Simplicity 01006-0 Operator's Manual

MEGAFORCE" 6500
GENERAC
EXTENDED LIFE GENERATOR OWNER’S MANUAL
! Danger! This generator is designed for outdoor use only. Do not use this generator inside any building or enclosure
including the generator compartment of a recreational vehicle (RV). Fire or an explosion may result. No user
performed modifications, including venting of exhaust and/or cooling ventilation, will eliminate the danger. Also,
allow at least two feet of clearance on all sides of the generator even while operating the unit outdoors.
Before connecting the generator to an electrical system, open main circuit breaker or main switch serving the system,
to isolate the generator system from the electric utility. Failure to isolate the generator and utility systems may result
in damage to the generator and may also result in injury or death to electric utility workers, due to a backfeed of
electrical energy.
! Danger! If unit is used for backup power in the event of a utility power failure, the following step must be taken:
The Emission Control System for this generator is warranted for standards set by the
Environmental Protection Agency. For warranty information refer to the Engine Owners manual.
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Model No. 1006-0 (6500 Watt AC Generator) Part No. B1225 (Revision 3 1/29/99)
This symbol points out important safety instructions, which, if not followed, could endanger the personal
safety and/or property of yourself and others. Read and follow all instructions in the manual before
attempting to operate this unit.
Generac MEGAFORCE™ 6500 Extended Life Generator
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EQUIPMENT DESCRIPTION
This generator is an engine-driven, revolving field,
alternating current (AC) generator. It was designed
to supply electrical power for operating compatible
electrical lighting, appliance, tool and motor loads.
This manual contains information for a generator that
operates 120 and/or 240 volts, single phase, 60 Hz
devices that require up to 6500 watts (6.5 kW) of
power that pull up to 54.1 amps at 120 volts or 27
amps at 240 volts.
A
CAUTION: Do not exceed the generator’s
wattage/amperage capacity. Add up the rated
watts of all devices you are connecting to
generator receptacles at one time. This total
should not be greater than 6500 watts for
this generator. In most cases rated watts of
the electrical device can be found on the
device nameplate. If device nameplate gives
only volts and amps, multiply volts times
amps to obtain watts (volts x amps = watts).
The generator’s revolving field is driven at
approximately 3600 rpm by a single-cylinder engine.
Every effort has been expended to make sure that
the information in this manual is both accurate and
current. However, Generac reserves the right to
change, alter or otherwise improve the product at
any time without prior notice.
A
DANGER: Do not tamper with engine
governed speed. High operating speeds are
dangerous and increase risk of personal
injury or damage to equipment. The
generator supplies correct rated frequency
and voltage only when running at proper
governed speed. Incorrect frequency and/or
voltage can damage some connected
electrical loads. Operating at excessively low
speeds imposes a heavy load at such
reduced speeds, when adequate engine
power is not available, and may shorten
engine life.
Model 8: Serial Numbers
In the spaces provided below, insert the Model and
Serial numbers of your generator. Retain these
numbers for future reference. You can find Model
and Serial numbers on the generator data plate,
along with other important information.
Model
Number
Serial
Number
SAFETY RULES
NN WARNING:
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
This generator set was designed and manufactured
for specific applications. Do not attempt to modify the
unit or use it for any application it was not designed
for. If you have any questions about your generator's
application, ask your Dealer/Distributor or consult the
factory.
The manufacturer could not possibly anticipate every
circumstance that might involve a hazard. For that
reason warnings in the Manual and warnings on tags
or decals affixed to the unit are not all-inclusive. If you
intend to handle, operate or service the generator by
a procedure or method not specifically recommended
by the manufacturer, first make sure such a procedure
or method will not render this equipment unsafe or
pose a threat to you and others.
Read this manual carefully and become familiar with
your generator set. Know its applications, its
limitations and any hazards involved.
* The generator produces a very powerful voltage
that can cause extremely dangerous electrical
shock. Avoid contact with bare wires, terminals, etc.
Never permit any unqualified person to operate or
service the generator.
* Never handle any kind of electrical cord or device
while standing in water, while barefoot or while
hands or feet are wet. Dangerous electrical shock
Will result.
* The National Electric Code requires the frame and
external electrically conductive parts of generator
be properly connected to an approved earth
ground. Local electrical codes may also require
proper grounding of the generator. Consult with a
local electrician for grounding requirements in your
area.
* Use a ground fault circuit interrupter in any damp or
highly conductive area (such as metal decking or
steel work).
* Do not use worn, bare, frayed or otherwise
damaged electrical cord sets with the generator.
Using any defective cord set may result in electrical
shock or damage to equipment and/or property.
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* Operate generator only on level surfaces where it
will not be exposed to excessive moisture, dirt, dust
Or Corrosive vapors.
