Generac Power Systems XT-EFI Series Manual
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Generac Power Systems XT-EFI Series Manual

50/60 hz gc/rs/xc/xg/xp//hl/xt and portable generators
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DIAGNOSTIC
REPAIR
MANUAL
50/60 Hz GC/RS/XC/XG/XP//HL/XT
and XT-EFI Series Portable Generators
60 HZ MODELS:
RS5500
XC6500
RS7000E
XC6500E
XC8000E
P O R T A B L E G E N E R AT O R S
XG4000
XP4000
XG5600
XP6500E
XG6400
XP8000E
XG6500
XP10000E
XG7000E
XG10000E
Important Note: Always use the unit specific Schematics and
Wiring Diagrams for troubleshooting.
50 HZ MODELS:
XT8000E
XG5600E
XT8000EFI
XG6400E
GC8100
HL6500E

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Summary of Contents for Generac Power Systems XT-EFI Series

  • Page 1 DIAGNOSTIC REPAIR MANUAL 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.

  • Page 2: Read This Manual Thoroughly

    Safety Read This Manual Thoroughly Throughout this publication and on tags and decals This diagnostic manual has been written and published affixed to the generator, DANGER, WARNING, and by Generac to aid dealer technicians and company CAUTION blocks are used to alert personnel to special service personnel when servicing the products described instructions about a particular operation that may be herein.

  • Page 3: Rotor And Stator Resistance Tables

    Rotor and Stator Resistance Tables Rotor Windings Power Windings Exciter Windings Series Model Alternator (Ohms) (Ohms) (Ohms) HW3250 5973 0H3578 0.62 1.72 6150 0H3578 0.62 1.72 HW5500 6036 0J8363 61.48 0.681 2.81 6151 61.48 0.681 2.81 HW5500E 6037 0J8363 61.48 0.681 2.81 HW6500...
  • Page 4 Wattage Reference Guide Device Running Watts Device Running Watts *Air Conditioner (12,000 Btu) 1700 Hand Drill 250 to 1100 *Air Conditioner (24,000 Btu) 3800 Hedge Trimmer *Air Conditioner (40,000 Btu) 6000 Impact Wrench Battery Charger (20 Amp) Iron 1200 Belt Sander (3") 1000 *Jet Pump Chain Saw...

  • Page 5: Table Of Contents

    Table of Contents Safety ................ ii Test 9 – Test Brushed Stator Windings ....14 Read This Manual Thoroughly ........ii Test 10 – Check Load Voltage & Frequency ..14 Replacement Parts ........... ii Test 11 – Check Load Watts & Amperage .....14 Rotor and Stator Resistance Tables ......
  • Page 6 Table of Contents Test 17 – Check START-RUN-STOP Switch Wiring Diagram and Electrical Schematic, (410/426cc Engine) ..........28 XP10000E Drawing No. 0H7214-D ....... 80 Wiring Diagram and Electrical Schematic, Test 18 – Test OFF-ON Switch .......28 XG4000 Drawing No. 0H3339-E ......84 Test 19 –...

  • Page 7: Section 1 Brushless Capacitor Excitation

    Brushless Capacitor Excitation Section 1 Introduction NOTE: This will only increase from no load to full load and will stop increasing at that point. Figure 1-1. A typical brushless type portable NOTE: The voltage of a brushless capacitive discharge generator needs 4 major components to function: a prime generator will start low and increase as load is applied.

  • Page 8: Operation

    Section 1 Brushless Capacitor Excitation Operation AC Power Winding Output A maintained voltage is induced into the stator AC power Startup windings. When electrical loads are connected across When engine started, residual/permanent the AC power windings to complete the circuit, current magnetism from the rotor induces a voltage into (a) the can flow in the circuit.

  • Page 9: Troubleshooting Flowcharts

    Section 1 Brushless Capacitor Excitation Troubleshooting Flowcharts Introduction Use the Flow Charts in conjunction with the AC Diagnostic Tests . Test numbers used in the flow charts correspond to the numbered tests in the AC Diagnostic Tests . The first step in using the flow charts is to identify the correct problem on the following pages.

  • Page 10: Problem 2 - Voltage & Frequency Are Both High Or Low

    Section 1 Brushless Capacitor Excitation Problem 2 – Voltage & Frequency Are Both High or Low GO TO FREQUENCY GOOD, LOW OR PROBLEM 1 RESIDUAL VOLTAGE TEST 30 – CHECK & ADJUST ENGINE GO TO NO-LOAD FREQUENCY & VOLTAGE GOOD BUT GOVERNOR, 410cc ENGINE PROBLEM 3 THEY DROOP TO MUCH WHEN LOAD IS APPLIED...

