Generac 09779-2 Portable Generator User Manual
Contents
1. GENERAC The Reliable Ones Z5O0O0EXL Portable Generator Owner s Manual DANGER This generator is designed for outdoor use only Never use this generator inside any building A or enclosure including the generator compartment of a recreational vehicle RV Carbon monoxide poisoning fire and or an explosion may result No user performed modifications including venting of exhaust and or cooling ventilation will eliminate the danger Always have at least two feet of clearance on all sides of the generator even while operating the unit outdoors DANGER You must isolate the generator from the electric utility by opening the electrical system s main circuit breaker or main switch 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 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 Model No 1019 1 7500 Watt AC Generator Manual No B4594 Revision 0 11 1 1999 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 gt IEEE Generac Portab2. NOTE In the future When adding oil to the engine crankcase use only high quality detergent oil rated with API service classification SF and SG Use no special additives DO NOT USE SAE 10W 40 Generac Portable Products 7500EXL Extended Life Generator Select the oil s viscosity grade according to your expected operating temperature X 32 F 0 warmer colder Although multi viscosity oils 5W30 10W30 etc improve starting in cold weather these multi viscosity oils will result in increased oil consumption when used above 32 F Check your engine oil level frequently to avoid possible damage from running low on oil See the engine owner s manual for further information To add oil to the engine Place generator on a level surface Clean area around oil fill and remove oil cap Slowly add oil through the oil fill opening until it reaches the top DO NOT OVERFILL Install oil cap hand tighten securely CAUTION Any attempt to crank or start the engine before it has been properly serviced with the recommended oil will result in an engine failure NOTE The generator s revolving field rides on a pre lubricated and sealed ball bearing that requires no additional lubrication for the life of the bearing Add Fuel DANGER 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 CAUTION Do Not overfill the fuel tank
3. Start unit then place box over it IMPORTANT Remove shelter when temperature is above 40 F 4 C For a more permanent shelter build a structure that will enclose 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 8 Figure 8 Temporary Cold Weather Shelter Qe MA ve ry gt Ensure a minimum of two feet clearance between open side of box and nearest object Face exposed end away from wind and elements Enclosure should hold enough heat created by the generator to prevent problems CAUTION NEVER run unit indoors Do Not enclose generator any more than shown Remove shelter when temperatures are above 40 F 4 C CORD SETS RECEPTACLES This generator is equipped with the following receptacles 120 Volt AC 20 Amp Receptacle This outlet is protected against overload by a 20 Amp push to reset circuit breaker Figure 9 120 Volt AC 20 Amp Receptacies Use each socket to operate 120 Volt AC single phase 60 Hz electrical loads requiring up to 2400 watts 2 4 kW at 20 Amps Figure 9 Use cord sets that are rated for 125 Volt 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 y Generac Portable
4. 134 134 1 ELECTRIC ev START ic BATTERY 4 SWITCH a 13 55 22 STARTER vn au ed 55 11B 120V reser CES L 39 304 106 C B Ao ead m a CO Leah ev 10A DC 15 11B EET 14 Generac Portable Products 7500EXL Extended Life Generator WIRING DIAGRAM BLU 1 11A BLU 444 115 d 11 11A ED 11B 214 NA 35 354 aga 118 20A aoa 30A C B C B C B CB C B C B C B AUTO RESET H GH t 13 i 44A T A LA 4 qi 44C 44b 15 cy 120v xz o o o C 120v 20A 9 1207240v 118 304 180 240V 50A dE 304 12V 10A DC TE c 11C ra GA GREE n Q i Dr Se 5 BLU WHITE S 13 SP L D 11A 444 SK HB 9 E IN ea 55 CONT
