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G PNortable PrRoduActs C ° 1 L Portable Generator Owner's Manual 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 A This is the safety alert symbol . It is used to alert you to potential personal injury hazards . Obey allsafety messagesthat follow this symbol to avoidpossible injury or death .
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GeneraPcortablPeroduct6s500XLExtendeLdifeGenerator SAFETY RULES EQUIPMENT DESCRIPTION This generator set was designed and manufactured for specific applications . Do Not attempt to modify the unit or This generator is an engine - driven , revolving field , use it for any application it was not designed for . If you have alternating current ( AC ) generator . It was designed to any questions about your generator's application , askyour supply electrical power for operating compatible electrical dealer or consult the factory . lighting , appliances , tools and motor loads . This manual The manufacturer could not possibly anticipate every contains informationfor a generator that operates circumstance that might involvea hazard . For that reason 120and / or 240Volt , single phase , 60 Hz devices that warnings in the manual and warnings on tags or decals require up to 6,500 watts ( 6.5 kW ) of power that pull up affixed to the unit are not all - inclusive . If you intendto to 54.2 Amps at 120Volts or 27.1Amps at 240Volts . handle , operate or service the unit by a procedure or method not specifically recommended by the manufacturer , CAUTION ! Do Not exceed the generator's first make sure that such a procedure or method will not wattage / amperage capacity . Add up the rated watts of all render this equipment unsafeor pose a threat to you and devices you are connecting to generator receptacles at one others . time . This total should not be greater than 6,500 watts . See " Don't Overload the Generator " on page 10 . Read this manual carefully and become familiar with your generator set . Know its applications , its The generator's revolving field is driven at about 3,600 rpm limitations and any hazards involved . 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 improvethe product and this document at any time without prior notice . _ ANGER ! You must isolatethe generator from the electric utility using approved transfer _ AUTION ! Do Not tamper with engine governed speed . High operating speeds are equipment if this unit is used for backup power . dangerous and increaserisk of personal injuryor Failure to isolate the generator from the damageto equipment . The generator supplies power utility may result in injury or death to correct rated frequency and voltage only when electric utility workers and damage to the running at proper governed speed . Incorrect generator due to a backfeed of electrical energy . frequency and / or voltage can damagesome Whenever unit is providing backup power , the connected electrical loads . Operating at excessively electric utility must be notified . low speedsimposesa heavy load . When adequate engine power is not availableengine life may be shortened . _ DANGER ! Generator exhaust gases contain DEADLY carbon monoxide gas . If breathed 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 . / 2
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Generac Portable Products 6500XL Extended Life Generator • The generator produces avery powerful voltage that can • Never operate the generator : cause serious injury or death by electrocution . Never in rain ; in any enclosed compartment ; when connected touch bare wires or receptacles . Never permit a child or electrical devices overheat ; if electrical output is lost ; if any unqualified person to operate the generator . engine or generator sparks ; if flame or smoke is observed while unit is running ; if unit vibrates excessively . • Never handle any kind of electrical cord or device while standing in water , while barefoot or while hands or feet GROUNDING THE are wet Death or serious injury from electrocution may result . G EN ERATO R • Use a ground fault circuit interrupter ( GFCI ) in any damp or highly conductive area ( such as metal decking or steel The National Electrical Code requires that the frame and work ) . external electrically conductive parts of this generator be properly connected to an approved earth ground . Local • Never use worn , bare , frayed or otherwise damaged electrical codes may also require proper grounding of the electrical cords with the generator . Death , serious injury unit . For that purpose , a GROUNDING WING NUT is and property damagefrom electrical shock may result provided on the generator end ( Figure I ) . • 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 handlingof 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 Generally , connecting a No . 