  • Page 11: Section 2 Direct Excitation (Brush Type)

    Direct Excitation (Brush Type) Section 2 Introduction Brush Holder and Brushes The brush holder has a positive (+) and a negative (-) Figure 2-1. A typical brush type portable generator brush, and is retained to the rear bearing carrier by needs 4 major components to function: prime mover, means of two Taptite screws.
  • Page 12 Section 2 Direct Excitation (Brush Type) via Wire 4, and the positive brush and slip ring. This TO LOAD excitation current flows through the rotor windings and through the negative (-) slip ring and brush on Wire 0. MLB = MAIN LINE CIRCUIT BREAKER The greater the current flow through the rotor windings, the more concentrated the lines of flux around the rotor...

  • Page 13: Troubleshooting Flowcharts

    Section 2 Direct Excitation (Brush Type) Troubleshooting Flowcharts Introduction Use the Flow Charts in conjunction with the AC Diagnostic Tests . Test numbers used in the flow charts correspond to the numbered tests in the AC Diagnostic Tests . The first step in using the flow charts is to identify the correct problem on the following pages.

  • Page 14: Problem 6 - Voltage & Frequency Are Both High Or Low

    Section 2 Direct Excitation (Brush Type) Problem 6 – Voltage & Frequency Are Both High or Low FREQUENCY GOOD, GO TO LOW OR RESIDUAL PROBLEM 5 VOLTAGE NO-LOAD FREQUENCY & TEST 29 – CHECK & ADJUST ENGINE GO TO VOLTAGE GOOD BUT THEY GOVERNOR, 220cc ENGINE PROBLEM 7 DROOP TOO MUCH WHEN...

  • Page 15: Section 3 Ac Diagnostic Tests

    AC Diagnostic Tests Section 3 Test 2 – Check Main Circuit Breaker Introduction Perform the Diagnostic Tests in this section in Procedure conjunction with Brushless Troubleshooting The generator has circuit breakers located on the control Flowcharts or the Brush Type Troubleshooting panel.

  • Page 16: Test 4 - Fixed Excitation Test/Rotor Amp Draw Test

    Section 1 AC Diagnostic Tests Results Procedure If any other reading than CONTINUITY was Remove positive and negative wires connected to measured, further troubleshooting needs to be done the brush assembly. to determine if it is the receptacle or the wiring. Connect one jumper wire to where the positive If receptacles test good, refer to flow chart.
  • Page 17 Section 1 AC Diagnostic Tests While the unit is running connect one jumper wire Record DC amperage measured. Approximately to the negative terminal of the battery and connect 0.22 DC amps should be measured. the other jumper wire to the positive terminal. NOTE: The DC voltage of the battery divided by the Record voltage measured on Wires 2 and 6 on the resistance measured in Step 17 will give a calculated...

  • Page 18: Test 5 - Field Flash Alternator

    Section 1 AC Diagnostic Tests Test 5 – Field Flash Alternator IMPORTANT NOTE: Do NOT energize the capacitor for more than 1 second at a time. (Configuration “A” Only) Momentarily turn on energizing cord (one second). General Theory Disconnect energizing cord from capacitor. The alternator utilizes residual magnetism within the Carefully re-connect the DPE winding leads to the windings to charge the capacitor.

  • Page 19: Test 6 - Check Capacitor

    Section 1 AC Diagnostic Tests Test 6 – Check Capacitor IMPORTANT NOTE: A capacitor that has gone bad has a tendency to explode. Use caution when dealing with an General Theory exploded capacitor. The gel from inside a capacitor can cause skin irritation.

  • Page 20: Test 8 - Test Brushless Stator Windings

    Section 1 AC Diagnostic Tests Test 8 – Test Brushless Stator Test 9 – Test Brushed Stator Windings Windings General Theory General Theory Most brushed stators have three main windings that are needed to produce voltage. The alternator has two main The brushless stator has three internal windings, two power windings which supply power to the load and a main power windings and a DPE winding.

  • Page 21: Test 12 - Adjust Voltage Regulator

    Section 1 AC Diagnostic Tests Results Verify all material is clear of the alternator before proceeding. If unit is overloaded, reduce load. Set START-STOP-RUN switch to START. If load is within limits but frequency and voltage still drop excessively, refer to flow chart. Figure 3-10 for location of adjustment screw.
  • Page 22 Section 1 AC Diagnostic Tests Place one test meter lead on contact 2 and the other on contact 3. If CONTINUITY is not measured, rock the switch. If CONTINUITY is still not measured, replace switch. Place one test meter lead on contact 5 and the other on contact 6.

  • Page 23: Section 4 Efi Engine Control Diagnostic Tests

    EFI Engine Control Diagnostic Tests Section 4 Basic EFI Theory Engine Requirements Electronic Fuel Injection was first introduced to The correct proportion of fuel is required to be mixed with automobiles in the late 1960s. EFI is not new, as its roots the incoming air for efficient operation.

  • Page 24: Air Metering And Measurement

    Section 1 EFI Engine Control Diagnostic Tests Air Metering and Measurement Air Temperature The amount of air entering the engine is controlled by a This is a secondary input required especially on speed conventional butterfly valve located in a throttle body density systems.

