Help with Generac Generator

I am trying to get my dads Generac 4000XL working for him but would appreciate any advice as to where to start as I am new to these things.
The two obvious problems it has are:
1. It starts fine but shuts down after about 15 seconds.
2. At idle it has power to supply a light, my dremel and even seems to want to run my skill saw but rather than throttle up under load it simply bogs down when a heavier load like the skill saw is added.
I have found that I can prevent it from shutting down if I disconnect the connector leading to what appears to be an oil pressure sender. Before I did this I checked the oil level to make sure there was plenty. Oil actually came out the fill hole so I guess it must have been over filled.
I think my dad took it apart to try and fix it but is not sure it was assembled properly. Also my dad thinks that he burned out his radial saw trying to operate off the malfunctioning generator.
If anyone can suggest possible causes for my problems I would be greatly appreciated.
Thanks

Lloyd Cimprich wrote:

I am trying to get my dads Generac 4000XL working for him but would appreciate any advice as to where to start as I am new to these things.
The two obvious problems it has are:
1. It starts fine but shuts down after about 15 seconds.

So *it* thinks there's a problem, too.

2. At idle it has power to supply a light, my dremel and even seems to want to run my skill saw but rather than throttle up under load it simply bogs down when a heavier load like the skill saw is added.

So kinda like choking, then.

I have found that I can prevent it from shutting down if I disconnect the connector leading to what appears to be an oil pressure sender. Before I did this I checked the oil level to make sure there was plenty. Oil actually came out the fill hole so I guess it must have been over filled.

I assume the warranty has come and gone on that unit?

I think my dad took it apart to try and fix it but is not sure it was assembled properly. Also my dad thinks that he burned out his radial saw trying to operate off the malfunctioning generator.

The only thing a generator could do to kill a radial saw is over-volt it.

If anyone can suggest possible causes for my problems I would be greatly appreciated.

Get a good RMS voltage meter that also measures hertz. Plug it in to the generator. There are, on the ones I usually see, some adjustment screws for both coarse and fine adjustment. I'd bet they're out of wack... or atleast, the best place to start.
And drain the excess oil if there is any.
DJ

"Lloyd Cimprich" wrote in message

I am trying to get my dads Generac 4000XL working for him but would appreciate any advice as to where to start as I am new to these things.
The two obvious problems it has are:
1. It starts fine but shuts down after about 15 seconds.
2. At idle it has power to supply a light, my dremel and even seems to want to run my skill saw but rather than throttle up under load it simply bogs down when a heavier load like the skill saw is added.
I have found that I can prevent it from shutting down if I disconnect the connector leading to what appears to be an oil pressure sender. Before I did this I checked the oil level to make sure there was plenty. Oil actually came out the fill hole so I guess it must have been over filled.
I think my dad took it apart to try and fix it but is not sure it was assembled properly. Also my dad thinks that he burned out his radial saw trying to operate off the malfunctioning generator.
If anyone can suggest possible causes for my problems I would be greatly appreciated.
Thanks

I had a very similar starting problem with an XL5000 that I acquired with the purchase of a new home. It did not seem to have many hours on it, but it would start, idle for a few seconds than stall out.
I removed the wire to the low oil shutdown plug in the engine block, and now it starts.
I did a quick test with a handheld grinder, and it seemed to run that load ok, but since then I have not used it at all.
Of course, I checked the oil level before I disconnected the sensor. I assumed that the low oil sensor was bad. Replacements are available, but so far I have not bothered to get one.
Don't know about your other problem.

Lloyd Cimprich wrote:

I am trying to get my dads Generac 4000XL working for him but would appreciate any advice as to where to start as I am new to these things.
The two obvious problems it has are:
1. It starts fine but shuts down after about 15 seconds.
2. At idle it has power to supply a light, my dremel and even seems to want to run my skill saw but rather than throttle up under load it simply bogs down when a heavier load like the skill saw is added.
I have found that I can prevent it from shutting down if I disconnect the connector leading to what appears to be an oil pressure sender. Before I did this I checked the oil level to make sure there was plenty. Oil actually came out the fill hole so I guess it must have been over filled.
I think my dad took it apart to try and fix it but is not sure it was assembled properly. Also my dad thinks that he burned out his radial saw trying to operate off the malfunctioning generator.
If anyone can suggest possible causes for my problems I would be greatly appreciated.
Thanks
This generator should have a switch on the panel called Idle control I

think. It senses if a load is present on the generator and drops the idle when no load is present. When I had mine serviced the tech didn't know about the switch and set the idle to low to run when auto idle was active. Generac does carry the service manual for this machine.
Just a thought
J. Vrzal

On Tue, 11 Apr 2006 20:57:45 -0400, "Lloyd Cimprich" wrote:

I am trying to get my dads Generac 4000XL working for him but would appreciate any advice as to where to start as I am new to these things.
The two obvious problems it has are:
1. It starts fine but shuts down after about 15 seconds.
2. At idle it has power to supply a light, my dremel and even seems to want to run my skill saw but rather than throttle up under load it simply bogs down when a heavier load like the skill saw is added.

Replace the oil pressure sensor and check the air filter.

Thanks to all for the excellent advice and suggestions.
I did download a manual from Generac site but could not find one for my exact model.
From what I have read as well as advice here and my testing I think this what I have to do:
1. Remove oil and replace to proper level with 30 wt oil.
2. Start engine with Idle control off and no load.
3. If the engine shuts down then verify adequate oil pressure and disconnect sender.
4. Find a way to adjust the rpm to 3600 with Idle Control System off.
3, Check voltage at 3600 and it should be about normal 110 - 120.
4. Activate Idle Control to verify RPM drop (ECO mode).
5. Add load to verify RPM rise back to 3600 as well as normal voltage.
I am not sure how I can verify RPM but maybe I can use one of my old auto Dwell/Tach meters.
In any case I am beginning to think that the unit is basically OK and at worst the Idel Control and/or Oil pressure sensing systems may be dead. But if they are it seems I can still let run at a steady 3600 and maybe replace sender or add a mechanical oil pressure guage as I have an old one somewhere.
Thanks.

We bought a combo tach/hour meter like this on: http://www.alliedelec.com/Search/ProductDetail.asp?SKU=207-0046&desc=PT15C2
you might also consider a kill-a-watt device which will give you voltage and hertz. The hertz times 60 is approximate RPM. we run our unit just over 3700 RPM. It is the larger 13500 surge unit.

Let me know how you do on bypassing the oil pressure or low oil device whatever it is.. We had those fail on some of our Hondas and it impacted starting and running.
Does it have an oil pump? Does it have an oil filter?
Lloyd Cimprich wrote:

Thanks to all for the excellent advice and suggestions.
I did download a manual from Generac site but could not find one for my exact model.
From what I have read as well as advice here and my testing I think this what I have to do:
1. Remove oil and replace to proper level with 30 wt oil.
2. Start engine with Idle control off and no load.
3. If the engine shuts down then verify adequate oil pressure and disconnect sender.
4. Find a way to adjust the rpm to 3600 with Idle Control System off.
3, Check voltage at 3600 and it should be about normal 110 - 120.
4. Activate Idle Control to verify RPM drop (ECO mode).
5. Add load to verify RPM rise back to 3600 as well as normal voltage.
I am not sure how I can verify RPM but maybe I can use one of my old auto Dwell/Tach meters.
In any case I am beginning to think that the unit is basically OK and at worst the Idel Control and/or Oil pressure sensing systems may be dead. But if they are it seems I can still let run at a steady 3600 and maybe replace sender or add a mechanical oil pressure guage as I have an old one somewhere.
Thanks.

Lloyd Cimprich wrote in message

Thanks to all for the excellent advice and suggestions.
I did download a manual from Generac site but could not find one for my exact model.
From what I have read as well as advice here and my testing I think this what I have to do:
1. Remove oil and replace to proper level with 30 wt oil.
2. Start engine with Idle control off and no load.

It sounds to me like your engine speed may be too low and that's killing the engine when a load is applied.

3. If the engine shuts down then verify adequate oil pressure and disconnect sender.
4. Find a way to adjust the rpm to 3600 with Idle Control System off.

What I do is use a Kill-A-Watt meter and adjust the frequency so it is very close to 60 Hz with about 1/3 load. From what I have read frequency is more important that voltage so as long as it's above 105 VAC or so it probably won't kill any motors etc. If you don't have a frequency meter you can sorta wing it by using a battery charger. Attach it to a battery and connect the charger to a regular AC outlet (the grid) and note the current reading. Then plug it into the generator and adjust the RPMs until the current reading is about the same. Also, some small appliances with digital displays won't work if the frequency is off by very much so they can be used to adjust it too (more or less). I'd check the voltage after any adjustments and make sure it's within reason.

3, Check voltage at 3600 and it should be about normal 110 - 120.

I'm more inclined to think about 105 to 125. We are probably not talking about a very sophisticated generator here.

4. Activate Idle Control to verify RPM drop (ECO mode).
5. Add load to verify RPM rise back to 3600 as well as normal voltage.
I am not sure how I can verify RPM but maybe I can use one of my old auto Dwell/Tach meters.

Please let me know if you figure out how to hook it up. I tried connecting mine and it killed the engine.

In any case I am beginning to think that the unit is basically OK and at worst the Idel Control and/or Oil pressure sensing systems may be dead. But if they are it seems I can still let run at a steady 3600 and maybe replace sender or add a mechanical oil pressure guage as I have an old one somewhere.
Thanks.