Generac 4000XL Generator - Solution to common problem - Won't stay running
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- čas přidán 12. 09. 2024
- Gernerac 4000XL Generator
A very common problem with the Generac generators is the oil pressure switch going bad. As shown in the video, a bad oil pressure switch will allow the engine to run only a few seconds before it stalls.
A simple fix is to replace the oil pressure sensor. The part number is "Generac 099236"
At the time of this video, I bought the replacement sensor for approximately $22 US shipped.
#briggsandstratton #realmanskills #smallenginerepair
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4strokerebuild....
![[4 Quick DIY Fixes] Generator only Runs on Choke / Half-choke!](http://i.ytimg.com/vi/fgxgdKl7Mw0/mqdefault.jpg)
I want to truly thank you, a thousand times over, for this video. I have a Generac 7550 EXL that I've had for several years, but only had to use a few times. It's been sitting up for quiet awhile, and I forgot to drain the gas, so, old stale gas means problems. Well, it of course wouldn't start, so I drained all the gas, cleaned the carburetor etc, but it wouldn't run properly. It would start, but only run for 10 seconds or so, and then shut off. I cleaned the carburetor again, but no go. I changed the oil and oil filter, but still no go. It would start fine, but after 10 or 15 seconds, it cut off. I finally gave up after several hours of frustration. I got on the internet, and searched for a solution to my problem, and after lots of searches, I found your video. All this was late last night, and I was too tired to go out in the dark to check it, so I waited till today. I was skeptical, after all the things I had already tried, but I disconnected the wires going to the low oil switch, just as you demonstrated, crossed my fingers, and the thing started up, and kept right on running. PROBLEM SOLVED!!! Now all I have to do is get me a new low oil switch. Thank you again Sir, for you have saved me a lot more headaches and money for someone else to fix this thing. You are appreciated.
I have been there many times myself with all kinds of small engine troubles. I am happy that this solved your problem. Thanks for watching.
Tried running, getting ready for winter. Same symptoms. Came across your video, disconnected wire, runs! Now looking for sender. Thanks very much. Saved me much time and fumbling.
Glad you found the problem. Thanks for watching!
Hurricane Laura hit us good here in north Louisiana, power has been off since Thursday. Cleaned the carb several times, new gas, new plug, couldn't figure it out. Your video saved the day.
Happy to help! Praying for your safety!
Thank you my friend, never would have thought to disconnect the oil sending unit. With this big storm coming, my wife thanks you, my dogs thank you and the cats thank you. (And, by the way, our XL4000 has been a good generator for many years. Hope yours has been as good to you.)
+Ron L. Happy to help! Hunker down for the coming storm! Thanks for watching!
I really want to thank you. Been fighting this generator for about 2 years now. New carb, new lines, gas filters, etc… finally came across your video and she runs like new now. All this time for a simple oil pressure switch! Thank you!!
Me too! Cleaned the carb, replaced the carb! And then I find the real problem! Happy to help! Thanks for watching.
Thank you very much for this video! You solved my problem. I had a clean fuel system and could not understand why mine was shutting down. I suspected oil pressure sensor, but you demonstrated the problem. By the way, I spent 45 minutes on the phone with the Generac support line and they were unable to help. I should have saved the time and gone right to you tube. You are a hero!
Happy to help! Thanks for watching!
Customer service is dead nowadays.
Thanks! I was 90 seconds from rolling this thing down a cliff!!!
Happy to help! Thanks for watching!
The online owner's manual doesn't even tell you the type of oil to use or the capacity! Ridiculous. Great tip, I'll keep this in mind.
Thanks for watching!
Thanks for the video. I’d tried everything else, but couldn’t figure out the problem. I unplugged the wires as you suggested, and it ran. Wished I had found your video earlier. It would have saved me hours of time and heartache. But I’ve learned A LOT through this experience. We’ve ordered the part and I’ll change it out later this week, BEFORE the hurricane hits. Thanks again.
You are not alone. I spent hours on this machine before I figured it out as well. Thanks for watching!
