Engine Diagnostics - Honeywell HW4000 Service Manual

8.1 ENGINE DIAGNOSTICS

Engine Fails to Crank
For All Models
Check Oil Level
Check Fuel Level
Check Fuel Valve Open
Check Choke Operation & Closed
Check Spark Plug
Dry Spark Plug =
Check Carburetor Fuel Solenoid
Wet Spark Plug =
Check Ignition System
Check Spark Plug Gap
Plug Condition Good =
Re-Gap Spark Plug
Plug Condition Dirty or Worn =
Replace Spark Plug
Check Ignition for Spark
Bright Blue Spark =
Reinstall Plug
Dull Spark =
Pull Coil & Check Resistance
Primary Coil = 0.8-1.0 Ohms
Secondary Coil = 5.9-7.1 Ohms
(measure at spark plug lead)
Replace Coil, if Necessary
Reinstall Coil with Proper
Coil / Flywheel Air Gap
Reinstall Plug
Check Low Oil Switch
Connection and Continuity
Check Flywheel Key
Repair or Replace Key
Perform Engine Compression Test
Honeywell Portable Generator Service Manual
Engine Fails to Crank
For Models: 5500E, 7500E
Check Battery Voltage
Higher than 12.5 Volts =
Check Starter Connections
& Starter
Less than 12.5 Volts =
Charge or Replace Battery
Check Battery Connections
Check Leads on Proper Post
Check Leads are Clean
Check Leads Tightly on Post
Check Voltage Drop
Between Posts and Starter Lugs
with Engine Switch in Start
Higher than 6 Volts =
Replace Starter Solenoid
Less than 6 Volts =
Replace Starter
Check Recoil for
Mechanical Binding
Engine Speed Unstable
Check Spark Plug & Gap
Check Ignition for Spark
Adjust Coil Air Gap
Check Spark Arrestor
Check Muffler Blockage
Check Governor
Idle Speed = 3600 rpm + 150
Check Governor Assembly
Adjustment
Engine Starts
Then Shuts Down
Check Fuel Level
Check Fuel Quality
Confirm Choke in Off Position
Check Oil Level
Check Ignition for Spark
Check Spark Plug & Gap
Adjust Coil Air Gap
Check Fuel Line & Blockage
Check Carburetor
Check Spark Arrestor
Check Muffler Blockage
Engine Smokes
Start Engine
Warm to Operating Temperature
Observe Smoke Color
White Smoke =
Poor Fuel Quality
Black Smoke =
Check Choke Operation
Check Ignition System
Blue Smoke =
Check Oil in Fuel
Check Oil Overfilled
Check Worn Piston Rings
Perform Engine Compression Test
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ENGINE DIAGNOSTICS
Engine Runs Rough
Check Fuel Level
Check Fuel Quality
Confirm Choke in Off Position
Check Air Cleaner
Check Ignition for Spark
Check Spark Plug & Gap
Check Fuel Line & Blockage
Check Carburetor
Check Spark Arrestor
Check Muffler Blockage
Check Valve Adjustment
Perform Engine Compression Test
Recoil Not Operating
For Models: 3000, 4000, 5500, 6200
Recoil Locked =
Disassemble and Repair Recoil
(see Manual Section
"Recoil Starter")
Then Check Recoil for
Mechanical Binding
Rope Not Retracting =
Disassemble and Repair
Broken Ratchets or Springs
(see Manual Section
"Recoil Starter")
8-2