Generac Power Systems MEGA 2500 User manual

GENERAC

MEGA 2500

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.

Danger: If this unit is used for backup power in the event of a utility power failure the fol-

lowing step must be taken: Before connecting the generator to an electrical system open

the 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.

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.

Model No.1 16 (2 Watt AC Generator) Part No. B1761 (Revision 9/2/97)

EQUIPMENT DESCRIPTION

This generator is an engine-driven revolving field alter-

nating current (AC) generator. It was designed to supply

electrical power for operating compatible electrical light-

ing appliance tool and motor loads. This manual

contains information for a generator that operates 120

volt single phase 60Hz devices that require up to 2000

watts (2.0 kW) of power that pull up to 15 amps at 120

volts.

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 2 watts for this

generator. 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).

The generators revolving field is driven at about 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.

DANGER: Do not tamper with engine gov-

erned speed. High operating speeds are

dangerous and increase risk of personal

injury or damage to equipment. The genera-

tor supplies correct rated frequency and

voltage only when running at proper gov-

erned speed. Incorrect frequency and/or

voltage can damage some connected electri-

cal loads. Operating at excessively low

speeds imposes a heavy load at such

reduced speeds, when adequate engine

power is not available, and may short engine

life.

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 applica-

tion ask your Dealer/Distributor or consult the factory.

The manufacturer could not possibly anticipate every cir-

cumstance 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 manufac-

turer first make sure that 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 ground-

ing 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 any worn bare frayed or otherwise dam-

aged electrical cord sets with the generator. Using any

defective cord set may result in electrical shock or

damage to equipment and/or property.

 Operate generator only on level surfaces and where

it will not be exposed to excessive moisture dirt dust

or corrosive vapors.

Extended Life Generator

GENERAC

Generac Mega 2500 Extended Life Generator

MODEL & 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

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects, or other reproductive harm.

WWAARRNNIINNGG::

Extended Life Generator

GENERAC

Generac Mega 2500 Extended Life Generator

 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 a hot engine. Comply with

all regulations requiring storage and handling of gaso-

line.

 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 FIRE or an EXPLO-

SION.

 Never store generator with fuel in tank where gaso-

line vapors might reach an open flame or 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 suf-

ficient 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 gen-

erator even while operating unit outdoors or you

could damage the unit.

 Never start or stop the engine-generator with elec-

trical loads connected to receptacles with the

connected devices turned ON. Start the engine and

let it stabilize before connecting electrical loads. Dis-

connect 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 engine speed changes; (d) if con-

nected electrical devices overheat; (e) if electrical

output is lost; (f) if engine or generator sparks; (g) if

flame or smoke is observed while unit is running; (h)

if unit vibrates excessively.

GROUNDING THE

GENERATOR

The National Electric Code requires the frame and exter-

nal 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 WING SCREW

(Figure 1) is provided on the cradle frame.

Generally connecting a No. 12 AWG (American Wire

Gauge) stranded copper wire to the grounding wing

screw 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 require-

ments 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.

Figure 1  Location of Grounding Wing Nut

CARTON CONTENTS

The following parts are shipped loose with your

Generator:

Main Unit  Generator with wheels and guide handle

 Wire Form

 Battery Charge Cables

Become familiar with each piece before assembling the

Generator. Check all contents against the illustration on

Page 5. If any parts are missing or damaged call the

Generator Helpline at 1-8 -27 14 8.

TO REMOVE GENERATOR

FROM CARTON

 Remove loose parts included with Generator.

 Slice two corners at guide handle end of carton from

top to bottom so the panel can be folded down flat

then remove all packing material.

 Raise guide handle and secure in place.

 Remove the unit by rolling it out the opening in the

carton then check carton for additional loose parts.

 Insert the wire support.

BEFORE STARTING THE

ENGINE

Perform the following tasks before trying to start the

generator engine:

ADD OIL TO ENGINE

Note: When adding oil to the engine crankcase in the

future use only high quality detergent oil rated with API

service classification SF and SG rated SAE 30 weight.

Use no special additives.

