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.
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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::

3
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
4
Extended Life Generator
Loosen knobs
to raise handle
Dipstick
Tighten knobs when
handle is straight.
colder 32°F warmer
5W30 10W30

5
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
6
Extended Life Generator
Choke Control Lever
Figure 6  On/Off Switch
On/Off Switch

Generac Mega 2500 Extended Life Generator
7
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.
8
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
9
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
10
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