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Generac Power Systems XP8000E User Manual

Generac Power Systems XP8000E
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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 XP8000E

Questions and Answers:

Generac Power Systems XP8000E Specifications

General IconGeneral
ModelXP8000E
TypePortable Generator
Starting Watts10000
Rated Watts8000
Running Watts8000
EngineGenerac OHV
Engine Type4-Stroke
Engine Displacement420 cc
Fuel TypeGasoline
Run Time at 50% Load11 hours
Voltage120/240V
Frequency60 Hz
Wheel KitIncluded
Weight200 lbs
Fuel Tank Capacity7.5 gallons
Outlets1 x 120/240V
Starting SystemElectric/Recoil

Summary

Safety

Read This Manual Thoroughly

Manual for technicians, assumes familiarity with servicing procedures for Generac products.

Replacement Parts

Proper installation and tightening of components are critical to prevent ignition of fuel vapors from leaks.

Section 1 Brushless Capacitor Excitation

Introduction

Explains the 4 major components of a brushless generator: prime mover, stator, rotor, and capacitor.

Stator Assembly

Describes the stator's three windings: two power windings and one Displaced Phase Excitation (DPE) winding.

Rotor Assembly

Explains the 2-pole rotor, its speed, diodes for AC to DC conversion, and North/South pole creation.

Operation

Explains startup, on-speed operation, and field excitation process for brushless generators.

AC Power Winding Output

Describes how maintained voltage is induced into stator AC power windings when loads are connected.

Troubleshooting Flowcharts

Guides users through diagnosing AC output problems using flow charts and AC diagnostic tests.

Problem 1 – Generator Produces Zero Voltage or Residual Voltage

Troubleshooting flowchart for zero or residual voltage issues, directing to specific tests.

Section 2 Direct Excitation (Brush Type)

Introduction

Introduces the 4 major components of a brush type generator: prime mover, rotor, stator, and voltage regulator.

Stator Assembly

Details the stator's three windings: two power windings and the DPE winding for excitation.

Brush Holder and Brushes

Describes the brush holder, positive/negative brushes, and their connection to the rotor windings.

Voltage Regulator

Explains how the voltage regulator senses AC output and regulates DC excitation to the rotor.

Operation

Covers startup and on-speed operation, explaining voltage induction and speed-dependent voltage increase.

Field Excitation

Explains how DPE winding, capacitor, and rotor interact to induce voltage and regulate output.

AC Power Winding Output

Explains how regulated voltage is induced into stator AC power windings when electrical loads are connected.

Troubleshooting Flowcharts

Guides users through diagnosing AC output problems for brush-type generators.

Problem 5 – Generator Produces Zero Voltage or Residual Voltage

Troubleshooting flowchart for zero or residual voltage in brush-type generators.

Problem 6 – Voltage & Frequency Are Both High or Low

Flowchart for diagnosing high/low voltage/frequency in brush-type generators.

Problem 7 – Excessive Voltage/Frequency Droop When Load is Applied

Flowchart for diagnosing voltage/frequency droop under load in brush-type generators.

Problem 8 – Generator Produces High Voltage at No-Load

Flowchart for diagnosing high voltage at no-load in brush-type generators.

Section 3 AC Diagnostic Tests

Test 1 – Check No-Load Voltage and Frequency

Procedure to measure AC voltage and frequency at no-load. Includes expected results.

Test 2 – Check Main Circuit Breaker

Tests circuit breaker continuity using a DMM to ensure proper operation.

Test 3 – Check Continuity of Receptacle Panel

Checks receptacle continuity and physical connection to the stator, noting resistance values.

Test 4 – Fixed Excitation Test/Rotor Amp Draw Test

Tests rotor excitation and amp draw using a 12V battery and DMM.

Test 5 – Field Flash Alternator

Procedure to restore residual magnetism by applying voltage to the capacitor.

Test 6 – Check Capacitor

Checks capacitor value using a DMM and visual inspection for defects.

Test 7 – Test Brushless DPE Windings

Tests the Displaced Phase Excitation winding resistance for continuity and shorts.

Test 8 – Test Brushless Stator Windings

Tests stator windings for open circuits, shorts to ground, or shorts between windings.

Test 9 – Test Brushed Stator Windings

Tests brushed stator windings for shorts to ground or chassis.

