Simplicity 01657-1 Manuel utilisateur
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Owner’s Manual / Manuel de l'Utilisateur
Questions? Help is just a moment away!
Vous avez des questions? Vous n'avez pas besoin d'aller loin pour trouver de l'aide!
Call: Generac Generator Helpline / Appelez la ligne d'assistance de Generac Motor - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-portables.com or www.briggsandstratton.com
Model No. 1657-1 (7,000 Watt AC Generator) Manual No. 191520GS Revision 1 (11/20/2002)
Safety Rules / Règles de Sécurité . . . . . . . . . . . . . . . . . . . 2-3 / 20-21
Know Your Generator / Connaissez Votre Générateur . . . . . . 4 / 22
Assembly / Assemblage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 / 23
Operation / Opération . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 / 24-28
Product Specifications / Caractéristiques du Produit . . . . . . . 11 / 29
Maintenance / Entretien . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 / 29
Storage / Rangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 / 30
Troubleshooting / Dépannage . . . . . . . . . . . . . . . . . . . . . . . . 13 / 32
Schematic / Schéma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram / Circuit de Câblage . . . . . . . . . . . . . . . . . . . . . . 15
Replacement Parts / Pièces de Rechange . . . . . . . . . . . . . . . . . 16-19
Notes / Remarques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31, 33-34
Garantie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page
• Generator / Générateur
• Wheel kit / Ensemble de roulettes
• Storage cover / Couverture d'emmagasinage
• Battery / Batterie
• Battery charge cables / Câbles de charge de batterie
• Battery float charger / Chargeur de flotteur de batterie
• Locking 30 Amp plug / Prise de verrouillage 30 Ampères
• Two bottles of engine oil / Deux bouteilles d'huile moteur
• Three packets of fuel stabilizer / Trois paquets de stabilisateur
d'essence
• Owner's manual / Manuel de l'utilisateur
• Engine manual / Manuel du moteur
*If any parts are missing or damaged, call 1-800-270-1408.
*Si certaines pièces sont manquantes ou endommagées, appelez le
1-800-270-1408.
Parts Included* / Pièces Incluses*
Table of Contents / Table des Matières
2
7000EXL Extended Life Generator
EQUIPMENT
DESCRIPTION
Read this manual carefully and become familiar
with your generator. Know its applications, its
limitations and any hazards involved.
This generator is an engine–driven, revolving field, alternating
current (AC) generator. It was designed to supply electrical
power for operating compatible electrical lighting, appliances,
tools and motor loads.The generator’s revolving field is
driven at about 3,600 rpm by a single-cylinder engine.
CAUTION! DO NOT exceed the generator’s
wattage/amperage capacity. See “Don’t Overload the
Generator” on page 10.
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.
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.
SAFETY RULES
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.
The safety alert symbol ( ) is used with a signal word
(DANGER, CAUTION,WARNING), a pictorial and/or a
safety message to alert you to hazards. DANGER indicates
a hazard which, if not avoided, will result in death or serious
injury. WARNING indicates a hazard which, if not avoided,
could result in death or serious injury. CAUTION
indicates a hazard which, if not avoided, might result in
minor or moderate injury. CAUTION, when used
without the alert symbol, indicates a situation that could
result in equipment damage. Follow safety messages to
avoid or reduce the risk of injury or death.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
In the State of California a spark arrester is required by law
(Section 4442 of the California Public Resources Code).
Other states may have similar laws. Federal laws apply on
federal lands. If you equip the muffler with a spark arrester,
it must be maintained in effective working order.
• Operate generator ONLY outdoors.
• Keep at least 2 feet of clearance on all sides of generator for
adequate ventilation.
• DO NOT operate generator inside any building or enclosure,
including the generator compartment of a recreational vehicle (RV).
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide will cause nausea,
fainting or death.
DANGER
• 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.
• 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.
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.
DANGER
• National Electric Code requires generator to be properly
grounded to an approved earth ground. Call an electrician for
local grounding requirements.
Failure to properly ground generator can result
in electrocution, especially if the generator is
equipped with a wheel kit.
DANGER
WHEN ADJUSTING OR MAKING REPAIRS TO YOUR
GENERATOR
• Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.
Unintentional sparking can result in fire or
electric shock.
WARNING
7000EXL Extended Life Generator
3
WHEN ADDING FUEL
• Turn generator OFF and let it cool at least 2 minutes before
removing gas 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.
• DO NOT light a cigarette or smoke.
WHEN OPERATING EQUIPMENT
• DO NOT tip engine or equipment at angle which causes fuel
to spill.
WHEN TRANSPORTING OR REPAIRING EQUIPMENT
• Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFF.
• Disconnect spark plug wire.
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.
Fuel and its vapors are extremely flammable and
explosive.
Fire or explosion can cause severe burns or
death.