DO NOT USE SAE

1 W-4 .

Select the oils viscosity grade according to your

expected operating temperature.

Although multi-viscosity oils (5W30 10W30 etc.)

improve starting in cold weather these multi-viscosity

oils will result in increased oil consumption when used

above 32°F. Check your engine oil level more frequently

to avoid possible damage from running low on oil.

 Place Generator on a level surface

 Clean area around oil fill and remove oil dipstick.

 Wipe dipstick clean.

 Pour oil into the oil fill opening until oil reaches FULL

mark on the dipstick. DO NOT OVERFILL.

 Install oil dipstick hand tighten securely.

CAUTION: Any attempt to crank or start the

engine before it has been properly serviced

with the recommended oil results in an engine

failure.

NOTE: The generators revolving field rides on a pre-

lubricated and sealed ball bearing that requires no

additional lubrication for the life of the bearing.

Figure 2  Raise Guide Handle

Figure 3  Insert Wire Support

Figure 4  Remove Oil Dipstick

GENERAC

Generac Mega 2500 Extended Life Generator

Extended Life Generator

Loosen knobs

to raise handle

Dipstick

Tighten knobs when

handle is straight.

colder 32°F warmer

5W30 10W30

Extended Life Generator

GENERAC

Generac Mega 2500 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 ref-

erence.

5.5 H.P. Engine

12 Volts DC Receptacle

Air Cleaner

15AMP AC Circuit Breaker

Recoil Starter

12 Volts Receptacles

Oil Drain Plug

Wire Form

Choke Control Lever

On/Off Switch

RECOIL STARTER  Used for starting the engine

manually.

15-AMP AC CIRCUIT BREAKER  Protects the genera-

tor against electrical overload. Breaker is push to reset

type.

AIR CLEANER  Filters intake air as it is drawn through

the engine.

5.5 H.P. ENGINE  Provides the power needed to

generate 2000 watts of AC output.

12VOLT D.C. RECEPTACLE  Recharge a

discharged 12 volt automotive type battery through this

receptacle.

FUEL TANK  Tank holds 1.6 quarts of unleaded

gasoline.

WIRE FORM  Use the wireform to hold your extension

cords.

ON/OFF SWITCH  Set this switch to ON to before

pulling the recoil handle. Set this switch to OFF to stop a

running engine.

12 VOLT RECEPTACLES  May be used to supply

electrical power for the operation of 120 volts at 15 amps

ac single phase 60 Hz ac electrical lighting appliance

tool and motor loads.

Oil Drain Plug  Use this plug to drain the oil.

ADD FUEL

DANGER! 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.

Use regular UNLEADED gasoline with the generator

engine. Regular leaded gasoline may also be used if

UNLEADED is not available.

CAUTION: Do not overfill the fuel tank. Always

allow room for fuel expansion.

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 mois-

ture which leads to separation and formation of acids

during storage. Acidic gas can damage the fuel system

of an engine while in storage.

To avoid engine problems the fuel system should be

emptied before storage of 30 days or longer. Drain the

gas tank start the engine and let it run until the fuel lines

and carburetor are empty. Use fresh fuel next season.

See Storage Instructions on page 10 for additional

information.

Never use engine or carburetor cleaner products in the

fuel tank or permanent damage may occur.

 Clean area around fuel fill cap remove cap.

 Add UNLEADED regular gasoline slowly to fuel

tank.

 Install fuel cap and wipe up any spilled gasoline.

OPERATING THE GENERATOR

CAUTION! Never start, or stop, the engine gen-

erator with electrical loads connected to the

receptacles with the connected devices turned

ON.

STARTING THE ENGINE

 Disconnect all electrical loads from the generator.

 Move engine CHOKE CONTROL LEVER to RUN

position.

 Move ON/OFF SWITCH to ON position.

 If engine is warm close choke only part way or leave

it fully open. A warm engine needs less choking than

a cold engine.

 Grasp starter grip and pull slowly until you feel some

resistance. Let rope return slowly. Then pull cord out

with rapid full arm stroke. Let rope return slowly. Do

not let rope snap back against starter.

