G N RAC°

1

Portable Generator Owner's Manual

L

A

Model No. 09779-2 (6,500 Watt AC Generator) Manual No. B2635 Revision 2 (05/23/200 I)

Visit our Generac website: www.generac-portables.com

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, appliances,tools and motor loads.This manual contains informationfor a generator that operates

120 and/or 240 Volt, single phase,60 Hz devices that require up to 6,500 watts (6.5 kW) of power that pull up to 54.2 Amps at 120Volts or 27.1Amps at 240Volts.

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 6,500 watts. See

"Don't Overload the Generator" on page 10.

The generator's revolving field is driven at about 3,600 rpm by a single-cylinder engine.

Every effort has been made to ensure that informationin this manual is accurate and current However, Generac reserves the right to change,alter or otherwise improve the product and this document at any time without prior notice.

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 application, ask your dealer or consult the factory.

The manufacturer could not possibly anticipate every circumstance that might involvea 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.

_ Do Not tamper with engine dangerous and increaserisk of personal injuryor damageto equipment.The generator supplies correct rated frequency and voltage only when running at proper governed speed. Incorrect frequency and/or voltage can damagesome connected electrical loads. Operating at excessively

low speeds imposesa heavy load.When adequate engine power is not availableengine life may be shortened.

_

ANGER!

You must isolatethe generator from equipment if this unit is 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 electrical energy.

Whenever unit is providing backup power, the electric utility must be notified.

_

DANGER!

Generator

exhaust

gases contain in sumcient concentrations, carbon

monoxide can cause unconsciousness or death.

Operate this equipment outdoors where adequate ventilation

is available.

The Emission Control System for this generator is warranted for standards set by the Environmental

Protection Agency.For warranty information refer to the engine owner's manual.

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2

Generac Portable Products 6500XL Extended Life Generator

• The generator produces a very powerful voltage that can cause serious injury or death by electrocution. Never touch bare wires or receptacles. Never permit a child or any unqualified person to operate the generator.

• Never handle any kind of electrical cord or device while standing in water, while barefoot or while hands or feet are wet Death or serious injury from electrocution may result.

• Use a ground fault circuit interrupter (GFCI) in any damp or highly conductive area (such as metal decking or steel work).

• Never use worn, bare,frayed or otherwise damaged electrical cords with the generator. Death, serious injury and property damagefrom electrical shock may result

• 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 with all laws regulating storage and handling of gasoline.

• Do Not overfitl the fuel tank.Always allow room for fuel expansion. If tank is overfllled, fuel can overflow

onto a hot engine and cause a FIRE or an

EXPLOSION.

• Never store a generator with fuel in the tank where gasoline vapors might reach an open flame, spark or pilot light (as on a furnace, water heater, clothes dryer). FIRE or an EXPLOSION may result.

• The unit 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.

Allow at least2 feet of clearance on all sides of generator, even while operating unit outdoors, or you could damage the unit

• Never start, or stop the unit with electrical loads connected to receptacles with the connected devices turned ON. Start the engine and let it stabilize before connecting any electrical loads. Disconnect all electrical loads before shutting down the generator.

• Do Not insert any object through cooling slots of the engine.Youcould damagethe unit or injure yourself.

• Never

operate the generator:

in rain; in any enclosed compartment;

when connected

electrical devices overheat; if electrical output

is lost; if

engine or generator sparks; if flame or smoke is observed while unit is running; if unit vibrates excessively.

GROUNDING THE

G EN ERATO R

The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground. Local electrical codes may also require proper grounding of the unit. For that purpose, a GROUNDING WING NUT is provided on the generator end (Figure I).

Generally, connecting a No. 12 AWG (American Wire

Gauge) stranded copper wire to the grounding wing nut and to an earth-driven copper or brass grounding rod

(electrode) provides adequate protection against electrical shock. Be careful to keep the grounding wire attached after connecting the stranded copper wire. However, locat codes may vary widely. Consult with a local electrician for grounding requirements in your area.

Properly grounding the generator helps prevent electrical shock if a ground fault condition exists in the generator or

in connected electrical devices. Proper grounding also helps dissipate static electricity, which often builds up in ungrounded devices.

