Generac Portable Generator 101 9 3 User Manual

Operator’s Manual  
WARNING  
Before using this product, read  
this manual and follow all Safety  
Rules and Operating Instructions.  
Questions? Help is just a moment away!  
Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT  
Model No. 1019-3 (7,500 Watt AC Generator) Manual No. 189713GS Revision 11 (12/15/2005)  
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7500EXL Extended Life Generator  
DANGER  
WARNING  
Storage batteries give off explosive hydrogen gas  
during recharging.  
Fuel and its vapors are extremely flammable and  
explosive.  
Hydrogen gas stays near battery for a long time  
after battery has been charged.  
Fire or explosion can cause severe burns or  
death.  
Slightest spark will ignite hydrogen and cause  
explosion.  
You can be blinded or severely injured.  
Battery electrolyte fluid contains acid and is  
extremely caustic.  
Contact with battery fluid will cause severe  
chemical burns.  
WHEN ADDING OR DRAINING FUEL  
Turn generator OFF and let it cool at least 2 minutes before  
removing fuel cap. Loosen cap slowly to relieve pressure in  
tank.  
• Fill or drain fuel tank outdoors.  
• DO NOT overfill tank.Allow space for fuel expansion.  
• Keep fuel away from sparks, open flames, pilot lights, heat, and  
other ignition sources.  
• DO NOT allow any open flame, spark, heat, or lit cigarette  
during and for several minutes after charging a battery.  
• DO NOT light a cigarette or smoke.  
• Wear protective goggles, rubber apron, and rubber gloves.  
WHEN STARTING EQUIPMENT  
• Ensure spark plug, muffler, fuel cap and air cleaner are in place.  
• DO NOT crank engine with spark plug removed.  
• If fuel spills, wait until it evaporates before starting engine.  
WARNING  
Running generator gives off carbon monoxide,  
an odorless, colorless, poison gas.  
Breathing carbon monoxide can cause nausea,  
fainting or death.  
WHEN OPERATING EQUIPMENT  
• DO NOT tip engine or equipment at angle which causes fuel  
to spill.  
• This generator is not for use in mobile equipment or marine  
applications.  
• Operate generator ONLY outdoors.  
• Keep exhaust gas from entering a confined area through  
windows, doors, ventilation intakes or other openings.  
• DO NOT operate generator inside any building or enclosure  
(even if doors or windows are open), including the generator  
compartment of a recreational vehicle (RV).  
WHEN TRANSPORTING OR REPAIRING  
EQUIPMENT  
Transport/repair with fuel tank EMPTY or with fuel shutoff  
valve OFF.  
• Disconnect spark plug wire.  
WARNING  
Generator produces powerful voltage.  
Failure to isolate generator from power utility  
can result in death or injury to electric utility  
workers due to backfeed of electrical energy.  
WHEN STORING FUEL OR EQUIPMENT WITH FUEL  
IN TANK  
• Store away from furnaces, stoves, water heaters, clothes  
dryers or other appliances that have pilot light or other  
ignition source because they can ignite fuel vapors.  
WARNING  
• This generator does not meet U. S. Coast Guard Regulation  
• When using generator for backup power, notify utility  
company. Use approved transfer equipment to isolate  
generator from electric utility.  
• Use a ground circuit fault interrupter (GFCI) in any damp or  
highly conductive area, such as metal decking or steel work.  
• DO NOT touch bare wires or receptacles.  
• DO NOT use generator with electrical cords which are worn,  
frayed, bare or otherwise damaged.  
33CFR-183 and should not be used on marine applications.  
• Failure to use the appropriate U. S. Coast Guard approved  
generator could result in bodily injury and/or property  
damage.  
• DO NOT operate generator in the rain or wet weather.  
• DO NOT handle generator or electrical cords while standing  
in water, while barefoot, or while hands or feet are wet.  
• DO NOT allow unqualified persons or children to operate or  
service generator.  
3
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CAUTION  
Excessively high operating speeds increase risk of injury  
and damage to generator.  
WARNING  
Rapid retraction of starter cord (kickback) will  
pull hand and arm toward engine faster than  
you can let go.  
Excessively low speeds impose a heavy load.  
Broken bones, fractures, bruises or sprains could  
result.  
• DO NOT tamper with governed speed. Generator supplies  
correct rated frequency and voltage when running at governed  
speed.  
• When starting engine, pull cord slowly until resistance is felt  
and then pull rapidly to avoid kickback.  
• NEVER start or stop engine with electrical devices plugged in  
and turned on.  
• DO NOT modify generator in any way.  
CAUTION  
Exceeding generators wattage/amperage capacity can  
damage generator and/or electrical devices connected  
to it.  
WARNING  
Running engines produce heat.Temperature of  
muffler and nearby areas can reach or exceed  
150°F (65°C).  
Severe burns can occur on contact.  
Exhaust heat/gases can ignite combustibles,  
structures or damage fuel tank causing a fire.  
• See “Don’t Overload Generator”.  
• Start generator and let engine stabilize before connecting  
electrical loads.  
• Connect electrical loads in OFF position, then turn ON for  
operation.  
