Guardian Technologies 04758-2, 04759-2, 04760-2 Adjusting Valve Clearance, Cooling System

Section 4 — Maintenance

Guardian Air-cooled 7 kW, 12 kW and 15 kW Generators

•Where electrolyte contacts the eyes, immediately flush thoroughly with water and seek medical atten- tion; and

•Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

Lead-acid batteries present a risk of fire because they generate hydrogen gas. The

following procedures are to be followed:

•DO NOT SMOKE when near the battery;

•DO NOT cause flame or spark in battery area; and

•Discharge static electricity from body before touching the battery by first touching a grounded metal sur- face.

Be sure the AUTO/OFF/MANUAL switch is set to ! the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the

battery cables are connected.

Be sure the utility power supply is turned off, and the 5A fuse is removed from the generator con- trol panel, or sparking may occur at the battery posts as the cables are attached, causing an explo- sion.

4.8ADJUSTING VALVE CLEARANCE

After the first 50 hours of operation, adjust the valve clearance in the engine.

Important: If feeling uncomfortable about doing this procedure or the proper tools are not available, please contact the Generac Authorized dealer for service assis- tance. This is a very important step to insure longest life for the engine.

To adjust valve clearance:

•Make sure the engine is at room temperature.

•Make sure that the spark plug wire is removed from the spark plug and out of the way.

•Remove the four screws attaching the valve cover with a #2 or #3 phillips screwdriver.

•Make sure the piston is at Top Dead Center (TDC) of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. Use a large socket and socket wrench to rotate the nut and hence the engine. While watching the piston through the spark plug hole. The piston should move up and down. The piston is at TDC when it is up as high as it can go.

20 Generac® Power Systems, Inc.

•Loosen the rocker jam nut. Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge. Correct clearance is 0.002-0.004 inch (0.05-0.1 mm).

NOTE:

Hold the rocker arm jam nut in place as the pivot ball stud is turned.

When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change.

Figure 4.10 - Valve Clearance Adjustment

Rocker

Pivot BallArm

Stud

Jam Nut

Valve

Stem

•Install new valve cover gasket.

•Re-attach the valve cover. NOTE:

Start all four screws before tightening or it will not be possible to get them in place. Make sure the valve cover gasket is in place.

•Re-attach the spark plug wire to the spark plug.

•Repeat the process for the other cylinder.

4.9COOLING SYSTEM

Air inlet and outlet openings in the generator compart- ment must be open and unobstructed for continued proper operation. This includes such obstructions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to quickly shut down. (See Figure 4.9 for vent locations.)

The exhaust from this product gets extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.