* Gasoline is highly FLAMMABLE and its vapors are
EXPLOSIVE. Do not permit smoking, open flames,
sparks or heat in the vicinity while handling gasoline.
Avoid spilling gasoline on hot engine. Comply with all
laws regulating storage and handling of gasoline.
* Do not overfill the fuel tank. Always allow room for
fuel expansion. If the tank is overfilled, fuel can
overflow onto a hot engine and cause FIRE or an
EXPLOSION.
* Never store generator with fuel in tank where
gasoline vapors might reach an open flame or a
spark or pilot light (as on a furnace, water heater or
clothes dryer). FIRE or an EXPLOSION might result.
* Generator exhaust gases contain DEADLY carbon
monoxide gas. This dangerous gas, if breathed in
sufficient concentrations, can cause
unconsciousness or even death. Operate this
equipment only in the open air where adequate
ventilation is available.
* The engine-generator requires an adequate flow of
cooling air for its continued proper operation. Never
operate the unit inside any room or enclosure where
the free flow of cooling air into and out of the unit
might be obstructed. Without sufficient cooling air
flow, the unit quickly overheats, damaging the
generator or nearby property.
* Allow at least 2 feet of clearance on all sides of
generator, even while operating unit outdoors, or you
could damage the unit.
* Never start, or stop, the engine-generator with
electrical loads connected to receptacles with the
connected devices turned ON. Start the engine and
let it stabilize before connecting electrical loads.
Disconnect all electrical loads before shutting down
the generator.
* Do not insert any object through cooling slots of the
engine-generator. You could damage the unit or
injure yourself.
* Never operate generator:
(a) in rain;
(b) in any enclosed compartment;
(c) if connected electrical devices overheat;
(d) if electrical output is lost;
(e) if engine or generator sparks;
(f) if flame/smoke is observed while unit is running;
(g) if unit vibrates excessively.
GROUNDING THE GENERATOR
The National Electric Code requires the frame and
external electrically conductive parts of generator be
properly connected to approved earth ground. Local
electrical codes may also require proper grounding of
the unit. For that purpose, a grounding lug (Figure 1) is
provided on the cradle frame.
Figure 1 — Grounding Lug
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding lug and
to an earth-driven copper or brass grounding rod
(electrode) provides adequate protection against
electrical shock. However, local codes may vary
widely. Consult with a local electrician for
grounding requirements in your area. Be sure to
keep the ground wire attached while you connect the
electrode.
Properly grounding the generator helps prevent
electrical shock if a ground fault conditions exists in the
generator or in connected electrical devices. Proper
grounding also helps dissipate static electricity, which
often builds up in ungrounded devices.
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Generac MEGAFORCE™ 6500 Extended Life Generator
Know Your Generator
Read this owner’s manual and safety rules before operating your generator. Compare the illustrations with
your generator, to familiarize yourself with the locations of various controls and adjustments. Save the manual for
future reference.
Circuit Breakers Lift Kit Fuel Tank
(AC) ~~
Hour Meter
idle Control
Switch
Choke Switch
A
12-Volt DC Receptacle
Run/Stop Switch
Air Cleaner
120-Volt AC, 30
AMP Receptacle
120/240-Volt AC, 30
AMP Receptacle A
120-Volt, 20 Amp AC GFCI Groundin Lu Spark Arrestor Muffler
Receptacles g tug
120-Volt AC, 30 AMP Receptacle — May be used to generator against electrical overload. Breakers are
supply electrical power for the operation of 120 volts "push to reset" type.
at 30 amps AC, single phase, 60 Hz, AC electrical Fuel Tank — Capacity of five U.S. gallons.
lighting, appliance, tool and motor loads. ,
Grounding Lug — Used for proper grounding of unit.
120-Volt, 20 Amp AC GFCI Receptacles — May be Hour Meter — Records how long the engine has
used to supply electrical power for the operation of been running.
120 volts at 20 amps AC, single phase, 60 Hz, AC .
p gep Idle Control Switch — With this switch set to ON,
electrical lighting, appliance, tool and motor loads. . ET , :
ghting., app printed circuit board in control panel automatically
120/240-Volt AC, 30 AMP Receptacle — May be reduces engine speed when no load is connected
used to supply electrical power for the operation of and increases engine to proper speed when load is
120 and/or 240 volts at 30 amps AC, single phase, 60 applied. However, be sure switch is OFF when
Hz, AC electrical lighting, appliance, tool and motor starting engine.
loads. Lift Kit — Use to lift generator.
12-Volt DC Receptacle — Recharge a discharged Recoil starter — (not shown) Used for starting the
12 Volt automotive type battery through this GN-Series engine.
receptacle. .
