EasyManua.ls Logo

Generac Power Systems XG10000E - User Manual

Generac Power Systems XG10000E
114 pages
Print Icon
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Loading...
DIAGNOSTIC
REPAIR
MANUAL
PORTABLE GENERATORS
50/60 Hz GC/RS/XC/XG/XP//HL/XT
and XT-EFI Series Portable Generators
60 HZ MODELS: 50 HZ MODELS:
RS5500 XC6500 XG4000 XP4000 XT8000E XG5600E
RS7000E XC6500E XG5600 XP6500E XT8000EFI XG6400E
XC8000E XG6400 XP8000E GC8100
XG6500 XP10000E HL6500E
XG7000E
XG10000E
Important Note: Always use the unit specific Schematics and
Wiring Diagrams for troubleshooting.

Table of Contents

Other manuals for Generac Power Systems XG10000E

Questions and Answers

Generac Power Systems XG10000E Specifications

General IconGeneral
ModelXG10000E
TypePortable Generator
Engine Displacement420 cc
Fuel TypeGasoline
Run Time at 50% Load10 Hours
Starting MethodElectric Start
Voltage120/240V
Frequency60 Hz
Wheel KitIncluded
Surge Wattage10000 Watts
Engine TypeOHV
Outlets1 x 120/240V 30A

Summary

Section 1 Brushless Capacitor Excitation

Introduction

Overview of generator components and function for brushless capacitor excitation.

Stator Assembly

Details on the three windings within the stator assembly.

Rotor Assembly

Explanation of the 2-pole rotor, its diodes, and operation.

Operation

How the generator operates, from startup to field excitation.

AC Power Winding Output

How maintained voltage is induced into AC power windings for load.

Troubleshooting Flowcharts

Guidance on diagnosing AC output problems using flow charts.

Problem 1 - Generator Produces Zero Voltage or Residual Voltage

Steps to diagnose zero or residual voltage issues in generator output.

Problem 2 - Voltage & Frequency Are Both High or Low

Diagnostic steps for voltage and frequency issues.

Problem 3 - Excessive Voltage;Frequency Droop When Load is Applied

Troubleshooting excessive voltage/frequency drop under load.

Problem 4 - Generator Produces High Voltage at No-Load

Diagnosing high voltage output at no-load conditions.

Section 2 Direct Excitation (Brush Type)

Introduction

Overview of brush type generator components and function.

Stator Assembly

Details on the three windings in the brush type stator.

Brush Holder and Brushes

Explanation of brush holder, brushes, and excitation current flow.

Voltage Regulator

How the voltage regulator senses and regulates excitation current.

Operation

How the brush type generator operates, from startup to field excitation.

On-Speed Operation

How voltage increases as engine speed accelerates.

Field Excitation

How voltage regulator controls DC excitation to the rotor.

Troubleshooting Flowcharts

Diagnosing AC output problems for brush type generators.

Problem 5 - Generator Produces Zero Voltage or Residual Voltage

Steps to diagnose zero or residual voltage in brush type generators.

Problem 6 - Voltage & Frequency Are Both High or Low

Diagnosing high/low voltage and frequency in brush type generators.

Problem 7 - Excessive Voltage;Frequency Droop When Load is Applied

Troubleshooting voltage/frequency droop under load.

Problem 8 - Generator Produces High Voltage at No-Load

Diagnosing high voltage at no-load for brush type generators.

Section 3 AC Diagnostic Tests

Introduction

Guidance on using diagnostic tests with troubleshooting flowcharts.

Test 1 - Check No-Load Voltage and Frequency

Procedure to measure no-load voltage and frequency.

Test 2 - Check Main Circuit Breaker

How to test the main circuit breaker for continuity.

Test 3 - Check Continuity of Receptacle Panel

Verifying receptacle panel continuity for power output.

Test 4 - Fixed Excitation Test;Rotor Amp Draw Test

Testing rotor excitation and amp draw with a DC source.

Test 5 - Field Flash Alternator (Configuration “A” Only)

Procedure to restore residual magnetism via field flashing.

Test 6 - Check Capacitor

How to test the generator's capacitor for proper function.

Test 7 - Test Brushless DPE Windings

Testing the Displaced Phase Excitation windings for continuity.

Test 8 - Test Brushless Stator Windings

Checking brushless stator windings for opens, shorts, or ground faults.

Test 9 - Test Brushed Stator Windings

Testing brushed stator windings for shorts to ground.

Test 10 - Check Load Voltage & Frequency

Measuring voltage and frequency under load.

Test 11 - Check Load Watts & Amperage

Determining load watts and amperage for generator limits.

Test 12 - Adjust Voltage Regulator

Procedure to adjust the voltage regulator for correct output.

Test 13 - Voltage Changeover Switch 120;240 Position

Testing the 120/240V changeover switch for continuity.

Section 4 EFI Engine Control Diagnostic Tests

Basic EFI Theory

Introduction to Electronic Fuel Injection systems in generators.

Basic Open-Loop Theory

Explanation of open-loop EFI operation without O2 sensor feedback.

Engine Requirements

Fuel-air mixture requirements for efficient engine operation.

Fuel System

Components and operation of the EFI fuel system.

Air Metering and Measurement

How airflow is measured and controlled in EFI systems.

Sensor Inputs

Key inputs measured by the ECU in EFI systems.

