Generac Portable Products 6500EXL Manuel utilisateur

GEN RAC°I

Portable Products

Portable Generator Owner's Manual

Model No. 9798-2 (6,500Watt AC Generator) ManualNo. B2649 Revision 3 (06/01/200 I)

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

_IL This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey allsafety messagesthat follow this symbol to avoidpossible injury or death.

GeneracPortableProducts6500EXLExtendedLifeGenerator

EQUIPMENT

DESCRIPTION

This generator isan engine-driven, revolving field,

alternating current (AC) generator. It was designedto

supply electrical power for operating compatible electrical

lighting, appliance,tools and motor loads.This manual

contains informationfor a generator that operates

120and/or 240Volt, single phase,60 Hz devicesthat

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.The total load 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.

_ANGER! 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 unit isproviding backup power, the

electric utility must be notified.

_DANGER! Generator exhaust gases contain

DEADLY carbon monoxide gas. If breathed in

sufficient concentrations, carbon monoxide

can cause unconsciousness or death. Operate

this equipment outdoors where adequate ventilation

isavailable.

Generac Portable Products 6500EXL Extended Life Generator

• 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.

GeneracPortableProducts6500EXLExtendedLifeGenerator

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 will result in an

engine failure.

REMOVE G EN ERATOR

FROM CARTON

•Set the carton on a rigid flat surfacewith "This Side Up"

arrows pointing upward.

• Carefully open the top flaps of the shippingcarton.

Review"Cold Weather Operation" on page 9.

• 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.

CARTON CONTENTS

Check all contents. If any parts are missingor damaged,call

the generator helpline at 1-800-270-1408.

• The generator

Electric start battery cables

Generator and engine owner's manuals

Locking 30Amp plugs

Battery charge cables

Battery tray mounting bracket/hardware

Spare spark plug and air filter element

Spark plug wrench

INSTALLING TRAY AND

BATTERY

You must purchase and installa 12Volt DC battery (Series

U IL).The battery should be serviced with electrolyte fluid

and fully charged prior to installation.Install the battery as

follows:

• Find the battery tray and fasteners shipped loose in the

carton.

• Remove the four battery tray screws from cradle.

• Position the battery tray and installwith supplied

hardware (see Figure2).

• Set battery onto tray.

• Retain battery to tray with one battery hold down

bracket, two J bolts, two lock washers,two flat washers

and two hex nuts (Figure 3).

GeneracPortableProducts6500EXLExtendedLifeGenerator

•Connect the red battery cable from the engine starter

switch to positive (+) terminal on the battery

(Figure 4).

RED wire from

starter switch

BLACK wire

from battery

• Connect the black battery cable to the negative (-)

terminal on the battery (Figure 4).

• Connect the other end of the black cableto the engine,

not the frame (Figure4).

CAUTION! Be sure the BLACK cableisconnected to

the enginemount and not the frame.You coulddamage the

ground wire.

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:

• Placegeneratoron 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 sealedball bearing that requires no

additional lubrication for the life of the bearing.

Add Gasoline

A WARNING! Never fill fuel tank indoors. Never

fill fuel tank when engine is running or hot. Do Not

light a cigarette or smoke when filling the fuel tank.

A WARNING! Do Not overfill the fuel tank.

Always allow room for fuel expansion.

• Use regular UNLEADED gasolinewith 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 gasolineto fuel tank. Be

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

fuel expansion (Figure 5).

1/2" Air Space Tank

• Install fuel capand wipe up any spilled gasoline.

IMPORTANT: It is important to prevent gum depositsfrom

forming in essentialfuel systemparts,suchasthe carburetor,

fuelfilter,fuel hoseor tank during storage.Also,experience

indicatesthat alcohol-blended fuels (calledgasohol,ethanol

or methanol) canattract moisture,which leadsto separation

andformation of acidsduring storage.Acidic gascandamage

the fuel systemof an enginewhile in storage.

To avoid engine problems, the fuel system should be

emptied before storage of 30 claysor longer.See"Storage"

on page 12.Never useengine or carburetor cleaner

products in the fuel tank or permanent damagemay occur.

GeneracPortableProducts6500EXLExtendedLifeGenerator

KNOWYOUR GENERATOR

Read this owner's manual and safety rules before operating your generator.

Compare the illustrationswith your generator, to familiarize yourself with the locationsof variouscontrols and

adjustments.Savethis manualfor future reference.

FuelTank

Circuit Breakers (AC) Recoil Starter

Choke Lever

120Volt AC, 30 Amp

Receptacle Run/Stop Switch

120/240Volt AC,

30 Amp Receptacle Cleaner

12Volt DC, 10Amp

Receptacle

120Volt AC, 20 Amp

Duplex Receptacle

Idle Control Switch

12Volt DC, 10Amp Receptacle- Recharge a

discharged 12Volt automotive type battery through this

receptacle.

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

used to supply electrical power for the operation of

120Volt AC, 20 Amp, singlephase,60 Hz electrical lighting,

appliance,tool and motor loads.

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

usedto supply electrical power for the operation of

120Volt AC, 30 Amp, singlephase,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, singlephase,60 Hz

electrical lighting,appliance,tool and motor loads.

Air Cleaner -- Uses a dry type filter element and foam

pre-cteaner to limitthe amount of dirt and dust sucked

into the engine.

Choke Lever -- Used when starting a cold engine.

