(000209a)
WARNING
This product is not intended to be used in
a critical life support application. Failure to
adhere to this warning could result in
death or serious injury.
Owner’s Manual
60 Hz Air-Cooled Generators
7.5 kW PowerPact™
001036
Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(888-436-3722)
Para español , visita: http://www.generac.com/service-support/product-support-lookup
Pour le français, visiter : http://www.generac.com/service-support/product-support-lookup
SAVE THIS MANUAL FOR FUTURE REFERENCE
Use this page to record important information about your generator set.
Model:
Serial:
Prod Date Week:
Volts:
LPV Amps:
NG Amps:
Hz:
Phase:
Controller P/N:
(000005)
WARNING
California Proposition 65. This product contains or
emits chemicals known to the state of California to
cause cancer, birth defects, and other reproductive
harm.
(000004)
WARNING
California Proposition 65. Engine exhaust and some
of its constituents are known to the state of California
to cause cancer, birth defects, and other reproductive
harm.
Record the information found on your unit data label on this
page. For the location of the unit data label, see Safety
Rules & General Information. The unit has a label plate
affixed to the inside partition, to the left of the control panel
console as shown in Figure 2-1. For directions on how to
open the top lid and remove the front panel, see Operation.
When contacting an independent authorized service dealer
about parts and service, always supply the complete model
number and serial number of the unit.
Operation and Maintenance: Proper maintenance and care
of the generator ensures a minimum number of problems
and keeps operating expenses at a minimum. It is the
operator’s responsibility to perform all safety checks, to
make sure that all maintenance for safe operation is
performed promptly. Generac recommends that the
equipment be checked periodically by an Independent
Authorized Service Dealer. Normal maintenance, service
and replacement of parts are the responsibility of the owner/
operator and, as such, are not considered defects in
materials or workmanship within the terms of the warranty.
Individual operating habits and usage may contribute to the
need for additional maintenance or service.
When the generator requires servicing or repairs, Generac
recommends contacting an Independent Authorized Service
Dealer for assistance. Authorized service technicians are
factory-trained and are capable of handling all service
needs.To locate the nearest independent authorized service
dealer, please visit the dealer locator at:
www.generac.com/Service/DealerLocator/.
ii Owner’s Manual for 7.5 kW PowerPact™
Table of Contents
Table of Contents
Section 1: Safety Rules & General
Information
Introduction ..........................................................1
Read This Manual Thoroughly ....................................1
How to Obtain Service .................................................1
Safety Rules .........................................................1
General Hazards .........................................................2
Exhaust Hazards .........................................................3
Electrical Hazards .......................................................3
Fire Hazards ................................................................3
Explosion Hazards ......................................................4
Section 2: General Information
The Generator ......................................................5
Protection Systems .............................................7
Emissions .............................................................7
Fuel Requirements ..............................................7
Battery Requirements .........................................7
Battery Charger ....................................................7
Engine Oil Requirements ....................................7
Section 3: Operation
Site Prep Verification ...........................................9
Controller Lid .......................................................9
Circuit Breaker .....................................................9
Control Panel .....................................................10
Alarm Response Procedures ............................11
Clearing an Alarm/Warning Condition .......................11
Setting the Exercise Timer ................................11
Automatic Sequence of Operation .................. 13
Utility Failure ..............................................................13
Cranking ....................................................................13
Cold Smart Start ........................................................ 13
Load Transfer ............................................................13
Shutting Generator Down While Under Load . 13
To turn the generator OFF (while running in AUTO and
online): ......................................................................13
To turn the generator back ON: .................................13
Section 4: Maintenance
Maintenance ....................................................... 15
Performing Scheduled Maintenance ............... 15
Clearing a Maintenance Due Condition ........... 15
Service Schedule ............................................... 16
Checking Engine Oil Level ............................... 18
Engine Oil Recommendations ...................................18
Changing the Oil ................................................ 19
Changing the Engine Air Cleaner .................... 19
Spark Plug .......................................................... 19
Valve Clearance Adjustment ............................ 20
Check Valve Clearance ............................................. 20
Adjust Valve Clearance .............................................20
Battery Maintenance ......................................... 21
Attention After Submersion .............................21
Corrosion Protection ........................................ 21
Remove From, and Return To Service Procedure
22
Remove From Service ...............................................22
Return to Service .......................................................22
Battery Charger ..................................................11
Manual Transfer Operation ...............................11
Transfer to Generator Power Source ........................11
Transfer Back to Utility Power Source .......................12
Section 5: Troubleshooting
Section 6: Quick Reference Guide
Automatic Transfer Operation ..........................12
Owner’s Manual for 7.5 kW PowerPact™ iii
Table of Contents
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iv Owner’s Manual for 7.5 kW PowerPact™
Safety Rules & General Information
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000001)
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000002)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Section 1: Safety Rules & General Information
Introduction
Thank you for purchasing this compact, high
performance, air-cooled, engine-driven generator. It is
designed to automatically supply electrical power to
operate critical loads during a utility power failure.
This unit is factory installed in an all-weather, metal
enclosure that is intended exclusively for outdoor
installation. This generator will operate using either vapor
withdrawn liquid propane (LP) or natural gas (NG).
NOTE: When sized properly, this generator is suitable for
supplying typical residential loads such as induction
motors (sump pumps, refrigerators, air conditioners,
furnaces, etc.), electronic components (computer,
monitor, TV, etc.), lighting loads and microwaves.
Read This Manual Thoroughly
NOTE: Notes provide additional information important to
a procedure or component.
These safety warnings cannot eliminate the hazards they
indicate. Observing safety precautions and strict
compliance with the special instructions while performing
the action or service are essential to preventing accidents.
The operator is responsible for proper and safe use of
the equipment. The manufacturer strongly recommends
that if the operator is also the owner, to read the Owner’s
Manual and thoroughly understand all instructions before
using this equipment. The manufacturer also strongly
recommends instructing other users to properly start and
operate the unit. This prepares them if they need to
operate the equipment in an emergency.
If any portion of this manual is not understood, contact
the nearest Independent Authorized Service Dealer for
starting, operating and servicing procedures.
This manual must be used in conjunction with the
appropriate Installation Manual.
SAVE THESE INSTRUCTIONS: The manufacturer
suggests that this manual and the rules for safe operation
be copied and posted near the unit installation site.
Safety should be stressed to all operators and potential
operators of this equipment.
Throughout this publication and on tags and decals
affixed to the generator, DANGER, WARNING, and
CAUTION blocks are used to alert personnel to special
instructions about a particular operation that may be
hazardous if performed incorrectly or carelessly. Observe
them carefully. Their definitions are as follows:
Owner’s Manual for 7.5 kW PowerPact™ 1
How to Obtain Service
When the generator requires servicing or repairs, Generac
recommends contacting an
Service Dealer
are factory-trained and are capable of handling all service
needs. For assistance locating a dealer, go to
www.generac.com/Service/DealerLocator/.
When contacting an IASD about parts and service, always
supply the complete model number and serial number of
the unit as given on its data decal, which is located on the
generator. Refer to
the model number and serial numbers in the spaces
provided on the inside front cover of this manual.
