Generac 101 9-3 Portable Generator User Manual
Contents
1. 30 Amp Locking Receptacle 120 Volt AC 30 Amp Locking Receptacle 120 Volt AC 20 Amp Duplex Receptacle 12 Volt DC Receptacle Use this 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 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 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 Protects engine by filtering dust and debris out of intake air Recoil Starter aN Fuel Tank Run Stop Switch Air Cleaner 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 overl2. DO NOT expose generator to excessive moisture dust dirt or corrosive vapors DO NOT insert any objects through cooling slots 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 GENERAC Portable Products 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 is 4 Jl Storage covers can be flammable DO NOT place a storage cover over a hot generator Let equipment cool for a sufficient time before placing the cover on the equipment 7500EXL Extended Life Generator Engine Storage See engine operator 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
3. 1 4 20x1 Capscrew Battery Charge Cables Spare Spark Plug Air Filter and Oil Filter Spark Plug Wrench 2 Locking 30 Amp Plugs Engine Oil Operator s Manual Engine Manual If any parts are missing or damaged call the generator helpline at 1 800 270 1408 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 the following tools to install this wheel kit 1 2 or 13mm socket wrench 1 2 or 13mm open end wrench 7 16 socket wrench 7 16 open end wrench Pliers Safety glasses Refer to Figure and install the wheel kit as follows Tip generator so that engine end is up Wheel Flat Washer 6 M8x20mm Capscrew E Ring M8 Lock Nut 2 3 Slide axle through both mounting brackets Slide a wheel over the axle NOTE Be sure to install both wheels with the air pressure valve on the outboard side 4 5 Place a washer on axle and then place an e ring in axle groove Install e ring with pliers squeezing from top of e ring to bottom of axle E rings can cause eye injury E E rings can spring back and become airborne when installing or removing Always wear eye protection when installing removing e rings Repeat step 3 thru 5 to secure second wheel Tip generator so that engine side is down Attach the vibration mounts to the support le
4. EAS 7 000 RATED WATT EXTENDED LIFE GENERATOR Operator s Manual WARNING Before using this product read this manual and follow all Safety Rules and Operating Instructions 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 0 05311 24847 1 Model No 1019 3 7 500 Watt AC Generator Manual No 189713GS Revision I 12 15 2005 GENERAC 7500EXL Extended Life Generator SAVE THESE INSTRUCTIONS TABLE OF CONTENTS Safety Rules neces uet ds eR So eu teca 2 4 Know Your Generator eese eA 5 Assembly 5er rper expe sete alee 6 8 Operation shat tassi x DR ER EE eSI Asta 9 16 Mairitenance sien iia sae ste terme eek am Rats 17 veli DNE a EE E D LU 18 Troubleshooting rete ehex x RR 19 Warranty sc c0vacoee ex E dh baaa Gua eee neste teas 20 EQUIPMENT DESCRIPTION Read this manual carefully and become L 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 ca
5. AC loads at 30 Amps or greater Figure 14 You can use the same 4 wire cord if you plan to run a 120 Volt load Figure 14 120 240 Volt AC 30 Amp Receptacle 4 Wire Cord Set 240V 120V 94 120V W Neutral X Hot Ne Y Hot NEMA L14 30 x 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 Ground Green 7500EXL Extended Life Generator GENERAC Portable Products 120 240 Volt AC 50 Amp Receptacle Use a NEMA 14 50 plug with this receptacle Figure 15 Connect a 4 wire cord set rated for 250 Volt AC loads at 50 Amps to the plug Figure 15 120 240 Volt AC 50 Amp Receptacle K 240 Volts AC Frame Ground 120 Volts p AC 120 Volts W Neutral NEMA 14 50 Use this receptacle to operate 120 240 Volt AC 60 Hz single phase loads requiring up to 7 500 watts 7 5 kW of power The outlet is protected by a 35 Amp push to reset circuit breaker GENERAC Portable Products 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 l Select the ite
6. are approximate only Check tool or appliance for actual wattage MAINTENANCE SPECIFICATIONS Starting Wattage 0 eee 13 500 watts Wattage situ saaddiguade e Ee Ra 7 500 watts AC Load Current At 20 Volts err rote RE RR 62 5 Amps At 240 Volts sorta 31 2 Amps Phase ides adepta renen dream dct ae Ra S DT phase Rated Frequency kinas eee eee 60 Hertz Fuel Tank Capacity 04 7 US gallons Shipping Weight 00 200005 240 Ibs 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 Should you have questions about replacing components on your Generac Portable Products generator please call 1 800 270 1408 for assistance Engine Maintenance See engine operator s manual for instructions Avoid prolonged or repeated skin contact with used motor oil Used motor oil has been shown to cause skin cancer in certain laboratory animals Thoroughly wash exposed areas with soap and water 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 un
7. excluded from the product warranty This warranty excludes failures due to acts of God and other force majeure events beyond the manufacturers control 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 JEFFERSON WISCONSIN U S A
8. 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 a EOUBIE 7500EXL Extended Life Generator GENERAC TROUBLESHOOTING Problem Cause Correction One of the circuit breakers is open Reset circuit breaker 2 Fault in generator Contact Generac service facility No AC output is available but engine is running 3 Poor connection or defective cord set Check and repair 4 Connected device is bad Connect another device that is in good condition Engine runs good at no l Shortcircuit in a connected load Disconnect shorted electrical load load but bogs down 2 Generator is overloaded See Don t Overload Generator when loads are connected 3 chorted generator circuit Contact Generac service facility Engine will not start or Fuel valve is in the Off position Turn fuel valve to On position starts and runs rough 2 Failed battery 2 Replace battery Engine shuts down during Out of gasoline Fill fuel tank operation Engine lacks power Load is too high See Don t Overload Generator GENERAC PORTABLE PRODUCTS OWNER EQUIPMENT WARRANTY POLICY Effective November 1 2004 LIMITED WARRANTY Generac Portable Products is a license
9. 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
10. resistance is felt and then pull rapidly to avoid kickback NEVER start or stop engine with electrical devices plugged in and turned on 7500EXL Extended Life Generator NOTE 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 A WARNING Running engines produce heat Temperature of muffler and nearby areas can reach or exceed g 150 F 65 C Severe burns can occur on contact Exhaust heat gases can ignite combustibles structures or damage fuel tank causing a fire DO NOT touch hot surfaces and avoid hot exhaust gases Allow equipment to cool before touching Keep at least 5 ft 152 cm clearance on all sides of generator including overhead Code of Federal Regulation CFR Title 36 Parks Forests and Public Property require equipment powered by an internal combustion engine to have a spark arrester maintained in effective working order complying to USDA Forest service standard 5100 IC or later revision In the State of California a spark arrester is required under section 4442 of the California Public resources code Other states may have similar laws 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
11. ING EQUIPMENT Ensure spark plug muffler fuel cap and air cleaner are in place DO NOT crank engine with spark plug removed If fuel spills wait until it evaporates before starting engine 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 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 GENERAC 7500EXL Extended Life Generator SAFETY RULES A WARNING Rapid retraction of starter cord kickback will pull hand and arm toward engine faster than m uw you can let go Broken bones fractures bruises or sprains could result When starting engine pull cord slowly until resistance is felt and then pull rapidly to avoid kickback NEVER start or stop engine with electrical devices plugged in and turned on A WARNING Running engines produce he
12. at Temperature of muffler and nearby areas can reach or exceed CZ ESO Severe burns can occur on contact Exhaust heat gases can ignite combustibles structures or damage fuel tank causing a fire DO NOT touch hot surfaces and avoid hot exhaust gases Allow equipment to cool before touching Keep at least 5 ft 152 cm clearance on all sides of generator including overhead Code of Federal Regulation CFR Title 36 Parks Forests and Public Property require equipment powered by an internal combustion engine to have a spark arrester maintained in effective working order complying to USDA Forest service standard 5100 1C or later revision In the State of California a spark arrester is required under section 4442 of the California Public resources code Other states may have similar laws CL 4 Unintentional sparking can result in fire or electric shock 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 WHEN TESTING FOR ENGINE SPARK Use approved spark plug tester DO NOT check for spark with spark plug removed A CAUTION Excessively high operating speeds increase risk of injury and damage to generator Excessively low speeds impose a heavy load DO NOT tamper with governed speed Generator supplies correct rated frequency and voltage when running at governed speed DO NOT modify generat
13. at could result in equipment damage Follow safety messages to avoid or reduce the risk of injury or death The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Hazard Symbols and Meanings oy Operator s Manual M Explosion Toxic Fumes Electrical Shock kan S 2 Hot Surface Kickback Chemical Burn Explosive Pressure SAFETY RULES 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 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 A WARNING Running generator gives off carbon monoxide an odorless colorless poison gas Breathing carbon monoxide can cause nausea fainting or death Operate generator ONLY outdoors Keep exhaust gas from entering a confined area through windows doors ventilation intakes or other openings DO NOT operate generator inside any building or enclosure even if doors or windows are open including the generator compar
14. d 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 in material or workmanship or both Transportation charges on product 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 800 270 1408 Warranty service may only be performed by a Briggs amp 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 WARRANTY PERIOD 90 ay Portable Generator 2 years 2n
15. d year parts only 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 amp 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 THEWARRANTY 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
16. e 17 for additional information 7500EXL Extended Life Generator COLD WEATHER OPERATION Under certain weather conditions temperatures below 40 F 4 C combined with high humidity your generator may experience icing of the carburetor and or the crankcase breather system To reduce this problem you need to perform the following Make sure generator has clean fresh fuel 2 Open fuel valve turn valve to open position 3 Use SAE 5W 30 oil synthetic preferred see engine operator s manual 4 Check oil level daily or after every eight 8 hours of operation 5 Maintain generator following Maintenance Schedule in engine operator s manual 6 Shelter unit from elements Creating a Temporary Shelter n an emergency use the original shipping carton 2 Cut off top carton flaps and one long side of carton to expose muffler side of unit If required tape up other sides of carton to fit over generator as shown in Figure 9 Figure 9 Permanent Cold Weather Shelter NOTE If required remove wheel kit to fit carton over generator as shown in Figure 9 3 Cutappropriate slots to access receptacles of unit 4 Face exposed end away from wind and elements 5 Locate generator as described in the section Generator Location Keep exhaust gas from entering a confined area through windows doors ventilation intakes or other openings A WARNING Running generator gives off carbon
17. e generator making sure muffler side of generator is exposed NOTE Structure should hold enough heat created by the generator to prevent icing problem 2 DO NOT enclose generator any more than shown in Figure 9 NOTE If a wheel kit is installed on the generator enlarge shelter accordingly 3 Follow steps 3 through 8 as described previously in Creating a Temporary Shelter GENERAC Portable Products GENERATOR ADAPTER CORD SET The generator is equipped with a 25 generator adapter cord set designed for a 240 Volt 30 Amp grounded neutral circuit Figure 10 The generator adapter cord set provides a convenient supply of emergency power into your dwelling so that your generator can be operated safely outside Figure 10 Generator Adapter Cord Set The maximum load on each outlet is 20 Amps The maximum total load on both yellow wire outlets or both black wire outlets is 30 Amps NOTE Follow all safety precautions when connecting any extension cord or device to the generator 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 pro
18. em 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 In some areas generators are required to be registered with local utility companies If 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 A WARNING 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 When using generator for backup power notify utility company Use approved transfer equipment to isolate generator from electric utility Use a ground fault circuit interrupter GFCI in any damp or highly conductive a
19. g with 1 4 20 x capscrews and 1 4 20 lock nuts Line up holes in support leg with holes in generator frame Attach support leg using 2 capscrews M8 x 20 mm and 2 hex nuts M8 Tighten with a 1 2 or 13mm socket wrench and 1 2 or 13mm wrench Return generator to normal operating position resting on wheels and support leg Check each fastener to ensure it is secure 7500EXL Extended Life Generator GENERAC 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 Cut off tie wrap securing loose end of negative black cable 2 Remove screw lock washer and flat washer on negative battery terminal 3 Slide lock washer flat washer and negative battery cable over screw Figure 2 Negative Battery Cable Lock Washer Positive Battery Cable 4 Reattach screw to negative battery terminal and tighten 5 Verify that connections to battery and generator are tight and secure GENERAC 7500EXL Extended Life Generator BEFORE STARTING THE ENGINE Add Engine Oil Place generator on a level surface CAUTION Any attempt to crank or start the engine before it has been properly filled with the recommended oil will result in equipment failure Refer to engine manual for oil fill information Damage to equipment resulting from failure to follow this ins
20. it 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 7500EXL Extended Life Generator GENERAC Portable Products 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 LA CL Unintentional sparking can result in fire or electric shock 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 WHEN TESTING FOR ENGINE SPARK Use approved spark plug tester DO NOT check for spark with spark plug removed 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 surfaces clean CAUTION Improper treatment of generator can damage it and shorten its life
21. monoxide an odorless colorless poison gas Breathing carbon monoxide can cause nausea fainting or death Operate generator ONLY outdoors Keep exhaust gas from entering a confined area through windows doors ventilation intakes or other openings DO NOT operate generator inside any building or enclosure even if doors or windows are open including the generator compartment of a recreational vehicle RY 7500EXL Extended Life Generator GENERAC Portable Products 6 Start generator as described in the section Starting the Engine then place carton over generator Keep at least 5 ft 152 cm clearance on all sides of generator including overhead with shelter in place Running engines produce heat Temperature of muffler and nearby areas can reach or exceed Sd s 150 F 65 C Severe burns can occur on contact A K amp Exhaust heat gases can ignite combustibles structures or damage fuel tank causing a fire DO NOT touch hot surfaces and avoid hot exhaust gases Allow equipment to cool before touching Keep at least 5 ft 152 cm clearance on all sides of generator including overhead Remove shelter when temperatures are above 40 F 4 C 7 Remove shelter when temperatures are above 40 F 4 C 8 Turn engine OFF and let cool two 2 minutes before refueling Wipe up any spilled fuel Creating a Permanent Shelter l Build a structure that will enclose three sides and the top of th