WARNING
• 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.
Storage batteries give off explosive hydrogen gas
during recharging.
Hydrogen gas stays around 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.
DANGER
• DO NOT touch hot surfaces.
• Allow equipment to cool before touching.
Running engines produce heat.Temperature of
muffler and nearby areas can reach or exceed
150°F (65°C).
Severe burns can occur on contact.
WARNING
• DO NOT tamper with governed speed. Generator supplies
correct rated frequency and voltage when running at governed
speed.
• DO NOT modify generator in any way.
Excessively high operating speeds increase risk of injury
and damage to generator.
Excessively low speeds impose a heavy load.
CAUTION
• See “Don’t Overload Your Generator” on page 10.
• Start generator and let engine stabilize before connecting
electrical loads.
• Connect electrical loads in OFF position, then turn ON for
operation.
• Turn electrical loads OFF and disconnect from generator
before stopping generator.
Exceeding generators wattage/amperage capacity can
damage generator and/or electrical devices connected
to it.
CAUTION
• Use generator only for intended uses.
• If you have questions about intended use, ask dealer or
contact Generac.
• Operate generator only on level surfaces.
• DO NOT expose generator to excessive moisture, dust, dirt,
or corrosive vapors.
• DO NOT insert any objects through cooling slots.
• If connected devices overheat, turn them off and disconnect
them from generator.
• Shut off generator if:
-electrical output is lost;
-equipment sparks, smokes, or emits flames;
-unit vibrates excessively.
Improper treatment of generator can damage it and
shorten its life.
CAUTION
4
7000EXL Extended Life Generator
KNOW YOUR GENERATOR
Read this owner’s manual and safety rules before operating your generator.
Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.
12 Volt DC,10 Amp Receptacle — Recharge a discharged
12 Volt automotive type battery through this receptacle.
120 Volt AC, 20 Amp Duplex Receptacle — May be used to
supply electrical power for the operation of 120 Volt AC, 20 Amp,
single phase, 60 Hz electrical lighting, appliance, tool and motor
loads.
120 Volt AC, 30 Amp Locking Receptacle — May be used to
supply electrical power for the operation of 120 Volt AC, 30 Amp,
single phase, 60 Hz electrical lighting, appliance, tool and motor
loads.
120/240 Volt AC, 30 Amp Locking Receptacle — May be
used to supply electrical power for the operation of 120 and/or
240 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
Air Cleaner — Uses a dry type filter element and foam
pre–cleaner to limit the amount of dirt and dust sucked into the
engine.
Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — The 120 Volt AC, 20 Amp duplex
receptacle is provided with "push to reset" circuit breakers to
protect the generator against electrical overload.
Double Pole Circuit Breaker (AC) — A double pole circuit
breaker is provided to protect all the receptacles and generator
against electrical overload.
Fuel Tank — Capacity of seven (7) U.S. gallons.
Grounding Wing Nut — Used for proper grounding of unit.
Idle Control Switch — With this switch set to ON, generator
automatically reduces engine speed when no load is connected
and increases engine to proper speed when load is applied.
However, be sure switch is OFF when starting engine.
Oil Fill Cap — Add oil to engine here.
Recoil starter — Used to start the engine manually.
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.
120 Volt AC, 20 Amp
Duplex Receptacle
Fuel Tank
Idle Control
Switch
Choke Lever
Start Button
12 Volt DC, 10 Amp
Receptacle
Run/Stop Switch
120 Volt AC, 30 Amp
Receptacle
Circuit Breakers (AC)
120/240 Volt AC,
30 Amp Receptacle
Spark Arrester Muffler
Air Cleaner
Grounding
Wing Nut
Oil Fill Cap
Recoil Starter
Double Pole
Circuit Breaker
7000EXL Extended Life Generator
5
ASSEMBLY
Check Battery / Attach Negative
Battery Wire
The sealed battery on the generator is fully charged and
pre–installed except for the negative (black) battery cable.
To install:
• Cut off tie wrap securing loose end of negative (black)
cable.
• Remove nut and washer on the negative battery
terminal.
• Slide the negative battery cable over the screw on the
negative terminal (Figure 1).
• Reattach washer and nut and tighten.
• Verify that the connections to the battery and generator
are correct and secure.
BEFORE STARTING THE
ENGINE
Add Oil
CAUTION! Any attempt to crank or start the engine
before it has been properly filled with the recommended
oil may result in an engine failure.
To fill your engine with oil:
• Place generator on a level surface.
• Follow the oil grade recommendations and oil fill
instructions given in the engine owner’s manual.
NOTE: The generator’s revolving field rides on a
prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
Add Fuel
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.
WARNING! DO NOT overfill the fuel tank.
Always allow room for fuel expansion.