(IASD) for assistance. Service technicians
Figure 2-1
Independent Authorized
for decal location. Record
Safety Rules
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The
generator can operate safely, efficiently and reliably only
if it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and
fundamental rules or precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings in
this manual and on tags and decals affixed to the unit are,
therefore, not all-inclusive. If using a procedure, work
method, or operating technique the manufacturer does not
specifically recommend, verify that it is safe for others.
Also, make sure the procedure, work method or operating
technique utilized does not render the generator unsafe.
Safety Rules & General Information
(000190)
DANGER
Loss of life. Property damage. Installation must always
comply with applicable codes, standards, laws and
regulations. Failure to do so will result in death
or serious injury.
Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury.
(000191)
DANGER
WARNING
This unit is not intended for use as a prime power
source. It is intended for use as an intermediate power
supply in the event of temporary power outage only.
See individual unit specifications for required
maintenance and run times pertaining to use.
(000247)
(000209a)
WARNING
This product is not intended to be used in
a critical life support application. Failure to
adhere to this warning could result in
death or serious injury.
(000187)
WARNING
(000130)
WARNING
Accidental Start-up. Disconnect the negative battery
cable, then the positive battery cable when working
on unit. Failure to do so could result in death
or serious injury.
(000182)
WARNING
(000155)
WARNING
Only a trained and licensed electrician should perform
wiring and connections to unit. Failure to follow proper
installation requirements could result in death, serious
injury, and damage to equipment or property.
(000115)
WARNING
Moving Parts. Do not wear jewelry when
starting or operating this product. Wearing
jewelry while starting or operating this product
could result in death or serious injury.
(000111)
WARNING
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
(000108)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces
could result in severe burns or fire.
(000146)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
General Hazards
WARNING
Risk of injury. Do not operate or service this
machine if not fully alert. Fatigue can impair the
ability to service this equipment and could result
in death or serious injury.
(000215)
WARNING
Injury and equipment damage. Do not use
generator as a step. Doing so could result in falling,
damaged parts, unsafe equipment operation,
and could result in death or serious injury.
Inspect the generator regularly. Generac recommends
contacting the nearest Independent Authorized Service
Dealer for parts needing repair or replacement.
(000216)
2 Owner’s Manual for 7.5 kW PowerPact™
Exhaust Hazards
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
DANGER
(000178a)
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so
could result in death or serious injury.
WARNING
(000144)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000150)
DANGER
Electrocution. Never connect this unit to the electrical
system of any building unless a licensed electrician
has installed an approved transfer switch. Failure to
do so will result in death or serious injury.
(000131a)
DANGER
Electrical backfeed. Use only approved switchgear to
isolate generator when electrical utility is the primary
power source. Failure to do so will result in death,
serious injury, and equipment damage.
(000152)
DANGER
Electrocution. Verify electrical system is
properly grounded before applying power.
Failure to do so will result in death or serious
injury.
(000188)
DANGER
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000104)
DANGER
Electrocution. Water contact with a power
source, if not avoided, will result in death
or serious injury.
(000144)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000145)
DANGER
Electrocution. In the event of electrical accident,
immediately shut power OFF. Use non-conductive
implements to free victim from live conductor. Apply
first aid and get medical help. Failure to do so will
result in death or serious injury.
•
Adequate, unobstructed flow of cooling and
ventilating air is critical to correct generator
operation. Do not alter the installation or permit
even partial blockage of ventilation provisions, as
this can seriously affect safe operation of the
generator. The generator must be installed and
operated outdoors only.
Safety Rules & General Information
Electrical Hazards
Fire Hazards
WARNING
Fire hazard. Do not obstruct cooling and
ventilating airflow around the generator. Inadequate
ventilation could result in fire hazard, possible
equipment damage, death or serious injury.
(000217)
WARNING
Fire and explosion. Installation must comply
with all local, state, and national electrical
building codes. Noncompliance could result in unsafe
operation, equipment damage, death or serious injury.
(000218)
WARNING
Fire hazard. Use only fully-charged fire
extinguishers rated “ABC” by the NFPA. Discharged or
improperly rated fire extinguishers will not extinguish
electrical fires in automatic standby generators.
(000219)
Owner’s Manual for 7.5 kW PowerPact™ 3
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000100a)
Safety Rules & General Information
WARNING
required safety equipment could result in
death or serious injury.
(000221)
Risk of electrocution. Refer to NFPA 70E for
safety equipment required when working with
with a live electrical system. Failure to use
(000147)
WARNING
Risk of Fire. Unit must be positioned in a
manner that prevents combustible material
accumulation underneath. Failure to do so
could result in death or serious injury.
(000192)
DANGER
(000151)
DANGER
Connection of fuel source must be done by a qualified
professional technician or contractor. Incorrect installation
of this unit will result in death, serious injury, and damage
to equipment and property damage.
(000174)
DANGER
Risk of fire. Allow fuel spills to completely dry
before starting engine. Failure to do so will
result in death or serious injury.
(000110)
WARNING
Risk of Fire. Hot surfaces could ignite
combustibles, resulting in fire. Fire could
result in death or serious injury.
Comply with regulations the Occupational Safety and
Health Administration (OSHA) has established. Also,
verify that the generator is installed in accordance with
the manufacturer’s instructions and recommendations.
Following proper installation, do nothing that might alter a
safe installation and render the unit in noncompliance
with the aforementioned codes, standards, laws and
regulations.
Explosion Hazards
4 Owner’s Manual for 7.5 kW PowerPact™
Section 2: General Information
001037
E
A
D
H
G
C
F
B
K
L
M
I
J
N
O
The Generator
General Information
A. Controller Lid F. Control Panel K. Air Box
B. Top Lid G. Data Label L. Spark Plug
C. Customer Connection Box H. Battery Access Panel M. Exhaust Enclosure
D. Front Panel I. Oil Drain Hose N. Alternator
E. Circuit Breaker J. Oil Fill / Dipstick O. Starter Motor
Figure 2-1. GA-420 Engine 7.5 kW Unit
Owner’s Manual for 7.5 kW PowerPact™ 5
General Information
Specifications
Generator
Model 7.5 kW
Rated Voltage 240
Rated Maximum Load Current
(Amps) at 220 Volts (LP)*
31.25
Main Circuit Breaker 35 Amp
Phase 1
Rated AC Frequency 60 Hz
Battery Requirement Group U1, 12 Volts and 300 CCA Minimum (see Replacement Parts)
Enclosure Galvanneal Steel
Unit Weight 280 lb (127.3 kg)
Normal Operating Range
These generators are rated in accordance with UL 2200, Safety Standard for Stationary Engine Generator Assemblies, and CSA-C22.2 No. 100-04
Standard for Motors and Generators.
* Natural Gas ratings will depend on specific fuel joules/Btu content. Typical derates are between 10-20% off the LP gas rating.
** Circuits to be moved must be protected by same size breaker. For example, a 15 amp circuit in the main panel must be a 15 amp circuit in the
transfer switch.
This unit is tested in accordance to UL 2200 standards with an operating temperature of -20 ºF (-29
ºC) to 122 ºF (50 ºC). For areas where temperatures fall below 32 ºF (0 ºC) a cold weather kit is
recommended. When operated above 77 ºF (25 ºC) there may be a decrease in engine power.
(Please reference the engine specifications section.)