5. A92432 A92531 A92731 92247 B1342G B1897G 65791 67451 22129 86307 47481 92609 82857 40976 66476 92532 22142 91153 90239 81917 B4986 66825C 74908 66449L 65795 66849C 67022 84132 66386 66849 B78388 22769 86494 B2153 77395 83465 57058 80270 78299 NNAN AAD A aaa aaa wech P o seh sech NO da Za ee v sech NS ve o d d Qe Qty Description CRADLE SUPPORT Engine SUPPORT Engine amp Muffler HOUSING Engine Adapter ASSEMBLY Rotor ASSEMBLY Stator BEARING WASHER Special Flat M8 WASHER Lock M8 HHMS 5 16 24 x 3 4 SEMS HHCS 5 16 24 x 10 625 MOUNT Vibration MOUNT Vibration SCREW MB 1 25 x 20 CAPSCREW M6 1 0 x 12mm BRACKET Muffler SCREW 5 16 18 x 3 4 MUFFLER GASKET Muffler PIN Roll 4mm x 10 DECAL Ground CARRIER Rear Bearing TAPTITE M5 0 8 x 10 BOLT Stator M6 1 x 190mm RECTIFIER Battery Charge TAPTITE M5 0 8 x 30 GROMMET Rubber ASSEMBLY Power Regulator ASSEMBLY Brush Holder TAPTITE M5 0 8 x 16 COVER Bearing Carrier WASHER Shakeproof int 10 SCREW M6 1 0 x 16 Wing HHCS 10 Self Driller NUT Flange Lock M6 GROMMET Tank HHMS M6 1 0 x 55 VALVE Tank BUSHING Tank 17 Item Part 43 B4363 44 B1998 45 B92039 46 92665 47 85000 48 14353621 49 26850 50 57593 51 92982 52 84569 55 25244 57 B4569 58 B4366 59 NSP 60 22531 62 93826 63 896068 64 56893 65 77282 66 22287 67 22097 68 22127 69 78289 70 22473 Part
6. 84134 10 WASHER 8 Shakeproof 25 B92069 1 OUTLET 30A 120V Locking 26 84028 1 OUTLET 30A 120V 240V 27 43181 Locking 28 43182 ER Qty 1 10 10 10 8 1 4 1 Za Za oe e oe Description OUTLET 20A 120V WASHER M4 Flat WASHER 8 M4 Lock NUT M4 0 7 Hex SCREW 6 32 x 3 8 BOARD System Control 3 4 Hex Standoff CIRCUIT BREAKER 10A automatic 12V ASSEMBLY Wire Harness GROMMET Rubber BOX Control Panel TRANSFORMER idie Control SCREW M3 0 5 x 10 mm WASHER M3 Lock NOTES Generac Portable Products 7500EXL Extended Life Generator A ES 19 LIMITED WARRANTY FOR GN ENGINE DRIVEN PORTABLE GENERATORS GENERAC PORTABLE PRODUCTS hereafter referred to as the COMPANY warrants to the original purchaser that the alternator and control panel for its portable generator will be free from defects in materials or workmanship for the items and period set forth below from the date of original purchase This warranty is not transferable and applies only to portable generators driven by a GN Series engine This warranty does not apply to starting battery rechargeable flashlight or battery charger Consumer Commercial Alternator 2 years 2nd year parts only 1 year Engine Warranted solely by the engine manufacturer With the exception of European Community Countries all units bound for export shall be warranted for One 1 Year in Consumer
7. A Always allow room for fuel expansion Use only regular UNLEADED 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 during storage Acidic gas can damage the fuel system of an engine while in storage Generac Portable Products 7500EXL Extended Life Generator To avoid engine problems the fuel system should be emptied before storage of 30 days or longer Drain the gas tank start the engine and let it run until the fuel lines and carburetor are empty Use fresh fuel next season See Storage on page 12 for additional information Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur To add fuel Clean area around fuel fill cap remove cap Slowly add UNLEADED regular gasoline slowly to fuel tank Leave about a 1 2 space in the fuel tank for fuel expansion Figure 5 Do Not overfill fuel tank Figure 5 Typical Fuel Expansion Space install fuel cap and wipe up any spilled gasoline OPERATING THE GENERATOR CAUTION Never start or stop the generator with electrical loads connected to the unit AND with the connected devices turned ON Starting the Engine Disconnect all e
8. Products 7500EXL Extended Life Generator E PN oe Figure 10 120 Volt AC 30 Amp Receptacle This receptacle powers 120 Volt AC single phase e 60 Hz loads requiring up to 3 600 watts of power 3 Wire Cord Set 3 6 kW Or it will operate 240 Volt AC single phase 60 Hz loads up to 7 200 watts 7 2 kW The outlet is protected by a 30 Amp push to reset circuit breaker ue 240 Volt AC 50 Amp Receptacle 120V Use a NEMA 14 50 plug with this receptacle Connect a 4 wire cord set rated for 240 Volt AC loads at Hot 50 Amps to the plug Figure 12 Figure 12 240 Volt 50 Amp Receptacle 240 Volts AC Ground NEMA L5 30 Green Use this receptacle to operate 120 Volt AC 60 Hz single phase loads requiring up to 3600 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 AC loads at 30 Amps or greater You can use the same 4 wire cord if you plan to run a 120 Volt load Figure 11 Figure 11 120 240 Volt AC 30 Amp Receptacle ei 4 Wire Cord Set Frame Ground 120 Volis 120 Volts NEMA 14 50 Use this receptacle to operate 240 Volt AC 60 Hz single phase loads requiring up to 7 500 watts 7 5 kW of power 250 Volt 50 Amp rating up to 12 500 watts the generator is only rated for 7 500 Watts Powering loads that excee
