Generac Portable Products 1315-0 User manual

GEN RAC °]
Portable Products
7500
Portable Generator Owner's Manual
Model No. 1315-0 (7,500 Watt AC Generator) ManualNo. B4369 Revision 3 (9/19/2000)
Visit our Generac website: www.generac-portables.com
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Obey all safety messagesthat follow this symbol to avoid possible injuryor death.

GeneracPortableProducts7,500EXLGenerator
EQUIPMENT
DESCRIPTION
This generator isan engine-driven, revolving field,
alternating current (AC) generator. It was designedto
supply electrical power for operating compatible electrical
lighting, appliances,tools and motor loads.This manual
contains information for a generator that operates
120and/or 240 Volt, singlephase,60 Hz devicesthat
require up to 7,500 watts (7.5 kW) of power that draw up
to 62.5 Amps at 120Volts or 31.2 Amps at 240 Volts.
_ CAUTION! Do Not exceed the generator's
wattage/amperagecapacity.Add up the rated watts
of all devicesyou are connecting to generator
receptaclesat one time. This total should not be
greater than 7,500 watts. See "Don't Overload The
Generator" on page 12.
The 7,500EXL generator hasthe following features:
•120/240Volt, 30 Amp locking receptacle, a 120Volt,
30 Amp locking receptacle, a 120Volt, 20 Amp
receptacle, and a 120/240Volt, 50 Amp receptacle.
• Low Oil Shutdown: Automatically shuts down the engine
if oil drops below safe operating pressure.
• Sevengallon overhead fuel tank with fuel gauge.
• The generator's revolving field isdriven at about
3600 rpm by a Generac Power Systems 15 HP electric
start engine.
_ANGER! Do Not tamper with enginegoverned
speed. High operating speeds are dangerousand
increase risk of personal injury or damageto
equipment. The generator supplies correct rated
frequency and voltage only when running at proper
governed speed. Incorrect frequency and/or voltage
candamagesome connected electrical loads.
Operating at excessivelylow speedsimposes a heavy
load. When adequate enginepower isnot available,
engine life may be shortened.
SAFETY RULES
This generator set was designed and manufactured for
specific applications. Do Not attempt to modify the unit
or useit for anyapplication it was not designed for. If you
haveanyquestions about your generator's application, ask
your dealer/distributor 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 unsafeor pose a threat to you and
others.
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
_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. Whenever unit is providing
backup power, the electric utility must be notified.
_DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. Carbon
monoxide, if breathed in sufficient
concentrations, can cause unconsciousness or
death. Operate this equipment outdoors where
adequateventilation is available.
The EmissionControl Systemfor this generator is
warranted for standardsset by the Environmental
Protection Agency.For warranty information refer to the
engine owner's manual.
/2

Generac Portable Products 7,500 EXL Generator
•The generator produces a very powerful voltage that can
causeserious injury or death by electrocution. Never
touch bare wires or receptacles. Never permit a child
or anyunqualified person to operate the generator.
• Never handle any kind of electrical cord or device while
standing in water, while barefoot or while hands or feet
are wet Death or serious injury from electrocution may
result.
• Use aground fault circuit interrupter (GFCI) in anydamp
or highly conductive area (such as metal deckingor steel
work).
• Never useworn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damagefrom electrical shock may result.
•Gasoline is highly FLAMMABLE and its vapors
are EXPLOSIVE. Never allow smoking, open
flames, sparks or heat in the vicinity while
handling gasoline. Avoid spillinggasoline on a hot
engine.Comply with all laws regulating storage and
handling of gasoline.
• Do Not overfill the fuel tank. Always allow room for
fuel expansion. If tank is overfllled, fuel can overflow
onto a hot engine and cause a FIRE or an
EXPLOSION.
•Never store a generator with fuel in the tank where
gasolinevapors might reach an open flame, spark or pilot
light (as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.
• The unit requires an adequateflow of cooling air for its
continued proper operation. Never operate the unit
insideanyroom or enclosure where the free flow of
cooling air into and out of the unit might be obstructed.
Allow at least2 feet of clearanceon all sides of generator,
evenwhile operating unit outdoors, or you could damage
the unit See"Cold Weather Operation" on page 10.
•Never start or stop the unit with electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting anyelectrical loads.Disconnect all electrical
loads before shutting down the generator.
•Do Not insertanyobject through cooling slots of the
engine.You could damagethe unit or injureyourself.
•Never operate the generator:
in rain; in any enclosedcompartment;when connected
electricaldevicesoverheat; if electrical output islost;if
engine or generator sparks; ifflame or smoke is
observed while unit isrunning; if unit vibrates
excessively.
GROUNDING THE
G EN ERATO R
The National ElectricCode requires the frame and
external electrically conductiveparts of the generator be
properly connected to approved earth ground. Local
electrical codes may also require proper grounding of the
unit For this purpose, a ground lug (Figure I) is provided
on the cradle.
Generally, connecting a No. 12AWG (American Wire
Gauge) stranded copper wire to the ground lug screw and
to an earth-driven copper or brassgrounding 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 ground wire attached while you
connect the electrode.
Properly grounding the generator helps prevent electrical
shock ifground fault conditions exists in the generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
mm_ 3

