Honeywell HW7500E Service Manual - Page 42

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 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 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") 8-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual