7000EXL
Portable Generator Owner’s Manual
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
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.
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Generac Portable Products 7000EXL Extended Life Generator
• The generator produces a very powerful voltage that can
• Never operate the generator:
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.
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.
• 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.
GROUNDINGTHE
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).
• 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
Figure 1 — Grounding Wing Nut
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.
Grounding Wing Nut
• 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.
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.
• 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.
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.
• Do Not insert any object through cooling slots of the
engine.You could damage the unit or injure yourself.
3
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Generac Portable Products 7000EXL Extended Life Generator
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.
CHECK BATTERY / ATTACH
NEGATIVE BATTERY
WIRE
IMPORTANT: Any attempt to run the unit before it has
been serviced with the recommended oil will result in an
engine failure.
The sealed battery on the generator is fully charged and
pre–installed except for the negative (black) battery cable.
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.
To install:
• Cut off tie wrap securing loose end of negative (black)
cable.
• Battery charge cables
• Remove nut and washer on the negative battery terminal.
• Battery float charger
• Slide the negative battery cable over the screw on the
negative terminal (Figure 2).
• Extenda Panel™ cord
• Generator and engine owner’s manuals
• Locking 30 Amp plug
Figure 2 — Negative Battery Connection
Nut
• Three packets of fuel stabilizer
• Two bottles of engine oil
Washer
Negative
battery
Screw
cable
Positive battery cable
• Reattach washer and nut and tighten.
• Verify that the connections to the battery and generator
are tight and secure.
4
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Generac Portable Products 7000EXL Extended Life Generator
• 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).
BEFORE STARTINGTHE
ENGINE
Figure 3 — Typical Fuel Expansion Space
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.
• 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.
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.
Never use engine or carburetor cleaner products in the
fuel tank or permanent damage may occur.
• 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.
5
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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.
Air Cleaner
Run/Stop Switch
Choke Lever
Fuel Tank
Spark Arrester Muffler
Start Button
120Volt AC, 20 Amp
Duplex Receptacle
Idle Control Switch
120/240Volt AC,
30 Amp Receptacle
12Volt DC, 10 Amp
Receptacle
Circuit Breakers (AC)
120Volt AC, 30 Amp
Grounding Wing Nut
Receptacle
12Volt DC,10 Amp Receptacle — Recharge a
discharged 12 Volt automotive type battery through this
receptacle.
120Volt AC, 20 Amp, Duplex Receptacle — May be
used to supply electrical power for the operation of
120Volt AC, 20 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
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.
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.
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.
FuelTank — 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.
Air Cleaner — Uses a dry type filter element and foam
pre–cleaner to limit the amount of dirt and dust sucked
into the engine.
6
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4. Place the choke lever in the “Full” choke position
OPERATINGTHE
(Figure 7).
GENERATOR
Figure 7 — Choke Positions
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:
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.
1. Turn the fuel valve to the “On” position (Figure 4).
Figure 4 — FuelValve
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.
FuelValve is shown
in the On position
6. Move the choke lever to “Half” choke position, and
pull recoil handle twice.
2. Make sure the Idle Control switch is in “Off” position
• If engine fails to start, repeat steps 4 thru 6.
(Figure 5).
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.
Figure 5 — Idle Control Switch
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.
3. Set the Run/Stop switch to “Run” position (Figure 6).
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes after
starting.
Figure 6 — Run/Stop 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.
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Generac Portable Products 7000EXL Extended Life Generator
• DO NOT OVERLOADTHE GENERATOR. Add up
To recharge 12Volt batteries, proceed as follows:
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.
• 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.
Stopping the Engine
• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with electrical
devices plugged in and turned on.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to panel
receptacle identified by the words “12 VOLTS D.C.”
• Put the idle control switch in the “Off” position.
• Connect battery charge cable clamp with red handle to
the positive (+) battery terminal (Figure 8).
• Let engine run at no–load for 30 seconds to stabilize the
internal temperatures of engine and generator.
Figure 8 — Battery Charge Cable Connection
• Move run/stop switch to “Stop.”
• Close the fuel shut–off valve.
Red
Operating Automatic Idle Control
Black
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
• Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 8).
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.
• 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.
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.
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.
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.
• 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 120Volt AC wall receptacle.
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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.
Figure 9 — Battery Charger Jack
NOTE: Follow all safety precautions when connecting any
extension cord or device to the generator.
RECEPTACLES
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 11).You can use the same 4-wire cord if
you plan to run a 120Volt load.
• Unplug the charger from the unit and the wall outlet
when generator is being started and while it is in
operation.
