Generac Power Systems 7000exl User manual

Portable Generator Owner’s Manual
7000EXL
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.
Model No. 1470-0 (7,000 Watt AC Generator) Manual No. 186744 Revision 0 (06/13/2001)
Visit our Generac website: www.generac-portables.com
Problems?
Questions?
Before taking your unit
back to the store,
call the generator
helpline at
1-800-270-1408
M-F 8-5 CT

Generac Portable Products 7000EXL Extended Life Generator
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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 11.
The generator’s revolving field is driven at about 3600 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.
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.
DANGER! 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 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 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.
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
WARNING:

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• 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

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Your generator requires attachment of the negative battery
cable and is ready for use after it has been properly
serviced with the recommended oil and fuel.
IMPORTANT: Any attempt to run the unit before it has
been serviced with the recommended oil will result in an
engine failure.
Check that the following is included with your unit. If any
parts are missing or damaged, call the generator helpline at
1-800-270-1408.
• Battery charge cables
• Battery float charger
• Extenda Panel™ cord
• Generator and engine owner’s manuals
• Locking 30 Amp plug
• Three packets of fuel stabilizer
• Two bottles of engine oil
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 tight and secure.
Figure 2 — Negative Battery Connection
Positive battery cable
Screw
Negative
battery
cable
Washer
Nut

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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. 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 gas can damage the fuel system of an engine while in
storage. Be sure to review the precautions given in
“Storage” on page 13.
Never use engine or carburetor cleaner products in the
fuel tank or permanent damage may occur.
Figure 3 — Typical Fuel Expansion Space

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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.
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.
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.
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

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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. Use the
following start instruction steps by 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
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.
Figure 5 — Idle Control Switch
Figure 4 — FuelValve
Fuel Valve is shown
in the On position
Figure 6 — Run/Stop Switch
Figure 7 — Choke Positions

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•DO NOT OVERLOAD THE GENERATOR. Add up
the rated watts (or amps) of all loads to be connected at
one time.This total should not be greater than the rated
wattage/amperage capacity of the generator. See “Don’t
Overload the Generator” on page 11.
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.
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 9).
Plug battery charger into a 120 Volt AC wall receptacle.
Red
Black
Figure 8 — Battery Charge Cable Connection

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• 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 12 for
additional information.
EXTENDA PANEL™
The generator is equipped with a 25’ Extenda Panel™
device designed for a 240Volt, 30 Amp grounded neutral
circuit (Figure 10).The Extenda Panel™ provides a
convenient supply of emergency power into your dwelling
so that your generator can be operated safely outside.The
cord/outlets may also be used as a heavy duty extension
cord.
The maximum load on each outlet is 20 Amps.The
maximum total load on both yellow wire outlets or black
wire outlets is 30 Amps.
NOTE: Follow all safety precautions when connecting any
extension cord or device to the generator.
RECEPTACLES
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 Volt AC loads at 30 Amps (or
greater) (Figure 11).You can use the same 4-wire cord if
you plan to run a 120Volt load.
This receptacle powers 120/240Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts of power (3.6 kW)
at 30 Amps for 120 Volts OR 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 states it has a
240Volt 30 Amp rating (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.
Figure 9 — Battery Charger Jack
Figure 10 — Extenda Panel™
Figure 11 — 120/240 Volt AC, 30 Amp Receptacle

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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 Volt AC loads at 30 Amps to
the plug (Figure 12).
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.
120 Volt AC, 20 Amp, Duplex
Receptacle
Each receptacle (Figure 13) is protected against overload by
a 20 Amp push–to–reset circuit breaker.
Use each receptacle to operate 120Volt AC, single–phase,
60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)
at 20 Amps of current. Use cord sets that are rated for
125 Volt AC loads at 20 Amps (or greater).
12 Volt DC, 10 Amp Receptacle
This receptacle allows you to recharge a 12 Volt
automotive or utility style storage battery with the battery
charge cables provided (Figure 14).This receptacle can not
recharge 6Volt batteries and can not be used to crank an
engine having a discharged battery. See the section
“Charging a Battery” (page 8) before attempting to
recharge a battery.
Figure 13 — 120Volt AC, 20 Amp Receptacles
Figure 12 — 120Volt, 30 Amp Receptacle
Figure 14 — 12Volt DC, 10 Amp Receptacle