• Use regular UNLEADED fuel with the generator
engine. DO NOT use premium fuel. DO NOT mix oil
with fuel.
• Clean area around fuel fill cap, remove cap.
• Slowly add unleaded regular fuel to fuel tank. Be careful
not to overfill.Allow about 1/2" of tank space for fuel
expansion (Figure 2).
• Install fuel cap and wipe up any spilled fuel.
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 fuel can damage the fuel system of an engine while
in storage. Be sure to review the precautions given in
“Storage” on page 12.
NEVER use engine or carburetor cleaner products in the
fuel tank or permanent damage may occur.
Figure 1 — Negative Battery Connection
Positive battery cable
Screw
Washer
Nut
Negative
battery
cable
Figure 2 — Typical Fuel Expansion Space
1/2” Air
Space
Tank
Fuel
6
7000EXL Extended Life Generator
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 3).
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth–driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, local codes
may vary widely. Consult with a local electrician for
grounding requirements in your area.
Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices, especially when the unit is
equipped with a wheel kit. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
OPERATING THE
GENERATOR
CAUTION! NEVER start or stop unit with
electrical loads connected AND with the connected
devices turned ON.
IMPORTANT: Always unplug the battery float charger
before starting the generator.
Starting the Engine
Disconnect all electrical loads from the generator. Follow
these start instruction steps in numerical order:
1. Turn the fuel valve to the “On” position (Figure 4).
2. Make sure the Idle Control switch is in “Off” position
(Figure 5).
3. Set the Run/Stop switch to “Run” position (Figure 6).
4. Place the choke lever in the “Full” choke position
(Figure 7).
Figure 4 — Fuel Shut-off Valve
Figure 5 — Idle Control Switch
Figure 6 — Run/Stop Switch
Figure 7 — Choke Positions
Figure 3 — Grounding Wing Nut
Grounding
Wing Nut
Fuel Valve shown in
the “On” position
7000EXL Extended Life Generator
7
5A. For electric starting, press start switch on
generator cradle.To prolong the life of the starter
components, press the starter button for no more
than 15 seconds, and pause for 30 seconds.
5B. For manual starting, grasp the recoil handle and pull
slowly until slight resistance is felt.Then pull rapidly
one time only to start engine.
• If engine starts, proceed to step 7.
• If engine fails to start, proceed to step 6.
6. Move the choke lever to “Half” choke position, and
press start button or pull recoil handle twice.
• If engine fails to start, repeat steps 4 thru 6.
7. Move choke lever to “Run” position. If engine falters,
move choke lever to “Half” choke position until the
engine runs smoothly and then to “Run” position.
NOTE: If engine still fails to start after 3 pulls, check for
proper oil level in crankcase.This unit is equipped with a
Low Oil Shutdown System. See engine manual.
Refer to the engine owner’s manual for complete
starting instructions.
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes after
starting.
• Plug in and turn on the desired 120 and/or 240 Volt AC,
single phase, 60 Hz electrical loads.
• DO NOT connect 240 Volt loads to the 120 Volt
receptacles.
• DO NOT connect 3–phase loads to the generator.
• DO NOT connect 50 Hz loads to the generator.
• DO NOT OVERLOAD THE GENERATOR. See
“Don’t Overload the Generator” on page 10.
Stopping the Engine
• Unplug all electrical loads from generator panel
receptacles. NEVER start or stop engine with electrical
devices plugged in and turned on.
• Put the idle control switch in the “Off” position.
• Let engine run at no–load for 30 seconds to stabilize the
internal temperatures of engine and generator.
• Move run/stop switch to “Stop”.
• Close the fuel shut–off valve.
Operating Automatic Idle Control
This switch is designed to greatly improve fuel economy.
When this switch is turned ON, the engine will only
run at its normal high governed engine speed when an
electrical load is connected.When an electrical load is
removed, the engine will run at a reduced speed. With
the switch off, the engine will run at the normal high
engine speed. Always have the switch off when
starting and stopping the engine.
Charging a Battery
WARNING! Storage batteries give off explosive
hydrogen gas while recharging.An explosive mixture
will remain around the battery for a long time after
it has been charged.The slightest spark can ignite
the hydrogen and cause an explosion, resulting in
blindness or other serious injury.
WARNING! DO NOT permit smoking, open
flame, sparks or any other source of heat around a
battery.Wear protective goggles, rubber apron and
rubber gloves when working around a battery.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe burns. If
spill occurs flush area with clear water immediately.
Your generator has the capability of recharging a
discharged 12 Volt automotive or utility style storage
battery. DO NOT use the unit to charge any 6 Volt
batteries. DO NOT use the unit to crank an engine having
a discharged battery.
To recharge 12 Volt batteries, proceed as follows:
• Check fluid level in all battery cells. If necessary, add
ONLY distilled water to cover separators in battery
cells. DO NOT use tap water.
