Generac 5550 Portable Generator User Manual
Contents
1. ASSEMBLY Power Regulator 900 UE 20 Part 4 67022 66825C 86494 23762 66386 66849 B4871 74908 B4605 66849C 65795 66449L 22145 22097 186744 BB5586 52858 86927 27007 42909 936936 4966 22247 87005 189302B 77282 188987 188989 22287 22097 22127 186704 B4489 189302C 185939H 73054 77816 39253 8927 52618 23897 52856 50190 96113 58359 189198 B4177 189208 65787 37806 188971 NSP Generac Portable Products 7000EXL Extended Life Generator Qty Description GROMMET Rubber CARRIER Rear Bearing SCREW M6 1 0 x 16 Wing WASHER Shakeproof 10 ASSEMBLY Brush Holder TAPTITE M5 0 8 x 16 COVER Bearing Carrier TAPTITE M5 0 8 x 10 GRIP TAPTITE M5 0 8 x 30 RECTIFIER Battery Charge BOLT Stator 6 1 x 190mm WASHER Flat 5 16 M8 LOCKWASHER 1 4 M6 MANUAL Operators HANDLE NUT Lock M8 LEG Support MOUNT Vibration CAPSCREW M8 1 25 x 30 AXLE WHEEL WASHER Wheel PIN Retaining WIRE ASM 16 SWITCH Starter BRACKET Switch ASM Jack DC HHCS 1 4 20 x 3 4 LOCKWASHER 1 4 M6 NUT 1 4 20 TRAY Battery BATTERY 12 18 AH WIRE ASM 13 WIRE ASM 55 DECAL Fuel Shut Off DECAL Hot Muffler HHCS M8 1 25 x 20 MANUAL Engine HHCS M5 0 8 x I2 WASHER M5 Flat NUT M5 Flange Hex WASHER Flat 10 GA 0 34 x I WIRE ASM 13 LUG 5 16 3222 18 1 5 DECAL Instruction ES CHARGE Battery Float F2. Let engine stabilize and warm up for a few minutes after starting Plug in and turn on the desired 120 and or 240 Volt AC single phase 60 Hz electrical loads Do Not connect 240 Volt loads to the 120 Volt receptacles Do Not connect 3 phase loads to the generator Do Not connect 50 Hz loads to the generator DO NOT OVERLOAD THE GENERATOR Add up the rated watts or amps of all loads to be connected at one time This total should not be greater than the rated wattage amperage capacity of the generator See Don t Overload the Generator page 11 Stopping the Engine Unplug all electrical loads from generator panel receptacles Never start or stop engine with electrical devices plugged in and turned on Put the idle control switch in the Off position Let engine run at no load for 30 seconds to stabilize the internal temperatures of engine and generator e Move run stop switch to Stop e Close the fuel shut off valve Operating Automatic Idle Control This switch is designed to greatly improve fuel economy When this switch is turned ON the engine will only run at its normal high governed engine speed when an electrical load is connected When an electrical load is removed the engine will run at a reduced speed With the switch off the engine will run at the normal high engine speed Always have the switch off when starting and stopping the engine Charging a Battery hydrogen gas
3. 13 auld O RESET 10 lt Ct 15 FLOAT CHARGER INPUT 1000V DIODE 44 GRN YEL 13A 0 Lisa i3 ELECTRIC e HB 20 START wA ATTERY C B SWITCH 55 STARTER gt a 55 11 22 ec 120 240V 16 2V 10A DC 30A Generac Portable Products 7000EXL Extended Life Generator WIRING DIAGRAM 9 180V 120v 44A 20A 22 30A 448 44A 11 WHI TE 44 22 ES a 11B 20A 20A 30A 30A 11A CB 22 22 DUTLET TAB noB MUST BE Lj BR KEN DFF GRNAYEL zc 11 118 44 11 11 11 CONTROL SWITCH 55 GRN BLU BLU WHT 12V 10A DC 11 15 55 ee 44 IDLE CUNTRDL 22755 TRANSFORMER 1 e 11 44 GRN iss 55 22 44 11 e 156 SYSTEM CONTROL
4. foam pre cleaner to limit the amount of dirt and dust sucked into the engine Choke Lever Run Stop Switch Spark Arrester Muffler 120 Volt AC 20 Amp Duplex Receptacle Idle Control Switch 120 240 Volt AC 30 Amp Receptacle 12 Volt DC 10 Amp Receptacle Grounding Wing Nut Choke Lever Used when starting a cold engine Circuit Breakers AC Each receptacle is provided with a push to reset circuit breaker to protect the generator against electrical overload Fuel Tank Capacity of seven 7 U S gallons Grounding Wing Nut Used for proper grounding of unit Idle Control Switch With this switch set to ON generator automatically reduces engine speed when no load is connected and increases engine to proper speed when load is applied However be sure switch is OFF when starting engine Run Stop Switch Set this switch to Run before starting engine Set switch to Stop to switch OFF engine Spark Arrester Muffler Exhaust muffler lowers engine noise and is equipped with a spark arrester screen Start Button When pressed cranks engine to start Generac Portable Products 7000EXL Extended Life Generator OPE RATI NG TH E 4 Place the choke lever in the Full choke position Figure 7 GENERATOR CAUTION Never start or stop unit with electrical loads connected AND with the connected devices turned ON IMPORTANT Always unplug the battery float charger before starting the gen
