Generac 7 kW PowerPact Generator Set

Tools: 13 mm Allen wrench, Feeler gauge

1. Ensure engine is at 60-80 F (16-27 C).
2. Remove enclosure lid and back panel if not already removed.
3. Ensure spark plug wire is removed and out of the way.
4. Remove the six screws attaching the valve cover.
5. Loosen the rocker jam nut; turn the pivot ball stud with a 13 mm Allen wrench while checking clearance with a feeler gauge to 0.002-0.004 in (0.05-0.1 mm).
6. Hold the pivot ball stud in place and tighten the rocker arm jam nut to 174 in-lb (19.68 N-m); recheck clearance.
7. Install new valve cover gasket, starting all six screws before tightening.
8. Install the valve cover; tighten fasteners to 35-62 in/lb (4-7 Nm).
9. Install the rubber plug into the fan screen.
10. Install the spark plug and attach the spark plug wire.
11. Install the back panel and enclosure top lid; tighten all fasteners securely.
12. Place the generator in AUTO.

⚠ Battery presents risk of electrical shock and high short circuit current.

⚠ Do not dispose of the battery by incineration.

⚠ Electrolyte is toxic dilute sulfuric acid; wear full eye protection and protective clothing.

Tools: Wire brush

1. With the generator shut down and battery charger power removed, remove the top lid, front panel and battery access panel.
2. Remove the battery bracket and carefully tilt/pull the battery through the access window.
3. Inspect battery posts and cables for tightness and corrosion; clean with a wire brush and tighten connections.
4. Check the battery fluid level of unsealed batteries; fill with distilled water only if necessary.
5. Place the battery into its original location, connect terminals and secure with the battery bracket.
6. Install the battery access panel, front panel and top lid; tighten all fasteners securely.

1. With the generator shut down, remove the top lid.
2. Disengage the wire clip and remove the air cleaner access cover.
3. Remove the old air filter and discard.
4. Thoroughly clean the air cleaner enclosure of dust or debris.
5. Install a new air cleaner.
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.

Tools: Suitable drain container

1. Start the engine with the MANUAL button and run until thoroughly warmed up, then press OFF.
2. After the engine cools slightly, remove the enclosure top lid and lift the front panel off.
3. Remove the battery access panel, disconnect the battery and remove the fuse.
4. Remove the drain hose from the retaining clamp and direct it into a suitable container.
5. Unscrew the drain hose cap and allow oil to drain; remove dipstick/fill plug to drain faster.
6. After draining, replace the drain hose cap.
7. Secure the drain hose with the retaining clamp.
8. Refill the engine with the proper recommended oil.
9. Reconnect the battery, secure the access panel, insert the fuse, switch to manual and start; run 1 minute and check for leaks.
10. Shut down the generator and recheck the oil level; add oil as needed. Do not overfill.
11. Re-insert dipstick/fill cap.
12. Install the front panel and enclosure top lid; tighten fasteners securely.
13. Press the control panel AUTO button.
14. Dispose of the used oil at a proper collection center.

⚠ Never operate the engine with oil level below the Add mark.

⚠ Hot oil may cause burns; avoid prolonged skin exposure with used oil.

1. Turn off all associated loads, turn Main Circuit Breaker OFF, press OFF button, remove the 7.5A ATO fuse and disconnect the battery leads.
2. Remove the enclosure top lid by unscrewing the fasteners and lift the front panel off.
3. Wait for 1 minute to allow the generator to cool down.
4. Remove the dipstick/fill cap and wipe it dry with a clean cloth.
5. Insert the dipstick/fill cap without threading it in, then remove it again.
6. Observe the oil level; it should be at the Full mark on the dipstick/fill cap.
7. If necessary, add oil until the level reaches the Full mark and reinsert the dipstick/oil fill cap.
8. Turn Main Circuit Breaker ON, connect battery leads, install the fuse, press AUTO, then turn on needed loads.

Tools: 24 mm socket and ratchet, Feeler gauge

1. Ensure engine is cool, at 60-80 F (16-27 C).
2. Turn the generator to OFF.
3. Remove enclosure lid fasteners and lid, then remove the back panel.
4. Remove spark plug wire and position away from the plug.
5. Remove spark plug.
6. Rotate the engine clockwise with a 24 mm socket to bring the piston to TDC of its compression stroke.
7. Check clearance between the rocker arm and valve stem with a feeler gauge.
8. If valve clearance is 0.002-0.004 in (0.05-0.1 mm), adjustment is not needed.

1. Start the engine and let it warm up.
2. Close the fuel shutoff valve and allow the unit to shut down.
3. Set the Main Circuit Breaker to OFF (OPEN).
4. Turn off the utility power to the transfer switch.
5. Remove the 7.5 Amp ATO fuse from the Control Panel.
6. Disconnect the battery cables, negative cable first.
7. Remove battery charger AC input T1/Neutral cable at Control Panel.
8. While the engine is still warm, drain the oil completely, then refill the crankcase with oil.
9. Attach a tag indicating the viscosity and classification of the new oil.
10. Remove the spark plug and spray a fogging agent into the threaded opening; reinstall the spark plug.
11. Remove the battery and store it in a cool, dry room on a wooden board.
12. Clean and wipe down the entire generator.

1. Verify utility power is turned off.
2. Check the tag on the engine for oil viscosity; drain and refill if necessary.
3. Check battery state; fill unsealed battery cells with distilled water; recharge to 100 percent or replace if defective.
4. Clean and wipe down the entire generator.
5. Make sure the 7.5 Amp ATO fuse is removed from the Control Panel.
6. Reconnect the battery, positive cable first.
7. Reconnect the battery charger AC input T1/Neutral cable at Control Panel.
8. Open the fuel shutoff valve.
9. Insert the 7.5 Amp ATO fuse into the Control Panel.
10. Start the unit with the MANUAL button and allow it to warm up.
11. Stop the unit with the OFF button.
12. Turn on utility power to the transfer switch.
13. Set the control panel to AUTO.

Tools: Wire feeler gauge, Torque wrench

1. With the generator shut down, remove the top lid.
2. Clean the area around the base of the spark plug.
3. Pull the spark plug boot off, remove the spark plug and check its condition; replace if worn.
4. Clean the plug by scraping or washing with a wire brush and commercial solvent.
5. Check the spark plug gap using a wire feeler gauge; adjust to 0.76 mm (0.030 in) for 7 kW units.
6. Install spark plug; torque to 20-22 ft/lb (27-30 Nm). Install spark plug boot.
7. Install top lid; tighten fasteners securely.

1. Place the generator in 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 weekly at this time.

1. Set the Main Circuit Breaker (Generator Disconnect) to OFF (OPEN).
2. Allow the engine to run for 2 minutes at no-load to stabilize internal temperatures.
3. Press the Control Panel OFF button; the engine should shut down.
4. Ensure utility power supply to the transfer switch is turned off.
5. Use the manual transfer handle to move the main contacts back to their UTILITY position.
6. Turn on the utility power supply to the transfer switch.
7. Press the Control Panel AUTO button.

⚠ Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been completely turned off.

1. Press the Control Panel OFF button.
2. Set the Main Circuit Breaker (Generator Disconnect) to OFF (OPEN).
3. Turn off the utility power supply to the transfer switch.
4. Use the manual transfer handle to move the main contacts to their STANDBY position.
5. Press the Control Panel MANUAL button to crank and start the engine.
6. Allow the engine to stabilize and warm up for a few minutes.
7. Set the Main Circuit Breaker to ON (CLOSED).