• If the battery is equipped with vent caps, make sure they
are installed and are tight.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to panel
receptacle identified by the words “12-VOLTS D.C.”.
• Connect battery charge cable clamp with red handle to
the positive (+) battery terminal (Figure 8).
8
7000EXL Extended Life Generator
• Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 8).
• Start engine. Let the engine run while battery recharges.
• When battery has charged, shut down engine.
NOTE: Use an automotive hydrometer to test battery state
of charge and condition. Follow the hydrometer
manufacturer’s instructions carefully. Generally, a battery is
considered to be at 100% state of charge when specific gravity
of its fluid (as measured by hydrometer) is 1.260 or higher.
COLD WEATHER
OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icing of the carburetor and/or the crankcase
breather system.
Build a structure that will enclose three sides and the top
of the generator.
• Make sure entire muffler-side of generator is exposed.
Note that your generator may appear different from that
shown in Figure 9.
• Ensure a minimum of two feet clearance between open
side of box and nearest object.
• Face exposed end away from wind and elements.
• Enclosure should hold enough heat created by the
generator to prevent problems.
CAUTION! NEVER run unit indoors. DO NOT
enclose generator any more than shown. Remove
generator from shelter when temperature is above
40°F [4°C].
How to Use the Battery Charger
Use battery float charger jack to keep the starting battery
charged and ready for use. Battery charging should be done
in a dry location, such as inside a garage.
• Plug the charger into the unit’s “Battery Float Charger”
jack, which is located on the starter switch (Figure 10).
Plug battery charger into a 120Volt AC wall receptacle.
• Unplug the charger from the unit and the wall outlet
when generator is being started and while it is in
operation.
• Keep this charger plugged in when generator is not in
use to prolong battery life.The charger has a built in
float equalizer and will not overcharge the battery, even
when plugged in for an extended period of time.
IMPORTANT: See “Battery Maintenance” on page 11 for
additional information.
RECEPTACLES
120 Volt AC, 20 Amp Duplex
Receptacle
Each of these outlets is protected against overload by
20 Amp push-to-reset type circuit breakers (Figure 11).
Figure 10 — Battery Charger Jack
Figure 9 — Permanent Cold Weather Shelter
Wind
Figure 8 — Battery Connections
7000EXL Extended Life Generator
9
Use each outlet to operate 120 Volt, 60 Hz, single phase
loads requiring 2,400 (2.4 kW) watts at 20 Amps of
current.
120/240 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L14-30 plug with this receptacle. Connect a
4-wire cord set rated for 250 Volts at 30 Amps (or greater)
(Figure 12).You can use the same 4-wire cord if you plan to
run a 120 Volt load.
This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts of power at
20 Amps for 120 Volts; 7,000 watts of power (7.0 kW) at
29.2 Amps for 240 Volts.The outlet is protected by a
double pole circuit breaker.
CAUTION! Although this outlet is rated for
240 Volt 30 Amp (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.
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L5-30 plug with this receptacle. Connect a
3-wire cord set rated for 125 Volts AC at 30 Amps to the
plug (Figure 13).
Use this receptacle to operate 120 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts (3.6 kW) of power
at 30 Amps.The outlet is protected by a double pole circuit
breaker.
12 Volt DC, 10 Amp Receptacle
This connector (identified by the legend “12-VOLT D.C.”)
supplies 12 Volts DC at 10 Amps through battery charging
cables for recharging 12 Volt batteries (Figure 14). See
“Charging a Battery” on page 7.
Figure 11 — 120 Volt AC, 20 Amp Duplex Receptacle
Figure 13 — 120 Volt AC, 30 Amp, Locking Receptacle
3-Wire Cord Set
Neutral
120V
Hot
Ground (Green)
NEMA L5-30
Figure 14 — 12 Volt DC, 10 Amp Receptacle
Figure 12 — 120/240 Volt AC, 30 Amp Receptacle
4-Wire Cord Set
240V
120V
120V
W (Neutral)
X (Hot)
Y (Hot)
NEMA L14-30
Ground (Green)
10
7000EXL Extended Life Generator
DON'T OVERLOAD YOUR
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:
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 15.
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.
Example:
Total Rated (Running) Watts = 3075
Highest Additional Surge Watts = 1800
Total Generator Output Required = 4875
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.
3. Permit the generator output to stabilize (engine runs
smoothly and attached device operates properly.
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.
*Wattages listed are approximate only. Check tool or
appliance for actual wattage.