, Run/Stop Switch — Set this switch to "RUN" before
Air Cleaner — Uses a dry type filter element and using recoil starter. Set switch to "STOP" to switch
foam pre-cieaner to limit the amount of dirt and dust OFF engine.
that gets in the engine. Spark Arrestor Muffler — Exhaust muffier lowers
Choke Switch — Used when starting a cold engine. engine noise and is equipped with a spark arrestor
Circuit Breakers (AC) — Each receptacle is screen.
provided with a circuit breaker to protect the
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ASSEMBLING THE WHEEL KIT
The wheel Kit is designed to greatly improve the
portability of the Mega Force 6500 Generator.
You will need a socket wrench with 1/2" or 13mm
sockets to install the wheel kit.
Install as follows:
* Place the generator on a hard flat surface.
e Slide the axle (ltem 3) through the holes in the
brackets provided on the generator cradle
(Figure 2) and then add the two spacers (Item 5) on
each protruding end of the axle.
* Stand at the engine end of the generator and gently
tilt the generator forward, high enough to place
blocks beneath the cradle. This will allow you to add
the wheels.
* Slide on the wheels (Item 2) on each end of the
axle and secure with washer (ltem10) and retaining
pin (Item 4). Remove the blocks.
* Attach the vibration mounts (item 7) to the support
leg (Item 6) with two M8 x 30mm Capscrews
(Item 8), M8 washers (Item 12) and M8 Lock Nuts
(Item 9).
* With the wheels on, you can now tilt the generator
end forward and attach the support leg with two
M8 x 20mm Capscrews (Item 11) and two lock nuts
(item 9).
* Set the generator down so it is level and attach the
handle with four M8x45mm Capscrews (Item 13)
and four lock nuts (litem 9).
ASSEMBLING THE LIFT KIT
The lift kit is designed to give the generator the ability
to be conveniently lifted by a crane. You must follow
these instructions to ensure proper center of gravity
You will need a socket wrench with 1/2" or 13mm
sockets to install the lift kit. Install as follows:
* Place the lift bar on top of the cradle making sure,
as you look at the bar from the control panel side,
that it forms a reverse “L” (see Figure 3).
* Make sure the lift bar is 9 1/4" from the outside of
the cradle on the right side to the base of the lift bar
bracket (see Figure 3).
» Attach the lift bar to the cradle using four M8 x
45 mm Capscrews and four M8 Lock Nuts.
Figure 2 — Assembling the Wheel Kit
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Description
Handle
Wheel
Axle
Retaining Pin
Wheel Spacer
Support Leg
Vibration Mount
Hex Head Capscrew,
M8 x 30mm
Lock Nut, M8
Flat Washer (Wheel)
Hex Head Capscrew,
M8 x 20mm
Flat Washer
(Vibration Mount)
Hex Head Capscrew,
M8 x 45mm
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Figure 3 — Assembling the Lift Kit
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OPERATING THE GENERATOR
CAUTION! Never start, or stop, the engine-
generator with electrical loads connected to
the receptacles with the connected devices
turned ON.
E Starting the Engine
Disconnect all electrical loads from the generator.
Refer to the Engine Owners Manual for starting
instructions.
EM Applying Electrical Loads
* Let engine stabilize and warm up for about five
minutes after starting.
* Plug in and turn on the desired 120 or 240 volts,
single phase, 60 Hertz, AC electrical loads. DO
NOT OVERLOAD THE GENERATOR. Add up the
rated watts (or amps) of all loads to be connected at
one time. This total should not be greater than the
rated wattage/amperage capacity of the generator
(See "Do Not Overload the Generator” for specific
information).
EH Stopping The Engine
» Disconnect all electrical loads and let engine run at
no-load for about five minutes
* Turn off the engine by moving the Run/Stop switch
to STOP position.
* Close fuel shut-off valve.
* Refer to your Engine Owner's Manual for more
information about stopping the engine.
E Operating Automatic Idle Control
An Automatic Idle Control system provides greatly
improved fuel economy by operating the unit at its
normal high governed speed only when electrical
loads are plugged in and turned ON. The system
consists of: (a) an Idle Control Circuit Board; (b) a
Sensing Transformer; (c) an Electromagnet; and,
(d) an Idle Control Switch located on the control
panel.
Engine-generator runs at high governed speed with
Idie Control Switch “ON” only when an electrical load
Is connected to the generator and turned on. When
the electrical load is disconnected, an Electromagnet
is energized to pull the engine throttle control against
its idle stop. The Engine then runs at a reduced (idle)
speed.
The Electromagnet cannot be energized with the Idle
Control Switch “OFF” since its power circuit is open.
The engine runs at high governed speed (about 3600
rpm) whether load(s) are connected or not.
E Charging a Battery
DANGER! Storage batteries give off
A explosive hydrogen gas while recharging. An
explosive mixture will remain around the
battery for a long time after it has been
charged. The slightest spark can ignite the
hydrogen and cause an explosion. Such an
explosion can shatter the battery and cause
blindness or other serious injury.
