Generac Power Systems 6500XL User manual

Owner's Manual

Generator

Wheel kit

Storage Cover

Battery charge cables

Spare Spark Plug,Air Filter, and Oil Filter

Spark PlugWrench

(2) Locking30 Amp plugs

Engineoil

Owner's manual

Enginemanual

If any parts are missing or damaged, call 1-800-270-1408.

SafetyRules.................................... 2-3

Assembly...................................... 4-5

Know Your Generator ............................. 6

Operation .................................... 7-I I

Product Specifications............................. 12

Maintenance.................................... 12

Storage........................................ 12

Troubleshooting ................................. 13

Schematic...................................... 14

Wiring Diagram ................................. 15

Replacement Parts............................. 16-19

Warranty ................................. Last Page

Questions? Help is just a moment away!

Call:Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT

Web: www.generac-portables.com or www.briggsandstratton.com

_This isthe safety alert symbol. It isusedto alert you to potential personal injury hazards.

Obey all safety messagesthat follow this symbol to avoid possible injury or death.

EQUIPMENT

DESCRIPTION

This generator isan engine-driven, revolving field,

alternating current (AC) generator. It was designedto

supply electrical power for operating compatible electrical

lighting, appliances,tools and motor loads.

This manualcontains information for a generator that

operates 120 and/or 240Volt, single phase,60 Hz devices

that require up to 6,500 watts (6.5 kW) of power that pull

up to 54.2Amps 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 I I.

The generator's revolving field is driven at about 3,600 rpm

by a single-cylinder engine.

Every effort hasbeen madeto ensure that informationin

this manualisaccurate and current However, Generac

reservesthe right to change,alter or otherwise improvethe

product and this document at anytime without prior

notice.

_AUTION! Do Not tamper with engine

governed speed.High operating speeds are

dangerousand 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 speedsimposesa heavy load.When adequate

engine power isnot availableengine life may be

shortened.

The Emission Control System for this generator is

warranted for standards set by the Environmental

Protection Agency.For warranty informationrefer to the

engine owner's manual.

SAFETY RULES

This generator set was designed and manufactured for

specific applications. Do Not attempt to modify the unitor

use it for anyapplication it was not designedfor. If you have

anyquestions about your generator's application, askyour

dealer or consult the factory.

The manufacturer could not possibly anticipate every

circumstance that might involvea hazard.For that reason

warnings in the manualand warnings on tags or decals

affixed to the unit are not all-inclusive. If you intendto

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 unsafeor 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.

or other re

_ARNING! You must isolatethe generator

from the electric utility usingapproved transfer

equipment ifthis unit isused 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 the unit isproviding backup power, the

electric utility must be notified.

_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 generator produces avery powerful voltage that can

cause serious injuryor 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 injuryfrom 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 useworn, 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 gasolineon 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

gasolinevapors might reach an open flame,spark or pilot

light (ason a furnace, water heater,clothes dryer). FIRE

or an EXPLOSION may result.

• The unit requires an adequateflow of cooling air for its

continued proper operation. Never operate the unit

inside anyroom or enclosure where the free flow of

cooling air intoand out of the unit might be obstructed.

Allow at least2 feet of clearanceon all sidesof generator,

evenwhile 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 anyobject 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. 12AWG (American Wire

Gauge) stranded copper wire to the grounding wing nut

and to an earth-driven copper or brassgrounding rod

(electrode) provides adequateprotection againstelectrical

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 ifa ground fault condition exists in the generator or

in connected electrical devices.Proper grounding also helps

dissipatestatic electricity, which often builds up in

ungrounded devices.

Yourgeneratorrequiressomeassemblyandisreadyfor

useafterit hasbeenproperlyservicedwiththe

recommendedoilandfuel.

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 wilt 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 shippingcarton.

Review"Cold Weather Operation" on page9.

• Cut down corners at one end of carton from top to

bottom and laythat side of carton down flat.

• Removeall packing material, carton fillers, etc.

• Removethe generator from the shipping carton.

INSTALL WHEEL KIT

The wheel kit isdesignedto greatly improvethe portability

of your generator.

NOTE:Wheel kit isnot intendedfor over-the-road use.

You will need a socket wrench with I/2" or 13mm sockets

and a needle-nose plier to installthis kit.

Refer to Figure 2 and install the wheel kit as follows:

• Placethe generator on a hard flat surface.

• Standat the engine end of the generator and gently tilt

the generator forward, high enough to placewooden

blocks beneath the cradle.This will allow you to add the

wheels.

