Generac Maintenance Kit for CorePower Home Standby Generator - Model 6003 User Manual

1. Product Overview

This Generac Maintenance Kit (Model 6003) is specifically designed to ensure the optimal performance and longevity of your Generac 7kW CorePower Home Standby Generator. Regular and timely maintenance using this kit is crucial for reliable operation and to extend the life of your generator.

Image: Generac Maintenance Kit Model 6003, showing the included air filter, oil filter, and spark plug.

Kit Contents:

• Air Filter: Essential for clean air intake, protecting the engine from dust and debris.
• Oil Filter: Removes contaminants from the engine oil, ensuring proper lubrication.
• Spark Plug (RC12YC): Provides the necessary spark for engine ignition.
• Funnel: Aids in clean oil filling.
• Cleaning Cloth: For general cleanup during maintenance.

2. Safety Information

Always prioritize safety when performing maintenance on your generator. Failure to follow safety guidelines can result in serious injury or damage to equipment.

• Disconnect Power: Ensure the generator is completely shut down and disconnected from any power source before beginning any maintenance.
• Allow Cooling: The engine and exhaust components can be extremely hot. Allow the generator to cool down completely before touching any parts.
• Wear Protective Gear: Use appropriate personal protective equipment (PPE) such as safety glasses, gloves, and long sleeves.
• Ventilation: Work in a well-ventilated area to avoid inhaling fumes.
• Fuel Handling: Exercise extreme caution when handling fuel and oil. Keep away from open flames or ignition sources.
• Read Generator Manual: Always refer to your specific Generac CorePower Generator owner's manual for additional safety instructions and model-specific procedures.

3. Preparation

Required Tools (Not Included):

• Wrench for oil filter removal.
• Spark plug socket (5/8 inch) and ratchet.
• Spark plug gap gauge (to set gap to 0.030 inches).
• Oil drain pan.
• New engine oil (e.g., 10W-30, approximately 0.75 to 1 quart, refer to generator manual for exact type and capacity).
• Torque wrench (optional, for spark plug installation).

Pre-Maintenance Checks:

• Ensure the generator is turned OFF and the main circuit breaker is in the OFF position.
• Allow the generator engine to cool completely before starting any work.
• Gather all necessary tools and kit components.
• Position the generator in a well-lit and ventilated area.

4. Maintenance Procedures

Follow these steps to perform routine maintenance on your Generac CorePower Generator using the provided kit components.

Step 1: Oil Change

1. Place an oil drain pan beneath the generator's oil drain plug.
2. Remove the oil drain plug and allow all old oil to drain completely.
3. Replace the oil drain plug and tighten securely.
4. Using the provided funnel, slowly add the recommended type and amount of new engine oil (refer to your generator manual for exact specifications). Do not overfill.
5. Check the oil level using the dipstick.

Step 2: Oil Filter Replacement

1. Locate the old oil filter. Place a rag or small pan underneath to catch any drips.
2. Use an oil filter wrench to loosen and remove the old filter.
3. Apply a thin film of new engine oil to the rubber gasket of the new oil filter.
4. Screw on the new oil filter by hand until the gasket makes contact with the engine. Then, tighten an additional 1/2 to 3/4 turn. Do not overtighten.

Step 3: Air Filter Replacement

1. Locate the air filter housing on your generator.
2. Open the housing and carefully remove the old air filter. Note its orientation.
3. Insert the new air filter, ensuring it is seated correctly within the housing.
4. Close and secure the air filter housing.

Step 4: Spark Plug Replacement

1. Carefully remove the spark plug wire from the old spark plug.
2. Use a 5/8 inch spark plug socket to remove the old spark plug.
3. Check the gap of the new spark plug (RC12YC) using a spark plug gap gauge. The recommended gap is 0.030 inches. Adjust if necessary.
4. Thread the new spark plug into the cylinder head by hand to prevent cross-threading.
5. Tighten the spark plug with the socket wrench. If using a torque wrench, tighten to the specification in your generator manual (typically around 18-22 ft-lbs). If not, tighten until snug, then an additional 1/4 to 1/2 turn.
6. Reconnect the spark plug wire firmly.

5. Post-Maintenance Checks

After completing the maintenance procedures, perform these checks before operating the generator:

• Verify All Connections: Ensure all components (oil filter, air filter housing, spark plug wire) are securely in place.
• Check for Leaks: Inspect for any oil leaks around the oil filter and drain plug.
• Clean Up: Remove any tools, rags, or spilled fluids from around the generator. Dispose of old oil and filters responsibly according to local regulations.
• Test Run: Start the generator and allow it to run for a few minutes. Listen for any unusual noises and observe for proper operation. Check for any warning lights.

6. Troubleshooting Common Issues

If you encounter issues after performing maintenance, consider the following:

• Generator Not Starting:
  • Ensure the spark plug wire is securely connected.
  • Verify the spark plug gap is correct (0.030 inches).
  • Check oil level; low oil can prevent starting.
• Oil Leaks:
  • Ensure the oil filter is tightened correctly (not overtightened or undertightened).
  • Check the oil drain plug for proper sealing.
• Unusual Engine Noise:
  • Recheck all components for proper installation.
  • Ensure air filter housing is closed securely.

If problems persist, consult your Generac CorePower Generator owner's manual or contact Generac customer support.

7. Specifications

8. Warranty and Support

This maintenance kit is designed to support the longevity of your Generac generator. For specific warranty information regarding your Generac generator or the components within this kit, please refer to the documentation provided with your generator or visit the official Generac website.

If you require technical assistance, have questions about the maintenance procedures, or need to order replacement parts, please contact Generac Customer Support:

• Generac Official Website: www.generac.com
• Customer Service: Refer to the 'Contact Us' section on the Generac website for phone numbers and support options.

Always provide your generator's model and serial number when contacting support for faster service.