Engine
Model 7.5 kW
Type of Engine GA-420
Number of Cylinders 1
Displacement
25.6 in
3
(420 cc)
Cylinder Block Aluminum w/ cast iron sleeve
Recommended Spark Plug see Replacement Parts
Spark Plug Gap
0.030 in (0.76 mm)
Valve Clearance 0.002 - 0.004 in
(0.05 - 0.1 mm)
Starter 12 VDC
Oil Capacity
Approx. 1.2 qt (1.1 L)
Recommended Air Filter see Replacement Parts
Engine power is subject to and limited by such factors as fuel Btu/joules, ambient temperature and altitude. Engine power decreases about 3.5 percent
for each 1000 feet (304.8 meters) above sea level, and also will decrease about 1 percent for each 10 °F (6 ºC) above 60 ºF (15 ºC) ambient temperature.
The specification sheet for your generator was included in the documentation provided with the unit at the time of
purchase. For additional copies, consult your local Independent Authorized Service Dealer for your specific generator
model.
6 Owner’s Manual for 7.5 kW PowerPact™
General Information
(000105)
DANGER
Explosion and Fire. Fuel and vapors are
extremely flammable and explosive. Add fuel
in a well ventilated area. Keep fire and spark
away. Failure to do so will result in death
or serious injury.
Protection Systems
The generator may have to run for long periods of time
with no operator present to monitor the engine/generator
conditions. Therefore, the generator is equipped with a
number of systems to automatically shut down the unit to
protect it against potentially damaging conditions. Some
of these systems are as follows:
•Low Oil Level Sensor
•High Temperature
Sensor
•Overcrank Detection
•Overspeed Detection
•RPM Sensor
•Underspeed Detection
The control panel contains LEDs which alert the operator
when a fault condition occurs. The above list is not all
inclusive. For more information about alarms and control
panel operation, see Section 3 Operation.
•Charger Problem
Detection
•Battery Problem
Detection
•Fuse Problem Detection
(missing or failed)
•Wiring Error Detection
Emissions
The United States Environmental Protection Agency (US
EPA) (and California Air Resources Board (CARB), for
engines/equipment certified to California standards)
requires that this engine/equipment complies with
exhaust and evaporative emissions standards. Locate
the emissions compliance decal on the engine to
determine applicable standards. For emissions warranty
information, please reference the included emissions
warranty. It is important to follow the maintenance
specifications in the manual to ensure that the engine
complies with the applicable emissions standards for the
duration of the product’s life.
This generator is certified to operate on Liquid Propane
Vapor fuel or pipeline Natural Gas.
The Emission Control System code is EM (Engine
Modification). The Emission Control System on this
generator consists of the following:
Fuel Requirements
The engine has been fitted with a dual fuel carburetion
system. The unit will run on natural gas or LP gas
(vapor), but it has been factory set to run on natural gas.
The fuel system will be configured for the available fuel
source during installation.
Recommended fuels should have a BTU content of at
least 1000 BTUs per cubic foot (37.26 megajoules per
cubic meter) for natural gas, or at least 2500 BTUs per
cubic foot (93.15 megajoules per cubic meter) for LP gas
(vapor).
NOTE: If converting to LP gas from natural gas, a
minimum LP tank size of 250 gallons (946 liters) is
recommended. See the Installation Manual for complete
procedures and details.
Battery Requirements
Group U1, 12V, minimum 300 CCA.
For proper battery maintenance procedures, see Section
4 Maintenance.
Battery Charger
The battery charger is integrated into the control panel
module in all models. It operates as a Smart Charger
which ensures output charging levels are safe and
continuously optimized to promote maximum battery life.
Engine Oil Requirements
For proper oil viscosity, see chart in Figure 4-2.
System Components
Air Induction
Fuel Metering
Ignition
Exhaust
- Airbox Assembly
- Air Cleaner
- Carburetor / Mixer Assembly
- Fuel Regulator
- Fuel Jet
- Spark Plug
- Ignition Module
- Exhaust Manifold
- Muffler
- Muffler System
Owner’s Manual for 7.5 kW PowerPact™ 7
General Information
Replacement Parts
Description 7.5 kW
U1 Exide Battery 0J5584
Spark Plug 0L3059
Air Filter 0E9371A
Control Panel Fuse (7.5 Amp) 0D7178T
Transfer Switch Fuses (5 Amp) 073590A
Accessories
Performance enhancing accessories are available for air-cooled generators.
Accessory Description
Cold Weather Kit Recommended in areas where temperatures fall below 32 ºF (0 ºC).
Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on the generator along
with oil recommendations.
Mobile Link™ (USA only)
006463-0
Touch-Up Paint Kit Very important to maintain the look and integrity of the generator enclosure.
Wireless Local Monitor
006664-0
Extended Warranty Coverage
(Available only in the U.S. and
Canada)
NOTE: Contact an Independent Authorized Service Dealer or visit www.generac.com for additional information on
replacement parts, accessories, and extended warranties.
Provides a personalized web portal that displays the generator status,
maintenance schedule, event history and much more. This portal is accessible
via computer, tablet or smart phone. Sends emails and/or text notifications the
moment there is any change in the generator’s status. Notification settings can
be customized to what type of alert is sent and how often. For more
information, visit www.MobileLinkGen.com.
This kit includes touch-up paint and instructions.
Completely wireless and battery powered, the Wireless Local Monitor provides
you with instant status without ever leaving the house. Status lights (red, yellow
and green) alert owners when the generator needs attention. Magnetic backing
permits refrigerator mounting and gives a 600 feet (183 meters) line of sight
communication.
Extend your generator warranty coverage by purchasing extended warranty
coverage. Covers both parts and labor. Extended coverage can be purchased
within 12 months of the end-users purchase date.
This extended coverage is applicable to registered units and end-user proof of
purchase must be available upon request.
Available for Generac
available for EcoGen™ products or all international purchases.
®
, Guardian®, Centurion®, and Synergy™ products. Not
8 Owner’s Manual for 7.5 kW PowerPact™
Section 3: Operation
Risk of fire. Keep air inlet and exhaust areas
WARNING
(000251)
free from leaves, grass, snow and other debris.
Failure to do so could result in death, serious injury,
property, and equipment damage.
(000182)
WARNING
001705
A
B
C
C
001039
A
B
Operation
Site Prep Verification
It is important that the generator is installed in such a way
that the airflow into and out of the generator is not
impeded. Verify that all shrubs or tall grasses have been
removed within 3 ft (0.91 m) of the intake and discharge
louvers on the sides of the enclosure. It is also important
that the generator is not subject to water intrusion. Verify
that all potential sources such as water sprinklers, roof
run-off, rain gutter down spouts and sump pump
discharges are directed away from the generator
enclosure.
DANGER
Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury.
(000191)
Turn the generator OFF before performing maintenance.
Remove 7.5 Amp fuse, T1 battery charge fuse, and
disconnect battery cables to prevent accidental start up.
Disconnect the NEGATIVE (–) cable first, then
disconnect the POSITIVE (+) cable. When connecting
the cables, connect the POSITIVE cable first, the
NEGATIVE cable last.
Controller Lid
To open or close the controller lid:
1. See view “A” in Figure 3-1. Lift lid from bottom to
open. Lid will lock in place when raised.
2. See view “B” in Figure 3-1. Pull raised lid up and
out sightly to unlock, then lower to close.
