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Simplicity 01019-1 Operator's Manual
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Simplicity 01019-1 is a portable generator designed to provide electrical power for operating compatible electrical lighting, appliance, tool, and motor loads. With a maximum output of 7500 watts (7.5 kW), it can power devices that require up to 62.5 Amps at 120 Volts or 31.2 Amps at 240 Volts. It features a variety of outlets, including 120V AC 20 Amp receptacles, a 120V AC 30 Amp locking receptacle, a 120/240V AC 30 Amp locking receptacle, and a 240V AC 50 Amp receptacle, allowing for the connection of various devices and appliances.
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GENERAC The Reliable Ones 7500EXL Portable Generator Owner’s Manual DANGER! This generator is designed for outdoor use only. Never use this generator inside any building 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 systems 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 Owners manual. Pro blem Q Bef ues ore tion s? t a k bac s? ing k you to the the st r unit o g 18 helplineneratore, 00 e at r 2 call MF 70 85 1 4 0 8 CT 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. Generac Portable Products 7500EXL Extended Life Generator EQUIPMENT DESCRIPTION SAFETY RULES This generator is an engine-driven, revolving field, alternating current (AC) generator. It 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. 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 generators 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. CAUTION: Do Not exceed the generators 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). Read this manual carefully and become familiar with your generator set. Know its applications, its limitations and any hazards involved. WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The generators 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. The generator produces a very powerful voltage that can cause extremely dangerous electrical shock. Avoid contact with bare wires, terminals, etc. Never permit any unqualified person to operate or service the generator. DANGER: Do Not tamper with engine governed speed. High operating speeds are dangerous and increase risk of personal injury or damage to equipment. The generator supplies correctly 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 at such reduced speeds, when adequate engine power is not available, and may shorten engine life. 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). 2 Generac Portable Products 7500EXL Extended Life Generator Do Not use worn, bare, frayed or otherwise damaged electrical cord sets with the generator. 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. 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. GROUNDING THE GENERATOR The National Electric Code 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 cradle frame. 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 flame, spark or pilot light (as on a furnace, water heater or clothes dryer). FIRE or an EXPLOSION might result. Figure 1 Grounding Wing Nut 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. Grounding Wing Nut 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. 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. 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. 3 Generac Portable Products 7500EXL Extended Life Generator KNOW YOUR GENERATOR Read this owners 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) Electric Start Button 12 Volt DC Receptacle Recoil Starter Idle Control Switch Choke Lever 120 Volt AC, 30 Amp Locking Receptacle Run/Stop Switch Spark Arrestor Muffler 120/240 Volt AC, 30 Amp Locking Receptacle 120 Volt AC, 20 Amp Receptacles Grounding Wing Nut 240 Volt AC, 50 Amp Receptacle Choke Lever Used when starting a cold engine. 12 Volt DC Receptacle Use this receptacle with battery charge cables to charge a 12 Volt battery. Circuit Breakers (AC) Each receptacle is provided with a "push to reset" circuit breaker to protect the generator against electrical overload. 120 Volt 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. Electric Start Switch Pressed to start the engine. Grounding Wing Nut Use this connection to properly ground the generator. 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. 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. 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. 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. 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. Spark Arrestor Muffler Exhaust muffler lowers engine noise and is equipped with a spark arrestor screen. 4 Generac Portable Products 7500EXL Extended Life Generator INSTALLING TRAY AND BATTERY 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. You must purchase and install a 12 Volt DC battery (Series U1-109). The battery should be serviced with electrolyte fluid and fully charged prior to installation. Install the battery as follows: IMPORTANT: Any attempt to run the unit before it has been serviced with the recommended oil will result in an engine failure. Find the battery tray and fasteners shipped loose in the carton. The battery bracket, two 7" J-bolts, two lock washers and two hex nuts are included. REMOVE GENERATOR FROM CARTON Remove the four battery tray screws from base. Position the battery tray and install (Figure 2). Figure 2 Installing Battery Tray Set the carton on a rigid flat surface with This Side Up arrows pointing upward. Carefully open 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 Set battery onto tray and attach bracket, J-bolts, lock washers, flat washers, and hex nuts (Figure 3). Tighten hardware with 3/8 wrench. Electric start battery cables Figure 3 Installing Battery Generator and engine owners 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 5 Generac Portable Products 7500EXL Extended Life Generator CAUTION: Be sure the black cable is Select the oils viscosity grade according to your expected operating temperature: connected to the engine mount and not the frame. You could damage the ground wire. colder Connect the red battery cable from the engine starter switch to positive (+) battery terminal (Figure 4). 