Generac EcoGen 6 kW Generator Set

Tools: feeler gauge, 10mm Allen wrench, torque wrench

1. Ensure the engine is cool (60-80°F) before checking
2. Remove spark plug wires and spark plugs
3. Rotate the flywheel nut clockwise to bring the piston to Top Dead Center (both valves closed)
4. Remove the four screws attaching the valve cover; remove and discard the rocker cover gasket
5. Loosen the rocker jam nut; use a 10mm Allen wrench to turn the pivot ball stud while checking clearance with a feeler gauge
6. Correct clearance is 0.002-0.004 inch (0.05-0.1 mm)
7. Hold the pivot ball stud and tighten the rocker arm jam nut to 174 in/lbs torque
8. Recheck valve clearance after tightening
9. Install new valve cover gasket and re-attach valve cover, torque fasteners in a cross pattern to 4 ft/lbs
10. Install spark plug and re-attach spark plug wire
11. Repeat for the other cylinder

⚠ Damage will result if battery connections are made in reverse

⚠ Sparking can occur at the battery posts and cause an explosion if switch is not OFF

1. Set the generator's AUTO/OFF/MANUAL switch to OFF
2. Remove the 7.5A fuse from the generator control panel
3. Connect the red battery cable (from starter contactor) to the positive (+) battery post
4. Connect the black battery cable (from frame ground) to the negative (-) battery post
5. Install battery post covers supplied with the generator

1. Install cold weather kit if temperature regularly falls below 32°F
2. Kit includes thermostat-controlled battery pad
3. Kit includes engine-block warmer

⚠ The generator is now electrically hot; contact with hot parts can cause fatal electrical shock

Tools: AC voltmeter, frequency meter

1. Set the generator's main circuit breaker to OFF (or OPEN)
2. Set the AUTO/OFF/MANUAL switch to OFF
3. Turn on the battery charger power supply to the generator
4. Check battery charger power source voltage across T1 and transfer switch neutral lug (should be 120 VAC line-to-neutral)
5. Turn OFF the power supply to the generator once voltage is confirmed compatible
6. Set the Auto/Off/Manual switch to MANUAL; engine should crank and start
7. Let the engine warm up for about 5 minutes, then set the main circuit breaker to ON
8. Connect AC voltmeter test leads across terminal lugs E1 and neutral (should read 125-120 VAC)
9. Set the main circuit breaker to OFF; let engine run at no-load a few minutes to stabilize
10. Set the AUTO/OFF/MANUAL switch to OFF; engine should shut down

⚠ Battery acid can cause severe injury or death

Tools: battery hydrometer

1. Inspect battery posts and cables for tightness and corrosion; tighten and clean as necessary
2. Check battery fluid level of unsealed batteries and fill with distilled water only if necessary
3. Have the state of charge and condition checked with an automotive-type battery hydrometer

1. Lift the roof and remove the door
2. Turn the two screws 1/4 turn counterclockwise to loosen
3. Remove the cover and air filter
4. Wipe away dust or debris from inside the air box and around edges
5. Install the new air cleaner into the air box
6. Install the cover, turn the two cover screws 1/4 turn clockwise to tighten

⚠ Never operate the engine with the oil level below the Add mark

1. Turn off all associated loads and the generator's main circuit breaker if running
2. Move the AUTO/OFF/MANUAL switch to OFF
3. Remove the dipstick and wipe it dry with a clean cloth
4. Completely insert the dipstick, then remove it again; oil level should be at the Full mark
5. If necessary, add oil to the Full mark only, do not overfill
6. Install the dipstick
7. Reset the AUTO/OFF/MANUAL switch to its original position
8. Repeat for the oil reservoir

⚠ Hot oil may cause burns; allow engine to cool before draining

1. Start the engine by moving the switch to MANUAL and run until warmed up, then shut OFF
2. Pull the oil drain hose free of its retaining clip, remove the cap, drain oil into a container
3. Replace the cap onto the drain hose and retain it in the clip
4. Remove the old oil filter by turning counterclockwise
5. Apply a light coating of clean engine oil to the new filter gasket
6. Screw on new filter by hand until gasket lightly contacts the adapter, then tighten an additional 3/4 to 1 turn
7. Refill with the recommended oil to proper capacity
8. Start the engine, run for 1 minute, check for leaks
9. Shut down and recheck oil level, add as needed
10. Reset the AUTO/OFF/MANUAL switch to AUTO
11. Dispose of used oil properly
12. Repeat for the oil reservoir

⚠ If the generator will be out of service longer than 90 days

Tools: fogging agent

1. Start the engine and let it warm up
2. Close the fuel shutoff valve and allow the unit to shut down
3. Switch to the OFF position
4. Set the main circuit breaker to OFF
5. Set the AUTO/OFF/MANUAL switch to OFF, turn off inverter load center, remove the 7.5A fuse, disconnect battery cables
6. While engine is warm, drain the oil completely and refill the crankcase; drain and refill the oil reservoir
7. Attach a tag indicating the oil viscosity and classification
8. Remove spark plugs, spray fogging agent into the openings, reinstall and tighten spark plugs
9. Remove the battery and store it in a cool, dry room on a wooden board
10. Clean and wipe the entire generator

Tools: wire feeler gauge, wire brush

1. Clean the area around the base of the spark plugs
2. Remove the spark plugs and check condition; replace if worn or reuse is questionable
3. Clean by scraping or washing with a wire brush and commercial solvent (do not blast clean)
4. Check the spark plug gap using a wire feeler gauge and adjust to 0.76 mm (0.030 inch) by bending the ground electrode