Generac Portable Products 7000EXL User manual

Owner’s Manual / Manuel de l'Utilisateur
Questions? Help is just a moment away!
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Call: Generac Generator Helpline / Appelez la ligne d'assistance de Generac Motor - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-portables.com or www.briggsandstratton.com
Model No. 1657-0 (7,000 Watt AC Generator) Manual No. 189702GS Revision 0 (10/12/2001)
Safety Rules / Règles de Sécurité . . . . . . . . . . . . . . . . . . . 2-3 / 20-21
Assembly / Assemblage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 / 22
Know Your Generator / Connaissez Votre Générateur . . . . . . 5 / 23
Operation / Opération . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 / 24-28
Product Specifications / Caractéristiques du Produit . . . . . . . 11 / 29
Maintenance / Entretien . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 / 29
Storage / Rangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 / 30
Troubleshooting / Dépannage . . . . . . . . . . . . . . . . . . . . . . . . 13 / 32
Schematic / Schéma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram / Circuit de Câblage . . . . . . . . . . . . . . . . . . . . . . 15
Replacement Parts / Pièces de Rechange . . . . . . . . . . . . . . . . . 16-19
Notes / Remarques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31, 33-34
Garantie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page
• Generator / Générateur
• Wheel kit / Ensemble de roulettes
• Storage cover / Couverture d'emmagasinage
• Battery / Batterie
• Battery charge cables / Câbles de charge de batterie
• Battery float charger / Chargeur de flotteur de batterie
• Locking 30 Amp plug / Prise de verrouillage 30 Ampères
• Two bottles of engine oil / Deux bouteilles d'huile moteur
• Three packets of fuel stabilizer / Trois paquets de stabilisateur
d'essence
• Owner's manual / Manuel de l'utilisateur
• Engine manual / Manuel du moteur
*If any parts are missing or damaged, call 1-800-270-1408.
*Si certaines pièces sont manquantes ou endommagées, appelez le
1-800-270-1408.
Parts Included* / Pièces Incluses* Table of Contents / Table des Matières

2
7000EXL Extended Life Generator
EQUIPMENT
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, appliances, tools and motor loads.
This manual contains information for a generator that
operates 120 and/or 240 Volt, single phase, 60 Hz devices
that require up to 7,000 watts (7.0 kW) of power that pull
up to 58.3 Amps at 120 Volts or 29.2 Amps at 240 Volts.
CAUTION! Do Not exceed the generator’s
wattage/amperage capacity.Add up the rated watts of all
devices you are connecting to generator receptacles at one
time.This total should not be greater than 7,000 watts. See
“Don’t Overload the Generator” on page 10.
The generator’s revolving field is driven at about 3,600 rpm
by a single-cylinder engine.
Every effort has been made to ensure that information in
this manual is accurate and current. However, Generac
reserves the right to change, alter or otherwise improve the
product and this document at any time without prior
notice.
CAUTION! Do Not tamper with engine
governed speed. High operating speeds are
dangerous and increase risk of personal injury or
damage to equipment.The generator supplies
correct rated frequency and voltage only when
running at proper governed speed. Incorrect
frequency and/or voltage can damage some
connected electrical loads. Operating at excessively
low speeds imposes a heavy load.When adequate
engine power is not available engine life may be
shortened.
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.
SAFETY RULES
This generator set was designed and manufactured for
specific applications. Do Not attempt to modify the unit or
use it for any application it was not designed for. If you have
any questions about your generator’s application, ask your
dealer 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 unsafe or 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.
WARNING! You must isolate the generator
from the electric utility using approved transfer
equipment 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 the unit is providing backup power, the
electric utility must be notified.
DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. If breathed in
sufficient concentrations, carbon monoxide
can cause unconsciousness or death. Operate
this equipment outdoors where adequate ventilation
is available.
The engine exhaust from this product contains
chemicals known to the State of California
to cause cancer, birth defects,
or other reproductive harm.
WARNING:
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.