  • Page 25: Efi Fault Code Diagnostics

    Section 1 EFI Engine Control Diagnostic Tests EFI Fault Code Diagnostics There are 3 failure levels: • Level 1 will flash and the generator will run. There Fault Indicator Light may be a slight impact on performance. When the EFI system is connected to a power source •...
  • Page 26 Section 1 EFI Engine Control Diagnostic Tests This page intentionally left blank. Diagnostic Repair Manual...

  • Page 27: Section 5 Engine Diagnostic Tests

    Engine Diagnostic Tests Section 5 Diagnostic Flow Charts Use the Flow Charts in conjunction with the numbered tests in this section. Test numbers used in the flow charts correspond to the numbered tests. The first step in using the flow charts is to identify the correct problem on the following pages.

  • Page 28: Problem 11 - Engine Turns Over But Will Not Start (208/389/420Cc Non-Efi Engines)

    Section 5 Engine Diagnostic Tests Problem 11 – Engine Turns Over But Will Not Start (208/389/420cc Non-EFI Engines) CHECK TEST 20 – TEST 28 – REMOVE CHECK FUEL FUEL GOOD CHECK WIRE 18 / SHUTOFF GOOD SUPPLY SPARK SHUTDOWN LEAD VALVE SPARK SPARK...

  • Page 29: Problem 13 - Engine Will Not Crank (220/410/530Cc Engines With Electric Start)

    Section 5 Engine Diagnostic Tests Problem 13 – Engine Will Not Crank (220/410/530cc Engines with Electric Start) TEST 16 – CHECK TEST 17 – CHECK TEST 15 – CHECK NO VOLTAGE VOLTAGE AT START-RUN-STOP BATTERY GOOD MEASURED STARTER SWITCH & CABLES CONTACTOR 12 VDC MEASURED...

  • Page 30: Problem 15 - Engine Cranks But Will Not Start (220/410/530Cc Non-Efi Engines)

    Section 5 Engine Diagnostic Tests Problem 15 – Engine Cranks But Will Not Start (220/410/530cc Non-EFI Engines) CHECK CHECK FUEL TEST 20 – PULL CHOKE FUEL SHUTOFF FULL OUT GOOD GOOD CHECK FULL OUT SUPPLY VALVE SPARK PULL OUT REPLENISH FUEL TURN SUPPLY...

  • Page 31: Problem 16 - Engine Starts Hard And Runs Rough (220/410/530Cc Non-Efi Engines)

    Section 5 Engine Diagnostic Tests Problem 16 – Engine Starts Hard and Runs Rough (220/410/530cc Non-EFI Engines) TEST 21 – TEST 20 – CHECK CHOKE CHECK FUEL CHECK CHECK GOOD GOOD POSITION AND GOOD GOOD SUPPLY SPARK PLUG SPARK OPERATION ENGINE MISFIRE LOW FUEL APPARENT...

  • Page 32: Problem 19 - Engine "Hunts" / Erratic Idle (220/410/530Cc Non-Efi Engines)

    Section 5 Engine Diagnostic Tests Problem 19 – Engine “Hunts” / Erratic Idle (220/410/530cc Non-EFI Engines) *Acceptable running limits for the engine are between 59-62 Hertz. TEST 23 – STILL CHOKE TEST SURGING TEST 24 – CHECK TEST 20 – SURGING VALVE GOOD...

  • Page 33: Introduction

    Section 5 Engine Diagnostic Tests Introduction Procedure A – Perform Starter Circuit Voltage Drop Test Perform the Diagnostic Tests in this section in Set a digital multimeter (DMM) to measure DC volt- conjunction with the Diagnostic Flow Charts. Test age. numbers in this chapter correspond to numbered tests in the flow charts.

  • Page 34: Test 17 - Check Start-Run-Stop Switch (410/426Cc Engine)

    Section 5 Engine Diagnostic Tests Connect one meter test lead to disconnected Wire 0 from Terminal 2 and connect the other meter test lead to the positive post of the battery, 12 VDC should be measured. If voltage is not measured, repair or replace Wire 13A between the starter contactor and the START-RUN-STOP switch.

  • Page 35: Test 20 - Check Ignition Spark

    Section 5 Engine Diagnostic Tests Checking The Pinion Broken, damaged or weak magnets. Starter drive dirty or binding. Figure 5-7. When starter motor is activated, the pinion gear should move and engage flywheel ring gear. If pinion does not move normally, inspect pinion for binding or sticking.

  • Page 36: Test 21 - Check Spark Plugs

    Section 5 Engine Diagnostic Tests Results Clean and gap or replace sparks plug as necessary. Refer to flow chart. Test 22 – Check Carburetion Procedure Before making a carburetion check, be sure fuel supply tank has fresh, clean gasoline. 002075 Check all shutoff valves are open and fuel flows freely Figure 5-10.

  • Page 37: Test 23 - Choke Test

    Section 5 Engine Diagnostic Tests Test 23 – Choke Test Procedure If generator is surging, it may be a carburetion problem. A lean condition can cause erratic RPM. Slowly pull choke out to see if surging stops. If it does stop, carburetion should be checked.

