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Portable Products
Portable Generator Owner’s Manual
Mode! No. 09779-2 (6,500 Watt AC Generator) Manual No. B2635 Revision 2 (05/23/2001)
Visit our Generac website: www.generac~portables.com
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
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Obey all safety messages that follov^ this symbol to avoid possible injury or death.
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Generac Portable Products 6500XL Extended Life Generator
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 ioads.This manual
contains information for 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 puli up
to 54.2 Amps at 120 Volts or 27.1 Amps at 240 Volts.
CAUTION! Do Not exceed the generator’s
wattage/amperage capacity. Add up the rated watts of aii
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 information in
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 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 m^ual carefully and become familiar
with your generator set- Know its applications, its
limitations and any hazards involved.
WARNING:
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
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CAUTION! Do Not tamper with engine
governed speed. High operating speeds are
dangerous and increase risk of personal injury or
damage to equipmentThe 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.When adequate
engine power is not available engine life may be
shortened.
DANGER! You must isolate the generator from
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The Emission Control System for this generator is
warranted for standards set by the Environmental
engine owner’s manual.
the electric utility using approved transfer
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 cont^n
DEADLY carbon monoxide gas. If breathed in
sufficient concentrations, carbon monoxide
can cause unconsciousness or death. Operate
this equipment outdoors where adequate ventilation
is available.
Protection Agency. For warranty information refer to the
Page 3
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 damage from electrical shock may result
Gasoline is highly FLAMMABLE and its vapors
EXPLOSIVE. Never allow smoking, open flames,
sparks or heat in the vicinity while h^dling
gasoline. Avoid spilling gasoline on a hot engine. Comply
with all laws regulating 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 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 least 2 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 ail electrical
loads before shutting down the generator.
Do Not insert any object through cooling slots of the
engine.You could damage the 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 ER/VTOR
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).
- Grounding Wing Nut
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, local 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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Generac Portable Products 6500XL Extended Life Generator
Your generator requires some assembly and is ready for
use after it has been properly serviced with the
recommended oil and fuel.
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 generator
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.
Qj^f^YON CONTENTS
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
WARNING! Never fill fuel tank indoors. Never
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fill fuel tank when engine is running or hot. Do Not
light a cigarette or smoke when filling the fuel tank.
WARNING! Do Not overfill the fuel tank.
Always allow room for fuel expansion.
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 1/2" of tank space for
fuel expansion (Figure 2).
Figure 2 —Typical Fuel Expansion Space
Check all contents. If any parts are missing or damaged, call
the generator helpline at I -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 has been properly filled with the recommended
oil may result in an engine failure.
_________________________________
• Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits from
forming in essential fuel system parts, such as the carburetor,
fuel filter, fuel hose or tank during storage. Also, experience
indicates that alcohol-blended fuels (called g^ohol, ethanol
or methanol) can attract moisture, which leads to separation
and formation of acids during storage. Acidic gas can damage
the fuel system of an engine while in storage.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See “Storage”
on page 11. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
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Generac Portable Products 6500XL Extended Life Generator
Know Your
m
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.
Circuit Breakers (AC)
120 Volt AC, 30 Amp
Receptacle
120/240 Voi
30 Amp Receptac
12 Volt DC
Receptacle
Idle Control Switch
Grounding Wing Nut
Fuel Tank
Choke Lever
Run/Stop Switch
Recoil Starter
Air Cleaner
Spark Arrester Muffler
120 Volt AC. 20 Amp
Duplex Receptacle
12 Volt DC, 10 Amp Receptacle — Recharge a
discharged 12 Volt automotive type battery through this
receptacle.
120 Volt AC, 20 Amp, Duplex Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting,
appliance, too! and motor loads.
120 Volt AC, 30 Amp Locking Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting,
appliance, tool 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) — Each receptacle is provided
with a "push to reset" circuit breaker to protect the
generator against electrical overload.
Fuel Tank — Capacity of seven (7) U.S. gallons.
