Guardian Technologies 4583, 4582 & 4987, 4451 & 4986, 5308 Test 42 Check Oil Pressure Switch Wire

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Section 6

DIAGNOSTIC TESTS

•Loose cylinder head bolts.

•Failed cylinder head gasket.

•Burned valves or valve seats.

•Insufficient valve clearance.

•Warped cylinder head.

•Warped valve stem.

•Worn or broken piston ring(s).

•Worn or damaged cylinder bore.

•Broken connecting rod.

•Worn valve seats or valves.

•Worn valve guides.

NOTE: Refer to Engine Service manual No. 0F6923 for further engine service information.

Test 42 - Check Oil Pressure Switch

and Wire 86

If the engine cranks and starts, then shuts down almost immediately, the cause may be one or more of the following:

•Low engine oil level.

•Low oil pressure.

•A defective oil pressure switch.

LOW OIL SWITCH

Figure 6-53. – Low Oil Pressure Switch

PROCEDURE:

1.Check engine crankcase oil level.

a.Check engine oil level.

b.If necessary, add the recommended oil to the dipstick FULL mark. DO NOT OVERFILL ABOVE THE FULL MARK.

2.Do the following:

a.Disconnect Wire 86 and Wire 0 from the oil pressure switch terminals. Remove the switch and install an oil pressure gauge in its place.

b. Start the engine while observing the oil pressure reading on gauge.

c. Note the oil pressure.

(1)Normal oil pressure is approximately 35-40 psi with engine running. If normal oil pres- sure is indicated, go to Step 4 of this test.

(2)If oil pressure is below about 10 psi, shut engine down immediately. A problem exists in the engine lubrication system. Refer to Service Manual, Generac P/N 0F6923 for engine service recommendations.

Note: The oil pressure switch is rated at 10 psi for v-twin engines.

3.Remove the oil pressure gauge and reinstall the oil pressure switch. Do NOT connect Wire 86 or Wire 0 to the switch termi- nals.

a.Set a voltmeter to measure resistance.

b.Connect the meter test leads across the switch terminals. With engine shut down, the meter should read CONTINUITY.

c.Crank and start the engine. The meter should read INFINITY.

d.Connect one test lead to Wire 0 ( disconnected from LOP). Connect the other test lead to a clean frame ground. Continuity should be measured. If con- tinuity is NOT measured repair or replace Wire 0 between the LOP and the ground terminal connection on the engine mount.

4.If the LOP switch tests good in Step 3 and oil pressure is good in Step 2, but the unit still shuts down with a LOP fault, check Wire 86 for a short to ground. Set a voltmeter to measure resistance. Disconnect the J2 Connector from the circuit board. Remove Wire 86 from the LOP switch. Connect one test lead to Wire 86. Connect the other test lead to a clean frame ground. INFINITY should be measured. If CONTINUITY is measured, repair or replace Wire 86 between the LOP switch and the J2 Connector.

RESULTS:

1.If switch tests good, refer to Flow Chart.

2.Replace switch if it fails the test.

TEST 43 - Check Start Stop Relay (SSR)

PROCEDURE:

1.Set a voltmeter to measure resistance.

2.Disconnect Wire 15 and Wire 229 from the Start Stop Relay (SSR). See Figure 6-54.

3.Connect one meter test lead to the terminal that Wire 15 was removed from. Connect the other meter test lead to the terminal that Wire 229 was removed from. Resistance measured should be approximately 100 ohms.

