Generac Power Systems 7500EXL Rated watt Extended Life Generator Bedienungsanleitung

Operator’s Manual

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)

Before using this product, read

this manual and follow all Safety

Rules and Operating Instructions.

WARNING

7500EXL Extended Life Generator

TABLE OF CONTENTS

Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Know Your Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

EQUIPMENT

DESCRIPTION

Read this manual carefully and become

familiar with your generator. Know its

applications, its limitations and any hazards

involved.

The generators are an engine–driven, revolving field,

alternating current (AC) generator. It was designed to

supply electrical power for operating compatible electrical

lighting, appliances, tools and motor loads.The generator’s

revolving field is driven at about 3,600 rpm by a single-

cylinder engine.

CAUTION! DO NOT exceed the generator’s

wattage/amperage capacity. See “Don’t Overload

Generator”.

Every effort has been made to ensure that information in

this manual is accurate and current. However, we reserve

the right to change, alter or otherwise improve the product

and this document at any time without prior notice.

The Emission Control System for this generator is

warranted for standards set by the Environmental

Protection Agency and the California Air Resources Board.

For warranty information refer to the engine operator’s

manual.

SAFETY RULES

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.

The safety alert symbol ( ) is used with a signal word

(DANGER, CAUTION,WARNING), a pictorial and/or a

safety message to alert you to hazards. DANGER indicates

a hazard which, if not avoided, will result in death or serious

injury. WARNING indicates a hazard which, if not avoided,

could result in death or serious injury. CAUTION

indicates a hazard which, if not avoided, might result in

minor or moderate injury. CAUTION, when used

without the alert symbol, indicates a situation that could

result in equipment damage. Follow safety messages to

avoid or reduce the risk of injury or death.

Hazard Symbols and Meanings

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

WARNING

Fire

Explosion

Toxic Fumes

Kickback

Operator’s Manual Electrical Shock

Explosive Pressure Chemical Burn

Hot Surface

may be reproduced or transmitted in any form by any

means without the express written permission of Briggs &

Stratton Power Products Group, LLC.

SAVE THESE INSTRUCTIONS

7500EXL Extended Life Generator

• This generator does not meet U. S. Coast Guard Regulation

33CFR-183 and should not be used on marine applications.

• Failure to use the appropriate U. S. Coast Guard approved

generator could result in bodily injury and/or property

damage.

WARNING

WHEN ADDING OR DRAINING FUEL

• Turn generator OFF and let it cool at least 2 minutes before

removing fuel cap. Loosen cap slowly to relieve pressure in

tank.

• Fill or drain fuel tank outdoors.

• DO NOT overfill tank.Allow space for fuel expansion.

• Keep fuel away from sparks, open flames, pilot lights, heat, and

other ignition sources.

• DO NOT light a cigarette or smoke.

WHEN STARTING EQUIPMENT

• Ensure spark plug, muffler, fuel cap and air cleaner are in place.

• DO NOT crank engine with spark plug removed.

• If fuel spills, wait until it evaporates before starting engine.

WHEN OPERATING EQUIPMENT

• DO NOT tip engine or equipment at angle which causes fuel

to spill.

• This generator is not for use in mobile equipment or marine

applications.

WHEN TRANSPORTING OR REPAIRING

EQUIPMENT

• Transport/repair with fuel tank EMPTY or with fuel shutoff

valve OFF.

• Disconnect spark plug wire.

WHEN STORING FUEL OR EQUIPMENT WITH FUEL

IN TANK

• Store away from furnaces, stoves, water heaters, clothes

dryers or other appliances that have pilot light or other

ignition source because they can ignite fuel vapors.

Fuel and its vapors are extremely flammable and

explosive.

Fire or explosion can cause severe burns or

death.

WARNING

• When using generator for backup power, notify utility

company. Use approved transfer equipment to isolate

generator from electric utility.

• Use a ground circuit fault interrupter (GFCI) in any damp or

highly conductive area, such as metal decking or steel work.

• DO NOT touch bare wires or receptacles.

• DO NOT use generator with electrical cords which are worn,

frayed, bare or otherwise damaged.

• DO NOT operate generator in the rain or wet weather.