5. of the negative battery cable and is ready for use after it has been properly serviced with the recommended oil and fuel IMPORTANT Any attempt to run the unit before it has been serviced with the recommended oil will result in an engine failure Check that the following is included with your unit If any parts are missing or damaged call the generator helpline at 1 800 270 1408 Battery charge cables Battery float charger Extenda Panel cord Generator and engine owner s manuals Locking 30 Amp plug Three packets of fuel stabilizer Two bottles of engine oil Generac Portable Products 7000EXL Extended Life Generator 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 Remove nut and washer on the negative battery terminal Slide the negative battery cable over the screw on the negative terminal Figure 2 Figure 2 Negative Battery Connection N Negative battery cable e Reattach washer and nut and tighten e Verify that the connections to the battery and generator are tight and secure Generac Portable Products 7000EXL Extended Life Generator BEFORE STARTING THE ENGINE Add Oil CAUTION Any attempt to crank or start the engine before it has been properly filled with the recommended oil may
6. result in an engine failure To fill your engine with oil Place generator on a level surface Follow the oil grade recommendations and oil fill instructions given in the engine owner s manual NOTE The generator s revolving field rides on a prelubricated and sealed ball bearing that requires no additional lubrication for the life of the bearing Add Gasoline WARNING Never fill fuel tank indoors Never fill fuel tank when engine is running or hot Do Not light a cigarette or smoke when filling the fuel tank 1 WARNING Do Not overfill the fuel tank Always allow room for fuel expansion Use regular UNLEADED gasoline with the generator engine Do Not use premium gasoline Do Not mix oil with gasoline e Clean area around fuel fill cap remove cap e Slowly add unleaded regular gasoline to fuel tank Be careful not to overfill Allow about 1 2 of tank space for fuel expansion Figure 3 Figure 3 Typical Fuel Expansion Space II IIR PIE IMPR Install fuel cap and wipe up any spilled gasoline IMPORTANT It is important to prevent gum deposits from forming in essential fuel system parts such as the carburetor fuel filter fuel hose or tank during storage Also experience indicates that alcohol blended fuels called gasohol ethanol or methanol can attract moisture which leads to separation and formation of acids
7. such as metal decking or steel work Never use worn bare frayed or otherwise damaged electrical cords with the generator Death serious injury and property damage from electrical shock may result Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE Never allow smoking open flames sparks or heat in the vicinity while handling gasoline Avoid spilling gasoline on a hot engine Comply with all laws regulating storage and handling of gasoline Do Not overfill the fuel tank Always allow room for fuel expansion If tank is overfilled fuel can overflow onto a hot engine and cause a FIRE or an EXPLOSION Never store a generator with fuel in the tank where gasoline vapors might reach an open flame spark or pilot light as on a furnace water heater clothes dryer FIRE or an EXPLOSION may result The unit requires an adequate flow of cooling air for its continued proper operation Never operate the unit inside any room or enclosure where the free flow of cooling air into and out of the unit might be obstructed Allow at least 2 feet of clearance on all sides of generator even while operating unit outdoors or you could damage the unit Never start or stop the unit with electrical loads connected to receptacles with the connected devices turned ON Start the engine and let it stabilize before connecting any electrical loads Disconnect all electrical loads before shutting down the generator Do Not insert any object throug
8. while recharging An explosive mixture will remain around the battery for a long time after it has been charged The slightest spark can ignite the hydrogen and cause an explosion resulting in blindness or other serious injury 1 WARNING Storage batteries give off explosive WARNING Do Not permit smoking open flame sparks or any other source of heat around a battery Wear protective goggles rubber apron and rubber gloves when working around a battery Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns If spill occurs flush area with clear water immediately Your generator has the capability of recharging a discharged 12 Volt automotive or utility style storage battery Do Not use the unit to charge any 6 Volt batteries Do Not use the unit to crank an engine having a discharged battery To recharge 12 Volt batteries proceed as follows Check fluid level in all battery cells If necessary add ONLY distilled water to cover separators in battery cells Do Not use tap water If the battery is equipped with vent caps make sure they are installed and are tight f necessary clean battery terminals Connect battery charge cable connector plug to panel receptacle identified by the words 12 VOLTS D C Connect battery charge cable clamp with red handle to the positive battery terminal Figure 8 Figure 8 Battery Charge Cable Connection 12 VOLT D C R
9. 5 Extenda Panel device designed for a 240 Volt 30 Amp grounded neutral circuit Figure I0 The Extenda Panel provides convenient supply of emergency power into your dwelling so that your generator can be operated safely outside The cord outlets may also be used as a heavy duty extension cord Figure 10 Extenda Panel JA The maximum load on each outlet is 20 Amps The maximum total load on both yellow wire outlets or black wire outlets is 30 Amps NOTE Follow all safety precautions when connecting any extension cord or device to the generator RECEPTACLES 120 240 Volt AC 30 Amp Locking Receptacle Use a NEMA 114 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 if you plan to run a 120 Volt load Figure 11 120 240 Volt AC 30 Amp Receptacle 4 Wire Cord Set NEMA L14 30 Green This receptacle powers 120 240 Volt AC 60 Hz single phase loads requiring up to 3 600 watts of power 3 6 kW at 30 Amps for 120 Volts OR 7 000 watts of power 7 0 kW at 29 2 Amps for 240 Volts The outlet is protected by a 30 Amp push to reset circuit breaker CAUTION Although this outlet states it has a 240 Volt 30 Amp rating up to 7 200 watts the generator is only rated for 7 000 watts Powering loads that exceed the wattage amperage capacity of the generator can damage
10. 92731 90239 B1342G 65791 96796 47481 B1897G 20566 40976 92532 66476 186747 92630 J96068 14353621 26850 BB306 81917 B4986 186798 56893 84132 Item CRADLE 53 SHIELD Heat 54 DECAL Danger 55 INSULATION 2 1 4 Thick 56 TANK Fuel Incls Item 12 amp 13 57 CAP with Gauge Fuel 58 CLIP Insulation 59 DECAL Start Instructions 60 4 HHMS M6 1 0 x 60 SEMS 61 4 Tank 62 8 NUT Flange Lock M6 63 VALVE Tank 64 BUSHING Tank 65 9 SCREW 12 14 x 7 8 Self Driller 66 4 6 1 0 I2 67 2 HHCS M8 1 25 x 50 68 2 PIN with Lanyard 69 4 WASHER Nylon 70 2 NUT M8 Nylok 71 SCREEN Spark Arrester 72 4 HHMS 5 16 24 x 3 4 73 HOUSING Engine Adapter 74 SUPPORT Engine 75 12 NUT 5 16 18 Flange Serrated 76 2 WASHER Lock M8 77 4 MOUNT Vibration 78 2 HHCS 5 16 18 x 1 3 4 79 2 MOUNT Vibration 80 2 SCREW 5 16 18 x 3 4 8l MUFFLER 82 SUPPORT Engine amp Muffler 83 GASKET Muffler 84 ASSEMBLY Rotor Incls Item 34 85 BEARING 86 WASHER Special Flat M8 87 HHCS 5 16 24 x 10 5 8 88 ASSEMBLY Stator 89 DECAL 1 800 90 2 SCREW M8 1 25 x 20 9 BRACKET Muffler 92 2 CAPSCREW M6 1 0 x 12mm 93 DECAL Control Panel 94 ASSEMBLY Control Box 95 SHIELD Heat 96 WIRE Ground 97 2 LW EXT Shakeproof M6 98 2 BOTTLE Oil 99 PIN Roll 4mm 10 100 DECAL Ground 101 2 DECAL Heat Shield 102 5 CRIMPTITE 10 24 x 1 2 103
11. BOARD U 1 t 11 33 9 9 44 55 f 6 BLU 11 IDLE BLU WHT CONTROL L vEL 22 e COLL T GRN YEL 0 STATUR GRN YEL 0 SUS Ss SNUBBER 3 PIN Bu i5 FEEDBACK NU connector Ries _ 66 UN ENGINE CUSTOMER h als DC FLOAT GROUND ANODE ny OL CHARGER 13 LUG BRUSH ho CLOSEST TO SHIELD 18 2L Ee SEE 971 775 BEARING x CATHODE 4 BLK WHT V 66 C1 1 b 13 45 ENGINE Hg RA 13A 77 RUN SWITCH ELECTRIC AREE 9 POWER START RECTIFIER 6 REGULATOR RN SWI TCH 2 BOARD L_ 664 SPARK 13A 16 4 PLUG 77 NUT UN BOTTOM ENGINE BLOCK I T iia STARTER FRAME GROUND SUPPLIED BATTERY lt Generac Portable Products 7000EXL Extended Life Generator Generac Portable Products 7000EXL Extended Life Generator E 277 f 3 EXPLODED VIEW FRAME DETAIL OF BATTERY TRAY DETAIL OF ELECTRIC START SWITCH TO STARTER TO RBC 61 TO TERMINAL ON BATTERY DETAIL OF JACK ASSEMBLY COAXIAL DC PARTS LIST ALTERNATOR amp FRAME Item Part Qty Description Ci CJ NO A187024 J189176 92982 92665 B1998 B4363 85000 93826 7883 1B 83465 77395 80270 78299 B2153 43116 51731 B4135 187104 49820 83083 86307 92247 A92531 189160 22129 82857 22531 92609 22142 A7433 A