Figure 3-1. Open and Close Controller Lid
NOTE: Local codes may require this compartment to be
locked. A hasp is provided so the owner/operator can
secure the compartment with a padlock (C in Figure 3-1).
Check local codes for side compartment locking
requirements.
NOTE: All appropriate panels must be in place during
any operation of the generator. This includes operation
by a servicing technician while conducting
troubleshooting procedures.
Circuit Breaker
The Main Line Circuit Breaker (MLCB) is located under
the Controller Lid. Open the Controller Lid to access the
circuit breaker (A in Figure 3-2).
Owner’s Manual for 7.5 kW PowerPact™ 9
Figure 3-2. Control Panel and Circuit Breaker
Operation
001052
A
B
C
Control Panel
The Control Panel is located under the Controller Lid.
Open the Controller Lid to access the control panel (B in
Figure 3-2).
The Auto/Off/Manual Interface located on the Control
Panel has the following features (see Figure 3-3):
• Alarm LEDs (A)
• Warning LEDs (B)
• Operation Mode Buttons and LEDs (C)
Figure 3-3. Generator Control Panel and LEDs
Using the Auto/Off/Manual Interface
Button Description of Operation
Selecting this button activates fully automatic system operation. It also allows the unit to automatically
AUTO (GREEN)
start and exercise the engine every seven days with the setting of the exercise timer (see
the Exercise Timer
).
Setting
MANUAL (BLUE)
OFF (RED) This button shuts down the engine and also prevents automatic operation of the unit.
SET EXERCISE (GREY)
This button will crank and start the generator. Transfer to standby power will not occur unless there is
a utility failure.
Used to establish generator exercise time. Hold the button for 3 seconds at the new exercise time
desired. NOTE: Exercise time can only be set at the time you wish exercise to actually take place.
NOTE: Loss of utility power will cause either the AUTO or OFF or MANUAL button to flash depending on which mode
the generator is in at the time of utility loss.
Using the LED Interface
The user interface includes seven (7) LEDs to indicate
generator alarms, warnings, and maintenance actions
due. See Figure 3-3 and the following table for details on
each indication.
The user interface also includes 3-mode LEDs to indicate
the current generator mode setting (AUTO, MANUAL, or
OFF). The active LED is also used to indicate whether
LED Alarm Description (LED Flashing) Description (LED Solid)
Temperature Alarm (Flashing)
Low Oil Level Alarm (Solid) *
Charger Warning (Flashing)
Battery Problem Warning (Solid) *
Temperature levels are excessive
Charging problem exists
the utility voltage is present. The active LED will be solid
when utility is available. It will flash to indicate the loss of
utility power. For example; when the generator is in
AUTO and Utility is present, the green AUTO LED will be
solid ON. When the generator is in AUTO and utility is
lost, the AUTO LED will flash.
—
—
—
Engine oil level is insufficient
—
Battery problem exists
RPM Sensor Alarm — RPM sensor problem exists
Overcrank Alarm — Overcranking condition exists
Speed Alarm * Overspeed condition exists Underspeed condition exists
Break-in Maintenance Due (Flashing)
Regular Maintenance Due (Solid) *
* These LEDs are shared with two alarm conditions. Solid light indicates one alarm. Flashing light indicates the other alarm
condition.
10 Owner’s Manual for 7.5 kW PowerPact™
20 hour break-in maintenance due
—
—
1 year / 100 hour maintenance due
Operation
(000132)
DANGER
Electrocution. Do not manually transfer under load.
Disconnect transfer switch from all power sources
prior to manual transfer. Failure to do so will result
in death or serious injury, and equipment damage.
Alarm Response Procedures
The generator is protected by a series of sensors that will
detect an Alarm/Warning condition and alert the owner/
operator of the condition via the Control Panel display.
When certain alarm conditions are detected, the
generator will shut down.
NOTE: Unless properly trained to clear and correct
Warning and Alarm conditions, contact the nearest
Independent Authorized Service Dealer or Trained
Technician.
Clearing an Alarm/Warning Condition
To clear an alarm or warning condition from the Control
Panel, press the OFF button. Press OFF button again.
The flashing or solid indicator LED will turn off.
LED
Condition
Clear Alarm /
Warning or
Maintenance
LED Alarm(s)
Clear
Maintenance
LED when
Alarm or
Warning LED is
also present
Action
press OFF
press OFF
2nd
Action
press OFF
again
press OFF
again
3rd
Action
—
press OFF
3rd time
To CHANGE the exercise time once it has been set, hold
the SET EXERCISE button on the generator for three (3)
seconds at the time you wish the new exercise time to
take place. The exercise timer does not correct for
daylight savings time.
NOTE: The exerciser will only work in the AUTO mode
and will default to exercise weekly at the time the Control
Panel was last powered ON unless this procedure is
performed. The exercise function will need to be reset
every time the 12 volt battery and T1 power to the
generator are disconnected and then reconnected, or
when the fuse is removed and T1 power is removed from
the generator, or both.
NOTE: If the unit is equipped with Mobile Link™, the
exercise time can be remotely set for any desired day or
time.
Battery Charger
NOTE: The battery charger is integrated into the control
panel.
The battery charger operates as a Smart Charger that:
• verifies output is continually optimized to promote
maximum battery life.
• verifies that charging levels are safe.
NOTE: Battery Problem LED is illuminated when the
battery needs service.
NOTE: Clearing a code will not correct the problem. It
will simply turn off the LED indicating that told you that a
problem occurred. The problem indicated must be
diagnosed and corrected to prevent a re-occurring alarm
condition.
NOTE: Removing or failure of the 7.5 Amp ATO
will turn off all the panel LEDs. Replacement of the fuse
will initiate the LED self test.
®
fuse
Setting the Exercise Timer
This generator is equipped with an exercise timer. Once it
is set, the generator will start and exercise every seven
days, on the day of the week and at the time of day this
procedure was initiated. During this exercise period, the
unit runs for approximately 12 minutes and then shuts
down. Transfer of loads to the generator output does not
occur during the exercise cycle unless utility power is lost
1. Place the generator in the AUTO mode.
2. Hold the SET EXERCISE Button for 3 seconds.
The generator will start, run an exercise cycle and
confirm the setting.
3. The exercise time is now established. The
generator will exercise each week at this time.
Owner’s Manual for 7.5 kW PowerPact™ 11
Manual Transfer Operation
Prior to automatic operation, manually exercise the
transfer switch to verify that there is no interference with
proper operation of the mechanism. Manual operation of
the transfer switch is required if electronic operation
should fail.
Transfer to Generator Power Source
1. Verify generator is in the OFF mode.
2. Set the main circuit breaker (Generator
Disconnect) to OFF or OPEN.
.
3. Turn off the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
4. Use the manual transfer handle (A in Figure 3-4)
inside the transfer switch to move the main
contacts to the STANDBY position (loads
connected to the standby power source, B in
Figure 3-4).
Operation
A
B
5. To crank and start the engine, press the control
panel MANUAL button.
6. Allow the engine to stabilize and warm up for a few
minutes.
7. Set the main circuit breaker (Generator
Disconnect) to ON or CLOSED. The standby
power source now powers the loads.
000947
Figure 3-4. Manual Transfer Switch Operation
IMPORTANT NOTE: Actual switch operation may vary. Follow directions in the appropriate transfer switch manual.
• Will not transfer to generator if utility is present.
