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
J
• 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.
iI
iI
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
i
f
(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.

DON'T OVERLOAD YOU R
GENERATOR
Capacity
You must make sure your generator cansupply enough
rated (running) and surge (starting) watts for the itemsyou
wilt power at the same time. Follow these simple steps:
I. Select the items you will power at the same time.
2. Total the rated (running) watts of these items.Thisis
the amount of power your generator must produce to
keep your items running.SeeFigure 14.
3. Estimate how many surge (starting) watts you will
need.Surge wattage isthe short burst of power
needed to start electric motor*driven tools or
appliancessuch asa circular saw or refrigerator.
Becausenot all motors start at the same time, total
surge watts can be estimated by adding only the
item(s) with the highest additional surge watts to the
total rated watts from step 2.
Example:
Tool or Appliance
Window Air
Conditioner
Refrigerator
Deep Freezer
Television
Light (75 Watts)
Rated (Running)
Watts
1200
800
50O
50O
75
3075 Total
Running Watts
Total Rated (Running)Watts = 3075
Highest Additional SurgeWatts = 1800
Total Generator Output Required = 4875
Additional Surge
(Starting)Watts
1800
1600
500
1800 Highest
SurgeWatts
Power Management
To prolong the life of your generator and attached devices,
it isimportantto take care when addingelectrical loads to
your generator.There should be nothing connected to the
generator outlets before starting it'sengine.The correct
and safeway to managegenerator power isto sequentially
add loads asfollows:
I. With nothingconnected to the generator, start the
engine asdescribed in this manual.
2. Plugin and turn on the first load,preferably the largest
load you have.
3. Permit the generator output to stabilize (engine runs
smoothly and attached device operates properly.
4. Plug in and turn on the next load.
5. Again,permit the generator to stabilize.
6. Repeat steps 4 and 5 for each additional load.
Never add more loadsthan the generator capacity.Take
specialcare to consider surgeloads ingenerator capacity,
asdescribed above.
Tool or Appliance
Essentials
LightBulb - 75 watt
Deep Freezer
SumpPump
Refrigerator/Freezer - 18Cu. Ft.
Water Well Pump- I/3 HP
Heating/Cooling
Window AC - 10,000BTU
Window Fan
FurnaceFanBlower - I/2 HP
Kitchen
Microwave Oven - 1000Watt
Coffee Maker
Electric Stove - SingleElement
Hot Plate
Family Room
DVD/CD Player
VCR
Stereo Receiver
Color Television - 27"
Personal Computer w/I 7" monitor
Other
Security System
AM/FM Clock Radio
GarageDoor Opener - I/2 HP
Electric Water Heater - 40 Gallon
DIY/Job Site
Quartz Halogen Work Light
Airless Sprayer - I/3 HP
Reciprocating Saw
Electric Drill - I/2 HP
Circular Saw- 7 I/4"
Miter Saw- I0"
Planer/Jointer - 6"
Table Saw/RadialArm Saw- I0"
Air Compressor - I-I/2 HP
Rated*
(Running)
Watts
75
500
8O0
8O0
1000
12O0
3OO
8O0
1000
1500
1500
25O0
Additional
Surge
(Starting)
Watts
5O0
1200
1600
20O0
1800
6O0
1300
I00
I00
450
50o
80o
18o
30o
480 520
40O0
1000
600 1200
960 960
1000 1000
1500 1500
1800 1800
1800 1800
2000 2000
2500 2500
*Wattages listed are approximate only. Check toot or
appliance for actual wattage.
II •