12. ECEPTACLE Connect battery charge cable clamp with black handle to the negative battery terminal Figure 8 Start engine Let the 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 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 9 Plug battery charger into a 120 Volt AC wall receptacle Generac Portable Products 7000EXL Extended Life Generator Figure 9 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 page 12 for additional information EXTENDA PANEL The generator is equipped with a 2
13. GENERAC Portable Products ZOOOEXL Portable Generator Owner s Manual Model No 1470 0 7 000 Watt AC Generator Manual No 186744 Revision 0 06 13 2001 Visit our Generac website www generac portables com 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 EQUIPMENT DESCRIPTION This generator is 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 This manual contains information for a generator that operates 120 and or 240 Volt single phase 60 Hz devices that require up to 7 000 watts 7 0 kW of power that pull up to 58 3 Amps at 120 Volts or 29 2 Amps at 240 Volts CAUTION Do Not exceed the generator s wattage amperage capacity Add up the rated watts of all devices you are connecting to generator receptacles at one time This total should not be greater than 7 000 watts See Don t Overload the Generator on page 11 The generator s revolving field is driven at about 3600 rpm by a single cylinder engine Every effort has been made to ensure that information in this manual is accurate and current However Generac reserves the right to change alter or otherwise improve the product and this document at any time without prior notice CAUTION D
14. TION OF THIS WRITTEN WARRANT Y Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For service see your nearest COMPANY authorized warranty service facility or call 1 877 544 0982 Or look on the internet at www generac portables com Warranty service can be performed only by a COMPANY authorized service facility This warranty will not apply to service at any other facility At the time of requesting warranty service evidence of original purchase date must be presented GENERAC PORTABLE PRODUCTS Jefferson Wisconsin U S A
15. UEL STABILIZER oz Tube CABLE Battery Charge PLUG 120V 30 Amp EXTENDA PANEL ENGINE Generac Portable Products 7000EXL Extended Life Generator Item Part Qty Description UJ F0 oO 0 O Os Ui 0 IN A92070 23897 49226 91526 82538 8288 43181 43182 90418 75207 75207 23365 68868 4 4 4 4 4 4 2 2 6 PANEL Control FLAT WASHER 10 M5 LOCK WASHER M5 SCREW M5 0 8 x 12mm SWITCH Idle Control LOCK WASHER 7 16 SCREW M3 0 5 x 10mm LOCK WASHER M3 OUTLET 12V CIRCUIT BREAKER 30A CIRCUIT BREAKER 20A WASHER 8 Shakeproof OUTLET 120 Volt 30 Amp Locking 21 Item Part Qty Description 43437 68759 43180 22264 51715 64526 83970 64525 87962 84335 84134 B92069 84028 OUTLET 120V 240V 30 Locking OUTLET 120V 20A Duplex FLAT WASHER M4 LOCK WASHER 48 M4 NUT M4 0 7 Hex SCREW 6 32 x 3 8 BOARD System Control STAND OFF 3 4 Hex CIRCUIT BREAKER I2V 10 auto ASSEMBLY Wire Harness GROMMET Rubber Conn BOX Control Panel TRANSFORMER Idle Control Generac Portable Products 7000EXL Extended Life Generator 22 Generac Portable Products 7000EXL Extended Life Generator NOTES 23 PORTABLE GENERATOR LIMITED WARRANTY GENERAC PORTABLE PRODUCTS hereafter referred to as the COMPANY warrants to the original purchaser that the components in its portable generator will be free from defects in materials or wor
