Generac Power Systems PowerPact G0069981 Owner's Manual
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Generac Power Systems PowerPact G0069981 Owner's Manual

Generac Power Systems PowerPact G0069981 Owner's Manual

60 hz air-cooled generators
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Owner's Manual
60 Hz Air-Cooled Generators
7.5 kW PowerPact™
Loss of life. 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.
Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(888-436-3722)
WARNING
(000209b)

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Summary of Contents for Generac Power Systems PowerPact G0069981

  • Page 1 Owner’s Manual 60 Hz Air-Cooled Generators 7.5 kW PowerPact™ WARNING Loss of life. 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. (000209b) Register your Generac product at: WWW.GENERAC.COM...
  • Page 2 Use this page to record important information about your generator set. Record the information found on your unit data label on this page. The unit has a label plate affixed to the inside partition, Model: above the battery access panel as shown in Figure 2-1.

  • Page 3: Table Of Contents

    Table of Contents Section 1: Safety Information Shutting Generator Down While Under Load Or During A Utility Outage ........15 Introduction ............1 Auxiliary Shutdown Switch ......16 Read This Manual Thoroughly ........1 How to Obtain Service ..........1 Section 4: Maintenance Safety Rules ............2 General Hazards ............2 Maintenance ............
  • Page 4 Table of Contents This page intentionally left blank. Owner’s Manual for 50 Hz Air-Cooled Generators...

  • Page 5: Section 1: Safety Information Introduction

    Safety Information Section 1: Safety Information Introduction DANGER Thank purchasing this compact, high Indicates a hazardous situation which, if not avoided, performance, air-cooled, engine-driven generator. It is will result in death or serious injury. designed to automatically supply electrical power to operate critical loads during a utility power failure.

  • Page 6: Safety Rules

    Safety Information Safety Rules WARNING Study these SAFETY RULES carefully before installing, Accidental Start-up. Disconnect the negative battery operating or servicing this equipment. Become familiar cable, then the positive battery cable when working with this Owner’s Manual and with the unit. The on unit.

  • Page 7: Exhaust Hazards

    Safety Information Electrical Hazards WARNING DANGER Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to service Electrocution. Contact with bare wires, this equipment and could result in death or serious terminals, and connections while generator injury.

  • Page 8: Fire Hazards

    Safety Information Fire Hazards Explosion Hazards DANGER WARNING Explosion and fire. Fuel and vapors are extremely Fire hazard. Do not obstruct cooling and flammable and explosive. No leakage of fuel is ventilating airflow around the generator. Inadequate permitted. Keep fire and spark away. Failure to do ventilation could result in fire hazard, possible so will result in death or serious injury.

  • Page 9: Section 2: General Information

    General Information Section 2: General Information The Generator 005568 Figure 2-1. Features and Components Top Lid Fuel Connection Hole Air Box Controller Lid Data Label Spark Plug Control Panel Battery Access Panel Exhaust Enclosure Circuit Breaker Oil Drain Hose Alternator Customer Connection Box Oil Fill / Dipstick Starter Motor...
  • Page 10 General Information Specifications Generator Model 7.5 kW Rated Voltage Rated Maximum Load Current 31.25 (Amps) at Rated Volts (LP)* Main Line Circuit Breaker 35 Amp (Generator Disconnect) Phase Rated AC Frequency 60 Hz Battery Requirement Group U1, 12 Volts and 300 CCA Minimum (see Replacement Parts) Enclosure...

  • Page 11: Data Decals

    General Information Data Decals Two decals on the generator provide information about the unit itself and the required fuel inlet pressure for proper operation. Model Data Decal Includes important information about the unit including: • model number 20xx/xx/xx • serial number •...

  • Page 12: Protection Systems

    General Information Protection Systems Fuel Requirements The generator may have to run for long periods of time DANGER with no operator present to monitor the engine/generator conditions. Therefore, the generator is equipped with a Explosion and Fire. Fuel and vapors are extremely flammable and explosive.
  • Page 13 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 Refer to Transfer Switch Owner’s Manual for part number Accessories Performance enhancing accessories are available for air-cooled generators. Accessory Description Cold Weather Kit...
  • Page 14 General Information This page intentionally left blank. Owner’s Manual for 7.5 kW PowerPact™...

  • Page 15: Section 3: Operation

    Operation Section 3: Operation Site Prep Verification Controller Lid It is important that the generator is installed in such a way To open or close the controller lid: that the airflow into and out of the generator is not 1. See view “A” in Figure 3-1.

  • Page 16: Control Panel

    Operation 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): •...

  • Page 17: Alarm Response Procedures

    Operation Alarm Response Procedures To CHANGE the exercise time once it has been set, hold the SET EXERCISE button on the generator for three (3) The generator is protected by a series of sensors that will seconds at the time you wish the new exercise time to detect an Alarm/Warning condition and alert the owner/ take place.