12AWG ( American Wire continued proper operation . Never operate the unit Gauge ) stranded copper wire to the grounding wing nut inside any room or enclosure where the free flow of and to an earth - driven copper or brassgrounding rod cooling air into and out of the unit might be obstructed . ( electrode ) provides adequate protection againstelectrical Allow at least2 feet of clearanceon all sidesof generator , shock . Be careful to keep the grounding wire attached after even while operating unit outdoors , or you could damage connecting the stranded copper wire . However , locat codes the unit may vary widely . Consult with a local electrician for • Never start , or stop the unit with electrical loads grounding requirements in your area . connected to receptacles with the connected devices Properly grounding the generator helps prevent electrical turned ON . Start the engine and let it stabilize before shock if a ground fault condition exists in the generator or connecting any electrical loads . Disconnect all electrical in connected electrical devices . Proper grounding also helps loads before shutting down the generator . dissipate static electricity , which often builds up in • Do Not insert any object through cooling slots of the ungrounded devices . engine . Youcould damagethe unit or injure yourself . / 3
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GeneraPcortablPeroduct6s500XLExtendeLdifeGenerator Yourgeneratorrequiressomeassembalyndisreadyfor To fill your engine with oil : useafterit hasbeenproperlyservicewdiththe • Place generator on a level surface . recommendoeidlandfuel . • Follow the oil grade recommendations and oil fill If you have any problems with the assembly of your instructions given in the engine owner's manual . generator , please call the generator helpline at NOTE : The generator's revolving field rides on a 1 - 800 - 270 - 1408 . prelubricated and sealed ball bearing that requires no IMPORTANT : Any attempt to run the unit before it has additional lubrication for the life of the bearing . been serviced with the recommended oil will result in an engine failure . Add Gasoline REMOVE G EN ERATOR _ WARNING ! Never fill fuel tank indoors . Never fill fuel tank when engine is running or hot . Do Not FROM CARTON light a cigarette or smoke when filling the fuel tank . • Set the carton on a rigid flat surface with " This Side Up " arrows pointing upward . _ WARNING ! Do Not overfill the fuel tank . Always allow room for fuel expansion . • Carefully open the top flaps of the shipping carton . • Use regular UNLEADED gasoline with the generator Review " Cold Weather Operation " on page 9 . engine . Do Not use premium gasoline . Do Not mix oil with gasoline . • Cut down corners at one end of carton from top to bottom and lay that side of carton down flat • Clean area around fuel fill cap , remove cap . • Remove all packing material , carton fillers , etc . • Add unleaded regular gasoline , slowly to fuel tank . Be careful not to overfill . Allow about I / 2 " of tank spacefor • Remove the generator from the shipping carton . fuel expansion ( Figure 2 ) . CARTON CONTENTS 1 / 2 " Air Space Tank 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 • Install fuel cap and wipe up any spilled gasoline . Spark plug wrench IMPORTANT : It is important to prevent gum deposits from forming inessentialfuel system parts , suchas the carburetor , BEFORE STARTING THE fuel filter , fuel hose or tank during storage . Also , experience indicatesthat alcohol - blended fuels ( calledgasohol , ethanol ENGINE or methanol ) canattract moisture , which leadsto separation andformation of acidsduring storage . Acidic gascan damage Add Oil the fuel system of an enginewhile in storage . To avoid engine problems , the fuel system should be CAUTION ! Any attempt to crank or start the engine emptied before storage of 30 daysor longer . See " Storage " before it hasbeen properly filled with the recommended on page I I . Never use engine or carburetor cleaner oil may result in an engine failure . products in the fuel tank or permanent damagemay occur . / 4