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents Section Disassembly and Exploded Views 66-71 Electromagnetic Induction MagnetismElectromagnetic Fields More Sophisticated AC Generator STATORs AC power windingsSimple AC Generator Generator Operating Diagram VOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawEngine-Generator Drive System Rotor AssemblyIntroduction AC Generator Other AC Generator Components Stator AssemblyBrush Holder and Brushes Excitation Circuit BreakerVoltage Regulator Underfrequency Adjust162 Operation Rotor Residual MagnetismField Boost Circuit Stator Insulation Resistance Test Insulation ResistanceMegohmmeter Testing ALL Stator Windings to Ground Test Between WindingsDrying the Generator Cleaning the GeneratorRotor Insulation Resistance Test Printed Circuit Board BatteryRecommended Battery Circuit Board ConnectionsControl Panel Component Identification ENGINE DC CONTROLTerminal Block Terminal BLOCKTB2 TB1 C1 Female Side C1 Male SideC2 Female Side C2 Male Side Page Circuit Condition Rest = 12 VDC Control Circuit Condition Start IM1 SP1 IM2 SP2 RED Black Battery Circuit Condition RUN = Idle Control Transformer Output CIRcUIT Condition Stop Fault Shutdown Introduction If Problem Involves AC OutputProblem 1 Voltage & Frequency Are Both High or Low Or Replace If BAD Load Watts Problem 4 No Battery Charge Output Problem 5 No 10A Battery Charge OutputProblem 6 Engine Will Not Crank Problem 7 Engine Cranks But Will Not Start Problem 8 Engine Starts Hard and Runs Rough Problem 9 Engine Starts Then Shuts DownProblem 10 10 Amp Fuse F1 Blowing Problem 14 Engine Hunts / Erratic Idle Problem 11 Unit OverspeedsProblem 12 Idle Control RPM Does Not Decrease Test 2 Check Main Circuit Breaker ProcedureTest 1 Check No-Load Voltage Frequency ResultsSet voltmeter to measure AC voltage Test 4 Fixed Excitation Test Rotor AMP DrawIf circuit breaker is good, go on to Test AC Voltage across Wires 11S and 44S= Refer to Test 4 Results chartRemove air cleaner cover to access stepper motor Set a voltmeter to measure resistanceTest 6 Wire Continuity Test 7 Check Field BoostSet volt meter to the diode test range Disconnect both wires from the Resistor R1Test 8 DIODE/RESISTOR Set volt meter to measure resistanceFrom the 50 Amp receptacle disconnect Wire Test 9 Test StatorUnplug the six pin connector at the Voltage Regulator Test 10 Sensing LeadsTest 12 Check Brush Leads Test 11 Excitation WiringGain access to the brushes and slip rings Test 13 Check Brushes & Slip RingsTest 16 Check Load Watts & Amperage Test 14 Check Rotor AssemblyTest 15 Check Load Voltage Frequency If the unit is overloaded, reduce the loadDisconnect all wires from the Battery Charge Rectifier Test 17 Check Battery Charge OutputTest 19 Check Battery Charge Rectifier BCR2 BCR1BCR2 Test 22- Check Battery & CablesTest 21- Check 10 Amp Fuse Test 24 Check Starter Contactor SC Refer back to flow chartTest 23 Check Voltage at Starter Contactor SC Test 25 Check Starter MotorChecking the Pinion Tools for Starter Performance TestTest 26 Test Starter Contactor Relay SCR Set voltmeter to measure DC voltageReconnect all wires to the switch Test 27 Check Start-Run-Stop Switch SW1Test 28 Check Start-Run-Stop Switch SW1 Wiring Procedure Set voltmeter to measure resistanceTest 30 Check Spark Plugs Refer back to the Flow ChartTest 29 Check Ignition Spark SSR and the Battery Charge Rectifier 2 BCR2 Test 31 Remove Wire 18 / Shutdown LeadRefer to Flow Chart Test 32 Test Start Stop Relay SSRTest 33 Test Wire RUNMagnetos Test 34 Test Start Stop Relay WiringTest 35 Check and Adjust Ignition Test 38 Check Fuel Pump Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage MagnetoTest 39 Check Carburetion Test 40 Valve AdjustmentAdjusting Valve Clearance Adjust the regulated pressure on the gauge to 80 psi 52 Tightening the Jam NutTest 42 Check Oil Pressure Switch Wire Test 43 Check Start Stop Relay SSRTest 44 Test Starter Contactor Relay SCR Test 45 Check Wire 15 CircuitTest 46 Check Wire 14 Circuit Test 47 Check Fuel Shutoff SolenoidTest 51 Check Wires 11S & 44S Test 50 Check WireTest 49 Check Wire 15B Test 48 Check HourmeterSW2 Test 52 Check Idle Control SwitchTest 53 Check Idle Control Wiring TB2Test 55 Check TR1 & TR2 Wiring Test 54 Check Idle Control Transformers ICTTest 56 Choke Test Continuity should be measuredMajor Disassembly Remove air deflector Figure B, Item #45 from cross memberSupport Alternator 3317 3026 20 22 25 QTY Description Detail of Battery Tray QTY. Description ELECTRICAL DATA RED Battery Charge Winding BA Brush Assembly Governor Actuator 167 229 15B Power Winding DPE Winding SCR Wiring Diagram 17.5 kW Drawing No G0731 Stator Closest to Bearing Electrical Schematic 17.5 kW Drawing No G0733 Circuit 11 ORG Circuit 13 DRK BLU Circuit 15 PNK ELECTRICAL DATA Page Frequency Hz 238-242 59-61 100 Rated Max DC Load Amperes Current @ 12 VoltsLoad % Torque Specifications Trim Torque SpecificationsPO BOX 297 WHITEWATER, WI

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