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3

useafterit hasbeenproperlyserviced oilandfuel.

If you have any problems with the assembly of your generator, please call the generator helpline at

1-800-270-1408.

IMPORTANT:

Any attempt to run the unit before it has been serviced with the recommended oil will result in an engine failure.

REMOVE G EN ERATOR

FROM CARTON

• Set the carton on a rigid flat surface with "This Side Up" arrows pointing upward.

• Carefully open the top flaps of the shipping carton.

Review"Cold Weather Operation" on page 9.

• Cut down corners at one end of carton from top to bottom and lay that side of carton down flat

• Remove all packing material, carton fillers, etc.

• Remove the generator from the shipping carton.

CARTON CONTENTS

Check all contents. If any parts are missing or damaged,call the generator helpline at 1-800-270-1408.

• The generator

Battery charge cables

Generator and engine owner's manuals

Locking 20 Amp and 30 Amp plugs

Spare spark plug

Spare air filter

Spark plug wrench

BEFORE STARTING THE

ENGINE

Add

Oil

CAUTION!

Any attempt to crank or start the engine before it hasbeen properly filled with the recommended oil may result in an engine failure.

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4

To fill your

engine with

oil:

• Place generator on a level surface.

• Follow the oil grade recommendations and oil fill instructions given in the engine owner's manual.

NOTE:The generator's revolving field rides on a prelubricated and sealed ball bearing that requires no

additional lubrication for the life of the bearing.

Add Gasoline

_

Never

fill fuel tank indoors. Never light a cigarette or smoke when filling the fuel tank.

_ Do Not overfill the fuel tank.

• Use regular UNLEADED gasoline with the generator engine. Do Not use premium gasoline. Do Not mix oil with gasoline.

• Clean area around fuel fill cap, remove cap.

• Add unleaded regular gasoline, slowly to fuel tank. Be careful not to overfill.Allow about I/2" of tank space for fuel expansion (Figure 2).

1/2"Air Space Tank

• Install fuel cap and wipe up any spilled gasoline.

IMPORTANT:

It is important to prevent gum deposits from forming in essentialfuel system parts, such as the carburetor, fuel filter, fuel hose or tank during storage.Also, experience indicatesthat alcohol-blended fuels (calledgasohol,ethanol or methanol) canattract moisture, which leadsto separation and formation of acids during storage.Acidic gascan 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. See"Storage" on page I I. Never use engine or carburetor cleaner products in the fuel tank or permanent damagemay occur.

KNOWYOUR 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 this manual for future reference.

Fuel Tank

Circuit Breakers (AC)

Choke Lever

120Volt AC, 30 Amp

Receptacle

Run/Stop Switch

Recoil Starter

120/240Volt AC,

30 Amp Receptacle

12Volt DC, 10Amp

Receptacle

Air Cleaner

Spark Arrester Muffler

Idle Control Switch

Grounding Wing Nut

120Volt AC, 20 Amp

Duplex Receptacle

12Volt DC, 10 Amp Receptacle- Recharge a discharged 12Volt automotive type battery through this receptacle.

120 Volt AC, 20 Amp, Duplex Receptacle -- May be

used to supply electrical power for the operation of

120Volt AC, 20 Amp, single phase,60 Hz electrical lighting, appliance,toot and motor loads.

120 Volt AC, 30 Amp Locking Receptacle-

May be

used to supply electrical power for the operation of

120Volt AC, 30 Amp, single phase,60 Hz electrical lighting, appliance,toot and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle -- May be used to supply electrical power for the operation of

120 and/or 240 Volt AC, 30 Amp, single phase,60 Hz electrical lighting, appliance,tool and motor loads.

Air Cleaner -- Uses a dry type filter element and foam pre-cleaner to limit the amount of dirt and dust sucked into the engine.

Choke Lever -- Used when starting a cold engine.

Circuit Breakers (AC) -- Eachreceptacle is provided with a "push to reset" circuit breaker to protect the generator against electrical overload.

FuelTank

-- Capacity of seven (7) U.S.galtons.

