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Page 1

Specifications .......................................................... 2

Part 1 – General Information .................................. 9

Section 1.1 – Generator Fundamentals ................ 10

Magnetism .......................................................10

Electromagnetic Fields.....................................10

Electromagnetic Induction................................10

A Simple AC Generator ...................................11

A More Sophisticated AC Generator ................11

Section 1.2 – Measuring Electricity ....................... 13

Meters ............................................................13

The VOM ..........................................................13

Measuring AC Voltage .....................................13

Measuring DC Voltage .....................................13

Measuring AC Frequency ................................13

Measuring Current ...........................................14

Measuring Resistance .....................................14

Electrical Units .................................................15

Ohm's Law .......................................................15

Section 1.3 – Brushless, Capacitor

Excitation System ............................ 16

Introduction ......................................................16

Stator Assembly ...............................................16

Rotor Assembly ................................................16

Circuit Breakers ...............................................16

Operation .........................................................17

Section 1.4 – Brushed Excitation System ............. 18

Introduction ......................................................18

Stator Assembly ...............................................18

Brush Holder and Brushes ...............................18

Rotor Residual Magnetism...............................18

Voltage Regulator ............................................18

Operation .........................................................18

Section 1.5 – Testing, Cleaning and Drying .......... 20

Insulation Resistance .......................................20

The Megohmmeter...........................................20

Stator Insulation Resistance Test .....................20

Cleaning the Generator ....................................21

Drying the Generator .......................................21

Part 2 – AC Generators ......................................... 21

Section 2.1 – Brushless Capacitor

Troubleshooting Flowcharts ............. 22

Section 2.2 – Brushed Excitation

Troubleshooting Flowcharts ............. 24

Section 2.3 – AC Diagnostic Tests ........................ 26

Introduction ......................................................26

Test 1 – Check No-Load Voltage

and Frequency ....................................26

Test 2 – Check Circuit Breaker.........................26

Test 3 – Check Continuity of

Receptacle Panel ................................26

Test 4 – Field Flash Alternator

(Configuration “A” Only) .......................27

Test 5 – Check Brushed Rotor Circuit ..............28

Test 6 – Check Capacitor .................................29

Test 7 – Test Brushless DPE Winding ..............30

Test 8 – Test Brushless Stator Windings ..........30

Test 9 – Test Brushed Stator Windings ............31

Test 10 – Check Load Voltage & Frequency ....31

Test 11 – Check Load Watts & Amperage .......31

Test 12 – Adjust Voltage Regulator ..................31

Part 3 – Engine Troubleshooting .......................... 33

Section 3.1 – 389/206/163cc Troubleshooting

Flowcharts ....................................... 34

Section 3.2 – 410cc Troubleshooting Flowcharts .. 37

Section 3.3 – Diagnostic Tests .............................. 42

Test 20 – Check 1.5 Amp Fuse ........................42

Test 21 – Check Battery & Cables ...................42

Test 22 – Check Voltage at

Starter Contactor (SC) ........................42

Test 23 – Check Start-Run-Stop Switch ..........42

Test 24 – Test OFF-ON Switch .........................43

Test 25 – Check Starter Motor .........................43

Test 25 – Check Ignition Spark ........................45

Test 26 – Check Spark Plugs ...........................46

Test 29 – Check Carburetion ...........................46

Test 30 – Choke Test ........................................47

Test 33 – Check Valve Adjustment ...................47

Test 36 – Check Engine / Cylinder Leak Down

Test / Compression Test ......................48

Test 38 – Check Flywheel ................................48

Test 39 – Remove Wire 18 / Shutdown Lead ...49

Test 40 – Check / Adjust Governor

(389cc Engine) ....................................49

Test 41 – Check / Adjust Governor

(410cc Engine) ....................................50

Test 45 – Check Oil Level Switch .....................51

Test 46 – Check Oil Pressure Switch ...............51

Test 49 – Test Recoil Function .........................52

Test 50 – Test Engine Function ........................52

Part 4 – Disassembly ............................................. 53

Section 4.1 – Major Disassembly .......................... 54

Part 5 – Electrical Data .......................................... 71

Electrical Schematic, GP1850 .............................. 72

Electrical Schematic, GP3250 .............................. 73

Electrical Schematic, GP5000/5500/GP6500 ....... 74

Wiring Diagram, GP5000/5500/GP6500 ............... 75

Electrical Schematic, GP7000E/GP8000E ........... 76

Wiring Diagram, GP7000E/GP8000E ................... 77

Electrical Formulas ............................................... 78

Brand	Generac Power Systems
Model	GP6500
Category	Portable Generator
Language	English

Generac Power Systems GP6500 Repair Manual

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