MANUAL
• Will transfer to generator if utility fails (below 65% of nominal for 10 consecutive seconds).
• Will transfer back when utility returns for 15 consecutive seconds. The engine will continue to
run until removed from the MANUAL mode.
• Will start and run if utility fails (below 65% of nominal for 5 consecutive seconds).
• Will start a 6 second engine warm-up timer (or 30 seconds; refer to Cold Smart Start).
–Will not transfer if utility subsequently returns.
AUTO
–Will transfer to generator if utility is not present.
• Will transfer back to utility once utility returns (above 80% of nominal) for 15 seconds.
• Will not transfer back to utility unless utility returns. The generator will shut down if the OFF
button is pressed or a shutdown alarm is present.
• Once utility power is returned, the generator will shut down after 1 minute cool-down time.
• Will not exercise if generator is already running in either AUTO or MANUAL mode.
EXERCISE
• During exercise, the control panel will only transfer if utility fails during exercise for 6 seconds
(or 30 seconds; refer to
Transfer Back to Utility Power Source
When utility power has been restored, transfer back to
utility source and shut down the generator. To manually
transfer back to utility power and shut down the
generator:
1. Set the Main Circuit Breaker (Generator
Disconnect) to OFF or OPEN.
2. Allow the engine to run for 2 minutes at no-load to
stabilize the internal temperatures.
3. Press the control panel OFF button. The engine
should shut down.
4. Verify that utility power supply to the transfer switch
is turned off.
5. Use the manual transfer handle inside the transfer
switch to move the main contacts back to the
UTILITY position (loads connected to the utility
power source, A in Figure 3-4).
6. Turn on the utility power supply to the transfer
switch using the means provided.
7. Press the control panel AUTO button.
Cold Smart Start) and will operate as normal in AUTO mode.
Automatic Transfer Operation
To select automatic operation:
1. Make sure the transfer switch main contacts are
set to the UTILITY position (loads connected to the
utility power source).
2.
Verify that normal UTILITY power source voltage is
available to transfer switch terminal lugs N1 and N2.
3. Press the AUTO button on the control panel
interface.
4. Set the main circuit breaker (Generator
Disconnect) to the ON (Closed) position.
With these steps complete, the generator will start
automatically when utility source voltage drops below a
preset level. After the unit starts, loads are transferred to
the standby power source.
12 Owner’s Manual for 7.5 kW PowerPact™
Operation
Automatic Sequence of Operation
Utility Failure
With the generator set to AUTO, when utility fails (below
65% of nominal) a 5 second line interrupt delay time is
started. If utility is still gone when the timer expires, the
engine will crank and start. Once started, a 6 second
engine warm-up timer will be initiated
warm-up timer; refer to
up time expires, the control panel will transfer the load to
the generator. If the utility power is restored (above 80%
nominal) at any time from the initiation of the engine start
until the generator is ready to accept load (warm-up time
has not elapsed), the control panel will complete the start
cycle and run the generator through its normal cool down
cycle, however, the load will remain on the utility source.
Cold Smart Start). When the warm-
Cranking
The system will control the cyclic cranking as follows:
• 5 cranking cycles as follows: 16 second crank,
seven (7) second rest, 16 second crank, seven (7)
second rest, followed by three (3) additional cycles
of seven (7) second cranks followed by seven (7)
second rests.
(or a 30 second
2. Turn the main line circuit breaker (MLCB) on the
generator to OFF (OPEN).
3. Turn the generator OFF.
To turn the generator back ON:
1. Put the generator back into AUTO and allow to
start and warm-up for a few minutes.
2. Set the MLCB on the generator to ON.
The system will now be operating in automatic mode.
The main utility disconnect can be turned ON (CLOSED).
To shut the unit OFF, this complete process must be
repeated.
Cold Smart Start
The Cold Smart Start feature enables the generator to
monitor ambient temperature. The warm-up delay will be
adjusted based on prevailing conditions.
On a startup in AUTO mode, if the ambient temperature is
below a fixed temperature (based on model) the generator
will warm up for 30 seconds. This allows the engine to
warm before a load is applied. If the ambient temperature
is at or above the fixed temperature, the generator will
start up with the normal warm-up delay of 6 seconds.
Load Transfer
The transfer of load when the generator is running is
dependent upon the operating mode.
Shutting Generator Down While Under Load
IMPORTANT NOTE: To turn the generator off during
utility outages to perform maintenance, or conserve fuel,
follow these steps:
To turn the generator OFF (while running in AUTO and online):
1. Turn the main utility disconnect OFF.
Owner’s Manual for 7.5 kW PowerPact™ 13
Operation
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14 Owner’s Manual for 7.5 kW PowerPact™
Section 4: Maintenance
(000182)
WARNING
Maintenance
Maintenance
Regular maintenance will improve performance and
extend engine/equipment life. Generac Power Systems,
Inc. recommends that all maintenance work be
performed by an Independent Authorized Service Dealer
(IASD). Regular maintenance, replacement or repair of
the emissions control devices and systems may be
performed by any repair shop or person of the owner’s
choosing. However, to obtain emissions control warranty
service free of charge, the work must be performed by an
IASD. See the emissions warranty.
Performing Scheduled Maintenance
It is important to perform maintenance as specified in the
Service Schedule for proper generator operation and to
verify that the generator complies with the applicable
emission standards for the duration of its useful life.
Service and repairs may be performed by any qualified
service person or repair shop.
Additionally, emissions-critical maintenance must be
performed as scheduled in order for the Emissions
Warranty to be valid. Emissions-critical maintenance
consists of servicing the air filter and spark plugs in
accordance with the Service Schedule. The Control
Panel will prompt for break-in or regular maintenance,
when it is required, to be performed. Break-in
maintenance consists of the oil change, valve clearance
and tune-up. Regular maintenance includes the oil, tuneup, air cleaner, spark plug and valve clearance.
Clearing a Maintenance Due Condition
After performing maintenance, the Maintenance Due light
must be cleared. To reset the Maintenance Due light, the
generator must be in OFF mode. Set the Generator to
OFF and press the OFF button to reset Maintenance
Due. If an alarm condition exists, the alarm condition
must be cleared prior to resetting the Maintenance Due
light.
NOTE: The control panel Maintenance Due light will
flash when the initial 20 hour break-in interval has been
reached. The same light will be lit solid when following
regular maintenance intervals are required (every 1 year/
100 hours).
Owner’s Manual for 7.5 kW PowerPact™ 15
Maintenance
Service Schedule
Table 4-1. Service Maintenance Schedule
System Component Procedure Frequency
X = Action
* = Notify dealer if repair is needed Inspect Change Clean
Fuel
Fuel lines and connections X M
Lubrication
Oil level X M or 24 hours of continuous operation
Oil X 6 M or 100 hours of operation **
Enclosure louvers X X W
Battery
Remove corrosion; ensure dryness X X Y
Clean and tighten battery terminals X X Y
Check charge state X X Y
Electrolyte level (unsealed batteries only)* X X Every 6 M
Engine and mounting
Air cleaner
Spark plug
XXX
XX
Valve clearance X 1 Y or 300 hours***
General condition
Vibration, noise, leakage * X M
Contact the nearest Independent Authorized Service Dealer for assistance if necessary.
* Contact the nearest Independent Authorized Service Dealer for assistance if necessary.
