Table of Contents
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The Reliable
Ones
7500
Portable
Generator
Owner's Manual
L
A
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. 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.
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Table of Contents
Related Manuals for Generac Power Systems 7500
Summary of Contents for Generac Power Systems 7500
- Page 1 Environmental Protection Agency, For warranty information refer to the Engine Owner's manual. Model No. 1019-1 (7500 Watt AC Generator) 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.
- Page 2 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.
- Page 3 Generac Portable Products 7 500EXL Extended L ifeGenerator • DoNot useworn,bare,frayedor otherwise damaged electrical cordsetswiththegenerator. • Operate generator onlyonlevelsurfaces a ndwhere it willnotbeexposed toexcessive moisture, dirt, dustor corrosive vapors. • Gasoline is highlyFLAMMABLE a nditsvaporsare EXPLOSIVE. DoNot permit s moking, openflames, sparksor heatin thevicinity whilehandling gasoline.
- Page 4 Generac Portable Products 7 500EXL Extended L ifeGenerator 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. Save this manual for future reference...
- Page 5 Generac Portable Products 7 500EXL Extended L ifeGenerator Yourgenerator requires someassembly a ndis ready foruseafterit hasbeenproperly serviced withthe recommended oilandfuel. If you have any problems with the assembly your generator, please call the generator at 1-800-270-1408. IMPORTANT: Any attempt to run the unit before it has been serviced with the recommended an engine failure.
- Page 6 Generac Portable Products 7 500EXL Extended L ifeGenerator CAUTION: Be sure the black cable is connected to the engine mount and not the frame. You could damage the ground wire. • Connect the red battery cable from the engine starter switch to positive...
- Page 7 Generac Portable Products 7 500EXL Extended L ifeGenerator Toavoidengine problems, thefuelsystem shouldbe emptied before storage of30daysorlonger. D rain the gastank,startthe engine andlet it rununtilthefuel linesandcarburetor areempty. U sefreshfuelnext season. S ee"Storage" onpage12foradditional information. Never u seengine or carburetor cleaner p roducts i nthe fueltankor permanent damage mayoccur.
- Page 8 Generac Portable Products 7 500EXL Extended L ifeGenerator Operating Automatic 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 wilt run at a reduced speed.
- Page 9 Generac Portable Products 7 500EXL Extended L ifeGenerator COLD WEATHER OPERATION Under certain weather conditions (temperatures 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: •...
- Page 10 Generac Portable Products 7500EXL Extended Life Generator 3-Wire Cord Set r7_7 Ground NEMA L5-30 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.
- Page 11 Generac Portable Products 7 500EXL Extended L ifeGenerator DON'T OVERLOAD GENERATOR 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: •...
- Page 12 Inspect cooling air slots and opening on generator. SERVICE/ADJUSTMENTS Refer to engine owner's manual for information Generac Portable Products 7500EXL Extended Life Generator STORAGE The generator should be started at least once every seven days and allowed to run at least 30 minutes...
- Page 13 Generac Portable Products 7 500EXL Extended L ifeGenerator 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, Engine shuts down during operation.
- Page 14 Generac Portable Products 7 500EXL Extended L ifeGenerator ID]_LF_i_]_ SCHEMATIC DIAGRAM IDLE SYSTEH CONTROL BOARD BLU/_HT...
- Page 15 Generac Portable Products 7500EXL Extended Life Generator WIRING DIAGRAM GRN/YEL TRAN_FDRHER IDLE ¢DNTRDL ¢ 120V/20A 120/240v ID_'! C_B_ AUTD RESET • IDLE CONTROL SWITCH ENGINE BLOCK...
- Page 16 Generac Portable Products 7500EXL Extended Life Generator _j/- MAIN UNIT EXPLODED VIEW 13-- < DETAIL OF TO STARTER ELECTRIC START SWITCH...
- Page 17 Generac Portable Products 7500EXL Extended Life Generator MAIN UNIT PARTS LIST Item Part # Qty. Description A92432 CRADLE A92531 SUPPORT, Engine A92731 SUPPORT, Engine & Muffler 92247 HOUSING, Engine Adapter B1342G ASSEMBLY, Rotor B1897G ASSEMBLY, Stator 65791 BEARING 67451 WASHER, Special Flat - M8...
- Page 18 Generac Portable Products 7500EXL Extended Life Generator I=&'_J-#J"d | ? j/_ CONTROL PANEL EXPLODED VIEW AND PARTS LIST L$.\ Item Pa_ # Qty. Description BB4461 PANEL, Control 23897 WASHER, #10 M5 Flat 49226 WASHER, M5 Lock 91526 SCREW, M5-0.8 x 12 mm...
- Page 19 Generac Portable Products 7 500EXL Extended L ifeGenerator NOTES...
- Page 20 FOR "GN" 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.