Tool or Appliance
Rated (Running)
Watts
Additional Surge
(Starting) Watts
Window Air
Conditioner
1200 1800
Refrigerator 800 1600
Deep Freezer 500 500
Television 500 -
Light (75 Watts) 75 -
3075 Total
Running Watts
1800 Highest
Surge Watts
Tool or Appliance
Rated*
(Running)
Watts
Additional
Surge
(Starting)
Watts
Essentials
Light Bulb - 75 watt 75 -
Deep Freezer 500 500
Sump Pump 800 1200
Refrigerator/Freezer - 18 Cu. Ft. 800 1600
Water Well Pump - 1/3 HP 1000 2000
Heating/Cooling
Window AC - 10,000 BTU 1200 1800
Window Fan 300 600
Furnace Fan Blower - 1/2 HP 800 1300
Kitchen
Microwave Oven - 1000 Watt 1000 -
Coffee Maker 1500 -
Electric Stove - Single Element 1500 -
Hot Plate 2500 -
Family Room
DVD/CD Player 100 -
VCR 100 -
Stereo Receiver 450 -
Color Television - 27” 500 -
Personal Computer w/17” monitor 800 -
Other
Security System 180 -
AM/FM Clock Radio 300 -
Garage Door Opener - 1/2 HP 480 520
Electric Water Heater - 40 Gallon 4000 -
DIY/Job Site
Quartz Halogen Work Light 1000 -
Airless Sprayer - 1/3 HP 600 1200
Reciprocating Saw 960 960
Electric Drill - 1/2 HP 1000 1000
Circular Saw - 7 1/4” 1500 1500
Miter Saw - 10” 1800 1800
Table Planer - 6” 1800 1800
Table Saw/Radial Arm Saw - 10” 2000 2000
Air Compressor - 1-1/2 HP 2500 2500
Figure 15 - Wattage Reference Chart
7000EXL Extended Life Generator
11
SPECIFICATIONS
Maximum Surge Watts . . . . . . . . . . . . . . 12,250 Watts
Continuous Wattage Capacity . . . . . . . . . . 7,000 Watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Rated Maximum Continuous Load Current
At 120 Volts . . . . . . . . . . . . . . . . . . . . . . 58.3 Amps
At 240 Volts . . . . . . . . . . . . . . . . . . . . . . 29.2 Amps
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-phase
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . 60 Hertz
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . 7 U.S. gallons
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . 240 lbs.
GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on a timely
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. NEVER operate a
damaged or defective generator.
NOTE: The proper tire inflation operating range should be
15-40 PSI.
Engine Maintenance
See engine owner’s manual for instructions.
CAUTION! Avoid prolonged or repeated skin
contact with used motor oil. Used motor oil has
been shown to cause skin cancer in certain
laboratory animals.Thoroughly wash exposed areas
with soap and water.
KEEP OUT OF REACH OF CHILDREN. DON'T
POLLUTE. CONSERVE RESOURCES. RETURN
USED OIL TO COLLECTION CENTERS.
Generator Maintenance
Generator maintenance consists of keeping the unit clean
and dry. Operate and store the unit in a clean dry
environment where it will not be exposed to excessive
dust, dirt, moisture or any corrosive vapors. Cooling air
slots in the generator must not become clogged with
snow, leaves or any other foreign material.
NOTE: DO NOT use a garden hose to clean generator.
Water can enter engine fuel system and cause problems. In
addition, if water enters generator through cooling air
slots, some of the water will be retained in voids and
cracks of the rotor and stator winding insulation.Water
and dirt buildup on the generator internal windings will
eventually decrease the insulation resistance of these
windings.
Battery Maintenance
Other than float charging, described elsewhere, no
maintenance is required for the battery. Keep the battery
and terminals clean and dry.
IMPORTANT: Battery charging should be performed in a
dry location, such as inside a garage.
To Clean the Generator
• Use a damp cloth to wipe exterior surfaces clean.
• A soft bristle brush may be used to loosen caked on dirt
or oil.
• A vacuum cleaner may be used to pick up loose dirt.
• Low pressure air (not to exceed 25 psi) may be used to
blow away dirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.
12
7000EXL Extended Life Generator
STORAGE
The generator should be started at least once every seven
days and allowed to run at least 30 minutes. If this cannot
be done and you must store the unit for more than
30 days, use the following guidelines to prepare it for
storage.
Generator Storage
• Clean the generator as outlined in “To Clean the
Generator.”
• Check that cooling air slots and openings on generator
are open and unobstructed.
CAUTION! Storage covers can be flammable.
DO NOT place a storage cover over a hot
generator. Let the unit cool for a sufficient time
before placing the cover on the unit.
Engine Storage
See engine owner’s manual for instructions.
Other Storage Tips
• To prevent gum from forming in fuel system or on
essential carburetor parts, empty all three supplied fuel
stabilizer containers into fuel tank and fill with fresh 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 24 months.Additional fuel stabilizer can
be purchased locally.
• DO NOT store fuel from one season to another unless
it has been treated as described above.