Figure 11 — 120/240Volt AC, 30 Amp Receptacle
• 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.
Figure 10 — Extenda Panel™
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 120Volts 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.
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Generac Portable Products 7000EXL Extended Life Generator
120Volt AC, 30 Amp Locking
Figure 13 — 120Volt AC, 20 Amp Receptacles
Receptacle
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 12).
Figure 12 — 120Volt, 30 Amp Receptacle
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 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.
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.
Figure 14 — 12Volt DC, 10 Amp Receptacle
120Volt 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
125Volt AC loads at 20 Amps (or greater).
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• The rated wattage of lights can be taken from wattage
DON’T OVERLOADTHE
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:
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.
• 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).
Figure 15 — Wattage Reference Guide
Recreational/Home Uses
Professional/Contractor 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
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
11
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Generac Portable Products 7000EXL Extended Life Generator
Generator Maintenance
SPECIFICATIONS
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.
Maximum Surge Watts . . . . . . . . . . . . . . . .12,250 watts
Continuous Wattage Capacity . . . . . . . . . . .7,000 watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0
Rated Maximum Continuous AC Load Current:
At 120Volts . . . . . . . . . . . . . . . . . . . . . . .58.3 Amps
At 240Volts . . . . . . . . . . . . . . . . . . . . . . .29.2 Amps
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . .60 Hertz
Fuel Tank Capacity. . . . . . . . . . . . . . . . . . . 7 U.S. gallons
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . .240 lbs.
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.
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.
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
Engine Maintenance
See engine owner’s manual for instructions.
• Use a damp cloth to wipe exterior surfaces clean.
• A soft bristle brush may be used to loosen caked on dirt
or oil.
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.
• 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.
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Engine Storage
STORAGE
See engine owner’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, 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.
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.
• Do Not store gasoline from one season to another
unless it has been treated as described above.
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.
• 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.
13
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NOTES
14
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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.
Engine is running, but no
AC output is available.
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. Engine speed is too slow.
3. Generator is overloaded.
1. Disconnect shorted electrical load.
2. Contact Generac service facility.
3. See “Don't Overload the Generator”
on page 12.
Engine runs good at no-
load but “bogs” down"
when loads are connected.
4. Shorted generator circuit.
1. Run/Stop Switch set to “STOP”.
2. Dirty air cleaner.
4. Contact Generac service facility.
1. Set switch to “RUN”.
2. Clean or replace air cleaner.
3. Fill fuel tank.
3. Out of gasoline.
4. Stale gasoline.
5. Spark plug wire not connected to
spark plug.
4. Drain gas tank; fill with fresh fuel.
5. Connect wire to spark plug.
Engine will not start; or
starts and runs rough.
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.
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. Load is too high.
1. Fill fuel tank.
2. Fill crankcase to proper level.
1. See “Don't Overload the Generator”
on page 12.
Engine lacks power.
2. Dirty air filter.
2. Replace air filter.
1. Choke is opened too soon.
1. Move choke to halfway position until
engine runs smoothly.
Engine “hunts” or falters.
2. Carburetor is running too rich or too
lean.
2. Contact Generac service facility.
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SCHEMATIC