16. als known to the State of California to cause cancer birth defects or other reproductive harm 1 DANGER You must isolate the generator from the electric utility using approved transfer equipment if this unit is used for backup power Failure to isolate the generator from the power utility may result in injury or death to electric utility workers and damage to the generator due to a backfeed of electrical energy Whenever unit is providing backup power the electric utility must be notified DANGER Generator exhaust gases contain DEADLY carbon monoxide gas If breathed in sufficient concentrations carbon monoxide can cause unconsciousness or death Operate this equipment outdoors where adequate ventilation is available 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 Generac Portable Products 7000EXL Extended Life Generator The generator produces a very powerful voltage that can cause serious injury or death by electrocution Never touch bare wires or receptacles Never permit a child or any unqualified person to operate the generator Never handle any kind of electrical cord or device while standing in water while barefoot or while hands or feet are wet Death or serious injury from electrocution may result Use a ground fault circuit interrupter GFCI in any damp or highly conductive area
17. battery Figure 14 12 Volt DC 10 Amp Receptacle Generac Portable Products 7000EXL Extended Life Generator DON T OVERLOAD THE GENERATOR Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and or connected electrical devices Observe the following to prevent overloading the unit Add up the total wattage of all electrical devices to be connected at one time This total should NOT be greater than the generator s wattage capacity If the appliance tool or motor does not give wattage multiply 120 Volts times ampere rating to determine watts volts x amps watts Figure 15 Wattage Reference Guide Recreational Home Uses Tool Appliance AM FM clock radio Deep freezer H Personal computer and 15 monitor 3 hp furnace fan blower Microwave oven hp water well pump 12 000 Btu window air conditioner Space heater Electric water heater The rated wattage of lights can be taken from wattage listed on the light bulbs The rated wattage of tools appliances and motors can usually be found on a data plate or decal affixed to the device Use Figure 15 below as a general reference Some electric motors such as induction types require about three times more watts of power for starting than for running This surge of power lasts for only a few seconds when starting such motors Be sure you allow for this high starting wattage when sele
18. cting electrical devices to connect to your generator First figure the watts needed to start the largest motor Add to that figure the running watts of all other connected loads Professional Contractor Uses Tool Appliance 3 hp airless sprayer 3 8 hammer drill Variable speed Sawzall power drill Quartz halogen work light Belt sander 7 4 circular saw 7 4 worm drive saw 1 hp air compressor 10 power miter saw 6 bench grinder 6 table planer 10 table radial arm saw Wire feed welder allow 3 times listed watts for starting this device SPECIFICATIONS Maximum Surge Watts 12 250 watts Continuous Wattage Capacity 7 000 watts Power Factor iss cr RR Er Ea RES 1 0 Rated Maximum Continuous AC Load Current AE E20 VolES necu eco Rl 58 3 Amps At 240 Volts iios reb 29 2 Amps Phase es uoan EEan phase Rated Frequency 60 Hertz Fuel Tank 7 US gallons Shipping Weight 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 Engine Maintenance See engine owner s manual for instructions A CAUTION Avoid pro
19. during storage Acidic gas can damage the fuel system of an engine while in storage Be sure to review the precautions given in Storage on page 13 Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur Generac Portable Products 7000EXL Extended Life Generator e 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 Air Cleaner Fuel Tank Start Button Circuit Breakers AC 120 Volt AC 30 Amp Receptacle 12 Volt DC 10 Amp Receptacle Recharge a discharged 12 Volt automotive type battery through this receptacle 120 Volt AC 20 Amp Duplex Receptacle May be used to supply electrical power for the operation of 120 Volt AC 20 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 120 Volt AC 30 Amp Locking Receptacle May be used to supply electrical power for the operation of 120 Volt AC 30 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 120 240 Volt AC 30 Amp Locking Receptacle May be used to supply electrical power for the operation of 120 and or 240 Volt AC 30 Amp single phase 60 Hz electrical lighting appliance tool and motor loads Air Cleaner Uses a dry type filter element and