  • Page 38: Test 25 - Check Engine / Cylinder Leak Down Test / Compression Test

    Section 5 Engine Diagnostic Tests Test 25 – Check Engine / Cylinder Rotate engine crankshaft until the piston reaches top dead center (TDC). Both valves should be Leak Down Test / Compression Test closed. General Theory Lock flywheel at top dead center. Attach cylinder leak down tester adapter to spark Most engine problems may be classified as one, or a plug hole.

  • Page 39: Test 26 - Check Ignition Coil

    Section 5 Engine Diagnostic Tests Test 26 – Check Ignition Coil If coil passes Step 4 and Step 5 but there is still no spark, replace ignition coil. General Theory NOTE: Before replacing ignition coil, check flywheel magnet. The ignition system used on these engines is a solid- state (breakerless) type.

  • Page 40: Test 28 - Remove Shutdown Wire

    Section 5 Engine Diagnostic Tests Test 29 – Check / Adjust Governor (208/389/420cc Non-EFI Engine) Rotor operating speed and AC output frequency are proportional. The generator delivers a frequency of 60 Hertz at 3600 Rotor rpm or 62 Hertz at 3720 Rotor rpm. The Voltage Regulator should be adjusted to deliver 120 VAC (line-to-neutral) at a frequency of 60 Hertz or 124 VAC (line-to-neutral at 62 Hertz.

  • Page 41: Test 30 - Check / Adjust Governor (220/410/530Cc Non-Efi Engine)

    Section 5 Engine Diagnostic Tests Test 30 – Check / Adjust Governor Test 31 – Check Oil Pressure Switch (220/410/530cc Non-EFI Engine) If engine cranks and starts, then shuts down almost immediately, check the following: generator AC frequency output directly proportional to the speed of the rotor.

  • Page 42: Test 32 - Check Oil Level Switch

    Section 5 Engine Diagnostic Tests Test 33 – Test Recoil Function d. Connect one test lead to Wire 0 (disconnected from LOP). Connect the other test lead to a clean Procedure frame ground. CONTINUITY should measured. If CONTINUITY is NOT measured Attempt to pull start engine and observe the repair or replace Wire 0 between the LOP and following:...

  • Page 43: Test 36 - Test Battery Charging Circuit (Efi Electric Start Models)

    Section 5 Engine Diagnostic Tests to 14 VDC. If voltage is not present, replace Start Engine and let run for about a minute. charger. If voltage is present, remove battery Measure voltage on battery positive and negative cables from battery. terminals.
  • Page 44 Section 5 Engine Diagnostic Tests If CONTINUITY was measured in step 6, continue testing. If CONTINUITY was not measured, replace switch and test. Set DMM to read AC volts and remove wire 11B from low idle switch. Place one meter lead on wire 11B and the other lead to the ground in control panel.

  • Page 45: Section 6 Major Disassembly

    Major Disassembly Section 6 Introduction Each generator model has a unique method of disassembly. Figure 6-1 is a simplified version of disassembly that does not go into step by step instructions. The figure below represents the basic disassembly and sequence of steps needed to remove the fuel tank, stator, rotor, and the engine.
  • Page 46 Section 6 Major Disassembly XC6500 Drawing No. 10000005845-A Diagnostic Repair Manual...
  • Page 47 Section 6 Major Disassembly XC6500 Drawing No. 10000005845-A Diagnostic Repair Manual...
  • Page 48 Section 6 Major Disassembly XC6500 Drawing No. 10000005845-A (;3/2'(' 9,(: (9 *(1(5$725  36 3257 ;& *5283 (9 '5$:,1*   ,7(0 3$57 47< '(6&5,37,21 3$*(   08))/(5 *7+ :6$ *% 6&5(: 6+& 0 ;  * 6(06 & *$6.(7 (;+$867 3257 / 0$1,)2/' (;+$867 &&...
  • Page 49 Section 6 Major Disassembly XC6500 Drawing No. 10000005845-A (;3/2'(' 9,(: (9 *(1(5$725  36 3257 ;& *5283 (9 '5$:,1*   ,7(0 3$57 47< '(6&5,37,21  67 %5$&.(7 +$1'/( + &$3 187 0 %/$&. =,1& / 635,1* 3/81*(5 0 ;   67 %5$&.(7 +$1'/( ...
  • Page 50 Section 6 Major Disassembly XC8000 Drawing No. 10000005884-A Diagnostic Repair Manual...
  • Page 51 Section 6 Major Disassembly XC8000 Drawing No. 10000005884-A Diagnostic Repair Manual...
  • Page 52 Section 6 Major Disassembly XC8000 Drawing No. 10000005884-A (;3/2'(' 9,(: (9 *(1(5$725  (6 3257 ;& *5283 (9 '5$:,1*   ,7(0 3$57 47< '(6&5,37,21 3$*(   08))/(5 *7+ :6$ *% 6&5(: 6+& 0 ;  * 6(06 & *$6.(7 (;+$867 3257 / 0$1,)2/' (;+$867 &&...
  • Page 53 Section 6 Major Disassembly XC8000 Drawing No. 10000005884-A (;3/2'(' 9,(: (9 *(1(5$725  (6 3257 ;& *5283 (9 '5$:,1*   ,7(0 3$57 47< '(6&5,37,21  67 %5$&.(7 +$1'/( + &$3 187 0 %/$&. =,1& / 635,1* 3/81*(5 0 ;   67 %5$&.(7 +$1'/( ...
  • Page 54 Section 6 Major Disassembly This page intentionally left blank. Diagnostic Repair Manual...