GeneracPortableProducts7,500EXLGenerator
INSTALL WHEEL KIT AND
BATTERY TRAY
To install these items, you need the following tools:
•Socket wrench with liT' or 13mm socket.
• Box or open end 3/8" wrench.
Install Wheel Kit
•Placethe generator on a hard fiat surface (Figure 2).
• Placetemporary blocks beneath the cradle.
• Slidethe axle through the holes in the brackets provided
on the generator cradle and then add one spacer on
eachprotruding end of the axle.
•Slide a wheel on eachend of the axle and secure with
washer and retaining pin. If wheel does not spin freely,
omit one or both washers.
NOTE: Make sure the air inflationvalvefacesoutward on
each wheel.
• Attach the vibration mounts to the support legwith
capscrews,washers, and lock nuts.
• Attach the support legwith two capscrews and two lock
nuts to the cradle. Removethe temporary blocks.
• Attach the handle with four capscrewsand four lock nuts
on the control panel end of the unit.
Handle
Capscrew,
M8 x 45mm /
Lock Nut, M8 F_
Support Leg_
Flat WasherF
_Hex Head
Capscrew,
M8 x 20mm
_Lock Nut, M8
Hex Head
\Capscrew,
M8 x 30mm
Wheel
Axle Spacer
Wheel
_0<_ i_er
/
Retaining Pin
/4

Generac Portable Products 7,500 EXL Generator
Installing Tray and Battery
To obtain electric start, you must purchase and installa
12Volt DC battery (SeriesU1-109). The battery should
be serviced asnecessaryand fully charged prior to
installation. Install the battery asfollows:
•Find the battery tray and fasteners shipped loose in the
carton. You should haveone battery hold down bracket,
a black battery cable, a red battery cable, two 7" Jbolts,
two lock washers, two fiat washers and two hex nuts.
• Remove the four battery tray screws from cradle.
• Position the battery tray and installwith screws removed
above (Figure 3).
• Set battery onto tray.
• Retain battery to tray with hold down bracket, two
Jbolts, two lock washers, two fiat washers and two hex
nuts (Figure 4). Tighten with 3/8" wrench.
•Connect one end of the red battery cable to the
outboard terminal of the engine start switch.
• Connect other end of the red battery cable from the
engine start switch to positive (+) terminal on the
battery (Figure5).
RED wire
from battery
BLACK wire
from battery
• Connect the black battery cable to the negative (-)
terminal on the battery (Figure 5).
• Connect the other end of the blackcableto the engine,
not the frame (Figure5).
_AUTION! Be sure the black cableisconnected
to the engine and not the frame. Failureto connect
cable to the engine block will result in damageto the
wiring which isnot covered under warranty.
• Double check all connections to ensure they are in the
correct locations and secure.
/5

GeneracPortableProducts7,500EXLGenerator
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.
Circuit Breakers (AC) Fuel Tank EngineStart Switch
I
12Volt DC, l0 Amp
Receptacle
Recoil Starter
Choke Lever
IdleControl Switch Run/Stop Switch
120 Volt AC,
30 Amp Receptacle
120/240 Volt AC,
30 Amp Receptacle
120Volt AC, 20Amp
Receptacle
120/240Volt AC,
S0Amp Receptacle Grounding Wing Nut SparkArrester Muffler
12 Volt DC, 10 Amp Receptacle -- Rechargea
discharged 12Vott automotive type battery through this
receptacle.
1201240 Volt AC, 50 Amp Receptacle -- May be used
to supply electrical power for the operation of
t20/240 Volt AC, 50 Amp, single phase,60 Hz electrical
loads.
120/240 Volt AC, 30 Amp Locking Receptacle --
May be usedto supply electrical power for the operation
of 120and/or 240 Volt AC, 30 Amp, single phase,60 Hz,
AC electrical lighting,appliance,tool and motor loads.
120 Volt AC, 20 Amp Receptacle -- May be used to
supply electrical power for the operation of 120Volt AC,
20 Amp, singlephase,60 Hz electrical lighting, appliance,
tool and motor loads.
Air Cleaner
120 Volt AC, 30 Amp Locking Receptacle -- May be
usedto supply electrical power for the operation of
t20 Volt AC, 30 Amp, single phase,60 Hz electrical
lighting, appliance,tool and motor loads.
Air Cleaner -- Uses a dry type filter element and foam
pre-cleaner to limitthe amount of dirt and dust sucked
into the engine.
Choke Lever -- Used when starting a cold engine.
Circuit Breakers (AC) -- Eachreceptacle is provided
with a circuit breaker to protect the generator against
electrical overload. Breakersare "push to reset" type.
Engine Start Switch - Pressedto start the engine.
Fuel Tank -- Capacity of seven (7) U.S.gallons.
Grounding Wing Nut -- Used for proper grounding of
unit.
Idle Control Switch -- With this switch set to ON,
printed circuit board in control panel automatically reduces
engine speedwhen no load is connected and increases
engine to proper speedwhen loadis applied. However, be
sure switch isOFF when starting engine.
Recoil Starter -- Used asbackup method of starting
engine.
Run/Stop Switch -- Setthis switch to "RUN" before
using recoil starter. Set switch to "STOP" to switch OFF
engine.
Spark Arrester Muffler -- Exhaustmuffler lowers
engine noiseand isequipped with a spark arrester screen.
/6

GeneracPortableProducts7,500EXLGenerator
BEFORE STARTING THE
ENGINE
Add Oil
_ARNING! Any attempt to crank or start the
engine before it has been properly filled with the
recommended oil may result in an engine failure.
To fill your engine with oil:
•Place generator on a level surface.
• Clean area around oil fill and remove oil fill cap.
• Select the oil's viscosity grade and fill engine with oil
following the instructions given in the engine owner's
manual. Do Not overfil!!
•Install oil fill cap.
NOTE: The generator's revolving field rides on a pre-
lubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
Add Gasoline
_ANGER! Explosion Hazard! Never fillfuel tank
indoors.Never fillfuel tank when engine isrunning
or hot Do Not light a cigarette or smoke when
filling the fuel tank.
_WARNING! Do Not overfill the fuel tank.
Always allow room for fuel expansion.
• Use regular UNLEADED gasoline with the Generator
engine. Do Not use premium gasoline. Do Not mix oil
with gasoline.
• Clean area around fuel fill cap, remove cap.
• Add unleaded regular gasoline, slowly to fuel tank. Be
careful not to overfill. Allow about I/2" of tank space for
fuel expansion (Figure 6).
1/2" Air Space Tank
• Install fuel cap and wipe up any spilled 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.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See "Storage"
on page 13. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
/7

