Generac Power Systems RS5500

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Diagnostic Repair Manual 49

Section 7 Electrical Data

Introduction

Go to www.generac.com (http://www.generac.com/service-support/product-support-lookup) for the most current wiring

diagrams and electrical schematics. Use model or serial number.

Main Page

Read this Manual Thoroughly2
Replacement Parts2
Rotor and Stator Resistance Tables3
Table of Contents5
Section 1 Brushless Capacitor Excitation7
Introduction7
Stator Assembly7
Rotor Assembly7
Operation8
Troubleshooting Flowcharts9
If Problem Involves AC Output9
Problem 1 - Generator Produces Zero Voltage or Residual Voltage9
Problem 2 - Voltage & Frequency Are both High or Low10
Problem 3 - Excessive Voltage/Frequency Droop When Load Is Applied10
Problem 4 - Generator Produces High Voltage at No-Load10
Section 2 Direct Excitation (Brush Type)11
Introduction11
Stator Assembly11
Brush Holder and Brushes11
Voltage Regulator11
Operation11
Troubleshooting Flowcharts13
If Problem Involves AC Output (Brush Type)13
Problem 5 - Generator Produces Zero Voltage or Residual Voltage13
Problem 6 - Voltage & Frequency Are both High or Low14
Problem 7 - Excessive Voltage/Frequency Droop When Load Is Applied14
Problem 8 - Generator Produces High Voltage at No-Load14
Section 3 AC Diagnostic Tests15
Test 1 - Check No-Load Voltage and Frequency15
Test 2 - Check Main Circuit Breaker15
Test 3 - Check Continuity of Receptacle Panel15
Test 4 - Fixed Excitation Test/Rotor Amp Draw Test16
Test 5 - Field Flash Alternator18
Test 6 - Check Capacitor19
Test 7 - Test Brushless DPE Windings19
Test 8 - Test Brushless Stator Windings20
Test 9 - Test Brushed Stator Windings20
Test 10 - Check Load Voltage & Frequency20
Test 11 - Check Load Watts & Amperage20
Test 12 - Adjust Voltage Regulator21
Test 13 - Voltage Changeover Switch 120/240 Position21
Section 4 EFI Engine Control Diagnostic Tests23
Basic EFI Theory23
Basic Open-Loop Theory23
Engine Requirements23
Fuel System23
Air Metering and Measurement24
Sensor Inputs24
Basic Operation24
EFI Fault Code Diagnostics25
Section 5 Engine Diagnostic Tests27
Diagnostic Flow Charts27
Problem 9 - Recoil Cord will Not Pull (208/389/420/459Cc Engines)27
Problem 10 - Engine Starts Hard and Runs Rough (208/389/420Cc Non-EFI Engines)27
Problem 11 - Engine Turns over but will Not Start (208/389/420Cc Non-EFI Engines)28
Problem 12 - Engine "Hunts" / Erratic Idle (208/389/420Cc Non-EFI Engines)28
Problem 13 - Engine will Not Crank (220/410/530Cc Engines with Electric Start)29
Problem 14 - Recoil Cord will Not Pull (if so Equipped) (220/410/459/530Cc Engines)29
Problem 15 - Engine Cranks but will Not Start (220/410/530Cc Non-EFI Engines)30
Problem 16 - Engine Starts Hard and Runs Rough (220/410/530Cc Non-EFI Engines)31
Problem 17 - Engine Starts then Shuts down (220/410/530Cc Non-EFI Engines)31
Problem 18 - Battery will Not Charge (220/410/459/530Cc Engines)31
Problem 19 - Engine "Hunts" / Erratic Idle (220/410/530Cc Non-EFI Engines)32
Problem 20 - Unit will Not Idle (220/410/426/530Cc Non-EFI Engines)32
Problem 21 - Unit will Not Come off Idle (220/410/426/530Cc Non-EFI Engines)32
Introduction33
Test 14 - Check Fuse33
Test 15 - Check Battery and Cables33
Test 17 - Check START-RUN-STOP Switch (410/426Cc Engine)34
Test 18 - Test OFF-ON Switch34
Test 19 - Check Starter Motor34
Test 20 - Check Ignition Spark35
Test 21 - Check Spark Plugs36
Test 22 - Check Carburetion36
Test 23 - Choke Test37
Test 24 - Check Valve Adjustment37
Test 25 - Check Engine / Cylinder Leak down Test / Compression Test38
Test 26 - Check Ignition Coil39
Test 27 - Check Flywheel39
Test 28 - Remove Shutdown Wire40
Test 29 - Check / Adjust Governor (208/389/420Cc Non-EFI Engine)40
Test 30 - Check / Adjust Governor (220/410/530Cc Non-EFI Engine)41
Test 31 - Check Oil Pressure Switch41
Test 32 - Check Oil Level Switch42
Test 33 - Test Recoil Function42
Test 34 - Test Engine Function42
Test 35 - Test Battery Charger (Non-EFI Units)42
Test 36 - Test Battery Charging Circuit (EFI Electric Start Models)43
Test 37 - Test Idle Control43
Section 6 Major Disassembly45
Introduction45
Section 7 Electrical Data55
Introduction55
Wiring Diagram and Electrical Schematic, RS5500 Drawing No. 0K6393-A56
Wiring Diagram and Electrical Schematic, RS7000E Drawing No. 0K6394-C60
Wiring Diagram and Electrical Schematic, XC6500 Drawing No. 10000010344-A64
Wiring Diagram and Electrical Schematic, XC6500E/XC8000E Drawing No. 10000010343-A68
Wiring Diagram and Electrical Schematic, XP4000 Drawing No. 0H8536-D72
Wiring Diagram and Electrical Schematic, XP5600E & XP6400E Drawing No. 0K2042-A76
Wiring Diagram and Electrical Schematic, XP6500E Drawing No. 0H6809-D78
Wiring Diagram and Electrical Schematic, XP6500E Drawing No. 0H6809-D81
Wiring Diagram and Electrical Schematic, XP8000E Drawing No. 0H7588-C82
Wiring Diagram and Electrical Schematic, XP10000E Drawing No. 0H7214-D86
Wiring Diagram and Electrical Schematic, XG4000 Drawing No. 0H3339-E90
Wiring Diagram and Electrical Schematic, XG4000 Drawing No. 0H5278-A92
Wiring Diagram and Electrical Schematic, XG5600E/XG6400E Drawing No. 0J8223-B94
Wiring Diagram and Electrical Schematic, XG6500 Drawing No. 0H2780-F96
Wiring Diagram and Electrical Schematic, XG7000E Drawing No. 0H3525-C98
Wiring Diagram and Electrical Schematic, XG8000E Drawing No. 0H5145-A100
Wiring Diagram and Electrical Schematic, XG10000E Drawing No. 0H3931-B102
Wiring Diagram and Electrical Schematic, XT8000E Drawing No. 0K2800-C106
Wiring Diagram and Electrical Schematic, HL6500E Drawing No. 0L2474-A107
Wiring Diagram and Electrical Schematic, HL6500E Drawing No. 0K9434-B109
Wiring Diagram and Electrical Schematic, HL6500E Drawing No. 0K9433-B110
Wiring Diagram, XT8000EFI Drawing no112
10000023894-A112
Electrical Formulas113

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