  • Page 55: Section 7 Electrical Data

    Electrical Data Section 7 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. Diagnostic Repair Manual...

  • Page 56: Wiring Diagram And Electrical Schematic, Rs5500 Drawing No. 0K6393-A

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, RS5500 Drawing No. 0K6393-A Diagnostic Repair Manual...
  • Page 57 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, RS5500 Drawing No. 0K6393-A Diagnostic Repair Manual...
  • Page 58 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, RS5500 Drawing No. 0K6393-A Diagnostic Repair Manual...
  • Page 59 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, RS5500 Drawing No. 0K6393-A Diagnostic Repair Manual...

  • Page 60: Wiring Diagram And Electrical Schematic, Rs7000E Drawing No. 0K6394-C

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, RS7000E Drawing No. 0K6394-C Diagnostic Repair Manual...
  • Page 61 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, RS7000E Drawing No. 0K6394-C Diagnostic Repair Manual...
  • Page 62 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, RS7000E Drawing No. 0K6394-C Diagnostic Repair Manual...
  • Page 63 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, RS7000E Drawing No. 0K6394-C Diagnostic Repair Manual...

  • Page 64: Wiring Diagram And Electrical Schematic, Xc6500 Drawing No. 10000010344-A

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XC6500 Drawing No. 10000010344-A WIRING - DIAGRAM REVISION: -A- XC6.5 PORTABLE DRAWING #:10000010344 DATE: 06/16/2017 Diagnostic Repair Manual...
  • Page 65 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XC6500 Drawing No. 10000010344-A WIRING - DIAGRAM REVISION:-A- XC6.5 PORTABLE DRAWING #: 10000010344 DATE: 06/16/2017 Diagnostic Repair Manual...
  • Page 66 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XC6500 Drawing No. 10000010344-A SCHEMATIC - DIAGRAM REVISION: -A- XC6.5 PORTABLE DRAWING #: 10000010344 DATE: 06/16/2017 Diagnostic Repair Manual...
  • Page 67 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XC6500 Drawing No. 10000010344-A SCHEMATIC - DIAGRAM REVISION: -A- XC6.5 PORTABLE DRAWING #: 10000010344 DATE: 06/16/2017 Diagnostic Repair Manual...

  • Page 68: Wiring Diagram And Electrical Schematic, Xc6500E/Xc8000E Drawing No. 10000010343-A

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XC6500E/XC8000E Drawing No. 10000010343-A WIRING - DIAGRAM REVISION: -A- XC6.5E/XC8.0E PORTABLE DRAWING #:10000010343 DATE: 12/13/16 Diagnostic Repair Manual...
  • Page 69 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XC6500E/XC8000E Drawing No. 10000010343-A WIRING - DIAGRAM REVISION:-A- XC6.5E/XC8.0E PORTABLE DRAWING #: 10000010343 DATE: 12/13/16 Diagnostic Repair Manual...
  • Page 70 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XC6500E/XC8000E Drawing No. 10000010343-A SCHEMATIC - DIAGRAM REVISION: -A- XC6.5E/XC8.0E PORTABLE DRAWING #: 110000010343 DATE: 12/13/16 Diagnostic Repair Manual...
  • Page 71 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XC6500E/XC8000E Drawing No. 10000010343-A SCHEMATIC - DIAGRAM REVISION: -A- XC6.5E/XC8.0E PORTABLE DRAWING #: 10000010343 DATE: 12/13/16 Diagnostic Repair Manual...