Test 10 – Check Load Voltage & Frequency

Tests generator voltage and frequency under load to ensure they are within limits.

Test 11 – Check Load Watts & Amperage

Determines generator load capacity by checking wattage and amperage against limits.

Section 4 EFI Engine Control Diagnostic Tests

Basic EFI Theory

Introduction to Electronic Fuel Injection, its history and use in portable generators.

Basic Open-Loop Theory

Explains how EFI uses solenoid valves and ECU signals to control fuel delivery.

Engine Requirements

Discusses the importance of the correct air-fuel ratio for efficient engine operation and power.

Fuel System

Details the components of an EFI fuel system: tank, pump, regulator, and injector.

Air Metering and Measurement

Explains how airflow is measured using a throttle body and pressure transducer.

Sensor Inputs

Lists the 6 basic inputs measured by the ECU: RPM, Airflow, Manifold Pressure, etc.

Basic Operation

Explains how the ECU processes sensor inputs to adjust injector pulse width for optimal operation.

EFI Fault Code Diagnostics

Explains how to interpret fault indicator light flash codes for EFI system failures.

Section 5 Engine Diagnostic Tests

Diagnostic Flow Charts

Guides users through engine diagnostic flow charts based on specific problems.

Problem 9 – Recoil Cord Will Not Pull (208/389/420/459cc Engines)

Troubleshooting flowchart for a recoil cord that will not pull on specific engine sizes.

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

Flowchart for diagnosing hard starting and rough running on non-EFI engines.

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

Flowchart for diagnosing engine starting issues where the engine turns but won't start.

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

Flowchart for diagnosing engine hunting or erratic idle issues in non-EFI engines.

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

Troubleshooting flowchart for electric start engines that will not crank.

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

Troubleshooting flowchart for recoil cord issues on specific engine sizes.

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

Flowchart for diagnosing starting issues where the engine cranks but won't start.

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

Flowchart for diagnosing hard starting and rough running in non-EFI engines.

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

Flowchart for diagnosing engine shutdown issues after starting.

Problem 18 – Battery Will Not Charge (220/410/459/530cc Engines)

Flowchart for diagnosing battery charging problems.

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

Flowchart for diagnosing engine hunting or erratic idle issues.

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

Flowchart for diagnosing issues where the unit will not idle.

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

Flowchart for diagnosing issues where the unit will not come off idle.

Test 14 – Check Fuse

Procedure to inspect the fuse that protects the wiring and battery charger.

Test 15 – Check Battery and Cables

Tests battery voltage and checks for voltage drop in cables and connections.

Test 20 – Check Ignition Spark

Tests engine ignition system spark using a spark tester for proper operation.

Test 25 – Check Engine / Cylinder Leak Down Test / Compression Test

Checks engine sealing ability and compression pressure to identify faults before disassembly.

Section 6 Major Disassembly

Introduction

Introduces typical disassembly steps for removing fuel tank, stator, rotor, and engine.

XC6500 Drawing No. 10000005845-A

Exploded view and parts list for the XC6500 generator.

XC8000 Drawing No. 10000005884-A

Exploded view and parts list for the XC8000 generator.

Section 7 Electrical Data

Introduction

Directs users to www.generac.com for the most current wiring diagrams and schematics.

Wiring Diagram and Electrical Schematic, RS5500 Drawing No. 0K6393-A

Provides the wiring diagram and electrical schematic for the RS5500 model.

Wiring Diagram and Electrical Schematic, XC6500 Drawing No. 10000010344-A

Provides the wiring diagram and electrical schematic for the XC6500 model.

Wiring Diagram and Electrical Schematic, XP4000 Drawing No. 0H8536-D

Provides the wiring diagram and electrical schematic for the XP4000 model.

Wiring Diagram and Electrical Schematic, XG4000 Drawing No. 0H3339-E

Provides the wiring diagram and electrical schematic for the XG4000 model.

Wiring Diagram and Electrical Schematic, XG10000E Drawing No. 0H3931-B

Provides the wiring diagram and electrical schematic for the XG10000E model.

Wiring Diagram, XT8000EFI Drawing No. 10000023894-A

Provides the wiring diagram and electrical schematic for the XT8000EFI model.

Electrical Formulas

Electrical Formulas

Lists common electrical formulas for calculations related to kW, KVA, Amperes, Watts, Resistance, etc.

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