• DO NOT touch hot surfaces and avoid hot exhaust gases.  
• Allow equipment to cool before touching.  
Turn electrical loads OFF and disconnect from generator  
before stopping generator.  
• Keep at least 5 ft. (152 cm) clearance on all sides of generator  
including overhead.  
CAUTION  
Improper treatment of generator can damage it and  
• Code of Federal Regulation (CFR) Title 36 Parks, Forests, and  
Public Property require equipment powered by an internal  
combustion engine to have a spark arrester, maintained in  
effective working order, complying to USDA Forest service  
standard 5100-1C or later revision. In the State of California a  
spark arrester is required under section 4442 of the California  
Public resources code. Other states may have similar laws.  
shorten its life.  
• Use generator only for intended uses.  
• If you have questions about intended use, ask dealer or call  
1-800-270-1408.  
• Operate generator only on level surfaces.  
• DO NOT expose generator to excessive moisture, dust, dirt,  
or corrosive vapors.  
WARNING  
• DO NOT insert any objects through cooling slots.  
• If connected devices overheat, turn them off and disconnect  
them from generator.  
Unintentional sparking can result in fire or  
electric shock.  
• Shut off generator if:  
-electrical output is lost;  
WHEN ADJUSTING OR MAKING REPAIRSTOYOUR  
GENERATOR  
-equipment sparks, smokes, or emits flames;  
-unit vibrates excessively.  
• Disconnect the spark plug wire from the spark plug and place  
the wire where it cannot contact spark plug.  
WHENTESTING FOR ENGINE SPARK  
• Use approved spark plug tester.  
• DO NOT check for spark with spark plug removed.  
4
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KNOWYOUR GENERATOR  
Read this Operator’s Manual and safety rules before operating your generator.  
Compare this illustration with your generator to familiarize yourself with the locations of various controls and  
adjustments. Save this manual for future reference.  
Electric Start Button  
Oil Fill Cap  
Recoil Starter  
Circuit Breakers (AC)  
Fuel Tank  
12Volt DC  
Receptacle  
Idle Control Switch  
Choke Lever  
Run/Stop Switch  
Air Cleaner  
120/240Volt AC,  
30 Amp Locking  
Receptacle  
Spark Arrester Muffler  
120Volt AC, 30 Amp  
Locking Receptacle  
120/240Volt AC,  
50 Amp Receptacle  
120Volt AC, 20 Amp  
Duplex Receptacle  
Grounding Fastener  
12Volt DC Receptacle — Use this receptacle with  
Choke Lever — Used when starting a cold engine.  
battery charge cables to charge a 12Volt battery.  
Circuit Breakers (AC) — Each receptacle is provided  
with a "push to reset" circuit breaker to protect the  
generator against electrical overload.  
120Volt AC, 20 Amp Duplex Receptacle — May be  
used to supply electrical power for the operation of  
120Volt AC, single phase, 60 Hz electrical lighting, appliance,  
tool and motor loads.  
FuelTank — Capacity of seven (7) U.S. gallons.  
Electric Start Switch — Press to start the engine.  
120Volt AC, 30 Amp Locking Receptacle — May be  
used to supply electrical power for the operation of  
120Volt AC, 30 Amp, single phase, 60 Hz electrical lighting,  
appliance, tool and motor loads.  
Grounding Fastener — Consult your local agency having  
jurisdiction for grounding requirements in your area.  
Idle Control Switch — The idle control runs the engine  
at normal (high) speeds when there is a load present and  
runs the engine at idle (low) speeds when a load is not  
present.  
120/240Volt AC, 30 Amp Locking Receptacle — May  
be used to supply electrical power for the operation of  
120 and/or 240Volt AC, 30 Amp, single phase, 60 Hz  
electrical lighting, appliance, tool and motor loads.  
Oil Fill Cap — Add oil to engine here.  
Recoil Starter — Used to start the engine manually.  
120/240Volt AC, 50 Amp Receptacle — May be used  
to supply electrical power for the operation of 240Volt AC,  
50 Amp, single phase, 60 Hz electrical loads.  
Run/Stop Switch — Must be in “Run” position to start  
engine. Set to “Stop” to stop a running engine.  
Air Cleaner — Protects engine by filtering dust and  
debris out of intake air.  
Spark Arrester Muffler — Exhaust muffler lowers engine  
noise and is equipped with a spark arrester screen.  
5
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• Battery Charge Cables  
• Spare Spark Plug,Air Filter, and Oil Filter  
• Spark Plug Wrench  
• (2) Locking 30 Amp Plugs  
• Engine Oil  
ASSEMBLY  
Your generator requires some assembly and is ready for  
use after it has been properly serviced with the  
recommended oil and fuel.  
• Operator's Manual  
• Engine Manual  
If any parts are missing or damaged, call the generator  
helpline at 1-800-270-1408.  
If you have any problems with the assembly of your  
generator, please call the generator helpline at  
1-800-270-1408.  
Unpack the Generator  
1. Set the carton on a rigid flat surface.  
Install Wheel Kit  
The wheel kit is designed to greatly improve the portability  
of your generator.  
2. Open carton completely by cutting each corner from  
top to bottom.  