  • Page 72: Wiring Diagram And Electrical Schematic, Xp4000 Drawing No. 0H8536-D

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP4000 Drawing No. 0H8536-D 30A/3PDT 120/240V TWISTLOCK L14-30R GRN/YEL NEUT 20A/1P C.B. 120V/20A DUPLEX 5-20R 120V/20A DUPLEX 5-20R 20A/1P C.B. 120/30A TWISTLOCK L5-30R WIRING - DIAGRAM REVISION: D XP4000 PORTABLE DRAWING #: 0H8536 DATE: 05/20/11 Diagnostic Repair Manual...
  • Page 73 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP4000 Drawing No. 0H8536-D CLOSEST TO BEARING GFCI C.B. 15A/2P MODULE STATOR RED(+) RED(+) IDLE CONTROL COIL C1-CAP C1-PLUG C2-PLUG C2-CAP SYSTEM CONTROL BOARD DK BLU DK BLU LEGEND AVR - AUTOMATIC VOLTAGE REGULATOR BA - BRUSH ASSEMBLY C1 - 2 POS FREE HANGING CONNECTOR, PLUG TO CAP...
  • Page 74 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP4000 Drawing No. 0H8536-D 120V/20A 120V/20A 120V 120V/240V DUPLEX DUPLEX 5-20R 5-20R TWISTLOCK TWISTLOCK L5-30R L14-30R 30A/3PDT WHT Y 120V/240V POSITION SHOWN C.B. C.B. 20A/1P 20A/1P LEGEND AVR - AUTOMATIC VOLTAGE REGULATOR BA - BRUSH ASSEMBLY C1 - 2 POS FREE HANGING CONNECTOR, PLUG TO CAP...
  • Page 75 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP4000 Drawing No. 0H8536-D GFCI RED(+) MODULE C.B. 15A/2P CLOSEST TO BEARING ROTOR DPE WINDING POWER WINDING (STATOR) NEUT DK BLU DK BLU SYSTEM IDLE C1-1 CONTROL CONTROL BOARD COIL C1-2 SCHEMATIC - DIAGRAM REVISION: D XP4000 PORTABLE...

  • Page 76: Wiring Diagram And Electrical Schematic, Xp5600E & Xp6400E Drawing No. 0K2042-A

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP5600E & XP6400E Drawing No. 0K2042-A Diagnostic Repair Manual...
  • Page 77 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP5600E & XP6400E Drawing No. 0K2042-A Diagnostic Repair Manual...

  • Page 78: Wiring Diagram And Electrical Schematic, Xp6500E Drawing No. 0H6809-D

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP6500E Drawing No. 0H6809-D C.B. 30A/2P 30A/3PDT 120/30A TWISTLOCK 30A/1P L5-30R C.B. GRN/YEL 20A/1P NEUT C.B. 120V/20A DUPLEX 5-20R 20A/1P C.B. 120V/20A DUPLEX 5-20R 120/240V TWISTLOCK L14-30R C.B. 30A/2P: 6.5kW WIRING - DIAGRAM REVISION: D XP6.5 PORTABLE DRAWING #: 0H6809...
  • Page 79 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP6500E Drawing No. 0H6809-D CLOSEST TO BEARING GFCI MODULE STATOR RED(+) RED(+) IDLE CONTROL COIL C1-CAP C1-PLUG C3-PLUG C3-CAP SYSTEM CONTROL BOARD DK BLU EXTERNAL DK BLU BATTERY CHARGER C2-PLUG C2-CAP LEGEND AVR - AUTOMATIC VOLTAGE REGULATOR BA - BRUSH ASSEMBLY...
  • Page 80 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP6500E Drawing No. 0H6809-D 120V/240V 120V 120V/20A 120V/20A TWISTLOCK TWISTLOCK DUPLEX DUPLEX L14-30R L5-30R 5-20R 5-20R 30A/3PDT C.B. 30A/2P C.B. C.B. C.B. 20A/1P 20A/1P 30A/1P 120V/240V POSITION SHOWN (RED) LEGEND AVR - AUTOMATIC VOLTAGE REGULATOR BATTERY BA - BRUSH ASSEMBLY BC - BATTERY CHARGER...

  • Page 81: Wiring Diagram And Electrical Schematic, Xp6500E Drawing No. 0H6809-D

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP6500E Drawing No. 0H6809-D GFCI MODULE C.B. RED(+) 30A/2P CLOSEST TO BEARING ROTOR DPE WINDING POWER WINDING (STATOR) DK BLU DK BLU NEUT SYSTEM IDLE CONTROL C1-1 CONTROL BOARD COIL C1-2 C2-2 EXTERNAL BATTERY...

  • Page 82: Wiring Diagram And Electrical Schematic, Xp8000E Drawing No. 0H7588-C

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP8000E Drawing No. 0H7588-C C.B. 35A/2P 120V/20A DUPLEX 20A/1P 5-20R C.B. 120V/20A DUPLEX 20A/1P 5-20R C.B. GRN/YEL NEUT 120/240V TWISTLOCK L14-30R C.B. 30A/2P LEGEND AVR - AUTOMATIC VOLTAGE REGULATOR BA - BRUSH ASSEMBLY BC - BATTERY CHARGER 120/30A BCR - BATTERY CHARGE RELAY...
  • Page 83 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP8000E Drawing No. 0H7588-C CLOSEST TO BEARING GFCI MODULE STATOR RED(+) RED(+) IDLE CONTROL COIL C1-CAP C1-PLUG SYSTEM CONTROL BOARD DK BLU DK BLU EXTERNAL BATTERY CHARGER C2-PLUG C2-CAP BATTERY SUPPLIED WITH UNIT WIRING - DIAGRAM REVISION:C XP8.0 PORTABLE...
  • Page 84 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP8000E Drawing No. 0H7588-C 120V 120V/240V 120V/20A 120V/20A TWISTLOCK TWISTLOCK GFCI GFCI L5-30R L14-30R 5-20R 5-20R C.B. 30A/2P C.B. C.B. C.B. 20A/1P 20A/1P 30A/1P (RED) LEGEND BATTERY AVR - AUTOMATIC VOLTAGE REGULATOR BA - BRUSH ASSEMBLY BC - BATTERY CHARGER BCR - BATTERY CHARGE RELAY...
  • Page 85 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP8000E Drawing No. 0H7588-C GFCI MODULE C.B. RED(+) 35A/2P CLOSEST TO BEARING ROTOR DPE WINDING POWER WINDING (STATOR) DK BLU DK BLU SYSTEM NEUT IDLE C1-1 CONTROL CONTROL BOARD COIL C1-2 C2-2 EXTERNAL BATTERY...