DANGER! Do not permit smoking, open
flame, sparks or any other source of heat
around a battery. Wear protective goggles,
rubber apron and rubber gloves when
working around a battery. Battery electrolyte
fluid is an extremely caustic sulfuric acid
solution that can cause severe burns. If spill
occurs flush area with clear water
immediately.
A
Your generator is capable of recharging a discharged
12-volt automotive or utility style storage battery. Do
not use the unit to charge any 6-volt batteries. Do not
use unit to crank an engine with a discharged battery.
To recharge 12-volt batteries, proceed as follows:
* Check fluid level in all battery cells. If necessary,
add ONLY distilled water to cover separators in
battery cells. DO NOT USE TAP WATER.
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* |f the battery is equipped with vent caps, make sure
they are installed and are tight.
* |f necessary, clean battery posts or terminals.
* Connect battery charge cable connector plug to
panel receptacle identified by the words
“12-VOLT DC” (Figure 5 ).
Connect battery charge cable clamp with red
handle to battery post or terminal indicated by a
POSITIVE, POS or (+).
Connect battery charge cable clamp with black
handie to battery post or terminal indicated by a
NEGATIVE, NEG, or (>). |
Figure 5 — Connect Battery Cables
£1 12 VOLT D.C.
1.) RECEPTACLE
12 VOLT BATTERY
* Start engine (see “Starting the Engine” in the
Engine Manual). Let the engine run while battery
recharges.
* When battery has charged, shut down engine (see
“Stopping the Engine”).
NOTE: Use an automotive hydrometer to test battery
state of charge and condition. Follow the hydrometer
manufacturer’s instructions carefully. Generally, а
battery is considered to be at 100% state of charge
when specific gravity of its fluid (as measured by
hydrometer) is 1.260 or higher.
RECEPTACLES
This generator is equipped with these receptacles:
H 120-Voit, 20 Amp GFCI
Receptacle
Each receptacle (Figure 6) is protected against
overioad by a 20-amp, push-to-reset circuit breaker.
Use each receptacle to operate 120 volts, single-
phase, 60 Hz, AC electrical loads requiring up to
2400 watts (2.4 kW) at 20 amps of current. Use cord
sets that are rated 125 volts at 20 amps (or greater).
Figure 6 — 120V, 20A GFCI Receptacle
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HE 120-volt, 30 Amp Locking
Receptacle
Use NEMA L5-30P type plug with this receptacle.
Connect a 3-wire cord set rated 125 volts at 30 AC
amps or greater to the plug (according to Figure 7).
Use this receptacle to operate 120 volts AC, 60 Hz,
single phase loads requiring up to 3600 watts
(3.6 kW) of power at 30 AC AMPs. The outlet is
protected by a 30 AMP push-to-reset circuit breaker.
Figure 7 — 120V, 30A Locking Receptacle
PURCHASED
3-WIRE CORD
N — NEUTRAL (N)
Ll LI 120 VAC
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Ш 120/240 Volt, 30 Amp Locking
Receptacle
Use NEMA L14-30P type plug with this receptacle.
Connect a 4-wire cord set rated 250 volts at 30 AC
amps (or greater) (Figure 8). You can use the same
4-wire cord if you plan only to run a 120 volt load.
This receptacle powers 120/240 volt AC, 60 Hz,
single phase loads requiring up to 3600 watts of
power (3.6 kW) at 30 AC amps for 120 volts; 6500
watts of power (6.5 kW) at 27 AC amps for 240 volts.
Outlet is protected by a 30 amp push-to-reset circuit
breaker.
Figure 8 — 120/240V, 30A Locking Receptacle
=, 4-Wire Cord Set
120/240 VOLTS PLUG
CAUTION: Although this outlet states it has
a 120/240 volts 30-amp rating (up t07200
watts), the generator is only rated for 6500
Watts. Powering loads that exceed the
wattage/amperage capacity of the generator
can damage it or cause serious injuries.
Loads with 240 volts powered through this
outlet should not exceed 27 amps of current;
120 volt loads should not exceed 30 amps.
Ш Don’t Overload the Generator
Overloading a generator in excess of its rated
wattage capacity can result in damage to generator
and to connected electrical devices.
То prevent overloading your generator, add up the
total wattage of all electrical devices to be
connected at one time. This total should not be
greater than the generators wattage capacity.
The chart on page 9 is provided to assist you in
determining how many items your generator can
operate at one time. For more accurate RUNNING
WATTS figures, refer to the light, appliance, tool or
motor nameplate.
Some electric motors, such as induction types,
require about two-and-a-half times or more watts
of power for starting than for running. This surge of
power lasts for only a few seconds when starting
such motors. Be sure you allow for this high starting
wattage when selecting electrical devices to
connect to your generator. First, figure the watts
needed to start the largest motor. Add to that figure
the running watts of all other connected loads.
