Generac Power Systems MEGAFORCE 6500 Manuel utilisateur

Model No. 1021-0 (6500 Watt AC Generator) Manual No. B1479 Rev s on 3 (3/14/2000)

Modèle No 1021-0 (Générateur c.a. de 6500 watts) Manuel No B1479 Rév s on 3 (14 Mars 2000)

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Problems?

Questions?

Before tak ng your

un t back to the store,

call the generator

helpl ne at

18002701408

MF 85 CT

MEGAFORCE 6500

GENERAC

The Reliable Ones

™

 Safety

 Assembly

 Operat on

 Ma ntenance

 Parts

 French

 Sûreté

 Assemblée

 Opérat on

 Entret en

 Part es

 França s

Les problèmes?

Les uestions?

Avant de prendre votre

dos d'un té au magas n,

appeler le helpl ne de

générateur à

18002701408

MF 85 CT

Extended Life Generator Owner’s Manual

Manuel de l’Utilisateur pour le Générateur à Durée de vie Prolongée

MEGAFORCE 6500 Extended L fe Generator

EQUIPMENT DESCRIPTION

Th s generator s an eng nedr ven, revolv ng f eld,

alternat ng current (AC) generator. It was des gned to

supply electr cal power for operat ng compat ble

electr cal l ght ng, appl ances, tools and motor loads.

Th s manual conta ns nformat on for a generator that

operates 120 and/or 240 Volt AC, s ngle phase, 60 Hz

dev ces that requ re 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.

The Em ss on Control System for th s generator s

warranted for standards set by the Env ronmental

Protect on Agency. For warranty nformat on refer to

the eng ne owners manual.

SAFETY RULES

Th s generator set was des gned and manufactured for

spec f c appl cat ons. Do Not attempt to mod fy the

un t or use t for any appl cat on t was not des gned

for. If you have any quest ons about your generators

appl cat on, ask your dealer or consult the factory.

The manufacturer could not poss bly ant c pate every

c rcumstance that m ght nvolve a hazard. For that

reason warn ngs n the manual and warn ngs on tags

or decals aff xed to the un t are not all nclus ve. If you

ntend to handle, operate or serv ce the un t by a

procedure or method not spec f cally recommended by

the manufacturer, f rst make sure that such a

procedure or method w ll not render th s equ pment

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.

DANGER! Th s generator s des gned for

outdoor use only. Never use th s generator

ns de any bu ld ng or enclosure nclud ng the

generator compartment of a recreat onal veh cle

(RV). Carbon monoxide poisoning, fire

and/or an explosion may result. No user

performed mod f cat ons, nclud ng vent ng of

exhaust and/or cool ng vent lat on, w ll el m nate

the danger. Always have at least two feet of

clearance on all s des of the generator wh le

operat ng the un t.

DANGER! You must solate the generator

from the electr c ut l ty us ng approved transfer

equ pment f th s un t s 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 electr cal

energy. Whenever un t s prov d ng backup

power, the electr c ut l ty must be not f ed.

DANGER! Do Not tamper w th eng ne

governed speed. H gh operat ng speeds are

dangerous and ncrease r sk of personal njury

or damage to equ pment. The generator

suppl es correct rated frequency and voltage

only when runn ng at proper governed speed.

Incorrect frequency and/or voltage can damage

some connected electr cal loads. Operat ng at

excess vely low speeds mposes a heavy load.

When adequate eng ne power s not ava lable

eng ne l fe may be shortened.

DANGER! Do Not exceed the generators

wattage/amperage capac ty. Add up the rated

watts of all dev ces you are connect ng to

generator receptacles at one t me. Th s total

should not be greater than 6,500 watts for th s

generator. See Do Not Overload the

Generator on page 12 for spec f c nformat on.

Th s s the safety alert symbol. It s used to alert you to potent al personal njury hazards.

Obey all safety messages that follow th s symbol to avo d poss ble njury or death.

The engine exhaust from this product contains

chemicals known to the State of California to

cause cancer, birth defects, or other

reproductive harm.