Grounding Wing 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 is OFF 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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Generac Portable Products 6500XL Extended Life Generator
OPERATING THE
CAUTION! Never start or stop the engine with
A
Starting the Engine
electrical loads connected to the receptacles AND
with the connected devices turned ON.
Unplug all electrical loads from generator receptacles
before starting the engine.
Make sure the unit is in a level position.
Open the fuel shut-off valve (Figure 3).
Figure 3 — Fuel Shut-offValve
Figure 5 — Choke Lever
resistance, then pull quickly. Do Not let handle “snapback” 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 manual. Also, 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.
Place Run/Stop switch in the “Run” position (Figure 4).
Figure 4 — Run/Stop Switch
Place the 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).
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 Volt AC,
single phase, 60 Hz electrical 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 OVERLOADTHE GENERATOR. Add up
the rated watts (or amps) of all loads to 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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Generac Portable Products 6500XL Extended Life Generator
Stopping the Engine
• Unplug all electrical bads 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 norma! 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
WARNING! Storage batteries give off explosive
hydrogen gas while recharging. An explosive mixture
A
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.
To recharge 12 Volt batteries, proceed as follows:
• Check fluid level in all battery cells. If necessary, add
ONLY distilled water to cover separators in battery cells.
Do Not use tap water.
• If the battery is equipped with vent caps, make sure they
are installed and are tight.
• If necessary, clean battery 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).
Figure 6 — Battery Connections
WARNING! Do Not permit smoking, open
flame, sparks or any other source of heat around a
battery.Wear protective goggles, rubber apron and
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rubber gloves when working around a battery.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe burns. If
spill occurs flush area with clear water immediately.
Your generator has the capability of recharging a discharged
12 Volt automotive or utility style storage battery. Do Not
use the unit to charge any 6 Volt batteries. Do Not use the
unit to crank an engine having a discharged battery.
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
manufecturer’s instructions carefully. Generally, a battery is
considered to be at 100% state of charge when specific
gravity of its fluid (as measured by hydrometer) is 1.260 or
higher.
Page 8
Generac Portable Products 6500XL Extended Life Generator
COLD WEATHER
OPERATION
Under certain weather conditions {temperatures below
40°F [4°C] and a high dew point), your generator may
experience icing of 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.
Figure 7 —Temporary Cold Weather Shelter
CAUTION! Never run unit indoors. Do Not
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enclose generator any more than shown.
120/240 Volt AC, 30 Amp, Locking
Receptacle
Use a NEMA 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
plan to run a 120 Volt load.
Figure 8 — 120/240 Volt AC, 30 Amp, Locking Receptacle
___________________________
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.
This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring 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 is protected by a 30 Amp
push-to-reset circuit breaker.
CAUTION! Although this outlet states it has a
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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 cause serious
injuries. 240 Volt loads powered through this outlet
should not exceed 27.1 Amps of current draw.
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Generac Portable Products 6500XL Extended Life Generator
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L5—30 plug with this receptacle. Connect a
3-wire cord set rated for 125 Volt AC loads at 30 Amps to
the plug {Figure 9).
Figure 9 — 120 Volt AC, 30 Amp, Locking Receptacle
Use this receptacle to operate l20Volt AC, 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 breaker.
___________________________
120 Volt AC, 20 Amp, Duplex
Receptacle
Each receptacle (Figure 10) is protected against overload by
a 20 Amp push—to-reset circuit breaker.
___________________________
Figure 10— l20Volt AC, 20 Amp, Duplex Receptacle
Use each receptacle to operate 120Volt AC, single-phase,
60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)
at 20 Amps of current. Use cord sets that are rated for
125 Volt AC loads at 20 Amps (or greater).
12 Volt DC, 10 Amp Receptacle_____________
This receptacle allows you to recharge a 12 Volt
automotive or utility style storage battery with the battery
charge cables provided (Figure I l).This receptacle can not
recharge 6 Volt 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.