• DO NOT handle generator or electrical cords while standing

in water, while barefoot, or while hands or feet are wet.

• DO NOT allow unqualified persons or children to operate or

service generator.

Generator produces powerful voltage.

Failure to isolate generator from power utility

can result in death or injury to electric utility

workers due to backfeed of electrical energy.

WARNING

• DO NOT allow any open flame, spark, heat, or lit cigarette

during and for several minutes after charging a battery.

• Wear protective goggles, rubber apron, and rubber gloves.

Storage batteries give off explosive hydrogen gas

during recharging.

Hydrogen gas stays near battery for a long time

after battery has been charged.

Slightest spark will ignite hydrogen and cause

explosion.

You can be blinded or severely injured.

Battery electrolyte fluid contains acid and is

extremely caustic.

Contact with battery fluid will cause severe

chemical burns.

DANGER

• Operate generator ONLY outdoors.

• Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings.

• DO NOT operate generator inside any building or enclosure

(even if doors or windows are open), including the generator

compartment of a recreational vehicle (RV).

Running generator gives off carbon monoxide,

an odorless, colorless, poison gas.

Breathing carbon monoxide can cause nausea,

fainting or death.

WARNING

7500EXL Extended Life Generator

• Use generator only for intended uses.

• If you have questions about intended use, ask dealer or call

1-800-270-1408.

• Operate generator only on level surfaces.

• DO NOT expose generator to excessive moisture, dust, dirt,

or corrosive vapors.

• DO NOT insert any objects through cooling slots.

• If connected devices overheat, turn them off and disconnect

them from generator.

• Shut off generator if:

-electrical output is lost;

-equipment sparks, smokes, or emits flames;

-unit vibrates excessively.

Improper treatment of generator can damage it and

shorten its life.

CAUTION

• When starting engine, pull cord slowly until resistance is felt

and then pull rapidly to avoid kickback.

• NEVER start or stop engine with electrical devices plugged in

and turned on.

Rapid retraction of starter cord (kickback) will

pull hand and arm toward engine faster than

you can let go.

Broken bones, fractures, bruises or sprains could

result.

WARNING

WHEN ADJUSTING OR MAKING REPAIRS TO YOUR

GENERATOR

• Disconnect the spark plug wire from the spark plug and place

the wire where it cannot contact spark plug.

WHEN TESTING FOR ENGINE SPARK

• Use approved spark plug tester.

• DO NOT check for spark with spark plug removed.

Unintentional sparking can result in fire or

electric shock.

WARNING

• DO NOT touch hot surfaces and avoid hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 ft. (152 cm) clearance on all sides of generator

including overhead.

• Code of Federal Regulation (CFR) Title 36 Parks, Forests, and

Public Property require equipment powered by an internal

combustion engine to have a spark arrester, maintained in

effective working order, complying to USDA Forest service

standard 5100-1C or later revision. In the State of California a

spark arrester is required under section 4442 of the California

Public resources code. Other states may have similar laws.

Running engines produce heat.Temperature of

muffler and nearby areas can reach or exceed

150°F (65°C).

Severe burns can occur on contact.

Exhaust heat/gases can ignite combustibles,

structures or damage fuel tank causing a fire.

WARNING

• DO NOT tamper with governed speed. Generator supplies

correct rated frequency and voltage when running at governed

speed.

• DO NOT modify generator in any way.

Excessively high operating speeds increase risk of injury

and damage to generator.

Excessively low speeds impose a heavy load.

CAUTION

• See “Don’t Overload Generator”.

• Start generator and let engine stabilize before connecting

electrical loads.

• Connect electrical loads in OFF position, then turn ON for

operation.

• Turn electrical loads OFF and disconnect from generator

before stopping generator.

Exceeding generators wattage/amperage capacity can

damage generator and/or electrical devices connected

to it.

CAUTION

7500EXL Extended Life Generator

KNOWYOUR 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.

12 Volt DC Receptacle — Use this receptacle with

battery charge cables to charge a 12Volt battery.

120 Volt AC, 20 Amp Duplex Receptacle — May be

used to supply electrical power for the operation of

120 Volt AC, single phase, 60 Hz electrical lighting, appliance,

tool and motor loads.