20. ed to pick up loose dirt Low pressure air not to exceed 25 psi may be used to blow away dirt Inspect cooling air slots and opening on generator These openings must be kept clean and unobstructed Generac Portable Products 7000EXL Extended Life Generator STORAGE The generator should be started at least once every seven days and allowed to run at least 30 minutes If this cannot be done and you must store the unit for more than 30 days use the following guidelines to prepare it for storage Generator Storage Clean the generator as outlined in To Clean the Generator Check that cooling air slots and openings on generator are open and unobstructed CAUTION Storage covers can be flammable Do Not place a storage cover over a hot generator Let the unit cool for a sufficient time before placing the cover on the unit Engine Storage See engine owner s manual for instructions Other Storage Tips To prevent gum from forming in fuel system or on essential carburetor parts empty all three supplied fuel stabilizer containers into fuel tank and fill with fresh gasoline Run the unit for several minutes to circulate the additive through the carburetor The unit and fuel can then be stored for up to 24 months Additional fuel stabilizer can be purchased locally Do Not store gasoline from one season to another unless it has been treated as described above Replace gasoline can if it starts to rust Ru
21. erator Starting the Engine Disconnect all electrical loads from the generator Use the 5A following start instruction steps by numerical order For electric starting press start switch on generator cradle To prolong the life of the starter components press the starter button for no more than 15 seconds Figure 4 Fuel Valve and pause for 30 seconds Turn the fuel valve to the On position Figure 4 FUEL TANK 5B For manual starting grasp the recoil handle and pull slowly until slight resistance is felt Then pull rapidly one time only to start engine f engine starts proceed to step 7 f engine fails to start proceed to step 6 Fuel Valve is shown in the On position 6 Move the choke lever to Half choke position and pull recoil handle twice 2 ny the Idle Control switch is in Off position If engine fails to start repeat steps 4 thru 6 Figure 5 7 Move choke lever to Run position If engine falters Figure 5 Idle Control Switch move choke lever to Half choke position until the IDLE engine runs smoothly and then to Run position NOTE If engine still fails to start after 3 pulls check for proper oil level in crankcase This unit is equipped with a Low Oil Shutdown System See engine manual Refer to the engine owner s manual for complete starting instructions 3 Setthe Run Stop switch to Run position Figure 6 Connecting Electrical Loads
22. h cooling slots of the engine You could damage the unit or injure yourself Never operate the generator in rain in any enclosed compartment when connected electrical devices overheat if electrical output is lost if engine or generator sparks if flame or smoke is observed while unit is running if unit vibrates excessively GROUNDING THE GENERATOR The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground Local electrical codes may also require proper grounding of the unit For that purpose a GROUNDING WING NUT is provided on the generator end Figure 1 Figure Grounding Wing Nut ibo Generally connecting a No 12 AWG American Wire Gauge stranded copper wire to the grounding wing nut and to an earth driven copper or brass grounding rod electrode provides adequate protection against electrical shock Be careful to keep the grounding wire attached after connecting the stranded copper wire However local codes may vary widely Consult with a local electrician for grounding requirements in your area Properly grounding the generator helps prevent electrical shock if a ground fault condition exists in the generator or in connected electrical devices Proper grounding also helps dissipate static electricity which often builds up in ungrounded devices Your generator requires attachment
