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GP6500
Generac Power Systems GP6500 Repair Manual
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Generac P
ower Systems, Inc.
S45 W29290 Hwy
. 59 • W
aukesha, WI 53189
1-888-GENERAC
(1-888-436-3722)
• generac.com
Par
t No. 0H0285 rev
. A / Printed in USA 02.09
© 2009 Generac Power Systems, Inc. All rights reserved.
83
Table of Contents
Default Chapter
3
Table of Contents
3
Specifications
4
Part 1 - General Information
11
Section 1.1 - Generator Fundamentals
12
Magnetism
12
Electromagnetic Fields
12
Electromagnetic Induction
12
A Simple AC Generator
13
A more Sophisticated AC Generator
13
Generator Fundamentals
14
Section 1.2 - Measuring Electricity
15
Meters
15
The vom
15
Measuring AC Voltage
15
Measuring DC Voltage
15
Measuring AC Frequency
15
Measuring Current
16
Measuring Resistance
16
Electrical Units
17
Ohm's Law
17
Section 1.3 - Brushless, Capacitor Excitation System
18
Introduction
18
Stator Assembly
18
Rotor Assembly
18
Circuit Breakers
18
Operation
19
Section 1.4 - Brushed Excitation System
20
Introduction
20
Stator Assembly
20
Brush Holder and Brushes
20
Rotor Residual Magnetism
20
Voltage Regulator
20
Operation
20
Section 1.5 - Testing, Cleaning and Drying
22
Insulation Resistance
22
The Megohmmeter
22
Stator Insulation Resistance Test
22
Cleaning the Generator
23
Drying the Generator
23
Part 2 - AC Generators
23
Section 2.1 - Brushless Capacitor Troubleshooting Flowcharts
24
Section 2.2 - Brushed Excitation Troubleshooting Flowcharts
26
Section 2.3 - AC Diagnostic Tests
28
Introduction
28
And Frequency
28
Test 2 - Check Circuit Breaker
28
Test 3 - Check Continuity of
28
Receptacle Panel
28
Test 1 - Check No-Load Voltage
28
Test 4 - Field Flash Alternator
29
(Configuration "A" Only)
29
Test 5 - Check Brushed Rotor Circuit
30
Test 6 - Check Capacitor
31
Test 7 - Test Brushless DPE Winding
32
Test 8 - Test Brushless Stator Windings
32
Test 9 - Test Brushed Stator Windings
33
Test 10 - Check Load Voltage & Frequency
33
Test 11 - Check Load Watts & Amperage
33
Test 12 - Adjust Voltage Regulator
33
Part 3 - Engine Troubleshooting
35
Section 3.1 - 389/206/163Cc Troubleshooting
36
Flowcharts
36
Section 3.1 - 389/206/163Cc Troubleshooting
38
Section 3.2 - 410Cc Troubleshooting Flowcharts
39
Flowcharts
44
Section 3.3 - Diagnostic Tests
44
Test 20 - Check 1.5 Amp Fuse
44
Test 21 - Check Battery & Cables
44
Starter Contactor (SC)
44
Test 23 - Check Start-Run-Stop Switch
44
Test 22 - Check Voltage at Starter Contactor (SC)
44
Test 24 - Test OFF-ON Switch
45
Test 25 - Check Starter Motor
45
Diagnostic Tests
46
Test 25 - Check Ignition Spark
47
Test 26 - Check Spark Plugs
48
Test 29 - Check Carburetion
48
Test 30 - Choke Test
49
Test 33 - Check Valve Adjustment
49
Test 36 - Check Engine / Cylinder Leak down Test / Compression Test
50
Test 38 - Check Flywheel
50
Test 39 - Remove Wire 18 / Shutdown Lead
51
Test 40 - Check / Adjust Governor
51
(389Cc Engine)
51
Test 41 - Check / Adjust Governor
52
(410Cc Engine)
52
Test 45 - Check Oil Level Switch
53
Test 46 - Check Oil Pressure Switch
53
Test 49 - Test Recoil Function
54
Test 50 - Test Engine Function
54
Section 4.1 - Major Disassembly
56
Part 4 - Disassembly
57
Major Disassembly
58
Part 5 - Electrical Data
73
Electrical Schematic, GP1850
74
Electrical Schematic, GP3250
75
Electrical Schematic, GP5000/5500/GP6500
76
Electrical Schematic
76
Wiring Diagram, GP5000/5500/GP6500
77
Electrical Data
77
Wiring Diagram
77
Electrical Schematic, GP7000E/GP8000E
78
Wiring Diagram, GP7000E/GP8000E
79
Electrical Formulas
80
Other manuals for Generac Power Systems GP6500
Owner's Manual
72 pages
Specifications
1 page
Quick Setup Guide
12 pages
5
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Generac Power Systems GP6500 Specifications
General
Brand
Generac Power Systems
Model
GP6500
Category
Portable Generator
Language
English
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