Generac 15 kW EcoGen Generator Set

⚠ Allow engine to cool before adjusting valve clearance

⚠ AVR fan operates for 80 minutes after shutdown

Tools: 13mm wrench, 10mm Allen wrench, Feeler gauge

1. Remove spark plug wires and spark plugs
2. Remove four screws attaching valve cover, discard gasket
3. Verify piston at top dead center (TDC) of compression stroke
4. Loosen rocker jam nut with 13mm wrench
5. Turn pivot ball stud with 10mm Allen wrench while checking clearance with feeler gauge
6. Tighten jam nut to 174 in-lbs (19.68 Nm) while holding pivot ball stud
7. Recheck valve clearance
8. Install new valve cover gasket and valve cover, torque fasteners to 60 in-lbs (6.8 Nm) in cross pattern
9. Install spark plugs, torque to 18 ft-lbs (25 Nm)
10. Connect AVR fan and 4-pin connector
11. Install AVR filter housing, torque to 50-96 in-lbs (6-11 Nm)
12. Repeat for other cylinder if necessary

⚠ Always disconnect negative battery cable first.

⚠ Always connect positive battery cable first during installation.

⚠ Sparks may cause battery explosion if positive contacts ground with negative installed.

Tools: Digital multimeter

1. Verify battery condition by visual inspection.
2. Clean battery and terminals if necessary.
3. Check fluid level in unsealed batteries only.
4. Fill with distilled water only if necessary. Do not use tap water.
5. Check state of charge using digital multimeter.
6. Recharge and retest if state of charge below manufacturer recommendations.
7. Replace battery if unable to hold charge or if damaged.

⚠ Never operate engine with oil level below ADD mark.

⚠ Hot oil may cause burns. Avoid prolonged skin contact with used oil.

1. Remove dipstick and wipe with clean cloth.
2. Completely insert dipstick, then remove it.
3. Verify oil level at or near FULL mark.
4. If necessary, slowly add recommended oil into dipstick tube until FULL.
5. Do not overfill. Install dipstick.

⚠ AVR charged up to 3 minutes after power down. Wait 5 minutes before removing filter housing.

⚠ Perform with engine at ambient air temperature.

⚠ If uncomfortable or tools unavailable, contact authorized service dealer.

Tools: 5/8 inch spark plug socket, Feeler gauge (0.002-0.004 inch / 0.05-0.1 mm), Large socket and socket wrench, Intake screen removal tool

1. Verify engine at ambient air temperature.
2. Remove AVR filter housing screw from back panel.
3. Remove AVR filter housing.
4. Depress external latch to disconnect 20-pin connector from AVR.
5. Remove two screws to release AVR brackets from back panel.
6. Remove spark plug cables from spark plug terminals by grasping boot.
7. Thoroughly clean area around spark plugs.
8. Remove spark plugs using 5/8 inch spark plug socket.
9. Remove four screws to release valve cover.
10. Move piston to Top Dead Center (TDC) of compression stroke.
11. Remove intake screen at front of engine to access flywheel nut.
12. Place large socket and wrench on flywheel nut, rotate engine clockwise watching piston through spark plug hole.
13. Piston at TDC when at highest point of travel.
14. Insert 0.002-0.004 inch (0.05-0.1 mm) feeler gauge between rocker arm and valve stem.
15. Verify clearance with slight drag felt sliding feeler gauge back and forth.

⚠ Allow engine to cool before draining oil

1. Turn MLCB to OFF (OPEN)
2. Disengage connected loads
3. Turn generator off; press OFF button and wait 5 minutes
4. Remove dipstick and wipe dry
5. Completely insert dipstick and remove again
6. Observe oil level; should be at FULL mark
7. Add oil to FULL mark if necessary
8. Press AUTO to restart, warm up a few minutes, set MLCB to ON

⚠ Never disconnect spark plug with engine running.

⚠ AVR charged up to 3 minutes after power down. Wait 5 minutes before removing filter housing.

⚠ Grasp spark plug cable boot when disconnecting, not cable itself.