22. ms 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 16 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 Additional Surge Tool or Appliance 7500EXL Extended Life Generator Watts Starting Watts Window Air 1200 1800 Conditioner Refrigerator 800 1600 Deep Freezer 500 500 Television 500 Light 75 Watts 75 3075 Total 1800 Highest Running Watts Surge Watts 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 l With nothing connected to the generator start the engine as described in this manual 2 Plug in and turn on the firs
23. oad Fuel Tank Capacity of seven 7 U S gallons Electric Start Switch Press to start the engine Grounding Fastener Consult your local agency having jurisdiction for grounding requirements in your area 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 7500EXL Extended Life Generator ASSEMBLY Your generator requires some assembly and is ready for use after it has been properly serviced with the recommended oil and fuel If you have any problems with the assembly of your generator please call the generator helpline at 1 800 270 1408 Unpack the Generator l Setthe carton on a rigid flat surface 2 Open carton completely by cutting each corner from top to bottom 3 Remove everything from carton except generator 4 Leave generator on carton to install wheel kit Carton Contents Check all contents against those listed below Generator Wheel kit Storage Cover Adapter Cord Set Battery Battery Float Charger Figure Install Wheel Kit
24. or in any way CAUTION Exceeding generators wattage amperage capacity can damage generator and or electrical devices connected to it See Don t Overload Generator 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 CAUTION Improper treatment of generator can damage it and shorten its life Use generator only for intended uses If you have questions about intended use ask dealer or call 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 KNOW YOUR GENERATOR KNOW YOUR GENERATOR 7500EXL Extended Life Generator GENERAC T Read this Operator s Manual and safety rules before operating your generator LII Compare this illustration with your generator to familiarize yourself with the locations of various controls and adjustments Save this manual for future reference Electric Start Button 2 Oil Fill Cap Circuit Breakers AC 12 Volt DC Receptacle Idle Control Switch 120 240 Volt AC
25. ormal 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 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 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 Portable Products To recharge 12 Volt batteries proceed as follows Check fluid level in all battery cells If necessary add ONLY distilled water to cover separators in battery cells DO NOT use tap water 2 If battery is equipped with vent caps make sure they are installed and are tight 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
26. pacity See Don t Overload Generator 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 and the California Air Resources Board For warranty information refer to the engine operator s manual Copyright 2005 Briggs amp Stratton Power Products Group LLC All rights reserved No part of this material may be reproduced or transmitted in any form by any means without the express written permission of Briggs amp Stratton Power Products Group LLC SAFETY RULES SAFETY RULES This is the safety alert symbol It is used to A 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 th
27. 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 CAUTION Exceeding generators wattage amperage capacity can damage generator and or electrical devices connected to it See Don t Overload Generator 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 Stopping the Engine I Turn off and 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 operator 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 n
28. rea 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 7500EXL Extended Life Generator GENERAC Portable Products Generator Location Generator Clearance A M Exhaust heat gases can ignite combustibles structures or damage fuel tank causing a fire Keep at least 5 ft 152 cm clearance on all sides of generator including overhead Place generator in a well ventilated area which will allow for removal of deadly exhaust gas DO NOT place generator where exhaust gas could accumulate and enter inside or be drawn into a potentially occupied building Ensure exhaust gas is kept away from any windows doors ventilation intakes or other openings that can allow exhaust gas to collect in a confined area Figure 4 Prevailing winds and air currents should be taken into consideration when positioning generator A WARNING Running generator gives off carbon monoxide an odorless colorless poison gas Breathing carbon monoxide can cause nausea fainting or death Operate generator ONLY outdoors Keep exhaust gas from entering a confined area thro