If the appliance, tool or motor does not identify the
wattage, multiply the voltage times ampere rating to
determine watts (volts x amps = watts).
The Wattage Reference Guide (Figure 9) is
provided to assist you in determining how many
items your generator can operate at one time.
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Generac MEGAFORCE™ 6500 Extended Life Generator
Figure 9 — WATTAGE REFERENCE GUIDE
RUNNING
WATTS
*Air Conditioner (12,000 Btu) .................——... 1700
Battery Charger (20 amp) ...................e.e........ 500
Belt Sander (3”).....................ee-e2er0rvesieerecen. 1000
Chain SaWw............eereeerreeeeneoceneenear eee eee. 1200
Circular Saw (6-12/) ......................... 800 to 1000
Coffee Maker......................e..meirieceoconece e. 1000
*Compressor (1 HP).....................eeeeeereccccnnea. 2000
*Compressor (3/4 HP)........................e..m..... 1800
*Compressor (1/2 HP)....................=...eemeeeeeno. 1400
Curling Iron «coven, 700
*Freezer ..................e.mrecenenarornnereneroone encarece. 500
Disc Sander (9”).......................eeverecerienreconee. 1200
Edge Trimmer.....................ee..evecererecaee eee, 500
Electric Nail Gun ...............e.e.eeeeemeeonecona ee 1200
Electric Range (one element) ...................... 1500
Electric Skillet... nern nenne nee nee 1250
*Ригпасе Fan (1/3 HP)... 1200
Hair Dryer... eevee cere, 1200
Hand Drill (17).......................eeeenenaenencaneenno 1100
Hand Drill (1/2”)................... e... 750 to 1000
Hand Drill (3/8”)......................eeee..re000000aeconen. 500
Hand Drill (1/4”)..................e.em..0reneaeeereneaneanee 250
Hedge Trimmer cco, 450
RUNNING
WATTS
Impact Wrench..….…..…..........…serrsercensensecencee 500
Net PUMP cre 800
Lawn MOower.................eereccerconececoneraccnennenee. 1200
Light Bulb ..................rccrecersrercccnnaa sec sesceren ee 100
Microwave Oven.….....…..….....………crrercererecncenses 700
1111. 07070) ere 1100
Oil Burner on Furnace ..................... SA 300
Oil Fired Space Heater (140,000 Btu)............ 400
ОН Fired Space Heater (85,000 Btu).............. 225
Oil Fired Space Heater (30,000 Btu).............. 150
*Paint Sprayer, Airless (1/3 HP) ..................... 600
Paint Sprayer, Airless (handheld)................... 150
Radio... rere 50 to 200
*Retrigerator.…........…...….......….….….….……….ecssereeserrers 600
10), 207010] 200
*Submersible Pump (1-1/2 HP).................... 2800
*Submersible Pump (1 HP) ........................ 2000
*Submersible Pump (1/2 HP) ....................... 1500
Sump PUMP eee 600
“Table Saw (10”).....................ecomonon. 1750 to 2000
Television ..…...................……rscrerrenssercense 200 to 500
Weed Trimmer.…...……...…......…..…esserercersereccnnne 500
* Allow 2-1/2 times the listed watts for starting
these devices.
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Generac MEGAFORCE™ 6500 Extended Life Generator
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GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure
that all periodic maintenance tasks are completed on
a timely basis, all discrepancies are corrected, and
the unit is kept clean and properly stored. Never
operate a damaged or defective generator.
spark plug and place wire where it cannot
come in contact with your spark plug before
working on your generator.
! CAUTION: Disconnect spark plug wire from
H Generator Maintenance
Generator maintenance consists of keeping the unit
clean and dry
Operate and store the unit in a clean dry environment
where it will not be exposed to excessive dust, dirt,
moisture or any corrosive vapors. Cooling air slots
must not become clogged with snow, leaves or any
other foreign material.
Check the cleanliness of the generator frequently and
clean when dust, dirt, oil, moisture or other foreign
substances are visible on its exterior surface.
NOTE: We DO NOT recommend using a garden
hose to clean generator. Water can enter engine fuel
system and cause problems. In addition, if water
enters the generator through its cooling air slots,
some water will be retained in voids and cracks of the
rotor and stator winding insulation. Water and dirt
buildup on generator internal windings will eventually
decrease the insulation resistance of these windings.
E To Clean the Generator
* Use a damp cloth to wipe exterior surfaces clean.
» A soft, bristle brush may be used to loosen caked
on dirt or oil.
® А vacuum cleaner may be used to pick up loose dirt
and debris.
* Low pressure air (not to exceed 25 psi) may be
used to blow away dirt. Inspect cooling air slots and
opening on generator. These openings must be
kept clean and unobstructed.
through the air cooling slots, even if the
engine is not running. Damage to the unit
or personal injury may result.