Tools: 5/8 inch spark plug socket, Wire feeler gauge, Wire brush, Commercial solvent, Spark plug socket, Torque wrench

1. Remove AVR filter housing screw from back panel.
2. Remove AVR filter housing.
3. Remove spark plug cables from spark plug terminals by grasping boot.
4. Thoroughly clean area around spark plugs.
5. Remove spark plugs using 5/8 inch spark plug socket.
6. Check condition of threads in cylinder head and plugs.
7. Clean spark plugs using wire brush and commercial solvent.
8. Check spark plug gap using wire feeler gauge.
9. Adjust gap to 1.02 mm (0.040 inch) by bending ground electrode.
10. Finger tighten spark plugs into cylinder head.
11. Using spark plug socket, tighten to 15-18 ft-lbs (20-25 Nm).
12. Install spark plug cables onto spark plug terminals.
13. Install AVR filter housing and screw to back panel, torque 50-96 in-lbs (6-11 Nm).

Tools: Clean-out tool, Pipe wrench

1. Remove intake side panel
2. Turn generator fuel supply off
3. Unscrew and remove cap
4. Use clean-out tool to remove accumulated moisture and particles from cap and body
5. Wipe inside of each component with clean, dry, lint-free cloth
6. Seal cap threads with sealing compound and hand-tighten
7. Tighten cap with pipe wrench, do not overtighten
8. Turn fuel supply on, check for leaks with gas leak detection fluid
9. Install intake side panel

⚠ Skin irritation from used motor oil

Tools: Oil System Drain Pump Kit P/N 0K3717, Drill

1. Place MLCB to OFF
2. Press MANUAL button to operate unit for minimum 20 minutes to reach operating temp
3. Press OFF button to shut down engine
4. Allow oil to settle for 10 minutes
5. Remove used oil filter, remove oil dipstick
6. Attach drill pump, insert 1/4in hose into oil tank, 1/2in hose into catch container
7. Spin pump on high speed, draw out 2.5-3.5 quarts (2.37-3.31 L) of oil
8. Apply light coat of new oil to new filter gasket, install filter hand-tight plus 3/4 to 1 full turn
9. Refill oil tank to FULL mark, start engine for one minute, check for leaks
10. Stop engine 10 minutes, recheck oil level, add if necessary
11. Place MLCB to ON, press AUTO button

⚠ Do not disconnect spark plug wires with engine running

Tools: Wire feeler gauge

1. Lift lid and remove front panel with generator shut down
2. Remove screw to release AVR filter housing
3. Clean area around spark plug base
4. Remove spark plug cables from terminals
5. Remove spark plugs and check condition
6. Clean by scraping or washing with wire brush and solvent
7. Check gap with feeler gauge, replace if out of spec
8. Install spark plugs and torque to 18.4 ft-lbs (25 Nm)
9. Attach spark plug cables
10. Install AVR filter housing

1. Start engine and let it warm up
2. Close fuel shutoff valve, allow engine to stop
3. Set MLCB to OFF (OPEN)
4. Disengage connected loads
5. Remove battery charger AC input cable at controller
6. Remove 7.5 amp fuse
7. Disconnect battery cables, negative first
8. Drain oil completely while warm, refill oil tank
9. Tag engine with oil viscosity/classification
10. Remove spark plugs, spray fogging agent, reinstall and torque to spec
11. Remove and store battery in cool dry room

⚠ Secondary 12V DC fan continues operating up to 1 hour after shutdown.

⚠ AVR remains charged 3 minutes after power down. Wait 5 minutes before removing filter housing to avoid electrical shock.

⚠ Exercise caution near AVR fan housing to avoid hand injury.

Tools: Torque wrench

1. Wait 5 minutes after shutdown before removing AVR filter to avoid electrical shock.
2. Remove screw to release AVR filter housing from back panel.
3. Remove AVR filter housing.
4. Grasp rubber lifting strap and remove filter from housing. Discard filter.
5. Install new filter so edge positioned inboard of two tabs on housing.
6. Install AVR filter housing so bottom drops into slots with rubber boot around fan opening.
7. Install screw and torque to 50-96 in-lbs (6-11 Nm).

⚠ Always disconnect negative (black) battery cable first.

⚠ Always connect positive (red) cable first during installation.

⚠ Sparks may cause battery explosion if positive contacts ground with negative installed.

1. Remove battery negative cable (black) from negative (-) terminal.
2. Remove battery positive cable (red) from positive (+) terminal.
3. Remove battery from battery tray.
4. Install new battery onto battery tray.
5. Install battery positive cable (red) to positive (+) terminal.
6. Install battery negative cable (black) to negative (-) terminal.