Generac Power Systems MEGAFORCE 6500 User manual

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)
V s t our Generac webs te: www.generac-portables.com
V s ter notre Generac webs te: www.generac-portables.com
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
2
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
3
 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
4
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
5
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
45mm Capscrew
Flat Washer
20mm
Capscrew
Flat Washer
Lock Nut
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
6
 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
7
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
8
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
9
 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
10
F gure 10  120 Volt AC, 15 Amp GFCI Receptacle

MEGAFORCE 6500 Extended L fe Generator
11
Th s receptacle powers 120/240 Volt AC, 60 Hz, s ngle
phase loads requ r ng up to 3,600 watts of power at
30 Amps for 120 Volts; 6,500 watts of power (6.5 kW)
at 30 Amps for 240 Volts. The outlet s protected by a
30 Amp pushtoreset c rcu t breaker.
CAUTION: Although th s outlet s rated for
30 Amps (up to 7,200 watts), the generator s
only rated for 6,500 watts. Power ng loads that
exceed the wattage/amperage capac ty of the
un t can damage t or cause ser ous njur es.
Loads of 240 Volts powered through th s outlet
should not exceed 27 Amps current draw;
120 Volt loads should not exceed 30 Amps.
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L530 plug w th th s receptacle. Connect
a 3w re cord set rated for 125 Volt AC loads at
30 Amps to the plug (F gure 12).
Use th s receptacle to operate 120 Volt AC, 60 Hz,
s ngle phase loads requ r ng up to 3,600 watts
(3.6 kW) of power at 30 Amps. The outlet s protected
by a 30 Amp pushtoreset c rcu t breaker.
12 Volt DC, 10 Amp Receptacle
Th s receptacle (F gure 13) allows you to recharge a
12 Volt automot ve or ut l ty style storage battery w th
the battery charge cables prov ded.
Th s receptacle can not recharge 6 Volt batter es and
can not be used to crank an eng ne hav ng a
d scharged battery. See Charg ng a Battery on
page 8 before attempt ng to recharge a battery. Th s
outlet s protected by a 10 Amp self resett ng c rcu t
breaker.
F gure 12  120 Volt AC, 30 Amp, Lock ng Receptacle
F gure 13  12 Volt DC, 10 Amp Receptacle
F gure 11  120/240 Volt AC, 30 Amp, Lock ng
Receptacle

MEGAFORCE 6500 Extended L fe Generator
12
DONT OVERLOAD THE
GENERATOR
Overload ng a generator n excess of ts rated wattage
capac ty can result n damage to the generator and/or
connected electr cal dev ces. Observe the follow ng, to
prevent overload ng the un t:
 Add up the total wattage of all electr cal dev ces to
be connected at one t me. Th s total should NOT be
greater than the generators wattage capac ty.
 If the appl ance, tool or motor does not g ve wattage,
mult ply 120 Volts t mes ampere rat ng to determ ne
watts (volts x amps = watts).
 The rated wattage of l ghts can be taken from
wattage l sted on the l ght bulbs. The rated wattage
of tools, appl ances and motors can usually be found
on a data plate or decal aff xed to the dev ce. Use
F gure 14 below as a general reference.
 Some electr c motors, such as nduct on types,
requ re about three t mes more watts of power for
start ng than for runn ng. Th s surge of power lasts
for only a few seconds when start ng such motors.
Be sure you allow for th s h gh start ng wattage
when select ng electr cal dev ces to connect to your
generator. F rst f gure the watts needed to start the
largest motor. Add to that f gure the runn ng watts of
all other connected loads.
Device . . . . . . . . . . . . . . . . . . . . . . . . . Load (watts)
*A r Cond t oner (12,000 Btu). . . . . . . . . . . . . . . 1700
*A r Cond t oner (24,000 Btu). . . . . . . . . . . . . . . 3800
*A r Cond t oner (40,000 Btu). . . . . . . . . . . . . . . 6000
Battery Charger (20 Amp) . . . . . . . . . . . . . . . . . . 500
Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . 1000
Cha n Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
C rcular Saw (6-1/2") . . . . . . . . . . . . . . . 800 to 1000
*Clothes Dryer (Electr c) . . . . . . . . . . . . . . . . . . 5750
*Clothes Dryer (Gas). . . . . . . . . . . . . . . . . . . . . . 700
*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . 1150
Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . 1750
*Compressor (1 HP) . . . . . . . . . . . . . . . . . . . . . 2000
*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . 1800
*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . 1400
Curl ng Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
*Freezer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
*Dehum d f er . . . . . . . . . . . . . . . . . . . . . . . . . . . 650
D sc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . 1200
Edge Tr mmer . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Electr c Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Electr c Na l Gun . . . . . . . . . . . . . . . . . . . . . . . . 1200
Electr c Range (per element) . . . . . . . . . . . . . . . 1500
Electr c Sk llet . . . . . . . . . . . . . . . . . . . . . . . . . . 1250
*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . 875
*Garage Door Opener . . . . . . . . . . . . . . . 500 to 750
Ha r Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Hand Dr ll . . . . . . . . . . . . . . . . . . . . . . . . 250 to 1100
Device . . . . . . . . . . . . . . . . . . . . . . . . . Load (watts)
Hedge Tr mmer . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
*Jet Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800
Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
L ght Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
M crowave Oven. . . . . . . . . . . . . . . . . . . 700 to 1000
*M lk Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100
O l Burner on Furnace. . . . . . . . . . . . . . . . . . . . . 300
O l F red Space Heater (140,000 Btu) . . . . . . . . . 400
O l F red Space Heater (85,000 Btu) . . . . . . . . . . 225
O l F red Space Heater (30,000 Btu) . . . . . . . . . . 150
*Pa nt Sprayer, A rless (1/3 HP) . . . . . . . . . . . . . . 600
Pa nt Sprayer, A rless (handheld). . . . . . . . . . . . . 150
Rad o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 200
*Refr gerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
Slow Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
*Submers ble Pump (1-1/2 HP) . . . . . . . . . . . . . 2800
*Submers ble Pump (1 HP) . . . . . . . . . . . . . . . . 2000
*Submers ble Pump (1/2 HP). . . . . . . . . . . . . . . 1500
*Sump Pump . . . . . . . . . . . . . . . . . . . . . 800 to 1050
*Table Saw (10"). . . . . . . . . . . . . . . . . . 1750 to 2000
Telev s on . . . . . . . . . . . . . . . . . . . . . . . . . 200 to 500
Toaster . . . . . . . . . . . . . . . . . . . . . . . . . 1000 to 1650
Weed Tr mmer . . . . . . . . . . . . . . . . . . . . . . . . . . 500
* Allow 3 t mes the l sted watts for start ng these dev ces.
F gure 14  Wattage Reference Gu de