WARNING:

MEGAFORCE 6500 Extended L fe Generator

 The generator produces a very powerful voltage that

can cause ser ous njury or death by electrocut on.

Never touch bare w res or receptacles. Never perm t

a ch ld or any unqual f ed person to operate the

generator.

 Never handle any k nd of electr cal cord or dev ce

wh le stand ng n water, wh le barefoot or wh le

hands or feet are wet.

 Use a ground fault c rcu t nterrupter (GFCI) n any

damp or h ghly conduct ve area (such as metal

deck ng or steel work).

 Never use worn, bare, frayed or otherw se damaged

electr cal cords w th the generator.

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 w th all laws regulat ng storage

and handl ng of gasol ne.

Do Not overf ll the fuel tank. Always allow room for

fuel expans on. If tank s overf lled, fuel can overflow

onto a hot eng ne and cause a FIRE or an

EXPLOSION.

 Never store a generator w th fuel n the tank where

gasol ne vapors m ght reach an open flame, spark or

p lot l ght (as on a furnace, water heater, clothes

dryer). FIRE or an EXPLOSION may result.

 The un t requ res an adequate flow of cool ng a r for

ts cont nued proper operat on. Never operate the

un t ns de any room or enclosure where the free

flow of cool ng a r nto and out of the un t m ght be

obstructed. Allow at least 2 feet of clearance on all

s des of generator or you could damage the un t.

Read Cold Weather Operat on on page 9.

 Never start or stop the un t w th electr cal loads

connected to receptacles AND w th the connected

dev ces turned ON. Start the eng ne and let t

stab l ze before connect ng any electr cal loads.

D sconnect all electr cal loads before shutt ng down

the generator.

Do Not nsert any object through the un ts cool ng

slots or damage to you or the un t could happen.

Never operate the generator:

n ra n; n any enclosed compartment; when

connected electr cal dev ces overheat; f electr cal

output s lost; f eng ne or generator sparks; f flame

or smoke s observed wh le un t s runn ng; f un t

v brates excess vely.

GROUNDING THE

GENERATOR

The Nat onal Electr cal Code requ res that the frame

and external electr cally conduct ve parts of th s

generator be properly connected to an approved earth

ground. Local electr cal codes may also requ re proper

ground ng of the un t. For that purpose, a

GROUNDING WING NUT s prov ded on the

generator end (F gure 1).

Generally, connect ng a No. 12 AWG (Amer can W re

Gauge) stranded copper w re to the ground ng w ng

nut and to an earthdr ven copper or brass ground ng

rod (electrode) prov des adequate protect on aga nst

electr cal shock. Be careful to keep the ground ng w re

attached after connect ng the stranded copper w re.

However, local codes may vary w dely. Consult w th a

local electr c an for ground ng requ rements n your

area.

Properly ground ng the generator helps prevent

electr cal shock f a ground fault cond t on ex sts n the

generator or n connected electr cal dev ces. Proper

ground ng also helps d ss pate stat c electr c ty, wh ch

often bu lds up n ungrounded dev ces.

Ground ng W ng Nut

F gure 1  Ground ng W ng Nut

MEGAFORCE 6500 Extended L fe Generator

12 Volt DC,10 Amp Receptacle  Recharge a

d scharged 12 Volt automot ve type battery through

th s receptacle.

120 Volt AC, 15 Amp GFCI Receptacle  May be

used to supply electr cal power for the operat on of

120 Volt AC, 15 Amp, s ngle phase, 60 Hz electr cal

l ght ng, appl ance, tool and motor loads.

120 Volt AC, 30 Amp Locking Receptacle  May be

used to supply electr cal power for the operat on of

120 Volt AC, 30 Amp, s ngle phase, 60 Hz electr cal

l ght ng, appl ance, tool and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle 

May be used to supply electr cal power for the

operat on of 120 and/or 240 Volt AC, 30 Amp, s ngle

phase, 60 Hz electr cal l ght ng, appl ance, tool and

motor loads.