Generac Portable Produc_s 7,500 EXL Generator
OPERATING THE
G EN ERATO R
_AUTION! Never s_rt or stop the engTnewTthelectrTc_l leads connected to die unit and wTth the
connected devices _urned ON.
Starting the Engine
Disconnect all electrTc_l loads from the generator. Use the
following s_r_ Tnstruc_ion steps by numerTcal order:
I. Mal(e sure the Idle Control switch is Tn_Off" positTon.
2. Turn the fuel valve to the "On" position (Figure 7).
3. Set the Run/Stop switch _o "Run" posTtTon(FTgure8).
4. Place the chol(e lever in the "Full" choke position
(Figure 9).
5A. For electric s_rUng, press star_ switch on genera_or
cradle until engine s_r_s. To prolong :he life of the
starter components, press the s_r_er buL_confor no
more :han I5 seconds, then pause for 30 seconds.
5B. For manual staring, grasp the recoil handle and pull
slowly until slight resistance is felt. Then pull rapidly
one _ime only to s_rt engine.
•If engine s_rts, proceed Co step 7.
•If engine fails to s_rt, proceed to step 6.
6. Move the choke lever to ==Half" choke position, and
pull recoil handle _vice,
•If engine fails to s_rt, repeat s_eps4 :hru 6.
7. Move choke leverto "Run" position.Ifen_ne falters,
move choke lever_o "Half' choke positionuntilthe
engineruns smoothly,and then to "Run" position.
NOTE: If engine s_ill fails to s_rt at_er 3 pulls, check for
proper oil level in crankcase. This unit is ec_uippedwith a
Low Oil Shutdown System. See engine manual.
Connecting Electrical Loads
• Let engine s_bilize and warm up for afew minu_es after
stari;ing,
• Plug in and turn on the desired 120 and/or 240 Volt AC,
single phase, 60 Hertz electrical loads.
•Do Not connec_ 240 Volt loads to 120 Volt receptacles.
•Do Not connec_ 3-phase loads _o :he generator.
•Do Not connec_ 50Hz leads to the generator.
•DO NOT OVERLOAD THE GENERATOR. Add up
:he ra_ed wa_s (or amps) of all loads m be connected at
one _ime. This torsi should not be grea_er :han the rated
watl:age/amperage c_paci_ of the generator. See "Don't
Overload the Generator" on p_ge I I.
Stopping the Engine
• Unplug all electrical loads from generater panel
recep_cles. Never star_ or stop engine with electrical
devices plugged in and turned on.
• Put :he Idle Control switch in the "Off" position.
• Let engine run at no-load for 30 seconds _o stabilize the
in_ernal _empera_ures of engine and genera_or.
• Move Run/Stop switch to "Stop".
•Close the fuel shu_-ofl'valve.
/8

Generac Pori_bleProducts7,500EXL Generator
Operating Automatic Idle Control
ThTscontrol Tsdesigned to greatly improve fuel economy,
When this switch is turned "ON", d_e engine wTI]only
run atTtsnormal highgoverned enginespeed when an
electrical load is connected. When the electrical load is
removed, the engTnewill run at a reduced speed. With
the switch "Off", the engTnewill run cons_ntly at hTgh
engTnespeed. Always have the switch "OFT" when
starting and stopping the engine.
Battery Safety
_IL ANGER! Storage batteries give off explosive
hydrogen gzs while rechargTng. An explosive mixture
will remain around the ba_cery for along time after
ft has been charged. The sligh_st sparl( can ignite
the hydrogen and cause an explosion. Such an
explosion can shatr.er the bakery and c_use
blindness or other serious injury.
_IL DANGER! Do Not permit smoking, open flame,
spar_ or am/or.her source of heat around a ba_cery.
Wear protective goggles,rubber apron and rubber
gloves when working around a battery. Bakery
electrolyte fluid is an extremely caustic sulfuric acid
solution that can cause severe burns. If spill occurs,
flush are_ with clear water immediately.
Charging a Battery
Your generator has the capability of recharging a discharged
12 Volt automotive or utility style storage battery. Do Not
use the generator to charge any 6 Volt ba_ceries. Do Not
use the generator to crank an engine hzving adischarged
battery.
To recharge 12 Volt batteries, proceed as follows:
•Checl( fluid level in all ba_cery cells. If necessary, add
ONLY distilled wa_r to each cell. Oo Not use tap
water,
•If the battery is equipped wir.hvent c_ps, make sure they
are ins_lled and are tight_
•If necessary, clean battery terminals.
• Connect b_ery charge c_ble connector plug to panel
receptacle identified by the words "12-VOLTS D.C;'
• Connect b_ery charge c_ble clamp with red handle to
the positive (÷) battery terminal (Figure I0).
12 VOLT D.C.
RECEPTACLE
+
POS NEG
12 VOLT BA'I-I'ERY
• Connect b_ery charge c_ble clamp with black handle
mthe negative (-) battery terminal (Figure I0).
• S_rt engine, Let the engine run while b_ery recharges,
•VVhen battery has charged, shut down engine,
NOTE: Use an automotive hydrometer to test battery
s_te of charge and condition, Follow the hydrometer
manufacturer's instructions carefully. Generally, ab_ery is
considered to be at 100% state of charge when specific
gravity of i_sfluid (as mezsured by hydrometer) is 1.260 or
higher.
/9