7000EXL Extended Life Generator
3
• The generator produces a very powerful voltage that can
cause serious injury or death by electrocution. Never
touch bare wires or receptacles. Never permit a child or
any unqualified 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 a ground fault circuit interrupter (GFCI) in any damp
or highly conductive area (such as metal decking or steel
work).
•Never use worn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damage from 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 spilling gasoline 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 overfilled, fuel can overflow
onto a hot engine and cause a FIRE or an
EXPLOSION.
•Never store a generator with fuel in the tank where
gasoline vapors 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 adequate flow of cooling air for its
continued proper operation. Never operate the unit
inside any room or enclosure where the free flow of
cooling air into and out of the unit might be obstructed.
Allow at least 2 feet of clearance on all sides of generator,
even while operating unit outdoors, or you could damage
the unit.
•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 any electrical loads. Disconnect all electrical
loads before shutting down the generator.
•Do Not insert any object through cooling slots of the
engine.You could damage the unit or injure yourself.
•Never operate the generator:
in rain; in any enclosed compartment; when connected
electrical devices overheat; if electrical output is lost; if
engine or generator sparks; if flame or smoke is observed
while unit is running; if unit vibrates excessively.
GROUNDING THE
GENERATOR
The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of the
unit. For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure 1).
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth–driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, local codes
may vary widely. Consult with a local electrician for
grounding requirements in your area.
Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
Figure 1 — Grounding Wing Nut
Grounding
Wing Nut

4
7000EXL Extended Life Generator
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:
• Cut off tie wrap securing loose end of negative (black)
cable.
• Remove nut and washer on the negative battery
terminal.
• Slide the negative battery cable over the screw on the
negative terminal (Figure 2).
• Reattach washer and nut and tighten.
• Verify that the connections to the battery and generator
are correct and secure.
BEFORE STARTING THE
ENGINE
Add Oil
CAUTION! 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.
• Follow the oil grade recommendations and oil fill
instructions given in the engine owner’s manual.
NOTE: The generator’s revolving field rides on a
prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
Add Gasoline
WARNING! Never fill fuel tank indoors. Never
fill fuel tank when engine is running or hot.Allow
unit to cool for two minutes before refueling. 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.
• Slowly add unleaded regular gasoline to fuel tank. Be
careful not to overfill.Allow about 1/2" of tank space for
fuel expansion (Figure 3).
• 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 fuel can damage the fuel system of an engine while
in storage. Be sure to review the precautions given in
“Storage” on page 12.
Never use engine or carburetor cleaner products in the
fuel tank or permanent damage may occur.
Figure 2 — Negative Battery Connection
Positive battery cable
Screw
Washer
Nut
Negative
battery
cable
Figure 3 — Typical Fuel Expansion Space
1/2” Air
Space
Tank
Fuel

7000EXL Extended Life Generator
5
KNOWYOUR 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.
12 Volt DC,10 Amp Receptacle — Recharge a
discharged 12 Volt automotive type battery through this
receptacle.
120 Volt AC, 20 Amp Duplex Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, 20 Amp, 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.
Air Cleaner — Uses a dry type filter element and foam
pre–cleaner to limit the amount of dirt and dust sucked
into the engine.
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.
Grounding Wing Nut — Used for proper grounding of
unit.
Idle Control Switch — With this switch set to ON,
generator automatically reduces engine speed when no
load is connected and increases engine to proper speed
when load is applied. However, be sure switch is OFF when
starting engine.
Oil Fill Cap — Add oil to engine here.
Recoil starter — Used to start the engine manually.
Run/Stop Switch — Set this switch to "Run" before
starting engine. Set switch to "Stop" to switch OFF engine.
Spark Arrester Muffler — Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.
Start Button — When pressed, cranks engine to start.
120 Volt AC, 20 Amp
Duplex Receptacle
Fuel Tank
Idle Control Switch
Choke Lever
Start Button
12 Volt DC, 10 Amp
Receptacle
Run/Stop Switch
120 Volt AC, 30 Amp
Receptacle
Circuit Breakers (AC)
120/240 Volt AC,
30 Amp Receptacle
Spark Arrester Muffler
Air Cleaner
Grounding Wing Nut
Oil Fill Cap
Recoil Starter

