Generac GP7000 Generator Set

⚠ Ensure all material is clear of the alternator before proceeding.

Tools: VOM

1. Remove cover from end of alternator assembly.
2. Remove two screws holding down the voltage regulator (AVR).
3. Leave AVR connected to stator and brushes.
4. Set VOM to measure AC voltage.
5. Connect VOM across a 240VAC socket.
6. Set START-STOP-RUN switch to START.
7. Turn adjustment screw clockwise to increase voltage, counterclockwise to lower.

⚠ Use a new rocker arm cover gasket.

Tools: feeler gauge, allen wrench, crow's foot

1. Adjust valve clearance with engine at room temperature.
2. Position piston at TDC of compression stroke (both valves closed).
3. Loosen the rocker arm jam nut.
4. Turn pivot ball stud while checking clearance with a feeler gauge.
5. Hold stud with allen wrench and tighten jam nut to specified torque with a crow's foot.
6. Recheck valve clearance after tightening.

⚠ Do not apply excessive torque to the governor shaft.

Tools: frequency meter

1. Loosen the governor lever clamp bolt.
2. Hold governor lever at full INC RPM; rotate governor shaft counterclockwise fully.
3. Tighten governor lever clamp bolt to 110 inch-pounds.
4. Turn speed adjustment screw counterclockwise three full turns.
5. Start engine and let it warm up and stabilize at no-load.
6. Connect frequency meter; set no-load frequency 62.0-62.5 hertz.
7. Add a drop of Loctite 241 to the speed adjust screw threads.

Tools: frequency meter

1. Loosen the governor clamp bolt.
2. Hold governor lever at wide open throttle; rotate governor shaft clockwise fully.
3. Tighten governor lever clamp bolt to 70 inch-pounds (8 Nm).
4. Start generator; let it stabilize and warm up at no-load.
5. Connect frequency meter across generator AC output leads.
6. Turn the primary adjust screw to obtain a frequency of 62.5 Hz.

Tools: VOM, AC frequency meter

1. Disconnect or turn OFF all electrical loads connected to the generator.
2. Set a VOM to measure AC voltage.
3. Reset all circuit breakers to the ON position.
4. Start engine and let it stabilize and warm up.
5. Place meter test leads into an outlet.
6. Read AC voltage; connect frequency meter and read frequency.

Tools: voltmeter (resistance)

1. Set a voltmeter to measure resistance.
2. Remove all wires from the START-RUN-STOP Switch.
3. Check terminal 2 to 1: CONTINUITY in START, INFINITY in STOP.
4. Check terminal 2 to 3: CONTINUITY in STOP, INFINITY in START.
5. Reconnect all wires to the switch.

⚠ DO NOT rotate engine with electric starter with spark plugs removed.

Tools: clamp-on ammeter, tachometer P/N 042223, 12 volt battery, starter test bracket

1. Remove starter motor and assemble to test bracket; clamp in vise.
2. Connect a fully charged 12 volt battery and clamp-on ammeter.
3. Activate the starter (jump terminal on Starter Contactor).
4. Note reading on clamp-on ammeter and tachometer.
5. Take readings after ammeter and tachometer stabilize (2-4 seconds).

Tools: cylinder leak down tester, compression gauge

1. Remove the spark plug.
2. Gain access to the flywheel and remove the valve cover.
3. Rotate crankshaft until piston reaches TDC (both valves closed).
4. Lock the flywheel at top dead center.
5. Attach leak down tester adapter to spark plug hole.
6. Connect an air source of at least 90 psi.
7. Adjust regulated pressure to 80 psi.
8. Read right hand gauge; 20 percent leakage is normally acceptable.

1. Attempt to pull start the engine and observe.
2. Check whether the cord pulls easily and smoothly.
3. Check whether the cord returns with no assistance.
4. Check whether the engine turns over as the cord is pulled.

1. Remove the recoil and front cover assembly.
2. Remove the spark plug from the unit.
3. Attempt to turn the engine over by hand.

⚠ The capacitor may need to be discharged before testing. Use proper protective equipment with an exploded capacitor.

Tools: capacitance meter

1. Consult meter owner's manual for measuring capacitance.
2. Connect meter leads directly across the capacitor terminals.
3. Read the µf; should display the rated value ± 5µf.
4. Replace capacitor if any other reading is displayed.

⚠ Do NOT energize the capacitor for more than 1 second at a time.

⚠ Do not field flash alternator more than two times in sequence.

Tools: energizing cord (12 AWG, momentary pushbutton switch)

1. Construct an energizing cord as shown and connect as shown.
2. Set START-RUN-STOP switch to OFF position.
3. Momentarily turn on the energizing cord (one second).
4. Disconnect the energizing cord from the capacitor.
5. Check generator produces approximately 240 VAC at main circuit breaker.