Manual

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The Reliable Ones

7500

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 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.

Summary of content (20 pages)

PAGE 1
The Reliable Ones 7500 Portable Generator L Owner's Manual A 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.
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GeneracPortableProducts 7500EXLExtendedLifeGenerator EQUIPMENT SAFETY RULES DESCRIPTION This generator is an engine-driven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, 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.
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GeneracPortableProducts7500EXLExtendedLifeGenerator • DoNot useworn,bare,frayedor otherwise damagedelectricalcordsetswiththegenerator. • Operategenerator onlyonlevelsurfacesandwhere it willnotbeexposedtoexcessivemoisture,dirt, dustor corrosivevapors. • Gasolineis highlyFLAMMABLE anditsvaporsare EXPLOSIVE. DoNot permitsmoking,openflames, sparksor heatin thevicinitywhilehandlinggasoline. Avoidspillinggasolineona hotengine.Complywith all regulations requiringstorageandhandlingof gasoline.
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GeneracPortableProducts 7500EXLExtendedLifeGenerator KNOW YOUR GENERATOR Read this owner's manual and safety rules before operating your generator. Compare the illustrations with your generator to familiarize yourself with the locations of various controls and adjustments.
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GeneracPortableProducts7500EXLExtendedLifeGenerator Yourgeneratorrequiressomeassemblyandis ready foruseafterit hasbeenproperlyservicedwiththe recommended oilandfuel. If you have any problems with the assembly of your generator, please call the generator at 1-800-270-1408. INSTALLING TRAY AND BATTERY 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.
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GeneracPortableProducts 7500EXLExtendedLifeGenerator ,_. Select the oil's viscosity grade according to your expected operating temperature: CAUTION: to Be the mount black cable is the connected thesure engine and not frame. You could damage the ground wire. ! • Connect the red battery cable from the engine starter switch to positive (+) battery terminal (Figure 4) I colder 5W-30 _ 32°F -_,_warmer 10W-30 Although multi-viscosity oils (5W30, 10W30, etc.
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GeneracPortableProducts7500EXLExtendedLifeGenerator Toavoidengineproblems,thefuelsystemshouldbe emptiedbeforestorageof30daysorlonger.Drainthe gastank,startthe engineandlet it rununtilthefuel linesandcarburetor areempty.Usefreshfuelnext season.See"Storage"onpage12foradditional information. Neveruseengineor carburetorcleanerproductsinthe fueltankor permanent damagemayoccur. To add fuel: For Electric • Clean area around fuel fitl cap, remove cap.
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GeneracPortableProducts 7500EXLExtendedLifeGenerator Operating Automatic To recharge Idle Control This switch is designed to greatly improve fuel economy. When this switch is turned ON, the engine will only run at its normal high governed engine speed when an electrical load is connected. When an • If the battery is equipped with vent caps, make sure they are installed and are tight. electrical load is removed, the engine wilt run at a reduced speed.
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GeneracPortableProducts7500EXLExtendedLifeGenerator COLD WEATHER OPERATION • Ensure a minimum of two feet clearance between open side of box and nearest object 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. • Enclosure should hold enough heat created by the generator to prevent problems. • Face exposed end away from wind and elements. ,_.
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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. 3-Wire Cord Set Neutral 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).
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GeneracPortableProducts7500EXLExtendedLifeGenerator DON'T OVERLOAD GENERATOR THE • 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.
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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.
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GeneracPortableProducts7500EXLExtendedLifeGenerator TROUBLESHOOTING Cause 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, 1. 2. 3. Circuit breaker is open. Poor connection or defective cord set Connected device is bad 4. 1. 2. Fault in generator. Short circuit in a connected load. Generator is overloaded. 3. 4. 1. 2. 3. 4. Engine speed is too slow. Shorted generator circuit.
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ID]_LF_i_]_ SCHEMATIC GeneracPortableProducts 7500EXLExtendedLifeGenerator DIAGRAM G 35_ L 155 156 2@ 44 SYSTEH CONTROL 18 s BOARD I L0P IDLE I 14 0 B BLU/_HT 2_
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Generac Portable Products 7500EXL Extended Life Generator ID_'! _ WIRING DIAGRAM 10A C_B_ AUTD RESET J • 120V/20A 120/240v IDLE CONTROL SWITCH GRN/YEL /x TRAN_FDRHER IDLE ¢DNTRDL ¢ RUN _N NUT ON ENGINE BLOCK I 15
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Generac Portable Products 7500EXL Extended Life Generator I _j/- I MAIN UNIT EXPLODED VIEW 62 66 67 / DETAIL OF ELECTRIC START SWITCH 51 68 / 65 TO STARTER 38 10 \\ < 1/ 65\ 51 \ 16\ 58 17 57 26 33 13-- _9 \ 37 55 57 \65 \ \, 21 / 16
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Generac Portable Products 7500EXL Extended Life Generator Ill I m MAIN UNIT PARTS LIST Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part # A92432 A92531 A92731 92247 B1342G B1897G 65791 67451 22129 86307 47481 92609 82857 40976 66476 Qty.
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I=&'_J-#J"d | Generac Portable Products 7500EXL Extended Life Generator I ? j/_ CONTROL I PANEL EXPLODED VIEW AND PARTS LIST 19 2C 21 25 28 27 26 lO lO 12 17 18 13 J24 7 18 17 >9 12 _ L$.\ 2 \ 3 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Pa_ # BB4461 23897 49226 91526 82538 82881 B4262 90418 75207N 75207A 75207 23365 68868 43437 Qty. 1 4 4 4 1 6 1 1 2 2 2 10 1 1 Description PANEL, Control WASHER, #10 M5 Flat WASHER, M5 Lock SCREW, M5-0.8 x 12 mm SWITCH, Idle Control WASHER, 7/16" Int.
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GeneracPortableProducts7500EXLExtendedLifeGenerator NOTES / 19
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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.