SPECIFICATIONS
Maximum SurgeWatts ................ 10,500watts
Continuous Wattage Capacity ........... 6,500 watts
Power Factor .............................. 1.0
Rated Maximum Continuous AC Load Current:
At 120Volts ....................... 54.2Amps
At 240 Volts ....................... 27.I Amps
Phase................................. I-phase
Rated Frequency ....................... 60 Hertz
FuelTank Capacity................... 7 U.S.gallons
ShippingWeight ......................... 200 Ibs.
GENERAL 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
Seeengine owner's manualfor instructions.
_AUTION! Avoid prolonged or repeated skin
contact with used motor oil. Used motor oil has
been shown to cause skin cancer in certain
laboratory animals.Thoroughly wash exposed areas
with soapand water.
KEEPOUT OF REACH OF CHILDREN. DON'T
POLLUTE.CONSERVERESOURCES.RETURN
USED OILTO COLLECTION CENTERS.
Generator Maintenance
Generator maintenanceconsists of keeping the unit clean
and dry. Operate and store the unit in a clean dry
environment where it will not be exposed to excessive
dust, dirt, moisture or anycorrosive vapors.Cooling air
slots in the generator must not become clogged with
snow, leavesor anyother foreign material.
NOTE: Do Not usea garden hose to cleangenerator.
Water canenter 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 cloth to wipe exterior surfaces clean.
• A soft bristle brush may be used to loosen caked on dirt
or oil.
• A vacuum cleaner may be used to pick up loose dirt and
debris.
• Low pressure air (not to exceed 25 psi) may be used to
blow awaydirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.
STO RAG E
The generator should be started at least once every seven
claysand allowed to run at least 30 minutes. If this cannot
be done and you must store the unit for more than
30 days,use the following guidelines to prepare it for
storage.
Generator Storage
• Clean the generator asoutlined in "To Clean the
Generator"
• Check that cooling air slots and openingson generator
are open and unobstructed.
_CAUTION! Storage covers can be flammable.
Do Not place a storage cover over ahot
generator. Let the unit coot for a sufficient time
before placingthe cover on the unit.
Engine Storage
Seeengine owner's manualfor instructions.
Other Storage Tips
•Do Not store gasoline from one season to another.
• Replace fuel container if it starts to rust. Rust andlor dirt
in fuel can cause problems if it's used with this unit.
• Store in clean and dry area.

TROUBLESHOOTING
Problem
Engine isrunning, 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.
Cause
I. Circuit breaker is open.
2. Poor connection or defective cord set.
3. Connected device is bad.
4. Faultin generator.
I. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shortedgeneratorcircuit.
I. Run/Stop switch set to "Stop".
2. Dirty air cleaner.
3. Out of gasoline.
4. Stalegasoline.
5. Spark plug wire not connected to spark
plug.
6. Badspark plug.
7. Water in gasoline.
8. Overchoking.
9. Low oil level.
10. Excessivelyrich fuel mixture.
I I. Intake valve stuck open or closed.
Solution
I. Resetcircuit breaker.
2. Check and repair.
3. Connect another device that isin good
condition.
4. Contact Generac service facility.
I. Disconnect shorted electrical load.
2. See "Don't Overload the Generator"
on page I I.
3. Contact Generac Power Systems
service facility.
4. Contact Generac service facility.
I. Set switch to "Run".
2. Clean or replace air cleaner.
3. Fillfuel tank.
4. Drain gastank andfill with fresh fuel.
5. Connect wire to spark plug.
6.
7.
8.
9.
10.
II.
12. Engine has lost compression. 12.
I. Out of gasoline. I.
Engine shuts down 2. Low oil level. 2.
during operation. 3. Fault in engine. 3.
I. Load is too high. I.
Engine lacks power. 2. Dirty air filter. 2.
3. Engine needs to be serviced. 3.
I. Choke is opened too soon. I.
Engine "hunts" or
falters. 2.
2. Carburetor is running too rich or too
lean.
Replacespark plug.
Drain gastank; fill with fresh fuel.
Put choke lever to "Run" position.
Fillcrankcase to proper level.
Contact Generac Power Systems
service facility.
Contact Generac Power Systems
service facility.
Contact Generac Power Systems
service facility.
Fillfuel tank.
Fillcrankcase to proper level.
Contact Generac Power Systems
service facility.
See "Don't Overload the Generator"
on page I I.
Replaceair filter.
Contact Generac Power Systems
service facility.
Move choke to halfwayposition till
engine runs smoothly.
Contact Generac Power Systems
service facility.