Air Cleaner  Uses a dry type f lter element and

foam precleaner to l m t d rt and dust ntake.

Choke Lever  Used when start ng a cold eng ne.

Circuit Breakers (AC)  Each receptacle s prov ded

w th a "push to reset" c rcu t breaker to protect the

generator aga nst electr cal overload.

Fuel Tank  Capac ty of seven (7) U.S. gallons.

Grounding Wing Nut  Used for ground ng of un t.

Hour Meter  Used to schedule preventat ve

ma ntenance tasks.

Idle Control Switch  W th th s sw tch set to ON,

pr nted c rcu t board n control panel automat cally

reduces eng ne speed when no load s connected and

ncreases eng ne to proper speed when load s

appl ed. However, be sure sw tch s OFF when start ng

eng ne.

Recoil starter  Used to start the eng ne.

Run/Stop Switch  Set th s sw tch to "Run" before

us ng reco l starter. Set sw tch to "Stop" to sw tch OFF

eng ne.

Spark Arrestor Muffler  Exhaust muffler lowers

eng ne no se, equ pped w th a spark arrestor screen.

KNOW YOUR GENERATOR

Read this owners manual and safety rules before operating your generator.

Compare the llustrat ons w th your generator, to fam l ar ze yourself w th the locat ons of var ous controls and

adjustments. Save th s manual for future reference.

120 Volt AC, 15 Amp

GFCI Receptacle

Hour Meter

Fuel Tank

Idle Control Sw tch

Choke Lever

Reco l Starter

12 Volt DC, 10 Amp

Receptacle

Run/Stop Sw tch

120 Volt AC,

30 Amp Receptacle

C rcu t Breakers

120/240 Volt AC,

30 Amp Receptacle

Spark Arrestor Muffler

A r Cleaner

Ground ng W ng Nut

MEGAFORCE 6500 Extended L fe Generator

Your generator requ res some assembly and s ready

for use after t has been properly serv ced w th the

recommended o l and fuel.

If you have any problems w th the assembly of your

generator, please call the generator helpl ne at

1-800-270-1408.

IMPORTANT: Any attempt to run the un t before t has

been serv ced w th the recommended o l w ll result n

an eng ne fa lure.

REMOVE GENERATOR

FROM CARTON

 Set the carton on a r g d flat surface w th Th s S de

Up arrows po nt ng upward.

 Carefully open the top flaps of the sh pp ng carton.

Rev ew Cold Weather Operat on on page 9.

 Cut down corners at one end of carton from top to

bottom and lay that s de of carton down flat.

 Remove all pack ng mater al, carton f llers, etc.

 Remove the generator from the sh pp ng carton.

CARTON CONTENTS

Check all contents. If any parts are m ss ng or

damaged, call the generator helpl ne at

1-800-270-1408.

 The generator

 Wheel and l ft k t

 Generator and eng ne owners manuals

 Lock ng 20 Amp and 30 Amp plugs

 Battery charge cables

 Battery tray mount ng bracket/hardware

 Spare spark plug and a r f lter element

 Spark plug wrench

INSTALL WHEEL AND LIFT

KIT

You need a socket wrench w th 1/2" or 13mm sockets

to assemble wheel/l ft k t.

Install Wheel Kit as follows: (See F gure 2)

 Place the generator on a hard flat surface.

Temporar ly ra se un t on blocks to ease assembly.

L ft Bar

45mm Capscrew

Flat Washer

20mm

Capscrew

Flat Washer

Lock Nut

Lock

Nut

30mm Capscrew

V brat on Mount

Support Leg

Wheel

Spacer

Reta n ng P n

Axle

Wheel

Handle

F gure 2  Assemble Wheel K t

Lock

Nut

MEGAFORCE 6500 Extended L fe Generator

 Sl de the axle through the holes n the brackets

prov ded on the generator cradle and then add the

two spacers on each protrud ng end of the axle.

 Sl de a wheel on each end of the axle and secure

each w th washer and reta n ng p n.