9. 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 DURATION 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 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 GENER AC PORTABLE PRO
10. 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 at such reduced speeds when adequate engine power is not available and may shorten engine life 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 H 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 YX WARNING JNK The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The generator produces a very powerful voltage that can cause extremely dangerous electrical shock Avoid co
11. the top flaps of the shipping carton Review Cold Weather Operation on page 9 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 CARTON CONTENTS Check all contents if any parts are missing or damaged call the generator helpline at 1 800 270 1408 The generator Electric start battery cables Generator and engine owner s manuals Locking 20 Amp and 30 Amp plugs Battery charge cables Battery tray mounting bracket hardware Spare spark plug and air filter element Spark plug wrench IMPORTANT Any attempt to run the unit before it has been serviced with the recommended oil will result in an engine failure Set battery onto tray and attach bracket J bolts lock washers flat washers and hex nuts Figure 3 Tighten hardware with 3 8 wrench Figure 3 installing Battery CAUTION Be sure the black cable is connected to the engine mount and not the frame You could damage the ground wire Connect the red battery cable from the engine starter switch to positive battery terminal Figure 4 Figure 4 Battery Starting Cable Connections battery terminal Figure 4 Connect the other end of the black cable to the engine not the frame BEFORE STARTING THE ENGINE Perform the following tasks before trying to start the generator engine Add Engine Oil
12. DUCTS Jefferson Wisconsin 53549
13. Locking Receptacle 120 240 Volt AC 30 Amp Locking Receptacle 120 Volt AC 20 Amp Receptacles 12 Volt DC Receptacle Use this receptacle with battery charge cables to charge a 12 Volt battery 120 Voit AC 20 Amp Receptacles 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 Voit 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 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 Electric Start Button Pe ae Recoil Starter Choke Lever Run Stop Switch Spark Arrestor Muffler 240 Volt AC 50 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 Electric Start Switch Pressed to start the engine Grounding Wing Nut Use this connection to properly grou
14. ROL 55 J SWI TCH oO OUTLET TAB S Lo ch MUST BE 11 dt BLU WHT d BROKEN OFF 44 GRN 55 55 22 11 GRN GRN GRN YEL ee 55 22 13 156 156 155 155 55 BEN 155 13 156 We e e 44 M SYSTEM 55 HH hd CONTROL n BOARD D GRN YEL iji IDLE CONTROL 19 er BLK D TRANSFORMER m 11 gg wu CONNECTOR Bie e T 8 44 D S BATTERY 1 ON IDLE CHARGE ji CONTROL e SE S RECTIFIER iji CODIL Te is is HE IDLE LT BLU WHT CONTROL NEL 44 77 iji GE RED 77 34 n YEL WHT Low DIL GRN YEL iji i PRESSURE SNUBBER 3 PIN STATOR FEEDBACK NJ connector Elele SWITCH VE 7 c 29A GRN YEL iji LOW DIL POS BRUSH n EATE BLK m PRESSURE ELECTRIC CLOSEST TO ul 18 bw LED START BEARING x Le Deg CATHODE SWITCH 4 WHT GL iji BLK WHT GROUND TO REAR SP Sp esch 134 O e BEEN BEARING CARRIER 1 BLK ENGINE i8 HE RUN BOTTOM H shiTcH T 66A POWER iji B CH EE ih oo os Lah 7 1 REGULATOR I CN m D 8 BDARD 0 g TO STARTER IF T HN SPARK FRAME Wt iji PLUG CUSTOMER GROUND iji K T DM SUPPLIED BATTERY IC Ji ENGINE BLOCK 15 oC Generac Portable Products 7500EXL Extended Life Generator E MAIN UNIT EXPLODED VIEW e y 62 4377 69 L SCH Y DETAIL OF 65 TO STARTER ELECTRIC START SWITCH Generac Portable Products 7500EXL Extended Life Generator MAIN UNIT PARTS LIST item Part