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GeneraPcortablPeroduct6s500XLExtendeLdifeGenerator 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 Air Cleaner 12Volt DC , 10Amp Receptacle Spark Arrester Muffler 120Volt AC , 20 Amp Idle Control Switch Grounding Wing Nut Duplex Receptacle 12Volt DC , 10Amp Receptacle - Recharge a Choke Lever - - Used when starting a cold engine . discharged 12Volt automotive type battery through this Circuit Breakers ( AC ) - - Eachreceptacle is provided receptacle . with a " push to reset " circuit breaker to protect the 120Volt AC , 20 Amp , Duplex Receptacle - - May be generator againstelectrical overload . usedto supply electrical power for the operation of FuelTank - - Capacity of seven ( 7 ) U . S . galtons . 120Volt AC , 20Amp , single phase , 60 Hz electrical lighting , GroundingWing Nut - - Used for proper grounding of appliance , toot and motor loads . unit . 120Volt AC , 30 Amp Locking Receptacle - May be Idle Control Switch - - With this switch set to ON , usedto supply electrical power for the operation of printed circuit board in control panel automatically reduces 120Volt AC , 30Amp , single phase , 60 Hz electrical lighting , engine speed when no load is connected and increases appliance , toot and motor loads . engine to proper speed when load is applied . However , be 120 / 240 Volt AC , 30 Amp Locking Receptacle - - May sure switch isOFF when starting engine . be usedto supply electrical power for the operation of Recoil starter - - Used to start the engine . 120and / or 240Volt AC , 30Amp , single phase , 60 Hz Run / Stop Switch - - Set this switch to " Run " before electrical lighting , appliance , tool and motor loads . using recoil starter . Set switch to " Stop " to switch OFF Air Cleaner - - Uses a dry type filter element and foam engine . pre - cleaner to limit the amount of dirt and dust sucked Spark Arrester Muffler - - Exhaust muffler lowers into the engine . engine noise and is equipped with a spark arrester screen . / 5
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GeneraPcortablPeroduct6s500XLExtendeLdifeGenerator OPERATING THE G EN ERATO R _ IIL CAUTION ! Never start or stop the engine Dwith electrical loadsconnectedto the receptaclesAN with the connected devices turned ON . Starting the Engine • Unplug all electrical loadsfrom generator receptacles • Grasp starter grip and pull slowly untilyou feel slight before starting the engine . resistance , then pull quickly . Oo Not let handle " snap - • Make sure the unit is in a levelposition . back " into recoil housing . • Open the fuel shut - off valve ( Figure 3 ) . • When engine starts , move choke leverto " Run " position by sliding it all the way to the right ( awayfrom 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 levelin crankcase . Unit is equipped with a low oil shutdown system . Seeengine owner's manual for information regarding the low oil shutdown system . • Make sure the Idle Control switch is " Off " . • Place Run / Stop switch in the " Run " position ( Figure 4 ) . 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 • Placethe choke leverin the " Full " choke position by the rated watts ( or amps ) of all loadsto be connected at sliding it to the left toward the valve cover in the one time . This total should not be greater than the rated direction indicated by the arrow ( Figure 5 ) . wattage / amperage capacity of the generator . See " Don't Overload the Generator " on page 10 . / 6
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GeneraPcortablPeroduct6s500XLExtendeLdifeGenerator To recharge 12Volt batteries , proceed as follows : Stopping the Engine • Check fluidlevel in atl battery cells . If necessary , add • Unplug all electrical loads from generator panel ONLY distilled water to cover separators in battery cells . receptacles . Never start or stop engine with electrical Do Not use tap water . devices plugged in and turned on . • If the battery isequipped with vent caps , make sure they • Put the idle control switch in the " Off " position . are installed and are tight . • Let engine run at no - load for 30 seconds to stabilize the • If necessary , clean battery terminals . internal temperatures of engine and generator . • Connect battery charge cable connector plug to panel • Move run / stop switch to " Stop . " receptacle identified by the words " 12 VOLTS D . C " • Close the fuel shut - off valve . • Connect battery charge cable clamp with red handle to the positive ( + ) battery terminal ( Figure 6 ) . Operating Automatic Idle Control This switch is designed to greatly improve fuel economy . When this switch is turned ON , the engine will only 12 VOLT D . C . run at its normal high governed engine speed when an RECEPTACLE electrical load is connected . When an electrical load is removed , the enginewill 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 _ ARNING ! Storage batteries give off explosive hydrogen gas while recharging . An explosive mixture ÷ will remain around the battery for a long time after POS NEG it has been charged . The slightest spark can ignite the hydrogen and causean explosion , resulting in blindness or other serious injury . 