5W30 32°F warmer 10W30 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 owners manual for further information. Figure 4 Battery Starting Cable Connections 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. RED battery cable NOTE: The generators revolving field rides on a prelubricated and sealed ball bearing that requires no additional lubrication for the life of the bearing. BLACK battery cable Add Fuel Connect the black battery cable to the negative () battery terminal (Figure 4). DANGER: NEVER fill fuel tank indoors. Connect the other end of the black cable to the engine, not the frame. NEVER fill fuel tank when engine is running or hot. Do Not light a cigarette or smoke when filling the fuel tank. BEFORE STARTING THE ENGINE CAUTION: Do Not overfill the fuel tank. Always allow room for fuel expansion. Perform the following tasks before trying to start the generator engine: 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. Add Engine Oil 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. 6 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. Figure 6 Fuel Valve Operation 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. For Electric Start: Prepare engine for starting according to engine owners manual. 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. Press starter switch until engine cranks and starts. For Manual Start: Prepare engine for starting according to engine owners manual. Figure 5 Typical Fuel Expansion Space 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 owners 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 Dont Overload the Generator on page 11. Install fuel cap and wipe up any spilled gasoline. OPERATING THE GENERATOR CAUTION! Never start, or stop, the generator Stopping the Engine with electrical loads connected to the unit AND with the connected devices turned ON. Disconnect all electrical loads. Starting the Engine Run engine at no-load for a few minutes to stabilize units internal temperatures. Disconnect all electrical loads from the generator. Turn off engine according to engine owners manual. Open the fuel shut-off valve, as shown in Figure 6. Close the fuel shutoff valve. 7 Generac Portable Products 7500EXL Extended Life Generator Operating Automatic Idle Control 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. 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. If the battery is equipped with 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.. Battery Safety Connect battery charge cable clamp with red handle to the positive (+) battery terminal (Figure 7). DANGER: Storage batteries give off explosive Figure 7 Battery Charge Cable Connection 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. Red Black DANGER: 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. Connect battery charge cable clamp with black handle to the negative () battery terminal, (Figure 7). Charging a Battery Start engine. Let the engine run while battery recharges. 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. When battery has charged, shut down engine NOTE: Use an automotive hydrometer to test battery state of charge and condition. Follow the hydrometer manufacturers instructions carefully. Generally, a battery is considered to be at 100% state of charge when specific gravity of its fluid (as measured by hydrometer) is 1.260 or higher. 8 Generac Portable Products 7500EXL Extended Life Generator COLD WEATHER OPERATION Ensure a minimum of two feet clearance between open side of box and nearest object. Face exposed end away from wind and elements. 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. Enclosure should hold enough heat created by the generator to prevent problems. 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. CORD SETS/RECEPTACLES CAUTION: NEVER run unit indoors; Do Not enclose generator any more than shown. Remove shelter when temperatures are above 40°F [4°C]. This generator is equipped with the following receptacles: Cut appropriate slots to access receptacles and clear handles. 120 Volt AC, 20 Amp Receptacle Start unit, then place box over it. This outlet is protected against overload by a 20 Amp push-to-reset circuit breaker. 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 9 120 Volt AC, 20 Amp Receptacles Figure 8 Temporary Cold Weather Shelter WIND 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). 9 Generac Portable Products 7500EXL Extended Life Generator This receptacle powers 120 Volt AC, single phase, 60 Hz loads requiring up to 3,600 watts of power (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. Figure 10 120 Volt AC, 30 Amp Receptacle 240 Volt AC, 50 Amp Receptacle Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire cord set rated for 240 Volt AC loads at 50 Amps to the plug (Figure 12). Figure 12 240 Volt, 50 Amp Receptacle 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 Use this receptacle to operate 240 Volt AC, 60 Hz, single phase loads requiring up to 7,500 watts (7.5 kW) of power. CAUTION! Although this outlet states it has a 250 Volt 50 Amp rating (up to 12,500 watts), the generator is only rated for 7,500 Watts. Powering loads that exceed the wattage/ amperage capacity of the generator can damage it or cause serious injuries. 