Having the same problem on the Generac 7500EXL generator. It would run for less than 10 seconds then die. Right before it stalled out the low oil alert light would light up for a second. After checking the oil level, I disconnected the two leads coming off the oil pressure sensor and jumped them together to complete the circuit and bypass ground to get it running for hurricane Dorian. With the machine off and no pressure to the oil pressure sensor it reads continuity to ground. A good working sensor would be isolated from the chassis ground while running. Thanks for the helpful video and part number.
Thanks for watching!
I disconnected that harness and mjbe still wont start
I'm getting ready a hurricane, I went outside tried this and it worked like a charm. You're a Godsend!!!! Thanks!!!!!!!
Hope the hurricane misses you. Happy to help!
Thanks very much for an excellent video. This solved the problem with my 4000 XL generator. By the way, every time I make a video my wife arrives and starts talking in the background. Making a video seems to be like a magnet to women. But they can't keep quiet!
Thanks for watching. Now before I begin recording I have to let my wife know what's going on.
Thanks for the video tip!!! I took a gamble on one of these machines for 70$ from a guy. After further inspection the gas tank had a 1/4 inch of "tar" in the bottom and a good layer of rust in the rest of the inside. After a day of cleaning, replacing fuel lines, new fuel filter,plug, and cleaning carb it done this. Your tip saved the day.
Sounds like it was well worth it. Thanks for watching.
I have the Generac 10.000 EXL and had the same problem I thought the carburetor float until I saw this you tube post I did the same disconnected the oil pressure switch and HOME RUN the generator stayed on. I ordered a new oil pressure switch (Generac part 060108) on E BAY for $ 33 from Schwalm Inc from Chino CA. Installed new switch now generator runs like a champ I thought I post this info and also to say thank you to sblg43 for posting this information.
+shindawg550 Thanks for watching. I am happy to have helped.
This just answered my question on, "WTF is wrong with my generator!!!??" Thanks much for the video!!!
Thanks for watching. Happy to know that you got it running again.
Thanks man! I have a 7550xle. Bought it in 2004 and never used. It started right up then stalled out after 6-8 seconds. Watched your video and Bam! That's it! Ordering part now.
Thanks for watching! Happy to help!
Yep, that did the trick. I unplugged that sucker and she runs like a fine tuned sewing machine. Thank you very much for that information.
So Glad I found this video, I was about to order a new carburator cause my generator has sat for many years and was given to me. After I watched this I unplugged my sensor and it runs great. Thank you.
And thank you! Happy to help!
I just mine unplugged. It's been running fine for the past 6 years now. No problem. Thanks for sharing...
Thanks for watching!
WOW!!! That's All I can Say... I thought it was the Shut-Off Valve Filter, As I took it Off, I Broke it,. Replaced the Shut-Off, And Still had the Same Problem. Back to CZcams I Go, Then, I Found Your Video. Tested as You did, THAT IS WHAT IT IS. Ordering Sensor Now. And The Part # is Much Appreciated. THANKS
Happy to help! Thanks for watching!
@@RealManSkills You are Welcome. Saved the Day.
Thank you so much for posting this video. I have a Generac 15000 that was giving me similar problems. I drained the fuel, cleaned the fuel filter, changed the oil, verified oil was filled to correct level, and even changed out the low oil pressure sensor/switch once and thought I had fixed the problem. Sadly, after one successful start up and cool down, the problem returned when I went to start it again. Everything pointed to the low oil pressure sensor/switch being the culprit. So, I begrudgingly bought and installed a second new one and then it ran like a champ. It is possible to get faulty new parts, it seems. I may buy another one just to have a spare.
By the way, disconnecting the faulty wires from my defective sensors/switches had no effect. The generator still stalled after about 10 seconds.
In any case, it is fixed now. Thanks again for a great video!
Thanks for watching!
Who are the 31 people that gave this video a thumbs down?! This video is awesome! Thanks fine sir (and bride haha). This is a fantastic video!
Thanks!
They are impatient negative types who don’t have the exact same generator and or don’t see an easy solution to their problem. You can be the sweetest peach in the orchard. There are always folks who don’t like peaches.
Just tried this...that was the problem. Generator running totally normal now. Friggin rights you did it buddy.