  • Page 86: Wiring Diagram And Electrical Schematic, Xp10000E Drawing No. 0H7214-D

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP10000E Drawing No. 0H7214-D Diagnostic Repair Manual...
  • Page 87 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP10000E Drawing No. 0H7214-D Diagnostic Repair Manual...
  • Page 88 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP10000E Drawing No. 0H7214-D Diagnostic Repair Manual...
  • Page 89 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XP10000E Drawing No. 0H7214-D Diagnostic Repair Manual...

  • Page 90: Wiring Diagram And Electrical Schematic, Xg4000 Drawing No. 0H3339-E

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG4000 Drawing No. 0H3339-E PBAR CLOSEST TO BEARING STATOR RED(+) CB 1 20A 44(BLK) 11(RED) CB 2 20A 11(RED) 44(BLK) GRN/YEL RED(+) RCT A 20A NEMA L14-20R 33(WHT) GRN/YEL GRN/YEL RCT B 20A GFCI NEMA 5-20R FOR BRUSH TYPE...
  • Page 91 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG4000 Drawing No. 0H3339-E SCHEMATIC - DIAGRAM REVISION: E GP/XG4000 DRAWING #: 0H3339 DATE: 8/12/09 Diagnostic Repair Manual...

  • Page 92: Wiring Diagram And Electrical Schematic, Xg4000 Drawing No. 0H5278-A

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG4000 Drawing No. 0H5278-A PBAR CLOSEST TO BEARING STATOR RED(+) CB 1 20A/2P 44(BLK) 11(RED) 11(RED) 44(BLK) GRN/YEL RED(+) RCT A 20A NEMA L14-20R 33(WHT) GRN/YEL GRN/YEL RCT B 20A GFCI NEMA 5-20R FOR BRUSH TYPE ALTERNATOR...
  • Page 93 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG4000 Drawing No. 0H5278-A SCHEMATIC - DIAGRAM REVISION: A XG4000 CAL/CSA DRAWING #: 0H5278 DATE: 9/09/09 Diagnostic Repair Manual...

  • Page 94: Wiring Diagram And Electrical Schematic, Xg5600E/Xg6400E Drawing No. 0J8223-B

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG5600E/XG6400E Drawing No. 0J8223-B Diagnostic Repair Manual...
  • Page 95 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG5600E/XG6400E Drawing No. 0J8223-B Diagnostic Repair Manual...

  • Page 96: Wiring Diagram And Electrical Schematic, Xg6500 Drawing No. 0H2780-F

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG6500 Drawing No. 0H2780-F PBAR CLOSEST TO BEARING STATOR RED(+) CB 1 44(BLK) 11(RED) CB 2 11(RED) 44(BLK) GRN/YEL RED(+) RCT A 30A NEMA L14-30R 33(WHT) GRN/YEL GRN/YEL RCT B 20A GFCI NEMA 5-20R FOR BRUSH TYPE ALTERNATOR...
  • Page 97 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG6500 Drawing No. 0H2780-F SCHEMATIC - DIAGRAM REVISION: F GP/XG5000-GP/XG8000 DRAWING #: 0H2780 DATE: 8/21/09 Diagnostic Repair Manual...

  • Page 98: Wiring Diagram And Electrical Schematic, Xg7000E Drawing No. 0H3525-C

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG7000E Drawing No. 0H3525-C PBAR CLOSEST TO BEARING STATOR RED(+) CB 1 44(BLK) 11(RED) CB 2 11(RED) 44(BLK) GRN/YEL RED(+) RCT A 30A NEMA L14-30R 33(WHT) GRN/YEL GRN/YEL RCT B 20A GFCI NEMA 5-20R FOR BRUSH TYPE ALTERNATOR...
  • Page 99 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG7000E Drawing No. 0H3525-C SCHEMATIC - DIAGRAM REVISION:C GP/XG5000-GP/XG8000 DRAWING #: 0H2780 DATE: 8/21/09 Diagnostic Repair Manual...