SCHEMATIC
POWER
REGULATOR
BOARD
1 2
18
YEL \/LOP
i/\LED
RED
LDP
SWITCH
POWER POWER
i i 22 44
155 156 22 44
I
I BLU/WHT £2 I 30A
G
A
T
E
S
I
G
N
A
L
ENG
IGNITION
BATTERY CHARGE
66 55 77
13 55
AUTO /_ _55_
RESET L_ ([_ _+ )_I OA C B
_tS_
IIA
30A

WIRING DIAGRAM
F
20A 1_0/240V 2_ 30A
0
GRN I
GROUND SHROUB ANODE LO_ OIL
_// Lm _ _ _i_ _o ,_ _ _o
/ / _ _4 _ ÷ _..... / _L_,'_s_
........ I <> ,_<IS_.=// N
NUT ON
ENGINE BLOCK

EXPLODEDVIEW- MAIN UNIT
62 _/40
45 /
27
58
50 55
31
6\
25
i
11\
77
8
38
10\
5
19
24
@
67
29
26
?
68
16_
49
78
\ \
7O \ 71
17
75
72 73
24 \\ \\24
\
74
25
59
79

PARTS LIST- MAIN UNIT
Item Part #
I NSP
2 A92531GS
3 A92731GS
4 92247GS
5 92679GGS
6 92681AGS
7 65791GS
8 96796GS
9 22129GS
10 86307GS
II 25254GS
12 92609GS
13 82857GS
14 40976GS
15 66476GS
16 92532GS
17 22142GS
18 A7433GS
19 90239GS
20 81917GS
21 B4986GS
22 83083GS
23 22531GS
24 189160GS
25 66825CGS
26 74908GS
27 86308BGS
28 65795GS
29 66849AGS
30 67022GS
31 84132GS
32 66386GS
33 66849GS
34 B4871GS
35 22769GS
36 86494GS
37 86292GS
38 77395GS
39 83465GS
40 78831BGS
41 80270GS
42 78299GS
Qty
2
4
I
2
4
2
2
I
2
I
I
I
I
I
2
12
I
4
4
I
I
I
I
I
2
I
I
I
I
4
4
4
I
I
Description
ENGINE
SUPPORT,Support
SUPPORT,Engine& Muffler
HOUSING, EngineAdapter
ASSEMBLY,Rotor (Inclds Item 7)
ASSEMBLY,Stator
BEARING
WASHER, 22.2 O.D. x 3Thk
WASHER, M8 Lock
HHMS,5/16 - 24 x 3/4 SEMS
HHCS, 5/16 - 24 x 9-7/8"
MOUNT, Vibration
MOUNT, Vibration
SCREW,M8 -1.25x 20
CAPSCREW,M6 -1.0x 12mm
BRACKET,Muffler
SCREW,5/16 -18x 3/4"
MUFFLER
GASKET,Muffler
PIN,4 mm x 10 Rott
DECAL, Ground
SCREEN,SparkArrester
HHCS, 5/16-18 x I-3/4"
NUT, 5/16-18 Serrated Flange
CARRIER,Rear Bearing
TAPTITE,M5-0.8 x 10
BOLT,M6 -I x 165mm Stator
RECTIFIER,Battery Charge
TAPTITE,M5-0.8 x 20
GROMMET,Rubber
ASSEMBLY,Power Regulator
ASSEMBLY,Brush Holder
TAPTITE,M5 - 0.8 x 16
COVER, Bearing Carrier
WASHER,#10 Int. Shakeproof
SCREW,M6 -I.0 x 16Wing
HHCS,# I0 SelfDriller
NUT, M6 FlangeLock
GROMMET,Tank
HHCS, M6-1.0 x 60,SEMS
VALVE,Tank
BUSHING, PlasticTank
Item Part #
43 B4363GS
44 BI998GS
45 J92039GS
46 92665GS
47 85000GS
48 14353621GS
49 26850GS
50 39287GS
51 92982GS
52 189407GS
53 49820GS
54 22145GS
55 187104GS
56 BB5586GS
57 B4605GS
58 B4135GS
59 AI87024GS
60 92630GS
61 189406GS
62 93826GS
63 J96068GS
64 56893GS
65 A8927GS
66 189417GS
67 43438GS
68 37806GS
69 70185GS
70 731 I IGS
71 65787GS
72 84882GS
73 72347GS
74 B4767GS
75 B2153GS
76 73054GS
77 77816GS
78 20566GS
79 AB3061GS
Qty Description
CAP, FuelGauge
TANK,ASM, 7- Gal (Includes
Items 41 & 42)
SHIELD,Heat
INSULATION #2- I/4" Thick
CLIP,Insulation
WIRE, Ground
2 WASHER, M6 Shakeproof
2 HHCS, M8- 1.25x45
I DECAL, Danger
2 DECAL, Heat Shield
2 NUT, M8 Nylok
4 WASHER, FIat,5/16- M8
4 WASHER, Nylon
2 HANDLE
2 GRIP
2 PIN,with Lanyard
CRADLE
ASSEMBLY,Control Panel
DECAL, Control Panel
DECAL, Start Instructions
SHIELD,Heat
CRIMPTITE, 10-24 x I/2"
MANUAL, Engine
MANUAL, Owners
PLUG,240V,30A 4-Prong
PLUG, 125V,30A 3-Prong
OIL FILTER
ELEMENT,Air Cleaner
CABLE, Battery Charge
WRENCH, Spark Plug
SPARKPLUG
COVER, Storage
6 SCREW,Self Driller, 12-14 x 7/8"
I DECAL, Fuel Shut Off
2 DECAL, Caution Hot Muffler
I DECAL, 1-800
2 OIL BOTTLES,28 oz.
Optional Accessories Not Included:
84883GS Cord Wrap