Happy to help! Thanks for watching! If you're in Florida, hope you're safe!
I have the 4000exl model, after 10 years sitting, I put in a new battery, had to replace the fuel on/off valve and I took the carb apart just because it sat so long, after all that it did exactly what you found, I disconnected the wires and it stayed running. I found this video while looking for the oil switch part# good job, thanks.
Thank you for watching! Happy to help!
The fuel valve on these broke like a twig.
Mike Smith If the fuel valve is plastic, I can see why it would get brittle after so long. I have a similar generator that somebody gave me because the fuel valve broke and he just didn't want the unit taking up space in his garage any longer. A free generator cannot be easily passed up! Now I just have to fix it.
Thanks again for watching.
I switched out the oil pressure sensing switch, and now it stays running, but will only run with the choke half on. Puts out a lot of thick smoke. Suggestions please? PS. I thought that was hilarious when your wife went by and you made that comment. Love your sense of humor.
Since you got the sensor taken care of, it sounds carburetor related. May need to clean or rebuild or replace the carb. Thanks for watching and thanks for enjoying the humor.
If you have a two stroke motor and your gas to fuel ratio is not correct that could be your problem. Just a suggestion my friend.
@@donleggett5973 thanks Don
Great video. This was exactly my problem and your solution was spot-on. Thanks!
Happy to help. Thanks for watching!
Thanks for the video! Unplugged the wires and it runs great. Saved me some money by not having to get someone to repair for me
Many thanks, 1 1/2 hours re.oving and cleaning carb wih no diff in engine shutting off after 10 seconds, unplugged low oil switch now good as new.thanks
Thanks for watching!
Great video, never would have checked this. I have a craftsman 7.8hp 4200 watt generator that i got for free. Thought this was a carb or fuel delivery issue and i was very wrong. Thanks for the great and to the point video.
I also thought it was a carb issue. I cleaned the carb, no change. Then I replaced the carb, no change. Finally found the problem. Easy fix. Thanks for watching!
I never knew these smaller engines had a pressurized oil system. I knew some had a low oil level sensor. Now I know to look at that sensor/switch in a different light.
Most of the small engines that I work on do NOT have a pressurized oil system. This one is unique in that regard. Thanks for watching.
Thanks so much! I have a champion with oil pressure switch and had the same issue lol. You saved our family camping trip!
Happy to help! Thanks for watching and have a great trip!
Thanks a lot. Thats exactly what was wrong with mine. I haven't replaced the sensor yet but it runs like a top. Dave
Happy to help!
Thank you for posting this video. I have the same the generator that did the same thing and your video saved me a lot of time tinkering with it. Unplugged the sensor and it ran perfectly.
Thanks for watching! Happy to help!
thanks, I searched for a fix to my Generac not keeping good RPM and not starting. The low oil pressure switch was the culprit. I have had this Generac 8K for 4 yrs and nothing but problems. Batteries dont last, I went through 3 or 4 of them, the last one went I noticed (as I always check)(The charger on it eventually went bad so I put a BatteryTender 600 on it with a huge 1000CCA deep cycle battery (with the onboard charger gone I can now put a bigger battery than a small group 26 bat) The winter battery warming blanket burnt itself out in a year. Another time the started didn't work, fixed that by taking it apart an noticed that only 2 of the 4 brushes were rubbing on the commutator (the spring pullback tabs were still pulling back 2 of them) An easy fix once that was noticed. These starting issues I hope are behind me now. My Generac 8K has 47 hours on it. If I had to do it again I would go with a commercial grade one instead of a consumer grade one.
Great video, gets to the point. With this hurricane on the way I am sure you helped many. Thank you.
Glad it helped
Thanks, you saved me a lot of headache and probably some $$$ too!
You are welcome! Thanks for watching.
Thanks for the Video Upload! we have a 7550xle that we have only used twice, used for Hurricane Irma, after 3 days it stopped running, this was the problem! THANK YOU AGAIN!!!!!!!
Happy to help! Thanks for watching! Glad you're safe!
Perfect,I have bought a 6500 XLT generator, I hope I don't have problems with it!!
