Simplicity 01006-1 Operator's Manual

MEGAFORCE
6500
™
Portable Generator Owner’s Manual
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Model No. 1006–1 (6,500 Watt AC Generator) Manual No. B4379 Revision 4 (1/24/2001)
Visit our Generac website: www.generac-portables.com
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
Generac Portable Products MegaForce™ 6,500 Watt Generator
EQUIPMENT
DESCRIPTION
SAFETY RULES
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 or consult the factory.
This generator is an engine-driven, revolving field,
alternating current (AC) generator. It was designed to
supply electrical power for operating compatible electrical
lighting, appliances, tools and motor loads. This manual
contains information for a generator that operates
120 and/or 240 Volt, single phase, 60 Hz devices that
require up to 6,500 watts (6.5 kW) of power that pull up
to 54.1 Amps at 120 Volts or 27 Amps at 240 Volts.
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 unit by a procedure or
method not specifically recommended by the manufacturer,
first make sure that such a procedure or method will not
render this equipment unsafe or pose a threat to you and
others.
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 6,500 watts. In
most cases rated watts of the electrical device can be found
on the device nameplate. If the device nameplate gives only
volts and amps, multiply volts times amps to obtain watts
(volts x amps = watts).
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
WARNING:
The Megaforce™ 6500 portable generator features:
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
• 120/240 Volt, 30 Amp locking receptacle.
• 120 Volt 30 Amp locking receptacle.
• 120 Volt, 20 Amp GFCI receptacle.
WARNING! You must isolate the generator
from the electric utility by opening the electrical
system’s main circuit breaker or main switch if this
unit is used for backup power. Failure to isolate
the generator from the power utility may
result in injury or death to electric utility
workers and damage to the generator due to a
backfeed of electrical energy. Whenever unit is
providing backup power, the electrical utility must be
notified.
• Low Oil Shutdown: Automatically shuts down the engine
if oil drops below safe operation level.
• Seven gallon overhead fuel tank with fuel gauge.
• The generator’s revolving field is driven at about
3600 rpm by a 13 h.p. engine.
CAUTION! 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. When adequate
engine power is not available engine life may be
shortened.
WARNING! Generator exhaust gases
contain DEADLY carbon monoxide gas.
Carbon monoxide, if breathed in sufficient
concentrations, can cause unconsciousness or
death. Operate this equipment outdoors where
adequate ventilation is available.
The Emission Control System for this generator is
warranted for standards set by the Environmental
Protection Agency. For warranty information refer to the
engine owner’s manual.
2
Generac Portable Products MegaForce™ 6,500 Watt Generator
• The generator produces a very powerful voltage that can
cause serious injury or death by electrocution. Never
touch bare wires or receptacles. Never permit a child
or any unqualified person to operate the generator.
• Never operate the generator:
in rain; in any enclosed compartment; when connected
electrical devices overheat; if electrical output is lost; if
engine or generator sparks; if flame or smoke is
observed while unit is running; if unit vibrates
excessively.
• Never handle any kind of electrical cord or device while
standing in water, while barefoot or while hands or feet
are wet. Death or serious injury from electrocution may
result.
GROUNDING THE
GENERATOR
• Use a ground fault circuit interrupter (GFCI) in any damp
or highly conductive area (such as metal decking or steel
work).
The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of the
unit. For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure 1).
• Never use worn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damage from electrical shock may result.
• Gasoline is highly FLAMMABLE and its vapors
are EXPLOSIVE. Never allow smoking, open
flames, sparks or heat in the vicinity while
handling gasoline. Avoid spilling gasoline on a 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 tank is overfilled, fuel can overflow
onto a hot engine and cause a FIRE or an
EXPLOSION.
• Never store a generator with fuel in the tank where
gasoline vapors might reach an open flame, spark or pilot
light (as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.
• The unit 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.
Allow at least 2 feet of clearance on all sides of generator,
even while operating unit outdoors, or you could damage
the unit. See “Cold Weather Operation” on page 10.
