To obtain the operator's manuals, illustrated parts list or detailed help information for your Vanguard™ engine, you must search by your engine model number. This is an 11- or 12-digit number stamped into metal directly on your engine. You must use the engine Model, Type and Trim with dashes, e.g.

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12H702-0505-01 - Use '-99' trim if the trim numbers (last 2 numbers) originally entered do not bring back results - Do not include spaces after the numbers - Add a leading '0' for a model number with 5 or less digits (must be 6 digits total prior to the first dash).

Paul Aldmon on Oct 31, 2015. Manual Manual reads good, printing is a pain!

Owner’s Manual Parts Included. Table of Contents Generator Wheel kit Storage Cover Battery Battery Float Charger Battery Charge Cables Spare Spark Plug, Air Filter, and Oil Filter Spark Plug Wrench (2) Locking 30 Amp Plugs Engine Oil Owner’s Manual Engine Manual.If any parts are missing or damaged, call 1-800-270-1408. Safety Rules 2-3 Assembly 4-5 Know Your Generator. 6 Operation 7-12 Product Specifications. 13 Maintenance 13 Storage 14 Troubleshooting. 15 Schematic 16 Wiring Diagram. Power Equipment User Manual Free Download.

Electric Generator for Power Manual. Free Manual Download PDF. 17 Replacement Parts. Last Page Questions?

Help is just a moment away! Call: Generac Generator Helpline – 1-800-270-1408 M-F 8-5 CT Web: 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.

1019-3 (7,500 Watt AC Generator) Manual No. 189713GS Revision 0 7500EXL Extended Life Generator EQUIPMENT DESCRIPTION This generator is an engine­driven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, appliance, 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 pull up to 62.5 Amps at 120 Volts or 31.2 Amps at 240 Volts. SAFETY RULES This generator set was designed and manufactured for specific applications. Do Not attempt to modify the unit or use it for any application it was not designed for. If you have any questions about your generator’s application, ask your dealer or consult the factory. The manufacturer could not possibly anticipate every circumstance that might involve a hazard.

For that reason warnings in the manual and warnings on tags or decals affixed to the unit are not all­inclusive. 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. Do Not exceed the generator’s wattage/amperage capacity.The total load should not be greater than 7,500 watts. See “Don’t Overload the Generator ” on page 12. The generator’s revolving field is driven at about 3,600 rpm by a single-cylinder engine.

Every effort has been made to ensure that information in this manual is accurate and current. However, Generac reserves the right to change, alter or otherwise improve the product and this document at any time without prior notice. WARNING: The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Do Not tamper with engine governed speed. High operating speeds are dangerous and increase risk of personal injury or damage to equipment.The generator supplies correct rated frequency and voltage only when running at proper governed speed.

Incorrect frequency and/or voltage can damage some connected electrical loads. Operating at excessively low speeds imposes a heavy load.When adequate engine power is not available engine life may be shortened. The Emission Control System for this generator is warranted for standards set by the Environmental Protection Agency. For warranty information refer to the engine owner’s manual. You must isolate the generator from the electric utility using approved transfer equipment if this unit is used for backup power. Failure to isolate the generator from the power utility may result in injury or death to electric utility workers and damage to the generator due to a backfeed of electrical energy.

Whenever unit is providing backup power, the electric utility must be notified. Generator exhaust gases contain DEADLY carbon monoxide gas.

If breathed in sufficient concentrations, carbon monoxide can cause unconsciousness or death. Operate this equipment outdoors where adequate ventilation is available. 2 7500EXL Extended Life Generator The generator produces a very powerful voltage that can cause serious injury or death by electrocution. Never touch bare wires or receptacles. Never permit a child or any unqualified person to operate the generator. Never handle any kind of electrical cord or device while standing in water, while barefoot or while hands or feet are wet.

Death or serious injury from electrocution may result. Use a ground fault circuit interrupter (GFCI) in any damp or highly conductive area (such as metal decking or steel work). Never use worn, bare, frayed or otherwise damaged electrical cords with the generator. Death, serious injury and property damage from electrical shock may result.

Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE. Never allow smoking, open flames, sparks or heat in the vicinity while handling gasoline. Avoid spilling gasoline on a hot engine.

Comply with all laws regulating storage and handling of gasoline. Do Not overfill the fuel tank. Always allow room for fuel expansion. If tank is overfilled, fuel can overflow onto a hot engine and cause a FIRE or an EXPLOSION. Never store a generator with fuel in the tank where gasoline vapors might reach an open flame, spark or pilot light (as on a furnace, water heater, clothes dryer). FIRE or an EXPLOSION may result. The unit requires an adequate flow of cooling air for its continued proper operation.

Never operate the unit inside any room or enclosure where the free flow of cooling air into and out of the unit might be obstructed. Allow at least 2 feet of clearance on all sides of generator, even while operating unit outdoors, or you could damage the unit. Never start or stop the unit with electrical loads connected to receptacles with the connected devices turned ON.