12VOLTBA ' I - rERY • Connect battery chargecable clamp with black handle _ WARNING ! Do Not permit smoking , uopennd flame , sparks or any other source of heat aro a to the negative ( - ) battery terminal ( Figure 6 ) . battery . Wear protective goggles , rubber apron and • Start engine . Let the engine run while battery recharges . rubber gloves when working around a battery . Battery electrolyte fluid isan extremely caustic • When battery has charged , shut down engine sulfuric acid solution that can cause severe burns . If NOTE : Use an automotive hydrometer to test battery spill occurs flush area with clear water immediately . state of charge and condition . Follow the hydrometer Your generator hasthe capability of recharging a discharged manufacturer's instructionscarefully . Generally , a battery is 12Volt automotive or utility style storage battery . Do Not considered to be at 100 % state of charge when specific use the unit to charge any 6Volt batteries . Do Not use the gravity of itsfluid ( as measured by hydrometer ) is 1.260or unit to crank an engine havinga discharged battery . higher . / 7
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GeneraPcortablPeroduct6s500XLExtendeLdifeGenerator COLD WEATH ER A CAUTION ! Never run unit indoors . Do Not enclose generator any more than shown . OPERATION RECEPTACLES 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 120 / 240 Volt AC , 30 Amp , Locking breather system . Receptacle In an emergency , use the original shipping box as a Use a N EMA LI4 - 30 plug with this receptacle . Connect a temporary shelter : 4 - wire cord set rated for 250Volt AC loads at 30 Amps ( or • Cut off all flaps . greater ) ( Figure 8 ) . You can use the same4 - wire cord if you ) lan to run a 120Volt load . • 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 . 4 - Wire Cord Set • Cut appropriate slots to accessreceptacles 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 sidesand the top of the generator : • Make sure entire muffler - side of generator is exposed . W ( Neutral ) Note that your generator mayappear different from that shown in Figure 7 . X ( Hot ) Y ( Hot ) Ground NEMA L14 - 30 ( 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 30Amp push - to - reset circuit breaker . A AUTION ! Although this outlet states it has a 240 Volt 30 Amp rating ( up to 7,200 watts ) , the generator is only rated for 6,500 watts . Powering loads that exceed the wattage / amperage capacity of the generator can damage it or causeserious • Ensure a minimum of two feet clearance between open injuries . 240 Volt loads powered through this outlet side of box and nearest object . should not exceed 27.1 Amps of current draw . • Face exposed end away from wind and elements . • Enclosure should hold enough heat created by the generator to prevent problems . / 8
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GeneraPcortablPeroduct6s500XLExtendeLdifeGenerator 120 Volt AC , 30 Amp Locking _ m IEo _ IIP + To'kv _ IHL + oT + , u , , • , m 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 Neutral Use each receptacle to operate 120Volt AC , single - phase , Hot _ _ _ _ 12ov 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 20Amps ( or greater ) . 12 Volt DC , I 0 Amp Receptacle , f _ _ / Ground This receptacle allows you to recharge a 12Volt NEMA L5 - 30 ( Green ) automotive or utility style storage battery with the battery Use this receptacle to operate 120VoltAC , 60 Hz , single charge cables provided ( Figure I I ) . This receptacle can not phase loads requiring up to 3,600 watts ( 3.6 kW ) of power recharge 6Volt batteries and can not be used to crank an at 30 Amps . The outlet is protected by a 30 Amp engine having a discharged battery . Seethe section push - to - reset circuit breaken " Charging a Battery " ( page7 ) before attempting to recharge a battery . 120 Volt AC , 20 Amp , Duplex _ lIB IIP & Vt _ IIIDZiO . . [ I [ _ _ Receptacle Eachreceptacle ( Figure 10 ) is protected againstoverload by a 20Amp push - to - reset circuit breaker . / 9
