Generac 7.5 kW PowerPact Generator Set

Tools: 10mm wrench, feeler gauge, torque wrench

1. Cool engine before adjustment
2. Remove enclosure lid, fasteners, back panel
3. Remove spark plug wire and spark plug
4. Remove 4 screws attaching valve cover, discard gasket
5. Loosen rocker jam nut with 10mm wrench
6. Turn pivot ball stud while checking clearance with feeler gauge to 0.002-0.004 in (0.05-0.1 mm)
7. Hold pivot ball stud, tighten rocker arm jam nut to 174 in-lbs (19.68 Nm)
8. Recheck clearance
9. Install new valve cover gasket
10. Install valve cover, tighten fasteners in cross pattern to 35-62 in-lbs (4-7 Nm)
11. Install rubber plug into fan screen
12. Install spark plug and wire
13. Install back panel and enclosure top lid
14. Place generator in AUTO

Tools: feeler gauge, socket wrench

1. Cool engine before checking
2. Turn generator OFF
3. Remove enclosure lid fasteners, lid, and back panel
4. Remove spark plug wire and spark plug
5. Rotate flywheel nut clockwise to bring piston to TDC of compression stroke
6. Check clearance between rocker arm and valve stem with feeler gauge
7. If clearance is 0.002-0.004 in (0.05-0.1 mm), no adjustment needed

⚠ Explosion hazard; connect positive cable first to avoid spark

⚠ Disconnect battery ground terminal before working on battery

1. Verify generator is turned OFF
2. Turn off utility power supply to transfer switch
3. Remove 7.5A fuse from generator control panel
4. Connect red battery cable (from starter contactor) to positive (+) post
5. Connect black battery cable (from frame ground) to negative (–) post
6. Install red battery post cover
7. Install battery bracket and screw
8. Install 7.5 Amp ATO fuse in control panel
9. Assemble battery access panel with 2 hex head screws
10. Assemble front door and top lid

Tools: Manometer

1. Remove top lid and rear panel
2. Check for leaks with non-corrosive gas leak detection fluid at all connection points
3. Close gas supply valve
4. Remove top gas pressure test port from regulator, install manometer
5. Open gas supply valve and verify pressure is within specified values
6. Close gas valve when completed
7. Reinstall rear access panel and top lid

⚠ High voltage present at transfer switch and terminals

Tools: AC voltmeter, Frequency meter

1. Verify generator OFF and main breaker OFF
2. Turn OFF all breakers/loads powered by generator
3. Turn on utility power to transfer switch
4. Check utility voltage across N1-N2 (240VAC nominal) and N1/N2-neutral (120VAC nominal)
5. Turn OFF utility power to transfer switch
6. Push MANUAL button, engine should crank and start
7. Let engine warm up 5 minutes, set main circuit breaker to ON
8. Check output voltage across E1-E2 (236-240V at 62-63Hz) and E1/E2-neutral (118-120V)
9. Set main breaker OFF, push generator OFF button

⚠ Connection of fuel source must be done by a qualified professional

Tools: 4mm and 6mm Allen wrenches, Needle nose pliers

1. Remove four 6mm Allen fasteners and lift top lid
2. Remove two 4mm Allen fasteners, lift and remove rear panel
3. Squeeze hose clamp and slide from fuel inlet
4. Remove hose from fuel inlet
5. Remove NG fuel jet from fuel inlet
6. Locate LP fuel jet (supplied, smaller ID than NG jet)
7. Insert LP fuel jet into end of fuel inlet
8. Reinstall hose on fuel inlet, secure with clamp
9. Verify hose is not kinked
10. Reinstall rear access panel and top lid

1. Obtain activation code via www.generac.com or 1-888-9ACTIVATE using unit serial number
2. Hold OFF button for 3 seconds until all LEDs flash twice
3. Enter 6-press activation code sequence using AUTO/OFF/SET EXERCISE buttons within 20 seconds
4. If incorrect, AUTO/OFF/MANUAL buttons flash 3 times; retry
5. If correct, all LEDs scroll bottom to top 5 times and OFF button lights

⚠ Remove 7.5 Amp fuse before working on battery

⚠ Wear eye protection and rubber gloves

1. Lift lid, remove front panel and battery access panel with generator shut down
2. Inspect battery posts and cables for tightness and corrosion, tighten/clean as necessary
3. Check battery fluid level of unsealed batteries, fill with distilled water only if necessary

1. Remove top lid with generator shut down
2. Disengage wire clip and remove air cleaner access cover
3. Remove old air filter and discard
4. Clean air cleaner enclosure of dust/debris without letting debris fall into intake
5. Install new air filter
6. Install air cleaner cover and engage wire clip
7. Install enclosure top lid, tighten fasteners securely
8. Place generator in AUTO

⚠ Allow engine to cool before draining oil

Tools: hex head screwdriver

1. Start engine via MANUAL button, run until warmed up, then press OFF
2. Remove enclosure top lid and front panel
3. Remove battery access panel (2 hex head screws)
4. Disconnect battery and remove fuse
5. Pull oil drain hose free of retaining clip
6. Remove cap from hose, direct into container
7. Unscrew drain hose cap, drain oil (remove dipstick to drain faster)
8. Replace drain hose cap and secure with retaining clip
9. Refill engine with recommended oil
10. Connect battery, secure access panel, insert fuse, switch to MANUAL
11. Start engine, run 1 minute, check for leaks
12. Shutdown engine, check oil level, add as needed, do not overfill
13. Insert dipstick/fill cap
14. Press AUTO button
15. Dispose of used oil and filter at proper collection center

1. Turn OFF all associated loads via electrical panel main disconnect if running during outage
2. Turn generator main circuit breaker to OFF
3. Press control panel OFF button
4. Remove 7.5 Amp fuse from control panel
5. Remove enclosure top lid and front panel
6. Remove dipstick/fill cap and wipe dry
7. Insert dipstick without threading, remove again, verify level at H mark
8. Add oil if necessary to FULL mark
9. Turn main circuit breaker ON if running during outage
10. Install 7.5 Amp fuse
11. Press control panel AUTO button
12. Turn ON needed loads

⚠ Required if unit cannot be exercised every 7 days and will be out of service longer than 90 days

1. Start engine and let it warm up
2. Close fuel shutoff valve, allow unit to shut down
3. Set generator main circuit breaker to OFF
4. Turn off utility power to transfer switch
5. Remove 7.5 Amp fuse from control panel
6. Disconnect battery cables, negative first
7. Remove battery charger AC input T1/Neutral cable at controller
8. Drain oil completely while engine warm, refill crankcase with oil
9. Tag engine indicating viscosity/classification of new oil
10. Remove spark plug(s), spray fogging agent into threaded openings, reinstall
11. Remove battery, store in cool dry room on wooden board
12. Clean and wipe down entire generator