Start the engine and let it stabilize before connecting any electrical loads. Disconnect all electrical loads before shutting down the generator. Do Not insert any object through cooling slots of the engine.You could damage the unit or injure yourself.

Never operate the generator: in rain; in any enclosed compartment; when connected electrical devices overheat; if electrical output is lost; if engine or generator sparks; if flame or smoke is observed while unit is running; if unit vibrates excessively. GROUNDING THE GENERATOR The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground. Local electrical codes may also require proper grounding of the unit. For that purpose, a GROUNDING WING NUT is provided on the generator end (Figure 1).

Figure 1 — Grounding Wing Nut Grounding Wing Nut Generally, connecting a No. 12 AWG (American Wire Gauge) stranded copper wire to the grounding wing nut and to an earth­driven copper or brass grounding rod (electrode) provides adequate protection against electrical shock. Be careful to keep the grounding wire attached after connecting the stranded copper wire.

However, local codes may vary widely. Consult with a local electrician for grounding requirements in your area. Properly grounding the generator helps prevent electrical shock if a ground fault condition exists in the generator or in connected electrical devices. Proper grounding also helps dissipate static electricity, which often builds up in ungrounded devices. 3 7500EXL Extended Life Generator Your generator requires some assembly and is ready for use after it has been properly serviced with the recommended oil and fuel. If you have any problems with the assembly of your generator, please call the generator helpline at 1-800-270-1408. IMPORTANT: Any attempt to run the unit before it has been serviced with the recommended oil will result in an engine failure.

INSTALL WHEEL KIT The wheel kit is designed to greatly improve the portability of your generator. NOTE: Wheel kit is not intended for over-the-road use.

You will need a socket wrench with 1/2 ” or 13mm sockets and a needle-nose plier to install this kit. Refer to Figure 2 and install the wheel kit as follows: Place the generator on a hard flat surface. Stand at the engine end of the generator and gently tilt the generator forward, high enough to place wooden blocks beneath the cradle.This will allow you to add the wheels. Slide the axle through the holes in the brackets provided on the generator cradle.

Slide a wheel and flat washer on one end of the axle. Make sure the air inflation valve is outward. Insert the retaining pin. Slide the axle through until wheel is tight against bracket.

Slide the other wheel and flat washer on the other end of the axle. Make sure the air inflation valve is outward.

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Insert the retaining pin using the needle-nose plier. Remove the wooden blocks. Attach the vibration mounts to the support leg with 30mm capscrews, washers and lock nuts. REMOVE GENERATOR FROM CARTON Set the carton on a rigid flat surface with “This Side Up ” arrows pointing upward.

Carefully open the top flaps of the shipping carton. Review “Cold Weather Operation ” on page 9. Cut down corners at one end of carton from top to bottom and lay that side of carton down flat. Remove all packing material, carton fillers, etc.

Remove the generator from the shipping carton. Figure 2 — Install Wheel Kit Axle Wheel Hex Nut Flat Washer Support Leg Vibration Mount Flat Washer 30mm Cap Screw 20mm Cap Screw Retaining Pin Hex Nut 4 7500EXL Extended Life Generator With the wheels on, you can now lift up the handle end and attach the support leg with 20mm cap screws and lock nuts. Check each fastener to ensure it is secure and the tires are inflated between 15-40 PSI. 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.

CHECK BATTERY / ATTACH NEGATIVE BATTERY WIRE The sealed battery on the generator is fully charged and pre­installed except for the negative (black) battery cable. To install: Cut off tie wrap securing loose end of negative (black) cable. Remove nut and washer on the negative battery terminal. Slide the negative battery cable over the screw on the negative terminal (Figure 3).

Figure 3 — Negative Battery Connection Add Gasoline WARNING! Never fill fuel tank indoors. Never fill fuel tank when engine is running or hot.Allow unit to cool for two minutes before refueling. Do Not light a cigarette or smoke when filling the fuel tank.

Do Not overfill the fuel tank. Always allow room for fuel expansion. Use regular UNLEADED gasoline with the generator engine. Do Not use premium gasoline.

Do Not mix oil with gasoline. Clean area around fuel fill cap, remove cap. Slowly add unleaded regular gasoline to fuel tank. Be careful not to overfill. Allow about 1/2 ” of tank space for fuel expansion (Figure 4).

Figure 4 — Typical Fuel Expansion Space Nut Washer 1/2 ” Air Space Negative battery cable Tank Fuel Screw Positive battery cable Install fuel cap and permit any spilled gasoline to evaporate. 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 alcohol­blended fuels. Dirty air filter. Choke is opened too soon. Carburetor is running too rich or too lean. Engine shuts down during operation. Engine lacks power.

Replace spark plug. Drain gas tank; fill with fresh fuel. Open choke fully and crank engine. Contact Generac Power Systems service facility.

Contact Generac Power Systems service facility. Contact Generac Power Systems service facility. Replace battery. Fill fuel tank. Fill crankcase to proper level.

See “Don’t Overload the Generator ” on page 12. Replace air filter. Move choke to halfway position until engine runs smoothly. Contact Generac Power Systems service facility.