** Change oil after the first 20 hours of operation or 1 month. Continue to check at intervals of 100 hours or 6 months, whichever occurs first. Severe duty oil drain
intervals: In cold weather conditions (ambient below 40 ºF [4.4 ºC]) change engine oil every 6 months or 50 hours of operation to prevent accumulation of water in
the oil. If the unit will be operated continuously in hot ambient conditions (ambient above 85 ºF [29.4 ºC]) or operation in an extremely dusty or dirty environment
change the engine oil every 3 months or 50 hours of operation to prevent oil breakdown.
*** Check valve clearance after the first 20 hours of operation. Continue to check at intervals of 300 hours.
W = Weekly
M = Monthly
Y = Yearly
3 M / 50 hours - clean
1 Y / 300 hours - replace
6 M or 100 hours - inspect
1 Y or 300 hours - change
NOTE: Contact an Independent Authorized Service Dealer or visit www.generac.com for additional information on
replacement parts.
16 Owner’s Manual for 7.5 kW PowerPact™
Maintenance Log
Battery inspection and charge check
Dates Performed:
Oil, oil filter, air filter and spark plug replacement
Dates Performed:
Valve Adjustment
Dates Performed:
Maintenance
Notes:
Owner’s Manual for 7.5 kW PowerPact™ 17
Maintenance
(000139)
WARNING
Risk of burns. Allow engine to cool before
draining oil or coolant. Failure to do so
could result in death or serious injury.
(000210)
WARNING
Skin irritation. Avoid prolonged or repeated contact with
used motor oil. Used motor oil has been shown to cause
skin cancer in laboratory animals. Thoroughly wash
exposed areas with soap and water.
(000135)
CAUTION
Engine damage. Verify proper type and quantity of
engine oil prior to starting engine. Failure to do so
could result in engine damage.
A
(000135)
CAUTION
Engine damage. Verify proper type and quantity of
engine oil prior to starting engine. Failure to do so
could result in engine damage.
Checking Engine Oil Level
When power outages necessitate running the generator
for extended periods, the oil level should be checked
daily. To check the engine oil level:
1.
If the generator is running during a utility outage, turn
OFF all associated loads running in the residence
using the electrical panel main disconnect.
2. Turn the generator main circuit breaker to OFF.
3. Press the control panel OFF button.
4. Remove the 7.5 Amp fuse from the generator
control panel.
5. Remove the enclosure top lid by unscrewing the
fasteners, and lift the front panel off.
6. Remove the dipstick/fill cap and wipe it dry with a
clean cloth.
7. Insert the dipstick/fill cap, but do not thread into the
crankcase threads, then again remove it.
8.
Verify oil level is within safe operating range. The
level should be at the “H” mark on the dipstick/fill cap.
See A in Figure 4-1.
9. If necessary, remove the dipstick/fill cap and add
oil to the engine until the level reaches the FULL
mark and reinsert the dipstick and fill cap.
10. If the generator was running during a utility outage,
turn the main circuit breaker to the ON position.
11. Install the 7.5 Amp fuse in the generator control
panel.
12. Press the control panel AUTO button.
13. Turn ON the needed loads in the residence.
Engine Oil Recommendations
To maintain the product warranty, the engine oil should
be serviced in accordance with the recommendations of
this manual. For your convenience, Generac
Maintenance Kits are available that include engine oil, oil
filter, air filter, spark plug(s), a shop towel and funnel.
These kits can be obtained from an Independent
Authorized Service Dealer (IASD).
All Generac Maintenance kits meet minimum American
Petroleum Institute (API) Service Class SJ, SL, or better.
Use no special additives. Select the appropriate viscosity
oil grade according to the expected operating
temperature. Synthetic oil also can be used in the
appropriate weight as standard.
SAE 30
10W-30
Synthetic 5W-30
000399
Figure 4-2. Recommended Oil Based on Temperature
• SAE 30 above 32 ºF (0 ºC)
• SAE 10W-30 between 40 º and -10 ºF
(4 º and -23 ºC)
• Synthetic SAE 5W-30 for all temperature ranges
Figure 4-1. Safe Oil Operating Range
18 Owner’s Manual for 7.5 kW PowerPact™
Maintenance
001058
B
A
C
001070
A
B
C
Changing the Oil
1. Start the engine by pressing the MANUAL button
on the control panel and allow the engine to run
until it is thoroughly warmed up. Then, press the
Control Panel OFF button to shut down the engine.
2.
A few minutes after the engine shuts OFF, when it
has cooled slightly, remove the enclosure top lid by
unscrewing the fasteners, and lift the front panel off.
3.
Remove the battery access panel (A) by loosening
the two hex head screws.
4.
Disconnect the battery and remove the fuse.
5. Pull the oil drain hose (B) free of its retaining clip
(C). See Figure 4-3.
6. Remove the cap from the hose and direct the hose
into a suitable container.
7. Unscrew the drain hose cap and allow engine oil to
drain. Remove dipstick/ fill plug to permit oil to
drain faster. For proper drainage, drain the oil into
a pan placed at a lower level than the engine.
See Figure 4-3.
Changing the Engine Air Cleaner
1. With the generator shut down, remove the top lid.
2. See Figure 4-4. Disengage the wire clip (A) and
remove the air cleaner access cover (B).
Figure 4-4. Air Filter Location
3. Remove the old air filter (C) and discard.
4. Thoroughly clean the air cleaner enclosure of any
dust or debris while ensuring that none of the
debris falls in to the engine intake.
5. Install a new air filter.
6. Install the air cleaner cover and engage the wire
clip.
7. Install the enclosure top lid. Tighten fasteners
securely.
8. Place generator in AUTO.
Spark Plug
Check the spark plug gap and replace the spark plug as
Figure 4-3. Oil Drain Location
8. After the oil has drained, replace the cap onto the
end of the oil drain hose. Reposition and secure
the hose with the retaining clip.
9. Refill the engine with the proper recommended oil.
For recommended oil, see Figure 4-2.
10. Connect the battery, secure the battery access
panel, insert the fuse, and switch the unit to
MANUAL.
11. Start the engine, run for one minute, and check for
leaks.
12. Shutdown the engine and check the oil level. Add
oil as needed. DO NOT OVERFILL.
13. Insert dipstick/fill cap.
14. Press the Control Panel AUTO button.
15. Dispose of the used oil and filter at a proper
collection center.
Owner’s Manual for 7.5 kW PowerPact™ 19
necessary:
1. With the generator shut down, remove the top lid.
2. Clean the area around the base of the spark plug
to keep dirt and debris out of the engine.
3. Gently pull the spark plug boot off of the spark
plug.
4. Remove the spark plug and check the condition.
Install a new plug if the old plug is worn or if reuse
is questionable.
5. Clean the plug by scraping or washing with a wire
brush and commercial solvent. Do not blast the
plug to clean.
6. See Figure 4-5. Check the spark plug gap using a
wire feeler gauge. The gap should measure 0.030
in (0.76 mm). If the gap is out of specification,
replace the spark plug. See Section 2—
Replacement Parts.
Maintenance
000211
001071
E
B
A
C
D
Figure 4-5. Spark Plug Gap Measurement
7. Install spark plug. Torque to 20–22 ft-lb (27–30
Nm).
8. Install spark plug boot.
9. Install the enclosure top lid. Tighten fasteners
securely.