• Never start or stop the unit with electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting any electrical loads. Disconnect all electrical
loads before shutting down the generator.
• Do Not insert any object through cooling slots of the
engine. You could damage the unit or injure yourself.
Figure 1 — Grounding Wing Nut
Grounding
Wing Nut
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth-driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, local codes
may vary widely. Consult with a local electrician for
grounding requirements in your area.
Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
3
Generac Portable Products MegaForce™ 6,500 Watt Generator
INSTALL WHEEL KIT
ASSEMBLING LIFT KIT
IMPORTANT: Off road use only. The wheel kit is not
designed to be towed behind a vehicle and/or used on
roads.
The lift kit is designed to provide a means to use a crane
to lift the unit. You must assemble kit with these
instructions to ensure proper center of gravity.
To install your wheel kit you need the following
tool:
• Socket wrench with 1/2" or 13mm sockets.
Install the lift kit as follows (Figure 3):
• 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”.
Install Wheel Kit as follows (Figure 2):
• Place the generator on a hard flat surface.
• 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.
• Slide the axle through the holes in the brackets provided
on the cradle and then add the two spacers on each
protruding end of the axle.
• Attach the lift bar to the cradle using four M8 x 45 mm
cap screws and four M8 lock nuts.
• Stand at the engine end of the generator and gently tilt
the generator forward, high enough to place blocks
beneath the cradle.
Figure 3 — Install Lift Kit
• Slide wheels on each end of the axle and secure with
washer and retaining pin. Remove the blocks.
• Attach vibration mounts to the support leg with M8 x
30mm cap screws, washers and lock nuts.
• With the wheels on, tilt the generator end forward and
attach the support leg with M8 x 20mm cap screws and
lock nuts.
• Attach the handle with M8 x 45mm cap screws and lock
nuts.
Figure 2 — Assemble Wheel Kit
Handle
Axle
Wheels
45mm
Capscrew
Locknut
Locknut
Washer
Support
Leg
Vibration
Mounts
Washers
Spacers
20mm
Capscrew
Locknuts
30mm
Capscrew
4
Retaining Pin
Generac Portable Products MegaForce™ 6,500 Watt 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 this manual for future reference.
Lift Kit
Fuel Tank
Circuit Breakers (AC)
Hour Meter
Choke Lever
Idle Control
Switch
Recoil Starter
12 Volt DC, 10 Amp
Receptacle
Run/Stop Switch
Air Cleaner
120 Volt AC, 30 Amp
Receptacle
120/240 Volt AC,
30 Amp Receptacle
120 Volt AC, 20 Amp
GFCI Receptacle
Grounding Wing Nut
Spark Arrester Muffler
12 Volt DC, 10 Amp Receptacle — Recharge a
discharged 12 Volt automotive type battery through this
receptacle.
Circuit Breakers (AC) — Each receptacle is protected
against electrical overload by a "push to reset" type circuit
breaker.
120 Volt AC, 20 Amp, GFCI Receptacle — May be used
to supply electrical power for the operation of 120 Volt AC,
20 Amp, single phase, 60 Hz electrical lighting, appliance, tool
and motor loads.
Fuel Tank — Capacity of seven (7) U.S. gallons.
Grounding Wing Nut — Used for proper grounding of
unit.
Hour Meter — Records how long the engine has been
running.
120 Volt AC, 30 Amp Receptacle — May be used to
supply electrical power for the operation of 120 Volt AC,
30 Amp, single phase, 60 Hz electrical lighting, appliance, tool
and motor loads.
Idle Control Switch — With this switch set to ON, engine
speed is automatically reduced when no load is connected
and increased to proper speed when load is applied.
120/240 Volt AC, 30 Amp Receptacle — May be used to
supply electrical power for the operation of 120 and/or
240 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
Lift Kit — Use to lift generator.
Recoil Starter — Used as backup engine starter.
Run/Stop Switch — Set this switch to "RUN" before using
starter. Set switch to "STOP" to turn off engine.