Well, if you do, you will know how to check the oil sensor. Thanks for watching.
Great tip. Solved same issue on my q-55g after I disconnected wire.
Thanks for watching!
By a chance, did you look inside the sensor to see what actually was wrong with it? I have used similar sensors (for some other applications) and found that there is unit to unit variation of the tripping point, even though the adjustable version I can match to my needs. However, the second problem comes with some months in use, when the small hole through the threaded plug gets blocked with some crud. Cleaning the hole can solve the issue in that case. Just be careful not to punch a a hole to the membrane inside as well!
Never even thought of looking at the bad sensor. Thanks for the info.
Great job ! worked like a charm !! thanks
+Guy Arcand Thanks for watching!
Excellent video. Mine does the same, and I thought since it ran for a minute or so then quit that it was a carb issue. I will disconnect the switch tomorrow and test.
Hope that is all it takes! Thanks for watching!
Doing a derive on one of these tomorrow, the guys genny is doing exactly what yours was doing, so I had him order the part, so doing a serive and replacing the oil pressure sensor, thanks for the advice...... I subbed, and rang the bell.
Thanks! Much appreciated!
Very helpful. Much appreciation
Thank you for the tip. I had the same problem. Unfortunately it went bad during a power outage and wouldn't stay running. I noticed you also had to keep yours at 1/2 choke as well. Seems to run better there under load.
You might notice that once the engine was warmed up a bit, I shut the choke off. That is how most small engines should operate if they are tuned properly. Hope you got it running again. Thanks for watching.
Thank for posing I have found this problem can also be caused by the poor float adjustment
thanks! it finally stayed started. i ordered new sending unit, and then will see if it will start without starting spray!
Thanks for watching!
Had the same issue and the same fix on my 24 yr old 5500xl. Unfortunately the socket cracked while was screwing in the new pressure switch and had to replace the oil filter adapter.
Thank you, Sir .................... just saved me a ton of $$$$$!!!
And me mine had the same problem i disconnected the bugger and it runs perfectly ,must remember to check the oil level occasianally thogh thanks for that
Seems to be a common issue with this model. Assuming the replacement part has some sort of improvement?
Thanks for that video.
Did what you did to yours and mine is working great. Thanks
Thanks for watching! Happy to help!
Praise Jeebus! Just borrowed from a buddy and outsmarted myself by plugging it back in. Undid it and GTG
Thanks for watching!
That's the way to do it, process of elimination, to find the problem. Good tip to check the sending unit.
Thanks for watching! I have to admit, the first time I dealt with this situation, it was a head scratcher.
Thanks for getting to the point sir! Your the best! Like the video guys!!!💯
Thanks for watching!
This is my problem! Thank you!
Happy to help!
this worked for my subaru powerstroke generator. thanks a million
Happy to help! Thanks for watching!
On the carburetor just under the idle screw there is a screw (idle jet) take that out and clean out the hole in the carburetor and that will fix the surging.
that screw is set in pretty tight, stiped out the Philips head trying to remove the screw.
1. The carburetor on the engine in the video needs to be replaced. I have been through two of them and a new carb solves the problem of the need to run at half choke which is hard on the engine.
2. I have also been through two low oil sensors switches. I removed the two wires to the sensor and taped the ends. No problems since.
The carburetor in the video is new and it did not fix the problem. Thanks for watching.
My neighbor bought one of these in 2001. He is OCD about maintenance and about changing the oil with Amsoil 10w40 small engine oil. He said he has never had this issue.
Well, if he ever does, he'll know where to look. Thanks for watching.
Thanks. This fix worked on my 7500 eco.
Happy to help! Thanks for watching.
Thanks for the video. Does it really have an oil pump that maintains pressure, or is it just an oil level switch like many lawn mowers have?
All I know, is that the switch is an "oil pressure sensor" but when it went bad, the low oil light did NOT light up. I did check the oil level and the level was just fine. As you see in the video, the engine ran fine just from unplugging the sensor. I did notice (from diagrams on the internet) that internally, the engine has a "rotor". That might be a sort of oil pressure pump but I am not certain - I have not had to open up one of these Generac engines yet. Thanks for watching.