  • Page 18: Transfer Back To Utility Power Source

    Operation 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 line circuit breaker (Generator Disconnect) to ON or CLOSED. The standby power source now powers the loads.

  • Page 19: Automatic Sequence Of Operation

    Operation Automatic Sequence of Operation Shutting Generator Down While Under Load Or During A Utility Utility Failure Outage With the generator set to AUTO, when utility fails (below DANGER 65% of nominal) a five second line interrupt delay time is started.

  • Page 20: Auxiliary Shutdown Switch

    Operation Auxiliary Shutdown Switch All generators are provided with an external means to shut down the generator that complies with the 2017 NEC code requirement. The primary generator shutdown sequence is described in the previous topic. Figure 3-5. An auxiliary shutdown switch is located on the exterior of the generator back panel.

  • Page 21: Section 4: Maintenance

    Clearing a Maintenance Due Condition Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, After performing maintenance, the Maintenance Due light Inc. recommends that all maintenance work be must be cleared. To reset the Maintenance Due light, the performed by an Independent Authorized Service Dealer generator must be in OFF mode.

  • Page 22: Service Schedule

    Maintenance Service Schedule Table 4-1. Service Maintenance Schedule System Component Procedure Frequency X = Action W = Weekly * = Notify dealer if repair is needed Inspect Change Clean M = Monthly Y = Yearly Fuel Fuel lines and connections Lubrication Oil level M or 24 hours of continuous operation...
  • Page 23 Maintenance Maintenance Log Battery inspection and charge check Dates Performed: Oil, oil filter, air filter and spark plug replacement Dates Performed: Valve Adjustment Dates Performed: Notes: Owner’s Manual for 7.5 kW PowerPact™...

  • Page 24: Checking Engine Oil Level

    Maintenance Checking Engine Oil Level 9. If necessary, remove the dipstick/fill cap and add oil to the engine until the level reaches the FULL WARNING mark and reinsert the dipstick and fill cap. 10. If the generator was running during a utility outage, Risk of burns.

  • Page 25: Changing The Oil

    Maintenance Changing the Oil 13. Insert dipstick/fill cap and hand tighten. 14. Press the Control Panel AUTO button. 15. Dispose of the used oil and filter at a proper WARNING collection center. Skin irritation. Avoid prolonged or repeated contact with Changing the Engine Air Cleaner used motor oil.

  • Page 26: Spark Plug

    Maintenance Spark Plug Check the spark plug gap and replace the spark plug as 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.

  • Page 27: Battery Maintenance

    Maintenance 7. Turn the pivot ball stud (B) while checking clearance WARNING between the rocker arm (C) and the valve stem (D) with a feeler gauge (E). Correct clearance is 0.002– Electrical shock. Disconnect battery ground 0.004 in. (0.05–0.1 mm). terminal before working on battery or battery wires.

  • Page 28: Attention After Submersion

    Maintenance Always recycle batteries in accordance with local laws and 11. Remove the battery and store it in a cool, dry room. regulations. Contact your local solid waste collection site or 12. Clean and wipe down the entire generator. recycling facility to obtain information on local recycling processes.

  • Page 29: Section 5: Troubleshooting

    Troubleshooting Section 5: Troubleshooting System Diagnosis Problem Cause Correction Engine will not crank. 1. Fuse blown. 1. Correct short circuit condition by replacing 7.5 Amp fuse in generator control panel. 2. Loose, corroded or defective battery cables. 2. Tighten, clean or replace as necessary.* 3.
  • Page 30 Troubleshooting This page intentionally left blank. Owner’s Manual for 7.5 kW PowerPact™...

  • Page 31: System Diagnosis

    Quick Reference Guide Section 6: Quick Reference Guide System Diagnosis To clear an active alarm, press the OFF button twice and then press AUTO. If the alarm reoccurs, contact an Independent Authorized Service Dealer (IASD). Table 6-1. System Diagnosis Active Alarm Problem Things to Check Solution...
  • Page 32 Quick Reference Guide Table 6-1. System Diagnosis (Continued) Active Alarm Problem Things to Check Solution 1 YEAR / 100 Control panel indicates None Perform scheduled maintenance. Clear Maintenance HOUR scheduled maintenance Due light. MAINTENANCE due.LED illuminates. NONE Utility present. Generator Check utility sense Contact IASD.
  • Page 33 Quick Reference Guide This page intentionally left blank. Owner’s Manual for 7.5 kW PowerPact™...
  • Page 34 Quick Reference Guide This page intentionally left blank. Owner’s Manual for 7.5 kW PowerPact™...
  • Page 36 ©2018 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved Waukesha, WI 53189 Specifications are subject to change without notice. 1-888-GENERAC (1-888-436-3722) No reproduction allowed in any form without prior written www.generac.com consent from Generac Power Systems, Inc.

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