Air Cleaner — Uses a dry type filter element and foam precleaner to limit the amount of dirt and dust that gets in the
engine.
Spark Arrester Muffler — Exhaust muffler lowers engine
noise and is equipped with a spark arrester screen.
Choke Lever — Used when starting a cold engine.
5
Generac Portable Products MegaForce™ 6,500 Watt Generator
BEFORE STARTING THE
ENGINE
• Use regular UNLEADED gasoline with the Generator
engine. Do Not use premium gasoline. Do Not mix oil
with gasoline.
• Clean area around fuel fill cap, remove cap.
Add Oil
• Add unleaded regular gasoline, slowly to fuel tank. Be
careful not to overfill. Allow about 1/2" of tank space for
fuel expansion (Figure 4).
CAUTION! Any attempt to crank or start the engine
before it has been properly filled with the recommended oil
may result in an engine failure.
Figure 4 — Fill Tank with Fuel
To fill your engine with oil:
• Place generator on a level surface.
• Clean area around oil fill and remove oil fill cap.
• Select the oil's viscosity grade and fill engine with oil
following the instructions given in the engine owner’s
manual. Do Not overfill!
• Install oil fill cap.
NOTE: The generator’s revolving field rides on a prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
• Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in essential fuel system parts such as the
carburetor, fuel filter, fuel hose or tank during storage.
Also, experience indicates that alcohol-blended fuels (called
gasohol, ethanol or methanol) can attract moisture which
leads to separation and formation of acids during storage.
Acidic gas can damage the fuel system of an engine while in
storage.
Add Gasoline
WARNING! Never fill fuel tank indoors. Never
fill fuel tank when engine is running or hot. Do Not
light a cigarette or smoke when filling the fuel tank.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See “Storage”
on page 12. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
WARNING! Do Not overfill the fuel tank.
Always allow room for fuel expansion.
6
Generac Portable Products MegaForce™ 6,500 Watt Generator
OPERATING THE
GENERATOR
Figure 6 — Choke Lever
Full Choke Position
CAUTION! Never start or stop the engine with
electrical loads connected to the unit AND with the
connected devices turned ON.
Starting the Engine
WARNING! Never run engine indoors or in
enclosed poorly ventilated areas. Engine exhaust
contains carbon monoxide, an odorless and deadly
gas.
• Grasp starter grip and pull slowly until you feel slight
resistance, then pull quickly. Ease the starter rope back
into the engine.
CAUTION! Temperature of muffler and nearby
areas may exceed 150°F (65°C). Avoid these areas.
• When engine starts, move choke lever to “Run” position
by sliding it all the way to the right (away from the valve
cover and under the arrow).
• Unplug all electrical loads from generator receptacles
before starting the engine.
• Make sure the unit is in a level position.
NOTE: If engine fails to start after 3 pulls, move the choke
lever to “Half” choke position and pull starter rope again
2 times.
• Open the fuel shut–off valve.
• Make sure the Idle control switch is “Off.”
NOTE: If the engine still fails to start, check for proper oil
level in crankcase. Unit is equipped with a low oil
shutdown system. See engine owner’s manual for
information regarding the low oil shutdown system.
• Place run/stop switch in the “Run” position (Figure 5).
Figure 5 — Run/Stop Switch
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes after
starting.
• Plug in and turn on the desired 120 and/or 240 Volt AC,
single phase, 60 Hertz electrical loads.
Run/Stop Switch
• Do Not connect 240 Volt loads to 120 Volt receptacles.
• Do Not connect 3–phase loads to the generator.
• Place the choke lever in the “Full” choke position by
sliding it to the left toward the valve cover in the
direction indicated by the arrow (Figure 6).
• Do Not connect 50Hz loads to the generator.
• 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 “Don’t
Overload the Generator” on page 11.
7
Generac Portable Products MegaForce™ 6,500 Watt Generator
Stopping the Engine
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.
• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with electrical
devices plugged in and turned on.
• If the battery is equipped with vent caps, make sure they
are installed and are tight.
• Put the idle control switch in the “Off” position.