23. it or cause serious injuries 240 Volt loads powered through this outlet should not exceed 29 2 Amps of current draw 120 Volt AC 30 Amp Locking Receptacle Use a NEMA 15 30 plug with this receptacle Connect a 3 wire cord set rated for 125 Volt AC loads at 30 Amps to the plug Figure 12 Figure 12 120 Volt 30 Amp Receptacle 3 Wire Cord Set Neutral 120V NEMA L5 30 Use this receptacle to operate 120 Volt AC 60 Hz single phase loads requiring up to 3 600 watts 3 6 kW of power at 30 Amps The outlet is protected by a 30 Amp push to reset circuit breaker 120 Volt AC 20 Amp Duplex Receptacle Each receptacle Figure 13 is protected against overload by a 20 Amp push to reset circuit breaker Use each receptacle to operate 120 Volt AC single phase 60 Hz electrical loads requiring up to 2 400 watts 2 4 kW at 20 Amps of current Use cord sets that are rated for 125 Volt AC loads at 20 Amps or greater Generac Portable Products 7000EXL Extended Life Generator Figure 13 120 Volt AC 20 Amp Receptacles 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 14 This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery See the section Charging a Battery page 8 before attempting to recharge a
24. ke fully and crank engine 9 Excessively rich fuel mixture 9 Contact Generac service facility 10 Intake valve stuck open or closed 10 Contact Generac service facility 11 Engine has lost compression 11 Contact Generac service facility 12 Failed battery 12 Replace battery Engine shuts down during Out of gasoline 1 Fill fuel tank operation 2 Low oil level 2 Fill crankcase to proper level 1 Load is too high See Don t Overload the Generator Engine lacks power on page 12 2 Dirty air filter 2 Replace air filter Choke is opened too soon I Move choke to halfway position until 35 engine runs smoothly Engine Dunes oF falters 2 Carburetor is running too rich or too 2 facility lean SCHEMATIC Generac Portable Products 7000EXL Extended Life Generator BATTERY CHARGE i POWER REGULATOR BOARD AN T A 1 e 6 4 s N uU DPE B R FIELD POWER POWER p H 1 p E L D 11 22 44 A Je AN IDLE E CDNTRUL TRANSFORMER exu N A L 155 aot cae TDLE cUNTRuL BLK ety cg BLIS CONTROL 2 BOARD YEL ty LOP p LED BLU ui RED 22 30A RED BLU WHT C Lop DN ime CONTROL SWITCH SWI TCH 4 18 120V RUN 30A STOP ENG M RUN E 0 SWITCH PLUG n 120V 20 448 0 0 ENG 1 IGNI TL UN
25. kmanship for the items and period set forth below from the date of original purchase This warranty does not include the gasoline engine when furnished or attached because such engine is covered solely by the engine manufacturer s warranty Starting batteries are not warranted by the COMPANY The term original purchaser means the person for whom the generator is originally purchased This warranty is not transferable and applies only to portable generators driven by an overhead valve engine Warranty Schedule Consumer Commercial Engine Warranted solely by the engine manufacturer All other parts 2 years 2nd year parts only Year With the exception of European Community Countries all units bound for export shall be warranted for One 1 Year in Consumer applications and 90 days in Commercial applications as defined below NOTE For the purpose of this warranty consumer use means personal residential household use by original purchaser This warranty does not apply to units used for Prime Power in place of utility Commercial Use means all other uses including rental construction commercial and income producing purposes Once a generator has experienced commercial use it shall thereafter be considered a commercial use generator for the purposes of this warranty During said warranty period the COMPANY will at is option repair or replace any part which upon examination by the COMPANY is found to be defective under normal use and
26. longed 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 unit in a clean dry environment where it will not be exposed to excessive dust dirt moisture or any corrosive vapors Cooling air slots in the generator must not become clogged with snow leaves or any other foreign material NOTE Do Not use a garden hose to clean generator Water can enter engine fuel system and cause problems In addition if water enters generator through cooling air slots some of the water will be retained in voids and cracks of the rotor and stator winding insulation Water and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings Battery Maintenance Other than float charging described elsewhere no maintenance is required for the battery Keep the battery and terminals clean and dry IMPORTANT Battery charging should be performed in a dry location such as inside a garage To Clean the Generator Use a damp cloth to wipe exterior surfaces clean A soft bristle brush may be used to loosen caked on dirt or oil vacuum cleaner may be us