EXPLODED VIEW AND PARTS LIST - CONTROL PANEL
19 2O 21
19
\\\\_
8
10
6
9
610 16 17 15 \
11 \
2
Item Part # Qty Description
I A92070GS I PANEL,Control
223897GS 4 FLATWASHER,#10 M5
349226GS 4 LOCKWASHER, M5
4 91526GS 4 SCREW,M5-0.8 x 12mm
5 82538GS I SWITCH, IdleControl
6 82881GS 4 LOCK WASHER,7/16"
7 43181GS 4 SCREW,M3-0.5xl0mm
8 43182GS 4 LOCKWASHER, M3
9 90418GS I OUTLET, 12V
I0 75207AGS 2 CIRCUIT BREAKER,30A
I I 75207GS 2 CIRCUIT BREAKER,20A
12 23365GS 6 WASHER,#8 Shakeproof
13 68868GS I OUTLET, 120Vott,30Amp
Locking
26 22
18 8
7
Item Part #
14 43437GS
15 68759GS
16 43180GS
17 22264GS
18 51715GS
19 64526GS
20 83970GS
21 64525GS
22 87962GS
23 84335GS
24 84134GS
25 B92069GS
26 84028GS
25
Qty Description
I OUTLET, 120V/240V,30A
Locking
I OUTLET, 120V,20A Duplex
6 FLATWASHER, M4
6 LOCKWASHER,#8 M4
6 NUT, M4-0.7 Hex
8 SCREW,#6-32 x 3/8"
I BOARD, System Control
4 STAND-OFF,3/4" Hex
I CIRCUIT BREAKER.12V,10A
I ASSEMBLY,Wire Harness
I GROMMET,Rubber Conn.
I BOX, Control Panel
I TRANSFORMER,Idle Control
I|:!