• Let engine run at no-load for 30 seconds to stabilize the
internal temperatures of engine and generator.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to panel
receptacle identified by the words “12-VOLT D.C.”
• Move run/stop switch to “Stop.”
• Close the fuel shut–off valve.
• Connect battery charge cable clamp with red handle to
the positive (+) battery terminal (Figure 7).
Operating Automatic Idle Control
Figure 7 — Battery Connections
This switch is designed to greatly improve fuel economy.
When this switch is turned ON, the engine will only
run at its normal high governed engine speed when an
electrical load is connected. When an electrical load is
removed, the engine will run at a reduced speed. With
the switch off, the engine will run at the normal high
engine speed. Always have the switch off when
starting and stopping the engine.
Charging a Battery
WARNING! Storage batteries give off explosive
hydrogen gas while recharging. This 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.
• Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 7).
• Start engine. Let the engine run while battery recharges.
WARNING! 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.
• When battery has charged, shut down engine.
NOTE: Use an automotive hydrometer to test battery
state of charge and condition. Follow the hydrometer
manufacturer’s instructions carefully. Generally, a 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.
Your generator has the capability 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
the unit to crank an engine having a discharged battery.
8
Generac Portable Products MegaForce™ 6,500 Watt Generator
COLD WEATHER
OPERATION
CAUTION! Never run unit indoors; Do Not
enclose generator any more than shown. Remove
shelter when temperatures are above 40°F [4°C].
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your Generac generator
may experience icing of the carburetor and/or the
crankcase breather system.
RECEPTACLES
In an emergency, use the original shipping box as a
temporary shelter:
This receptacle (Figure 9) is protected against overload by
a 20 Amp, push-to-reset, circuit breaker.
120 Volt, 20 Amp GFCI Receptacle
• Cut off all flaps.
Figure 9 — 120 Volt, 20 Amp GFCI Receptacle
• Cut out one of the long sides of the box to expose
exhaust side of unit. Ensure a minimum of two feet
clearance between open side of box and nearest object.
• Cut appropriate slots to access receptacles of unit. You
may also need to cut a clearance slot for the handle.
• Start unit, then place box over it.
IMPORTANT: Remove shelter when temperature is
above 40°F [4°C].
Use each receptacle to operate 120 Volt AC, single-phase,
60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)
at 20 Amps of current. Use cord sets that are rated for
125 Volts at 20 Amps (or greater).
For a more permanent shelter, build a structure that will
enclose three sides and the top of the generator:
• Make sure entire muffler-side of generator is exposed. A
typical shelter is shown in Figure 8.
120/240 Volt, 30 Amp Locking
Receptacle
Figure 8 — Temporary Cold Weather Shelter
Use a NEMA L14-30 plug with this receptacle. Connect a
4-wire cord set rated for 250 Volts AC at 30 Amps (or
greater) (Figure 10). You can use the same 4–wire cord if
you plan to run a 120 Volt load.
Wind
Figure 10 — 120/240 Volt, 30 Amp Locking Receptacle
• Ensure a minimum of two feet clearance between open
side of box and nearest object.
• Face exposed end away from wind and elements.
• Enclosure should hold enough heat created by the
generator to prevent icing problems.
9
Generac Portable Products MegaForce™ 6,500 Watt Generator
GROUND FAULT
PROTECTION
This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts of power at
30 Amps for 120 Volts; 6,500 watts of power (6.5 kW) at
27 Amps for 240 Volts. The outlet is protected by a
30 Amp push-to-reset circuit breaker.
This unit is equipped with a Ground Fault Circuit
Interrupter (GFCI). This device meets applicable federal,
state and local codes.
CAUTION! Although the 120/240 Volt outlet
states it has a 240 Volt 30 Amp rating (up to
7,200 watts), the generator is only rated for
6,500 watts. Powering loads that exceed the
wattage/amperage capacity of the generator can
damage it or cause serious injuries. Loads of
240 Volts powered through this outlet should not
exceed 27 Amps of current; 120 Volt loads should
not exceed 30 Amps.