6
7000EXL Extended Life Generator
OPERATING THE
GENERATOR
CAUTION! Never start or stop unit with
electrical loads connected AND with the connected
devices turned ON.
IMPORTANT: Always unplug the battery float charger
before starting the generator.
Starting the Engine
Disconnect all electrical loads from the generator. Follow
these start instruction steps in numerical order:
1. Turn the fuel valve to the “On” position (Figure 4).
2. Make sure the Idle Control switch is in “Off” position
(Figure 5).
3. Set the Run/Stop switch to “Run” position (Figure 6).
4. Place the choke lever in the “Full” choke position
(Figure 7).
5A. For electric starting, press start switch on
generator cradle.To prolong the life of the starter
components, press the starter button for no more
than 15 seconds, and pause for 30 seconds.
5B. For manual starting, grasp the recoil handle and pull
slowly until slight resistance is felt.Then pull rapidly
one time only to start engine.
• If engine starts, proceed to step 7.
• If engine fails to start, proceed to step 6.
6. Move the choke lever to “Half” choke position, and
press start button or pull recoil handle twice.
• If engine fails to start, repeat steps 4 thru 6.
7. Move choke lever to “Run” position. If engine falters,
move choke lever to “Half” choke position until the
engine runs smoothly and then to “Run” position.
NOTE: If engine still fails to start after 3 pulls, check for
proper oil level in crankcase.This unit is equipped with a
Low Oil Shutdown System. See engine manual.
Refer to the engine owner’s manual for complete
starting instructions.
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 240 Volt 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 the Generator” on page 10.
Figure 4 — Fuel Shut-offValve
Figure 5 — Idle Control Switch
Figure 6 — Run/Stop Switch
Figure 7 — Choke Positions

7000EXL Extended Life Generator
7
Stopping the Engine
• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with electrical
devices plugged in and turned on.
• Put the idle control switch in the “Off” position.
• Let engine run at no–load for 30 seconds to stabilize the
internal temperatures of engine and generator.
• Move run/stop switch to “Stop”.
• Close the fuel shut–off valve.
Operating Automatic 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 electrical load is
removed, the engine will run at a reduced speed. With
the switch off, the engine will run at the normal high
engine speed. Always have the switch off when
starting and stopping the engine.
Charging a Battery
WARNING! Storage batteries give off explosive
hydrogen gas while recharging.An explosive mixture
will remain around the battery for a long time after
it has been charged.The slightest spark can ignite
the hydrogen and cause an explosion, resulting in
blindness or other serious injury.
WARNING! Do Not permit smoking, open
flame, sparks or any other source of heat around a
battery.Wear protective goggles, rubber apron and
rubber gloves when working around a battery.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe burns. If
spill occurs flush area with clear water immediately.
Your generator has the capability of recharging a
discharged 12 Volt automotive or utility style storage
battery. Do Not use the unit to charge any 6Volt
batteries. Do Not use the unit to crank an engine having a
discharged battery.
To recharge 12Volt batteries, proceed as follows:
• Check fluid level in all battery cells. If necessary, add
ONLY distilled water to cover separators in battery
cells. Do Not use tap water.
• If the battery is equipped with vent caps, make sure they
are installed and are tight.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to panel
receptacle identified by the words “12-VOLTS D.C.”.
• Connect battery charge cable clamp with red handle to
the positive (+) battery terminal (Figure 8).
• Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 8).
• Start engine. Let the engine run while battery recharges.
• When battery has charged, shut down engine.
NOTE: Use an automotive hydrometer to test battery
state of charge and condition. Follow the hydrometer
manufacturer’s instructions carefully. Generally, a battery is
considered to be at 100% state of charge when specific
gravity of its fluid (as measured by hydrometer) is 1.260 or
higher.
COLD WEATHER
OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icing of the carburetor and/or the crankcase
breather system.
Build a structure that will enclose three sides and the 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 9.
Figure 8 — Battery Connections

8
7000EXL Extended Life Generator
• Ensure a minimum of two feet clearance between open
side of box and nearest object.
• Face exposed end away from wind and elements.
• Enclosure should hold enough heat created by the
generator to prevent problems.
CAUTION!Neverrun unit indoors. Do Not
enclose generator any more than shown. Remove
generator from shelter when temperature is above
40°F [4°C].
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.
• Plug the charger into the unit’s “Battery Float Charger”
jack, which is located on the starter switch (Figure 10).
Plug battery charger into a 120 Volt AC wall receptacle.
• Unplug the charger from the unit and the wall outlet
when generator is being started and while it is in
operation.
• Keep this charger plugged in when generator is not in
use to prolong battery life.The charger has a built in
float equalizer and will not overcharge the battery, even
when plugged in for an extended period of time.
IMPORTANT: See “Battery Maintenance” on page 11 for
additional information.
RECEPTACLES
120 Volt AC, 20 Amp Duplex
Receptacle
Each of these outlets is protected against overload by
20 Amp push-to-reset type circuit breakers (Figure 12).
Use each outlet to operate 120 Volt, 60 Hz, single phase
loads requiring 2,400 (2.4 kW) watts at 20 Amps of
current.
Figure 12 — 120Volt AC, 20 Amp Duplex Receptacle
Figure 10 — Battery Charger Jack
Figure 9 — Permanent Cold Weather Shelter
Wind

