Engine Diagnostics (All Models) - Honeywell HW5500 - 5500 Portable Generator Service Manual

ENGINE DIAGNOSTICS (ALL MODELS)

8.3 ENGINE DIAGNOSTICS (ALL MODELS)
Engine Fails to Start
Check Oil Level
Check Fuel Level
Check Fuel Shut-off Valve Open
Confirm Choke in On Position
Check Spark Plug
Dry Spark Plug =
Check Carburetor
Fuel Cutout 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
Drain Oil and
Check Low Oil Switch
Connection and Continuity
(Yellow Wire on Side of Engine)
Check Flywheel Woodruff Key
Repair or Replace Key
Perform Engine Compression Test
8-10 www.honeywellgenerators.com
Engine Fails to Crank
Using Electric Starter
Check Recoil for
Mechanical Binding
Check Battery Voltage
Higher than 12.5 Volts =
Check Voltage Across Components
Less than 12.5 Volts =
Charge or Replace Battery
Check Voltage Across Components
Check Battery Connections
Check Leads on Proper Post
Check Leads are Clean & Tight
Check Voltage Across Components
are Within .5V of Battery Voltage
Replace Out of Spec Components
Check Engine Control Switch
Voltage
Drop in Start Position
Check Battery Post / Solenoid
Voltage Drop
Check Battery Post / Starter Lugs
Voltage Drop
NOTE: Generator has Charging
Coil During Operation; Replace
Coil if Repeated Battery Discharge
Engine Speed Unstable
Check Spark Plug & Gap
Check Ignition for Spark
Adjust Coil Air Gap
Check Spark Arrestor
Check Muffler Blockage
Check Governor
Frequency = 60 Hz + 3
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
Honeywell Portable Electrical Generator Service Manual
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
Recoil Locked =
Disassemble and Repair Recoil
(see Manual Section
"Recoil Starter")
Check Recoil for
Mechanical Binding
Rope Not Retracting =
Disassemble and Repair
Broken Ratchets or Springs
(see Manual Section
"Recoil Starter")