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GeneraPcortablPeroduct6s500XLExtendeLdifeGenerator The rated wattage of lights can be taken from wattage DON'T OVERLOAD TH E listed on the lightbulbs . The rated wattage of tools , G EN ERATO R appliancesand motors can usually be found on a data plate or decal affixed to the device . Use Figure 12below Overloading a generator in excess of its rated wattage as a general reference . capacity can result in damage to the generator and / or Some electric motors , such as inductiontypes , require connected electrical devices . Observe the following , to about three times more watts of power for starting than prevent overloading the unit : for running . This surge of power lasts for only a few • Add up the total wattage of all electrical devices to be seconds when starting such motors . Be sure you allow connected at one time . This total should NOT be greater for this high starting wattage when selecting electrical than the generator's wattage capacity . devices to connect to your generator . First figure the watts needed to start the largest motor . Add to that • If the appliance , tool or motor does not give wattage , figure the running watts of alt other connected loads . multiply 120Volts times ampere rating to determine watts ( volts x amps = watts ) . Recreational / Home Uses Professional / Contractor Uses Tool / Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watts Tool / Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Watts AM / FM clock radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . 0 " 1 / 3 hp airless sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 3 / 8 " hammer drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . 00 Light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 Variable speed Sawzall ® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 960 20 " color TV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . 00 _ / 2 " power drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 * Deep freezer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Quartz - halogen work light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 Belt sander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 Personal computer and 15 " monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 7 ¼ " circular saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 * 1 / 3 hp furnace fan blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 Microwave oven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 7 ¼ " worm drive saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600 * 18 cuft refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 * 1 / 2 hp air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800 Sump pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 * I 0 " power miter saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800 Electric skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 6 " bench grinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800 * Y2 hp water well pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 * 6 " table planer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800 * 12,000 Btu window air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 * I 0 " table / radial arm saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 Wire feed welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 Space heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800 Electric water heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . 000 * allow 3 times listed watts for starting this device I I0
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Generac Portable Products 6500XL Extended Life Generator To Clean the Generator SPECIFICATIONS Maximum SurgeWatts . . . . . . . . . . . . . . . . . 8,125 watts • Use a damp cloth to wipe exterior surfaces clean . Continuous Wattage Capacity . . . . . . . . . . . 6,500 watts • A soft bristle brush may be used to loosen caked on dirt Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 or oil . Rated Maximum Continuous AC Load Current : • A vacuum cleaner may be used to pick up loose dirt and debris . At 120Volts . . . . . . . . . . . . . . . . . . . . . . . 54.2 Amps At 240 Volts . . . . . . . . . . . . . . . . . . . . . . . 27 . I Amps • Low pressure air ( not to exceed 25 psi ) may be used to Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I - phase blow awaydirt . Inspect cooling air slots and opening on Rated Frequency . . . . . . . . . . . . . . . . . . . . . . . 60 Hertz generator . These openings must be kept clean and unobstructed . FuelTank Capacity . . . . . . . . . . . . . . . . . . . 