NOTE: Wheel kit is not intended for over-the-road use.  
You will need the following tools to install this wheel kit:  
• 1/2" or 13mm socket wrench  
• 1/2" or 13mm open end wrench  
• 7/16" socket wrench  
3. Remove everything from carton except generator.  
4. Leave generator on carton to install wheel kit.  
Carton Contents  
Check all contents against those listed below:  
• Generator  
• 7/16" open end wrench  
• Wheel kit  
• Pliers  
• Storage Cover  
• Safety glasses  
• Adapter Cord Set  
• Battery  
• Battery Float Charger  
Refer to Figure 1 and install the wheel kit as follows:  
1. Tip generator so that engine end is up.  
Figure 1 — Install Wheel Kit  
Axle  
Wheel  
Flat Washer  
1/4x20 Lock Nut  
Support Leg  
M8x20mm Capscrew  
E-Ring  
Vibration Mount  
M8 Lock Nut  
1/4-20x1” Capscrew  
6
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2. Slide axle through both mounting brackets.  
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.  
3. Slide a wheel over the axle.  
NOTE: Be sure to install both wheels with the air  
pressure valve on the outboard side.  
4. Place a washer on axle and then place an e-ring in axle  
groove.  
To install:  
1. Cut off tie wrap securing loose end of negative (black)  
cable.  
5. Install e-ring with pliers, squeezing from top of e-ring  
to bottom of axle.  
2. Remove screw, lock washer and flat washer on  
negative battery terminal.  
CAUTION  
E-rings can cause eye injury.  
E-rings can spring back and become airborne  
when installing or removing.  
3. Slide lock washer, flat washer and negative battery  
cable over screw (Figure 2).  
Figure 2 — Negative Battery Connection  
Negative  
Battery Cable  
• Always wear eye protection when installing/removing e-rings.  
6. Repeat step 3 thru 5 to secure second wheel.  
7. Tip generator so that engine side is down.  
Screw  
8. Attach the vibration mounts to the support leg with  
1/4-20 x 1” capscrews and 1/4-20 lock nuts.  
9. Line up holes in support leg with holes in generator  
frame.  
Flat Washer  
Lock Washer  
Positive  
Battery Cable  
10. Attach support leg using 2 capscrews (M8 x 20 mm)  
and 2 hex nuts (M8).Tighten with a 1/2” or 13mm  
socket wrench and 1/2” or 13mm wrench.  
4. Reattach screw to negative battery terminal and  
tighten.  
11. Return generator to normal operating position (resting  
on wheels and support leg).  
5. Verify that connections to battery and generator are  
tight and secure.  
12. Check each fastener to ensure it is secure.  
7
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7500EXL Extended Life Generator  
Add Fuel  
NOTE: This gasoline engine is certified to operate on  
gasoline. Exhaust Emission Control System: EM (Engine  
Modifications).  
BEFORE STARTINGTHE  
ENGINE  
Add Engine Oil  
WARNING  
Fuel and its vapors are extremely flammable and  
explosive.  
Fire or explosion can cause severe burns or  
death.  
• Place generator on a level surface.  
CAUTION  
Any attempt to crank or start the engine before it has  
been properly filled with the recommended oil will result  
in equipment failure.  
WHEN ADDING FUEL  
Turn generator OFF and let it cool at least 2 minutes before  
removing fuel cap. Loosen cap slowly to relieve pressure in tank.  
• Fill fuel tank outdoors.  
• DO NOT overfill tank.Allow space for fuel expansion.  
• Keep fuel away from sparks, open flames, pilot lights, heat, and  
other ignition sources.  
• Refer to engine manual for oil fill information.  
• Damage to equipment resulting from failure to follow this  
instruction will void warranty.  
• Refer to engine operator’s manual and follow oil  
recommendations and instructions.  
• DO NOT light a cigarette or smoke.  
NOTE: Check oil often during engine break–in. Refer to  
engine operator’s manual for recommendations.  
1. Use clean, fresh, regular UNLEADED fuel with a  
minimum of 85 octane. DO NOT use fuel which  
contains Methanol. DO NOT mix oil with fuel.  
NOTE: The generator assembly rotates on a prelubricated  
and sealed ball bearing that requires no additional  
lubrication for the life of the bearing.  
2. Clean area around fuel fill cap, remove cap.  
3. Slowly add regular unleaded fuel to fuel tank. Be careful  
not to overfill.Allow at least 1.5" of tank space for fuel  
expansion (Figure 3).  
Figure 3 - Fuel Expansion  
Tank  
Fuel  
4. Install fuel cap and wipe up any spilled fuel.  
8
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Generator Location  
Generator Clearance  
USINGTHE GENERATOR  
System Ground  
WARNING  
Exhaust heat/gases can ignite combustibles,  
structures or damage fuel tank causing a fire.  
The generator has a system ground that connects the  
generator frame components to the ground terminals on  
the AC output receptacles.The system ground is connected  
to the AC neutral wire (see “Equipment Description”,  
earlier in this manual).  
• Keep at least 5 ft. (152 cm) clearance on all sides of generator  
including overhead.  