GroundingWing

Nut -- Used for proper grounding of unit.

Idle Control Switch --With this switch set to ON, printed circuit board in control panel automatically reduces engine speed when no load is connected and increases engine to proper speed when load is applied. However, be sure switch isOFF when starting engine.

Recoil starter -- Used to start the engine.

Run/Stop Switch -- Set this switch to "Run" before using recoil starter. Set switch to "Stop" to switch OFF engine.

Spark Arrester Muffler -- Exhaust muffler lowers engine noise and is equipped with a spark arrester screen.

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5

OPERATING THE

G EN ERATO R

_IIL

CAUTION!

Never start or stop the engine with with the connected devices turned ON.

Starting the Engine

• Unplug all electrical loadsfrom generator receptacles before starting the engine.

• Make sure the unit is in a level position.

• Open the fuel shut-off valve (Figure 3).

• Make sure the Idle Control switch is "Off".

• Place Run/Stop switch in the "Run" position (Figure 4).

• Placethe choke lever in the "Full" choke position by sliding it to the left toward the valve cover in the direction indicated by the arrow (Figure 5).

• Grasp starter grip and pull slowly until you feel slight resistance,then pull quickly. Oo Not let handle "snap- back" into recoil housing.

• When engine starts, move choke lever to "Run" position by sliding it all the way to the right (away from the valve cover and under the arrow).

NOTE: If engine fails to start after 3 pulls, move the choke

lever to "Half" choke position and pull starter rope again

2 times.

NOTE: If the engine still fails to start, review the engine owner's manuaLAIso,check for proper oil level in crankcase.Unit is equipped with a low oil shutdown system. See engine owner's manual for information regarding the low oil shutdown system.

Connecting Electrical Loads

• Let engine stabilize and warm up for a few minutes after starting.

• Plug in and turn on the desired 120 and/or 240 VottAC, single phase,60 Hz electrical loads.

• Do Not connect 240Volt loads to the 120Volt receptacles.

• Do Not connect 3_hase loads to the generator.

• Do Not connect 50 Hz loads to the generator.

• DO NOT OVERLOADTHE

GENERATOR.

Add up the rated watts (or amps) of all loadsto be connected at one time.This total should not be greater than the rated wattage/amperage capacity of the generator. See"Don't

Overload the Generator" on page 10.

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6

Stopping the Engine

• Unplug all electrical loads from generator panel receptacles.Never start or stop engine with electrical devices plugged in and turned on.

• Put the idle control switch in the "Off" position.

• Let engine run at no-load for 30 seconds to stabilize the

internal temperatures of engine and generator.

• Move run/stop switch to "Stop."

• Close the fuel shut-off valve.

Operating

Automatic Idle Control

This switch is designed to greatly improve fuel economy.

When this switch is turned ON, the engine will only run at its normal high governed engine speed when an electrical load is connected.When an electrical load is removed, the engine will run at a reduced speed. With

the

switch off, the engine will run at the normal high engine speed. Always have the switch off when starting and

stopping the engine.

Charging a Battery

To recharge 12 Volt batteries, proceed as follows:

• Check fluid level in atl battery cells. If necessary,add

ONLY distilled water to cover separators in battery cells.

Do Not use tap water.

• If the battery isequipped with vent caps,make sure they are installed and are tight.

• If necessary,clean battery terminals.

• Connect battery charge cable connector plug to panel receptacle identified by the words "12 VOLTS D.C"

• Connect battery charge cable clamp with red handle to the positive (+) battery terminal (Figure 6).

12 VOLT D.C.

RECEPTACLE

_

ARNING!

Storage batteries give off explosive will remain around the battery for a long time after

it has been charged.The slightest spark can ignite the hydrogen and cause an explosion, resulting in blindness or other serious injury.

÷

POS

12VOLTBA'I-rERY

NEG

_ Do Not permit smoking, open battery.Wear protective goggles,rubber apron and rubber gloves when working around a battery.

Battery electrolyte fluid isan extremely caustic sulfuric acid solution that can cause severe burns. If spill occurs flush area with clear water immediately.