Thanks ! I wonder how did you figure the problem out initially
After cleaning the carb, and then replacing the carb, it was still a problem. Just like everybody else, I scoured the Internet. I found a chat forum that mentioned the oil sensor and decided to try that. It worked, obviously. So I made this video to help others. Thanks for watching!
Thank-You Well done video. Solves a frustrating problem.
I was frustrated too until I figured it out. That's why I shared. Thanks for watching!
Hey there buddy, I was wondering I was needing some help on troubleshooting my generator
Worked like a champ! Thank you.
Thanks for watching!
Mine is a 9hp Vangard with a Briggs & Stratton Engine # 185432. It doesnt have one. It did start once before I started working on it. Drained the oil & filled it back up. Rebuilt the carb. Darn thing still wont even get going..thinking sensor but...
Very good video,,,,Thanks alot!!!!
Thanks for watching!
Had the same problem with a Coleman generator with a Briggs engine but it would not start due to no spark disconnected the wire to the oil sensor and it fired right up
gracias, el video resulto excelente, me haorraste quisas $200dls, compre la parte en ebay, hice exactamente paso por paso y pues mi generador esta al 100, gracias otra vez
Gracias por ver.
I watched your video and noticed toward the end you had to run the generator on partial choke. When you put the machine under load did it still run without bogging down??? Usually a properly running generator shouldn't need any choke if the carburetor is in tune!!!
I just forgot to turn the choke off. Once it's warm, it runs great with the choke fully off. Thanks for watching.
Thanks Buddy, just saved me pulling my hair out.
I know what you mean. Thanks for watching!
Save your hair man, lol... I can't wait to get home to try this!
I have a Generac power washer that does the same thing. I will try disconnecting the OPS tomorrow and see what happens. I sure hope that's it. It's been driving me crazy. I cleaned the carburetor twice and even removed the gas tank and petcock and cleaned them too.
That's what I did too. I even replaced the carburetor. But ultimately, I found the real problem. Thanks for watching.
Nice Video. Thanks. Would you happen to know the difference between the 4000xl and the 4000exl? Is the exl electric start? If So Any other differences? Thanks.
Thanks for watching. Sorry, I don't know the difference. I don't actually see very many generators in my shop.
@@RealManSkills Thanks for getting back to me.
@@RealManSkills EXL is extended life. I'm not sure what XL is
Install a fuel cut off in line with the fuel line,shut the fuel off when done using,run the carburetor dry,and you won't have any carb problems as it will not gum up when you are not using it. when ready to use it,turn the fuel on,you have a clean carb and off you go...You may not use it all the time,( the generator ),drain the tank and run it till the carb is dry with the fuel shut off,after draining the tank.Have had mine for 15 + years and never had the carb off,just keep it drained AND DRY,NO PROBLEMS DOWN THE LINE...
Do you drain the fuel out of the carb bowl too? If you don't, your carb can still have old gas in it and not run months later. happened to me.
Helpful information, thank you for sharing !
Happy to help! Thanks for watching!
in case of emergency use can it run without the sensor plugged in. just having the same problem and need to run the generator can not wait for part to come in but is ordered.
Yes. Just make sure to keep an eye on the oil level. Thanks for watching.
Thanks. I'm in the same boat. As a precaution, i changed my oil before running it with the sensor disconnected to be sure it was clean and full.
Why doesn't the RED low pressure light come one with the switch is disabled??
Thanks for pointing me to this video. I have a 17500 watt guardian ultra generac, and it doesn't have a plug for that oil pressure sensor. Can i just disconnect the two wires from the sensor? Or will that break a circuit?
Thanks again for help and advice.
Edit:
I tried with two wired disconnected from oil sensor and connected them together to no avail.
Im still gas fouling plugs, even though Ive cleaned carb 3 times this past week. Added a new fuel sensor, and wonder if it could be defective. Is there a way to test the fuel sensor that screws in bottom of float bowl?
if you have something that screws into the bottom of the carburetor, that is probably a fuel shutoff valve. To test that, take it out of the carb but keep the wires connected. Turn the key to the run position and see if it moves. It may be stuck or may need to be replaced.