7 U . S . gallons GENERAL MAINTENANCE STO RAG E RECOMMENDATIONS The generator should be started at least once every seven claysand allowed to run at least 30 minutes . If this cannot The Owner / Operator is responsible for making sure that be done and you must store the unit for more than 30 alt periodic maintenance tasks are completed on atimely days , use the following guidelines to prepare it for storage . basis ; that all discrepancies are corrected ; and that the unit is kept clean and properly stored . Never operate a Generator Storage damaged or defective generator . • Clean the generator as outlined in " To Clean the Generator " Engine Maintenance • Check that cooling air slots and openings on generator See engine owner's manual for instructions . are open and unobstructed . , _ cCoAnUtaTcItOwNit ! h usAevdomidoptoror loonilg . eUdseodr mreopteoarteodil shkains been shown to cause skin cancer in certain _ DANGER ! Storage covers can be flammable . Do Not place a storage cover over a hot generator . Let laboratory animals . Thoroughly wash exposed areas the unit cool for a sufficient time before placing the with soap and water . cover on the unit . KEEPOUT OF REACH OF CHILDREN . DON'T POLLUTE . CONSERVE RESOURCES . RETURN USED OIL TO COLLECTION CENTERS . Engine Storage Seeengine owner's manual for instructions . Generator Maintenance Other Storage Tips Generator maintenance consists of keeping the unit clean and dry . Operate and store the unit in a clean dry • Do Not store gasoline from one season to another . environment where it will not be exposed to excessive • Replace your gasoline can if it starts to rust . Rust andlor dust , dirt , moisture or any corrosive vapors . Cooling air dirt in a gasoline can cause problems when you use that slots in the generator must not become clogged with snow , fuel with this unit . leaves or any other foreign material . • Store in clean and dry area . 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 . I II
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Generac Portable Products 6500XL Extended Life Generator TROUBLESHOOTING Problem Cause Solution I . Reset circuit breaker . I . Circuit breaker is open . 2 . Poor connection or defective cord set . Engine is running , but 2 . Check and repair . 3 . Connected device is bad . no AC output is 3 . Connect another device that is in good available . condition . 4 . Fault in generator . 4 . Contact Generac service facility . I . Short circuit in a connected load . I . Disconnect shorted electricalload . 2 . Generator is overloaded . 2 . See " Don't Overload the Generator " Engine runs good but bogs clown when loads on page 10 . are connected . 3 . Enginespeed istoo slow . 3 . Contact Generac service facility . 4 . Shortedgenerator circuit . 4 . Contact Generac service facility . I . Set switch to " Run " . I . Run / Stop switch set to " Stop " . 2 . Dirty air cleaner . 2 . Clean or replace air cleaner . 3 . Fill fuel tank . 3 . Out of gasoline . 4 . Stalegasoline . 4 . Drain gas tank and fill with fresh fuel . 5 . Spark plug wire not connected to spark 5 . Connect wire to spark plug . plug . Engine will not start ; or 6 . Badspark plug . 6 . Replacespark plug . starts and runs rough . 7 . Waterin gasoline . 7 . Drain gastank ; fill with fresh fuel . 8 . Put choke leverto " No Choke " 8 . Overchoking . position . 9 . Low oil level . 9 . Fill crankcaseto proper level . 10 . Excessively rich fuel mixture . 10 . Contact Generac service facility . II . Intake valve stuck open or closed . I I . Contact Generac service facility . 12 . Engine has lost compression . 12 . Contact Generac service facility . I . Fill fuel tank . I . Out of gasoline . Engine shuts down 2 . Low oil level 2 . Fill crankcaseto proper level . during operation . 3 . Fault in engine . 3 . Contact Generac service facility . I . See " Don't Overload the Generator " I . Loadis too high . on page 10 . Engine lacks power . 2 . Dirty air filter . 2 . Replaceair filter . 3 . Engine needs to be serviced . 3 . Contact Generac service facility . I . Choke is opened too soon . I . Move choke to halfway position till Engine " hunts " or engine runs smoothly . falters . 2 . Carburetor is running too rich or too 2 . Contact Generac service facility . lean . / 12
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Generac Portable Products 6500XL Extended Life Generator NOTES / 13
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GeneraPcortablPeroduct6s500XLExtendeLdifeGenerator B I SCHEMATIC POWER REGULATOR BOARD POWER POWER 22 44 G A T E IDLE CONTROL S TRANSFORMER I G N A L . . . . . 155 156 22 44 I ) 30A \ LED EL _ LOP I BLU / WHT 22 ) I C B RED LOP IDLE ; WITCH SWITCH 18 30A C B ] 20V 20A ENG 44B _ D20 A ( _ lbNITIO BATTE _ CHARbE llA 44A _ _ C B 66 55 77 20A 13 55 C I _ ] IA AUTO / _ ) _ 55 _ t OA C B 30A / 14
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Generac Portable Products 6500XL Extended Life Generator m WIRING DIAGRAM o 12ov 20A 2C BRBKEH BFF L IDLE _ WITCH CELOUN / T _ HRTBL 11 44 _ 55 6 gHIELD _ GATE gIBNAL 4 _ EARING NUT BN ENGINE _ LBgK / 15
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Generac Portable Products 6500XL Extended Life Generator l / | 1 - @ 2 / ' i _ LvB EXPLODEDVIEW - MAIN UNIT 46 11 51 \ 6 \ 5O 25 \ \ 27 14 36 49 \ \ 55 \ 37 \ \ 55 21 \ 37 / 16