7000EXL Extended Life Generator
9
120/240 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L14-30 plug with this receptacle. Connect a
4-wire cord set rated for 250 Volts at 30 Amps (or greater)
(Figure 13).You can use the same 4-wire cord if you plan to
run a 120 Volt load.
This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts of power at
20 Amps for 120 Volts; 7,000 watts of power (7.0 kW) at
29.2 Amps for 240 Volts.The outlet is protected by a
30 Amp push-to-reset circuit breaker.
CAUTION! Although this outlet is rated for
240 Volt 30 Amp (up to 7.200 watts), the generator
is only rated for 7,000 watts. Powering loads that
exceed the wattage/amperage capacity of the
generator can damage it or cause serious injuries.
240 Volt loads powered through this outlet should
not exceed 29.2 Amps of current draw.
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L5-30 plug with this receptacle. Connect a
3-wire cord set rated for 125 Volts AC at 30 Amps to the
plug (Figure 14).
Use this receptacle to operate 120Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts (3.6 kW) of power
at 30 Amps.The outlet is protected by a 30 Amp
push-to-reset circuit breaker.
12 Volt DC, 10 Amp Receptacle
This connector (identified by the legend “12-VOLT D.C.”)
supplies 12 Volts DC at 10 Amps through battery charging
cables for recharging 12 Volt batteries (Figure 15). See
“Charging a Battery” on page 7.
Figure 14 — 120 Volt AC, 30 Amp, Locking Receptacle
3-Wire Cord Set
Neutral
120V
Hot
Ground (Green)
NEMA L5-30
Figure 15 — 12Volt DC, 10 Amp Receptacle
Figure 13 — 120/240 Volt AC, 30 Amp Receptacle
4-Wire Cord Set
240V
120V 120V W (Neutral)
X (Hot)
Y (Hot)
NEMA L14-30 Ground (Green)

10
7000EXL Extended Life Generator
DON'T OVERLOADYOUR
GENERATOR
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. Select the items you will power at the same time.
2. Total the rated (running) watts of these items.This is
the amount of power your generator must produce to
keep your items running. See Figure 16.
3. Estimate how many surge (starting) watts you will
need. Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliances such as a circular saw or refrigerator.
Because not all motors start at the same time, total
surge watts can be estimated by adding only the
item(s) with the highest additional surge watts to the
total rated watts from step 2.
Example:
Total Rated (Running) Watts = 3075
Highest Additional Surge Watts = 1800
Total Generator Output Required = 4875
Power Management
To prolong the life of your generator and attached devices,
it is important to take care when adding electrical loads to
your generator.There should be nothing connected to the
generator outlets before starting it's engine.The correct
and safe way to manage generator power is to sequentially
add loads as follows:
1. With nothing connected to the generator, start the
engine as described in this manual.
2. Plug in and turn on the first load, preferably the largest
load you have.
3. Permit the generator output to stabilize (engine runs
smoothly and attached device operates properly.
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.
*Wattages listed are approximate only. Check tool or
appliance for actual wattage.
Tool or Appliance Rated (Running)
Watts Additional Surge (Starting) Watts
Window Air
Conditioner 1200 1800
Refrigerator 800 1600
Deep Freezer 500 500
Television 500 -
Light (75 Watts) 75 -
3075 Total
Running Watts 1800 Highest Surge Watts
Tool or Appliance Rated* (Running)
Watts
Additional
Surge
(Starting)
Watts
Essentials
Light Bulb - 75 watt 75 -
Deep Freezer 500 500
Sump Pump 800 1200
Refrigerator/Freezer - 18 Cu. Ft. 800 1600
Water Well Pump - 1/3 HP 1000 2000
Heating/Cooling
Window AC - 10,000 BTU 1200 1800
Window Fan 300 600
Furnace Fan Blower - 1/2 HP 800 1300
Kitchen
Microwave Oven - 1000 Watt 1000 -
Coffee Maker 1500 -
Electric Stove - Single Element 1500 -
Hot Plate 2500 -
Family Room
DVD/CD Player 100 -
VCR 100 -
Stereo Receiver 450 -
Color Television - 27” 500 -
Personal Computer w/17” monitor 800 -
Other
Security System 180 -
AM/FM Clock Radio 300 -
Garage Door Opener - 1/2 HP 480 520
Electric Water Heater - 40 Gallon 4000 -
DIY/Job Site
Quartz Halogen Work Light 1000 -
Airless Sprayer - 1/3 HP 600 1200
Reciprocating Saw 960 960
Electric Drill - 1/2 HP 1000 1000
Circular Saw - 7 1/4” 1500 1500
Miter Saw - 10” 1800 1800
Table Planer - 6” 1800 1800
Table Saw/Radial Arm Saw - 10” 2000 2000
Air Compressor - 1-1/2 HP 2500 2500
Figure 16 - Wattage Reference Chart