Generac Porr_ble Produc_s 7,500 EXL Generator
COLD WEATH ER
OPERATION
Under cer_in weather conditions (temperatures below
40°F [4°C] and a high dew point), your Generac generator
may experience icing of :he carburetor and/or the
crankcase breather system.
In an emergency, use :he original shipping box as a
temporary shelter:
•Cut off all flaps.
•Cut out one of the long sides of the box to expose
exhaust side of unit_ Ensure aminimum of _vo feet
clearance between open side of box and nearest obiect.
•Cut appropriate slots to access receptacles and clear
handles.
•S_r!; unit, then place box over it,
IMPORTANT: Removeshelterwhen temperature is
above40=F [4°C].
For amore permanent shelter, build a structure :hat will
enclose three sides and :he 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 I I,
_CAUTION! Never run unitindoors. Do No_;
enclose generator ary more :hart shown. Remove
shelter when temperatures are above 40=F [4=C].
RECEPTACLES
This generator is equipped with :he following receptacles:
120 Volt AC, 20 Amp Receptacle
This outlet is protec:ed zgainst overload by a 20 Amp
_ush-to-raset circuit breaker (Figure 12).
_ iiiii i
i iiii ?!i
_iiiiiii:
Use eachsocketto operat.e120Volt AC, singlephase,
60 FIzelectricalloadsrecIuiring upto 2/t00 wa_;s(2,4 kVV)
at 20 Amps, Use cord setsthat are ra:ed for 125Volt loads
at 20 Amps (or gre_ter).
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA 1_-30 plug with this recep=cle. Connect a
3-wire cord set rated for 125 Volts AC at 30 Amps :o the
plug (Figure 13).
•Ensure aminimum of W0o feet clearance bewceen open
side of box and nearest object.
•Face exposed end aw_y from wind and elemen:s.
•Enclosure should hold enough heat created by the
generator to prevent problems.
I10

Generac Pori:ableProducts7,500F..XLGenerator
8-WssO dSst
Use this receptacleto operate 120Volt AC, 60 Hz, single
phaseloads requiring up to 3,600 w_cs (3.6 EW) of power
•t 30Amps. The outlet is protected by a 30 Amp
push-to-reset circuit breaker.
120/240 Volt AC, 30 Amp Locking
Receptacle
Use • NEMA LI4-30 plugwith this receptacle. Connect a
4-wire cord set rated for 250 Volt AC loads at 30 Amps
(or greater). You c_n use the same 4-wire cord if you piton
to run a 120 Volt load (Figure 14).
4Wte od 8el
<...................£@V ................>
This receptacle powers 120 Volt AC, single phase, 60 Hz
loads requiring up to 3,600 w_cs of power (3.6 IcW). Or it
will operate 240 Volt AC, single phase, 60Hz loads up to
7,200 w_cs (7.2 IcVV).This outlet is protected by • 30 Amp
push-to-reset circuit breaker.
120/240 Volt AC, 50 Amp Receptacle
Use • NEMA 14-50 plug with this receptacle. Connect
4-wire cord set rated for 240 Volt AC Io_ds _t 50 Amps to
the plug (Figure 15).
i
Y (Hot)
W (Neutral)
X (Hot)
NEMA 14-50
Use this receptacle to operate 240 Volt AC, 60 Hz, single
phase loads requiring up to 7,500 w_cs (7.5 kVV) of power.
_{_ CAUTION! Although this outlet states it has a
240 Volt 50 Amp rating (up to 12,500 watts), the
generator is only rated for 7,500 watts. Powering
loads that exceed the w_age/amperage cap_city of
the generator c_n damzge it or c_use serious
fnjurfes.
/II