Place generator in a well ventilated area, which will allow  
for removal of deadly exhaust gas. DO NOT place  
generator where exhaust gas could accumulate and enter  
inside or be drawn into a potentially occupied building.  
Ensure exhaust gas is kept away from any windows, doors,  
ventilation intakes or other openings that can allow exhaust  
gas to collect in a confined area (Figure 4). Prevailing winds  
and air currents should be taken into consideration when  
positioning generator.  
Special Requirements  
There may be Federal or State Occupational Safety and  
Health Administration (OSHA) regulations, local codes, or  
ordinances that apply to the intended use of the generator.  
Please consult a qualified electrician, electrical inspector, or  
the local agency having jurisdiction.  
• In some areas, generators are required to be registered  
with local utility companies.  
WARNING  
Running generator gives off carbon monoxide,  
an odorless, colorless, poison gas.  
• If the generator is used at a construction site, there may  
be additional regulations which must be observed.  
Connecting to a Building’s Electrical  
System  
Connections for standby power to a building’s electrical  
system must be made by a qualified electrician.The  
connection must isolate the generator power from utility  
power, and must comply with all applicable laws and  
electrical codes.  
Breathing carbon monoxide can cause nausea,  
fainting or death.  
• Operate generator ONLY outdoors.  
• Keep exhaust gas from entering a confined area through  
windows, doors, ventilation intakes or other openings.  
• DO NOT operate generator inside any building or enclosure  
(even if doors or windows are open), including the generator  
compartment of a recreational vehicle (RV).  
WARNING  
Generator produces powerful voltage.  
Figure 4 — Generator Clearance  
Failure to isolate generator from power utility  
can result in death or injury to electric utility  
workers due to backfeed of electrical energy.  
• When using generator for backup power, notify utility  
company. Use approved transfer equipment to isolate  
generator from electric utility.  
• Use a ground fault circuit interrupter (GFCI) in any damp or  
highly conductive area, such as metal decking or steel work.  
• DO NOT touch bare wires or receptacles.  
Typical Generator Shown  
• DO NOT use generator with electrical cords which are worn,  
frayed, bare or otherwise damaged.  
• DO NOT operate generator in the rain.  
• DO NOT handle generator or electrical cords while standing  
in water, while barefoot, or while hands or feet are wet.  
• DO NOT allow unqualified persons or children to operate or  
service generator.  
Exhaust Port  
9
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NOTE: If engine starts after 3 pulls but fails to run, or if  
OPERATINGTHE  
GENERATOR  
unit shuts down during operation, make sure unit is on a  
level surface and check for proper oil level in crankcase.  
This unit may be equipped with a low oil protection device.  
See engine manual.  
Starting the Engine  
WARNING  
Running engines produce heat.Temperature of  
muffler and nearby areas can reach or exceed  
150°F (65°C).  
IMPORTANT: Always unplug the battery float charger  
before starting the generator.  
Disconnect all electrical loads from the generator. Use the  
following start instruction steps by numerical order:  
Severe burns can occur on contact.  
Exhaust heat/gases can ignite combustibles,  
structures or damage fuel tank causing a fire.  
1. Make sure unit is on a level surface.  
IMPORTANT: Failure to start and operate unit on a level  
surface will cause the unit not to start or shut down during  
operation.  
• DO NOT touch hot surfaces and avoid hot exhaust gases.  
• Allow equipment to cool before touching.  
• Keep at least 5 ft. (152 cm) clearance on all sides of generator  
including overhead.  
2. Turn the fuel valve to the “On” position (Figure 5).The  
fuel valve handle should be vertical (pointing toward  
the ground) for fuel to flow.  
• Code of Federal Regulation (CFR) Title 36 Parks, Forests, and  
Public Property require equipment powered by an internal  
combustion engine to have a spark arrester, maintained in  
effective working order, complying to USDA Forest service  
standard 5100-1C or later revision. In the State of California a  
spark arrester is required under section 4442 of the California  
Public resources code. Other states may have similar laws.  
Figure 5 — FuelValve  
FuelValve is shown  
in the On position  
Connecting Electrical Loads  
• Let engine stabilize and warm up for a few minutes after  
starting.  
3. Make sure the Idle Control switch is in “Off” position  
(Figure 6).  
Figure 6 — Idle Control Switch  
• Plug in and turn on the desired 120 and/or 240 Volt AC,  
single phase, 60 Hz electrical loads.  
• DO NOT connect 240Volt loads to the 120Volt  
receptacles.  
• DO NOT connect 3–phase loads to the generator.  
• DO NOT connect 50 Hz loads to the generator.  
DO NOT OVERLOADTHE GENERATOR. See  
“Don’t Overload Generator”.  
4. Start the engine according to instructions given in the  
engine operator’s manual.  
CAUTION  
Exceeding generators wattage/amperage capacity can  
damage generator and/or electrical devices connected  
to it.  
WARNING  
Rapid retraction of starter cord (kickback) will  
pull hand and arm toward engine faster than  
you can let go.  
Broken bones, fractures, bruises or sprains could  
result.  
• See “Don’t Overload Generator”.  
• Start generator and let engine stabilize before connecting  
electrical loads.  
• Connect electrical loads in OFF position, then turn ON for  
operation.  
• When starting engine, pull cord slowly until resistance is felt  
and then pull rapidly to avoid kickback.  
Turn electrical loads OFF and disconnect from generator  
before stopping generator.  
• NEVER start or stop engine with electrical devices plugged in  
and turned on.  
10  
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7500EXL Extended Life Generator  
To recharge 12Volt batteries, proceed as follows:  
Stopping the Engine  
1. Turn off and unplug all electrical loads from generator  
panel receptacles. NEVER start or stop engine with  
electrical devices plugged in and turned on.  
1. Check fluid level in all battery cells. If necessary, add  
ONLY distilled water to cover separators in battery  
cells. DO NOT use tap water.  
2. If battery is equipped with vent caps, make sure they  
are installed and are tight.  
2. Put idle control switch in “Off” position.  
3. Let engine run at no–load for 30 seconds to stabilize  
internal temperatures of engine and generator.  
3. If necessary, clean battery terminals.  
4. Connect battery charge cable connector plug to panel  
receptacle identified by the words “12-VOLTS D.C.”  
4. Turn engine off according to instructions given in  
engine operator’s manual.  
5. Connect battery charge cable clamp with red handle  
to the positive (+) battery terminal (Figure 7).  
5. Move fuel valve to “Off” position.  
Figure 7 — Battery Connections  
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  
6. Connect battery charge cable clamp with black handle  
to the negative (–) battery terminal (Figure 7).  
Your generator has the capability of recharging a discharged  
12Volt 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.  
7. Start engine. Let engine run while battery recharges.  
8. 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.  
DANGER  
Storage batteries give off explosive hydrogen gas  
during recharging.  
Hydrogen gas stays near battery for a long time  
after battery has been charged.  
Slightest spark will ignite hydrogen and cause  
explosion.  
You can be blinded or severely injured.  
Battery electrolyte fluid contains acid and is  
extremely caustic.  
Contact with battery fluid will cause severe  
chemical burns.  
• DO NOT allow any open flame, spark, heat, or lit cigarette  
during and for several minutes after charging a battery.  
• Wear protective goggles, rubber apron, and rubber gloves.  
11  
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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.  
COLD WEATHER  
OPERATION  
Under certain weather conditions (temperatures below  
40°F [4°C] combined with high humidity), your generator  
may experience icing of the carburetor and/or the  
crankcase breather system.To reduce this problem, you  
need to perform the following:  
• Plug the charger into the unit’s “Battery Float Charger”  
jack, which is located on the starter switch (Figure 8).  
Plug battery charger into a 120Volt AC wall receptacle.  
Figure 8 — Battery Charger Jack  
1. Make sure generator has clean, fresh fuel.  
2. Open fuel valve (turn valve to open position).  
3. Use SAE 5W-30 oil (synthetic preferred, see engine  
operator’s manual).  
4. Check oil level daily or after every eight (8) hours of  
operation.  
5. Maintain generator following “Maintenance Schedule”  
in engine operator’s manual.  
• Unplug the charger from the unit and the wall outlet  
when generator is being started and while it is in  
operation.  
6. Shelter unit from elements.  
• 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 17 for  
additional information.  
12  
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7500EXL Extended Life Generator  
6. Start generator as described in the section “Starting  
Creating aTemporary Shelter  
the Engine”, then place carton over generator. Keep at  
least 5 ft. (152 cm) clearance on all sides of generator  
including overhead with shelter in place.  
1. In an emergency, use the original shipping carton.  
2. Cut off top carton flaps and one long side of carton to  
expose muffler side of unit. If required, tape up other  
sides of carton to fit over generator as shown in  
Figure 9.  
WARNING  
Running engines produce heat.Temperature of  
muffler and nearby areas can reach or exceed  
150°F (65°C).  
Figure 9 — Permanent Cold Weather Shelter  
Wind  
Severe burns can occur on contact.  
Exhaust heat/gases can ignite combustibles,  
structures or damage fuel tank causing a fire.  
• DO NOT touch hot surfaces and avoid hot exhaust gases.  
• Allow equipment to cool before touching.  
• Keep at least 5 ft. (152 cm) clearance on all sides of generator  
including overhead.  
• Remove shelter when temperatures are above 40°F [4°C].  
7. Remove shelter when temperatures are above 40°F  
[4°C].  
NOTE: If required, remove wheel kit to fit carton over  
generator as shown in Figure 9.  
8. Turn engine OFF and let cool two (2) minutes before  
refueling.Wipe up any spilled fuel.  
3. Cut appropriate slots to access receptacles of unit.  
4. Face exposed end away from wind and elements.  
Creating a Permanent Shelter  
5. Locate generator as described in the section  
“Generator Location”. Keep exhaust gas from entering  
a confined area through windows, doors, ventilation  
intakes or other openings.  
1. Build a structure that will enclose three sides and the  
top of the generator, making sure muffler side of  
generator is exposed.  
NOTE: Structure should hold enough heat created by the  
generator to prevent icing problem.  
WARNING  
Running generator gives off carbon monoxide,  
an odorless, colorless, poison gas.  
