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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
Model No. 1019-3 (7,500 Watt AC Generator) Manual No. 189713GS Revision 11 (12/15/2005)
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7500EXL Extended Life Generator SAVE THESE INSTRUCTIONS TABLE OF CONTENTS SAFETY RULES Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Know Your Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This is the safety alert symbol. It is used to Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 alert you to potential personal injury hazards. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7500EXL Extended Life Generator DANGER WARNING Storage batteries give off explosive hydrogen gas Fuel and its vapors are extremely flammable and during recharging. explosive. Hydrogen gas stays near battery for a long time Fire or explosion can cause severe burns or after battery has been charged. death. Slightest spark will ignite hydrogen and cause WHEN ADDING OR DRAINING FUEL explosion. Turn generator OFF and let it cool at least 2 minutes before You can be blinded or severely injured. remo
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7500EXL Extended Life Generator WARNING CAUTION Rapid retraction of starter cord (kickback) will Excessively high operating speeds increase risk of injury pull hand and arm toward engine faster than and damage to generator. you can let go. Excessively low speeds impose a heavy load. Broken bones, fractures, bruises or sprains could DO NOT tamper with governed speed. Generator supplies result. correct rated frequency and voltage when running at governed When starting engine, pull cord slowly
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7500EXL Extended Life Generator KNOW YOUR GENERATOR Read this Operator’s Manual and safety rules before operating your generator. 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 Recoil Starter Oil Fill Cap Circuit Breakers (AC) Fuel Tank 12 Volt DC Receptacle Idle Control Switch Choke Lever Run/Stop Switch 120/240 Volt AC, 30 Amp Locking Air Cleaner Receptacl
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7500EXL Extended Life Generator Battery Charge Cables ASSEMBLY Spare Spark Plug,Air Filter, and Oil Filter Your generator requires some assembly and is ready for Spark Plug Wrench use after it has been properly serviced with the (2) Locking 30 Amp Plugs recommended oil and fuel. Engine Oil If you have any problems with the assembly of your Operator's Manual generator, please call the generator helpline at Engine Manual 1-800-270-1408. If any parts are missing or damaged, call the g
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7500EXL Extended Life Generator 2. Slide axle through both mounting brackets. Check Battery / Attach Negative 3. Slide a wheel over the axle. Battery Wire NOTE: Be sure to install both wheels with the air The sealed battery on the generator is fully charged and pressure valve on the outboard side. pre–installed except for the negative (black) battery cable. 4. Place a washer on axle and then place an e-ring in axle To install: groove. 1. Cut off tie wrap securing loose end of negative (black) ca
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7500EXL Extended Life Generator Add Fuel BEFORE STARTING THE NOTE: This gasoline engine is certified to operate on ENGINE gasoline. Exhaust Emission Control System: EM (Engine Modifications). Add Engine Oil WARNING Place generator on a level surface. Fuel and its vapors are extremely flammable and explosive. CAUTION Fire or explosion can cause severe burns or Any attempt to crank or start the engine before it has death. been properly filled with the recommended oil will result WHEN ADDING FUEL
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7500EXL Extended Life Generator Generator Location USING THE GENERATOR Generator Clearance System Ground WARNING The generator has a system ground that connects the Exhaust heat/gases can ignite combustibles, generator frame components to the ground terminals on structures or damage fuel tank causing a fire. the AC output receptacles.The system ground is connected Keep at least 5 ft. (152 cm) clearance on all sides of generator to the AC neutral wire (see “Equipment Description”, including ove
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7500EXL Extended Life Generator NOTE: If engine starts after 3 pulls but fails to run, or if OPERATING THE unit shuts down during operation, make sure unit is on a level surface and check for proper oil level in crankcase. GENERATOR This unit may be equipped with a low oil protection device. See engine manual. Starting the Engine WARNING IMPORTANT: Always unplug the battery float charger Running engines produce heat.Temperature of before starting the generator. muffler and nearby areas can reach
