Generac Power Systems 7500EXL Rated watt Extended Life Generator User manual

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Portable Generator Owner’s Manual
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Obey all safety messages that follow this symbol to avoid possible injury or death.
Model No. 1315-0 (7,500 Watt AC Generator) Manual No. B4369 Revision 3 (9/19/2000)
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7500EXL

Generac Portable Products 7,500 EXL Generator
2
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 7,500 watts (7.5 kW) of power that draw up
to 62.5 Amps at 120 Volts or 31.2 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 7,500 watts. See “Don’t Overload The
Generator” on page 12.
The 7,500EXL generator has the following features:
• 120/240 Volt, 30 Amp locking receptacle, a 120 Volt,
30 Amp locking receptacle, a 120 Volt, 20 Amp
receptacle, and a 120/240 Volt, 50 Amp receptacle.
• Low Oil Shutdown: Automatically shuts down the engine
if oil drops below safe operating pressure.
• Seven gallon overhead fuel tank with fuel gauge.
• The generator’s revolving field is driven at about
3600 rpm by a Generac Power Systems 15 HP electric
start engine.
DANGER! 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/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 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 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
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. 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 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 Electric Code requires the frame and
external electrically conductive parts 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 1) is provided
on the cradle.
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the ground lug screw and
to an earth–driven copper or brass grounding 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 if ground 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.
Figure 1 — Grounding Wing Nut
Grounding Wing Nut

Generac Portable Products 7,500 EXL Generator
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INSTALL WHEEL KIT AND
BATTERY TRAY
To install these items, you need the following tools:
• Socket wrench with 1/2" or 13mm socket.
• Box or open end 3/8” wrench.
Install Wheel Kit
• Place the generator on a hard flat surface (Figure 2).
• Place temporary blocks beneath the cradle.
• Slide the axle through the holes in the brackets provided
on the generator cradle and then add one spacer on
each protruding end of the axle.
• Slide a wheel on each end 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 inflation valve faces outward on
each wheel.
• Attach the vibration mounts to the support leg with
capscrews, washers, and lock nuts.
• Attach the support leg with two capscrews and two lock
nuts to the cradle. Remove the temporary blocks.
• Attach the handle with four capscrews and four lock nuts
on the control panel end of the unit.
Figure 2 — Assemble Wheel Kit
Handle
Wheel
Axle
Retaining Pin
Wheel
Spacer
Support Leg
Vibration Mount
Hex Head
Capscrew,
M8 x 30mm
Lock Nut, M8
Flat
Washer
5/8
Hex Head
Capscrew,
M8 x 20mm
Flat Washer
Hex Head
Capscrew,
M8 x 45mm
Lock Nut, M8

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Installing Tray and Battery
To obtain electric start, you must purchase and install a
12 Volt DC battery (Series U1–109). The battery should
be serviced as necessary and fully charged prior to
installation. Install the battery as follows:
• Find the battery tray and fasteners shipped loose in the
carton. You should have one battery hold down bracket,
a black battery cable, a red battery cable, two 7" J bolts,
two lock washers, two flat washers and two hex nuts.
• Remove the four battery tray screws from cradle.
• Position the battery tray and install with screws removed
above (Figure 3).
• Set battery onto tray.
• Retain battery to tray with hold down bracket, two
J bolts, two lock washers, two flat 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 (Figure 5).
• Connect the black battery cable to the negative (–)
terminal on the battery (Figure 5).
• Connect the other end of the black cable to the engine,
not the frame (Figure 5).
CAUTION! Be sure the black cable is connected
to the engine and not the frame. Failure to connect
cable to the engine block will result in damage to the
wiring which is not covered under warranty.
• Double check all connections to ensure they are in the
correct locations and secure.
Figure 3 — Install Battery Tray
Figure 4 — Secure 12 Volt Battery
Figure 5 — Wire Connections
RED wire
from battery
BLACK wire
from battery

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12 Volt DC,10 Amp Receptacle — Recharge a
discharged 12 Volt automotive type battery through this
receptacle.
120/240 Volt AC, 50 Amp Receptacle — May be used
to supply electrical power for the operation of
120/240 Volt AC, 50 Amp, single phase, 60 Hz electrical
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,
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 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.
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 circuit breaker to protect the generator against
electrical overload. Breakers are "push to reset" type.
Engine Start Switch - Pressed to 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 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.
Recoil Starter — Used as backup method of starting
engine.
Run/Stop Switch — Set this switch to "RUN" before
using recoil starter. Set switch to "STOP" to switch OFF
engine.
Spark Arrester Muffler — Exhaust muffler lowers
engine noise and is equipped with a spark arrester screen.
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.
120 Volt AC, 20 Amp
Receptacle
120/240 Volt AC,
50 Amp Receptacle
Fuel Tank
Idle Control Switch
Engine Start Switch
Choke Lever
Recoil Starter
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