Generac Portable Products 7000EXL Extended Life Generator
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DON’T OVERLOAD THE
GENERATOR
Overloading a generator in excess of its rated wattage
capacity can result in damage to the generator and/or
connected electrical devices. Observe the following, to
prevent overloading the unit:
• Add up the total wattage of all electrical devices to be
connected at one time.This total should NOT be greater
than the generator’s wattage capacity.
• If the appliance, tool or motor does not give wattage,
multiply 120Volts times ampere rating to determine
watts (volts x amps = watts).
• The rated wattage of lights can be taken from wattage
listed on the light bulbs.The rated wattage of tools,
appliances and motors can usually be found on a data
plate or decal affixed to the device. Use Figure 15 below
as a general reference.
• Some electric motors, such as induction types, require
about three times more watts of power for starting than
for running.This surge of power lasts for only a few
seconds when starting such motors. Be sure you allow
for this high starting wattage when selecting electrical
devices to connect to your generator. First figure the
watts needed to start the largest motor.Add to that
figure the running watts of all other connected loads.
Recreational/Home Uses
Tool/Appliance....................................................Watts
AM/FM clock radio ....................................................................50
Light bulb....................................................................................100
Fan................................................................................................200
20" color TV..............................................................................400
*Deep freezer ...........................................................................500
Personal computer and 15" monitor...................................800
*1/3 hp furnace fan blower....................................................800
Microwave oven........................................................................800
*18 cu ft refrigerator...............................................................800
Sump pump..............................................................................1000
Electric skillet..........................................................................1250
*½ hp water well pump.......................................................1400
*12,000 Btu window air conditioner ................................1400
Space heater............................................................................1800
Electric water heater ............................................................4000
Professional/Contractor Uses
Tool/Appliance....................................................Watts
*1/3 hp airless sprayer ............................................................600
3/8" hammer drill .....................................................................600
Variable speed Sawzall® .........................................................960
½" power drill ........................................................................1000
Quartz-halogen work light ..................................................1000
Belt sander...............................................................................1200
7 ¼" circular saw...................................................................1500
7 ¼" worm drive saw...........................................................1600
*1½ hp air compressor........................................................1800
*10" power miter saw...........................................................1800
6" bench grinder.....................................................................1800
*6" table planer.......................................................................1800
*10" table/radial arm saw.....................................................2000
Wire feed welder...................................................................2400
* allow 3 times listed watts for starting this device
Figure 15 — Wattage Reference Guide

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SPECIFICATIONS
Maximum Surge Watts . . . . . . . . . . . . . . . .12,250 watts
Continuous Wattage Capacity . . . . . . . . . . .7,000 watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0
Rated Maximum Continuous AC 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.
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.

Generac Portable Products 7000EXL Extended Life Generator
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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 gasoline can if it starts to rust. Rust and/or dirt
in gasoline can cause problems when that fuel is used
with this unit.
• Store in clean and dry area.

Generac Portable Products 7000EXL Extended Life Generator
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NOTES

Generac Portable Products 7000EXL Extended Life Generator
15
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 service facility.
3. See “Don't Overload the Generator”
on page 12.
4. Contact Generac service facility.
Engine will not start; or
starts and runs rough.
1. Run/Stop Switch set to “STOP”.
2. Dirty air cleaner.
3. Out of gasoline.
4. Stale gasoline.
5. Spark plug wire not connected to
spark plug.
6. Bad spark plug.
7. Water in gasoline.
8. Overchoking.
9. Excessively rich fuel mixture.
10. Intake valve stuck open or closed.
11. Engine has lost compression.
12. Failed battery.
1. Set switch to “RUN”.
2. Clean or replace air cleaner.
3. Fill fuel tank.
4. Drain gas tank; fill with fresh fuel.
5. Connect wire to spark plug.
6. Replace spark plug.
7. Drain gas tank; fill with fresh fuel.
8. Open choke fully and crank engine.
9. Contact Generac service facility.
10. Contact Generac service facility.
11. Contact Generac service facility.
12. 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 12.
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 service facility.

Generac Portable Products 7000EXL Extended Life Generator
16
SCHEMATIC

Generac Portable Products 7000EXL Extended Life Generator
17
WIRING DIAGRAM

Generac Portable Products 7000EXL Extended Life Generator
18
EXPLODED VIEW – ALTERNATOR

Generac Portable Products 7000EXL Extended Life Generator
19
EXPLODED VIEW – FRAME