@@RealManSkills thanks for the reply and help. I took the fuel shut off out and tested to a battery. The plunger pulls in when touched to positive. I just tested as you recommended and it's working. But why am i gas fouling plugs so bad? Gas soaks the air cleaner box!
Is there anything else that would cause fuel to foul the spark plugs? After each time it dies, i pull the plugs and they are wet with gas. That air filter box also gets soaked with gas. Is that shut off sensor the only piece that could allow that to happen?
@@SmittybuiltHD It sounds like a carburetor issue. Fouling plugs can be caused by too much fuel. It's possible that the needle and seat aren't sealing properly and allowing fuel to flow past.
Thank you! Solved my problem.
Happy to help! Thanks for watching!
Try using your knipex (k is silent) flipped the other way. Much better results :-)
According to the German manufacturer of Knipex tools, the K is not silent. Thanks for watching.
sblg43 good to know, I was misinformed about the pronunciation. Does your generator by chance have a 220v outlet? I have a similar generator which is an older generac and mine has no model or serial numbers listed anywhere. By the way, I just recently picked up the knipex smooth jaw channel locks 8603250. Best tool I've ever purchased hands down.
The generator is not mine. I fixed it and sent it back to the man who owns it. Sorry but I can't recall if it had 220v outlet.
Noticed both of those things as well, was hoping this was about valve timing.
Thanks for the tip
what is the name of that part where you screw the oil pressure sensor that's what I need that part
I replaced the "oil pressure switch" - it was a "Generac 099236".
I was given a generator w less than 1 hr but hasn't been started in 8 years.i totally cleaned carb inside out w carb cleaner,put new gas,new oil,new plug,fired up 2nd pull,turned down choke after 10 min then bogged down? Only runs when choke is full? Thoughts? Thanks
Carb adjustment?
Excellent! Thank you.
Happy to help!
wow thanks just what i needed BIG THANKS
Thanks for watching! Happy to help!
THANKS!
Thanks for watching!
Mine surges when its not half choked. Any suggestions to fix that? I just put in some Starbrite carb cleaner to see if that helps. Mine has very low hours of use.
Thank you! This solved my problem also.
Thanks for watching. Happy to help!
I was given a generac 4000 watt. My neighbor doesn't want to bother with it. It is leaking gas. There is a dent on the top of metal gas tank. Question? Is it worth to get fixed? I live in fl..so could really use it...esp after last hurricane. Lost alot of food in frig..$$$
Since I fix them myself, I would say yes. But I don't know what somebody else might charge. They are expensive so it still would be cheaper than a new one. Thanks for watching.
One of three or four things. The gas tank bushing, the fuel needle seat, the float bowl gasket, or fuel lines. I had to replace all of these on an old generator that was given to me. Fixed it for less than 15 bucks. Doesn't leak now and runs great. It's worth it if it's just leaking gas.
Thanks 🙏 this saved me today!
Thanks for watching!
Co2 sensor on Honda generator needs replacing or by-pass any ideas?
That was my issue! Thanks!!!
And I was about to rip apart the carb!....I have the similar generator but its a 4000 EXL, any idea if its the same part # ?
Sorry, I don't know. You would have to search the interweb with the model of your engine or generator.
Fixed my power washer thanks
figures i found this video after the 11oclock cutt off for noise .....lol ill give this a try tomorrow, i was goign nuts out there had the carb off, the tank off, went tru everything. fuel related any way lol thanks for posting ..... love you tube !!!!@
That is what I did too. All things fuel related but no change. Thanks for watching.
I need the oli pressure sensor housing
excellent information
Thanks for watching!
Works for me.. thanks
Thank you for watching!
Do you know how to bypass the Carbon Monoxide detector. It would be in an open space outside but my husband has read it causes problems unless it's just setting directly outside in the yard.
Sorry no. That generator wasn't mine and it was a few years ago now.
great tip.....wouldnt the removal be easier with a plug socket wrench?
+Terry Dixon It wouldn't fit down there and I didn't have a wrench large enough. I should just go buy a wrench but that machine is back with it's owner. Thanks for watching!