2. DO NOT enclose generator any more than shown in  
Figure 9.  
NOTE: If a wheel kit is installed on the generator, enlarge  
shelter accordingly.  
Breathing carbon monoxide can cause nausea,  
fainting or death.  
3. Follow steps 3 through 8 as described previously in  
“Creating a Temporary Shelter”.  
• Operate generator ONLY outdoors.  
• Keep exhaust gas from entering a confined area through  
windows, doors, ventilation intakes or other openings.  
• DO NOT operate generator inside any building or enclosure  
(even if doors or windows are open), including the generator  
compartment of a recreational vehicle (RV).  
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Figure 11 — 12Volt DC, 10 Amp Receptacle  
GENERATOR ADAPTER  
CORD SET  
The generator is equipped with a 25’ generator adapter cord  
set designed for a 240Volt, 30 Amp grounded neutral circuit  
(Figure 10).The generator adapter cord set provides a  
convenient supply of emergency power into your dwelling so  
that your generator can be operated safely outside.  
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 11) before  
attempting to recharge a battery.  
Figure 10 — Generator Adapter Cord Set  
120Volt AC, 20 Amp, Duplex  
Receptacle  
Each receptacle (Figure 12) is protected against overload by  
a 20 Amp push–to–reset circuit breaker.  
Figure 12 — 120Volt AC, 20 Amp, Duplex Receptacle  
The maximum load on each outlet is 20 Amps.The  
maximum total load on both yellow wire outlets or both  
black wire outlets is 30 Amps.  
NOTE: Follow all safety precautions when connecting any  
extension cord or device to the generator.  
RECEPTACLES  
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  
125Volt AC loads at 20 Amps (or greater).  
CAUTION  
Receptacles may be marked with rating value greater  
than generator output capacity.  
• NEVER attempt to power a device requiring more amperage  
than generator or receptacle can supply.  
120Volt AC, 30 Amp Locking  
Receptacle  
• DO NOT overload the generator. See “Don’t Overload  
Generator”.  
Use a NEMA L5–30 plug with this receptacle. Connect a  
3–wire cord set rated for 125Volt AC loads at 30 Amps to  
the plug (Figure 13).  
12Volt DC, 10 Amp Receptacle  
This receptacle allows you to recharge a 12Volt  
automotive or utility style storage battery with the battery  
charge cables provided (Figure 11).  
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Figure 13 — 120Volt AC, 30 Amp, Locking Receptacle  
3-Wire Cord Set  
120/240Volt AC, 50 Amp Receptacle  
Use a NEMA 14–50 plug with this receptacle (Figure 15).  
Connect a 4-wire cord set rated for 250Volt AC loads at  
50 Amps to the plug.  
NEMA L5-30  
Neutral  
120V  
Hot  
Figure 15 — 120/240Volt AC, 50 Amp Receptacle  
240Volts AC  
Frame Ground  
Ground (Green)  
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.  
Y (Hot)  
X (Hot)  
120/240Volt AC, 30 Amp, Locking  
Receptacle  
Use a NEMA L14–30 plug with this receptacle. Connect a  
4–wire cord set rated for 250Volt AC loads at 30 Amps (or  
greater) (Figure 14).You can use the same 4–wire cord if  
you plan to run a 120Volt load.  
120Volts  
AC  
120Volts  
AC  
W (Neutral)  
Figure 14 — 120/240Volt AC, 30 Amp Receptacle  
4-Wire Cord Set  
NEMA 14-50  
Use this receptacle to operate 120/240Volt AC, 60 Hz,  
single phase loads requiring up to 7,500 watts (7.5 kW) of  
power.The outlet is protected by a 35 Amp push–to–reset  
circuit breaker.  
240V  
120V  
120V  
W (Neutral)  
X (Hot)  
Ground (Green)  
Y (Hot)  
NEMA L14-30  
This receptacle powers 120/240Volt AC, 60 Hz, single  
phase loads requiring up to 3,600 watts of power at  
30 Amps for 120Volts; 7,200 watts of power (7.2 kW) at  
30 Amps for 240Volts.The outlet is protected by a 30 Amp  
push–to–reset circuit breaker.  
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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.  
DON'T OVERLOAD  
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:  
Figure 16 - Wattage Reference Chart  
Additional  
Surge  
(Starting)  
Watts  
Rated*  
(Running)  
Watts  
Tool or Appliance  
Essentials  
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.  
Light Bulb - 75 watt  
Deep Freezer  
Sump Pump  
Refrigerator/Freezer - 18 Cu. Ft.  
Water Well Pump - 1/3 HP  
Heating/Cooling  
Window AC - 10,000 BTU  
Window Fan  
Furnace Fan Blower - 1/2 HP  
Kitchen  
Microwave Oven - 1000 Watt  
Coffee Maker  
Electric Stove - Single Element  
Hot Plate  
Family Room  
DVD/CD Player  
VCR  
Stereo Receiver  
Color Television - 27”  
Personal Computer w/17” monitor  
Other  
75  
500  
800  
800  
1000  
-
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.  
