Honda Ex5500 Generator Service Manual
OK, need some help here guys. I've got an EX5500 which went through a fire about 11 years ago. Actually, the exhaust caught the wall on fire and the heat scorched the paint on the area near the muffler and over the fuel tank. After the fire, the generator ran great, but the power wasn't stable and would spike.
Honda Generator Ex5500 Oil Filter
I turned off the fuel, ran the carb dry, and put it aside with the intention of fixing it later. Well, later turned out to be 11 years.
I've replaced the fuel tank due to rust inside, replaced filters, oil, and battery. It starts and runs great, but now I only have 4 volts output on the 110 side of the generator and 2 volts on the 12 volt side. I figured the automatic voltage regulator had been overheated and died while sitting so I replaced it. Same voltage outputs. Anyone have any other ideas? I keep going through the schematics, but just don't see anything else in the circuit to cause this. Hi, I have the very same 1996 EX5500 generator, it's been great.
Additionally I have the factory shop manual (paper not electronic) which supplies far greater detail than the 'Wiring Diagram' on page #43 of the owners manual. The owners is a PDF file and can be sent your way if needed, Happy to email you a few pictures of the electrical system if that is of any help. My guess is that the coil got hot and shorted, however that is only a guess. You would need to have a quality DVM to determine if indeed this is the problem. All the parts are still available from many places on line. Hi, I have the very same 1996 EX5500 generator, it's been great. Additionally I have the factory shop manual (paper not electronic) which supplies far greater detail than the 'Wiring Diagram' on page #43 of the owners manual.
The owners is a PDF file and can be sent your way if needed, Happy to email you a few pictures of the electrical system if that is of any help. My guess is that the coil got hot and shorted, however that is only a guess. You would need to have a quality DVM to determine if indeed this is the problem. All the parts are still available from many places on line. KenThanks Ken, I have the owners manual and ordered the factory shop manual today. I'm thinking the same thing you are about the coil shorting.
Being an electrician by trade, I have several good quality DVMs. Does the shop manual give exploded views with part numbers or will I need the parts manual as well? You may want to try this prior to starting on major repairs. I've never had to do that but here's a link about a rather easy thing to try: Field Flashing of Portable Generators This tip comes from the Briggs & Stratton Customer Education Department. As an alternative to flashing a rotor winding with a battery applied to the brushes, an electric drill may be used.
Follow these steps to flash the generator: Plug the electric drill into the generator receptacle. (Cordless drills do not work) If the drill is reversible, move the direction switch to the forward position. Start the generator While depressing the trigger on the drill, spin the drill chuck in reverse direction.
(A neighbor tried this and used a small wooden dowel that will break easily and a batterry drill to spin the electric drill in reverse)This will excite the field and the generator will now produce electricity. If spinning the chuck one direction does not work, try spinning the chuck in the other direction as you may have the reverse switch positioned backwards. Use caution not to get your hand or other materials caught in the chuck. As soon as the field is excited, the generator will produce power and the drill will turn on. The reason this works is because the electric motor in the drill will act as a small generator when spun backwards. The magnets in the drill's motor induce a voltage into the motor windings, which is fed back through the trigger, cord and into the generators receptacle. From there it goes into the power winding of the stator.
The voltage going through the power winding creates a magnetic field, which is intensified due to the iron core of the stator laminations. The rotor intersects this magnetic field as it is spun past the power winding, thus inducing a voltage in the rotor winding. Once current flow is present in the rotor winding the rotor has been flashed. If flashing the field does not make the generator work, you may have additional problems, besides a lack of magnetism in the rotor. Further testing will be needed. Hopefully, this will give a simple way to field flash your generator if needed.
Honda Ex5500 Generator
You may want to try this prior to starting on major repairs. I've never had to do that but here's a link about a rather easy thing to try: Field Flashing of Portable Generators This tip comes from the Briggs & Stratton Customer Education Department. As an alternative to flashing a rotor winding with a battery applied to the brushes, an electric drill may be used. Follow these steps to flash the generator: Plug the electric drill into the generator receptacle.
(Cordless drills do not work) If the drill is reversible, move the direction switch to the forward position. Start the generator While depressing the trigger on the drill, spin the drill chuck in reverse direction. (A neighbor tried this and used a small wooden dowel that will break easily and a batterry drill to spin the electric drill in reverse)This will excite the field and the generator will now produce electricity.
If spinning the chuck one direction does not work, try spinning the chuck in the other direction as you may have the reverse switch positioned backwards. Use caution not to get your hand or other materials caught in the chuck. As soon as the field is excited, the generator will produce power and the drill will turn on. The reason this works is because the electric motor in the drill will act as a small generator when spun backwards. The magnets in the drill's motor induce a voltage into the motor windings, which is fed back through the trigger, cord and into the generators receptacle. From there it goes into the power winding of the stator.