Your generator hasthe capability of recharging a discharged

12Volt automotive or utility style storage battery. Do Not use the unit to charge any 6Volt batteries. Do Not use the unit to crank an engine havinga discharged battery.

• Connect battery chargecable clamp with black handle to the negative (-) battery terminal (Figure 6).

• Start engine. Let the engine run while battery recharges.

• When battery has charged, shut down engine

NOTE: Use an automotive hydrometer to test battery state of charge and condition. Follow the hydrometer manufacturer's instructionscarefully. Generally, a battery is considered to be at 100%state of charge when specific gravity of itsfluid (as measured by hydrometer) is 1.260or

higher.

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7

COLD WEATH ER

OPERATION

Under certain weather conditions (temperatures below

40°F [4°C] and a high clew point), your generator may experience icingof the carburetor and/or the crankcase breather system.

In an emergency, use the original shipping box as a temporary shelter:

• Cut off all flaps.

• Cut out one of the long sides of the box to expose exhaust side of unit. Ensure a minimum of two feet clearance between open side of box and nearest object.

• Cut appropriate slots to access receptacles of unit.

• Start unit, then place box over it.

IMPORTANT!

Remove shelter when temperature is above 40°F [4°C].

For a more permanent shelter, build a structure that will enclose three sides and the top of the generator:

• Make sure entire muffler-side of generator is exposed.

Note that your generator may appear different from that shown in Figure 7.

A Never run unit indoors.Do Not

RECEPTACLES

120/240 Volt AC, 30 Amp, Locking

Receptacle

Use a N EMA LI4-30 plug with this receptacle. Connect a

4-wire cord set rated for 250 Volt AC loads at 30 Amps (or greater) (Figure 8).You can use the same 4-wire cord if you

)lan to run a 120Volt load.

4-Wire Cord Set

W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-30

Ground

(Green)

This receptacle powers 120/240Volt AC, 60 Hz, single phase loads requiring up to 3,600 watts of power at

30 Amps for 120Volts; 6,500 watts of power (6.5 kW) at

30 Amps for 240Volts.The outlet is protected by a 30 Amp push-to-reset circuit breaker.

• Ensure a minimum of two feet clearance between open side of box and nearest object.

• Face exposed end away from wind and elements.

• Enclosure should hold enough heat created by the generator to prevent problems.

/

8

A

AUTION!

Although this outlet states it has a generator is only rated for 6,500 watts. Powering loads that exceed the wattage/amperage capacity of the generator can damage it or cause serious injuries. 240 Volt loads powered through this outlet should not exceed 27.1 Amps of current draw.

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5-30 plug with this receptacle. Connect a

3-wire cord set rated for 125Volt AC loads at 30 Amps to the plug (Figure 9).

3-Wire Cord Set

_m IEo_ IIP+To'kv_IHL+T • , m

Neutral

NEMA L5-30

____

,f__/

Ground

(Green)

Use this receptacle to operate 120VoltAC, 60 Hz, single phase loads requiring up to 3,600 watts (3.6 kW) of power at 30 Amps.The outlet is protected by a 30 Amp push-to-reset circuit breaken

120 Volt AC, 20 Amp, Duplex

Receptacle

Eachreceptacle (Figure 10) is protected against overload by a 20 Amp push-to-reset circuit breaker.

Use each receptacle to operate 120Volt AC, single-phase,

60 Hz electrical loads requiring up to 2,400 watts (2.4 kW) at 20Amps of current. Use cord sets that are rated for

125Volt AC loads at 20 Amps (or greater).

12 Volt DC, I 0 Amp Receptacle

This receptacle allows you to recharge a 12Volt automotive or utility style storage battery with the battery charge cables provided (Figure I I).This receptacle can not recharge 6Volt batteries and can not be used to crank an engine having a discharged battery. See the section

"Charging a Battery" (page 7) before attempting to recharge a battery.

_

lIB IIP&Vt_IIIDZi..

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9

DON'T OVERLOAD TH E

G EN ERATO R

Overloading a generator in excess of its rated

wattage

capacity can result in damage to the generator and/or connected 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.