15. ac Portable Products 7500EXL 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 Clean the generator as outlined in To Clean the Generator Check that cooling air slots and openings on generator are open and unobstructed Disconnect the negative battery cable from the battery DANGER 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 on how to properly store the engine Other Storage Tips Do Not store gasoline from one season to the next Replace your gasoline can if it starts to rust Rust and or dirt in a gasoline can cause problems when you use that fuel with this unit Store unit in clean and dry area SPECIFICATIONS Rated Maximum Continuous AC Power Output 7500 watts 7 5 kW Rated Voltage 120 240 Volts Rated Maximum AC Current at 120 Volts oo AA MABALA MEAN 62 5 Amps at 240 Volts ia 31 2 Amps base Ziegler eec ets 1 Rated AC Frequency oonan 60 Hertz Number of Rotor Poles 2 Driven Speed of Hotor 3600 rpm Generac Portable Products 7500EXL Extended Life Generator TROUBLESHOOTING Problem Cause Circ
16. ame spark or pilot light as on a furnace water heater or clothes dryer FIRE or an EXPLOSION might result Generator exhaust gases contain DEADLY carbon monoxide gas This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Operate this equipment only in the open air where adequate ventilation is available 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 Without sufficient cooling air flow the unit quickly overheats damaging the generator or nearby property Allow at least 2 feet of clearance on all sides of generator even while operating unit outdoors or you could damage the unit Review Cold Weather Operation on page 9 Never start or stop the unit with electrical loads connected to receptacles AND with the connected devices turned ON Start the engine and let it stabilize before connecting electrical loads Disconnect all electrical loads before shutting down the generator Sh Never operate generator in rain in any enclosed compartment if engine speed changes if 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 Electric Cod
17. 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 service Starting batteries are not warranted by the COMPANY 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 need periodic parts service and replacement to perform well This warranty will not cover repair when normal use has
18. cted and that the unit is kept clean and properly stored Never operate a damaged or defective generator Engine Maintenance See engine manual for instructions 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 any foreign material Check the cleanliness of the generator frequently and clean when dust dirt oil moisture or other foreign substances are visible on its exterior surface 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 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 A vacuum cleaner may be used to pick up loose dirt and debris Low pressure air not to exceed 25 psi may be used to blow away dirt Inspect cooling air slots and opening on generator SERVICE ADJUSTMENTS Refer to engine owner s manual for information 12 Gener
19. d the wattage X Hot amperage capacity of the generator can Se damage it or cause serious injuries 240 Volt roun loads powered through this outlet should not NEMA L14 30 Green exceed 31 2 Amps of current draw W Neutral CAUTION Although this outlet states it has a 10 Generac Portable Products 7500EXL Extended Life Generator DON T OVERLOAD THE GENERATOR Overloading a generator in excess of its rated wattage capacity can result in damage to generator and to 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 The rated wattage of lights can be taken from light bulbs The rated wattage of tools appliances and motors can usually be found on a data plate or decal affixed to the device Figure 13 Wattage Reference Guide Air Conditioner 12 000 Btu Air Conditioner 24 000 Btu Air Conditioner 40 000 Btu Battery Charger 20 Amp Belt Sander 3 Circular Saw 6 1 2 Clothes Dryer Electric Clothes Dryer Gas Clothes Washer Coffee Maker Compressor 1 HP Compressor 3 4 HP Compressor 1 2 HP Disc Sander 9 Edge Trimmer Electric Blanket Electric Nail Gun Electric Range per element Electric Skillet Furnace Fan 3 5 HP Garage Door Opener Hand Drill 11 KH NS we SS if the app