• Replace fuel container if it starts to rust. Rust and/or dirt
in fuel can cause problems if it's used with this unit.
• Store in clean and dry area.
7000EXL Extended Life Generator
13
TROUBLESHOOTING
Problem
Cause
Correction
Engine is running, but no
AC output is available.
1. One of the circuit breakers is open.
2. Fault in generator.
3. Poor connection or defective cord set.
4. Connected device is bad.
1. Reset circuit breaker.
2. Contact Generac service facility.
3. Check and repair.
4. Connect another device that is in
good condition.
Engine runs good at no-
load but “bogs” down"
when loads are connected.
1. Short circuit in a connected load.
2. Engine speed is too slow.
3. Generator is overloaded.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. Contact Generac Power Systems
service facility.
3. See “Don't Overload the Generator”
on page 10.
4. Contact Generac service facility.
Engine will not start; or
starts and runs rough.
1. Run/Stop Switch set to “STOP”.
2. Fuel shutoff valve in the “Closed”
position.
3. Dirty air cleaner.
4. Out of gasoline.
5. Stale gasoline.
6. Spark plug wire not connected to
spark plug.
7. Bad spark plug.
8. Water in gasoline.
9. Overchoking.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
13. Failed battery.
1. Set switch to “RUN”.
2. Turn the fuel shutoff valve to the
“Open” position.
3. Clean or replace air cleaner.
4. Fill fuel tank.
5. Drain gas tank; fill with fresh fuel.
6. Connect wire to spark plug.
7. Replace spark plug.
8. Drain gas tank; fill with fresh fuel.
9. Open choke fully and crank engine.
10. Contact Generac Power Systems
service facility.
11. Contact Generac Power Systems
service facility.
12. Contact Generac Power Systems
service facility.
13. Replace battery.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
1. Fill fuel tank.
2. Fill crankcase to proper level.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
1. See “Don't Overload the Generator”
on page 10.
2. Replace air filter.
Engine “hunts” or falters.
1. Choke is opened too soon.
2. Carburetor is running too rich or too
lean.
1. Move choke to halfway position until
engine runs smoothly.
2. Contact Generac Power Systems
service facility.
14
7000EXL Extended Life Generator
SCHEMATIC
7000EXL Extended Life Generator
15
WIRING DIAGRAM
16
7000EXL Extended Life Generator
EXPLODED VIEW – ALTERNATOR
7000EXL Extended Life Generator
17
EXPLODED VIEW – FRAME
18
7000EXL Extended Life Generator
Item Part # Qty Description
1 A187024GS 1 CRADLE
2 J189176GS 1 SHIELD, Heat
3 94479GS 1 DECAL, Danger
4 92665GS 1 INSULATION
5 B1695GS 1 ASSY,Tank, Fuel
(Includes Items 12 & 13)
6 B4363GS 1 CAP, with Gauge, Fuel
7 85000GS 1 CLIP, Insulation
8 94480GS 1 DECAL, Start Instructions
9 78831BGS 4 SCREW
10 83465GS 4 GROMMET,Tank
11 77395GS 8 NUT, Lock
12 80270GS 1 VALVE,Tank
13 78299GS 1 BUSHING,Tank
14 B2153GS 8 SCREW
15 43116GS 4 SCREW
16 51731GS 2 SCREW
17 B4135GS 2 PIN, with Lanyard
18 187104GS 4 WASHER, Nylon
19 49820GS 2 NUT, Nylok
20 83083GS 1 SCREEN, Spark Arrester
21 86307GS 4 SCREW
22 92247GS 1 HOUSING, Engine Adapter
23 A92531GS 1 SUPPORT, Engine
24 189160GS 12 NUT
25 22129GS 4 WASHER, Lock
26 82857GS 4 MOUNT,Vibration
27 22531GS 2 SCREW
28 92609GS 2 MOUNT,Vibration
29 22142GS 2 SCREW
30 A7433GS 1 MUFFLER
31 A92731GS 1 SUPPORT, Engine & Muffler
32 90239GS 1 GASKET, Muffler
33 B1342GGS 1 ASSY, Rotor
34 49813GS 1 NUT
35 96796GS 1 WASHER
36 47481GS 1 SCREW