Generac Pori_ble Produc_s 7,5,00 EXL Generator
DON'T OVERLOAD THE
GENERATOR
Overloading a generator in excess of its rated w_e
capaci_/_n result in dam_e to the generator and/or
connected electrical devices. Observe the following, to
prevent overloadingthe unit:
• Add up the total ware of all electri_l devices to be
connected at one _ime. This t_t_l should NOT be
grea_er than the generator's wa_e capacity.
•The rated ware of lights can be taken from light bulbs.
The rated ware of tools, appliances and motors can
usually be found on a dat_ pla_eor decal affixed to the
device.
•If the appliance, tool or motor does not give wa_i_ge,
multiply 120 Volts times ampere rating to determine
wa_s (volts x amps =wa_i_),
•Some electric motors, such as inductJon _/pes, require
about three times more watts of power for starting than
for running, This surge of power lastsfor only a few
seconds when starting such motors, Be sure you allow
for this high starting wa_age when selec_Jng electrical
devices to connect to your generator. First figure the
wa_s needed to start the largest motor. Add to that
figure the running watts of all other connected loads.
•I_emsin the wattage reference guide (Figure 16) are
provided to help you to determine how many items the
generator can operate at one time,
m " v •
Recrea_;ional/Home Uses
Tool/Appllance .................................................... Watts
AM/FM clock radio .....................................................................5,0
Light bulb ....................................................................................100
Fan................................................................................................200
20" color TV .............................................................................,400
_Deep freezer ............................................................................5,00
Personal computer and 15,"monitor ...................................800
_1/3 hp furnace fan blower .....................................................800
Microwave oven ........................................................................800
18 cuft refrigerator ...............................................................800
Sump pump ..............................................................................1000
Electric skillet ..........................................................................125,0
_Yzhp water well pump ........................................................1400
12,000 Btu window air conditioner .................................1400
Space heater ............................................................................1800
Electric water heater .............................................................4000
Professlon al/Cont race;or Uses
Tool/Appllance .................................................... Watts
"1/3 hp airless sprayer.............................................................600
3/8" hammer drill .....................................................................600
Variable speed SawT._ll®..........................................................960
Y_"power drill .........................................................................I000
Quartz-halogen work light ...................................................1000
Belt sander ...............................................................................1200
7¼" cimular saw ...................................................................1500
7¼" worm drive saw............................................................1600
*1 ½ hp air compressor ........................................................1800
*10" power mi%er sew...........................................................1800
6" bench grinder .....................................................................1800
*6" table planer .......................................................................1800
*10" table/radial arm saw .....................................................2000
Wire feed welder ...................................................................2400
* allow 3 times listed wa_s for starring this device
/12

Generac Portable Products 7500 EXL.Generater
SPECIFICATIONS
Maximum SurgeWatts ................... 9.375 watts
Continuous Wattage Capacit7............. 7.500 watts
Power Factor ................................. 1.0
I_ted Maximum Continuous Load Current
At 120 Volts ......................... 62.5 Amps
At 240 Volts ......................... 31.2 Amps
Phase ................................... I-phase
I_ted Frequency .......................... 60 Her_
Fuel Tank Capacity ..................... 7U,S,gallons
GENERAL MAINTENANCE
RECOMMENDATIONS
The owner/operator Tsresponsible for m_ldng sure Chic _11
periodTc maTnten_nce r_s_ _re completed on _tTmely
basis;that rdldiscrepancies _re corracced; and d'mCthe unit
Tskept cle_n _nd properly stored, Never opera_ a
damaged or defective generat_r,
Engine Haintenance
See engTneowner's m_nual for instructions.
Generator Maintenance
Generator m_in_enance consis:s of keeping the unic clean
and dry. Operate and store the unic in aclean dry
environment where ic will not be exposed co excessive
dust, dir_ moisture or any corrosive vapors. Cooling air
slo:s in the generator must not become clogged with snow,
le_vasor _ny ocher foreign materi_l.
NOTE; Do Not use a g_rden hose to clean generator.
W_er c_n enter engine fuel system _nd cause problems. In
addition, it"water enters generator through cooling air
slo:s, some of the w_Cer will be re_ined in voids _nd
cracks of the rotor and s_:or winding insulation. Water
and dir_ buildup on the genera:or in_ernal windings will
eventually decrease the insulation resistance of these
windings.
To Clean the Generator
• Use ad_mp cloth :o wipe exterior surfaces cle_n.
•Soft, bristle brush m_y be used to loosen c_ked on dire
or oil,
•Avacuum cleaner may be used to pick up loose dirt and
debris.
•Low pressure air (noc :o exceed 23 psi) may be used :o
blow _y dirt. Inspect cooling air slo:s and opening on
generator. These openings must be kept cle_n _nd
unobstructed.
STO RAG E
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 guidelinesto prepare it for storage.
Generator Storage
* Clean the generator as outlined in "To Clean the
Generator;'
* Check that cooling air slots and openlnga On generator are
open and unobstructed.
* Disconnect negative battery cable from battery. Protect
bakery from freezing temperatures.
ADANGER! Storage covers can be flammable. Do
Not place a storage cover over a hot generator. Let
the unit cool for a su_icient time before placing a cover
on the unit.
Engine Storage
See engine owner's manual for instructions.
Other Storage Tips
* Do Not; storegasoline from one season to another.
*Replace your gasoline can if it starts to rust. Rust and/or
dirt in agasoline can cause problems if you use
contaminated fuel.
*Store unit in aclean and dry area.
/13