Generac Portable Products 7,500 EXL Generator
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BEFORE STARTING THE
ENGINE
Add Oil
WARNING! 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 overfill!
• 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
DANGER! Explosion Hazard! 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.
• Add unleaded regular gasoline, slowly to fuel tank. Be
careful not to overfill. Allow about 1/2" of tank space for
fuel expansion (Figure 6).
• 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.
Figure 6 — Fuel Expansion Space

Generac Portable Products 7,500 EXL Generator
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OPERATING THE
GENERATOR
CAUTION! Never start or stop the engine with
electrical loads connected to the unit and with the
connected devices turned ON.
Starting the Engine
Disconnect all electrical loads from the generator. Use the
following start instruction steps by numerical order:
1. Make sure the Idle Control switch is in “Off” position.
2. Turn the fuel valve to the “On” position (Figure 7).
3. Set the Run/Stop switch to “Run” position (Figure 8).
4. Place the choke lever in the “Full” choke position
(Figure 9).
5A. For electric starting, press start switch on generator
cradle until engine starts. To prolong the life of the
starter components, press the starter button for no
more than 15 seconds, then 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.
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 Hertz electrical loads.
•Do Not connect 240 Volt loads to 120 Volt receptacles.
•Do Not connect 3–phase loads to the generator.
•Do Not connect 50Hz loads to the generator.
•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.
Figure 9 — Choke Lever
“Full” choke
Position
Figure 7 — Fuel Valve Operation
Figure 8 — Run/Stop Switch

Generac Portable Products 7,500 EXL Generator
9
Operating Automatic Idle Control
This control 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 the electrical load is
removed, the engine will run at a reduced speed. With
the switch “Off”, the engine will run constantly at high
engine speed. Always have the switch “Off” when
starting and stopping the engine.
Battery Safety
DANGER! 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. Such an
explosion can shatter the battery and cause
blindness or other serious injury.
DANGER! 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.
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 batteries. Do Not
use the generator to crank an engine having a discharged
battery.
To recharge 12 Volt batteries, proceed as follows:
• Check fluid level in all battery cells. If necessary, add
ONLY distilled water to each cell. 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 10).
• Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 10).
• 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.
Figure 10 — Battery Connections

Generac Portable Products 7,500 EXL Generator
10
COLD WEATHER
OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your Generac generator
may experience icing of the carburetor and/or the
crankcase breather system.
In an emergency, use the original shipping box as a
temporary shelter:
• Cut off all flaps.
• Cut out one of the long sides of the box to expose
exhaust side of unit. Ensure a minimum of two feet
clearance between open side of box and nearest object.
• Cut appropriate slots to access receptacles and clear
handles.
• Start unit, then place box over it.
IMPORTANT: Remove shelter when temperature is
above 40°F [4°C].
For a more permanent shelter, 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 11.
• 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! Never run unit indoors. Do Not
enclose generator any more than shown. Remove
shelter when temperatures are above 40°F [4°C].
RECEPTACLES
This generator is equipped with the following receptacles:
120 Volt AC, 20 Amp Receptacle
This outlet is protected against overload by a 20 Amp
push-to-reset circuit breaker (Figure 12).
Use each socket to operate 120 Volt AC, single phase,
60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)
at 20 Amps. Use cord sets that are rated for 125 Volt loads
at 20 Amps (or greater).
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 13).
Figure 12 — 120 Volt AC, 20 Amp Receptacle
Wind
Figure 11 — Temporary Cold Weather Shelter

Generac Portable Products 7,500 EXL Generator
11
Use this receptacle to operate 120 Volt 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.
120/240 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). You can use the same 4–wire cord if you plan
to run a 120 Volt load (Figure 14).
This receptacle powers 120 Volt AC, single phase, 60 Hz
loads requiring up to 3,600 watts of power (3.6 kW). Or it
will operate 240 Volt AC, single phase, 60Hz loads up to
7,200 watts (7.2 kW). This outlet is protected by a 30 Amp
push–to–reset circuit breaker.
120/240 Volt AC, 50 Amp Receptacle
Use a NEMA 14–50 plug with this receptacle. Connect a
4-wire cord set rated for 240 Volt AC loads at 50 Amps to
the plug (Figure 15).
Use this receptacle to operate 240 Volt AC, 60 Hz, single
phase loads requiring up to 7,500 watts (7.5 kW) 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 wattage / amperage capacity of
the generator can damage it or cause serious
injuries.
Figure 13 — 120 Volt AC, 30 Amp Locking Receptacle
Figure 14 — 120/240 Volt AC, 30 Amp Locking Receptacle
Figure 15 — 120/240 Volt AC, 50 Amp Receptacle

