the next load 5 Again permit the generator to stabilize 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 Figure 13 Wattage Reference Chart Additional Surge Starting Watts Essentials Light Bulb 75 watt Deep Freezer 500 500 Sump Pump 800 1200 Refrigerator Freezer 18 Cu Ft Water Vell Pump 1 3 HP Heating Cooling ss iji a Window AC 10 000 BTU Window Fan 30 60 Furnace Fan Blower 1 2 HP 800 130 Kitchen y y Microwave Oven 1000 Watt 1060 Coffee Maker 1500 Ratod Running Watts Tool or Appliance 1800 Electric Stove Single Element 1500
22. gt Support Leg Vibration Mount 1 30mm Cap Screw 7500EXL Extended Life Generator Install Wheel Kit The wheel kit is designed to greatly improve the portability of your generator NOTE Wheel kit is not intended for over the road use You will need a socket wrench with 1 2 or 13mm sockets and a needle nose plier to install this kit Refer to Figure and install the wheel kit as follows Place the bottom of the generator cradle on a flat even surface Temporarily place unit on blocks to ease assembly 2 Slide zxle through both axle mounting brackets on cradle frame as shown in Figure 3 Slide a wheel over the axle NOTE Be sure to install both wheels with the air pressure valve on the outboard side 4 Place the e ring onto the groove in the axle You may add the flat washer if desired NOTE Use retaining pins instead of e clip if applicable 5 Place one end of the needle nose pliers on the bottom of the axle and the other end of the pliers on top of the e r ng Seat the e ring by pressing the pliers closed 6 Repeat step 3 through 5 to secure second wheel 7500EXL Extended Life Generator GENERAC 7 Remove the temporary blocks 8 Attach the vibration mounts to the support leg with 30mm capscrews washers and lock nuts 9 With the wheels on you can now lift up the handle end and attach the support leg with 20mm cap screws and lock nuts 19 Check that all f
23. h 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 chat have pil t light or other ignition source because they can ignite fuel vapors WARNING This gencrator docs 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 GENERAC 7500EXL Extended Life Generator Portable Products Exceeding generators wattage amperage capacity can Unintentional sparking can result in fire or damage generator and or electrical devices connected 2 electric shock Lo it Seo Don t Overload Generator on page 13 WHEN ADJUSTING OR MAKING REPAIRS TO YOUR San ibd ux cene De dore ee GENERATOR i Connect electrical loads in OFF position then turn ON for operation Turn electrical loads OFF and disconnect from generator WARN I NG before stopping generator Running engines produce heat Temperature of CAUTION muffler and nearby areas can reach or exceed I50 F 65 C Severe burns can occur on contact Use generator only for intended uses DO NOT touch hot surfaces If you have questions about intended use ask dealer or call Allow equipment to cool before touching 1 800 270 1408 Disconnect t
24. he spark plug wire from the spark plug and place the wire where it cannot contact spark plug Improper treatment of generator can damage it and shorten its life Operate generator only on level surfaces CAUTION DO NOT expose generator to excessive moisture dust dirt Excessively high operating speeds increase risk of injury Al OSN VHP and damage to generator DO NOT insert any objects through cooling slots Excessively low speeds Impose a heavy load 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 flares unit vibrates excessively DO NOT tamper with governed speed Generator supplies correct rated frequency and voltage when running ac governed speed DO NOT modify generator in any way Lee 7500EXL Extended Life Generator GENERAC 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 Electric Start Button il Fill Circuit Breakers AC oT 12 Vole DC Receptacle Idle Control Switch 20 240 Volt AC 30 Amp Locking Receptacle 120 Volt AC 30 Amp Locking Receptacle 120 Volt AC 20 Amp Duplex Receptacle I2 Volt DC Receptacle Use this
25. his warranty The engine and starting batteries are warranted solely by the manufacturers of those products WARRANTY REGISTRATION I NOT NECESSARY TO OBTAIN WARRANTY ON BRIGGS amp STRATTON POWER PRODUCTS EQUIPMENT SAVEYOUR 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 aquipment 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 n
26. m 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 THE GENERATOR See Don t Overload Generator on page 13 7500EXL Extended Life Generator GENERAC Stopping the Engine 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 zn electrical load is connected When an electrical load is removed the engirie will run at a reduced speed With the switch off the engine wil run at the normal high engine speed Always have the switch off when starting and stopping the engine Charging a Batter Your generator has the capability of recharging a discharged 12 Volt automotive or utility style storage battery DO NGT use the unit