500  
1200  
1600  
2000  
1200  
300  
800  
1800  
600  
1300  
Example:  
Rated (Running)  
Watts  
Additional Surge  
(Starting) Watts  
1800  
1000  
1500  
1500  
2500  
-
-
-
-
Tool or Appliance  
Window Air  
Conditioner  
Refrigerator  
Deep Freezer  
Television  
1200  
800  
500  
500  
1600  
500  
-
-
100  
100  
450  
500  
800  
-
-
-
-
-
Light (75 Watts)  
75  
3075 Total  
Running Watts  
1800 Highest  
Surge Watts  
Total Rated (Running) Watts  
Highest Additional Surge Watts  
= 3075  
= 1800  
Security System  
180  
300  
480  
-
-
AM/FM Clock Radio  
Garage Door Opener - 1/2 HP  
Electric Water Heater - 40 Gallon  
DIY/Job Site  
Total Generator Output Required = 4875  
520  
-
4000  
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.  
Quartz Halogen Work Light  
Airless Sprayer - 1/3 HP  
Reciprocating Saw  
Electric Drill - 1/2 HP  
Circular Saw - 7 1/4”  
Miter Saw - 10”  
Planer/Jointer - 6”  
Table Saw/Radial Arm Saw - 10”  
Air Compressor - 1-1/2 HP  
1000  
600  
960  
1000  
1500  
1800  
1800  
2000  
2500  
-
1200  
960  
1000  
1500  
1800  
1800  
2000  
2500  
*Wattages listed are approximate only. Check tool or  
appliance for actual wattage.  
3. Permit the generator output to stabilize (engine runs  
smoothly and attached device operates properly.  
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NOTE: DO NOT use a garden hose to clean generator.  
SPECIFICATIONS  
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.  
Starting Wattage . . . . . . . . . . . . . . . . . . . . . .13,500 watts  
Wattage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,500 watts  
AC Load Current:  
At 120Volts . . . . . . . . . . . . . . . . . . . . . . . . .62.5 Amps  
At 240Volts . . . . . . . . . . . . . . . . . . . . . . . . .31.2 Amps  
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase  
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . . . .60 Hertz  
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . 7 U.S. gallons  
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . .240 lbs.  
WARNING  
Unintentional sparking can result in fire or  
electric shock.  
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.  
WHEN ADJUSTING OR MAKING REPAIRSTOYOUR  
GENERATOR  
• Disconnect the spark plug wire from the spark plug and place  
the wire where it cannot contact spark plug.  
WHENTESTING FOR ENGINE SPARK  
• Use approved spark plug tester.  
• DO NOT check for spark with spark plug removed.  
NOTE: Should you have questions about replacing  
components on your Generac Portable Products generator,  
please call 1-800-270-1408 for assistance.  
Battery Maintenance  
Other than float charging, described elsewhere, no  
maintenance is required for the battery. Keep the battery  
and terminals clean and dry.  
Engine Maintenance  
See engine operator’s manual for instructions.  
IMPORTANT: Battery charging should be performed in a  
dry location, such as inside a garage.  
CAUTION  
Avoid prolonged or repeated skin contact with used  
To Clean the Generator  
• Use a damp cloth to wipe exterior surfaces clean.  
motor oil.  
• Used motor oil has been shown to cause skin cancer in  
certain laboratory animals.  
CAUTION  
Improper treatment of generator can damage it and  
shorten its life.  
• 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.  
• DO NOT expose generator to excessive moisture, dust, dirt,  
or corrosive vapors.  
• DO NOT insert any objects through cooling slots.  
• Use a soft bristle brush to loosen caked on dirt or oil.  
• Use a vacuum cleaner to pick up loose dirt.  
Generator Maintenance  
• Use low pressure air (not to exceed 25 psi) to blow  
away dirt. Inspect cooling air slots and opening on  
generator.These openings must be kept clean and  
unobstructed.  
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.  
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Engine Storage  
STORAGE  
See engine operator’s manual for instructions.  
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.  
Other StorageTips  
To prevent gum from forming in fuel system or on  
essential carburetor parts, add fuel stabilizer into fuel  
tank and fill with fresh fuel. Run the unit for several  
minutes to circulate the additive through the carburetor.  
The unit and fuel can then be stored for up to  
Generator Storage  
• Clean the generator as outlined in “To Clean the  
Generator.”  
24 months. Fuel stabilizer can be purchased locally.  
• DO NOT store fuel from one season to another unless  
it has been treated as described above.  
• Check that cooling air slots and openings on generator  
are open and unobstructed.  
• Replace fuel container if it starts to rust. Rust and/or dirt  
in fuel can cause problems if it's used with this unit.  
WARNING  
Storage covers can be flammable.  
• Store unit in a clean and dry area.  
• DO NOT place a storage cover over a hot generator.  
• Let equipment cool for a sufficient time before placing the  
cover on the equipment.  
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TROUBLESHOOTING  
Problem  
Cause  
Correction  
1. One of the circuit breakers is open.  
2. Fault in generator.  
1. Reset circuit breaker.  
2. Contact Generac service facility.  
No AC output is available,  
but engine is running.  
3. Poor connection or defective cord set. 3. Check and repair.  
4. Connected device is bad.  
4. Connect another device that is in  
good condition.  