20. e requires the frame and external electrically conductive parts of generator be properly connected to approved earth ground Local electrical codes may also require proper grounding of the unit For that purpose a GROUNDING WING NUT Figure 1 is provided on the cradie frame mS K E SL 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 However local codes may vary widely Consult with a local electrician for grounding requirements in your area Be sure to keep the grounding wire secure while you connect to the grounding rod 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 Figure 1 Grounding Wing Nut Grounding Wing Nut KNOW YOUR GENERATOR Generac Portable Products 7500EXL Extended Life 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 Circuit Breakers AC 12 Voit DC Receptacle Idie Control Switch 120 Volt AC 30 Amp
21. ectrical 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 Battery Safety DANGER Storage batteries give off explosive A hydrogen gas 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 which can shatter the battery and cause blindness or other injury 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 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 DANGER Do Not permit smoking open Generac Portable Products 7500EXL Extended Life Generator To recharge 12 Voit 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 wit
22. h vent caps make sure they are installed and are tight if 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 7 Figure 7 Battery Charge Cable Connection Connect battery charge cable clamp with black handle to the negative battery terminal Figure 7 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 10096 state of charge when specific gravity of its fluid as measured by hydrometer is 1 260 or higher Generac Portable Products 7500EXL Extended Life Generator COLD WEATHER OPERATION Under certain weather conditions temperatures below 40 F 4 C and a high dew point your Generac generator may experience icing of the carburetor and or the crankcase breather system in an emergency use the original shipping box as a temporary shelter Cut off all flaps Cut out one of the long sides of the box to expose exhaust side of unit Ensure a minimum of two feet clearance between open side of box and nearest object Cut appropriate slots to access receptacles and clear handles
23. le Products 7500EXL Extended Life Generator eu EQUIPMENT DESCRIPTION This generator is an engine driven revolving field alternating current AC generator H was designed to supply electrical power for operating compatible electrical lighting appliance tool and motor loads This manual contains information for a generator that operates 120 and or 240 Volts single phase 60Hz devices that require up to 7500 watts 7 5 KW of power that pull up to 62 5 Amps at 120 Volts or 31 2 Amps at 240 Volts CAUTION Do Not exceed the generator s A 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 7 500 watts for this generator In most cases rated watts of the electrical device can be found on the device nameplate If the device nameplate gives only volts and amps multiply volts times amps to obtain watts volts x amps watts The generator s revolving field is driven at about 3600 rpm by a single cylinder engine Every effort has been expended to make sure that the information in this manual is both accurate and current However Generac reserves the right to change alter or otherwise improve the product at any time without prior notice DANGER Do Not tamper with engine governed speed High operating speeds are dangerous and increase risk of personal injuty or damage to equipment The generator supplies correctly rated