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WIRING DIAGRAM
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Generac Portable Products 7000EXL Extended Life Generator
EXPLODEDVIEW – ALTERNATOR
18
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EXPLODEDVIEW – FRAME
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Generac Portable Products 7000EXL Extended Life Generator
PARTS LIST – ALTERNATOR & FRAME
Item Part #
Qty Description
Item Part #
Qty Description
GROMMET, Rubber
1
A187024
J189176
92982
92665
B1998
B4363
85000
93826
78831B
83465
77395
80270
78299
B2153
43116
51731
B4135
187104
49820
83083
86307
92247
A92531
189160
22129
82857
22531
92609
22142
A7433
A92731
90239
B1342G
65791
96796
47481
B1897G
20566
40976
92532
66476
186747
92630
J96068
14353621
26850
BB3061
81917
B4986
186798
56893
84132
1
1
1
1
1
1
1
1
4
4
8
1
1
9
4
2
2
4
2
1
4
1
1
CRADLE
SHIELD, Heat
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
67022
66825C
86494
1
1
1
3
1
2
1
4
2
1
2
4
4
5
1
2
4
1
2
2
1
2
2
2
1
1
1
1
2
4
5
1
1
1
1
1
2
2
1
2
2
2
2
1
1
1
1
3
1
1
1
1
2
CARRIER, Rear Bearing
SCREW, M6-1.0 x 16 Wing
WASHER, Shakeproof #10
ASSEMBLY, Brush Holder
TAPTITE, M5-0.8 x 16
COVER, Bearing Carrier
TAPTITE, M5-0.8 x 10
GRIP
3
DECAL, Danger
4
INSULATION, #2-1/4" Thick
TANK, Fuel (Incls Item 12 & 13)
CAP, with Gauge, Fuel
CLIP, Insulation
23762
5
66386
6
66849
7
B4871
74908
8
DECAL, Start Instructions
HHMS, M6-1.0 x 60, SEMS
GROMMET,Tank
NUT, Flange Lock - M6
VALVE,Tank
BUSHING,Tank
SCREW, 12-14 x 7/8, Self Driller
HHCS, M6 - 1.0 x 12
HHCS, M8 - 1.25 x 50
PIN, with Lanyard
WASHER, Nylon
NUT, M8 Nylok
9
B4605
66849C
65795
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
TAPTITE, M5-0.8 x 30
RECTIFIER, Battery Charge
BOLT, Stator M6-1 x 190mm
WASHER, Flat 5/16 - M8
LOCKWASHER, 1/4" - M6
MANUAL, Operators
HANDLE
66449L
22145
22097
186744
BB5586
52858
B186927
27007
42909
93693G
B4966
22247
87005A
189302B
77282
NUT, Lock M8
LEG, Support
MOUNT,Vibration
CAPSCREW, M8 - 1.25 x 30
AXLE
SCREEN, Spark Arrester
HHMS, 5/16-24 x 3/4"
HOUSING, Engine Adapter
SUPPORT, Engine
WHEEL
WASHER,Wheel
12 NUT, 5/16-18 Flange Serrated
PIN, Retaining
2
4
2
2
2
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
2
2
1
1
2
5
1
WASHER, Lock - M8
MOUNT,Vibration
WIRE ASM, #16
SWITCH, Starter
HHCS, 5/16-18 x 1-3/4"
MOUNT,Vibration
188987
188989
22287
22097
22127
BRACKET, Switch
ASM, Jack, DC
SCREW, 5/16 - 18 x 3/4"
MUFFLER
HHCS, 1/4 - 20 x 3/4"
LOCKWASHER, 1/4 - M6
NUT, 1/4 - 20
SUPPORT, Engine & Muffler
GASKET, Muffler
J186704
B4489
189302C
185939H
73054
TRAY, Battery
ASSEMBLY, Rotor (Incls Item 34)
BEARING
BATTERY, 12V 18 AH
WIRE ASM, #13
WASHER, Special Flat - M8
HHCS, 5/16-24 x 10-5/8
ASSEMBLY, Stator
DECAL, 1-800
SCREW, M8 - 1.25 x 20
BRACKET, Muffler
WIRE ASM, #55
DECAL, Fuel Shut-Off
DECAL, Hot Muffler
HHCS, M8 - 1.25 x 20
MANUAL, Engine
77816
39253
A8927
52618
HHCS, M5 - 0.8 x 12
WASHER, M5 Flat
NUT, M5 Flange Hex
WASHER, Flat 10 GA 0.34 x 1
WIRE ASM, #13
LUG, 5/16 #22/18 I-S
DECAL, Instruction, ES
CHARGE, Battery Float
FUEL STABILIZER, 1oz Tube
CABLE, Battery Charge
PLUG, 120V/30 Amp
EXTENDA PANEL
ENGINE
CAPSCREW, M6 - 1.0 x 12mm
DECAL, Control Panel
ASSEMBLY, Control Box
SHIELD, Heat
23897
52856
50190
96113
WIRE, Ground
58359
LW, EXT, Shakeproof M6
BOTTLE, Oil
189198
B4177
189208
PIN, Roll 4mm x 10
DECAL, Ground
101 65787
102 37806
103 188971
900 NSP
DECAL, Heat Shield
CRIMPTITE, 10-24 x 1/2"
ASSEMBLY, Power Regulator
20
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Generac Portable Products 7000EXL Extended Life Generator
EXPLODEDVIEW AND PARTS LIST – CONTROL PANEL
Item Part #
Qty Description
Item Part #
Qty Description
1
2
A92070
23897
49226
91526
82538
82881
43181
43182
90418
75207A
75207
23365
68868
1
4
4
4
1
4
4
4
1
2
2
6
1
PANEL, Control
14
43437
1
OUTLET, 120V/240V, 30A
FLAT WASHER, #10 M5
LOCK WASHER, M5
SCREW, M5-0.8 x 12mm
SWITCH, Idle Control
LOCK WASHER, 7/16"
SCREW, M3 - 0.5 x 10mm
LOCK WASHER, M3
OUTLET, 12V
CIRCUIT BREAKER, 30A
CIRCUIT BREAKER, 20A
WASHER, #8 Shakeproof
OUTLET, 120Volt, 30 Amp
Locking
Locking
OUTLET, 120V, 20A Duplex
FLAT WASHER, M4
LOCK WASHER, #8 M4
NUT, M4-0.7 Hex
SCREW, #6-32 x 3/8"
BOARD, System Control
STAND-OFF, 3/4" Hex
CIRCUIT BREAKER. 12V, 10A
(auto)
3
15
16
17
18
19
20
21
22
68759
43180
22264
51715
64526
83970
64525
87962
1
6
6
6
8
1
4
1
4
5
6
7
8
9
10
11
12
13
23
24
25
26
84335
84134
B92069
84028
1
1
1
1
ASSEMBLY,Wire Harness
GROMMET, Rubber Conn.