The GFCI protects against electrical shock that may be
caused if your body becomes a path which electricity
travels to reach ground. This could happen if you touch a
“Live” appliance or wire, or are touching plumbing or other
materials that connect to the ground.
When protected by a GFCI, one may still feel a shock, but
the GFCI should cut current off quickly enough so that a
person in normal health should not suffer any serious
electrical injury.
120 Volt, 30 Amp Locking
Receptacle
WARNING! The GFCI will not protect you
against the following situations: (1) Line-to-line
shocks; (2) Current overloads or line-to-line short
circuits. The fuse or circuit breaker at the
distribution panel must provide such protection.
Use a NEMA L5-30 plug with this receptacle. Connect a
3-wire cord set rated for 125 Volts AC at 30 Amps to the
plug (Figure 11).
Figure 11 — 120 Volt, 30 Amp Locking Receptacle
Testing the GFCI
Test your GFCI outlet every month, as follows:
• Push the black “Test” button. The red “Reset” button
should pop out, which should allow no power to reach
the outlet. Use a test lamp in each outlet to test this.
CAUTION! If the “Reset” button does not pop
out or the test lamp remains lit when the “Reset”
button is popped out. Do Not use any outlets on
the circuit. Call a qualified electrician.
• If the GFCI tests good, restore power by pressing the
“Reset” button firmly until it is fully in place and locks
in that position. If the GFCI outlet does not reset
properly, Do Not use the outlet — call a qualified
electrician.
Use this receptacle to operate 120 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts (3.6 kW) of power
at 30 Amps. The outlet is protected by a 30 Amp push-toreset circuit breaker.
• If the GFCI trips by itself at any time, reset and test the
outlet. If the reset button does not pop out when
the test button is pressed, Do Not use the outlet.
Call a qualified electrician.
10
Generac Portable Products MegaForce™ 6,500 Watt Generator
DON’T OVERLOAD THE
GENERATOR
• If the appliance, tool or motor does not give wattage,
multiply 120 Volts times ampere rating to determine
watts (volts x amps = watts).
• Some electric motors, such as induction types, require
about three times 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.
Overloading a generator in excess of its rated wattage
capacity can result in damage to the generator and/or
connected electrical devices. Observe the following, to
prevent overloading the unit:
• Add up the total wattage of all electrical devices to be
connected at one time. This total should NOT be
greater than the generator’s wattage capacity.
• The rated wattage of lights can be taken from light bulbs.
The rated wattage of tools, appliances and motors can
usually be found on a data plate or decal affixed to the
device.
• Items in the wattage reference guide (Figure 12) are
provided to help you to determine how many items the
generator can operate at one time.
Figure 12 — Wattage Reference Guide
Recreational/Home Uses
Tool/Appliance . . . . . . . . . . . . . . . . . . . . . . . . . Watts
AM/FM clock radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Light bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
20" color TV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
*Deep freezer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Personal computer and 15" monitor . . . . . . . . . . . . . . . 800
*1/3 hp furnace fan blower . . . . . . . . . . . . . . . . . . . . . . . 800
Microwave oven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800
*18 cu ft refrigerator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 800
Sump pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Electric skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250
*½ hp water well pump . . . . . . . . . . . . . . . . . . . . . . . . 1400
*12,000 Btu window air conditioner . . . . . . . . . . . . . . 1400
Space heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
Electric water heater . . . . . . . . . . . . . . . . . . . . . . . . . . 4000
Professional/Contractor Uses
Tool/Appliance . . . . . . . . . . . . . . . . . . . . . . . . . Watts
*1/3 hp airless sprayer. . . . . . . . . . . . . . . . . . . . . . . . . . . 600
3/8" hammer drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
Variable speed Sawzall® . . . . . . . . . . . . . . . . . . . . . . . . . 960
½" power drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Quartz-halogen work light . . . . . . . . . . . . . . . . . . . . . . 1000
Belt sander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
7 ¼" circular saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
7 ¼" worm drive saw . . . . . . . . . . . . . . . . . . . . . . . . . . 1600
*1½ hp air compressor. . . . . . . . . . . . . . . . . . . . . . . . . 1800
*10" power miter saw. . . . . . . . . . . . . . . . . . . . . . . . . . 1800
6" bench grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
*6" table planer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
*10" table/radial arm saw . . . . . . . . . . . . . . . . . . . . . . . 2000
Wire feed welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400
* allow 3 times listed watts for starting this device
11
Generac Portable Products MegaForce™ 6500 Watt Generator
SPECIFICATIONS
To Clean the Generator
Maximum Surge Watts. . . . . . . . . . . . . . . . . . . 8,125 watts
Continuous Wattage Capacity . . . . . . . . . . . . . 6,500 watts
Power Factor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Rated Maximum Continuous Load Current
At 120 Volts . . . . . . . . . . . . . . . . . . . . . . . . . 54.1 Amps
At 240 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Amps
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-phase
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hertz
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . 7 U.S. gallons
• Use a damp cloth to wipe exterior surfaces clean.