27. o Not tamper with engine governed speed High operating speeds are dangerous and increase risk of personal injury or damage to equipment The generator supplies correct rated frequency and voltage only when running at proper governed speed Incorrect frequency and or voltage can damage some connected electrical loads Operating at excessively low speeds imposes a heavy load When adequate engine power is not available engine life may be shortened S Generac Portable Products 7000EXL Extended Life Generator SAFETY RULES This generator set was designed and manufactured for specific applications Do Not attempt to modify the unit or use it for any application it was not designed for If you have any questions about your generator s application ask your dealer or consult the factory The manufacturer could not possibly anticipate every circumstance that might involve a hazard For that reason warnings in the manual and warnings on tags or decals affixed to the unit are not all inclusive If you intend to handle operate or service the unit by a procedure or method not specifically recommended by the manufacturer first make sure that such a procedure or method will not render this equipment unsafe or pose a threat to you and others Read this manual carefully and become familiar with your generator set Know its applications its limitations and any hazards involved M WARNING M The engine exhaust from this product contains chemic
28. service All transportation costs under warranty including return to the factory if necessary are to be borne by the purchaser and prepaid by the purchaser This warranty does not cover normal maintenance and service and does not apply to a generator set alternator or parts which have been subjected to improper or unauthorized installation or alteration misuse negligence accident overloading overspeeding improper maintenance repair or storage so as in the COMPANY s judgement to adversely affect its performance and reliability NORMAL WEAR As with all mechanical devices the generator needs periodic parts service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part or generator THERE IS NO OTHER EXPRESS WARRANTY THE COMPANY HEREBY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW THE DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO THE TIME PERIOD AS SPECIFIED IN THE EXPRESS WARRANTY LIABILITY FOR CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED THE COMPANY ALSO DISCLAIMS ANY RESPONSIBILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SUCH AS THE LOSS OF TIME OR THE USE OF THE POWER EQUIPMENT OR ANY COMMERCIAL LOSS DUE TO THE FAILURE OF THE EQUIPMENT AND ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURA
29. st and or dirt in gasoline can cause problems when that fuel is used with this unit Store in clean and dry area Generac Portable Products 7000EXL Extended Life Generator Generac Portable Products 7000EXL Extended Life Generator TROUBLESHOOTING Problem Cause Correction One of the circuit breakers is open Reset circuit breaker Ensine i 2 Fault in generator 2 Contact Generac service facility ngine is running but no AC output is available 3 Poor connection or defective cord set 3 Check and repair E 4 Connected device is bad 4 Connect another device that is in good condition l Short circuit in a connected load Disconnect shorted electrical load Engine runs good at no 2 Engine speed is too slow 2 Contact Generac service facility load but bogs down 3 Generator is overloaded 3 See Don t Overload the Generator when loads are connected on page 12 4 Shorted generator circuit 4 Contact Generac service facility Run Stop Switch set to STOP 1 Set switch to RUN 2 Dirty air cleaner 2 Clean or replace air cleaner 3 Out of gasoline 3 Fill fuel tank 4 Stale gasoline 4 Drain gas tank fill with fresh fuel 5 Spark plug wire not connected to 5 Connect wire to spark plug spark plug hc dibus dr 6 Bad spark plug 6 Replace spark plug 7 Water in gasoline 7 Drain gas tank fill with fresh fuel 8 Overchoking 8 Open cho
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