MEGAFORCE 6500 Extended L fe Generator
13
GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator s respons ble for mak ng sure
that all per od c ma ntenance tasks are completed on a
t mely bas s; that all d screpanc es are corrected; and
that the un t s kept clean and properly stored. Never
operate a damaged or defective generator.
Engine Maintenance
See eng ne owners manual for nstruct ons.
Generator Maintenance
Generator ma ntenance cons sts of keep ng the un t
clean and dry. Operate and store the un t n a clean
dry env ronment where t w ll not be exposed to
excess ve dust, d rt, mo sture or any corros ve vapors.
Cool ng a r slots n the generator must not become
clogged w th snow, leaves or any other fore gn
mater al.
NOTE: Do Not use a garden hose to clean generator.
Water can enter eng ne fuel system and cause
problems. In add t on, f water enters generator
through cool ng a r slots, some of the water w ll be
reta ned n vo ds and cracks of the rotor and stator
w nd ng nsulat on. Water and d rt bu ldup on the
generator nternal w nd ngs w ll eventually decrease
the nsulat on res stance of these w nd ngs.
To Clean the Generator
 Use a damp cloth to w pe exter or surfaces clean.
 A soft br stle brush may be used to loosen caked on
d rt or o l.
 A vacuum cleaner may be used to p ck up loose d rt
and debr s.
 Low pressure a r (not to exceed 25 ps ) may be
used to blow away d rt. Inspect cool ng a r slots and
open ng on generator. These open ngs must be kept
clean and unobstructed.
STORAGE
The generator should be started at least once every
seven days and allowed to run at least 30 m nutes. If
th s cannot be done and you must store the un t for
more than 30 days, use the follow ng gu del nes to
prepare t for storage.
Generator Storage
 Clean the generator as outl ned n To Clean the
Generator.
 Check that cool ng a r slots and open ngs on
generator are open and unobstructed.
DANGER! Storage covers can be flammable.
Do Not place a storage cover over a hot
generator. Let the un t cool for a suff c ent t me
before plac ng the cover on the un t.
Engine Storage
See eng ne owners manual for nstruct ons.
Other Storage Tips
Do Not store gasol ne from one season to another.
 Replace the gasol ne can f t starts to rust. Rust
and/or d rt n gasol ne can cause problems when
you use that fuel w th th s un t.
 Store n clean and dry area.
SPECIFICATIONS
Cont nuous Wattage Capac ty . . . . . . . 6,500 watts
Max mum Surge Watts . . . . . . . . . . . . 8,125 watts
Power Factor . . . . . . . . . . . . . . . . . . . 1.0
Rated Max mum Cont nuous AC Load Current:
At 120 Volts . . . . . . . . . . . . . . . . . . 54.1 Amps
At 240 Volts . . . . . . . . . . . . . . . . . . 27.0 Amps
Phase. . . . . . . . . . . . . . . . . . . . . . . . . 1 phase
Rated Frequency . . . . . . . . . . . . . . . . 60 Hertz
Fuel Tank Capac ty . . . . . . . . . . . . . . . 7 U.S. gallons