24. lectrical loads from the generator Open the fuel shut off valve as shown in Figure 6 OPERATION e A p For Electric Start Prepare engine for starting according to engine owner s manual Press starter switch until engine cranks and starts For Manual Start Prepare engine for starting according to engine owner s manual Pull slowly on recoil handle until you feel some resistance Then pull rapidly to start engine Return recoil slowly Do Not let it snap back Refer to the engine owner s manual for complete starting instructions Applying Electrical Loads Let engine stabilize and warm up for about five minutes after starting Plug in and turn on the desired 120 or 240 Volt AC single phase 60 Hz electrical loads DO NOT OVERLOAD THE GENERATOR The total rated watts or amps of all loads to be connected at one time should not be greater than the rated wattage amperage capacity of the generator See Don t Overload the Generator on page 11 Stopping the Engine Disconnect all electrical loads Run engine at no load for a few minutes to stabilize unit s internal temperatures Turn off engine according to engine owner s manual Close the fuel shut off valve oO OPERATION a WS 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 el
25. liance tool or motor does not give wattage multiply volts times ampere rating to determine watts volts x amps watts 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 selecting 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 The Wattage Guide shown in Figure 13 is provided to help you to determine how many items the generator can operate at one time Hedge Trimmer impact Wrench Jet Pump Lawn Mower Light Bulb Microwave Oven Milk Cooler Oil Burner on Furnace Oil Fired Space Heater 140 000 Btu Oil Fired Space H eater 85 000 Btu Oil Fired Space Heater 30 000 Btu Paint Sprayer Airless 1 3 HP Paint Sprayer Airless handheld Refrigerator Slow Cooker Submersible Pump 1 1 2 HP Submersible Pump 1 HP Submersible Pump 1 2 HP Sump Pump Table Saw 10 1750 to 2000 Television 200 to 500 Toaster Weed Trimmer Allow 3 times the listed watts for starting these devices 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 corre
26. nd the generator Idie Control Switch The idle control runs the engine at normal high speeds when there is a load present and runs the engine at idle ow speeds when a load is not present Recoil Starter Used as an alternate means of starting the engine Run Stop Switch Must be in Run position to start engine Set to Stop to stop a running engine Spark Arrestor Muffler Exhaust muffler lowers engine noise and is equipped with a spark arrestor screen Generac Portable Products 7500EXL Extended Life Generator Your generator requires some assembly and is ready INSTALLING TRAY AND for use after it has been properly serviced with the recommended oil and fuel B ATTE RY If you have any problems with the assembly of d You must purchase and install a 12 Volt DC battery our generator please call the generator helpline d 100053071 WA Series U1 109 The battery should be serviced with electrolyte fluid and fully charged prior to installation install the battery as follows Find the battery tray and fasteners shipped loose in the carton The battery bracket two 7 J bolts two REMOVE GENERATOR lock washers and two hex nuts are included Remove the four battery tray screws from base FROM CARTON Position the battery tray and install Figure 2 Set the carton on a rigid flat surface with This Side Figure 2 Installing Battery Tray Up arrows pointing upward Carefully open
27. nnect wire to spark plug Replace spark plug Drain gas tank fill with fresh fuel Put choke lever at No Choke position Fill crankcase to proper level Contact Generac service facility Contact Generac service facility Contact Generac service facility Fill fuel tank Fill crankcase to proper level Contact Generac service facility See Don t Overload the Generator on page 11 Replace air filter Contact Generac service facility Move choke to halfway position till engine runs smoothly Contact Generac service facility SCHEMATIC DIAGRAM POWER REGULATOR BOARD ji T 1 2 6 4 S N RADA u DPE B B E R FIELD g POWER 2 POWER FA OTA Et e E ery YY D L B D 11 ee 44 A E Ze A IDLE E CONTROL TRANSFORMER E uu aJ Uo G N E fo e 354 L C B 155 s oe id IDLE CONTROL mi zm ig COM CONTROL BOARD e T GEN A ON 354 85 LOP E LED BLU Be RED E RED BLU WHT P DE o wo 11 Pct SNETEM SWITCH Sr 18 Em U 114 M 444 RUN stop 120 840V Ae 504 304 9 ENG C B 304 22 SPARK RUN Sc C B F SWI TCH 22 4 PLUG 180V 804 448 ENG IGNI TL UN 22 44B BATTERY CHARGE 664 77A 55 66 77 e