37 B1897AGS 1 ASSY, Stator
38 20566GS 1 DECAL, 1-800
39 40976GS 2 SCREW
40 92532GS 1 BRACKET, Muffler
41 66476GS 2 SCREW
42 191516GS 1 DECAL, Control Panel
43 191514GS 1 ASSY, Control Panel (see page 19)
44 J96068GS 1 SHIELD, Heat
45 14353621GS 1 WIRE, Ground
46 26850GS 2 WASHER
47 BB3061GS 2 BOTTLE, Oil
48 81917GS 1 PIN, Roll
49 76247GS 1 DECAL, French Neutral Ground
50 189780GS 2 DECAL, Heat Shield
51 56893GS 5 SCREW
52 84132GS 1 ASSY, Power Regulator
53 67022GS 1 GROMMET, Rubber
Item Part # Qty Description
54 SRV66825DGS 1 CARRIER, Rear Bearing
55 86494GS 1 SCREW,Wing
56 23762GS 4 WASHER
57 66386GS 1 ASSY, Brush Holder
58 66849GS 2 SCREW
59 B4871GS 1 COVER, Bearing Carrier
60 74908GS 4 SCREW
61 B4605GS 2 GRIP
62 66849CGS 1 SCREW
63 65795GS 2 RECTIFIER, Battery Charge
64 66449LGS 4 BOLT, Stator
65 22145GS 4 WASHER
66 22097GS 5 WASHER, Lock
67 191520GS 1 MANUAL, Owner's
68 BB5586GS 2 HANDLE (Includes Item 61)
69 52858GS 2 NUT, Lock
70 189956GS 1 SUPPORT,Wheel Kit, Riveted
73 191267GGS 1 AXLE
74 B4966GS 2 WHEEL
75 22247GS 2 WASHER
76 191265GS 2 E-RING
77 189302BGS 1 ASSY,Wire
78 77282GS 1 SWITCH, Starter
79 188987GS 1 BRACKET, Switch
80 188989GS 1 ASSY, Jack, DC
81 22287GS 2 SCREW
82 22097GS 2 WASHER, Lock
83 22127GS 2 NUT
84 J186704GS 1 TRAY, Battery
85 B4489GS 1 BATTERY
86 189302CGS 1 ASSY,Wire
87 185939HGS 1 ASSY,Wire
88 191435GS 1 DECAL, Fuel Shut-Off
89 191436GS 2 DECAL, Hot Muffler
90 39253GS 2 SCREW
91 A8927GS 1 MANUAL, Engine
92 52618GS 2 SCREW
93 23897GS 2 WASHER
94 52856GS 2 NUT
96 191698GS 1 ASSY,Wire
97 58359GS 1 LUG
98 189198GS 1 DECAL, Instruction, ES
99 B4177GS 1 CHARGE, Battery Float
100 189208GS 3 STABILIZER, Fuel
101 65787GS 1 CABLE, Battery Charge
102 37806GS 1 PLUG, 120V/30A
103 B4767GS 1 COVER, Storage
104 74728GS 1 DECAL, English Neutral Ground
105 B4986GS 1 DECAL, Ground
106 NSP 1 NAME PLATE, CSA
107 188333GS 1 DECAL, Instruction, Fuel Level
109 22159GS 2 NUT
110 86292GS 1 SCREW
900 NSP 1 ENGINE
PARTS LIST – ALTERNATOR & FRAME
7000EXL Extended Life Generator
19
EXPLODED VIEW AND PARTS LIST – CONTROL PANEL
Item Part # Qty Description
1 A191486GS 1 PANEL, Control
2 23897GS 4 WASHER
3 49226GS 4 WASHER, Lock
4 91526GS 4 SCREW
5 82538GS 1 SWITCH, Idle Control
6 82881GS 2 WASHER, Lock
7 43181GS 4 SCREW
8 43182GS 4 WASHER, Lock
9 90418GS 1 OUTLET, 12V
10 191480AGS 1 BREAKER, Circuit, 30A, 2P
11 75207GS 2 BREAKER, Circuit, 20A
12 23365GS 6 WASHER, Shakeproof
13 68868GS 1 OUTLET, 120V, 30A Lock
Item Part # Qty Description
14 43437GS 1 OUTLET, 120/240V, 30A Lock
15 68759GS 1 OUTLET, 120V, 20A Duplex
16 43180GS 6 WASHER
17 22264GS 6 WASHER, Lock
18 51715GS 6 NUT
19 64526GS 8 SCREW
20 83970GS 1 BOARD, System Control
21 64525GS 4 STAND-OFF
22 87962GS 1 BREAKER, Circuit, 12V, 10A
23 84335GS 1 ASSY,Wire
24 84134GS 1 GROMMET, Rubber
25 B92069GS 1 BOX, Control Panel
26 84028GS 1 TRANSFORMER, Idle Control
7000EXL Générateur Qui Dure Longtemps
20
DESCRIPTION DE L ÉQUIPEMENT
Lisez avec soin ce manuel et familiarisez-vous avec
votre générateur. Connaissez ses applications, ses
limitations et les dangers qu'il implique.
Ce générateur est un générateur entraîné par un moteur à champ
magnétique rotatif produisant du courant alternatif (c.a.). Il a été
conçu pour fournir du courant électrique pour faire marcher des
charges compatibles d'éclairage, d'appareils ménagers, d'outil et de
moteur. Le champ tournant du générateur est entraîné à
3,600 T/M par un moteur monocylindrique.