! CAUTION: Never insert any object or too!
ME Engine Maintenance
* Refer to the Engine Owner's Manual for information
on how to properly maintain your engine.
STORAGE INSTRUCTIONS
* The generator should be started at least once every
seven days and allowed to run at least 30 minutes.
If this cannot be done and you must store the unit
for more than 30 days, use the following guidelines
to prepare it for storage.
the tank indoors or in enclosed, poorly
ventilated areas where fumes can reach an
open flame, spark or pilot light as on a
furnace, water heater, clothes dryer or other
gas furnace.
! WARNING: Never store engine with fuel in
H Engine storage
See the Engine Owner's Manual for information on
how to properly store the engine.
M Generator Storage
* Clean the generator as outlined in “To Clean the
Generator”.
* Check that cooling air siots and openings on your
generator are open and unobstructed.
E Other Storage Tips
Do not store gasoline from one season to another.
* Replace your gasoline can if it starts to rust. Rust
and/or dirt in a gasoline can cause problems when
you use that fuel with this unit.
* Store in clean and dry area.
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Generac MEGAFORCE™ 6500 Extended Life Generator
SPECIFICATIONS
H Generator
Rated Maximum Continuous
AC Power Output …….……….…...…..…...……esrnrees 6500 watts (6.5 kW)
Rated Voltage ..........................020...ireem eres 120/240 Volts
Rated Maximum Current at 240 Volts.................. 27 AC amperes
Rated Maximum Current at 120 Volts............... 54.1 AC amperes
Phase..............—..... eee eee eter e aero ace cenar er arre ee eran nenenenncenanrer. 1
Rated AC Frequency essen EEE EEE EEE RER EEE 60 Hertz
Number of Rotor Poles.......................ereieeeee e eee 2
Driven Speed of Rotor .......................eiieee eee ARTE 3600 rpm
Fuel Capacity ..................eeeicerierne re nee. 5 U.S. gallons
H Engine
Моде! eee GN-360
BOE eee eee eee 80mm
Stroke .............eeeeeneecenneenecenroreanene racer one ea reee enero ceca 64mm
ET OT 101310 erre 0.05—0.10mm
Displacement ..........................-.e..eceerrece eee 360cc
RPM at no-load ........................eeereireceneene e ne eee ERE 3720
Maximum Tilt Angle while Operating......................... 15 degrees
Oil Capacity with Filter eee 1500ml (51 oz.)
Oil Capacity without Filter me... 1350ml (46 oz.)
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Generac MEGAFORCE™ 6500 Extended Life Generator
TROUBLESHOOTING
Problem
Engine is running, but no
AC output is available.
Engine runs good at no-load but “bogs
down" when loads are connected
Engine will not start; or starts
and runs rough.
Engine shuts down during operation
Engine lacks power.
Engine “hunts” or falters.
Cause
1.0ne of the circuit breakers is open.
2.Fault in generator.
3. Poor connection or defective
cord set.
4.Connected device is bad.
1.Short circuit in a connected load.
2.Engine speed is too slow.
3.Generator is overloaded.
4.Shorted generator circuit.
1.Run/Stop Switch set to STOP.
2.Dirty air cleaner
3.0ut of gasoline.
4. Stale gasoline.
5.Spark plug wire not connected
to spark plug.
6.Bad spark plug.
7.Water in gasoline.
8.Overchoking.
9.Excessively rich fuel mixture.
10.Intake valve stuck open or closed.
11.Engine has lost compression.
1.0ut of gasoline.
2.Low oil level.
1.Load is too high.
2.Dirty air filter.
1.Choke is opened too soon.
2.Carburetor is running too rich or too lean.
Extended Life Generator
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Correction
1. Reset circuit breaker.
2.
3. Check and repair.
Contact Generac Service Facility.
Connect another device that
is in good condition.
. Disconnect shorted electrical —
load.
Contact Generac Service Facility.
See “Don't Overload the
Generator”
Contact Generac Service Facility.
Set switch to RUN.
Clean or replace air cleaner.
Fill fuel tank.
Drain gas tank; fill with fresh fuel.
Connect wire to spark plug.
Replace spark plug.
Drain gas tank; fill with fresh fuel.
Open choke fully and crank engine.
Contact Generac Service Facility.
Contact Generac Service Facility.
Contact Generac Service Facility.
Fill fuel tank.
Fill crankcase to proper level.
See “Don't Overload the Generator”
. Replace air filter.
Move choke to halfway position until
engine runs smoothly.
Contact Generac Service Facility.