MEGAFORCE 6500 Extended L fe Generator
14
NOTES

MEGAFORCE 6500 Extended L fe Generator
15
TROUBLESHOOTING
Problem Cause Correction
Engine is running, but no
AC output is available.
1. One of the c rcu t breakers s open.
2. Fault n generator.
3. Poor connect on or defect ve cord
set.
4. Connected dev ce s bad.
1. Reset c rcu t breaker.
2. Contact Generac serv ce fac l ty.
3. Check and repa r.
4. Connect another dev ce that s n
good cond t on.
Engine runs good at no-
load but bogs down
when loads are
connected.
1. Short c rcu t n a connected load.
2. Eng ne speed s too slow.
3. Generator s overloaded.
4. Shorted generator c rcu t.
1. D sconnect shorted electr cal load.
2. Contact Generac serv ce fac l ty.
3. See Dont Overload the Generator
on page 12.
4. Contact Generac serv ce fac l ty.
Engine will not start; or
starts and runs rough.
1. Run/Stop sw tch set to Stop.
2. D rty a r cleaner.
3. Out of gasol ne.
4. Stale gasol ne.
5. Spark plug w re not connected to
spark plug.
6. Bad spark plug.
7. Water n gasol ne.
8. Overchok ng.
9. Excess vely r ch fuel m xture.
10. Intake valve stuck open or closed.
11. Eng ne has lost compress on.
1. Set sw tch to Run.
2. Clean or replace a r cleaner.
3. F ll fuel tank.
4. Dra n gas tank; f ll w th fresh fuel.
5. Connect w re to spark plug.
6. Replace spark plug.
7. Dra n gas tank; f ll w th fresh fuel.
8. Open choke fully and crank eng ne.
9. Contact Generac serv ce fac l ty.
10. Contact Generac serv ce fac l ty.
11. Contact Generac serv ce fac l ty.
Engine shuts down
during operation. 1. Out of gasol ne.
2. Low o l level.
1. F ll fuel tank.
2. F ll crankcase to proper level.
Engine lacks power. 1. Load s too h gh.
2. D rty a r f lter.
1. See Dont Overload the Generator
on page 12.
2. Replace a r f lter.
Engine hunts or falters.
1. Choke s opened too soon.
2. Carburetor s runn ng too r ch or
too lean.
1. Move choke to halfway pos t on unt l
eng ne runs smoothly.
2. Contact Generac serv ce fac l ty.