GeneracPortable Produces 7,500 EXL Generator
TROUBLESHOOTING
Problem
Engine is running, but no AC
output is available,
Engine runs good but bogs
down when loads are
connected.
C_use
I. CTrcuTt breaker is open.
2. Poor connectTon or defectivecord
set.
3. Connected device Tsbad.
4. Fault Tngenerator.
I. ShorI; circuit in aconnected load.
2. Generator is overloaded.
3. EngTnespeed Tstoo slow.
4. ShorI;ed generator circuit.
I. Run/Stop switch set to "Stop".
2. Oir_ air cleaner.
3, Out ofgaso/Tne,
4. Stale gasoline.
5. Spark p/ugwire not connectedto
Solution
I. Reset circuit breaker.
2. Check and repair.
3. C-onnect another device thatis in
good condition.
4. Contact Generac service facility,
I. Disconnect shorted electrical load.
2. See "Don't Overload the
Generator" on page 12.
3. Contact Generac service facility.
4. Contact Generac service faci/fty.
I. Set switch to "Run".
2. Clean or replace air cleaner.
3. Fill fuel tank.
4. Drain gas tank and f_/]with fresh fuel.
5. Connect wire to spark plug,
Engine will not start; or
starts and runs rough.
spark plug,
6, Bad spark plug,
7, Water in gasoline.
8, Overcholdng,
9. Low oil level
6. Replace spark plug.
7. Drain gas tank; ffl/with fresh fuel,
8, Put choke/ever to "no choke"
position.
9, Fill crankcase to proper level,
I0.
II.
12.
13.
Excessively rich fuel mixture, 10.
Intake valve stuck open or closed. I I.
Engine has lost compression, 12.
Battery is dead. 13.
2.
Contact Generac service facility,
Contact Generac service facility,
Contact Generac service facility,
Recharge or replace battery,
I, Out of gasoline, I, Fill fueltanK
Engine shuts down during 2, Low oil level 2, Fill crankcase to proper level,
operation. 3. Fault in engine, 3. Contact Generac service facility,
I, Load is too high, I, See "Don't Overload the
Generator" on page 12,
Engine lacks power. 2, Oily air t_/_er. 2. Replace air t_/ter.
3. Engine needs to be serviced. 3. Contact Generac service facility.
I. Choke is opened too soon. I.
Engine "hunts" or falters. 2.
Carbur_or is running too rich or
too lean,
Move choke to ha/fitca¥position till
engine runs smoothly,
Contact Generac service facility,
/14

GerleracPortableProdu_s 7,500EXL Generator
NOTES
/15

Generac Pori_ble Products 7,5.00 F_XL Generator
ELECTRICAL SCH EMATIC
LRE_
LD P
_LrI TCH
PDWER _ PDWER
11 2E 44
IDLE
E
D
B
T
E
G
N
A
L
/16

GerleracPortableProdu_s 7,500EXL Generator
WIRING DIAGRAM
156
155
"X//
IDLE CBNTRBL
TRANSFDRHER
4
55
ELECTRIC
START
GRDUND TD REAR
3EARINO CARRIER
BDTTDH
FEEDbaCK
• PDS_ BRUSH
CLDSE_T TD
PDVER
REGULATDR
_BARD
IOA
CB
AUTD RESET
11
IDLE
CDNTRDL
SWITCH
11 _ BLUfWHT
55
5R_
RUN
GRN
0
NUT DN
ENGINE BLDCK
SP_EK
PLUG
I17

Generac Pori_ble Produces 7,S00 EXL Generator
EXPLODED VIEW- MAIN UNIT
44\\\\
46 51
62
<DETAL OF
E_ECIRIC 8TART
SWITCH
_TO $TART_
29
34_
26
24
L
58
17
9 j
55
57
_9
55
/18