© Generac MEGAFORCE™ 6500 Extended Life Generator
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Drawing No. 92709
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ELECTRICAL DATA
Extended Life Generator
2s ~ Drawing No. B1209
Extended Life Generator
— ОДНЕ
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{ Generac MEGAFORCE™ 6500 Extended Life Generator
Accessories not pictured:
* Owner's Manual (order #81225)
* Outlet Extension Plug, 125 volts, 30 amp (order #37806)
* Outlet Extension Plug, 125/250 volts, 30 amp (order #43438)
* Battery Charge Cable (order #65787)
* Spark Plug (order 472347)
Spark Plug Wrench (order #84882)
Extended Life Generator
TT
15
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2 Drawing No. B1209
EXPLODED VIEW — GENERATOR
ITEM DESCRIPTION PART NO. QTY. ITEM DESCRIPTION PART NO. QTY.
1 CRADLE 92432 1 33 TAPTITE, M5-0.8 x 16 66849 2
2 SUPPORT, Engine 92531 1 34 COVER, Bearing Carrier 67025 1
3. . SUPPORT, Engine & Muffler 92731 1 35 WASHER, #10 int. Shakeproof 22769 1
4 HOUSING, Engine Adapter 92247 1 36 SCREW, M6-1.0 x 16 Wing 86494 1
5 ASSEMBLY, Rotor 92679G 1 37 SCREW, #10 Self Drilling 86292 1
6 ASSEMBLY, Stator 92681G 1 38 NUT, M6 Flange Lock 77395 4
7 BEARING 65791 1 39 GROMMET, Tank 83465 4
8 WASHER, M8 Flat 67451 1 40 HHMS, M6-1.0 x 60 (blk) 78831B 4
9 WASHER, M8 Lock 22129 14 41 VALVE, Tank 80270 1
10 SCREW, 5/16-24 x 3/4 Mach. 86307 4 42 BUSHING, Plastic Tank 78299 1
11 SCREW, 5/16-24 x 9-7/8” 25254 1 43 CAP, Fuel 94834 1
12 MOUNT, Vibration 92609 2 44 TANK, Fuel 93595 1
13 MOUNT, Vibration 82857 4 45 SHIELD, Heat 92039 1
14 SCREW, M8 - 1.25 x 20 40976 2 46 INSULATION, #2-1/4" 92665 1
15 CAPSCREW, M6 - 1.0 x 12mm 66476 2 47 CLIP, Insulation 85000 1
16 BRACKET, Mufiler 92532 1 48 WIRE, Ground 143-53621 1
17 SCREW, 5/16 - 18 x 3/4” 22142 2 49 WASHER, M6 Shakeproof 26850 2
18 MUFFLER 91153 1 50 MOUNT, Cable Tie 57593 1
19 GASKET, Muffler 90239 1 51 DECAL, Danger 92982 1
20 PIN, 4mm x 10 Roll 81917 1 52 DECAL, Heat Shield B1223 2
21 SCREEN, Spark Arrest 83083 1 55 NUT, 5/16-18 Hex 25244 2
22 SCREW, #12 Self Drilling B2153 6 57 DECAL, Control Panel B1224 1
25 CARRIER, Rear Bearing 66825C 1 58 ASSEMBLY, Control Box 92631 1
26 TAPTITE, M5-0.8 x 10 74908 4 59 ENGINE, 13 HP, EHF 00958-0 NSP 1
27 BOLT, M6-1 x 165mm Stator 86308B 4 60 HHCS, 5/16-18 x 1-3/4 22531 2
28 RECTIFIER, Battery Charge 65795 1 62 DECAL, Cradle 93221 1
29 TAPTITE, M5-0.8 x 20 66849A 1 63 DECAL, Start Instructions 93826 1
30 GROMMET, Rubber 67022 1 64 SHIELD, Heat 96068 1
31 ASSEMBLY, Power Regulator 84132 1 65 CRIMPTITE, 10-24 x 1/2 56893 5
32 ASSEMBLY, Brush Holder 66386 1
O Generac MEGAFORCE™ 6500 Extended Life Generator
Extended Life Generator
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16
Generac MEGAFORCE™ 6500 Extended Life Generator
Drawing No. 93621
TEM PARTNO. QTY. DESCRIPTION ITEM PARTNO. QTY. DESCRIPTION
1 92570 1 PANEL, Control 15 80409 1 RECEPTACLE, Duplex GFCI
2 23897 4 FLAT WASHER, #10 M5 20A
3 49226 4 LOCK WASHER, M5 16 43180 6 FLAT WASHER, M4
4 91526 4 SCREW, M5-0.8 x 12 mm 17 22264 6 LOCK WASHER, #8 M4
5 82538 1 SWITCH, RKR On - Off 18 51715 6 NUT, M4 - 0.7 Hex
6 82881 3 LOCK WASHER, 7/16” Int. 19 64526 8 SCREW, #6-32 x 3/8”
7 43181 4 SCREW, M3 - 0.5 x 10 mm 20 83970 1 BOARD, System Control
8 43182 4 LOCK WASHER, M3 21 64525 4 3/4" Hex Standoff
9 90418 1 OUTLET, 12 VDC Snap 22 87962 1 CIRCUIT BREAKER, 10A
10 75207A 2 CIRCUIT BREAKER, 30 AMP (automatic), 12V
11 75207 1 CIRCUIT BREAKER, 20 AMP 23 84335 1 ASSEMBLY, Wire Hamess
12 23365 6 WASHER, #8 Shakeproof 24 84134 1 GROMMET, Rubber Connector
13 68868 1 OUTLET, 30A, 120V Locking 25 92069 1 BOX, Control Panel
Type 26 84028 1 TRANSFORMER, Idle Control
14 43437 1 OUTLET, 30A, 120V/240V 28 77604 1 HOURMETER
Locking Type 29 51714 2 NUT, M3 - 0.5 Hex
Extended Life Generator
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17
© Generac MEGAFORCE™ 6500 Extended Life Generator
Extended Life Generator
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18
© Generac MEGAFORCE™ 6500 Extended Life Generator
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O Drawing No. B1219
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ITEM DESCRIPTION PART NO. QTY.