The voltage going through the power winding creates a magnetic field, which is intensified due to the iron core of the stator laminations. The rotor intersects this magnetic field as it is spun past the power winding, thus inducing a voltage in the rotor winding. Once current flow is present in the rotor winding the rotor has been flashed.
If flashing the field does not make the generator work, you may have additional problems, besides a lack of magnetism in the rotor. Further testing will be needed. Hopefully, this will give a simple way to field flash your generator if neededInteresting. I've never heard of something like that. I'll have to take some time to read the link you gave.
NORBERTO ALAMO on Mar 17, 2018. SERCICE TECHINCIAN GOOD SERVICES. IT IS GREAT PRODUCT Thank you for purchasing a Honda generator. We want to help you get the best results from your new generator and to operate it safely.
This manual contains the information on how to do that; please read it carefully. This owner’s manual describes the operation and maintenance of the Honda Generator: EX5500.
All information in this publication is based on the latest product information available at the time of printing. Honda Motor Co., Ltd. Reserves the right to make changes at any time without notice and without incurring any obligation.
Honda Power Equipment User Manual Free Download. Honda Generator for Power Manual. Free Manual Download PDF. No part of this publication may be reproduced without written permission. This manual should be considered a permanent part of the generator and should remain with it if it is resold. Safety Messages Your safety and the safety of others is very important. We have provided important safety messages in this manual and on the generator.
Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is receded by a safety alert symbol and one of three words: DAN c!f El?, WARNING, or CAUTION. A These mean m follow B follow w You WILL instructions. You CAN instructions. Be KILLED or SERIOUSLY HURT if you don’t be KILLED or SERIOUSLY HURT if you don’t You CAN be HURT if you don’t follow instructions.
Each message tells you what the hazard is, what can happen, what you can do to avoid or reduce injury. Damage Prevention Messages and You will also see other important word NOTICE. This word means: 1 NOTICE 1Your generator don’t follow instructions. Or other messages that are preceded by the property could be damaged if you The purpose of these messages is to help prevent damage generator, other property, or the environment. To your 1 CONTENTS SAFETY. Safety Label Locations Safety Information. COMPONENT IDENTIFICATION CONTROLS.
Engine Switch. Circuit Breaker Fuel Valve.
Ground Terminal Voltage Adjustment Knob. Auto-throttle System. Oil Pressure Lamp GENERATOR USE Connections to a Building’s Electrical System Ground System Special Requirements AC Applications AC Operation AC Receptacle Selection Auto-throttle System. High Altitude Operation. PRE-OPERATION CHECK Engine Oil. Fuel Recommendation Coolant STARTING THE ENGINE.
STOPPING THE ENGINE. MAINTENANCE Maintenance Schedule Emission Control System Engine Oil and Oil Filter Change. Air Cleaner Service Spark Plug Service. Fuel Sediment Cup Cleaning Fuse Replacement. Spark Arrester Maintenance Battery. TRANSPORTING/STORAGE TROUBLESHOOTING WIRING DIAGRAM SPECIFICATIONS. INSTALLATION OF OPTIONAL PARTS CUSTOMER SERVICE INFORMATION.
39 41 ii 45 49 50 3 SAFETY SAFETY LABEL LOCATIONS These labels warn you of potential injury. Read them carefully. Hazards that can cause serious If a label comes off or becomes hard to read, contact your Honda Generator dealer for a replacement WITH RECOMMENDED WITH RECOMMENDED OIL AND COOLANT /r CAUTION BE SURE TO FILL CRANKCASE RESERVE TANK OF RADIATOR BEFORE USING. FOR DETAILED EXPLANATION, 1 SEE THE OWNER’S MANUAL.
I OF CARBON 1 WARNING NOT USE INDOORS DUE TO DANGER NOXIDE POISONING. IGASOLINE CAUTION LABEL I AC VOLTAGE FREQUENCY RATED OUTPUT MAX OUTPUT PHASE FUEL EX5500 120 VI240 v SO Hz 5.0 KVA 5.5 KVA 10 GASOLINE (PETROL) EXHAUST CAUTION LABEL EXHAUST HOT ECHAPPEMENT l l 3 CHAUD I 5 SAFETY INFORMATION Honda generators are designed to give safe and dependable service if operated according to instructions. Read and understand this owner’s manual before operating your generator. You can help prevent accidents by being familiar with your generator’s controls, and by observing safe operating procedures. Wikipedia’s page for Publisher: Post navigation.