240 Volt loads powered through this outlet should not exceed 31.2 Amps of current draw. 10 Generac Portable Products 7500EXL Extended Life Generator DONT OVERLOAD THE GENERATOR If the appliance, 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. 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 generators 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. The Wattage Guide shown in Figure 13 is provided to help you to determine how many items the generator can operate at one time. Figure 13 Wattage Reference Guide Device . . . . . . . . . . . . . . . . . . . . . . . . Running Watts Device . . . . . . . . . . . . . . . . . . . . . . . . Running Watts *Air Conditioner (12,000 Btu) . . . . . . . . . . . . . . . . . . . . 1700 *Air Conditioner (24,000 Btu) . . . . . . . . . . . . . . . . . . . . 3800 *Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . . . . . 6000 Battery Charger (20 Amp) . . . . . . . . . . . . . . . . . . . . . . . . 500 Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 Chain Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 Circular Saw (6-1/2") . . . . . . . . . . . . . . . . . . . . . 800 to 1000 *Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . . . . . . 5750 *Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 *Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1150 Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 *Compressor (1 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 *Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . 1800 *Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 Curling Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 *Freezer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 *Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650 Disc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 Electric Range (per element). . . . . . . . . . . . . . . . . . . . . 1500 Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 *Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . 875 *Garage Door Opener . . . . . . . . . . . . . . . . . . . . . 500 to 750 Hair Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 to 1100 Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 *Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Microwave Oven. . . . . . . . . . . . . . . . . . . . . . . . . 700 to 1000 *Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . . . . . . 400 Oil Fired Space H eater (85,000 Btu) . . . . . . . . . . . . . . . 225 Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . . . . . . 150 *Paint Sprayer, Airless (1/3 HP) . . . . . . . . . . . . . . . . . . . 600 Paint Sprayer, Airless (handheld) . . . . . . . . . . . . . . . . . . 150 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 200 *Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 Slow Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 *Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . . . . . . 2800 *Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . . . . . . 2000 *Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . . . . . . 1500 *Sump Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 to 1050 *Table Saw (10"). . . . . . . . . . . . . . . . . . . . . . . . 1750 to 2000 Television . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 to 500 Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 to 1650 Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 * Allow 3 times the listed watts for starting these devices. 11 Generac Portable Products 7500EXL Extended Life Generator GENERAL MAINTENANCE RECOMMENDATIONS 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. 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. Clean the generator as outlined in To Clean the Generator. Check that cooling air slots and openings on generator are open and unobstructed. Engine Maintenance See engine manual for instructions. Disconnect the negative battery cable from the battery. Generator Maintenance DANGER: Storage covers can be flammable. 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. 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 Check the cleanliness of the generator frequently and clean when dust, dirt, oil, moisture or other foreign substances are visible on its exterior surface. See engine owners manual for instructions on how to properly store the engine. Other Storage Tips 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. 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 To Clean the Generator Rated Maximum Continuous Use a damp cloth to wipe exterior surfaces clean. A soft bristle brush may be used to loosen caked-on dirt or oil. AC Power Output ...................................7500 watts (7.5 kW) A vacuum cleaner may be used to pick up loose dirt and debris. Rated Maximum AC Current Rated Voltage.........................................120/240 Volts at 120 Volts .........................................62.5 Amps Low pressure air (not to exceed 25 psi) may be used to blow away dirt. Inspect cooling air slots and opening on generator. at 240 Volts .........................................31.2 Amps Phase .....................................................1 Rated AC Frequency..............................60 Hertz SERVICE/ADJUSTMENTS Number of Rotor Poles...........................2 Driven Speed of Rotor............................3600 rpm Refer to engine owners manual for information. 