7000EXL Extended Life Generator
11
SPECIFICATIONS
Maximum Surge Watts . . . . . . . . . . . . . . 12,250 Watts
Continuous Wattage Capacity . . . . . . . . . . 7,000 Watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Rated Maximum Continuous Load Current
At 120 Volts . . . . . . . . . . . . . . . . . . . . . . 58.3 Amps
At 240 Volts . . . . . . . . . . . . . . . . . . . . . . 29.2 Amps
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-phase
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . 60 Hertz
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . 7 U.S. gallons
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . 240 lbs.
GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on a timely
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. Never operate a
damaged or defective generator.
NOTE: The proper tire inflation operating range should be
15-40 PSI.
Engine Maintenance
See engine owner’s manual for instructions.
CAUTION! Avoid prolonged or repeated skin
contact with used motor oil. Used motor oil has
been shown to cause skin cancer in certain
laboratory animals.Thoroughly wash exposed areas
with soap and water.
KEEP OUT OF REACH OF CHILDREN. DON'T
POLLUTE. CONSERVE RESOURCES. RETURN
USED OIL TO COLLECTION CENTERS.
Generator Maintenance
Generator maintenance consists of keeping the unit clean
and dry. Operate and store the unit in a clean dry
environment where it will not be exposed to excessive
dust, dirt, moisture or any corrosive vapors. Cooling air
slots in the generator must not become clogged with
snow, leaves or any other foreign material.
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.
Battery Maintenance
Other than float charging, described elsewhere, no
maintenance is required for the battery. Keep the battery
and terminals clean and dry.
IMPORTANT: Battery charging should be performed in a
dry location, such as inside a garage.
To Clean the Generator
• Use a damp cloth to wipe exterior surfaces clean.
• A soft bristle brush may be used to loosen caked on dirt
or oil.
• A vacuum cleaner may be used to pick up loose dirt.
• Low pressure air (not to exceed 25 psi) may be used to
blow away dirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.

12
7000EXL Extended Life Generator
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.
Generator Storage
• Clean the generator as outlined in “To Clean the
Generator.”
• Check that cooling air slots and openings on generator
are open and unobstructed.
CAUTION! Storage covers can be flammable.
Do Not place a storage cover over a hot
generator. Let the unit cool for a sufficient time
before placing the cover on the unit.
Engine Storage
See engine owner’s manual for instructions.
Other Storage Tips
• To prevent gum from forming in fuel system or on
essential carburetor parts, empty all three supplied fuel
stabilizer containers into fuel tank and fill with fresh
gasoline. Run the unit for several minutes to circulate the
additive through the carburetor.The unit and fuel can
then be stored for up to 24 months.Additional fuel
stabilizer can be purchased locally.
•Do Not store gasoline from one season to another
unless it has been treated as described above.
• Replace fuel container if it starts to rust. Rust and/or dirt
in fuel can cause problems if it's used with this unit.
• Store in clean and dry area.

7000EXL Extended Life Generator
13
TROUBLESHOOTING
Problem
Cause
Correction
Engine is running, but no
AC output is available.
1. One of the circuit breakers is open.
2. Fault in generator.
3. Poor connection or defective cord set.
4. Connected device is bad.
1. Reset circuit breaker.
2. Contact Generac service facility.
3. Check and repair.
4. Connect another device that is in
good condition.
Engine runs good at no-
load but “bogs” down"
when loads are connected.
1. Short circuit in a connected load.
2. Engine speed is too slow.
3. Generator is overloaded.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. Contact Generac Power Systems
service facility.
3. See “Don't Overload the Generator”
on page 10.
4. Contact Generac service facility.
Engine will not start; or
starts and runs rough.
1. Run/Stop Switch set to “STOP”.
2. Fuel shutoff valve in the “Closed”
position.
3. Dirty air cleaner.
4. Out of gasoline.
5. Stale gasoline.
6. Spark plug wire not connected to
spark plug.
7. Bad spark plug.
8. Water in gasoline.
9. Overchoking.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
13. Failed battery.
1. Set switch to “RUN”.
2. Turn the fuel shutoff valve to the
“Open” position.
3. Clean or replace air cleaner.
4. Fill fuel tank.
5. Drain gas tank; fill with fresh fuel.
6. Connect wire to spark plug.
7. Replace spark plug.
8. Drain gas tank; fill with fresh fuel.
9. Open choke fully and crank engine.
10. Contact Generac Power Systems
service facility.
11. Contact Generac Power Systems
service facility.
12. Contact Generac Power Systems
service facility.
13. Replace battery.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
1. Fill fuel tank.
2. Fill crankcase to proper level.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
1. See “Don't Overload the Generator”
on page 10.
2. Replace air filter.
Engine “hunts” or falters.
1. Choke is opened too soon.
2. Carburetor is running too rich or too
lean.
1. Move choke to halfway position until
engine runs smoothly.
2. Contact Generac Power Systems
service facility.