 If engine hunts or falters after starting apply choke

until engine begins running smoothly. Then return the

choke to the open position. If engine continues to

hunt you may need to have the carburetor adjusted.

See Engine Owners Manual.

Figure 5  Choke Control Lever

GENERAC

Generac Mega 2500 Extended Life Generator

Extended Life Generator

Choke Control Lever

Figure 6  On/Off Switch

On/Off Switch

Generac Mega 2500 Extended Life Generator

Extended Life Generator

APPLYING ELECTRICAL LOADS

 Let engine stabilize and warm up for about five min-

utes after starting.

Use this generator to operate 120 volts single phase 60

Hz ac lighting appliance tool and motor loads.

DO NOT connect 240 volts to 120 volts outlets.

DO NOT connect any 3-phase loads to panel recep-

tacles.

DO NOT connect any 50 Hz loads to the generator.

DO NOT overload the generator.

Add up rated watts of all lights tool appliance and motor

loads you are powering at one time. This total should

NOT be greater than (a) generators rated wattage

capacity or (b) circuit breaker rating of the receptacle

supplying power. See Dont Overload the Generator on

Page 8.

STOPPING THE ENGINE

 Disconnect all electrical loads

 Run engine at no-load for about five minutes

 Turn off the engine by moving the On/Off Switch to the

OFF position. See engine manual.

BATTERY SAFETY

DANGER: Storage batteries give off explosive

hydrogen gas while charging. An explosive mix-

ture will remain around battery for a long time

after it has been charged. The slightest spark

can ignite gas and cause an explosion. Such an

explosion can shatter battery and cause blind-

ness or other serious injury.

DANGER: Do Not Permit smoking, open flame,

sparks or any other source of heat around a bat-

tery. Do not use a lighter or other flame for

checking battery fluid levels. Wear protective

goggles, rubber apron and rubber gloves when

working around a battery. Battery electrolyte

fluid is an extremely caustic sulfuric acid solu-

tion that can cause severe burns. Do not permit

fluid contact with eyes, skin, clothing etc. If

Spill occurs, flush area with clear water imme-

diately.

CHARGING A BATTERY

Your generator has the capability of recharging a dis-

charged 12-volt automotive or utility style storage

battery. Do not use the unit to charge any 6-volt batter-

ies. Do not use the unit to crank an engine having a

discharged battery. To recharge 12-volt batteries pro-

ceed 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.

 If the battery is equipped with vent caps make sure

they are installed and are tight.

 If necessary clean battery posts or terminals.

 Connect battery charge cable connector plug to panel

receptacle identified by the words 12-VOLT D.C.

(Figure 7).

 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 handle

to battery post or terminal indicated by a NEGATIVE

NEG or ().

 Start engine (see Starting the Engine on Page 6). Let

the engine run while battery recharges.

 When battery has charged shut down engine (see

Stopping the Engine on Page 7).

NOTE: Use an automotive hydrometer to test battery

state of charge and condition. Follow the hydrometer

manufacturers instructions carefully. Generally a bat-

tery is considered to be at 100% state of charge when

specific gravity of its fluid (as measured by hydrometer)

is 1.260.

Figure 8  Connect Battery Cables

Figure 7  12 Volt D.C. Receptacle

GENERAC

12VOLT D.C.

CORD SETS FOR

RECEPTACLES

This generator is equipped with the following

receptacles:

TWO 12 -VOLT, 15 AMP

RECEPTACLES

This pair of receptacles is protected against overload by

a 15-amp push-to-reset circuit breaker. Use each recep-

tacle to operate 120 volt single phase 60 Hz AC

electrical loads requiring up to 1800 watts (1.8 kW) at 15

amps of current. Use cord sets that are rated 125 volts

at 15 amps (or greater).

Caution: Although the generator has two 12

volt, 15 amp receptacles rated at 18 watts

apiece, you cannot connect more than 2

watts to the generator. Powering loads that

exceed the wattage/amperage capacity of the

generator can damage it.