28. ntact with bare wires terminals etc Never permit any unqualified person to operate or service the generator Never handle any kind of electrical cord or device while standing in water while barefoot or while hands or feet are wet The National Electric Code requires the frame and external electrically conductive parts of generator be properly connected to an approved earth ground Local electrical codes may also require proper grounding of the generator Consult with a local electrician for grounding requirements in your area Use a ground fault circuit interrupter in any damp or highly conductive area such as metal decking or steel work Generac Portable Products 7500EXL Extended Life Generator pru LQ Ki Do Not use worn bare frayed or otherwise damaged electrical cord sets with the generator Operate generator only on level surfaces and where it will not be exposed to excessive moisture dirt dust or corrosive vapors Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE Do Not permit smoking open flames sparks or heat in the vicinity while handling gasoline Avoid spilling gasoline on a hot engine Comply with all regulations requiring 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 FIRE or an EXPLOSION Never store generator with fuel in tank where gasoline vapors might reach an open fl
29. s Not lillustrate A96923 96924 22129 45771 22145 15453621 15553621 37806 43438 65787 A96925 B4594 72347 73111 84882 Qty Description RANNNAT ARAN AAA HY AAA AAA AR e ch sch YA o sch sch A AD AQ AD sch CAP with Gauge Fuel TANK Fuel SHIELD Heat INSULATION 2 1 4 Thick CLIP insulation WIRE Ground LW EXT Shakeproof M6 MOUNT Cable Tie DECAL Danger DECAL Heat Shield NUT 5 16 18 Hex DECAL Control Panel ASSEMBLY Control Box ENGINE HHCS 5 16 18 x 1 3 4 DECAL Start Instructions SHIELD Heat CRIMPTITE 10 24 x 1 2 SWITCH Starter SCREW 1 4 20 x 3 4 LOCKWASHER M6 NUT 1 4 20 Hex BRACKET Starter Switch WASHER M6 Flat Tray Battery J Bolt M8 1 25 Lockwasher Hex nut M8 Flat Washer Cable Positive Battery Cable Negative Battery 120V 30 A plug 120 240V 30 A plug Cable Battery Charge Bracket Tie Down Manual owner s Spark Plug Air Cleaner Element Spark Plug Wrench Item Part BB4461 23897 49226 91526 82538 82881 B4262 90418 75207N 75207A 75207 23365 68868 43437 Qty Description item Part 1 PANEL Control 15 68759 WASHER 10 M5 Flat 16 43180 4 WASHER M5 Lock 17 22264 4 SCREW M5 0 8 x 12 mm 18 51715 1 SWITCH idle Control 19 64526 6 WASHER 7 16 Int Lock 20 83970 1 OUTLET 50A 240V 21 64525 1 OUTLET 10A 12VDC 22 87962 2 CIRCUIT BREAKER 35 Amp 2 CIRCUIT BREAKER 30 Amp 23 84335 2 CIRCUIT BREAKER 20 Amp 24
30. uit breaker is open Poor connection or defective cord set Connected device is bad Engine is running but no AC output is available Fault in Short circuit in a connected load Generator is overloaded Engine runs good but bogs down when loads are connected Shorted Spark plug wire not connected to Engine will not start spark plug 6 Bad spark plug 7 Water in gasoline 8 Overchoking or starts and runs rough 9 Low oil level 10 Excessively rich fuel mixture 11 Intake valve stuck open or closed 12 Engine has lost com 1 Outof gasoline 2 Low oil level 3 Faultin engine Load is too high Engine shuts down during operation Engine lacks power Engine hunts or falters 2 Carburetor is running too rich or too lean Dirty air filter Engine needs to be serviced 1 Choke is opened too soon Engine speed is too slow generator circuit Run Stop switch set to Stop Dirty air cleaner Out of gasoline Stale gasoline pression 13 Solution NAE BON S ta Reset circuit breaker Check and repair Connect another device that is in good condition Contact Generac service facility Disconnect shorted electrical load See Don t Overload the Generator on page 11 Contact Generac service facility Contact Generac service facility Set switch to Run Clean or replace air cleaner Fill fuel tank Drain gas tank and fill with fresh fuel Co
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