1. Short circuit in a connected load.  
2. Generator is overloaded.  
1. Disconnect shorted electrical load.  
2. See "Don't Overload Generator".  
3. Contact Generac service facility.  
Engine runs good at no-  
load but "bogs" down"  
when loads are connected.  
3. Shorted generator circuit.  
1. Fuel valve is in the "Off" position.  
2. Failed battery.  
1. Turn fuel valve to "On" position.  
2. Replace battery.  
Engine will not start; or  
starts and runs rough.  
Engine shuts down during  
operation.  
Out of gasoline.  
Load is too high.  
Fill fuel tank.  
Engine lacks power.  
See "Don't Overload Generator".  
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GENERAC PORTABLE PRODUCTS OWNER EQUIPMENT WARRANTY POLICY  
Effective November 1, 2004  
LIMITED WARRANTY  
"Generac Portable Products is a licensed trademark of Briggs & Stratton Power Products. Briggs & Stratton Power Products will  
repair or replace, free of charge, any part, or parts of the equipment** that are defective in material or workmanship or both.  
Transportation charges on product submitted for repair or replacement under this warranty must be borne by purchaser.This  
warranty is effective for the time periods and subject to the conditions provided for in this policy. For warranty service, find your  
nearest Authorized service dealer by calling 1-800-270-1408.Warranty service may only be performed by a Briggs & Stratton  
Power Products Authorized service dealer.  
THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND  
FITNESS FOR A PARTICULAR PURPOSE,ARE LIMITED TO THE TIME PERIOD SPECIFIED, OR TO THE EXTENT PERMITTED  
BY LAW.ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED. LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER  
ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW. Some countries or  
states do not allow limitations on how long an implied warranty lasts, and some countries or states do not allow the exclusion or  
limitation of incidental or consequential damages, so the above limitation and exclusion may not apply to you.This warranty gives  
you specific legal rights and you may also have other rights that vary from country to country or state to state.”  
WARRANTY PERIOD*  
PRODUCTS**  
Pressure Washer  
Portable Generator  
CONSUMER USE  
1 year  
COMMERCIAL USE  
90 days  
2 years (2nd year parts only)  
1 year  
* The warranty period begins on the date of purchase by the first retail consumer or commercial end user, and continues for the  
period of time stated in the table above. "Consumer use" means personal residential household use by a retail consumer.  
"Commercial use" means all other uses, including use for commercial, income producing or rental purposes. Once equipment has  
been used commercially, it shall thereafter be considered to be in commercial use for purposes of this warranty.  
** The engine and starting batteries are warranted solely by the manufacturers of those products.  
WARRANTY REGISTRATION IS NOT NECESSARYTO OBTAINWARRANTY ON BRIGGS & STRATTON POWER  
PRODUCTS EQUIPMENT.SAVEYOUR PROOF OF PURCHASE RECEIPT.IFYOU DO NOT PROVIDE PROOF OFTHE  
INITIAL PURCHASE DATEATTHETIMEWARRANTY SERVICE IS REQUESTED,THE MANUFACTURING DATE OFTHE  
EQUIPMENTWILL BE USEDTO DETERMINETHEWARRANTY PERIOD.  
About your equipment warranty:  
We welcome warranty repair and apologize to you for being inconvenienced.Any Authorized service dealer may perform warranty  
repairs. Most warranty repairs are handled routinely, but sometimes requests for warranty service may not be appropriate. For  
example, warranty service would not apply if equipment damage occurred because of misuse, lack of routine maintenance, shipping,  
handling, warehousing or improper installation. Similarly, the warranty is void if the manufacturing date or the serial number on the  
equipment has been removed or the equipment has been altered or modified. During the warranty period, the Authorized service  
dealer, at its option, will repair or replace any part that, upon examination, is found to be defective under normal use and service.This  
warranty will not cover following repairs and equipment:  
Normal Wear: Outdoor power equipment, like all mechanical devices, needs periodic parts, service and replacement to perform  
well.This warranty does not cover repair when normal use has exhausted the life of a part or the equipment.  
Installation and Maintenance:This warranty does not apply to equipment or parts that have been subjected to improper or  
unauthorized installation or alteration and modification, misuse, negligence, accident, overloading, overspeeding, improper  
maintenance, repair or storage so as, in our judgment, to adversely affect its performance and reliability.This warranty also does not  
cover normal maintenance such as adjustments, fuel system cleaning and obstruction (due to chemical, dirt, carbon or lime, etc.).  
Other Exclusions: Also excluded from this warranty are wear items such as quick couplers, oil gauges, belts, o-rings, filters,  
pump packing, etc., pumps which have been run without water supplied or damage or malfunctions resulting from accidents,  
abuse, modifications, alterations, or improper servicing or freezing or chemical deterioration.Accessory parts such as guns,  
hoses, wands and nozzles are excluded from the product warranty.This warranty excludes failures due to acts of God and other  
force majeure events beyond the manufacturers control.Also excluded is used, reconditioned, and demonstration equipment;  
equipment used for prime power in place of utility power and equipment used in life support applications.  
BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC  
JEFFERSON,WISCONSIN, U.S.A.  
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