Generac Portable Products 7000EXL Extended Life Generator
20
PARTS LIST – ALTERNATOR & FRAME
Item Part # Qty Description
1 A187024 1 CRADLE
2 J189176 1 SHIELD, Heat
3 92982 1 DECAL, Danger
4 92665 1 INSULATION, #2-1/4" Thick
5 B1998 1 TANK, Fuel (Incls Item 12 & 13)
6 B4363 1 CAP, with Gauge, Fuel
7 85000 1 CLIP, Insulation
8 93826 1 DECAL, Start Instructions
9 78831B 4 HHMS, M6-1.0 x 60, SEMS
10 83465 4 GROMMET,Tank
11 77395 8 NUT, Flange Lock - M6
12 80270 1 VALVE,Tank
13 78299 1 BUSHING,Tank
14 B2153 9 SCREW, 12-14 x 7/8, Self Driller
15 43116 4 HHCS, M6 - 1.0 x 12
16 51731 2 HHCS, M8 - 1.25 x 50
17 B4135 2 PIN, with Lanyard
18 187104 4 WASHER, Nylon
19 49820 2 NUT, M8 Nylok
20 83083 1 SCREEN, Spark Arrester
21 86307 4 HHMS, 5/16-24 x 3/4"
22 92247 1 HOUSING, Engine Adapter
23 A92531 1 SUPPORT, Engine
24 189160 12 NUT, 5/16-18 Flange Serrated
25 22129 2 WASHER, Lock - M8
26 82857 4 MOUNT,Vibration
27 22531 2 HHCS, 5/16-18 x 1-3/4"
28 92609 2 MOUNT,Vibration
29 22142 2 SCREW, 5/16 - 18 x 3/4"
30 A7433 1 MUFFLER
31 A92731 1 SUPPORT, Engine & Muffler
32 90239 1 GASKET, Muffler
33 B1342G 1 ASSEMBLY, Rotor (Incls Item 34)
34 65791 1 BEARING
35 96796 1 WASHER, Special Flat - M8
36 47481 1 HHCS, 5/16-24 x 10-5/8
37 B1897G 1 ASSEMBLY, Stator
38 20566 1 DECAL, 1-800
39 40976 2 SCREW, M8 - 1.25 x 20
40 92532 1 BRACKET, Muffler
41 66476 2 CAPSCREW, M6 - 1.0 x 12mm
42 186747 1 DECAL, Control Panel
43 92630 1 ASSEMBLY, Control Box
44 J96068 1 SHIELD, Heat
45 14353621 1 WIRE, Ground
46 26850 2 LW, EXT, Shakeproof M6
47 BB3061 2 BOTTLE, Oil
48 81917 1 PIN, Roll 4mm x 10
49 B4986 1 DECAL, Ground
50 186798 2 DECAL, Heat Shield
51 56893 5 CRIMPTITE, 10-24 x 1/2"
52 84132 1 ASSEMBLY, Power Regulator
Item Part # Qty Description
53 67022 1 GROMMET, Rubber
54 66825C 1 CARRIER, Rear Bearing
55 86494 1 SCREW, M6-1.0 x 16 Wing
56 23762 3 WASHER, Shakeproof #10
57 66386 1 ASSEMBLY, Brush Holder
58 66849 2 TAPTITE, M5-0.8 x 16
59 B4871 1 COVER, Bearing Carrier
60 74908 4 TAPTITE, M5-0.8 x 10
61 B4605 2 GRIP
62 66849C 1 TAPTITE, M5-0.8 x 30
63 65795 2 RECTIFIER, Battery Charge
64 66449L 4 BOLT, Stator M6-1 x 190mm
65 22145 4 WASHER, Flat 5/16 - M8
66 22097 5 LOCKWASHER, 1/4" - M6
67 186744 1 MANUAL, Operators
68 BB5586 2 HANDLE
69 52858 4 NUT, Lock M8
70 B186927 1 LEG, Support
71 27007 2 MOUNT,Vibration
72 42909 2 CAPSCREW, M8 - 1.25 x 30
73 93693G 1 AXLE
74 B4966 2 WHEEL
75 22247 2 WASHER,Wheel
76 87005A 2 PIN, Retaining
77 189302B 1 WIRE ASM, #16
78 77282 1 SWITCH, Starter
79 188987 1 BRACKET, Switch
80 188989 1 ASM, Jack, DC
81 22287 2 HHCS, 1/4 - 20 x 3/4"
82 22097 4 LOCKWASHER, 1/4 - M6
83 22127 5 NUT, 1/4 - 20
84 J186704 1 TRAY, Battery
85 B4489 1 BATTERY, 12V 18 AH
86 189302C 1 WIRE ASM, #13
87 185939H 1 WIRE ASM, #55
88 73054 1 DECAL, Fuel Shut-Off
89 77816 2 DECAL, Hot Muffler
90 39253 2 HHCS, M8 - 1.25 x 20
91 A8927 1 MANUAL, Engine
92 52618 2 HHCS, M5 - 0.8 x 12
93 23897 2 WASHER, M5 Flat
94 52856 2 NUT, M5 Flange Hex
95 50190 2 WASHER, Flat 10 GA 0.34 x 1
96 96113 1 WIRE ASM, #13
97 58359 1 LUG, 5/16 #22/18 I-S
98 189198 1 DECAL, Instruction, ES
99 B4177 1 CHARGE, Battery Float
100 189208 3 FUEL STABILIZER, 1oz Tube
101 65787 1 CABLE, Battery Charge
102 37806 1 PLUG, 120V/30 Amp
103 188971 1 EXTENDA PANEL
900 NSP 1 ENGINE