EXPLODED VIEWAND PARTS LIST-WHEEL KIT
5 14 ®
11
4
8
Item Part # Qty Description
I BB5586GS 2 HANDLE
2 B4966GS 2 WHEEL
3 93693GGS I AXLE
4 87005AGS 2 PIN,Retaining
5 39287GS 2 HHCS, M8- 1.25x45
6 BI86927GS I LEG,Support
7 27007GS 2 MOUNT, Vibratlon
8 42909GS 2 CAPSCREW,Hex Hd. M8- 1.25
x 30
Item Part #
9 52858GS
I0 22247GS
II 39253GS
12 22145GS
13 49820GS
14 187104GS
15 B4605GS
16 B4135GS
Qty Description
4 NUT, Lock M8
2 WASHER,Wheel
2 CAPSCREW,Hex Hd. - M8 -
1.25x 20
6 WASHER,Flat,5/16-M8
2 NUT, M8 Nylok
4 WASHER,Nylon
2 GRIP
2 PIN,with Lanyard

GENERACPORTABLEPRODUCTS,LLC(hereafterreferredto astheCOMPANY)warrantstotheoriginalpurchaserthatthe
componentsinitsportablegeneratorwillbefreefromdefectsinmaterialsorworkmanshipfortheitemsandperiodsetforth
belowfromthedateoforiginalpurchase.Thiswarrantydoesnotincludethegasolineenginewhenfurnishedorattachedbecause
suchengineiscoveredsolelybytheenginemanufacturer'swarranty.StartingbatteriesarenotwarrantedbytheCOMPANY.The
term"originalpurchaser"meansthepersonforwhomthegeneratorisoriginallypurchased.Thiswarrantyisnottransferableand
appliesonlyto portablegeneratorsdrivenbyanoverheadvalveengine.
Warranty Schedule: Consumer* Commercial*
Engine Warranted solely by the engine manufacturer
All other parts 2 years (2rid year parts only) I Year
With the exception of European Community Countries, all unitsbound for export shall be warranted for One (I) Yearin
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
waJ'ranty.
During the warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination bythe
COMPANY, is found to be defective under normal useand service**.AII transportation costs under warranty, including return to
the factory if necessary,are to be borne by the purchaser and prepaid by the purchaser.Thiswarranty does not cover normal
maintenance and service and does not applyto agenerator set,alternator, or parts which havebeen 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 adverselyaffect its performance and reliability.
**NORMAL WEAR: As with all mechanical devices, the generator needs periodic parts service and replacement to
perform well.This warranty will not cover repair when normal wear has exhausted the life of a part or generator.
THERE ISNO OTHER EXPRESSWARRANTY.THE COMPANY HEREBYDISCLAIMSANY AND ALL IMPLIED
WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESSFOR A
PARTICULAR PURPOSETOTHE EXTENT PERMITTED BY LAW.THE DURATION OFANY IMPLIEDWARRANTIES
WHICH CANNOT BEDISCLAIMED ISLIMITEDTO THETIME PERIODAS SPECIFIEDIN THE EXPRESS
WARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIALDAMAGES UNDER ANY AND ALL
WARRANTIES ISEXCLUDED. THE COMPANY ALSO DISCLAIMSANY RESPONSIBILITYFOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES,SUCH ASTHE LOSSOFTIME ORTHE USEOFTHE POWER EQUIPMENT,OR ANY
COMMERCIAL LOSSDUETOTHE FAILUREOFTHE EQUIPMENT:AND ANY IMPLIEDWARRANTIES ARE
LIMITEDTO THE DURATION OFTHISWRITTEN WARRANTY.
Some states do not allow limitations on how long an impliedwarranty lasts,or the exclusion or limitation of incidentalor
consequential damages,so the above limitations or exclusions may not applyto you.Thls warranty givesyou specific legal rights and
you may also haveother rights,which vary from state to state.
For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982.Or look on the internet at
www.generac-portables.com.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.