NOTE: Install the wheels w th the a r nflat on valve

fac ng outward.

 Attach the v brat on mounts to the support leg w th

capscrews, washers and lock nuts.

 Attach the support leg to the cradle w th capscrews

and lock nuts. Remove the temporary blocks.

 Attach the handle to the un ts control panel end w th

four cap screws and four lock nuts.

 Check that all fasteners are t ght.

Follow these nstruct ons prec sely to ensure proper

center of grav ty for crane or ho st l ft ng. Referr ng to

F gure 3, nstall as follows:

 Place the l ft bar on top of the cradle mak ng sure,

as you look at the bar from the control panel s de,

that t forms a reverse L.

 Make sure the l ft bar s 9 1/4" from the outs de of

the cradle on the r ght s de to the base of the l ft bar

bracket.

 Attach the l ft bar to the cradle us ng four cap screws

and four lock nuts.

BEFORE STARTING THE

ENGINE

Add Oil

WARNING! Any attempt to crank or start the

eng ne before t has been properly f lled w th the

recommended o l may result n eng ne fa lure.

To fill your engine with oil:

 Place generator on a level surface.

 Follow the o l grade recommendat ons and o l f ll

nstruct ons g ven n the eng ne owners manual.

NOTE: The generators revolv ng f eld r des on a

permanent prelubr cated sealed ball bear ng.

Add Gasoline

DANGER! NEVER f ll fuel tank ndoors.

NEVER f ll fuel tank when eng ne s runn ng or

hot. Do Not smoke when f ll ng the fuel tank.

WARNING! Do Not overf ll the fuel tank.

Always allow room for fuel expans on.

 Use regular UNLEADED gasol ne w th the generator

eng ne. Do Not use prem um gasol ne. Do Not m x

o l w th gasol ne.

 Clean area around fuel f ll cap, remove cap.

 Slowly add unleaded regular gasol ne to fuel tank.

Be careful not to overf ll. Allow about 1/2" of tank

space for fuel expans on (F gure 4).

 Install fuel cap and w pe up any sp lled gasol ne.

F gure 3  Assemble L ft K t

F gure 4  Typ cal Fuel Expans on Space

MEGAFORCE 6500 Extended L fe Generator

IMPORTANT: It s mportant to prevent gum depos ts

from form ng n essent al fuel system parts, such as

the carburetor, fuel f lter, fuel hose or tank dur ng

storage. Also, exper ence nd cates that

alcoholblended fuels (called gasohol, ethanol or

methanol) can attract mo sture, wh ch leads to

separat on and format on of ac ds dur ng storage.

Ac d c gas can damage the fuel system of an eng ne

wh le n storage.

To avo d eng ne problems, the fuel system should be

empt ed before storage of 30 days or longer. See

Storage on page 13. Never use eng ne or carburetor

cleaner products n the fuel tank or permanent

damage may occur.

OPERATING THE

GENERATOR

CAUTION! Never start or stop the eng ne w th

electr cal loads connected to the receptacles

AND w th the connected dev ces turned ON.

Starting the Engine

DANGER! Never run eng ne ndoors or n

enclosed poorly vent lated areas. Eng ne

exhaust conta ns carbon monox de, an odorless

and deadly gas.

WARNING! Temperature of muffler and nearby

areas may exceed 150°F (65°C). Avo d these

areas.

 Unplug all electr cal loads from generator

receptacles before start ng the eng ne.

 Make sure the un t s n a level pos t on.

 Open the fuel shutoff valve (F gure 5).

 Make sure the Idle Control sw tch s Off.

 Place Run/Stop sw tch n the Run pos t on

(F gure 6).

 Place the choke lever n the Full choke pos t on by

sl d ng t to the left n the d rect on nd cated by the

arrow molded nto the cover (F gure 7).

 Grasp starter gr p and pull slowly unt l you feel sl ght

res stance, then pull uickly. Do Not let handle

snap-back nto reco l hous ng.

 When eng ne starts, slowly move choke lever to the

Run pos t on (to the r ght) as the eng ne warms.