DONT OVERLOAD THE

GENERATOR

Overloading a generator in excess of its rated wattage

capacity can result in damage to generator and to con-

nected 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.

 If the appliance tool or motor does not give wattage

multiply volts times ampere rating to determine watts

(volts x amps = watts).

 Some electric motors such as induction types require

about two-and-a-half 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 gener-

ator. First figure the watts needed to start the largest

motor. Add to that figure the running watts of all other

connected loads.

 Items in the guide below are provided to help you to

determine how many items the generator can oper-

ate at one time.

Extended Life Generator

GENERAC

Generac Mega 2500 Extended Life Generator

RUNNING

WATTS

*Air Conditioner (12 000 Btu) ........................................1700

Battery Charger (20 amp) ...............................................500

Belt Sander (3).............................................................1000

Chain Saw.....................................................................1200

Circular Saw (6-12/) ..........................................800 to 1000

Coffee Maker.................................................................1000

*Compressor (1 HP)......................................................2000

*Compressor (1/2 HP)...................................................1400

Curling Iron......................................................................700

*Freezer ..........................................................................500

Disc Sander (9) ............................................................1200

Electric Nail Gun ...........................................................1200

Electric Range (one element)........................................1500

Electric Skillet................................................................1250

*Furnace Fan (1/3 HP) ..................................................1200

Hair Dryer......................................................................1200

Hand Drill (1) ................................................................1100

Hand Drill (1/2)..................................................750 to 1000

Hand Drill (1/4)...............................................................250

Hedge Trimmer ...............................................................450

RUNNING

WATTS

*Jet Pump........................................................................800

Lawn Mower..................................................................1200

Light Bulb ........................................................................100

Microwave Oven .............................................................700

*Milk Cooler ...................................................................1100

Oil Burner on Furnace.....................................................300

Oil Fired Space Heater (140 000 Btu) .............................400

Oil 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......................................................................50 to 200

*Refrigerator....................................................................600

*Submersible Pump (1 HP) ...........................................2000

*Submersible Pump (1/2 HP) ........................................1500

Sump Pump ................................................................... 600

*Table Saw (10)...............................................1750 to 2000

Television .............................................................200 to 500

Weed Trimmer.................................................................500

* Allow 2-1/2 times the listed watts for starting these devices.

WATTAGE REFERENCE GUIDE

Figure 9  Connect Battery Cables

12 volt Receptacles.

GENERAC

Generac Mega 2500 Extended Life Generator

Extended Life Generator

GENERAL MAINTENANCE

RECOMMENDATIONS

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.

ENGINE MAINTENANCE

See engine manual for instructions.

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 in the generator 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 sub-

stances 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 genera-

tor through cooling air slots some of the water will be

retained in voids and cracks of the rotor and stator wind-

ing insulation. Water and dirt buildup on the generator

internal windings will eventually decrease the insulation

resistance of these windings.

TO CLEAN THE GENERATOR

 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 open-

ing on generator. These openings must be kept clean

and unobstructed.

SERVICE AND ADJUSTMENTS

Refer to engine manual for information.

GENERAC

Generac Mega 2500 Extended Life Generator

Extended Life Generator

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.

GENERATOR

 Clean the generator as outlined in To Clean the Gen-

erator.

 Check that cooling air slots and openings on genera-

tor are open and unobstructed.

DANGER: If you use a storage cover, do not

place over a hot generator. Let the unit cool

for a sufficient time before placing a cover on

the unit. Placing a cover on the unit before

generator is sufficiently cool could could start

the cover on fire.

ENGINE

See Engine Owners Manual for instructions on how to

properly store the engine.

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.

SPECIFICATIONS

GENERATOR

Rated Maximum Continuous

AC Power Output ...................................2000 Watts (2.0 kW)

Rated Voltage.........................................120

Rated Maximum Current at 120 Volts ....15 AC amperes

Phase.....................................................1

Rated AC Frequency..............................60 Hertz

Number of Rotor Poles...........................1

Driven Speed of Rotor............................3600 rpm

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