120 Volt AC, 30 Amp Locking Receptacle — May be

used to supply electrical power for the operation of

120 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting,

appliance, tool and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle — May

be used to supply electrical power for the operation of

120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz

electrical lighting, appliance, tool and motor loads.

120/240 Volt AC, 50 Amp Receptacle — May be used

to supply electrical power for the operation of 240 Volt AC,

50 Amp, single phase, 60 Hz electrical loads.

Air Cleaner — Protects engine by filtering dust and

debris out of intake air.

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.

Electric Start Switch — Press to start the engine.

Grounding Fastener — Consult your local agency having

jurisdiction for grounding requirements in your area.

Idle Control Switch — The idle control runs the engine

at normal (high) speeds when there is a load present and

runs the engine at idle (low) speeds when a load is not

present.

Oil Fill Cap — Add oil to engine here.

Recoil Starter — Used to start the engine manually.

Run/Stop Switch — Must be in “Run” position to start

engine. Set to “Stop” to stop a running engine.

Spark Arrester Muffler — Exhaust muffler lowers engine

noise and is equipped with a spark arrester screen.

120 Volt AC, 20 Amp

Duplex Receptacle

Idle Control Switch

Recoil Starter

Run/Stop Switch

Choke Lever

120/240 Volt AC,

30 Amp Locking

Receptacle

120/240 Volt AC,

50 Amp Receptacle

Circuit Breakers (AC)

120 Volt AC, 30 Amp

Locking Receptacle

12 Volt DC

Receptacle

Spark Arrester Muffler

Electric Start Button

Grounding Fastener

Air Cleaner

Fuel Tank

Oil Fill Cap

7500EXL Extended Life Generator

ASSEMBLY

Your generator requires some assembly and is ready for

use after it has been properly serviced with the

recommended oil and fuel.

If you have any problems with the assembly of your

generator, please call the generator helpline at

1-800-270-1408.

Unpack the Generator

1. Set the carton on a rigid flat surface.

2. Open carton completely by cutting each corner from

top to bottom.

3. Remove everything from carton except generator.

4. Leave generator on carton to install wheel kit.

Carton Contents

Check all contents against those listed below:

• Generator

• Wheel kit

• Storage Cover

• Adapter Cord Set

• Battery

• Battery Float Charger

• Battery Charge Cables

• Spare Spark Plug,Air Filter, and Oil Filter

• Spark Plug Wrench

• (2) Locking 30 Amp Plugs

• Engine Oil

• Operator's Manual

• Engine Manual

If any parts are missing or damaged, call the generator

helpline at 1-800-270-1408.

Install Wheel Kit

The wheel kit is designed to greatly improve the portability

of your generator.

NOTE: Wheel kit is not intended for over-the-road use.

You will need the following tools to install this wheel kit:

• 1/2" or 13mm socket wrench

• 1/2" or 13mm open end wrench

• 7/16" socket wrench

• 7/16" open end wrench

• Pliers

• Safety glasses

Refer to Figure 1 and install the wheel kit as follows:

1. Tip generator so that engine end is up.

Support Leg

M8 Lock Nut

Axle

Flat Washer

M8x20mm Capscrew

1/4x20 Lock Nut

Wheel

E-Ring

Figure 1 — Install Wheel Kit

1/4-20x1” Capscrew

Vibration Mount

7500EXL Extended Life Generator

2. Slide axle through both mounting brackets.

3. Slide a wheel over the axle.

NOTE: Be sure to install both wheels with the air

pressure valve on the outboard side.

4. Place a washer on axle and then place an e-ring in axle

groove.

5. Install e-ring with pliers, squeezing from top of e-ring

to bottom of axle.

6. Repeat step 3 thru 5 to secure second wheel.

7. Tip generator so that engine side is down.

8. Attach the vibration mounts to the support leg with

1/4-20 x 1” capscrews and 1/4-20 lock nuts.

9. Line up holes in support leg with holes in generator

frame.