• Slidethe axle through the holes in the brackets provided

on the generator cradle.

• Slideone wheel and flat washer on eachend of the axle.

Make sure the air inflation valve isoutward. Insert both

retaining pins usingthe needle-nose plier.Removethe

wooden blocks.

• Attach the vibration mounts to the support leg with

30mm capscrews,washers and lock nuts.

Axle Wheel

Lock Washer

_20mm

Capscrew

Lock Nut Retaining Pin

Capscrew

• Withthewheelson,youcannowllftupthehandleend

andattachthesupportlegwith20mmcapscrewsand

locknuts.

• Checkeachfastenertoensureitissecureandthetires

areinflatedbetween15-40PSL

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.

To fill your engine with oil:

• Placegenerator on a levelsurface.

•Followthe oilgrade recommendations andoil fill

instructionsgiven inthe engine owner's manual.

NOTE: The generator's revolving field rides on a

prelubricated and sealedball bearing that requires no

additional lubricationfor the life of the bearing.

Add Gasoline

_ARNING! Never fill fuel tank indoors. Never

fill fuel tank when engine is running or hot_Allow

unit to cool for two minutes before refueling. Do

Not light acigarette 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.

• Slowly add unleaded regular gasoline to fuel tank. Be

careful not to overfill.Allow about I/2" of tank space for

fuel expansion (Figure 3).

1/2" Air Tank

• 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 asthe

carburetor, fuel filter, fuel hose or tank during storage.Also,

experience indicates that alcohol-blended fuels (called

gasohol, ethanol or methanol) can attract moisture, which

leads to separation and formation of acids during storage.

Acidic fuel 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 12. Never use engine or carburetor cleaner

products in the fuel tank or permanent damage may 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.

Oit FillCap

Circuit Breakers (AC)__,,_

120Volt AC, 30 A

Receptacle

FuelTank

Choke Lever

Run/Stop Switch

120/240Volt AC,

30 Amp Receptacle

12Volt DC, 10Amp

Receptacle

Air Cleaner

SparkArrester Muffler

Idle Control Switch GroundingWing Nut

12Volt DC, I0 Amp Receptacle -- Rechargea

discharged 12Volt automotive type battery through this

receptacle.

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

usedto supply electrical power for the operation of

120Volt AC, 20Amp, single phase,60 Hz electrical lighting,

appliance,toot and motor loads.

120Volt AC, 30 Amp Locking Receptacle -- May be

usedto 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 usedto supply electrical power for the operation of

120and/or 240Volt AC, 30Amp, single phase,60 Hz

electrical lighting,appliance,tool and motor loads.

Air Cleaner -- Usesa 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.

120Volt AC, 20 Amp

Duplex Receptacle

Circuit Breakers (AC) -- Eachreceptacle isprovided

with a "push to reset" circuit breaker to protect the

generator againstelectrical overload.

Fuel Tank -- Capacity of seven (7) U.S.gallons.

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 speedwhen no toadisconnected and increases

engine to proper speedwhen loadisapplied.However, be

sure switch isOFF when starting engine.

Oil Fill Cap --Add oit to engine here.

Recoil starter -- Used to start the engine.

Run/Stop Switch -- Setthis switch to "Run" before

using recoil starter. Set switch to "Stop" to switch OFF

engine.

Spark Arrester Muffler- Exhaust muffler lowers

engine noise and isequipped with a spark arrester screen.

OPERATING THE

GENERATOR

4. Placethe choke lever in the "Full" choke position

(Figure7).

_CAUTION! Never start or stop unitwithelectrical loadsconnected AND with the connected

devicesturned ON.

Starting the Engine

Disconnect all electrical loadsfrom the generator. Follow

these start instructionsteps in numerical order:

I. Turn the fuel valveto the "On" position (Figure 4).

2. Make sure the IdleControl switch isin "Off' position

(Figure 5).

IDLE

3. Set the Run/Stop switch to "Run" position (Figure 6).

5. Grasp the recoil handle and pull slowly until slight

resistance is felt.Then pull rapidly one time only to

start engine.

• If engine starts,proceed to step7.

•Ifengine fails to start, proceed to step 6.

6. Move the choke lever to "Half" choke position, and

pull recoil handle twice.

• If enginefails to start, repeat steps 4 thru 6.

7. Move choke lever to "Run" position. If engine falters,

move choke lever to "Half" chokeposition until the

engine runs smoothly and then to "Run" position.

NOTE: If engine still fails to start after 3 pulls,check for

proper oil level in crankcase.This unit isequipped with a

Low Oil Shutdown System.Seeengine manual.