NOTE: If eng ne fa ls to start after 3 pulls, move the

choke lever to Half choke pos t on and pull starter

rope aga n 2 t mes.

NOTE: If the eng ne st ll fa ls to start, rev ew the

eng ne owners manual. Also, check for proper o l level

n crankcase. Un t s equ pped w th a low o l shutdown

system, as descr bed n the eng ne owners manual.

F gure 6  Run/Stop Sw tch

F gure 5  Fuel Shut-off Valve

F gure 7  Choke Lever

MEGAFORCE 6500 Extended L fe Generator

Connecting Electrical Loads

 Let eng ne stab l ze and warm up for three m nutes

after start ng.

 Plug n and turn on the des red 120 and/or 240 Volt

AC, s ngle phase, 60 Hz electr cal loads.

Do Not connect 240 Volt loads to the 120 Volt

receptacles.

Do Not connect 3phase loads to the generator.

Do Not connect 50 Hz loads to the generator.

DO NOT OVERLOAD THE GENERATOR. Add up

the rated watts (or amps) of all loads to be run at

one t me. Th s total should not be greater than the

rated wattage/amperage capac ty of the generator.

See Dont Overload the Generator on page 12.

Stopping the Engine

 Unplug all electr cal loads from generator panel

receptacles. Never start or stop eng ne w th

electr cal dev ces plugged n and turned on.

 Put the dle control sw tch n the Off pos t on.

 Let eng ne run at noload for three m nutes to

stab l ze the un ts nternal temperatures.

 Move run/stop sw tch to Stop.

 Close the fuel shutoff valve.

Operating Automatic Idle Control

Th s sw tch s des gned to greatly mprove fuel

economy. When this switch is turned ON, the eng ne

w ll only run at ts normal h gh governed eng ne speed

when an electr cal load s connected. When the load s

removed, the eng ne w ll run at a reduced speed. With

the switch Off, the eng ne runs constantly at the

normal h gh eng ne speed. Always have the switch

Off when starting and stopping the engine.

Charging a Battery

DANGER! Storage batter es g ve off explos ve

hydrogen gas wh le recharg ng. An explos ve

m xture w ll rema n around the battery for a long

t me after t has been charged. The sl ghtest

spark can gn te the hydrogen and cause an

explos on, result ng n bl ndness or other

ser ous njury.

DANGER! Do Not perm t smok ng, open

flame, sparks or any other source of heat

around a battery. Wear protect ve goggles,

rubber apron and rubber gloves when work ng

around a battery. Battery electrolyte flu d s an

extremely caust c sulfur c ac d solut on that can

cause severe burns. If a sp ll occurs, flush area

w th clear water mmed ately.

Your generator has the capab l ty of recharg ng a

d scharged 12 Volt automot ve or ut l ty style storage

battery. Do Not use the un t to charge any 6 Volt

batter es. Do Not use the un t to crank an eng ne

hav ng a d scharged battery.

To recharge 12 Volt batteries, proceed as follows:

 Check flu d level n all battery cells. If necessary,

add ONLY d st lled water to cover separators n

battery cells. Do Not use tap water.

 If the battery s equ pped w th vent caps, make sure

they are nstalled and are t ght.

 If necessary, clean battery term nals.

 Connect battery charge cable connector plug to

panel receptacle dent f ed by the words

12 VOLTS D.C..

 Connect battery charge cable clamp w th red handle

to the positive (+) battery term nal (F gure 8).

MEGAFORCE 6500 Extended L fe Generator

 Connect battery charge cable clamp connected to

black lead to the negative () battery term nal

(F gure 8).

 Start eng ne. Let the eng ne run wh le battery

recharges.

 When battery has charged, shut down eng ne

NOTE: Use an automot ve hydrometer to test battery

state of charge and cond t on. Follow the hydrometer

manufacturers nstruct ons carefully. Generally, a

battery s cons dered to be at 100% state of charge

when spec f c grav ty of ts flu d (as measured by

hydrometer) s 1.260 or h gher.