10. Attach support leg using 2 capscrews (M8 x 20 mm)

and 2 hex nuts (M8).Tighten with a 1/2” or 13mm

socket wrench and 1/2” or 13mm wrench.

11. Return generator to normal operating position (resting

on wheels and support leg).

12. Check each fastener to ensure it is secure.

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:

1. Cut off tie wrap securing loose end of negative (black)

cable.

2. Remove screw, lock washer and flat washer on

negative battery terminal.

3. Slide lock washer, flat washer and negative battery

cable over screw (Figure 2).

4. Reattach screw to negative battery terminal and

tighten.

5. Verify that connections to battery and generator are

tight and secure.

Figure 2 — Negative Battery Connection

Negative

Battery Cable

Screw

Flat Washer

Lock Washer Positive

Battery Cable

• Always wear eye protection when installing/removing e-rings.

E-rings can cause eye injury.

E-rings can spring back and become airborne

when installing or removing.

CAUTION

7500EXL Extended Life Generator

BEFORE STARTING THE

ENGINE

Add Engine Oil

• Place generator on a level surface.

• Refer to engine operator’s manual and follow oil

recommendations and instructions.

NOTE: Check oil often during engine break–in. Refer to

engine operator’s manual for recommendations.

NOTE: The generator assembly rotates on a prelubricated

and sealed ball bearing that requires no additional

lubrication for the life of the bearing.

Add Fuel

NOTE: This gasoline engine is certified to operate on

gasoline. Exhaust Emission Control System: EM (Engine

Modifications).

1. Use clean, fresh, regular UNLEADED fuel with a

minimum of 85 octane. DO NOT use fuel which

contains Methanol. DO NOT mix oil with fuel.

2. Clean area around fuel fill cap, remove cap.

3. Slowly add regular unleaded fuel to fuel tank. Be careful

not to overfill.Allow at least 1.5" of tank space for fuel

expansion (Figure 3).

4. Install fuel cap and wipe up any spilled fuel.

Fuel

Tank

1.5” Air Space

Figure 3 - Fuel Expansion

CAUTION

• Refer to engine manual for oil fill information.

• Damage to equipment resulting from failure to follow this

instruction will void warranty.

Any attempt to crank or start the engine before it has

been properly filled with the recommended oil will result

in equipment failure. WHEN ADDING FUEL

• Turn generator OFF and let it cool at least 2 minutes before

removing fuel cap. Loosen cap slowly to relieve pressure in tank.

• Fill fuel tank outdoors.

• DO NOT overfill tank.Allow space for fuel expansion.

• Keep fuel away from sparks, open flames, pilot lights, heat, and

other ignition sources.

• DO NOT light a cigarette or smoke.

Fuel and its vapors are extremely flammable and

explosive.

Fire or explosion can cause severe burns or

death.

WARNING

7500EXL Extended Life Generator

USING THE GENERATOR

System Ground

The generator has a system ground that connects the

generator frame components to the ground terminals on

the AC output receptacles.The system ground is connected

to the AC neutral wire (see “Equipment Description”,

earlier in this manual).

Special Requirements

There may be Federal or State Occupational Safety and

Health Administration (OSHA) regulations, local codes, or

ordinances that apply to the intended use of the generator.

Please consult a qualified electrician, electrical inspector, or

the local agency having jurisdiction.

• In some areas, generators are required to be registered

with local utility companies.

• If the generator is used at a construction site, there may

be additional regulations which must be observed.

Connecting to a Building’s Electrical

System

Connections for standby power to a building’s electrical

system must be made by a qualified electrician.The

connection must isolate the generator power from utility

power, and must comply with all applicable laws and

electrical codes.

Generator Location

Generator Clearance

Place generator in a well ventilated area, which will allow

for removal of deadly exhaust gas. DO NOT place

generator where exhaust gas could accumulate and enter

inside or be drawn into a potentially occupied building.

Ensure exhaust gas is kept away from any windows, doors,

ventilation intakes or other openings that can allow exhaust

gas to collect in a confined area (Figure 4). Prevailing winds

and air currents should be taken into consideration when

positioning generator.

Figure 4 — Generator Clearance

Exhaust Port

Typical Generator Shown

• When using generator for backup power, notify utility

company. Use approved transfer equipment to isolate

generator from electric utility.