Airflow

How airflow is calculated by the ECU in generator applications.

Manifold Pressure

Role of manifold pressure in EFI airflow calculation.

Throttle Position

Note on throttle position sensor not being used on this generator.

Engine Temperature

How engine temperature affects EFI fuel delivery.

Air Temperature

Impact of air temperature on EFI fuel mixture.

Basic Operation

How EFI computer processes sensor data to control fuel injection.

EFI Fault Code Diagnostics

Interpreting fault codes from the EFI system's indicator light.

Section 5 Engine Diagnostic Tests

Diagnostic Flow Charts

General guidance for using engine diagnostic flow charts.

Problem 9 - Recoil Cord Will Not Pull (208;389;420;459 cc Engines)

Troubleshooting steps for a recoil cord that won't pull.

Problem 10 - Engine Starts Hard and Runs Rough (208;389;420 cc Non-EFI Engines)

Diagnosing issues with engines that start hard or run rough.

Problem 11 - Engine Turns Over But Will Not Start (208;389;420 cc Non-EFI Engines)

Troubleshooting steps for engines that crank but don't start.

Problem 12 - Engine “Hunts”; Erratic Idle (208;389;420 cc Non-EFI Engines)

Diagnosing hunting or erratic idle conditions in engines.

Problem 13 - Engine Will Not Crank (220;410;530 cc Engines with Electric Start)

Troubleshooting no-crank issues in electric start engines.

Problem 14 - Recoil Cord Will Not Pull (If So Equipped) (220;410;459;530 cc Engines)

Diagnosing recoil cord issues in specific engine models.

Problem 15 - Engine Cranks But Will Not Start (220;410;530 cc Non-EFI Engines)

Troubleshooting engines that crank but fail to start.

Problem 16 - Engine Starts Hard and Runs Rough (220;410;530 cc Non-EFI Engines)

Diagnosing hard starting and rough running in engines.

Problem 17 - Engine Starts Then Shuts Down (220;410;530 cc Non-EFI Engines)

Troubleshooting engines that start then shut down.

Problem 18 - Battery Will Not Charge (220;410;459;530 cc Engines)

Diagnosing battery charging circuit failures.

Problem 19 - Engine “Hunts”; Erratic Idle (220;410;530 cc Non-EFI Engines)

Troubleshooting engine hunting and erratic idle conditions.

Problem 20 - Unit Will Not Idle (220;410;426;530 cc Non-EFI Engines)

Diagnosing issues when the unit will not idle.

Problem 21 - Unit Will Not Come Off Idle (220;410;426;530 cc Non-EFI Engines)

Troubleshooting when the unit fails to come off idle.

Test 14 - Check Fuse

Procedure to inspect the fuse for the wiring and battery charger.

Test 15 - Check Battery and Cables

Performing voltage drop tests on the starter circuit.

Test 17 - Check START-RUN-STOP Switch (410;426 cc Engine)

Testing the START-RUN-STOP switch for continuity.

Test 18 - Test OFF-ON Switch

Verifying the function of the OFF-ON switch.

Test 19 - Check Starter Motor

Identifying conditions affecting starter motor performance.

Checking The Pinion

Inspecting the starter pinion gear for proper engagement.

Test 20 - Check Ignition Spark

Procedure to test the engine's ignition system spark.

Test 21 - Check Spark Plugs

Inspecting and cleaning or replacing spark plugs.

Test 22 - Check Carburetion

Procedures for checking and cleaning the carburetor.

Test 23 - Choke Test

Testing the choke function to diagnose surging or RPM issues.

Test 24 - Check Valve Adjustment

Adjusting valve clearance to correct engine problems.

Test 25 - Check Engine; Cylinder Leak Down Test; Compression Test

Performing leak down and compression tests on the engine.

Test 26 - Check Ignition Coil

Testing the ignition coil for proper resistance and shorts.

Test 27 - Check Flywheel

Checking flywheel magnetism and key integrity.

Test 28 - Remove Shutdown Wire

Testing the shutdown wire for shorts to ground.

Test 29 - Check; Adjust Governor (208;389;420 cc Non-EFI Engine)

Checking and adjusting the governor for proper speed.

Test 30 - Check; Adjust Governor (220;410;530 cc Non-EFI Engine)

Adjusting governor speed for 220/410/530cc engines.

Test 31 - Check Oil Pressure Switch

Diagnosing issues related to the low oil pressure switch.

Test 32 - Check Oil Level Switch

Testing the oil level switch for proper function.

Test 33 - Test Recoil Function

Checking the recoil starter for proper operation.

Test 34 - Test Engine Function

Basic checks for engine function, including seizure.

Test 35 - Test Battery Charger (Non EFI Units)

Testing the battery charger circuit for non-EFI units.

Test 36 - Test Battery Charging Circuit (EFI Electric Start Models)

Testing the battery charging circuit for EFI models.

Test 37 - Test Idle Control

Testing the idle control system for proper operation.

Section 6 Major Disassembly

Introduction

Overview of typical generator disassembly steps.

Section 7 Electrical Data

Introduction

Guidance to find current wiring diagrams and schematics online.

Wiring Diagram, XT8000 EFI Drawing No. 10000023894-A

Electrical schematic for the XT8000EFI model.

Electrical Formulas

Related product manuals