12 Volt DC, 10 Amp Receptacle
Page 10
Generac Portable Products 6500XL Extended Life Generator
DON’T OVERLOAD THE
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 120 Volts times ampere rating to determine
watts (volts X amps = watts).
-Wattage Reference Guide
Recreational/Home Uses
TOOl/^X|)pliariCee**eee**ee**ee**ee**ee***ee**ee**ee**ee***ee**ee**eeAA^attS
AM/FM clock radio.................................................................50
Light bulb.............................................................................100
Fan.......................................................................................200
20" color TV
*Deep freezer.......................................................................500
Personal computer and 15" monitor
*1/3 hp furnace fen blower...................................................800
Microwave oven...................................................................800
*18 cu ft refrigerator.............................................................800
Sump pump........................................................................1000
Electric skillet.....................................................................1250
*14 hp water well pump
*12,000 Btu window air conditioner
Space heater
Electric water heater..........................................................4000
.........................................................................
....................................
.....................................................
...................................
.....................................................................
1400
1400
1800
400
800
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 induction types, 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 all other connected loads.
Professional/Contractor Uses
Tool/AppI ian ce..............................
*1/3 hp airless sprayer
3/8" hammer drill
Variable speed Sawzall®...
14" power drill
Quartz-halogen work light
Belt Sander.
1 'A" circular saw
7 14" worm drive saw
*1/4 hp air compressor....
*10" power miter saw.
6" bench grinder.
*6" table planer.
*10" table/radial arm saw
Wire feed welder............................................................
* allow 3 times listed watts for starting this device
.Watts
600
600
960
1000
1000
1200
1500
1600
....
1800
1800
1800
1800
2000
....
2400
10
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Generac Portable Products 6500XL Extended Life Generator
SPECIFICATIONS
Maximum Surge Watts
Continuous Wattage Capacity
Power Factor .....................................................................1.0
Rated Maximum Continuous AC Load Current:
At 120 Volts
At 240 Volts
Phase........................................................................I-phase
Rated Frequency .....................................................60 Hertz
Fuel Tank Capacity..........................................7 U.S. gallons
...................................................
........................................
.....................................................
.....................................................
8,125 watts
6,500 watts
54.2 Amps
27.1 Amps
CENEPAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on a timely
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. Never operate a
damaged or defective generator.
Engine Maintenance
See engine owner’s manual for instructions.
CAUTION! Avoid prolonged or repeated skin
contact with used motor oil. Used motor oil has
been shown to cause skin cancer in certain
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laboratory animals. Thoroughly wash exposed areas
with soap and water.
KEEP OUT 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 dean 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 dogged 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.
______________________
To Clean the Generator
• Use a damp doth 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.
STORAGE
The generator should be started at least once every seven
days and allowed to run at least 30 minutes. If this cannot
be done and you must store the unit for more than 30
days, use the following guidelines to prepare it for storage.
Generator Storage
Clean the generator as outlined in "To Clean the
Generator.”
Check that cooling air slots and openings on generator
are open and unobstructed.
DANGER! Storage covers can be flammable. Do
A
See engine owner’s manual for instructions.
Other Storage Tips
Not place a storage cover over a hot generator. Let
the unit cool for a sufficient time before placing the
cover on the unit.
Engine Storage
Do Not store gasoline from one season to another.
Replace your gasoline can if it starts to rust. Rust and/or
dirt in a gasoline can cause problems when you use that
fuel with this unit.
Store in clean and dry area.
Page 12
Generac Portable Products 6500XL Extended Life Generator
TROUBLESHOOTING
Problem
Engine is running, but
no AC output is
available.
Engine runs good but
bogs down when loads
are connected.
Engine will not start; or
starts and runs rough.
Engine shuts down
during operation.
Engine lacks power.
Engine “hunts” or
falters.
Cause
!. Circuit breaker is open.
2. Poor connection or defective cord set.
3. Connected device is bad.
4. Fault in generator.
!. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Run/Stop switch set to “Stop”.
2. Dirty air cleaner.
3. Out of gasoline.
4. Stale gasoline.
5. Spark plug wire not connected to spark
plug.
6. Bad spark plug,
7. Water in gasoline.
8. Overchoking.
9. Low oil level.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. Choke is opened too soon.
2. Carburetor is running too rich or too
lean.
Solution
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in good
condition.
4. Contact Generac service facility.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator”
on page 10.
3. Contact Generac service facility.
4. Contact Generac service facility.
1. 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. Replace spark plug.
7. Drain gas tank; fill with fresh fuel.
8. Put choke lever to “No Choke”
position.
9. Fill crankcase to proper level.
10. Contact Generac service facility.
11. Contact Generac service facility.
12. Contact Generac service facility.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Generac service facility.
1. See “Don’t Overload the Generator”
on page 10.
2. Replace air filter.
3. Contact Generac service facility.
1. Move choke to halfway position till
engine runs smoothly.
2. Contact Generac service facility.
Page 13
NOTES
Generac Portable Products 6500XL Extended Life Generator
Page 14
SCHEMATIC
Generac Portable Products 6500XL Extended Life Generator
14
Page 15
Generac Portable Products 6500XL Extended Life Generator
WIRING DIAGRAM
Page 16
Generac Portable Products 6500XL Extended Life Generator
EXPLODED VIEW - MAIN UNIT
40
Page 17
Generac Portable Products 6500XL Extended Life Generator
PARTS LIST - MAIN UNIT
Item
Part # Qty
1 A92432 ! CRADLE
2
A92531
3 A92731
4 92247 1
5 92679G
6 9268IG
7 65791 1
8 67451
9 22129 2 WASHER, M8 Lock
10 86307 4
11 25254 !
12 92609 2 MOUNTVibration
82857 4 MOUNTVibration 52 92612 2
13
14
40976
15 66476
92532 !
16
17 22142 2 SCREW, 5/16 - 18 x 3/4"
18 A7433
19 90239 i
81917 1
20
21
B4986
22
83083
25 66825C
26 74908
27 86308B 4
28 65795
29 66849A i
30 67022 1 GROMMET, Rubber
84132 1
31
32
66386
66849 2
33
34 B487I 1 COVER, Bearing Carrier
22769 !
35
86494 1
36
37 86292
38 77395
Description
1
SUPPORT, Support ..............................
1
SUPPORT Engine & Muffler
HOUSING, Engine Adapter
! ASSEMBLY, Rotor
i ASSEMBLY, Stator
BEARING
1
WASHER, M8 Flat
HHMS, 5/16 - 24 X 3/4 SEMS
HHCS, 5/16-24x9-7/8"
2
SCREW, M8 - 1.25 x 20
2 CAPSCREW, M6 - 1.0 x 12mm
BRACKET Muffler
! MUFFLER
GASKET, Muffler
PIN, 4 mm x 10 Roll
1 DECAL, Ground
i SCREEN, Spark Arrester
! CARRIER, Rear Bearing
4
TAPTITE, M5-0.8 x 10
BOLT, M6 -1 x 165 mm Stator
1 RECTIFIER, Battery Charge A8927
TAPTITE, M5-0.8 X 20
ASSEMBLY Power Regulator
1
ASSEMBLY Brush Holder
TAPTITE, M5 - 0.8 X 16
WASHER, #10 Int. Shakeproof
SCREW, M6 -1.0 X 16 Wing
HHCS, #10 Self Driller
7
4
NUT M6 Flange Lock 84883 Cord Wrap
.............
Item Part # Qty
39 83465
40 7883IB 4
41 80270
42 78299 1 BUSHING, Plastic Tank
43 B4363
44 BI695
45 B92039 1 SHIELD, Heat
46 92665
47 85000
48 14353621 1 WIRE, Ground
49 26850
51 92982
55 189160
57 92640
58 92630
59 NSP
60 22531
62 93826
63 B96068
64 56893
Items Not Illustrated;
65787
.....
