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Do not open or mutilate the battery. Released elec-
trolyte has been known to be harmful to the skin
and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is harm-
ful to the skin and eyes. It is electrically conductive
and corrosive. The following
procedures 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, 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 touch-
ing 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 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 control
panel, or sparking may occur at the battery posts
as the cables are attached, causing an explosion.
4.8
ADJUSTING 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 Authorized dealer for service assistance.
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.
20
Section 4 — Maintenance
Air-cooled 7 kW, 12 kW and 15 kW Generators
• 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.
• 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).
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
Pivot Ball
Stud
Jam Nut
• Install new valve cover gasket.
• Re-attach the valve cover.
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.
4.9
COOLING 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.
NOTE:
Rocker
Arm
Valve
Stem
NOTE:
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