12 Generac Portable Products 7500EXL Extended Life Generator TROUBLESHOOTING Problem Engine is running, but no AC output is available. Engine runs good but bogs down when loads are connected. Engine will not start; or starts and runs rough. Engine shuts down during operation. Engine lacks power. Engine hunts or falters. Cause 1. Circuit breaker is open. 2. Poor connection or defective cord set. 3. Connected device is bad. 4. Fault in generator. 1. Short circuit in a connected load. 2. Generator is overloaded. 3. 4. 1. 2. 3. 4. Engine speed is too slow. Shorted generator circuit. Run/Stop switch set to Stop. Dirty air cleaner. Out of gasoline. Stale gasoline. 5. Spark plug wire not connected to spark plug. 6. Bad spark plug. 7. Water in gasoline. 8. Overchoking. 9. 10. 11. 12. 1. 2. 3. 1. Low oil level. Excessively rich fuel mixture. Intake valve stuck open or closed. Engine has lost compression. Out of gasoline. Low oil level. Fault in engine. Load is too high. 2. Dirty air filter. 3. Engine needs to be serviced. 1. Choke is opened too soon. 2. Carburetor is running too rich or too lean. 13 Solution 1. Reset circuit breaker. 2. Check and repair. 3. Connect another device that is in good condition. 4. Contact Generac service facility. 1. Disconnect shorted electrical load. 2. See Dont Overload the Generator on page 11. 3. Contact Generac service facility. 4. Contact Generac service facility. 1. Set switch to Run. 2. Clean or replace air cleaner. 3. Fill fuel tank. 4. Drain gas tank and fill with fresh fuel. 5. Connect wire to spark plug. 6. Replace spark plug. 7. Drain gas tank; fill with fresh fuel. 8. Put choke lever at No Choke position. 9. Fill crankcase to proper level. 10. Contact Generac service facility. 11. Contact Generac service facility. 12. Contact Generac service facility. 1. Fill fuel tank. 2. Fill crankcase to proper level. 3. Contact Generac service facility. 1. See Dont Overload the Generator on page 11. 2. Replace air filter. 3. Contact Generac service facility. 1. Move choke to halfway position till engine runs smoothly. 2. Contact Generac service facility. Generac Portable Products 7500EXL Extended Life Generator SCHEMATIC DIAGRAM 14 Generac Portable Products 7500EXL Extended Life Generator WIRING DIAGRAM 15 Generac Portable Products 7500EXL Extended Life Generator MAIN UNIT EXPLODED VIEW 16 Generac Portable Products 7500EXL Extended Life Generator MAIN UNIT PARTS LIST Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Part # Qty. Description A92432 1 CRADLE A92531 1 SUPPORT, Engine A92731 1 SUPPORT, Engine & Muffler 92247 1 HOUSING, Engine Adapter B1342G 1 ASSEMBLY, Rotor B1897G 1 ASSEMBLY, Stator 65791 1 BEARING 67451 1 WASHER, Special Flat - M8 22129 12 WASHER, Lock - M8 86307 4 HHMS, 5/16-24 x 3/4 SEMS 47481 1 HHCS, 5/16-24 x 10.625 92609 2 MOUNT, Vibration 82857 4 MOUNT, Vibration 40976 2 SCREW, M8 - 1.25 x 20 66476 2 CAPSCREW, M6 - 1.0 x 12mm 92532 1 BRACKET, Muffler 22142 2 SCREW, 5/16 - 18 x 3/4 91153 1 MUFFLER 90239 1 GASKET, Muffler 81917 1 PIN, Roll 4mm x 10 B4986 1 DECAL, Ground 66825C 1 CARRIER, Rear Bearing 74908 4 TAPTITE, M5-0.8 x 10 66449L 4 BOLT, Stator M6-1 x 190mm 65795 2 RECTIFIER, Battery Charge 66849C 1 TAPTITE, M5-0.8 x 30 67022 1 GROMMET, Rubber 84132 1 ASSEMBLY, Power Regulator 66386 1 ASSEMBLY, Brush Holder 66849 2 TAPTITE, M5-0.8 x 16 B78388 1 COVER, Bearing Carrier 22769 1 WASHER, Shakeproof Int. #10 86494 1 SCREW, M6-1.0 x 16 Wing B2153 9 HHCS, - #10 Self Driller 77395 4 NUT, Flange Lock - M6 83465 4 GROMMET, Tank 57058 4 HHMS, M6-1.0 x 55 80270 1 VALVE, Tank 78299 1 BUSHING, Tank Item 43 44 45 46 47 48 49 50 51 52 55 57 58 59 60 62 63 64 65 66 67 68 69 70 Part # Qty. B4363 1 B1998 1 B92039 1 92665 1 85000 1 14353621 1 26850 2 57593 1 92982 1 B4569 2 25244 12 B4569 1 B4366 1 NSP 1 22531 2 93826 1 B96068 1 56893 5 77282 1 22287 2 22097 2 22127 2 78289 1 22473 4 Parts Not Illustrated A96923 1 96924 2 22129 2 45771 2 22145 2 15453621 1 15553621 1 37806 1 43438 1 65787 1 A96925 1 B4594 1 72347 1 73111 1 84882 1 17 Description 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, owners Spark Plug Air Cleaner Element Spark Plug Wrench Generac Portable Products 7500EXL Extended Life Generator CONTROL PANEL EXPLODED VIEW AND PARTS LIST Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part # Qty. Description BB4461 1 PANEL, Control 23897 4 WASHER, #10 M5 Flat 49226 4 WASHER, M5 Lock 91526 4 SCREW, M5-0.8 x 12 mm 82538 1 SWITCH, Idle Control 82881 6 WASHER, 7/16" Int. Lock B4262 1 OUTLET, 50A, 240V 90418 1 OUTLET, 10A, 12VDC 75207N 2 CIRCUIT BREAKER, 35 Amp 75207A 2 CIRCUIT BREAKER, 30 Amp 75207 2 CIRCUIT BREAKER, 20 Amp 23365 10 WASHER, #8 Shakeproof 68868 1 OUTLET, 30A, 120V Locking 43437 1 OUTLET, 30A, 120V/240V Locking Item 15 16 17 18 19 20 21 22 23 24 25 26 27 28 18 Part # 68759 43180 22264 51715 64526 83970 64525 87962 84335 84134 B92069 84028 43181 43182 Qty. 1 10 10 10 8 1 4 1 1 1 1 1 4 4 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, Idle Control SCREW, M3 - 0.5 x 10 mm WASHER, M3 Lock Generac Portable Products 7500EXL Extended Life Generator NOTES 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. Alternator Engine Consumer* Commercial* 2 years (2nd year parts only) 1 year 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 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 COMPANYs 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 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 WARRANTY. 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. GENERAC PORTABLE PRODUCTS Jefferson, Wisconsin 53549
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