  • Page 100: Wiring Diagram And Electrical Schematic, Xg8000E Drawing No. 0H5145-A

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG8000E Drawing No. 0H5145-A PBAR CLOSEST TO BEARING STATOR RED(+) CB 1 44(BLK) 11(RED) CB 2 11(RED) 44(BLK) GRN/YEL RED(+) RCT A 30A NEMA L14-30R 33(WHT) GRN/YEL GRN/YEL RCT B 20A GFCI NEMA 5-20R FOR BRUSH TYPE ALTERNATOR...
  • Page 101 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG8000E Drawing No. 0H5145-A SCHEMATIC - DIAGRAM REVISION:B XG8000 DRAWING #: 0H5145 DATE: 1/08/16 Diagnostic Repair Manual...

  • Page 102: Wiring Diagram And Electrical Schematic, Xg10000E Drawing No. 0H3931-B

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG10000E Drawing No. 0H3931-B 120V/240V 120V/20A 120V/20A 120V 120V/240V GFCI GFCI 5-20R 5-20R TWISTLOCK OUTLET TWISTLOCK C.B. 14-50R L5-30R L14-30R 30A/2P GREEN WHITE C.B. 42A/2P C.B. C.B. C.B. 20A/1P 20A/1P 30A/1P GRN/YEL GRN/YEL NEUT...
  • Page 103 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG10000E Drawing No. 0H3931-B PBAR STATOR CLOSEST TO BEARING VOLTAGE REGULATOR EXTERNAL BATTERY CHARGER LEGEND BA - BRUSH ASSEMBLY BC - BATTERY CHARGER BCR - BATTERY CHARGE RECTIFIER CB1 - CIRCUIT BREAKER, AUTO RESET, 5A FSS - FUEL SHUT OFF SOLENOID F1 - FUSE 5 AMP F2 - FUSE 1.5 AMP, SLO-BLO...
  • Page 104 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG10000E Drawing No. 0H3931-B 120V/240V 120V/240V 120V 120V/20A 120V/20A OUTLET TWISTLOCK TWISTLOCK GFCI GFCI 14-50R L14-30R L5-30R 5-20R 5-20R C.B. C.B. 30A/2P 42A/2P C.B. C.B. C.B. 20A/1P 20A/1P 30A/1P LEGEND BA - BRUSH ASSEMBLY BC - BATTERY CHARGER BCR - BATTERY CHARGE RECTIFIER CB1 - CIRCUIT BREAKER, AUTO RESET, 5A...
  • Page 105 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XG10000E Drawing No. 0H3931-B POWER WINDING PBAR FIELD NEUT VOLTAGE REGULATOR DPE WINDING EXTERNAL (STATOR) BATTERY CHARGER BATTERY PORTABLE CONTROLLER BLACK C1-3 C1-2 C1-1 C1-5 C1-4 SCHEMATIC - DIAGRAM REVISION:B 10.0 PORTABLE DRAWING #: 0H3931 DATE: 1/11/11 Diagnostic Repair Manual...

  • Page 106: Wiring Diagram And Electrical Schematic, Xt8000E Drawing No. 0K2800-C

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, XT8000E Drawing No. 0K2800-C Diagnostic Repair Manual...

  • Page 107: Wiring Diagram And Electrical Schematic, Hl6500E Drawing No. 0L2474-A

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, HL6500E Drawing No. 0L2474-A Diagnostic Repair Manual...
  • Page 108 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, HL6500E Drawing No. 0K9434-B Diagnostic Repair Manual...

  • Page 109: Wiring Diagram And Electrical Schematic, Hl6500E Drawing No. 0K9434-B

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, HL6500E Drawing No. 0K9434-B Diagnostic Repair Manual...

  • Page 110: Wiring Diagram And Electrical Schematic, Hl6500E Drawing No. 0K9433-B

    Section 7 Electrical Data Wiring Diagram and Electrical Schematic, HL6500E Drawing No. 0K9433-B Diagnostic Repair Manual...
  • Page 111 Section 7 Electrical Data Wiring Diagram and Electrical Schematic, HL6500E Drawing No. 0K9433-B Diagnostic Repair Manual...

  • Page 112: Wiring Diagram, Xt8000Efi Drawing No

    Section 7 Electrical Data Wiring Diagram, XT8000EFI Drawing No. 10000023894-A WIRING - DIAGRAM REVISION: A 8000EFI DRAWING #: 10000023894 DATE: 01/15/2018 Diagnostic Repair Manual...

  • Page 113: Electrical Formulas

    Electrical Formulas To Find Known Values 1-phase 3-phase E X I E x I x 1.73 x PF Kilowatts (kW) Volts, Current, Power Factor 1000 1000 E x I E x I x 1.73 Volts, Current 1000 1000 kW x 1000 kW x 1000 Amperes kW, Volts, Power Factor...
  • Page 114 ©2018 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved Waukesha, WI 53189 Specifications are subject to change without notice. 1-888-GENERAC (1-888-436-3722) No reproduction allowed in any form without prior written www.generac.com consent from Generac Power Systems, Inc.

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