Generac Portable Products 7,500 EXL Generator
12
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.
• The rated wattage of lights can be taken from light bulbs.
The rated wattage of tools, appliances and motors can
usually be found on a data plate or decal affixed to the
device.
• If the appliance, tool or motor does not give wattage,
multiply 120 Volts times ampere rating to determine
watts (volts x amps = watts).
• 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.
• Items in the wattage reference guide (Figure 16) are
provided to help you to determine how many items the
generator can operate at one time.
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 16 — Wattage Reference Guide

Generac Portable Products 7500 EXL Generator
13
SPECIFICATIONS
Maximum Surge Watts . . . . . . . . . . . . . . . . . . .9,375 watts
Continuous Wattage Capacity . . . . . . . . . . . . .7,500 watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0
Rated Maximum Continuous Load Current
At 120 Volts . . . . . . . . . . . . . . . . . . . . . . . . .62.5 Amps
At 240 Volts . . . . . . . . . . . . . . . . . . . . . . . . .31.2 Amps
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . . . . .60 Hertz
Fuel Tank Capacity. . . . . . . . . . . . . . . . . . . . . 7 U.S. gallons
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.
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.
To Clean the Generator
• Use a damp cloth to wipe exterior surfaces clean.
• Soft, bristle brush may be used to loosen caked on dirt
or oil.
• A vacuum cleaner may be used to pick up loose dirt and
debris.
• 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.
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.
• Disconnect negative battery cable from battery. Protect
battery from freezing temperatures.
DANGER! 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 a cover
on the unit.
Engine Storage
See engine owner’s manual for instructions.
Other Storage Tips
•Do Not store gasoline from one season to another.
• Replace your gasoline can if it starts to rust. Rust and/or
dirt in a gasoline can cause problems if you use
contaminated fuel.
• Store unit in a clean and dry area.

Generac Portable Products 7,500 EXL Generator
14
TROUBLESHOOTING
Problem Cause Solution
Engine is running, but no AC
output is available.
1. Circuit breaker is open.
2. Poor connection or defective cord
set.
3. Connected device is bad.
4. Fault in generator.
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in
good condition.
4. Contact Generac service facility.
Engine runs good but bogs
down when loads are
connected.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the
Generator” on page 12.
3. Contact Generac service facility.
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. Low oil level.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
13. Battery is dead.
1. Set switch to “Run”.
2. Clean or replace air cleaner.
3. Fill fuel tank.
4. Drain gas tank and fill with fresh fuel.
5. Connect wire to spark plug.
6. Replace spark plug.
7. Drain gas tank; fill with fresh fuel.
8. Put choke lever to “no choke”
position.
9. Fill crankcase to proper level.
10. Contact Generac service facility.
11. Contact Generac service facility.
12. Contact Generac service facility.
13. Recharge or replace battery.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Generac service facility.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. See “Don’t Overload the
Generator” on page 12.
2. Replace air filter.
3. Contact Generac service facility.
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 till
engine runs smoothly.
2. Contact Generac service facility.

