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SECTION 4.4
DIAGNOSTIC TESTS
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 4.5 psi, shut
engine down immediately. A problem exists
in the engine lubrication system.
Note: The oil pressure switch is rated at 10 psi
for v-twin engines, and 8 psi for single cylinder
engines.
4. Remove the oil pressure gauge and reinstall the oil pres-
sure switch. Do NOT connect Wire 86 or Wire 0 to the
switch terminals.
a. Set a VOM to measure resistance.
b. Connect the VOM test leads across the switch
terminals. With engine shut down, the meter
should read CONTINUITY.
sured with the engine shutdown, replace the LOP
switch.
c. Crank and start the engine. The meter should
read INFINITY.
5. Set a VOM to measure resistance.
a. Disconnect the J1 Connector from the printed
circuit board.
b. Connect one test lead to Wire 86 (disconnected
from LOP). Connect the other test lead to Pin
Location 4 (Wire 86) of the J1 Connector at the
Circuit Board (for all models). CONTINUITY
should be measured. If CONTINUITY is not
measured, repair or replace Wire 86 between
the LOP switch and the J1 Connector.
c. Connect one test lead to Wire 0 ( disconnected
from LOP). Connect the other test lead to a clean
frame ground. CONTINUITY should be mea-
sured. If CONTINUITY is NOT measured repair or
replace Wire 0 between the LOP and the ground
terminal connection on the engine mount.
7. If the LOP switch tests good in Step 4 and oil pressure
is good in Step 3 but the unit still shuts down with a LOP
fault, check Wire 86 for a short to ground. Set a VOM to
measure resistance. Disconnect the J1 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 mea-
sured. If CONTINUITY is measured, repair or replace
Wire 86 between the LOP switch and the J1 Connector.
Page 118
If INFINITY is mea-
PART 4
RESULTS:
1. Replace switch if it fails the test.
TEST 61- CHECK HIGH OIL TEMPERATURE
SWITCH
DISCUSSION:
If the temperature switch contacts have failed
in a closed position, the engine will fault out on
"OVERTEMP". If the unit is in an overheated condition,
the switch contacts will close at 284° F. This will normal-
ly occur from inadequate airflow through the generator.
PROCEDURE:
1. Verify that the engine has cooled down (engine block
is cool to the touch). This will allow the contacts in the
High Oil Temperature Switch to close.
2. Check the installation and area surrounding the gen-
erator. There should be at least three feet of clear area
around the entire unit. Make sure that there are no
obstructions preventing incoming and outgoing air.
3. Disconnect Wire 85 and Wire 0 from the High Oil
Temperature Switch.
4. Set a VOM to measure resistance. Connect the test
leads across the switch terminals. The meter should
read INFINITY.
5. If the switch tested good in Step 4, and a true overtem-
perature condition has not occurred, check Wire 85 for a
short to ground. Remove J1 Connector from the circuit
board. Set the VOM to measure resistance. Connect
one test lead to Wire 85 (disconnected from High Oil
Temperature Switch). Connect the other test lead to a
clean frame ground. INFINITY should be measured.
TESTING HIGH OIL TEMPERATURE SWITCH:
6. Remove the High Oil Temperature Switch.
7. Immerse the sensing tip of the switch in oil as shown in
Figure 34, along with a suitable thermometer.
8. Set a VOM to measure resistance. Then, connect the
VOM test leads across the switch terminal and the
switch body. The meter should read INFINITY.
9. Heat the oil in the container. When the thermometer
reads approximately 274°-294° F. (134°-146° C.), the
VOM should indicate CONTINUITY.
DC CONTROL
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Table of Contents
Troubleshooting