Refer to the engine owner's manual for complete

starting instructions.

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,

singlephase,60 Hz electrical loads.

•Do Not connect 240Volt loadsto the 120Volt

receptacles.

•Do Not connect 3-phase loadsto the generator.

•Do Not connect 50 Hz loads to the generator.

•DO NOT OVERLOADTHE GENERATOR. See

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

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 secondsto stabilize the

internaltemperatures of engine and alternator.

• Move run/stop switch to "Stop".

• Close the fuel shut-off valve.

Operating Automatic Idle Control

This switch isdesignedto 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 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 gaswhile recharging.An explosive mixture

will remain around the battery for a long time after

it hasbeen charged.The slightest spark canignite

the hydrogen and causean explosion, resulting in

blindness or other serious injury.

_hl WARNING! Do Not permit smoking,open

flame,sparks or any other source of heat around a

battery.Wear protective goggles,rubber apron and

rubber gloves when working around a battery.

Battery electrolyte fluid isan extremely caustic

sulfuric acid solution that cancause 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

usethe unit to charge any6Volt batteries. Do Not use the

unit to crank an engine havinga discharged battery.

To recharge 12Volt batteries, proceed as follows:

• Check fluidlevel in all 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 installedand are tight.

• If necessary,clean battery terminals.

• Connect battery charge cable connector plug to panel

receptacle identifiedby the words "12-VOLTS D.C".

• Connect battery charge cable clamp with red handle to

the positive (+) battery terminal (Figure8).

12 VOLT D.C.

RECEPTACLE

POS NEG

12 VOLT BA'rrERY

• Connect battery chargecable clamp with black handle

to the negative (-) battery terminal (Figure8).

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

• When battery hascharged,shut down engine

NOTE: Use an automotive hydrometer to test battery

state of charge and condition. Follow the hydrometer

manufacturer's instructions carefully.Generally,a battery is

considered to be at 100%state of charge when specific

gravity of its fluid (asmeasured by hydrometer) is 1.260or

higher.

I:|

COLD WEATH ER

OPERATION

Under certain weather conditions (temperaturesbelow

40°F [4°C] and a high dew point),your generator may

experience icingof the carburetor and/or the crankcase

breather system.

In an emergency,usethe original shipping box asa

temporary shelter:

•Cut off all flaps.

• Cut out one of the longsides of the box to expose

exhaust sideof unit.Ensurea minimum of two feet

clearance between open side of box and nearest object.

• Cut appropriate slots to accessreceptaclesof unit.

• Start unit, then place box over it.

IMPORTANT: Removeshelter 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 9.

Wind

• 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.

ACAUTION! Never run unit indoors.Do Not

enclose generator any more than shown.

RECEPTACLES

120 Volt AC, 20 Amp, Duplex

Receptacle

Eachreceptacle (Figure 10) is protected againstoverload

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 20Amps (or greater).

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 250VoltAC loads at 30 Amps

(or greater) (FigureI I).You can usethe same 4-wire cord

you plan to run a 120Volt load. pa_ Ip,(o]kv_aF.'T o, . . -" ._ m

_l_ Ill IlP,Tolp,11loltllHr:T_r_l

4-Wire Cord Set

(Neutral)

Y(Hot) | X (Hot)

NEMA L14-30 /_7 Ground(Green)

This receptacle powers 120/240Volt AC, 60 Hz,single

phaseloadsrequiring up to 3,600watts of power at

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

30 Amps for 240Volts.The outlet isprotected by a 30 Amp

push-to-reset circuit breaker.

_AUTION!Although this outlet israted for

120/240Volt 30Amp (up to 7,200 watts), the

generator isonly rated for 6,500 watts. Powering

loads that exceed the wattage/amperagecapacity of

the generator can damageit or causeserious

injuries. 240 Volt loadspowered 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 125Volts AC at 30 Amps to the

plug (Figure 12).

3-Wire Cord Set

iNEMA L5-30

Neutral

120V

Hot

Ground (Green)

Usethis receptacle to operate 120VoltAC, 60 Hz, single

phaseloads requiring up to 3,600 watts (3.6 kW) of power

at 30Amps.The outlet isprotected by a 30Amp

push-to-reset circuit breaker.

12 Volt DC, I 0 Amp Receptacle

This connector (identified by the legend"I2-VOLT D.C")

supplies 12Volts DC at I0Amps through battery charging

cablesfor recharging 12Volt batteries (Figure 13).See

"Charging a Battery" on page 8.

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