RoySalisbury
Could someone point me to where I can get a Maintenance Manual for the EcoGen 6kw generator. Specifically I am looking for the location of the spark plugs. For the life of me, I cant find them. Do I have to take the housing apart to get at them?

Thanks
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Birken Vogt
One is facing toward the muffler area firewall at about a 45 degree angle. The other is facing toward the oil tank. They are both down in among some junk. But look for the valve covers and you will find them.
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RoySalisbury
Birken Vogt;52456 wrote:
One is facing toward the muffler area firewall at about a 45 degree angle. The other is facing toward the oil tank. They are both down in among some junk. But look for the valve covers and you will find them.


I swear I have looked. The one thing I assumed was the plug wire seems that its molded into the housing and does not come out like I would expect.

If possible, can you post some photos?
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Birken Vogt
I don't have any photos but the plug boot is kind of caught under the sheet metal sometimes and needs to be pried out sometimes. The wire comes off at a downward 45 degree angle, bent way back toward the engine but the wire is somewhat visible, you can grab it if you want to.
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Ziller Tech
If you go to Generac.com you can use the Find My Manual section and punch in the serial number.
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RoySalisbury
Finally got back out to my remote site and got the plugs replaced. Unfortunately that did not help. Still wont fire up.

And my backup is now burning oil and blowing white smoke everywhere. So I now have 2 completely useless Ecogen 6k generators. Talked to the service tech that was SUPPOSED to have solved all these issues when under warranty, and they want a minimum of $1800 just to come out and service them (2 hours travel one way).

Now I know why they discontinued these generators.

Roy
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Birken Vogt
Blowing smoke is most likely the crazy fuel pumps used as oil pumps system grossly overfilling the crankcase. One way to deal with it might just be to cap all that junk off, and run it with 1.75 qts in the crankcase filled to the dipstick like a normal engine.
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RoySalisbury
Birken Vogt;52784 wrote:
Blowing smoke is most likely the crazy fuel pumps used as oil pumps system grossly overfilling the crankcase. One way to deal with it might just be to cap all that junk off, and run it with 1.75 qts in the crankcase filled to the dipstick like a normal engine.


So just cap off the line coming out of the reservoir? Or would I also need to disconnect the pump somewhere?

Roy

BTW, If I ran it while it was blowing smoke like this, would it be ok for a few hours? I really need to power up my battery bank. :)
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RoySalisbury
So coming out of the oil reservoir is two lines. One goes to a small square device that has to other lines from that to other spots. There is also a larger line that goes directly into the air intake. And that filter has oil all over it. And the air intake... just filled with oil. I stuck a paper towel done to wipe out the oil and it came back soaked.

So I would say your suspicion is correct. That pump is working overtime. And I let it run for a while (5 min) and thought it started to clear.. then a massive cloud of white smoke. Like it just injected a huge amount of oil. So I shut it down.

Roy
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Birken Vogt
The oil in the intake is not coming from the little hose. It is coming from the breather which is larger and further in. The breather connects to the crankcase which is where the real trouble is. The oil is real high and contacting moving parts such as the crankshaft. When this happens it turns like whipped cream in a few seconds and comes out every place it can.

Take the oil drain hose from the engine and drain it back down to the proper level per the engine dipstick. (You have to stop draining for a sec to read the dipstick level.) It will run fine for at least a while when you do this.
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RoySalisbury
I took the air filter out and let it run. Wow. Every so often and gusher of oil comes out if the top of the of the housing and right into the intake. White smoke, and engine almost stops. Then it clears and goes for another minute or two.

If it could keep it from spitting out so much oil, this one would run like a champ.

Roy
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RoySalisbury
Birken Vogt;52787 wrote:

Take the oil drain hose from the engine and drain it back down to the proper level per the engine dipstick. (You have to stop draining for a sec to read the dipstick level.) It will run fine for at least a while when you do this.


Just to be safe, I drained ever drop of oil from the engine, then filled it fresh with just enough oil to get the dipstick reading about 3/4 (since it gonna keep filling it).

No more billowing white clouds. Still some puffs ever now and then, but thats probably just extra that needs burned off from the intake.

How long do you think this will last? Hours, days, weeks? I only run the generator about 4 or 5 hours a week.

Roy
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Birken Vogt
I can't imagine those gasoline pumps pump thick oil very fast either direction so I would expect it to last quite a while.
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RoySalisbury
Birken Vogt;52790 wrote:
I can't imagine those gasoline pumps pump thick oil very fast either direction so I would expect it to last quite a while.


Great. Thanks for your guidance. That helped that issue.

However, after it had ran for about 15 min, I shut it down just to check the oil, air filter etc and make sure I did not need to add any more oil now that it had time to circulate. When I went to start it, it just cranked and cranked. Now it wont start.

If its not one thing its another with these ecogen's. :(

EDIT: Well, it finally started. I'll se how long it runs.
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RoySalisbury
Well, that lasted about 30 min. Over temp shutdown. But this one I know what it is.

With the hot oil spewing out and covering the bottom of the generator, the foam seal between the engine compartment and the exhaust compartment has been "eroded".

So, when its all closed up, the hot exhaust can get into the engine compartment. And since its air-cooled... overheat.

So now I need to either find a new seal for this generator and replace the bad one, or possible find some high-temp spray sealant (fireproof) and seal the gap.

I'll let it cool down and then try to let it run with the front cover off and lid open and see if that helps.

Roy
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Birken Vogt
You mean hot air is coming back over the top?

Normally the engine/generator area on this model stays dead cold because the engine sucks in air in the cooling fan like a hurricane and blows it out the bottom, into the exhaust chamber and out the side and gone.
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RoySalisbury
Birken Vogt;52794 wrote:
You mean hot air is coming back over the top?

Normally the engine/generator area on this model stays dead cold because the engine sucks in air in the cooling fan like a hurricane and blows it out the bottom, into the exhaust chamber and out the side and gone.


No, its coming in the bottom I believe.. There is a seal between the plate that the engine sits on and the exhaust chamber. Its coming in via the cracks.

If thats not the issue, then I dont know why it is overheating when closed up. I let it cool down for an hour, and left the front and lid open, and now its been running for over an hour without issue.
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RoySalisbury
RoySalisbury;52795 wrote:
No, its coming in the bottom I believe..


Well, it is coming in form the bottom, but may not be because of the seal. I guess its meant to by that open under there. But the heat is definatly coming from under the engine. And I can also feel hot air coming out from the left side of the plastic housing around the engine.

So its something else. I ran it for over 5 hours last night with the from cover off and lid open. Ran fine. But as soon as I seal it up, it just has no ventilation for that hot air.
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