14
7000EXL Extended Life Generator
SCHEMATIC

7000EXL Extended Life Generator
15
WIRING DIAGRAM

16
7000EXL Extended Life Generator
EXPLODED VIEW – ALTERNATOR

7000EXL Extended Life Generator
17
EXPLODED VIEW – FRAME

18
7000EXL Extended Life Generator
Item Part # Qty Description
1 A187024GS 1 CRADLE
2 J189176GS 1 SHIELD, Heat
3 94479GS 1 DECAL, Danger
4 92665GS 1 INSULATION, #2-1/4" Thick
5 B1695GS 1 TANK, Fuel
6 B4363GS 1 CAP, with Gauge, Fuel
7 85000GS 1 CLIP, Insulation
8 94480GS 1 DECAL, Start Instructions
9 78831BGS 4 HHMS, M6-1.0 x 60, SEMS
10 83465GS 4 GROMMET,Tank
11 77395GS 8 NUT, Flange Lock - M6
12 80270GS 1 VALVE,Tank
13 78299GS 1 BUSHING,Tank
14 B2153GS 9 SCREW, 12-14 x 7/8, Self Driller
15 43116GS 4 HHCS, M6 - 1.0 x 12
16 51731GS 2 HHCS, M8 - 1.25 x 50
17 B4135GS 2 PIN, with Lanyard
18 187104GS 4 WASHER, Nylon
19 49820GS 2 NUT, M8 Nylok
20 83083GS 1 SCREEN, Spark Arrester
21 86307GS 4 HHMS, 5/16-24 x 3/4" SEMS
22 92247GS 1 HOUSING, Engine Adapter
23 A92531GS 1 SUPPORT, Engine
24 189160GS 12 NUT, 5/16-18 Flange Serrated
25 22129GS 2 WASHER, Lock - M8
26 82857GS 4 MOUNT,Vibration
27 22531GS 2 HHCS, 5/16-18 x 1-3/4"
28 92609GS 2 MOUNT,Vibration
29 22142GS 2 SCREW, 5/16 - 18 x 3/4"
30 A7433GS 1 MUFFLER
31 A92731GS 1 SUPPORT, Engine & Muffler
32 90239GS 1 GASKET, Muffler
33 B1342GGS 1 ASSEMBLY, Rotor
34 65791GS 1 BEARING
35 96796GS 1 WASHER, Special Flat - M8
36 47481GS 1 HHCS, 5/16-24 x 10-5/8
37 B1897AGS 1 ASSEMBLY, Stator
38 20566GS 1 DECAL, 1-800
39 40976GS 2 SCREW, M8 - 1.25 x 20
40 92532GS 1 BRACKET, Muffler
41 66476GS 2 CAPSCREW, M6 - 1.0 x 12mm
42 189779GS 1 DECAL, Control Panel
43 92630GS 1 ASSEMBLY, Control Box
44 J96068GS 1 SHIELD, Heat
45 14353621GS 1 WIRE, Ground
46 26850GS 2 LW, EXT, Shakeproof M6
47 BB3061GS 2 BOTTLE, Oil
48 81917GS 1 PIN, Roll 4mm x 10
49 76247GS 1 DECAL, French Neutral Ground
50 186798GS 2 DECAL, Heat Shield
51 56893GS 5 CRIMPTITE, 10-24 x 1/2"
52 84132GS 1 ASSEMBLY, Power Regulator
Item Part # Qty Description
53 67022GS 1 GROMMET, Rubber
54 SRV66825DGS 1 CARRIER, Rear Bearing
55 86494GS 1 SCREW, M6-1.0 x 16 Wing
56 23762GS 3 WASHER, Shakeproof #10
57 66386GS 1 ASSEMBLY, Brush Holder
58 66849GS 2 TAPTITE, M5-0.8 x 16
59 B4871GS 1 COVER, Bearing Carrier
60 74908GS 4 TAPTITE, M5-0.8 x 10
61 B4605GS 2 GRIP
62 66849CGS 1 TAPTITE, M5-0.8 x 30
63 65795GS 2 RECTIFIER, Battery Charge
64 66449LGS 4 BOLT, Stator M6-1 x 190mm
65 22145GS 4 WASHER, Flat, 5/16 - M8
66 22097GS 5 LOCKWASHER, 1/4" - M6
67 189702GS 1 MANUAL, Operators
68 BB5586GS 2 HANDLE
69 52858GS 2 NUT, Lock M8
70 189956GS 1 SUPPORT,Wheel Kit, Riveted
73 93693GGS 1 AXLE
74 B4966GS 2 WHEEL
75 22247GS 2 WASHER,Wheel
76 87005AGS 2 PIN, Retaining
77 189302BGS 1 WIRE ASM, #16
78 77282GS 1 SWITCH, Starter
79 188987GS 1 BRACKET, Switch
80 188989GS 1 ASM, Jack, DC
81 22287GS 2 HHCS, 1/4 - 20 x 3/4"
82 22097GS 4 LOCKWASHER, 1/4 - M6
83 22127GS 5 NUT, 1/4-20
84 J186704GS 1 TRAY, Battery
85 B4489GS 1 BATTERY, 12V 18 AH
86 189302CGS 1 WIRE ASM, #13
87 185939HGS 1 WIRE ASM, #55
88 73054GS 1 DECAL, Fuel Shut-Off
89 77816GS 2 DECAL, Hot Muffler
90 39253GS 2 HHCS, M8 - 1.25 x 20
91 A8927GS 1 MANUAL, Engine
92 52618GS 2 HHCS, M5 - 0.8 x 12
93 23897GS 2 WASHER, M5 Flat
94 52856GS 2 NUT, M5 Flange Hex
96 96113GS 1 WIRE ASM, #13
97 58359GS 1 LUG, 5/16 #22/18 I-S
98 189198GS 1 DECAL, Instruction, ES
99 B4177GS 1 CHARGE, Battery Float
100 189208GS 3 FUEL STABILIZER, 1oz Tube
101 65787GS 1 CABLE, Battery Charge
102 37806GS 1 PLUG, 120V/30Amp
103 B4767GS 1 COVER, Storage
104 74728GS 1 DECAL, English Neutral Ground
105 B4986GS 1 DECAL, Ground
900 NSP 1 ENGINE
PARTS LIST – ALTERNATOR & FRAME