• Soft, bristle brush may be used to loosen caked on dirt
or oil.
• A 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.
STORAGE INSTRUCTIONS
GENERAL MAINTENANCE
RECOMMENDATIONS
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 Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on a timely
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. Never operate a
damaged or defective generator.
Generator Storage
Engine Maintenance
• Clean the generator as outlined in “To Clean the
Generator.”
See engine manual for instructions.
• Check that cooling air slots and openings on generator
are open and unobstructed.
Generator Maintenance
CAUTION! Storage covers can be flammable. Do
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 in the generator must not become clogged with snow,
leaves or any other foreign material.
Not place a storage cover over a hot generator. Let
the unit cool for a sufficient time before placing the
cover on the unit.
Engine Storage
NOTE: Do Not use a garden hose to clean generator.
Water can enter engine fuel system and cause problems. In
addition, if water enters generator through cooling air
slots, some of the water will be retained in voids and
cracks of the rotor and stator winding insulation. Water
and dirt buildup on the generator internal windings will
eventually decrease the insulation resistance of these
windings.
See engine owner’s manual for instructions.
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
contaminated fuel with this unit.
• Store in clean and dry area.
12
Generac Portable Products MegaForce™ 6,500 Watt Generator
TROUBLESHOOTING
Problem
Engine is running, but no
AC output is available.
Engine runs good 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
Solution
1.
2.
1.
2.
Reset circuit breaker.
Check and repair.
3.
Circuit breaker is open.
Poor connection or defective cord
set.
Connected device is bad.
3.
4.
1.
2.
Fault in generator.
Short circuit in a connected load.
Generator is overloaded.
4.
1.
2.
3.
4.
1.
2.
3.
4.
5.
3.
4.
1.
2.
3.
4.
5.
6.
7.
8.
Engine speed is too slow.
Shorted generator circuit.
Run/Stop switch set to “Stop”.
Dirty air cleaner.
Out of gasoline.
Stale gasoline.
Spark plug wire not connected to
spark plug.
Bad spark plug.
Water in gasoline.
Overchoking.
Connect another device that is in good
condition.
Contact Generac service facility.
Disconnect shorted electrical load.
See “Don’t Overload the Generator”
on page 11.
Contact Generac service facility.
Contact Generac service facility.
Set switch to “Run”.
Clean or replace air cleaner.
Fill fuel tank.
Drain gas tank and fill with fresh fuel.
Connect wire to spark plug.
9.
10.
11.
12.
1.
2.
3.
1.
Low oil level.
Excessively rich fuel mixture.
Intake valve stuck open or closed.
Engine has lost compression.
Out of gasoline.
Low oil level.
Fault in engine.
Load is too high.
2.
3.
1.
Dirty air filter.
Engine needs to be serviced.
Choke is opened too soon.
2.
Carburetor is running too rich or
too lean.
13
6.
7.
8.
Replace spark plug.
Drain gas tank; fill with fresh fuel.
Put choke lever to “No” choke
position.