27. or feet arc wee DO NOT allow unqualified persons or children to operate or service generator Storage batteries give off explosive hydrogen gas during recharging Hydrogen gas stays around battery for a long time after battery has been charged Slighzest 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 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 7500EXL Extended Life Generator GENERAC WARNING KK Fuel and irs vapors are extremely flammable and explosive Fire or explosion can cause severe burns or death WHEN ADDING FUEL Turn generator OFF and let ic cool atleast 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 wit
28. ot 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 amp STRATTON POWER PRODUCTS GROUP LLC
29. readonal vehicle RV Remove generator from shelter when temperature is above 40 F AC RECEPTACLES CAUTION Receptacles may be marked with rating value greater than generator output capacity 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 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 8 Figure 8 12 Volt DC 16 Amp Receptacle 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 9 before attempting to recharge a battery 120 Volt AC 20 Amp Duplex Receptacle Each receptacle Figure 9 is protected against overload by a 20 Amp push to reset circuit breaker Figure 9 126 Volt AC 20 Amp Duplex Receptacle 7500EXL Extended Life Generator Use each receptacle to operate 20 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 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
30. receptacle with battery charge cables to charge a 12 Volt battery 120 Volt AC 20 Amp Duplex Receptacle May be used to supply electrical power for the operation of 120 Volt AC single phase 60 Hz electrical lighting appliance tool and motor loads 120 Volt AC 30 Amp Locking Receptacle May be used to supply electrical power for the operation of 120 Volt AC 30 Amp single phase 60 Hz electrical lighting appliance too arid 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 120 240 Volt AC 50 Amp Receptacle May be used to supply electrical power for the operation of 240 Volt AC 50 Amp single phase 60 Hz electrical loads Air Cleaner Uses a dry type filter element and foam pre cleaner to limit the amount of dirt and dust sucked into the engine SS Recoil Starter Q K Fuel Tank Spark Arrester Muffler 120 240 Volt AC 50 Amp Receptacle Grounding Fastener 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 severi 7 U S gallons Electric Start Switch Press to start the engine Grounding Fastener If required pl
31. 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 experierice icing of the carburetor and or the crankcase breather system 7500EXL Extended Life Generator Build a structure that will ericlose 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 7 Figure 7 Permanent Cold Weather Shelter Ensure a minimum of two feet cleararice between open side of box and nearest object 3 Face exposed end away from wind and elements 4 Enclosure should hold enough heat created by generator to prevent problems Running generator gives off carbon monoxide an odorless colorless poison gas Breathing carbon monoxide will cause nausea fainting or death Operate generator ONLY outdoors Keep at least 2 fect 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 rec
32. rom this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Hazard Symbols and Meanings 7 Electrocution Electrical Shock 4 M Toxic Fumes Explosion Electrical Shock C 2 Chemical Burn Hot Surface Explosive Pressure DANGER Running generator gives off carbon monoxide an odorless colorless poison gas Breathing carbon monoxide will cause nausea fainting or death Operate generator ONLY outdoors Keep at least 2 foot of clearance on all sides of generator for adequate ventilation DO NOT operate generator inside any building or enclosure including the generator comparoment of a recreational vehicle RY Generator produces powerful voltage Failure to isolare generator from power utility can result in death or injury to electric utility workers due to backfeed of electrical energy 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 arca such as metal decking or steel work DO NOT touch bare wires or receptacles DO NOT use generator with electrical cords which arc 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
33. rrent 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 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 7500EXL Extended Life Generator 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 wif 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 miner 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 The engine exhaust f
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