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.
7500EXL Extended Life Generator SAVE THESE INSTRUCTIONS TABLE OF CONTENTS SAFETY RULES Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7500EXL Extended Life Generator WARNING DANGER 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. Fuel and its vapors are extremely flammable and explosive.
7500EXL Extended Life Generator CAUTION WARNING Excessively high operating speeds increase risk of injury and damage to generator. Excessively low speeds impose a heavy load. 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. • 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.
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.
7500EXL Extended Life Generator ASSEMBLY • 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. Your generator requires some assembly and is ready for use after it has been properly serviced with the recommended oil and fuel.
500EXL Extended Life Generator 2. Slide axle through both mounting brackets. 3. Slide a wheel over the axle. Check Battery / Attach Negative Battery Wire 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.
7500EXL Extended Life Generator BEFORE STARTING THE ENGINE Add Fuel NOTE: This gasoline engine is certified to operate on 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. Fire or explosion can cause severe burns or death. CAUTION Any attempt to crank or start the engine before it has been properly filled with the recommended oil will result in equipment failure.
7500EXL Extended Life Generator USING THE GENERATOR Generator Location Generator Clearance System Ground WARNING 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). Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire. • Keep at least 5 ft.
7500EXL Extended Life Generator OPERATING THE GENERATOR 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. Starting the Engine WARNING IMPORTANT: Always unplug the battery float charger before starting the generator. Running engines produce heat.
7500EXL Extended Life Generator Stopping the Engine 1. Turn off and unplug all electrical loads from generator panel receptacles. NEVER start or stop engine with electrical devices plugged in and turned on. 2. Put idle control switch in “Off” position. 3. Let engine run at no–load for 30 seconds to stabilize internal temperatures of engine and generator. 4. Turn engine off according to instructions given in engine operator’s manual. 5. Move fuel valve to “Off” position.
7500EXL Extended Life Generator COLD WEATHER OPERATION How to Use the Battery Charger Use battery float charger jack to keep the starting battery 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 40°F [4°C] combined with high humidity), your generator may experience icing of the carburetor and/or the crankcase breather system.
7500EXL Extended Life Generator Creating a Temporary Shelter 1. In an emergency, use the original shipping carton. 2. Cut off top carton flaps and one long side of carton to expose muffler side of unit. If required, tape up other sides of carton to fit over generator as shown in Figure 9. 6. Start generator as described in the section “Starting the Engine”, then place carton over generator. Keep at least 5 ft. (152 cm) clearance on all sides of generator including overhead with shelter in place.
7500EXL Extended Life Generator GENERATOR ADAPTER CORD SET Figure 11 — 12 Volt DC, 10 Amp Receptacle 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 not be used to crank an engine having a discharged battery.
7500EXL Extended Life Generator 120/240 Volt AC, 50 Amp Receptacle Figure 13 — 120 Volt AC, 30 Amp, Locking Receptacle 3-Wire Cord Set Use a NEMA 14–50 plug with this receptacle (Figure 15). Connect a 4-wire cord set rated for 250 Volt AC loads at 50 Amps to the plug. NEMA L5-30 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.
7500EXL Extended Life Generator DON'T OVERLOAD GENERATOR 4. Plug in and turn on the next load. 5. Again, permit the generator to stabilize. 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, as described above. Capacity You must make sure your generator can supply enough rated (running) and surge (starting) watts for the items you will power at the same time. Follow these simple steps: 1.
7500EXL Extended Life Generator SPECIFICATIONS 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. Starting Wattage . . . . . . . . . . . . . . . . . . . . . .
7500EXL Extended Life Generator STORAGE Engine 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 be done and you must store the unit for more than 30 days, use the following guidelines to prepare it for storage. Other Storage Tips • To prevent gum from forming in fuel system or on essential carburetor parts, add fuel stabilizer into fuel tank and fill with fresh fuel.
7500EXL Extended Life Generator TROUBLESHOOTING Problem No AC output is available, but engine is running. Cause Correction 1. One of the circuit breakers is open. 1. Reset circuit breaker. 2. Fault in generator. 2. Contact Generac service facility. 3. Poor connection or defective cord set. 3. Check and repair. 4. Connected device is bad. 4. Connect another device that is in good condition. Short circuit in a connected load. 1. Disconnect shorted electrical load.
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.