• If the appliance, tool or motor does not give wattage, multiply 120Volts times ampere rating to determine watts (volts x amps = watts).

The rated wattage of lights can be taken from wattage listed on the light bulbs.The rated wattage of tools, appliances and motors can usually be found on a data plate or decal affixed to the device. Use Figure 12 below as a general reference.

Some electric motors, such as inductiontypes, require about three 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 generator. First figure the watts needed to start the largest motor.Add to that figure the running watts of alt other connected loads.

Recreational/Home Uses

Tool/Appliance

....................................................

Watts

AM/FM clock radio ....................................................................50

Light bulb ....................................................................................100

Fan................................................................................................200

20" color TV ..............................................................................400

*Deep freezer ...........................................................................500

Personal computer and 15" monitor ...................................800

*1/3 hp furnace fan blower ....................................................800

Microwave oven ........................................................................800

*18 cuft refrigerator ...............................................................800

Sump pump ..............................................................................1000

Electric skillet ..........................................................................1250

*Y2 hp water well pump .......................................................1400

*12,000 Btu window air conditioner ................................1400

Space heater ............................................................................1800

Electric water heater ............................................................4000

Professional/Contractor Uses

Tool/Appliance

....................................................

Watts

"1/3 hp airless sprayer ............................................................600

3/8" hammer drill .....................................................................600

Variable speed Sawzall® .........................................................960

_/2" power drill ........................................................................1000

Quartz-halogen work light ..................................................1000

Belt sander ...............................................................................1200

7 ¼" circular saw ...................................................................1500

7 ¼" worm drive saw ...........................................................1600

*1/2 hp air compressor ........................................................1800

* I 0" power miter saw ...........................................................1800

6" bench grinder .....................................................................1800

*6" table planer .......................................................................1800

* I 0" table/radial arm saw .....................................................2000

Wire feed welder ...................................................................2400

* allow 3 times listed watts for starting this device

I

I0

Generac Portable Products 6500XL Extended Life Generator

SPECIFICATIONS

Maximum SurgeWatts .................

Continuous Wattage Capacity ...........

Power Factor ..............................

8,125 watts

6,500 watts

Rated Maximum Continuous AC Load Current:

1.0

At 120Volts .......................

At 240 Volts .......................

Phase.................................

Rated Frequency .......................

FuelTank Capacity ...................

54.2 Amps

27. I Amps

I-phase

60 Hertz

7 U.S.gallons

GENERAL MAINTENANCE

RECOMMENDATIONS

The Owner/Operator is responsible for making sure that alt 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 owner's manual for

instructions.

To Clean the Generator

• Use a damp cloth to wipe exterior surfaces clean.

• A 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 opening on generator.These openings must be kept clean and unobstructed.

STO RAG E

The generator should be started at least once every seven claysand 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 Storage

• Clean the generator as outlined in "To Clean the

Generator"

• Check that cooling air slots and openings on generator are open and unobstructed.

,_

CAUTION!

Avoid prolonged or repeated skin been shown to cause skin cancer in certain laboratory animals.Thoroughly wash exposed areas with soap and water.

KEEPOUT OF REACH OF CHILDREN. DON'T

POLLUTE. CONSERVE RESOURCES.RETURN

USED OIL TO COLLECTION CENTERS.

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.

NOTE: Do Not use a garden hose to clean generator.

Water can enter engine fuel system and cause problems. In addition, if water enters generator through cooling air slots, some of the water will be retained in voids and cracks of the rotor and stator winding insulation.Water

and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings.

_

DANGER!

Storage covers can be flammable. Do the unit cool for a sufficient time before placing the cover on the unit.

Engine Storage

See engine owner's manual for instructions.

Other

Storage Tips

• Do Not store gasoline from one season to another.

• Replace your gasoline can if it starts to rust. Rust andlor dirt in a gasoline can cause problems when you use that fuel with this unit.

• Store in clean and dry area.

I

II

Generac Portable Products 6500XL Extended Life Generator

TROUBLESHOOTING

Problem

Engine

is running,

but no AC output is available.

Cause

I.

Circuit breaker is open.

2.