1 Handle 93393A 1
2 Wheel 89742 2
3 Axle 93693A 1
4 Retaining Pin 87005 2
5 Wheel Spacer 89635 2
6 Support Leg 93696 1
7 Vibration Mount 27007 2
8 Capscrew, Hex Hd. M8—1.25 x 30 Long 42909 2
9 Lock Nut-M8 52858 12
10 Washer (Wheel) 22247 2
11 Capscrew, Hex Hd. — M8-1.25 x 20 Long 39253 2
12 Washer (Vibration Mtg.) 22145 2
13 HHCS — M8-1.25 x 45 Long GR 10.9 B1214 8
14 Lift Kit Assy. B1212 1
Extended Lite Generator
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19
Two-Year Limited Warranty For "GN" Engine
Driven Portable Generators
GENERAC PORTABLE PRODUCTS warrants to the original purchaser that the alternator and contro! panel for its
portable generator will be free from defects in materials or workmanship for the items and period set forth below
from the date of original purchase. This warranty is not transferable and applies only to portable generators driven
by a GN-Series engine.
Consumer” Commercial*
Alternator 2 years (2nd year parts only) 1 year
Engine Warranted solely by the engine manufacturer
With the exception of European Community Countries, all units bound for export shall be warranted for
One (1) Year in Consumer applications, and 90 days in Commercial applications as defined below.
*NOTE: For the purpose of this warranty "consumer use" means personal residential household use by
original purchaser. This does not apply to units used for Prime Power in place of utility. "Commercial Use"
means all other uses, including rental, construction, commercial and income producing purposes. Once a
generator has experienced commercial use, it shall thereafter be considered a commercial use generator
for the purposes of this warranty.
During said warranty period, GENERAC PORTABLE PRODUCTS will, at is option, repair or replace any part
which, upon examination by GENERAC PORTABLE PRODUCTS, is found to be defective under normal use and
service. Starting batteries are not warranted by GENERAC PORTABLE PRODUCTS. All transportation costs
under warranty, including return to the factory if necessary, are to be borne by the purchaser and prepaid by him.
This warranty does not cover normal maintenance and service and does not apply to a generator set, alternator,
or parts which have been subjected to improper or unauthorized installation or alteration, misuse, negligence,
accident, overloading, overspeeding, improper maintenance, repair or storage so as, in GENERAC PORTABLE
PRODUCTS’ judgement, to adversely affect its performance and reliability.
**NORMAL WEAR: As with all mechanical devices, the generator need periodic parts service and
replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of
a part or generator.
THERE IS NO OTHER EXPRESS WARRANTY. GENERAC PORTABLE PRODUCTS HEREBY DISCLAIMS ANY
AND ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE DURATION OF ANY
IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO THE TIME PERIOD AS SPECIFIED
IN THE EXPRESS WARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES
UNDER ANY AND ALL WARRANTIES IS EXCLUDED. GENERAC ALSO DISCLAIMS ANY RESPONSIBILITY
FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SUCH AS THE LOSS OF TIME OR THE USE OF THE
POWER EQUIPMENT, OR ANY COMMERCIAL LOSS DUE TO THE FAILURE OF THE EQUIPMENT: AND ANY
IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. Some states do
not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or
consequential damages, so the above limitations or exciusions may not apply to you. This warranty gives you
specific legal rights and your may also have other rights, which vary from state to state.
For service, see your nearest GENERAC PORTABLE PRODUCTS authorized warranty service facility or call 1-
877-544-0982. Warranty service can be performed only by a GENERAC PORTABLE PRODUCTS authorized
service facility. This warranty will not apply to service at any other facility. At the time of requesting warranty
service, evidence of original purchase date must be presented.
GENERAC PORTABLE PRODUCTS, LLC
Jefferson, WI 53549

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