Generac PortableProducts7,500EXL Generator E%
_. 2¸¸¸¸¸¸
.........,........
m
PARTS LIST- MAIN UNIT
Item Pat't# Qty Deser!pt!on Item Part# QL'_/ Description
IG02432 i CRADLE 47 850001 CLIP,i_sula_ie_
2 G9253! ! SUPPORT,E_gine 48!4:353621 ! WIREi Gou_d
3 G9273! !SUPPORT,E_gine &Muffler 49 26850 2 LW,
4922471 HOUSING, Engi_e DECALi
5 B!342G !ASSEMBLY,_oter 32 DECAL, He_ Shield..................
6 B1897G iASSEMBLY,S_or 35 252_ i2 NU% 51i6.18 Hex
BEARING 37 1343681 DECALi Control P_nel
867451 I WASHER, SpecialFl_t. M8 58 84366A IASSEMBLY,C0r_trol BOx
922129 LOCk= NSP I ENGINE
1086307 HHNSi 5/16,24 x 3/4 SEHS 60 22531 2HHCSi 5/16,18 x 1,3/4'! .............
I I 47481 1 HHC& 5/16,24 x 10;625 62 93826 1 DECAL_ Star_I_s:rucUons
1292609 2MOUNT, Vibr_ti0_ 63 896068 iSHIELD,
1382857 56893 5 CRIMPTITE, 10,24x I/2
SCREW,M8. 1125X 2065772821 SWITCH; S_r_er
1566476 2CAIPSCREW, M6, 1.0x12ram 66 22287 2SCREW, I/4,20 x 3/4
....1692532 ......... IBRACKET, Muffler................ 67 22097 2LOCKWASHER, M6
17 22142 2 SCRE_ 5/16. 18X3/4 68 22127 2 NU% i14,20 H_
18 A7433 IMUFFLER 69 782891 BRACKET,S_arterSwitch
19902391 GASKET, Muffler 70 22473 WASHER. M6Flat
2081917! pINi R0!14ram_! 07183083! scREENi SparkAr_s_r
DECALi 961131 ASSY.i
!CARRIER, Rear
2674908 TAPTITE, M5-0.8 x 10 items Not Illustrated
27 66449L BOLT, Sr_t0r M6-] x !65ram 65787! Ba_ery Charge Cable
28 6579_ 2RECTIFIER, Battery charge [34369! Ge_er_or Owner 'sMagus!
29 66849C I TAPTITE, M5,0.8 X 30 A8927 1 EmgimeOwner!s M_nual
30 6702_ ! GROP1MET,Rubber BB3061 2Ofli 28 oz; ................................
31 84132 1 ASSEMBLY,Power Regulator 96113 1 Wirei Assembly S_r_er
32663861 ASSEMBLY,Brush Holder 22129 LOCk,shot M8
3366849 2 TAPTITE, M5.0.8 X 16 22145 2 Finisher M8
3_ B4871 !COVER,Bearing €_r!er _577 ! 2H_N_t M8_1i25
35227691 WASHER, Sh_k_proef I_t:#10 969231 Bakery TiedOWn
36 86494 ! SCREW, M6,!;0 X!6Wing %924 2J,Bel; M8,!;25
37 86292 9 HHCS;-#10 SelfDriller 969231 Battery Tray
:38 77:39_ NUT, FlangeLOCk"M6 !5453621 !Bakery Cable Positive
:39 8346_ GROMMET, Ta_k 15553621 ! Ba_er_ CableNegative
4037058 HHHSi h'16"!io X 5537806!!20Volt 30 AmP LoCkingpl_g
4180270! VALVE,T_nk 4343811201240 Vo!t 30 Amp Lockf_g
42 78299 1 BUSHING, Plastic Plug
43 B4363 !
44 81695 I TANK; Fuel7 Accessories Not
45 B92039 ISHIELD,
INSULATION_ 43630 1201240Volt 50 Amp Plug
/19

/Generac Pori;_ble Produc_s 7,500 EXL Generator
EXPLODED VIEW AND PARTS LIST -WHEEL KIT
/
12
1
/
_9
Item
I
2
3
4
5
6
7
8
9
10
II
12
13
Part#
B93393A
89742
93693A
87005
B89635
B93696
27007
42909
52858
22247
39253
22145
39287
QL7Description
IHANDLE
2 WHEEL
I AXLE
2 PIN, Rer_T_T_g
2 SPACER,Wheel
ILEG,Support
2 MOUNT, Vibration
2CAPSCREW, Hex Hd. M8 -1.25x 30
8NUT, Lock M8
2 WASHER, Wheel
2 CAPSCREW, Hex Hd. -M8 - 1.25x 20
2 WASHER, VTbra_TonM_.
AHHCS, M8 - 1.25x 45 GR 10.9
/2O