Poor connection or defective cord set.

3.

Connected device is bad.

4.

Fault in generator.

I.

Short circuit in a connected

load.

2.

Generator is overloaded.

Engine

runs good

but bogs clown when loads are connected.

Engine will not start; or

starts and runs rough.

Engine shuts down during operation.

3.

Enginespeed istoo slow.

4.

Shortedgenerator circuit.

I.

Run/Stop switch set to "Stop".

2.

Dirty air cleaner.

3.

Out of gasoline.

4.

Stalegasoline.

5.

Spark plug wire not connected to spark plug.

6.

Bad spark plug.

7.

Waterin gasoline.

8.

Overchoking.

9.

Low oil level.

10.

II.

Excessively rich fuel mixture.

Intake valve stuck open or closed.

12.

Engine has lost compression.

I.

Out of gasoline.

2.

Low oil level

3.

Fault in engine.

I.

Loadis too high.

Engine lacks power.

2.

Dirty air filter.

3.

Engine needs to be serviced.

I.

Choke is opened too soon.

Engine

"hunts"

or

falters.

2.

Carburetor is running too rich or too

lean.

Solution

I.

Reset circuit breaker.

2.

Check and repair.

3.

Connect another device that is in good condition.

4.

Contact Generac service facility.

I.

Disconnect shorted electricalload.

2.

See "Don't Overload the Generator" on page 10.

3.

Contact Generac service facility.

4.

Contact Generac service facility.

I.

Set switch to "Run".

2.

Clean or replace air cleaner.

3.

Fill fuel tank.

4.

Drain gas tank and fill with fresh fuel.

5.

Connect

wire

to spark plug.

6.

Replacespark plug.

7.

Drain gastank; fill with fresh fuel.

8.

Put choke lever to "No Choke" position.

9.

Fill crankcase to proper level.

10. Contact Generac service facility.

I I. Contact Generac service facility.

12. Contact Generac service facility.

I.

Fill fuel tank.

2.

Fill crankcaseto proper level.

3.

Contact Generac service facility.

I.

See"Don't Overload the Generator" on page 10.

2.

Replace air filter.

3.

Contact Generac service facility.

I.

Move choke to halfway position till engine runs smoothly.

2.

Contact Generac service facility.

/

12

NOTES

Generac Portable Products 6500XL Extended Life Generator

/

13

B

I

SCHEMATIC

POWER

REGULATOR

BOARD

POWER

IDLE

CONTROL

TRANSFORMER

22

POWER

44

.....

155 156 22 44

G

A

T

E

N

A

L

I

S

G

18

LOP

;WI TCH

EL _

\

LED

LOP

RED

30A

C B

I) 30A

IDLE

SWITCH

I

BLU/WHT 22 )I C B

]20V 20A

44B_D20 A(_

ENG lbNITIO

BATTE_ CHARbE

66

AUTO t OA C B

/_)

13

55

55

_55_

77 llA

]IA

__

20A

C I_

C B

44A

30A

/

14

Generac Portable Products 6500XL Extended Life Generator m

WIRING DIAGRAM

o 12ov

20A

BRBKEH BFF

IDLE

_WITCH

L

2C

11 44 _55 6

4 _EARING

_GATE gHIELD gIBNAL

NUT BN

ENGINE _LBgK

/

15

l/|

1-@

2 / 'i_

LvB

EXPLODEDVIEW-

Generac Portable Products 6500XL Extended Life Generator

MAIN UNIT

46

27

5O

\\

51

25

6

\

11

\

14

36 49

21

/

16

\

37

\

37

55

\

\

\

\

55

Generac Portable Products 6500XL Extended Life Generator

im|

1-©

2 J _i_

kliE

PARTS LISTMAIN UNIT

34

35

36

37

38

30

31

32

33

Item PaX#

I

2

3

4

5

6

7

8

9

A92432

A92531

A92731

92247

92679G

92681G

65791

67451

22129

10 86307

I1 25254

12 92609

13 82857

14 40976

15 66476

16 92532

17 22142

18 A7433

19 90239

20

21

81917

B4986

22

25

26

27

28

29

83083

66825C

74908

86308B

65795

66849A

67022

84132

66386

66849

B4871

22769

86494

86292

77395

Qty Description

CRADLE

SUPPORT,Support

SUPPORT,Engine & Muffler

HOUSING, EngineAdapter

ASSEMBLY,Rotor

ASSEMBLY,Stator

BEARING

WASHER, M8 Flat

2 WASHER, M8 Lock

4 HHMS, 5/16 - 24 x 3/4 SEMS

I H HCS,5/16 - 24 x 9-7/8"