B2635
37806
43438
72347 Spark Plug
731II
84882
Optional Accessories Not Included;
Description
4 GROMMETTank
HHCS, M6-I.0x60, SEMS
1 VALVE,Tank
1
CAP, Fuel Gauge
1 TANK,Tank 7- Gal
1 INSULATION #2-1/4" Thick
1 CLIP, Insulation
2
WASHER, M6 Shakeproof
1 DECAL, Danger
DECAL, Heat Shield
12
NUT, 5/16-18 Serrated Flange
1
DECAL, Control Panel
1
ASSEMBLY, Control Box
1 ENGINE
2 HHCS, 5/16-18 X 1-3/4"
1
DECAL, Start Instructions
1
SHIELD, Heat
CRIMPTITE, 10-24 X 1/2"
5
Battery Charge Cable
Generator Owner's Manual
Engine Owner’s Manual
120 Volt AC 30 Amp Locking
Plug
120/240 Volt AC 30 Amp Locking
Plug ...............................................
Air Cleaner Element
Spark Plug Wrench
.........................
Page 18
Generac Portable Products 6500XL Extended Life Generator
E)CPL0DED VIEW AND PARTS LIST ™ CONTROL PANEL
25
Item
Part # Qty
1 A92070 !
2 23897 4
3 49226
4
91526
5 82538
6 82881
7
43181
43182 4 LOCK WASHER. M3
8
9
90418
75207A 2 CIRCUIT BREAKER, 30A 22 87962 I CIRCUIT BREAKER. 12V, lOA
10
11 75207 2 CIRCUIT BREAKER, 20A
12
23365 6 WASHER, #8 Shakeproof
13 68868
Description Item
PANEL, Control
FLAT WASHER. #!0 M5
4 LOCK WASHER. M5
4 SCREW. M5-0.8 X 12mm
!
SWITCH. Idle Control
4
LOCK WASHER. 7/16"
4
SCREW. M3 - 0.5 X lOmm
1 OUTLET. 12V 21
1
OUTLET. 120 Volt, 30 Amp 25
Locking
Part # Qty
43437 i OUTLET. I20V/240V.30A
14
68759 1 OUTLET, I20V.20A Duplex
15
16 43180 6
17 22264
18 51715 6
19
64526 8
20 83970
64525
23 84335
24 84134 1 GROMMET. Rubber Conn.
B92069 1
26 84028
Description
Locking
FLAT WASHER. M4
6 LOCK WASHER. #8 M4
NUT, M4-0.7 Hex
SCREW, #6-32 x 3/8"
i
BOARD, System Control
4 STAND-OFF, 3/4" Hex
1
ASSEMBLY.Wire Harness
BOX, Control Panel
I
TRANSFORMER, Idle Control
Page 19
NOTES
Generac Portable Products 6500XL Extended Life Generator
Page 20
LIMITED 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 pane! 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, ali 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, including return 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 installation or 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 IS NO OTHER EXPRESS WARRANTY.THE COMPANY HEREBY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND
FITNESS FORA PARTICULAR PURPOSETOTHE EXTENT PERMITTED BY LAW.THE DURATION OF
ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO THETIME PERIOD AS
SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL
DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS ANY
RESPONSIBILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. SUCH AS THE LOSS OF TIME OR
THE USE OFTHE POWER EQUIPMENT, OR ANY COMMERCIAL LOSS DUETOTHE FAILURE OFTHE
EQUIPMENT: AND ANY IMPLIED WARRANTIES ARE LIMITEDTOTHE DURATION OFTHIS WRITTEN
WARRANTY.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or
consequential damages, so the above limitations or 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 I-877-544-0982. Warranty service can
be performed only by a COMPANY authorized service fecility.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.
€j HEISi HEFt yVC? |i3 (3 113 L E cn cn i.. i fjss
jefferson.Wisconsin U.S.A.
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