• Use a ground fault circuit interrupter (GFCI) in any damp or

highly conductive area, such as metal decking or steel work.

• DO NOT touch bare wires or receptacles.

• DO NOT use generator with electrical cords which are worn,

frayed, bare or otherwise damaged.

• DO NOT operate generator in the rain.

• DO NOT handle generator or electrical cords while standing

in water, while barefoot, or while hands or feet are wet.

• DO NOT allow unqualified persons or children to operate or

service generator.

Generator produces powerful voltage.

Failure to isolate generator from power utility

can result in death or injury to electric utility

workers due to backfeed of electrical energy.

WARNING

• Operate generator ONLY outdoors.

• Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings.

• DO NOT operate generator inside any building or enclosure

(even if doors or windows are open), including the generator

compartment of a recreational vehicle (RV).

Running generator gives off carbon monoxide,

an odorless, colorless, poison gas.

Breathing carbon monoxide can cause nausea,

fainting or death.

WARNING

• Keep at least 5 ft. (152 cm) clearance on all sides of generator

including overhead.

Exhaust heat/gases can ignite combustibles,

structures or damage fuel tank causing a fire.

WARNING

7500EXL Extended Life Generator

OPERATING THE

GENERATOR

Starting the Engine

IMPORTANT: Always unplug the battery float charger

before starting the generator.

Disconnect all electrical loads from the generator. Use the

following start instruction steps by numerical order:

1. Make sure unit is on a level surface.

IMPORTANT: Failure to start and operate unit on a level

surface will cause the unit not to start or shut down during

operation.

2. Turn the fuel valve to the “On” position (Figure 5).The

fuel valve handle should be vertical (pointing toward

the ground) for fuel to flow.

3. Make sure the Idle Control switch is in “Off” position

(Figure 6).

4. Start the engine according to instructions given in the

engine operator’s manual.

NOTE: If engine starts after 3 pulls but fails to run, or if

unit shuts down during operation, make sure unit is on a

level surface and check for proper oil level in crankcase.

This unit may be equipped with a low oil protection device.

See engine manual.

Connecting Electrical Loads

• Let engine stabilize and warm up for a few minutes after

starting.

• Plug in and turn on the desired 120 and/or 240 Volt AC,

single phase, 60 Hz electrical loads.

• DO NOT connect 240Volt loads to the 120 Volt

receptacles.

• DO NOT connect 3–phase loads to the generator.

• DO NOT connect 50 Hz loads to the generator.

•DO NOT OVERLOAD THE GENERATOR. See

“Don’t Overload Generator”.

Fuel Valve is shown

in the On position

Figure 5 — FuelValve

Figure 6 — Idle Control Switch

• See “Don’t Overload Generator”.

• Start generator and let engine stabilize before connecting

electrical loads.

• Connect electrical loads in OFF position, then turn ON for

operation.

• Turn electrical loads OFF and disconnect from generator

before stopping generator.

Exceeding generators wattage/amperage capacity can

damage generator and/or electrical devices connected

to it.

CAUTION

• When starting engine, pull cord slowly until resistance is felt

and then pull rapidly to avoid kickback.

• NEVER start or stop engine with electrical devices plugged in

and turned on.

Rapid retraction of starter cord (kickback) will

pull hand and arm toward engine faster than

you can let go.

Broken bones, fractures, bruises or sprains could

result.

WARNING

• DO NOT touch hot surfaces and avoid hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 ft. (152 cm) clearance on all sides of generator

including overhead.

• Code of Federal Regulation (CFR) Title 36 Parks, Forests, and

Public Property require equipment powered by an internal

combustion engine to have a spark arrester, maintained in

effective working order, complying to USDA Forest service

standard 5100-1C or later revision. In the State of California a

spark arrester is required under section 4442 of the California

Public resources code. Other states may have similar laws.

Running engines produce heat.Temperature of

muffler and nearby areas can reach or exceed

150°F (65°C).

Severe burns can occur on contact.

Exhaust heat/gases can ignite combustibles,

structures or damage fuel tank causing a fire.

WARNING

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