2 MOUNT, Vibration

4 MOUNT, Vibration

2 SCREW,M8 - 1.25x 20

2 CAPSCREW, M6 - 1.0x 12mm

I BRACKET, Muffler

2 SCREW,5/16 - 18 x 3/4"

MUFFLER

GASKET,Mumer

PIN, 4 mm x 10 Roll

DECAL, Ground

SCREEN,SparkArrester

CARRIER, Rear Bearing

4 TAPTITE, M5-0.8 x l0

4 BOLT, M6 -I x i65 mm Stator

I RECTIFIER,Battery Charge

I TAPTITE, M5-0.8 x 20

I GROMMET, Rubber

I ASSEMBLY,Power Regulator

I ASSEMBLY,Brush Holder

2 TAPTITE, M5 - 0.8 x 16

I COVER, Bearing Carrier

I WASHER,#10 Int. Shakeproof

I SCREW,M6 -l.0 x 16Wing

7 HHCS,#10 Self Driller

4 NUT, M6 FlangeLock

Item Part#

39 83465

49

51

52

55

57

58

59

60

62

63

64

40

41

42

43

44

45

46

47

48

78831B

80270

78299

B4363

B1695

B92039

92665

85000

14353621

26850

92982

92612

189160

92640

92630

NSP

22531

93826

B96068

56893

Qty Description

4 GROMMET,Tank

4

2

I

I

I

5

HHCS, M6- 1.0x 60, SEMS

VALVE,Tank

BUSHING, PlasticTank

CAP, Fuel Gauge

TANK,Tank 7- Gal

SHIELD, Heat

INSULATION #2-1/4"Thlck

CLIP,Insulation

WIRE, Ground

2 WASHER, M6 Shakeproof

I DECAL, Danger

DECAL, Heat Shield

12 NUT, 5/16-18 Serrated Flange

I DECAL, Control Panel

ASSEMBLY,Control Box

ENGINE

2 HHCS, 5/I 6-18 x 1-3/4"

I DECAL, Start Instructions

SHIELD, Heat

CRIMPTITE, 10-24 x I/2"

Items Not Illustrated:

65787

B2635

A8927

37806

43438

72347

73111

84882

Battery Charge Cable

Generator Owner's Manual

Engine Owner's Manual

120Volt AC 30 Amp Locking

Plug

120/240VottAC 30Amp Locking

Plug

Spark Plug

Air Cteaner Element

Spark PlugWrench

Optional Accessories Not Included:

84883 CordWrap

/

17

Generac Portable Products 6500XL Extended Life Generator l/|

1-@

2 / 'i_

LvB

EXPLODED VIEW AND PARTS LIST

- CONTROL PANEL

19

\\

21 20

19

\x

\

\\

8

6

10

6

10

1

11

22

16

8

9

/

2

5

Item PaX#

6

7

4

5

8

9

I

2

3

A92070

23897

49226

91526

82538

82881

43181

43182

90418

10 75207A

II 75207

12 23365

13 68868

Qty Description

I PANEL,Control

4 FLATWASHER, #10 M5

4 LOCK WASHER, M5

4 SCREW, M5-0.8 x 12mm

I SWITCH, Idle Control

4 LOCK WASHER, 7/16"

4 SCREW, M3 - 0.5 x 10mm

4 LOCK WASHER, M3

I OUTLET, 12V

2 CIRCUIT BREAKER,30A

2 CIRCUIT BREAKER,20A

6 WASHER, #8 Shakeproof

1 OUTLET, 120Volt, 30 Amp

Locking

/

18

Item

PaX#

14 43437

22

23

24

25

26

15 68759

16 43180

17 22264

18 51715

19 64526

20

21

83970

64525

87962

84335

84134

B92069

84028

Qty Description

I OUTLET, 120V/240V,30A

Locking

I OUTLET, 120V,20A Duplex

6 FLAT WASHER, M4

6 LOCK WASHER, #8 M4

6 NUT, M4-0.7 Hex

8 SCREW,#6-32 x 3/8"

I BOARD, System Control

4 STAND-OFF, 3/4" Hex

I CIRCUIT BREAKER.12V,10A

I

I

1 ASSEMBLY,

1 GROMMET, Rubber Conn.

BOX, Control Panel

TRANSFORMER, Idle Control

NOTES

Generac Portable Products 6500XL Extended Life Generator

/

19

LI M ITED WARRANTY

FOR

"GN"

ENGINE DRIVEN PORTABLE GENERATORS

GENERAC PORTABLE PRODUCTS (hereafter referred to as the COMPANY) warrants to the original purchaser that the alternator and control panel for its portable generator will be free from defects in materials or workmanship for the items and period set forth below from the date of original purchase.This warranty is not transferable and applies only to portable generators driven by a GN-Series engine.

Consumer* Commercial*

Alternator

Engine

2 years (2nd year parts only) I year

Warranted solely by the engine manufacturer

With the exception of European Community Countries, all units bound for export shall be warranted for One (I)

Year in Consumer applications, and 90 days in Commercial applications as defined below.

*NOTE: For the purpose of this warranty

"consumer use" means personal residential

household use by original purchaser.This warranty does not apply to units used for Prime Power in place of utility.

"Commercial Use" means all other uses, including rental, construction, commercial and income producing

purposes. Once a generator has experienced commercial

use, it shall thereafter be considered a commercial

use generator for the purposes of this warranty.

During said warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination by the

COMPANY, is found to be defective under normal use and service**. Starting batteries are not warranted by the

COMPANY.All transportation costs under warranty, includingreturn to the factory if necessary,are to be borne by the purchaser and prepaid by the purchaser.This warranty does not cover normal maintenance and service and does not apply to a generator set, alternator, or parts which have been subjected to improper or unauthorized installationor alteration, misuse, negligence,accident, overloading, overspeeding, improper maintenance, repair or storage so as, in the COMPANY's judgement, to adversely affect its performance and reliability.

**NORMAL

WEAR: As with all mechanical devices, the generator need periodic parts service and replacement to perform well.This warranty will not cover repair when normal use has exhausted the life of

a part or generator.

THERE ISNO OTHER EXPRESSWARRANTY.THE COMPANY HEREBY DISCLAIMSANYANDALL

IMPLIEDWARRANTIES, INCLUDING BUT NOT LIMITED TOTHOSE OF MERCHANTABILITY AND

FITNESSFORA PARTICULAR PURPOSETOTHE EXTENT PERMITTED BY LAW.THE DURATION OF

ANY IMPLIEDWARRANTIESWHICH CANNOT BE DISCLAIMED IS LIMITEDTOTHETIME PERIODAS

DAMAGES UNDERANYAND ALLWARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS ANY

RESPONSIBILITYFOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, SUCH AS THE LOSS OF TIME OR

THE USEOETHE POWER EQUIPMENT,ORANY COMMERCIAL LOSS DUETOTHE FAILUREOFTHE

EQUIPMENT:AND ANY IMPLIEDWARRANTIESARE LIMITEDTOTHE DURATION OFTHISWRITTEN

WARRANTY.

Some states do not allow limitations on how longan impliedwarranty lasts, or the exclusion or limitation of incidentalor consequential damages,so the above limitationsor exclusions may not apply to you.This warranty gives you specific legal rights and you may also have other rights, which vary from state to state.

For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982.Warranty service can be performed only by a COMPANY authorized service facility.This warranty will not apply to service at any other facility.

At the time of requesting warranty service, evidence of original purchase date must be presented.

GENERAC PORTABLE

Jefferson,Wisconsin

PRODUCTS

U,S,A,