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generac 4000 exl problem

20 years ago

I have Generac 4000 EXL generator that is 3 years old and has less than 100 hours use, I use it at my cabin and used it about a month ago and it worked fine but when I got it out the other day it started fine but it is not generating any electricity. I reset the the circuit breakers but still no power, I would appreciate any help on this. thanks Rick

Comments (9)

  • 20 years ago

    Remove the end plate and make sure the brushes are not sticking in the holders. If that is not the problem and you dont see anything obvious like a broken wire you will need to have it checked by a generator service shop

  • 20 years ago

    A trip to the service shop likely isn't necessary....."flashing" the generator should get it working again. I've included a link below to a "tool" that's available for doing what needs to be done. You don't need this tool.....I included it more for illustration purposes than anything. It looks like a flashlight body with a 3 prong plug in place of the bulb assembly, because that's basically all it is. You start the generator and then the tool sends 1-2 volts DC into your genset via the 3 prong plug to get the generator working again.

    I've used batteries to do the job many times, but now I use an old (non-variable speed) drill to do the job. The old drill has a short piece of broken hex key in the chuck. I use my cordless drill to spin the old drill by attaching it to the other end of the hex key so the drills are together nose to nose. If I put a voltmeter set on the DC scale across the prongs on the plug of the old drill while I'm spinning it with my cordless one, I get 1-1 1/2 volts DC.....plenty to do the job.

    I start the generator that's not working, plug the old drill into it, and spin it up with my cordless drill. Once it's up and spinning, I depress the trigger for a second or so on the old drill. (You'll have no DC output at the plug from the drill until you depress the trigger.) Within a second or so of squeezing the trigger, you'll feel the drill "pull" as the genset begins producing electricity again. Your drill will not be damaged, and the procedure is simple and safe. Just be ready to release the drill trigger when the genset begins producing power. Also remember that the drill should be a simple single-speed model. Variable speed triggers will keep this from working.

    Here's the link to the "tool" I mentioned:

    Here is a link that might be useful: Generator

  • 20 years ago

    Broke not,
    I have heard that you need to keep the positive and negative right. When you use your drill procedure is there any problem doing that?
    I have also heard you can start your generator, hook up an automotive style battery to the plug in on your generator for a brief moment to get it running again.

  • 20 years ago

    Something else is wrong if it needs to be flashed after only a month. If this procedure needs to be repeated each time, the rotor may be the problem.

  • 20 years ago

    If this appears more than once forgive me, I'm having PC troubles this morning.

    Has anyone else heard that Generac Power Systems might be for sale? I heard this week that they might be looking for a buyer?

  • 20 years ago

    Briggs bought their generator and power washer divisions some time ago. They could be liquidating, I am having problems sourcing some engine parts.

  • 20 years ago

    The powerwasher thing is probably true. But their website still says the own their generator business. Wonder what's going on?

  • 20 years ago

    They sold their "small engine" division to B & S two years ago. They still make large generators/engines.

  • 15 years ago

    How do I remove the small 12volt starting battery?

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