7000EXL Extended Life Generator
19
EXPLODED VIEW AND PARTS LIST – CONTROL PANEL
Item Part # Qty Description
1 A92070GS 1 PANEL, Control
2 23897GS 4 FLAT WASHER, #10 M5
3 49226GS 4 LOCK WASHER, M5
4 91526GS 4 SCREW, M5-0.8 x 12mm
5 82538GS 1 SWITCH, Idle Control
6 82881GS 4 LOCK WASHER, 7/16"
7 43181GS 4 SCREW, M3 - 0.5 x 10mm
8 43182GS 4 LOCK WASHER, M3
9 90418GS 1 OUTLET, 12V
10 75207AGS 2 CIRCUIT BREAKER, 30A
11 75207GS 2 CIRCUIT BREAKER, 20A
12 23365GS 6 WASHER, #8 Shakeproof
13 68868GS 1 OUTLET, 120 Volt, 30 Amp
Locking
Item Part # Qty Description
14 43437GS 1 OUTLET, 120V/240V, 30A
Locking
15 68759GS 1 OUTLET, 120V, 20A Duplex
16 43180GS 6 FLAT WASHER, M4
17 22264GS 6 LOCK WASHER, #8 M4
18 51715GS 6 NUT, M4-0.7 Hex
19 64526GS 8 SCREW, #6-32 x 3/8"
20 83970GS 1 BOARD, System Control
21 64525GS 4 STAND-OFF, 3/4" Hex
22 87962GS 1 CIRCUIT BREAKER. 12V, 10A
(auto)
23 84335GS 1 ASSEMBLY,Wire Harness
24 84134GS 1 GROMMET, Rubber Conn.
25 B92069GS 1 BOX, Control Panel
26 84028GS 1 TRANSFORMER, Idle Control