Grounding Wing Nut

Circuit Breakers (AC) -- Eachreceptacle isprovided

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

generator againstelectrical overload.

FuelTank -- 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 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.

RunlStop 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.

GeneracPortableProducts6500EXLExtendedLifeGenerator

OPERATING THE

GEN ERATO R

_AUTION! Never start or stop the engine with

electrical loadsconnected to the receptaclesAND

with the connected devices turned ON.

Starting the Engine

•Unplug all electrical loads from generator receptacles

before starting the engine.

• Make sure the unitis in a level position.

• Open the fuel shut-off valve(Figure 6).

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

• Place Run/Stop switch in the "Run" position (Figure 7).

• Placethe choke leverin the "Full" choke position by

sliding it to the left toward the valvecover in the

direction indicated by the arrow (Figure 8).

• Grasp starter grip and pull slowly untilyou feel slight

resistance,then pull quickly. Oo Not let handle"snap-

back" into recoil housing.

• When engine starts, move choke lever to "Run" position

by sliding it all the way to the right (awayfrom the valve

cover and under the arrow).

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

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

2 times.

NOTE= If the engine still fails to start, review the engine

owner's manual.Also,check for proper oil levelin

crankcase.Unit is equipped with a low oil shutdown

system.Seeengine owner's manualfor information

regarding the low oil shutdown system.

Connecting Electrical Loads

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

starting.

• Plug in and turn on the desired 120 and/or 240 VottAC,

singlephase,60 Hz electrical loads.

•Do Not connect 240Volt loadsto the 120Volt

receptacles.

•Do Not connect 3_hase loadsto the generator.

•Do Not connect 50 Hz loads to the generator.

•DO NOT OVERLOADTHE GENERATOR. Add up

the rated watts (or amps) of all loadsto be connected at

one time.This total should not be greater than the rated

wattage/amperagecapacity of the generator. See"Don't

Overload the Generator" on page I I.

GeneracPortableProducts6500EXLExtendedLifeGenerator

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 idlecontrol switch in the "Off" position.

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

internaltemperatures of engine and generator.

• 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 enginewitl 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 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.

_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

use the unit to chargeany 6Volt batteries. Do Not usethe

unit to crank an engine havinga discharged battery.

To recharge 12Volt batteries, proceed as follows:

• Check fluidlevel in atl battery cells.If necessary,add

ONLY distilled water to cover separators in battery cells.

Do Not use tap water.

• If the battery isequipped with vent caps,make sure they

are installed and are tight.

• If necessary,clean battery terminals.

• Connect battery charge cable connector plug to panel

receptacle identified by the words "12 VOLTSD.C"

• Connect battery charge cable clamp with red handle to

the positive (+) battery terminal (Figure9).

12 VOLT D.C.

RECEPTACLE

POS NEG

• Connect battery chargecable clamp with black handle

to the negative (-) battery terminal (Figure9).

• 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 instructionscarefully.Generally,a battery is

considered to be at 100%state of charge when specific

gravity of itsfluid (asmeasured by hydrometer) is 1.260or

higher.

GeneracPortableProducts6500EXLExtendedLifeGenerator

COLD WEATH ER

OPERATION

Under certain weather conditions (temperatures below

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 long sides of the box to expose

exhaust side of unit.Ensurea minimum of two feet

clearance between open sideof box and nearest object.

• Cut appropriate slots to accessreceptacles of unit.

• Start unit, then place box over it.

IMPORTANT; Remove shelter when temperature is

above 40°F [4°C].

For a more permanent shelter, build a structure that will

enclose three sidesand the top of the generator:

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

Note that your generator mayappear different from that

shown in Figure 10.

• 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

120/240 Volt AC, 30 Amp, Locking

Receptacle

Use a NEMA LI4-30 plug with this receptacle. Connect a

4-wire cord set rated for 250Volt AC loads at 30 Amps (or

greater) (Figure I I).You can use the same4-wire cord if

you plan to run a 120Volt load.

4-Wire CordSet

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

phaseloads requiring up to 3,600 watts of power at

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

30 Amps for 240Volts.The outlet is protected by a 30Amp

push-to-reset circuit breaker.

ACAUTION! Although this outlet states it has a

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

generator is only rated for 6,500 watts. Powering

loads that exceed the wattage/amperage capacity of

the generator can damage it or cause serious

injuries.

120 Volt AC, 30 Amp Locking

Receptacle

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

3-wire cord set rated for 125Volt AC loads at 30 Amps to

the plug (Figure 12).

mm_ 9

GeneracPortableProducts6500EXLExtendedLifeGenerator

_IlC_ IlF,(o]kv."/J_."T o• ,, hi, ••.m

3-Wire CordSet

NEMA L5-30

r T Neutral

(_ _ 120v

---_ Hot

/_ Ground

(Green)

Use this receptacle to operate 120VoltAC, 60 Hz,single

phaseloads 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

Eachreceptacle (Figure 13) is protected againstoverload by

a 20Amp push-to-reset circuit breaker.

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

60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)

at 20Amps of current. Use cord sets that are rated for

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

12 Volt DC, I 0 Amp Receptacle

This receptacle allows you to recharge a 12Volt

automotive or utility style storage battery with the battery

chargecables provided (Figure 14).This receptacle can not

recharge 6Volt batteries and can not be used to crank an

engine havinga discharged battery. Seethe section

"Charging a Battery" (page8) before attempting to

recharge a battery.

_IE_ Ilplv//JIIIIZi., _11

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