Owner’s Manual 60 Hz Air-Cooled Generators 7.5 kW PowerPact™ 001036 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. (000209a) 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.
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: 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.
Table of Contents Section 1: Safety Rules & General Information Introduction ..........................................................1 Read This Manual Thoroughly ....................................1 Table of Contents Automatic Sequence of Operation .................. 13 Utility Failure ..............................................................13 Cranking ....................................................................13 Cold Smart Start ........................................................
Table of Contents This page intentionally left blank. iv Owner’s Manual for 7.
Safety Rules & General Information Section 1: Safety Rules & General Information Introduction CAUTION 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. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Safety Rules & General Information General Hazards WARNING 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. (000190) 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) WARNING This unit is not intended for use as a prime power source.
Safety Rules & General Information Exhaust Hazards DANGER DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. (000103) Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) DANGER WARNING Asphyxiation.
Safety Rules & General Information WARNING Risk of electrocution. Refer to NFPA 70E for safety equipment required when working with with a live electrical system. Failure to use required safety equipment could result in death or serious injury. (000221) 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.
General Information Section 2: General Information The Generator A B G C H D K I J M L E F N O 001037 Figure 2-1. GA-420 Engine 7.5 kW Unit 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 Owner’s Manual for 7.
General Information Specifications Generator Model Rated Voltage 7.5 kW 240 Rated Maximum Load Current (Amps) at 220 Volts (LP)* Main Circuit Breaker Phase 31.25 35 Amp 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 This unit is tested in accordance to UL 2200 standards with an operating temperature of -20 ºF (-29 ºC) to 122 ºF (50 ºC).
General Information 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.
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).
Operation Section 3: Operation Site Prep Verification Controller Lid 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.
Operation Control Panel A The Control Panel is located under the Controller Lid. Open the Controller Lid to access the control panel (B in Figure 3-2). B 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) C 001052 Figure 3-3.
Operation 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.
Operation 5. To crank and start the engine, press the control panel MANUAL button. A 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. B 000947 Figure 3-4. Manual Transfer Switch Operation IMPORTANT NOTE: Actual switch operation may vary. Follow directions in the appropriate transfer switch manual. MANUAL • Will not transfer to generator if utility is present.
Operation Automatic Sequence of Operation 2. Turn the main line circuit breaker (MLCB) on the generator to OFF (OPEN). Utility Failure 3. Turn the generator OFF. 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 (or a 30 second warm-up timer; refer to Cold Smart Start).
Operation This page intentionally left blank. 14 Owner’s Manual for 7.
Maintenance Section 4: 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.
Maintenance Service Schedule Table 4-1.
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.
Maintenance Checking Engine Oil Level WARNING Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (000139) 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.
Maintenance Changing the Oil Changing the Engine Air Cleaner 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.
Maintenance 000211 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. 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. D 8.
Maintenance Battery Maintenance • Do not place tools or metallic objects on top of the The battery should be regularly inspected per the Service Schedule: • Disconnect the charging source prior to connecting 1. With the generator shut down, lift the lid and remove the front panel and the battery access panel. • Wear full eye protection and protective clothing. • Where electrolyte contacts the skin, wash it off 2. Inspect the battery posts and cables for tightness and corrosion.
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). 9. Insert the 7.5 Amp fuse into the generator control panel.
Troubleshooting Section 5: Troubleshooting System Diagnosis Problem Engine will not crank. Cause 1. Fuse blown. Correction 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. Defective starter contact. 3. *See #2. 4. Defective starter motor. 4. *See #2. 5. Dead battery. 5. Charge or replace battery. 1. Out of fuel. 1. Replenish fuel / Turn on fuel valve. 2.
Troubleshooting This page intentionally left blank. 24 Owner’s Manual for 7.
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 NONE GREEN Unit running in AUTO Check MLCB. but no power in house. Check MLCB. If it is in the ON position, contact an 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. Check the LED’s / Screen for alarms. Contact Independent Authorized Service Dealer. BATTERY PROBLEM Control panel indicates battery problem. Check for additional Contact Independent Authorized information. Service Dealer. CHARGER PROBLEM Control panel indicates charging problem.
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.