Generac Power Systems 5413, 5412, 5411, 5415, 5414, 5410 manual Test 36 Check Oil Pressure Switch

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Section 7

DIAGNOSTIC TESTS

Discussion:

The Cylinder Leak Down Tester checks the sealing (compression) ability of the engine by measuring air leakage from the combustion chamber. Compression loss can present many different symptoms. This test is designed to detect the section of the engine where the fault lies before disassembling the engine.

Procedure:

1.Remove a spark plug.

2.Gain access to the flywheel. Remove the valve cover.

3.Rotate the engine crankshaft until the piston reaches top dead center (TDC). Both valves should be closed.

4.Lock the flywheel at top dead center.

5.Attach cylinder leak down tester adapter to spark plug hole.

6.Connect an air source of at least 90 psi to the leak down tester.

7.Adjust the regulated pressure on the gauge to 80 psi.

8.Read the right hand gauge on the tester for cyl- inder pressure. 20 percent leakage is normally acceptable. Use good judgement, and listen for air escaping at the carburetor, the exhaust, and the crankcase breather. This will determine where the fault lies.

9.Repeat Steps 1 through 8 on remaining cylinder.

Results:

❏Air escapes at the carburetor – check intake valve.

❏Air escapes through the exhaust – check exhaust valve.

❏Air escapes through the breather – check piston rings.

❏Air escapes from the cylinder head – the head gas- ket should be replaced.

Check Compression:

Lost or reduced engine compression can result in (a) failure of the engine to start, or (b) rough operation. One or more of the following will usually cause loss of compression:

❏Blown or leaking cylinder head gasket.

❏Improperly seated or sticking-valves.

❏Worn Piston rings or cylinder. (This will also result in high oil consumption).

NOTE: It is extremely difficult to obtain an accu- rate compression reading without special equip- ment. For that reason, compression values are not published for the V-Twin engine. Testing has proven that an accurate compression indication can be obtained using the following method.

PROCEDURE:

1.Remove both spark plugs.

2.Insert a compression gauge into either cylinder.

3.Crank the engine until there is no further increase in pressure.

4.Record the highest reading obtained.

5.Repeat the procedure for the remaining cylinder and record the highest reading.

RESULTS:

The difference in pressure between the two cylinders should not exceed 25 percent. If the difference is greater than 25 percent, loss of compression in the lowest reading cylinder is indicated.

Example 1: If the pressure reading of cylinder #1 is 165 psi and of cylinder #2, 160 psi, the difference is 5 psi. Divide “5” by the highest reading (165) to obtain the percentage of 3.0 percent.

Example 2: No. 1 cylinder reads 160 psi; No. 2 cylinder reads 100 psi. The difference is 60 psi. Divide “60” by “160” to obtain “37.5” percent. Loss of compression in No. 2 cylinder is indicated.

If compression is poor, look for one or more of the fol- lowing causes:

❏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 P/N xxxxxx for further engine service information.

Test 36 – Check Oil Pressure Switch

DISCUSSION:

Also see “Operational Analysis” on Pages 18-23. The Low Oil Pressure Switch is normally-closed, but is held open by engine oil pressure during cranking and startup. Should oil pressure drop below a safe level, the switch contacts will close to ground the Wire 85 circuit. Printed Circuit Board action will then initiate an automatic shutdown.

If the switch fails closed, the engine will crank and start, but will then shut down after a few seconds.

If the switch fails open, low oil pressure will not result in automatic shutdown.

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Induction MagnetismElectromagnetic Fields Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Field Boost Generator AC Connection SystemConnection for 120 Volts Only Rotor Assembly Stator AssemblyBrush Holder Excitation Circuit ComponentsCrankcase Breather DescriptionControl Panel Component Identification Control Panel ComponentsInsulation Resistance Testers Cleaning the GeneratorEffects of Dirt and Moisture Drying the GeneratorStator Insulation Resistance Testing Rotor Insulation Testing Rotor InsulationTesting Stator Insulation MegohmmeterMeasuring AC Voltage MetersVOM Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohm’s LawIntroduction Operational AnalysisCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Battery Cables BatteryRecommended Battery Printed Circuit BoardStart-Stop Switch Amp FuseStart-Stop Switch Starter Contactor Relay Starter MotorIf Problem Involves AC Output Problem 1 Voltage & Frequency Are Both High or LowTest Troubleshooting Flowcharts Proble 5 Priming Function Does Not Work Gasoline Models Problem 6 Engine Will Not Crank Test 26 Check Test 20 Check Check Fuel Wire 14 Power Good Troubleshooting Flowcharts Problem 8 Engine Starts Hard and Runs Rough Gasoline Units Problem 8 Engine Starts Hard and Runs Rough LP Units LOW OIL Pressure Flashes on SW1 LED Problem 10 7.5A F1 Fuse Blowing YESTest 2 Check Stepper Motor Control ProcedureTest 1 Check No-Load Voltage Frequency DiscussionSix Pin J2 Connector Wire Colors Test 4 Fixed Excitation Test/Rotor Amp DrawFixed Excitation Test, Step B Test 5 Check Field Boost Test 6 Test Stator DPE WindingTest 7 Check Sensing Leads / Power Windings Stator Excitation WindingStator Power Winding Leads Test 8 Check Brush LeadsTest 10 Check Rotor Assembly Test 9 Check Brushes & Slip RingsTest 12 Check Load Voltage Frequency SchematicTest 11 Check Main Circuit Breaker Test 13 Check Load Watts AmperageTest 14 Try Cranking the Engine Test 15 Check Fuel PumpTest 16 Check 7.5 Amp Fuse Test 17 Check Battery & CablesTest 18 Check Power Supply to Printed Circuit Board Test 19 Check Continuity of Wire Test 20 Check Start-Stop SwitchTest 21 Check Power Supply to Wire Test 22 Check Starter Contactor RelayTest 23 Check Starter Contactor Test 24 Check Starter MotorTools for Starter Performance Test Checking the PinionPinion Minimum rpm 4500 Maximum Amps Test 25 Check Fuel Supply To Carburetor GASTest 26 Check Wire 14 Power Supply 29. Fuel RegulatorTest 27 Check Wire Test 28 Check Fuel Solenoid Gasoline ModelsTest 29 Check Ignition Spark Tools RequiredTwo Ignition Testers Generac P/N 0C5969Test 31 Check and Adjust Ignition Magnetos Test 30 Check Spark Plugs37. Setting Ignition Magneto Armature Air Gap Flywheel KEY Test 32 Check Valve AdjustmentChecking Flywheel Magnet Test 33 Check Carburetion Test 34 Check Choke SolenoidTo Control Solenoid PanelTest 36 Check Oil Pressure Switch Test 37 Check Wire 86 for Continuity Test 38 Test Oil Temperature SwitchTest 39 Check Wire 85 for Continuity Test 40 Test Choke HeaterTest 41 Check LPG Fuel Solenoid Section Exploded Views QTY Description Enclosure Drawing No G3881-C Enclosure Door Views Screw Plastite HI-LOW #10X3/8 Engine Accessories Drawing No G7718-B QTY Description 48,49 Square Head Plug Rotor & Stator Drawing No G3953-b NUT TOP Lock FL M8-1.25 Charts Generator Specifications Nominal Resistances of Generator Windings at 68fElectrical Data Electrical Data OG7515 REV. a

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