ATTENTION! NE PAS dépasser la capacité en watts ou en
Ampères du générateur.Voir "Ne Pas Surcharger le Générateur"
sur la page 28 pour l'information spécifique.
Tout a été mis en oeuvre pour que les informations contenues
dans ce manuel soient exactes et à jour. Cependant, Generac se
réserve le droit de changer, d'altérer ou d'améliorer le produit à
n'importe quel moment sans avis préalable.
Le Système de contrôle de l'émission du générateur est garanti
pour des normes établies par L'Agence de protection de
l'environnement. Pour des informations sur la garantie, se reporter
au manuel du moteur.
RÈGLES DE SÉCURITÉ
Ceci est la sûreté le symbole vif. Il est utilisé pour
vous alerter aux dangers de blessure personnels
potentiels. Obéir tous messages de sûreté qui suivent
ce symbole éviter la blessure ou la mort possibles.
Le symbole indiquant un message de sécurité est accompagné d'un
mot indicateur (DANGER,ATTENTION,AVERTISSEMENT), d'un
message illustré et/ou d'un message de sécurité visant à vous
avertir des dangers. DANGER indique un danger qui, s'il n'est pas
évité, provoquera des blessures graves, voire fatales.
AVERTISSEMENT indique un danger qui, s'il n'est pas évité, peut
provoquer des blessures graves, voire fatales. ATTENTION
indique un danger qui, s'il n'est pas évité, peut provoquer des
blessures mineures ou légères. Le mot ATTENTION, lorsqu'il est
utilisé sans le symbole d'alerte, indique une situation pouvant
endommager l'équipement. Suivez les messages de sécurité pour
éviter ou réduire les risques de blessures ou de mort.
L’échappement du moteur de ce produit contient des produits
chimiques que l’État de Californie considère comme causant le
cancer, des déformations à la naissance ou d’autres dangers
concernant la reproduction.
AVERTISSEMENT
Dans l'état de Californie un pare-étincelles est requis par la loi
(section 4442 du Code des ressources publiques de Californie).
D'autres états ont des lois similaires. Les lois fédérales
s'appliquent aux terres fédérales. Si vous équipez le silencieux
d'un pare-étincelles, il doit être en bon état de fonctionnement.
• Faites fonctionner le générateur SEULEMENT à l'extérieur.
• Laissez un espace d'au moins 2 pieds tout autour du générateur, pour
permettre une ventilation adéquate.
• NE FAITES PAS fonctionner le générateur à l'intérieur d'un bâtiment
ou d'un abri, y compris à l'intérieur du compartiment d'un véhicule de
plaisance.
Le générateur, lorsqu'il fonctionne, produit du monoxyde
de carbone, un gaz toxique inodore et incolore.
Le fait de respirer du monoxyde de carbone provoque
des nausées, des évanouissements ou peut être fatal.
DANGER
• Le Code national de l'électricité requiert que le générateur soit
correctement relié à la terre par un branchement homologué. Faites appel
à un électricien pour connaître les exigences de mise à la terre régionales.
Si la génératrice n'est pas mise à la masse comme il
se doit, il y a risque d'électrocution, particulièrement
si la génératrice est équipée de roues.
DANGER
• Lorsque vous utilisez le générateur comme source d'énergie de
secours, il est nécessaire d'aviser les services publics d'électricité.
• Utilisez un disjoncteur différentiel lorsque vous utilisez l'appareil dans
des endroits humides ou extrêmement conductibles, comme les
terrasses en métal ou les ouvrages métalliques.
• NE touchez pas les fils dénudés ou les boîtiers.
• N'UTILISEZ pas le générateur avec des cordons électriques usés,
effilochés ou dénudés, ou abîmés de quelque sorte que ce soit.
• N'UTILISEZ pas le générateur sous la pluie.
• NE manipulez pas le générateur ou les cordons d'alimentation lorsque
vous êtes debout dans l'eau, pieds nus ou avec les mains ou les pieds
humides.
• NE laissez pas des personnes non qualifiées ou des enfants se servir
ou réparer le générateur.
Le générateur produit une tension élevée.
Ne pas isoler le générateur de l'installation électrique
risque de provoquer des blessures ou même d'être fatal
pour les ouvriers électriciens et de causer des dommages
au générateur dus à un "backfeed" d'énergie électrique.
DANGER
LORSQUE VOUS RÉGLEZ OU RÉPAREZ VOTRE
GÉNÉRATEUR
• Débranchez toujours le câble de bougie et placez-le de façon à ce
qu'il ne soit pas en contact avec la bougie.
Unintentional peut résulter dans feu ou électrique.
AVERTISSEMENT
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Simplicity 01657-1 Manuel utilisateur
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