MEGAFORCE 6500 Extended L fe Generator
16
SCHEMATIC DIAGRAM

MEGAFORCE 6500 Extended L fe Generator
17
WIRING DIAGRAM

MEGAFORCE 6500 Extended L fe Generator
18
EXPLODED VIEW  MAIN UNIT

MEGAFORCE 6500 Extended L fe Generator
19
Item Part # Qty Description
1 B92432 1 CRADLE
2 B92531 1 SUPPORT, Eng ne
3 B92731 1 SUPPORT, Eng ne & Muffler
4 92247 1 HOUSING, Eng ne Adapter
5 92679G 1 ASSEMBLY, Rotor
6 92681G 1 ASSEMBLY, Stator
7 65791 1 BEARING
8 67451 1 WASHER, M8 Flat
9 22129 14 WASHER, M8 Lock
10 86307 4 SCREW, 5/16-24 x 3/4 Mach.
11 25254 1 SCREW, 5/16-24 x 9-7/8"
12 92609 2 MOUNT, V brat on
13 82857 4 MOUNT, V brat on
14 40976 2 SCREW, M8 - 1.25 x 20
15 66476 2 CAPSCREW, M6 - 1.0 x
12mm
16 92532 1 BRACKET, Muffler
17 22142 2 SCREW, 5/16 - 18 x 3/4"
18 91153 1 MUFFLER
19 90239 1 GASKET, Muffler
20 81917 1 PIN, 4 mm x 10 Roll
24 83083 1 SCREEN, Spark Arrest
25 66825C 1 CARRIER, Rear Bear ng
26 74908 4 SCREW, M5-0.8 x 10 Tapt te
27 86308B 4 BOLT, M6-1 x 165mm Stator
28 65795 1 RECTIFIER, Battery Charge
29 66849A 1 SCREW, M5-0.8 x 20 Tapt te
30 67022 1 GROMMET, Rubber
31 84132 1 ASSEMBLY, Power Regulator
32 66386 1 ASSEMBLY, Brush Holder
33 66849 2 SCREW, M5-0.8 x 16 Tapt te
34 B67025 1 COVER, Bear ng Carr er
35 22769 1 WASHER, #10 Int.
Shakeproof
36 86494 1 SCREW, M6-1.0 x 16 W ng
37 86292 7 SCREW, #10 Self Dr ll ng
38 77395 4 NUT, M6 Flange Lock
39 83465 4 GROMMET, Tank
40 57058 4 HHCS, M6-1.0 x 55
Item Part # Qty Description
41 80270 1 VALVE, Tank
42 78299 1 BUSHING, Plast c Tank
43 B4363 1 CAP, Fuel Gauge
44 B1695 1 TANK, Fuel 7-Gal
45 B92039 1 SHIELD, Heat
46 92665 1 INSULATION, #2-1/4"
47 85000 1 CLIP, Insulat on
48 14353621 1 WIRE, Ground
49 26850 2 WASHER, M6 Shakeproof
51 94479 1 DECAL, Danger
52 B1223 2 DECAL, Heat Sh eld
55 25244 12 NUT, 5/16-18 Hex
57 B1224 1 DECAL, Control Panel
58 B1473 1 ASSEMBLY, Control Box
59 NSP 1 ENGINE
60 22531 2 HHCS, 5/16-18 x 1-3/4
61 22473 4 WASHER, Flat M6
62 93221 2 DECAL, Cradle
63 94480 1 DECAL, Start Instruct ons
64 B96068 1 SHIELD, Heat
65 56893 5 CRIMPTITE, 10-24 x 1/2
66 NSP 1 DECAL, CSA
67 74728 1 DECAL, Neutral ground
68 76247 1 DECAL, Neutral ground
69 20566 1 DECAL, 1-800
70 B4986 1 DECAL, Ground
Items Not Illustrated:
37806 120 Volt AC 30 Amp Lock ng
Plug
43438 120/240 Volt AC 30 Amp
Lock ng Plug
65787 Battery Charge Cable
72347 Spark Plug
73111 A r F lter Element
84882 Spark Plug Wrench
84883 Cord Wrap
B1479 Generator Owners Manual
PARTS LIST  MAIN UNIT

MEGAFORCE 6500 Extended L fe Generator
20
Item Part # Qty. Description
1 F92570 1 PANEL, Control
2 23897 4 WASHER, #10 M5 Flat
3 49226 4 WASHER, M5 Lock
4 91526 4 SCREW, M5 - 0.8 x 12mm
5 87968 1 SWITCH, Idle Control
6 82881 4 WASHER, 7/16" Lock
7 43181 8 SCREW, M3 - 0.5 x 10mm
8 43182 8 WASHER, M3 Lock
9 66822 1 BRACKET, 12V Outlet & Ret.
10 75207A 2 CIRCUIT BREAKER, 30A
11 75207D 1 CIRCUIT BREAKER, 15A
12 23365 6 WASHER, #8 Shakeproof
13 68868 1 OUTLET, 120 Volt, 30 A
Lock ng
14 43437 1 OUTLET, 120V/240V, 30A
Lock ng
15 94373 1 RECEP, GFCI 15A
Item Part # Qty. Description
16 43108 6 WASHER, M4 Flat
17 22264 6 WASHER, #8 M4 Lock
18 51715 6 NUT, M4 - 0.7 Hex
19 64526 8 SCREW, #6 - 32 x 3/8"
20 83907 1 BOARD, System Control
21 64525 4 3/4" Hex Stand - Off
22 87692 1 CIRCUIT BREAKER, 12V,
10A (auto)
23 84335 1 ASSEMBLY, W re Harness
24 84134 1 CONNECTION, Rubber
Grommet
25 B92069 1 BOX, Control Panel
26 84028 1 TRANSFORMER , Idle
Control
27 75475 6 SCREW, M4 - 0.7 x 10mm
28 77604 1 HOUR METER
29 51714 2 NUT, M3 - 0.5 Hex
EXPLODED VIEW AND PARTS LIST  CONTROL PANEL