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7500EXL Extended Life Generator To recharge 12 Volt batteries, proceed as follows: Stopping the Engine 1. Check fluid level in all battery cells. If necessary, add 1. Turn off and unplug all electrical loads from generator ONLY distilled water to cover separators in battery panel receptacles. NEVER start or stop engine with cells. DO NOT use tap water. electrical devices plugged in and turned on. 2. If battery is equipped with vent caps, make sure they 2. Put idle control switch in “Off” positio
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7500EXL Extended Life Generator How to Use the Battery Charger COLD WEATHER Use battery float charger jack to keep the starting battery OPERATION charged and ready for use. Battery charging should be done in a dry location, such as inside a garage. Under certain weather conditions (temperatures below Plug the charger into the unit’s “Battery Float Charger” 40°F [4°C] combined with high humidity), your generator jack, which is located on the starter switch (Figure 8). may experience icing of th
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7500EXL Extended Life Generator 6. Start generator as described in the section “Starting Creating a Temporary Shelter the Engine”, then place carton over generator. Keep at 1. In an emergency, use the original shipping carton. least 5 ft. (152 cm) clearance on all sides of generator 2. Cut off top carton flaps and one long side of carton to including overhead with shelter in place. expose muffler side of unit. If required, tape up other WARNING sides of carton to fit over generator as shown in F
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7500EXL Extended Life Generator Figure 11 — 12 Volt DC, 10 Amp Receptacle 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. This receptacle can not recharge 6 Volt batteries and can Figure 10 — Generator Adapter Cord Set not be used to c
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7500EXL Extended Life Generator Figure 13 — 120 Volt AC, 30 Amp, Locking Receptacle 120/240 Volt AC, 50 Amp Receptacle 3-Wire Cord Set Use a NEMA 14–50 plug with this receptacle (Figure 15). NEMA L5-30 Connect a 4-wire cord set rated for 250 Volt AC loads at 50 Amps to the plug. Neutral Figure 15 — 120/240 Volt AC, 50 Amp Receptacle 120V 240 Volts AC Hot Frame Ground 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
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7500EXL Extended Life Generator 4. Plug in and turn on the next load. DON'T OVERLOAD 5. Again, permit the generator to stabilize. GENERATOR 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, Capacity as described above. You must make sure your generator can supply enough Figure 16 - Wattage Reference Chart rated (running) and surge (starting) watts for the items you Additional will po
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7500EXL Extended Life Generator NOTE: DO NOT use a garden hose to clean generator. SPECIFICATIONS Water can enter engine fuel system and cause problems. In Starting Wattage . . . . . . . . . . . . . . . . . . . . . .13,500 watts addition, if water enters generator through cooling air slots, Wattage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,500 watts some of the water will be retained in voids and cracks of AC Load Current: the rotor and stator winding insulation.Water and dirt b
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7500EXL Extended Life Generator Engine Storage STORAGE See engine operator’s manual for instructions. The generator should be started at least once every seven days and allowed to run at least 30 minutes. If this cannot Other Storage Tips be done and you must store the unit for more than To prevent gum from forming in fuel system or on 30 days, use the following guidelines to prepare it for essential carburetor parts, add fuel stabilizer into fuel storage. tank and fill with fresh fuel. Run th
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7500EXL Extended Life Generator TROUBLESHOOTING Problem Cause Correction 1. One of the circuit breakers is open. 1. Reset circuit breaker. 2. Fault in generator. 2. Contact Generac service facility. No AC output is available, 3. Poor connection or defective cord set. 3. Check and repair. but engine is running. 4. Connected device is bad. 4. Connect another device that is in good condition. 1. Short circuit in a connected load. 1. Disconnect shorted electrical load. Engine runs good at no- load b
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GENERAC PORTABLE PRODUCTS OWNER EQUIPMENT WARRANTY POLICY Effective November 1, 2004 LIMITED WARRANTY "Generac Portable Products is a licensed trademark of Briggs & Stratton Power Products. Briggs & 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