COLD WEATHER

OPERATION

Under certa n weather cond t ons (temperatures below

40°F [4°C] and a h gh dew po nt), your generator may

exper ence c ng of the carburetor and/or the

crankcase breather system.

In an emergency, use the or g nal sh pp ng box as a

temporary shelter:

 Cut off all flaps.

 Cut out one of the long s des of the box to expose

exhaust s de of un t. Ensure a m n mum of two feet

clearance between open s de of box and nearest

object.

 Cut appropr ate slots to access receptacles of un t.

 Start un t, then place box over t.

IMPORTANT! Remove shelter when temperature s

above 40°F [4°C].

For a more permanent shelter, bu ld a structure that

w ll enclose three s des and the top of the generator:

 Make sure ent re muffler-s de of generator s

exposed. Note that your generator may appear

d fferent from that shown n F gure 9.

 Ensure a m n mum of two feet clearance between

open s de of box and nearest object.

 Face exposed end away from w nd and elements.

 Enclosure should hold enough heat created by the

generator to prevent problems.

CAUTION!NEVER run un t ndoors. Do Not

enclose generator any more than shown.

Remove shelter when temperatures are above

40°F [4°C].

F gure 8  Battery Connect ons

Black lead

W nd

F gure 9  Temporary Cold Weather Shelter

CONTROL PANEL/

RECEPTACLES

Th s un t s equ pped w t the follow ng receptacles and

controls:

120 Volt AC, 15 Amp, GFCI

Receptacle

Each receptacle (F gure 10) s protected aga nst

overload by a 15 Amp pushtoreset c rcu t breaker.

Use each receptacle to operate 120 Volt AC,

s nglephase, 60 Hz electr cal loads requ r ng up to

1,800 watts (1.8 kW) at 15 Amps of current. Use cord

sets that are rated for 125 Volt AC loads at 15 Amps

(or greater).

Ground Fault Protection

Th s un t s equ pped w th a Ground Fault C rcu t

Interrupter (GFCI). Th s dev ce meets appl cable

federal, state and local codes.

The GFCI protects aga nst electr cal shock that may

be caused f your body becomes a path wh ch

electr c ty travels to reach ground. Th s could happen f

you touch a L ve appl ance or w re, or are touch ng

plumb ng or other mater als that connect to the

ground.

When protected by a GFCI, one may st ll feel a shock,

but the GFCI should cut current off qu ckly enough so

that a person n normal health should not suffer any

ser ous electr cal njury.

DANGER: The GFCI w ll not protect you

aga nst the follow ng s tuat ons: (1) L ne-to-l ne

shocks; (2) Current overloads or l ne-to-l ne

short c rcu ts. The fuse or c rcu t breaker at the

d str but on panel must prov de such protect on.

Testing the GFCI

Test your GFCI outlet every month, as follows:

 Push the black Test button. The red Reset button

should pop out, wh ch should allow no power to

reach the outlet. Use a test lamp n each outlet to

test th s.

DANGER: If the Reset button does not pop

out or the test lamp rema ns l t when the

Reset button s popped out, do not use any

outlets on the c rcu t. Call a qual f ed electr c an.

 If the GFCI tests good, restore power by press ng

the Reset button f rmly unt l t s fully n place and

locks n that pos t on. If the GFCI outlet does not

reset properly, do not use the outlet  call a

ualified electrician.

 If the GFCI tr ps by tself at any t me, reset and test

the outlet. If the reset button does pop out when

the test button is pressed, do not use the outlet.

Call a ualified electrician.

120/240 Volt AC, 30 Amp, Locking

Receptacle

Use a NEMA L1430 plug w th th s receptacle.

Connect a 4w re cord set rated for 250 Volt AC loads

at 30 Amps (or greater) (F gure 11). You can use the

same 4w re cord f you plan to run a 120 Volt load.

MEGAFORCE 6500 Extended L fe Generator

F gure 10  120 Volt AC, 15 Amp GFCI Receptacle

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