7000EXL Générateur Qui Dure Longtemps
20
DESCRIPTION DE L ÉQUIPEMENT
Ce générateur est un générateur entraîné par un moteur à champ
magnétique rotatif produisant du courant alternatif (c.a.). Il a été
conçu pour fournir du courant électrique pour faire marcher des
charges compatibles d'éclairage, d'appareils ménagers, d'outil et de
moteur.
Ce manuel contient des informations sur un générateur qui fait
marcher des appareils de 120 et/ou 240 Volts, monophasés,
60 Hertz nécessitant jusqu'à 7,000 watts (7,0 kW) de puissance
qui tirent jusqu'à 58,3 Ampères à 120 Volts ou 29,2 Ampères à
240 Volts.
ATTENTION! Ne Pas dépasser la capacité en watts ou en
ampères du générateur.Ajoutez les watts de tous les appareils que
vous branchez aux prises du générateur en même temps. Ce total
ne doit pas être supérieur à 7,000 watts pour ce générateur.Voir
"Ne Pas Surcharger le Générateur" sur la page 28 pour
l'information spécifique.
Le champ tournant du générateur est entraîné à 3600 T/M par un
moteur monocylindrique.
Tout a été mis en oeuvre pour que les informations contenues
dans ce manuel soient exactes et à jour. Cependant, Generac se
réserve le droit de changer, d'altérer ou d'améliorer le produit à
n'importe quel moment sans avis préalable.
ATTENTION! Ne Pas toucher à la vitesse préréglée
du moteur. Des vitesses élevées d'opération sont
dangereuses et augmentent le risque de blessures
personnelles ou d'endommagement de l'équipement. Le
générateur ne fournit une fréquence et un voltage
corrects que lorsque le moteur tourne à la vitesse
préréglée correcte. Une fréquence et/ou un voltage
incorrect peut endommager certaines charges électriques
branchées. Le fait de faire marcher l'appareil à des vitesses
plus lentes que celle qui est prévue impose une lourde
charge au moteur, lorsque la puissance adéquate du
moteur n'est pas disponible et cela peut raccourcir la
durée de vie du moteur.
Le Système de contrôle de l'émission du générateur est garanti
pour des normes établies par L'Agence de protection de
l'environnement. Pour des informations sur la garantie, se reporter
au manuel du moteur.
RÈGLES DE SÉCURITÉ
Ce générateur a été conçu et fabriqué pour des applications
particulières. Ne Pas essayer de modifier l'appareil ni de l'utiliser
pour une application pour laquelle il n'a pas été conçu. Si vous
avez des questions au sujet de l'application de votre générateur,
posez-les à votre Concessionnaire/ Distributeur ou consultez
l'usine.
Le fabricant n'a pas pu prévoir toutes les circonstances qui
peuvent provoquer un danger. Pour cette raison les
avertissements qui se trouvent dans le manuel et ceux qui sont
collés sur la machine ne sont pas exhaustifs. Si vous avez
l'intention de manipuler, de faire marcher ou de réparer cet
appareil selon des procédures ou des méthodes qui ne sont pas
spécialement recommandées par le fabricant, il faut vous assurer
d'abord que ces procédures et ces méthodes ne risquent pas de
rendre l'appareil dangereux ou posent un danger à vous ou aux
autres.
Lisez avec soin ce manuel et familiarisez-vous avec votre
générateur. Connaissez ses applications, ses limitations et
les dangers qu'il implique.
AVERTISSEMENT! Vous devez isoler le générateur
de l'installation électrique avec un équipement de transfert
homologué, au cas où vous utiliseriez cette unité pour une
alimentation de secours. Le manquement à isoler le
générateur de l'installation électrique, risque de
provoquer des blessures ou même d'être fatal pour
les ouvriers et de causer des dommages au
générateur dus à un backfeed d'énergie électrique. Les
services publics d'électricité doivent être avisés si l'unité
produit de l'énergie de secours.
DANGER! Le générateur épuise des gaz
contiennent le gaz de monoxide de carbone
MORTEL. Si a aspiré suffisant concentrations,
carbone peut causer unconsciousness ou mort.
Ceci opérer l'équipement extérieur où ventilation suffisant
est disponible.
L’échappement du moteur de ce produit contient des produits
chimiques que l’État de Californie considère comme causant le
cancer, des déformations à la naissance ou d’autres dangers
concernant la reproduction.
AVERTISSEMENT
Ceci est la sûreté le symbole vif. Il est utilisé à l'alerte vous aux dangers de blessure personnels potentiels.
Obéir tous messages de sûreté qui suivent ce symbole à évite la blessure ou la mort possibles.