9. Fill crankcase to proper level.
10. Contact Generac service facility.
11. Contact Generac service facility.
12. Contact Generac service facility.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Generac service facility.
1. See “Don’t Overload the Generator”
on page 11.
2. Replace air filter.
3. Contact Generac service facility.
1. Move choke to halfway position till
engine runs smoothly.
2. Contact Generac service facility.
Generac Portable Products MegaForce™ 6,500 Watt Generator
SCHEMATIC DIAGRAM
14
Generac Portable Products MegaForce™ 6,500 Watt Generator
WIRING DIAGRAM
15
Generac Portable Products MegaForce™ 6,500 Watt Generator
EXPLODED VIEW – MAIN UNIT
16
Generac Portable Products MegaForce™ 6,500 Watt Generator
PARTS LIST – MAIN UNIT
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Part #
B92432
B92531
B92731
92247
92679G
92681G
65791
67451
22129
86307
25254
92609
82857
40976
66476
92532
22142
A7433
90239
81917
83083
56893
B96068
93826
66825C
74908
86308B
65795
66849A
67022
84132
66386
66849
B4871
22769
86494
86292
Qty
1
1
1
1
1
1
1
1
12
4
1
2
4
2
2
1
2
1
1
1
1
5
1
1
1
4
4
1
1
1
1
1
2
1
1
1
1
Description
CRADLE
SUPPORT, Engine
SUPPORT, Engine & Muffler
HOUSING, Engine Adapter
ASSEMBLY, Rotor
ASSEMBLY, Stator
BEARING
WASHER, M8 Flat
WASHER, M8 Lock
SCREW, 5/16-24 x 3/4 Mach.
SCREW, 5/16-24 x 9-7/8"
MOUNT, Vibration
MOUNT, Vibration
SCREW, M8 - 1.25 x 20
CAPSCREW, M6 - 1.0 x 12mm
BRACKET, Muffler
SCREW, 5/16 - 18 x 3/4"
MUFFLER
GASKET, Muffler
PIN, 4mm x 10 Roll
SCREEN, Spark Arrest
SCREW, 10-24 x 1/2 Crimptite
SHIELD, Heat
DECAL, Start Instructions
CARRIER, Rear Bearing
TAPTITE, M5-0.8 x 10
BOLT, M6-1 x 165mm Stator
RECTIFIER, Battery Charge
TAPTITE, M5-0.8 x 20
GROMMET, Rubber
ASSEMBLY, Power Regulator
ASSEMBLY, Brush Holder
TAPTITE, M5-0.8 x 16
COVER, Bearing Carrier
WASHER, #10 Int. Shakeproof
SCREW, M6-1.0 x 16 Wing
SCREW, #10 Self Drilling
Item
38
39
40
41
42
43
44
45
46
47
48
49
51
52
53
54
55
56
57
58
60
Part #
Qty Description
77395
4
NUT, M6 Flange Lock
83465
4
GROMMET, Tank
78831B
4
HHMS, M6-1.0 x 60, SEMS
80270
1
VALVE, Tank
78299
1
BUSHING, Plastic Tank
B4363
1
CAP, Fuel
B1998
1
TANK, Fuel
B92039
1
SHIELD, Heat
92665
1
INSULATION, #2-1/4"
85000
1
CLIP, Insulation
14353621 1
WIRE, Ground
26850
2
WASHER, M6 Shakeproof
92982
1
DECAL, Danger
B4377
2
DECAL, Heat Shield
22531
2
HHCS, 5/16-18 x 1-3/4
NSP
1
ENGINE
25244
12 NUT, 5/16-18 Hex
92631
1
ASSEMBLY, Control Box
B4378
1
DECAL, Control Panel
B4986
1
DECAL, Ground
B2153
6
SCREW, Self Drill 12-14 x 7/8"
Accessories (Not
65787
NSP
37806
43438
B4379
65787
72347
73111
84882
BB3061
Illustrated)
1
Battery Charge Cable
1
Engine Manual
1
120 Volt 30 Amp Plug
1
120/240 Volt 30 Amp Plug
1
Owner’s Manual
1
Battery Charge Cable
1
Spark Plug
1
Paper Air Cleaner
1
Spark Plug Wrench
2
Oil Bottle
Optional Accessories Not Included
84883
Cord Wrap
17
Generac Portable Products MegaForce™ 6,500 Watt Generator
EXPLODED VIEW AND PARTS LIST – LIFT/WHEEL KIT
Item
1
2
3
4
5
6
7
8
Part # Qty. Description
B93393A 1
HANDLE
89742
2
WHEEL, 12" Dia.
