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 following 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.10160 (2000 Watt AC Generator) Part No. B1761 (Revision 0 9/2/97)
EQUIPMENT DESCRIPTION
This generator is an engine-driven, revolving field, alternating current (AC) generator. It was designed to supply
electrical power for operating compatible electrical lighting, 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 generators
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 2000 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 generators 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 governed speed. High operating speeds are
dangerous and increase risk of personal
injury or damage to equipment. The generator supplies correct rated frequency and
voltage only when running at proper governed speed. Incorrect frequency and/or
voltage can damage some connected electrical loads. Operating at excessively low
speeds imposes a heavy load 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 generators application, ask your Dealer/Distributor or consult the factory.
The manufacturer could not possibly anticipate every circumstance that might involve a hazard. For that reason
warnings in the Manual and warnings on tags or decals
affixed to the unit are not all-inclusive. If you intend to
handle, operate or service the unit by a procedure or
method not specifically recommended by the manufacturer, first make sure that such a procedure or method
will not render this equipment unsafe or pose a threat to
you and others.
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 grounding 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::
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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 gasoline.
Do not overfill the fuel tank. Always allow room for
fuel expansion. If tank is overfilled, fuel can overflow
onto a hot engine and cause FIRE or an EXPLOSION.
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 sufficient 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. Disconnect 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 connected 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 external 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 requirements 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 1-800-2701408.
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
10W-40.
Select the oils 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 generators 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
5W30 10W30
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Extended Life Generator
GENERAC
Generac Mega 2500 Extended Life Generator
KNOW YOUR GENERATOR
Read this owners 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 reference.
5.5 H.P. Engine
12 Volts DC Receptacle
Air Cleaner
15AMP AC Circuit Breaker
Recoil Starter
120 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.
12VOLT 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.
120 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.