29. t 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 Figure 16 Wattage Reference Chart Additional Surge Starting Watts Rated Running Watts Tool or Appliance Essentials Light Bulb 75 watt 75 Deep Freezer 500 Sump Pump 1200 Refrigerator Freezer 18 Cu Ft 1600 Water Well Pump 1 3 HP 2000 Heating Cooling Window AC 10 000 BTU 1800 Window Fan 600 Furnace Fan Blower 1 2 HP Kitchen Microwave Oven 1000 Watt Coffee Maker Electric Stove Single Element Hot Plate Family Room DVD CD Player VCR Stereo Receiver Color Television 27 Personal Computer w l7 monitor Other Security System AM FM Clock Radio Garage Door Opener 1 2 HP Electric Water Heater 40 Gallon DIY Job Site Quartz Halogen Work Light Airless Sprayer 1 3 HP Reciprocating Saw Electric Drill 1 2 HP Circular Saw 7 1 4 Miter Saw 10 Planer Jointer 6 Table Saw Radial Arm Saw 10 Air Compressor 1 2 HP Wattages listed
30. tment of a recreational vehicle RY A WARNING 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 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 or wet weather 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 7500EXL Extended Life Generator GENERAC GENERAC Products A WARNING Fuel and its vapors are extremely flammable and explosive Fire or explosion can cause severe burns or death WHEN ADDING OR DRAINING FUEL Turn generator OFF and let it cool at least 2 minutes before removing fuel cap Loosen cap slowly to relieve pressure in tank Fill or drain 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 START
31. to the positive battery terminal Figure 7 Figure 7 Battery Connections 12 VOLT D C RECEPTACLE 6 Connect battery charge cable clamp with black handle to the negative battery terminal Figure 7 7 Start engine Let engine run while battery recharges When battery has charged shut down engine NOTE Use an automotive hydrometer to test battery state of charge and condition Follow the hydrometer manufacturer s instructions carefully Generally a battery is considered to be at 10076 state of charge when specific gravity of its fluid as measured by hydrometer is 1 260 or higher GENERAC Portable Products 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 unit s Battery Float Charger jack which is located on the starter switch Figure 8 Plug battery charger into a 120 Volt AC wall receptacle Figure 8 Battery Charger Jack 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 pag
32. truction will void warranty Refer to engine operator s manual and follow oil recommendations and instructions NOTE Check oil often during engine break in Refer to engine operator 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 Add Fuel NOTE This gasoline engine is certified to operate on gasoline Exhaust Emission Control System EM Engine Modifications fet Fuel and its vapors are extremely flammable and explosive Fire or explosion can cause severe burns or death WHEN ADDING FUEL Turn generator OFF and let it cool at least 2 minutes before removing fuel 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 Use clean fresh regular UNLEADED fuel with a minimum of 85 octane DO NOT use fuel which contains Methanol DO NOT mix oil with fuel 2 Clean area around fuel fill cap remove cap Slowly add regular unleaded fuel to fuel tank Be careful not to overfill Allow at least 1 5 of tank space for fuel expansion Figure 3 Figure 3 Fuel Expansion 4 Install fuel cap and wipe up any spilled fuel OPERATION y N re USING THE GENERATOR Syst
33. ugh windows doors ventilation intakes or other openings DO NOT operate generator inside any building or enclosure even if doors or windows are open including the generator compartment of a recreational vehicle RV Figure 4 Generator Clearance Typical Generator Shown Exhaust Port GENERAC Portable Products OPERATING THE GENERATOR Starting the Engine IMPORTANT Always unplug the battery float charger before starting the generator Disconnect all electrical loads from the generator Use the following start instruction steps by numerical order 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 5 The fuel valve handle should be vertical pointing toward the ground for fuel to flow Figure 5 Fuel Valve Fuel Valve is shown in the On position 3 Make sure the Idle Control switch is in Off position Figure 6 Figure 6 Idle Control Switch IDLE 4 Start the engine according to instructions given in the engine operator s manual A WARNING Rapid retraction of starter cord kickback will pull hand and arm toward engine faster than you can let go Broken bones fractures bruises or sprains could result MT When starting engine pull cord slowly until
34. vided Figure 1 7500EXL Extended Life Generator Figure 12 Volt DC 10 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 1 before attempting to recharge a battery 120 Volt AC 20 Amp Duplex Receptacle Each receptacle Figure 12 is protected against overload by a 20 Amp push to reset circuit breaker Figure 12 120 Volt AC 20 Amp Duplex Receptacle 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 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 13 Figure 13 120 Volt AC 30 Amp Locking Receptacle 3 Wire Cord Set Ly NEMA L5 30 Neutral 120V Hot zi 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 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
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