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Generac Portable Products 6500XL Extended Life Generator im | 1 - © 2 J _ _ i kliE PARTS LIST - MAIN UNIT Item PaX # Qty Description Item Part # Qty Description I A92432 CRADLE 39 83465 4 GROMMET , Tank 2 A92531 SUPPORT , Support 40 78831B 4 HHCS , M6 - 1.0x 60 , SEMS 3 A92731 SUPPORT , Engine & Muffler 41 80270 VALVE , Tank 4 92247 HOUSING , EngineAdapter 42 78299 BUSHING , PlasticTank 5 92679G ASSEMBLYR , otor 43 B4363 CAP , Fuel Gauge 6 92681G ASSEMBLYS , tator 44 B1695 TANK , Tank 7 - Gal 7 65791 BEARING 45 B92039 SHIELD , Heat 8 67451 WASHER , M8 Flat 46 92665 INSULATION # 2 - 1 / 4 " Thlck 9 22129 2 WASHER , M8 Lock 47 85000 CLIP , Insulation 10 86307 4 HHMS , 5 / 16 - 24 x 3 / 4 SEMS 48 14353621 WIRE , Ground I1 25254 I H HCS , 5 / 16 - 24 x 9 - 7 / 8 " 49 26850 2 WASHER , M6 Shakeproof 12 92609 2 MOUNT , Vibration 51 92982 I DECAL , Danger 13 82857 4 MOUNT , Vibration 52 92612 2 DECAL , Heat Shield 14 40976 2 SCREW , M8 - 1.25x 20 55 189160 12 NUT , 5 / 16 - 18 Serrated Flange 15 66476 2 CAPSCREW , M6 - 1.0x 12mm 57 92640 I DECAL , Control Panel 16 92532 I BRACKET , Muffler 58 92630 I ASSEMBLYC , ontrol Box 17 22142 2 SCREW , 5 / 16 - 18x 3 / 4 " 59 NSP I ENGINE 18 A7433 MUFFLER 60 22531 2 HHCS , 5 / I 6 - 18 x 1 - 3 / 4 " 19 90239 GASKET , Mumer 62 93826 I DECAL , Start Instructions 20 81917 PIN , 4 mm x 10Roll 63 B96068 I SHIELD , Heat 21 B4986 DECAL , Ground 64 56893 5 CRIMPTITE , 10 - 24x I / 2 " 22 83083 SCREEN , SparkArrester 25 66825C CARRIER , Rear Bearing Items Not Illustrated : 26 74908 4 TAPTITE , M5 - 0.8 x l0 65787 Battery Charge Cable 27 86308B 4 BOLT , M6 - I x i65 mm Stator B2635 Generator Owner's Manual 28 65795 I RECTIFIER , Battery Charge A8927 EngineOwner's Manual 29 66849A I TAPTITE , M5 - 0.8 x 20 37806 120Volt AC 30 Amp Locking 30 67022 I GROMMET , Rubber Plug 31 84132 I ASSEMBLYP , ower Regulator 43438 120 / 240VottAC 30Amp Locking 32 66386 I ASSEMBLYB , rush Holder Plug 33 66849 2 TAPTITE , M5 - 0.8 x 16 72347 Spark Plug 34 B4871 I COVER , Bearing Carrier 73111 Air Cteaner Element 35 22769 I WASHER , # 10 Int . Shakeproof 84882 Spark PlugWrench 36 86494 I SCREW , M6 - l . 0 x 16Wing 37 86292 7 HHCS , # 10 Self Driller Optional Accessories Not Included : 38 77395 4 NUT , M6 FlangeLock 84883 CordWrap / 17
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Generac Portable Products 6500XL Extended Life Generator l / | 1 - @ 2 / ' i _ LvB EXPLODED VIEW AND PARTS LIST - CONTROL PANEL 19 \ \ 20 21 19 \ x \ \ \ 8 10 10 1 6 11 22 6 8 16 / 2 9 5 Item PaX # Item PaX # Qty Description Qty Description I A92070 I PANEL , Control 14 43437 I OUTLET , 120V / 240V , 30A 2 23897 4 FLATWASHER , # 10 M5 Locking 3 49226 15 68759 4 LOCK WASHER , M5 I OUTLET , 120V , 20A Duplex 4 91526 16 43180 4 SCREW , M5 - 0.8 x 12mm 6 FLATWASHER , M4 5 82538 17 22264 I SWITCH , Idle Control 6 LOCK WASHER , # 8 M4 6 82881 18 51715 4 LOCK WASHER , 7 / 16 " 6 NUT , M4 - 0.7 Hex 7 43181 19 64526 4 SCREW , M3 - 0.5 x 10mm 8 SCREW , # 6 - 32 x 3 / 8 " 8 43182 20 83970 4 LOCK WASHER , M3 I BOARD , System Control 9 90418 21 64525 I OUTLET , 12V 4 STAND - OFF , 3 / 4 " Hex 10 75207A 2 CIRCUIT BREAKER , 30A 22 87962 I CIRCUIT BREAKER . 12V , 10A II 75207 23 84335 2 CIRCUIT BREAKER , 20A 1 ASSEMBLYW , ire Harness 12 23365 24 84134 1 GROMMET , Rubber Conn . 6 WASHER , # 8 Shakeproof 13 68868 25 B92069 I BOX , Control Panel 1 OUTLET , 120Volt , 30 Amp 26 84028 I TRANSFORMER , Idle Control Locking / 18
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Generac Portable Products 6500XL Extended Life Generator NOTES / 19
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LI M ITED WARRANTY FOR " GN " ENGINE DRIVEN PORTABLE GENERATORS GENERAC PORTABLEPRODUCTS ( 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 2 years ( 2nd year parts only ) I year Engine 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 improperor 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 HEREBYDISCLAIMSANYANDALL 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 SPECIFIEDIN THE EXPRESSWARRANTY . LIABILITY FOR CONSEQUENTIAL , INCIDENTAL OR SPECIAL DAMAGES UNDERANYAND ALLWARRANTIES IS EXCLUDED . THE COMPANY ALSO DISCLAIMS ANY RESPONSIBILITYFOR INCIDENTAL OR CONSEQUENTIAL DAMAGES , SUCH ASTHE LOSSOF TIME OR THE USEOETHE POWER EQUIPMENT , ORANY COMMERCIAL LOSSDUETOTHE 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 givesyou 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 PRODUCTS Jefferson , Wisconsin U , S , A ,
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