Generac Portable Products 7,500 EXL Generator
15
NOTES

Generac Portable Products 7,500 EXL Generator
16
ELECTRICAL SCHEMATIC

Generac Portable Products 7,500 EXL Generator
17
WIRING DIAGRAM

Generac Portable Products 7,500 EXL Generator
18
EXPLODED VIEW – MAIN UNIT

Generac Portable Products 7,500 EXL Generator
19
Item Part # Qty Description
1 G92432 1 CRADLE
2 G92531 1 SUPPORT, Engine
3 G92731 1 SUPPORT, Engine & Muffler
4 92247 1 HOUSING, Engine Adapter
5 B1342G 1 ASSEMBLY, Rotor
6 B1897G 1 ASSEMBLY, Stator
7 65791 1 BEARING
8 67451 1 WASHER, Special Flat - M8
9 22129 12 WASHER, Lock - M8
10 86307 4 HHMS, 5/16-24 x 3/4 SEMS
11 47481 1 HHCS, 5/16-24 x 10.625
12 92609 2 MOUNT, Vibration
13 82857 4 MOUNT, Vibration
14 40976 2 SCREW, M8 - 1.25 x 20
15 66476 2 CAPSCREW, M6 - 1.0 x 12mm
16 92532 1 BRACKET, Muffler
17 22142 2 SCREW, 5/16 - 18 x 3/4
18 A7433 1 MUFFLER
19 90239 1 GASKET, Muffler
20 81917 1 PIN, Roll 4mm x 10
24 B4986 1 DECAL, Ground
25 66825C 1 CARRIER, Rear Bearing
26 74908 4 TAPTITE, M5-0.8 x 10
27 66449L 4 BOLT, Stator M6-1 x 165mm
28 65795 2 RECTIFIER, Battery Charge
29 66849C 1 TAPTITE, M5-0.8 x 30
30 67022 1 GROMMET, Rubber
31 84132 1 ASSEMBLY, Power Regulator
32 66386 1 ASSEMBLY, Brush Holder
33 66849 2 TAPTITE, M5-0.8 x 16
34 B4871 1 COVER, Bearing Carrier
35 22769 1 WASHER, Shakeproof Int. #10
36 86494 1 SCREW, M6-1.0 x 16 Wing
37 86292 9 HHCS, - #10 Self Driller
38 77395 4 NUT, Flange Lock - M6
39 83465 4 GROMMET, Tank
40 57058 4 HHMS, M6-1.0 x 55
41 80270 1 VALVE, Tank
42 78299 1 BUSHING, Plastic Tank
43 B4363 1 CAP, with Gauge, Fuel
44 B1695 1 TANK, Fuel 7 Gal.
45 B92039 1 SHIELD, Heat
46 92665 1 INSULATION, #2-1/4" Thick
Item Part # Qty Description
47 85000 1 CLIP, Insulation
48 14353621 1 WIRE, Gound
49 26850 2 LW, EXT, Shakeproof M6
51 92982 1 DECAL, Danger
52 B4367 2 DECAL, Heat Shield
55 25244 12 NUT, 5/16-18 Hex
57 B4368 1 DECAL, Control Panel
58 B4366A 1 ASSEMBLY, Control Box
59 NSP 1 ENGINE
60 22531 2 HHCS, 5/16-18 x 1-3/4"
62 93826 1 DECAL, Start Instructions
63 B96068 1 SHIELD, Heat
64 56893 5 CRIMPTITE, 10-24 x 1/2
65 77282 1 SWITCH, Starter
66 22287 2 SCREW, 1/4 - 20 x 3/4
67 22097 2 LOCKWASHER, M6
68 22127 2 NUT, 1/4 - 20 Hex
69 78289 1 BRACKET, Starter Switch
70 22473 4 WASHER, M6 Flat
71 83083 1 SCREEN, Spark Arrester
72 96113 1 ASSY., Wire Starter
Items Not Illustrated
65787 1 Battery Charge Cable
B4369 1 Generator Owner’s Manual
A8927 1 Engine Owner’s Manual
BB3061 2 Oil, 28 oz.
96113 1 Wire, Assembly Starter
22129 2 Lockwasher M8
22145 2 Flatwasher M8
45771 2 Hex Nut M8-1.25
96925 1 Battery Tiedown
96924 2 J-Bolt M8-1.25
96923 1 Battery Tray
15453621 1 Battery Cable Positive
15553621 1 Battery Cable Negative
37806 1 120 Volt 30 Amp Locking Plug
43438 1 120/240 Volt 30 Amp Locking
Plug
Optional Accessories Not Included
84883 Cord Wrap
43630 120/240 Volt 50 Amp Plug
PARTS LIST – MAIN UNIT

Generac Portable Products 7,500 EXL Generator
20
EXPLODED VIEW AND PARTS LIST – WHEEL KIT
Item Part # Qty Description
1 B93393A 1 HANDLE
2 89742 2 WHEEL
3 93693A 1 AXLE
4 87005 2 PIN, Retaining
5 B89635 2 SPACER, Wheel
6 B93696 1 LEG, Support
7 27007 2 MOUNT, Vibration
8 42909 2 CAPSCREW, Hex Hd. M8 - 1.25 x 30
9 52858 8 NUT, Lock M8
10 22247 2 WASHER, Wheel
11 39253 2 CAPSCREW, Hex Hd. - M8 - 1.25 x 20
12 22145 2 WASHER, Vibration Mtg.
13 39287 4 HHCS, M8 - 1.25 x 45 GR 10.9