BOX, Control Panel
TRANSFORMER, Idle Control
21
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Generac Portable Products 7000EXL Extended Life Generator
NOTES
22
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Generac Portable Products 7000EXL Extended Life Generator
NOTES
23
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PORTABLE GENERATOR LIMITED WARRANTY
GENERAC PORTABLE PRODUCTS (hereafter referred to as the COMPANY) warrants to the original purchaser that the
components in its portable generator will be free from defects in materials or workmanship for the items and period set
forth below from the date of original purchase.This warranty does not include the gasoline engine when furnished or
attached because such engine is covered solely by the engine manufacturer’s warranty. Starting batteries are not warranted
by the COMPANY.The term “original purchaser” means the person for whom the generator is originally purchased.This
warranty is not transferable and applies only to portable generators driven by an overhead valve engine.
Warranty Schedule:
Consumer*
Commercial*
Engine
Warranted solely by the engine manufacturer
All other parts
2 years (2nd year parts only)
1Year
With the exception of European Community Countries, all units bound for export shall be warranted for One (1)
Year in Consumer applications, and 90 days in Commercial applications as defined below.
*NOTE: For the purpose of this warranty "consumer use" means personal residential household use by
original purchaser.This warranty does not apply to units used for Prime Power in place of utility.
"Commercial Use" means all other uses, including rental, construction, commercial and income producing
purposes. Once a generator has experienced commercial use, it shall thereafter be considered a commercial
use generator for the purposes of this warranty.
During said warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination by the
COMPANY, is found to be defective under normal use and service**.All transportation costs under warranty, including
return to the factory if necessary, are to be borne by the purchaser and prepaid by the purchaser.This warranty does not
cover normal maintenance and service and does not apply to a generator set, alternator, or parts which have been
subjected to improper or unauthorized installation or alteration, misuse, negligence, accident, overloading, overspeeding,
improper maintenance, repair or storage so as, in the COMPANY’s judgement, to adversely affect its performance and
reliability.
**NORMALWEAR: As with all mechanical devices, the generator needs periodic parts service and
replacement to perform well.This warranty will not cover repair when normal use has exhausted the life of
a part or generator.
THERE IS NO OTHER EXPRESSWARRANTY.THE COMPANY HEREBY DISCLAIMS ANY AND ALL
IMPLIEDWARRANTIES, INCLUDING BUT NOT LIMITEDTOTHOSE OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSETOTHE EXTENT PERMITTED BY LAW.THE DURATION OF ANY
IMPLIEDWARRANTIESWHICH CANNOT BE DISCLAIMED IS LIMITEDTOTHETIME PERIOD AS
SPECIFIED INTHE EXPRESSWARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL
DAMAGES UNDER ANY AND ALLWARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS ANY
RESPONSIBILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, SUCH ASTHE LOSS OFTIME OR
THE USE OFTHE POWER EQUIPMENT, OR ANY COMMERCIAL LOSS DUETOTHE FAILURE OFTHE
EQUIPMENT:AND ANY IMPLIEDWARRANTIES ARE LIMITEDTOTHE DURATION OFTHISWRITTEN
WARRANTY.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or
consequential damages, so the above limitations or exclusions may not apply to you.This warranty gives you specific legal
rights and you may also have other rights, which vary from state to state.
For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Or look on the
facility.This warranty will not apply to service at any other facility.At the time of requesting warranty service, evidence of
original purchase date must be presented.
GENERAC PORTABLE PRODUCTS
Jefferson,Wisconsin U.S.A.
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