93693A
1
AXLE
87005
2
PIN, Quick Release 1/4"
B89635
2
SPACER, Wheel
B93696
1
BRACKET, Support Leg
27007
2
MOUNT, Vibration
42909
2
CAPSCREW, Hex Hd. M8 1.25 x 30
18
Item
9
10
11
Part #
52858
22247
39253
Qty.
12
2
2
12
13
14
22145
B1214
BB1212
2
8
1
Description
NUT, Lock M8
WASHER, Wheel
CAPSCREW, Hex Hd. - M8 1.25 x 20
WASHER, Vibration Mtg.
HHCS, M8 - 1.25 x 45 GR 10.9
ASSEMBLY, Lift Kit
Generac Portable Products MegaForce™ 6,500 Watt Generator
EXPLODED VIEW AND PARTS LIST – CONTROL PANEL
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part#
F92570
23897
49226
91526
82538
82881
43181
43182
90418
75207A
75207
23365
68868
43437
Qty.
1
4
4
4
1
3
4
4
1
2
1
6
1
1
Description
PANEL, Control
FLAT WASHER, #10 M5
LOCK WASHER, M5
SCREW, M5-0.8 x 12 mm
SWITCH, RKR On - Off
LOCK WASHER, 7/16" Int.
SCREW, M3 - 0.5 x 10 mm
LOCK WASHER, M3
OUTLET, 12 VDC Snap
CIRCUIT BREAKER, 30 AMP
CIRCUIT BREAKER, 20 AMP
WASHER, #8 Shakeproof
OUTLET, 30A, 120V Locking
OUTLET, 30A, 120V/240V
Locking
19
Item
15
16
17
18
19
20
21
22
Part#
80409
43180
22264
51715
64526
83970
64525
87962
Qty.
1
6
6
6
8
1
4
1
23
24
25
26
28
29
84335
84134
B92069
84028
77604
51714
1
1
1
1
1
2
Description
RECEPTACLE, Dplx GFCI 20A
FLAT WASHER, M4
LOCK WASHER, #8 M4
NUT, M4 - 0.7 Hex
SCREW, #6-32 x 3/8"
BOARD, System Control
3/4" Hex Standoff
CIRCUIT BREAKER, 10A
(automatic), 12V
ASSEMBLY, Wire Harness
GROMMET, Rubber Connector
BOX, Control Panel
TRANSFORMER, Idle Control
HOURMETER
NUT, M3 - 0.5 Hex
LIMITED WARRANTY
FOR "GN" ENGINE DRIVEN PORTABLE GENERATORS
GENERAC PORTABLE PRODUCTS (hereafter referred to as the COMPANY) warrants to the original purchaser that the
alternator and control 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.
Alternator
Engine
Consumer*
Commercial*
2 years (2nd year parts only)
1 year
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 warranty 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, the COMPANY will, at is option, repair or replace any part which, upon examination by the
COMPANY, is found to be defective under normal use and service**. Starting batteries are not warranted by the
COMPANY. All transportation costs under warranty, including return to the factory if necessary, are to be borne by the
purchaser and prepaid by the purchaser. 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 the COMPANY’s
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. THE COMPANY 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. THE COMPANY 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 exclusions may not apply to you. This warranty gives you specific legal
rights and you may also have other rights, which vary from state to state.
For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Warranty service can
be performed only by a COMPANY 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
Jefferson, Wisconsin 53549

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