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Maintenance
4.6
BATTERY MAINTENANCE
The battery should be inspected per the "Service Schedule" sec-
tion. The following procedure should be followed for inspection:
1.
Inspect the battery posts and cables for tightness and corro-
sion. Tighten and clean as necessary.
2.
Check the battery fluid level of unsealed batteries and, if nec-
essary, fill with Distilled Water Only. Do not use tap water in
batteries.
3.
Have the state of charge and condition checked. This should
be done with an automotive-type battery hydrometer.
Do not dispose of the battery in a fire. The
battery is capable of exploding.
A battery presents a risk of electrical shock
and high short circuit current. The following
precautions are to be observed when working
on batteries:
• Remove the 7.5A fuse from the generator control
panel.
• Remove watches, rings or other metal objects.
• Use tools with insulated handles.
• Wear rubber gloves and boots.
• Do not lay tools or metal parts on top of the
battery.
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to
the skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following proce-
dures are to be observed:
• Wear full eye protection and protective clothing.
• Where electrolyte contacts the skin, wash it off
immediately with water.
• Where electrolyte contacts the eyes, flush thor-
oughly and immediately with water and seek medi-
cal attention.
• 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) of water. The bicar-
bonate 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:
22
• DO NOT SMOKE when near the battery.
• DO NOT cause flame or spark in battery area.
• Discharge static electricity from body before
touching the battery by first touching a grounded
metal surface.
Be sure the AUTO/OFF/MANUAL switch is set
to the OFF position before connecting the bat-
tery 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 7.5A fuse is removed from the genera-
tor control panel, or sparking may occur at the
battery posts as the cables are attached and
cause an explosion.
4.7
ADJUSTING GT-530/990/999
VALVE CLEARANCE
After the first six (6) months of operation, check the valve clear-
ance in the engine, adjust if necessary.
Important: If you feel uncomfortable about doing this procedure
or the proper tools are not available, please contact the Dealer for
service assistance. This is a very important step to ensure longest
life for the engine.
To check valve clearance:
• The engine should be cool before checking. If valve clearance is
0.002" - 0.004" (0.05 - 0.1mm), adjustment is not needed.
• Remove spark plug wires and position wires away from plugs.
• Remove spark plugs.
• Make sure the piston is at Top Dead Center (TDC) of its com-
pression 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 in a clockwise
direction. While watching the piston through the spark plug
hole. The piston should move up and down. The piston is at
TDC when it is at its highest point of travel.
To adjust valve clearance (if necessary), (Figure 4.9):
• Make sure the engine is at 60° to 80° F.
• 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.
• Loosen the rocker jam nut. Use a 8mm (for GT530) or a 10mm
(for GT990/999) 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).
Hold the rocker arm jam nut in place as the pivot ball stud is
turned.
NOTE:
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