Valve Clearance Adjustment
Check the valve clearance after the first 20 hours of
operation, then after 300 hour intervals. Adjust if
necessary.
Important: Please contact an Independent Authorized
Service Dealer for service assistance. This is a very
important step to ensure longest life for the engine.
6. Make sure the piston is at top dead center (TDC) of
its compression stroke (both valves closed). To get
the piston at TDC, remove the intake screen at the
front of the engine to gain access to the flywheel
nut. Use a large socket and socket wrench to
rotate the nut and hence the engine in a clockwise
direction. While watching the piston through the
spark plug hole. The piston should move up and
down. The piston is at TDC when it is at its highest
point of travel.
7. See Figure 4-6. Check clearance between the
rocker arm (C) and the valve stem (D) with a feeler
gauge (E).
8. If valve clearance is 0.002–0.004 in. (0.05–0.1
mm), adjustment is not needed.
Adjust Valve Clearance
See Figure 4-6:
1. The engine should be cool before adjustment.
2. Remove enclosure lid fasteners and lid. Then
remove the back panel (if not already removed).
3. Remove spark plug wire and position wire away
from plug.
4. Remove spark plug.
5. Remove the four screws attaching the valve cover.
Remove and discard gasket.
6. Loosen the rocker jam nut (A) using a 10mm
wrench.
7.
Turn the pivot ball stud (B) while checking clearance
between the rocker arm (C) and the valve stem (D)
with a feeler gauge (E). Correct clearance is
0.004 in. (0.05–0.1 mm).
0.002–
Figure 4-6. Valve Clearance Adjustment
Check Valve Clearance
1. The engine should be cool before checking.
Adjustment is not needed if valve clearance is
within the specification in Section 2 —
Specifications.
2. Turn the generator OFF.
3. Remove enclosure lid fasteners and lid. Then
remove the back panel.
4. Remove spark plug wire and position wire away
from plug.
5. Remove spark plug.
NOTE: Hold the rocker arm jam nut in place as the pivot
ball stud is turned.
8.
When valve clearance is correct, hold the pivot ball
stud in place with the wrench and tighten the rocker
arm jam nut. Tighten the jam nut to 174 in-lbs (19.68
Nm) torque. After tightening the jam nut, recheck
valve clearance to make sure it did not change
9. Install new valve cover gasket.
10. Install the valve cover. Tighten fasteners in a cross
pattern, torquing to 35–62 in-lbs (4–7 Nm).
NOTE: Start all four screws before tightening or it will
not be possible to get all the screws in place. Make sure
the valve cover gasket is in place.
11. Install the rubber plug into the fan screen.
12.
Install the spark plug and attach the spark plug wire.
13. Install the back panel. Ensure that the alternator
intake bellow is captured by the frame on back
panel securely with out any kinks. Install enclosure
top lid. Tighten all fasteners securely.
14. Place the generator in AUTO.
.
20 Owner’s Manual for 7.5 kW PowerPact™
Maintenance
(000162)
WARNING
Explosion. Do not dispose of batteries in a fire.
Batteries are explosive. Electrolyte solution can cause
burns and blindness. If electrolyte contacts skin or eyes,
flush with water and seek immediate medical attention.
(000137a)
WARNING
(000164)
WARNING
Electrical shock. Disconnect battery ground
terminal before working on battery or battery
wires. Failure to do so could result in death
or serious injury.
(000138a)
WARNING
WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death or serious injury.
(000228)
Battery Maintenance
The battery should be regularly inspected per the
Service Schedule:
1. With the generator shut down, lift the lid and
remove the front panel and the battery access
panel.
2. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
3. Check the battery fluid level of unsealed batteries,
and if necessary, fill with distilled water only. DO
NOT use tap water. Also, have the Independent
Authorized Service Dealer or a qualified Service
Technician check the state of charge and condition.
• Do not place tools or metallic objects on top of the
battery.
• Disconnect the charging source prior to connecting
or disconnecting battery terminals.
• Wear full eye protection and protective clothing.
• Where electrolyte contacts the skin, wash it off
immediately with water.
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention.
• Wash down spilled electrolyte with an aid
neutralizing agent. A common practice is to use a
solution of 1 pound (500 grams) bicarbonate of
soda to 1 gallon (4 liters) of water. The bicarbonate
of soda solution is to be added until the evidence of
reaction (foaming) has ceased. The resulting liquid
is to be flushed with water and the area dried.
• DO NOT smoke when near the battery.
• DO NOT cause flame or spark in the battery area.
• Discharge static electricity from the body before
touching the battery by first touching a grounded
metal surface.
Always recycle batteries in accordance with local laws
and regulations. Contact your local solid waste collection
site or recycling facility to obtain information on local
recycling processes. For more information on battery
recycling, visit the Battery Council International website
at: http://batterycouncil.org/.
Strictly observe the following precautions when working
on batteries:
• Remove the 7.5 Amp fuse from the generator
control panel.
• Remove all jewelry—watches, rings, metal objects,
etc.
• Use tools with insulated handles.
• Wear rubber gloves and boots.
Owner’s Manual for 7.5 kW PowerPact™ 21
Attention After Submersion
If the generator has been submerged in water, it MUST
NOT be started and operated. Following any submersion
in water, have an Independent Authorized Service Dealer
thoroughly clean, dry, and inspect the generator. If the
structure (home) has been flooded, it should be
inspected by a certified electrician to verify there won’t be
any electrical problems during generator operation or
when utility power is returned.
Corrosion Protection
Periodically wash and wax the enclosure using
automotive type products. Do not spray the unit with a
hose or power washer. Use warm, soapy water and a soft
cloth. Frequent washing is recommended in salt water/
coastal areas. Spray engine linkages with a light oil such
as WD-40
®
.
Maintenance
Remove From, and Return To Service Procedure
Remove From Service
If the generator cannot be exercised every 7 days and
will be out of service longer than 90 days, prepare the
generator for storage:
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.
3. Once the unit has shut down, set the generator
main circuit breaker (Generator Disconnect) to
OFF (OPEN).
4. Turn off the utility power to the transfer switch.
5. Remove the 7.5 Amp fuse from the generator’s
control panel.
6. Disconnect the battery cables. Remove negative
cable first.
7. Remove battery charger AC input T1/Neutral cable
(has white sleeve) at controller.
8. While the engine is still warm, drain the oil
completely, and then refill the crankcase with oil.
9. Attach a tag to the engine indicating the viscosity
and classification of the new oil in the crankcase.
10. Remove the spark plug(s) and spray a fogging
agent into the spark plug(s) threaded openings.
Reinstall and tighten the spark plug(s).
11. Remove the battery and store it in a cool, dry room
on a wooden board.
12. Clean and wipe down the entire generator.
9. Insert the 7.5 Amp fuse into the generator control
panel.
10. Start the unit by pressing the MANUAL button.
Allow the unit to warm up for a few minutes.
11. Stop the unit by pressing the control panel OFF
button.
12. Turn on the utility power to the transfer switch.
13. Set the control panel to AUTO.
The generator is ready for service.
NOTE: When a battery is dead or has been
disconnected, the exercise timer and current date and
time must be reset.
Return to Service
To return the unit to service after storage:
1. Verify utility power is OFF.
2. Check the tag on the engine for oil viscosity and
classification. If necessary, drain and refill with
proper oil.
3. Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with distilled
water. DO NOT use tap water. Recharge the
battery to 100% state of charge. If defective,
replace the battery.
4. Clean and wipe down the entire generator.
5. Make sure the 7.5 Amp fuse is removed from the
generator Control Panel.
6. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected
incorrectly. Install positive cable first.
7. Reconnect the battery charger AC input T1/Neutral
cable (has white sleeve) at controller.
8. Open the fuel shutoff valve.
22 Owner’s Manual for 7.5 kW PowerPact™
Section 5: Troubleshooting
System Diagnosis
Problem Cause Correction
Troubleshooting
Engine will not crank. 1. Fuse blown.
2. Loose, corroded or defective battery cables.
3. Defective starter contact.
4. Defective starter motor.
5. Dead battery.
Engine cranks but will
not start.
Engine starts hard and
runs rough.
1. Out of fuel.
2. Defective fuel solenoid (FS).
3. Defective spark plug(s).
4. Valve clearance out of adjustment.
5. In cold weather condition.
1. Air cleaner plugged or damaged.
2. Defective spark plug(s).
3. Fuel pressure incorrect.
4. Fuel selector in wrong position.
1. Correct short circuit condition by
replacing 7.5 Amp fuse in generator
control panel.
2. Tighten, clean or replace as necessary.*
3. *See #2.
4. *See #2.
5. Charge or replace battery.
1. Replenish fuel / Turn on fuel valve.
2. *
3. Clean, re-gap or replace plug(s).
4. Reset valve clearance.
5. Install recommended cold weather kit.
1. Check / replace air cleaner.
2. Clean, re-gap or replace plug(s).
3. C
onfirm fuel pressure to regulator is 10–
12 in. water column (19-22 mm mercury)
for LP, and 5–7 in. water column (9-13
mm mercury) for natural gas.
4. Turn fuel conversion valve to correct
position.
Generator is set to
OFF, but the engine
continues to run.
No AC output from
generator.
No transfer to standby
after utility source
failure.
Unit consumes large
amounts of oil.
* Contact an independent authorized service dealer for assistance.
1. Controller wired incorrectly
2. Defective control board.
1. Main line circuit breaker is in the OFF (or
OPEN) position.
2. Generator internal failure.
1. Main line circuit breaker is in the OFF (or
OPEN) position.
2. Defective transfer switch coil.
3. Defective transfer relay.
4. Transfer relay circuit open.
5. Defective control logic board.
1. Engine overfilled with oil.
2. Engine breather defective.
3. Improper type or viscosity of oil.
4. Damaged gasket, seal or hose.
1. Repair wiring.*
2. Replace control panel*
1. Reset circuit breaker to ON (or
CLOSED).
2. *
1. Reset circuit breaker to ON (or
CLOSED).
2. *
3. *
4. *
5. *
1. Adjust oil to proper level.
2. *
3. See Engine Oil Requirements.
4. Check for oil leaks.
Owner’s Manual for 7.5 kW PowerPact™ 23
Troubleshooting
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24 Owner’s Manual for 7.5 kW PowerPact™
Quick Reference Guide
Section 6: Quick Reference Guide
System Diagnosis
To clear an active alarm, press the ENTER button twice and then press AUTO. If the alarm reoccurs, contact an independent authorized service dealer.
Table 6-1. System Diagnosis
Active Alarm LED Problem Things to Check Solution
NONE GREEN Unit running in AUTO
but no power in house.
HIGH
TEMPERATURE
RPM SENSE
LOSS
NOT ACTIVATED NONE Unit will not start in
LOW OIL
PRESSURE
RPM SENSE
LOSS
RED Unit shuts down during
operation.
RED Unit was running and
shuts down. Attempts
to restart.
AUTO with utility loss.
RED Unit will not start in
AUTO with utility loss.
RED Unit will not start in
AUTO with utility loss.
Check MLCB. Check MLCB. If it is in the ON position,
contact an Independent Authorized
Service Dealer.
Check the LED’s /
Screen for alarms.
Check the LED’s /
Screen for alarms.
See if screen says
unit not activated.
Check the LED’s /
Screen for alarms.
Check the LED’s /
Screen for alarms.
Check ventilation around the
generator, intake, exhaust and rear of
generator. If no obstruction, contact an
Independent Authorized Service
Dealer.
Clear alarm and remove household
loads from the generator. Put back in
AUTO and restart. If generator does
not start, contact an Independent
Authorized Service Dealer.
Refer to activation section in
Installation Manual.
Check oil level. Add oil per Engine Oil
Requirements. If oil level is correct,
contact an Independent Authorized
Service Dealer.
Clear alarm. Using the control panel,
check the battery by navigating to the
BATTERY MENU option from the
MAIN MENU. If battery is GOOD,
contact an Independent Authorized
Service Dealer. If display reads
CHECK BATTERY, replace the
battery.
OVERCRANK RED Unit will not start in
AUTO with utility loss.
NO LEDs LIT NONE Unit will not start in
AUTO with utility loss.
OVERSPEED
UNDERSPEED
Owner’s Manual for 7.5 kW PowerPact™ 25
RED Unit will not start in
AUTO with utility loss.
Check the LED’s /
Screen for alarms.
Check the LED’s /
Screen for alarms.
Check the LED’s /
Screen for alarms.
Verify fuel line shutoff valve is in the
ON position. Clear alarm. Attempt to
start the unit in MANUAL. If it does not
start or starts and runs rough, contact
Independent Authorized Service
Dealer.
Check ATO 7.5 Amp ATO® fuse.
Replace with same type fuse if bad.
Contact Independent Authorized
Service Dealer if fuse is good.
Contact Independent Authorized
Service Dealer.
Quick Reference Guide
Table 6-1. System Diagnosis (Continued)
Active Alarm LED Problem Things to Check Solution
WIRING ERROR RED Unit will not start in
AUTO with utility loss.
BATTERY
PROBLEM
CHARGER
PROBLEM
Break-In
Maintenance Due
1 Year / 100 Hour
Maintenance Due
NONE Utility present. Active
Control panel
indicates
battery problem.
Control panel
indicates charging
problem.
Control panel
indicates break-in
maintenance due.
Control panel
indicates maintenance
due.
mode LED (AUTO/
MANUAL/OFF) is
flashing.
Check the LED’s /
Screen for alarms.
Check for additional
information.
Check for additional
information.
Check for additional
information.
Check for additional
information.
Check utility sense
lines / utility
disconnect.
Contact Independent Authorized
Service Dealer.
Contact Independent Authorized
Service Dealer.
Contact Independent Authorized
Service Dealer.
Perform break-in maintenance. Clear
maintenance due light.
Perform scheduled maintenance.
Clear maintenance due light.
Contact Independent Authorized
Service Dealer. Close utility
disconnect.
26 Owner’s Manual for 7.5 kW PowerPact™
Part No. 0L6457 Rev. A 12/11/15 Printed in USA
©2015 Generac Power Systems, Inc. All rights reserved
Specifications are subject to change without notice.
No reproduction allowed in any form without prior written
consent from Generac Power Systems, Inc.
Generac Power Systems, Inc.
S45 W29290 Hwy. 59
Waukesha, WI 53189
1-888-GENERAC (1-888-436-3722)
generac.com
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