Table Of Contents - Generac Power Systems XT-EFI Series Manual

Safety ........................................................................ ii
Read This Manual Thoroughly .................................. ii
Replacement Parts ................................................... ii
Rotor and Stator Resistance Tables ........................ iii
Section 1 Brushless Capacitor Excitation ..................1
Introduction ...............................................................1
Stator Assembly ........................................................1
Rotor Assembly ........................................................1
Operation ..................................................................2
Troubleshooting Flowcharts ......................................3
If Problem Involves AC Output.................................. 3
Problem 1 - Generator Produces Zero Voltage
or Residual Voltage .................................................. 3
Problem 2 - Voltage & Frequency Are Both
High or Low............................................................... 4
Problem 3 - Excessive Voltage/Frequency
Droop When Load is Applied .................................... 4
Problem 4 - Generator Produces High Voltage
at No-Load ................................................................ 4
Section 2 Direct Excitation (Brush Type)....................5
Introduction ...............................................................5
Stator Assembly ........................................................5
Brush Holder and Brushes ........................................5
Voltage Regulator .....................................................5
Operation ..................................................................5
Troubleshooting Flowcharts ......................................7
If Problem Involves AC Output (Brush Type)............ 7
Problem 5 - Generator Produces Zero Voltage or
Residual Voltage....................................................... 7
Problem 6 - Voltage & Frequency Are Both
High or Low............................................................... 8
Problem 7 - Excessive Voltage/Frequency
Droop When Load is Applied .................................... 8
Problem 8 - Generator Produces High Voltage
at No-Load ................................................................ 8
Section 3 AC Diagnostic Tests ....................................9
Test 1 - Check No-Load Voltage and Frequency .....9
Test 2 - Check Main Circuit Breaker ........................9
Test 3 - Check Continuity of Receptacle Panel ........9
Test 4 - Fixed Excitation Test/Rotor Amp
Draw Test ................................................................10
Test 5 - Field Flash Alternator ................................12
Test 6 - Check Capacitor .......................................13
Test 7 - Test Brushless DPE Windings ..................13
Test 8 - Test Brushless Stator Windings ................14
Diagnostic Repair Manual
Test 9 - Test Brushed Stator Windings ..................14
Test 10 - Check Load Voltage & Frequency ..........14
Test 11 - Check Load Watts & Amperage .............14
Test 12 - Adjust Voltage Regulator ........................15
Test 13 - Voltage Changeover Switch
120/240 Position .....................................................15
Section 4 EFI Engine Control Diagnostic Tests.......17
Basic EFI Theory ....................................................17
Basic Open-Loop Theory ........................................17
Engine Requirements .............................................17
Fuel System ............................................................17
Air Metering and Measurement ..............................18
Sensor Inputs ..........................................................18
Basic Operation ......................................................18
EFI Fault Code Diagnostics ....................................19
Section 5 Engine Diagnostic Tests ...........................21
Diagnostic Flow Charts ...........................................21
Problem 9 - Recoil Cord Will Not Pull
(208/389/420/459cc Engines)................................. 21
Problem 10 - Engine Starts Hard and Runs
Rough (208/389/420cc Non-EFI Engines).............. 21
Problem 11 - Engine Turns Over But Will
Not Start (208/389/420cc Non-EFI Engines) .......... 22
Problem 12 - Engine "Hunts" / Erratic Idle
(208/389/420cc Non-EFI Engines) ......................... 22
Problem 13 - Engine Will Not Crank
(220/410/530cc Engines with Electric Start) ........... 23
Problem 14 - Recoil Cord Will Not Pull
(If So Equipped) (220/410/459/530cc Engines)...... 23
Problem 15 - Engine Cranks But Will Not Start
(220/410/530cc Non-EFI Engines) ......................... 24
Problem 16 - Engine Starts Hard and Runs
Rough (220/410/530cc Non-EFI Engines).............. 25
Problem 17 - Engine Starts Then Shuts Down
(220/410/530cc Non-EFI Engines) ......................... 25
Problem 18 - Battery Will Not Charge
(220/410/459/530cc Engines)................................. 25
Problem 19 - Engine "Hunts" / Erratic Idle
(220/410/530cc Non-EFI Engines) ......................... 26
Problem 20 - Unit Will Not Idle
(220/410/426/530cc Non-EFI Engines) .................. 26
Problem 21 - Unit Will Not Come Off Idle
(220/410/426/530cc Non-EFI Engines) .................. 26
Introduction .............................................................27
Test 14 - Check Fuse .............................................27
Test 15 - Check Battery and Cables ......................27

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