Page 3 - CONTENTS
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com i CONTENTS IMPORTANT SAFETY INSTRUCTIONS ....................................................................... 1-1 WARRANTIES ............................................................................................
Page 4 - THIS PAGE INTENTIONALLY LEFT BLANK
ii www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual THIS PAGE INTENTIONALLY LEFT BLANK
Page 5 - S AV E T H E S E I N S T RU C T I O N S; : IMPORTANT SAFETY INSTRUCTIONS; Signal Words; WARNING; NOTICE; DANGER
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 1-1 S AV E T H E S E I N S T RU C T I O N S 1: IMPORTANT SAFETY INSTRUCTIONS NOTE: Since there are many variations in the circumstances sur-rounding the installation, operation, service, and mainte-nance of this gener...
Page 6 - SAFETY MESSAGES; Electric Shock Hazards
SAFETY MESSAGES 1-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Electric Shock Hazards Fire and Burn Hazards Medical and Life Support Uses Generator Damage Hazards California Proposition 65 Generators produce powerful voltage that can cause death or great physi...
Page 7 - Honeywell Portable Generator; LIMITED WARRANTY; MEDICAL AND LIFE SUPPORT USES.; This warranty; DISCLAIMER OF OTHER WARRANTIES.; NORTHSHORE POWER; REGISTRATION; Warranty inquiries can be addressed to:
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will repair or replace, free of charge, to the original retail customer...
Page 8 - WARRANTIES; WARRANTY STATEMENT; Claims
WARRANTIES 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Environmental Protection Agency (EPA) and Califor-nia Air Resources Board (CARB) require manu...
Page 9 - Repair or Replacement Cost; . Repair or Replacement; Consequential Coverage; . Coverage noted hereunder; Maintenance; QUESTIONS
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3 WARRANTIES 4. Repair or Replacement Cost . Repair or Replacement Cost. Repair or replacement of any emissions control part will be performed at no charge to the owner, includ-ing diagnostic labor which leads to th...
Page 10 - WARRANTY CLAIMS; Warranty claim forms and inquiries can be addressed to:
WARRANTIES 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY Honeywell Portable Generator For a period of 90 days from the date of sale or installation of a Northshore Power Systems, LLC supplied part, N...
Page 11 - : SPECIFICATIONS AND WIRING DIAGRAMS; GENERATOR
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-1 3: SPECIFICATIONS AND WIRING DIAGRAMS 3.1 SPECIFICATIONS GENERATOR HW3000 HW3000L HW4000 HW4000L HW5500 HW5500E HW5500EL HW5500L HW6200 HW6200L HW7000E HW7000EL HW7500E HW7500EL POWER Rated [watts] (+/-10% under l...
Page 12 - BOLT AND FASTENER TORQUE INFORMATION
BOLT AND FASTENER TORQUE INFORMATION 3-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 3.2 BOLT AND FASTENER TORQUE INFORMATION Component-Specific Fastener Fastener Size Torque Values N•m lb. ft. Alternator End Cover Bolts M5 x 0.75 x 12 4 3 Alternator Housing Bo...
Page 13 - WIRING DIAGRAMS
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-3 WIRING DIAGRAMS 3.3 WIRING DIAGRAMS HW3000 & HW3000L FIGURE 3-1: HW3000 & HW3000L Wiring Diagram AL TERNA T O R CONTR OL P ANEL ENGINE OIL ALER T SENDER SP ARK PLUG OIL SHUTDO WN SWITCH IGNITION COIL ENGIN...
Page 14 - gg
WIRING DIAGRAMS 3-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual HW4000 & HW4000L FIGURE 3-2: HW4000 & HW4000L Wiring Diagram G Y W X AL TERNA T O R CONTR OL P ANEL ENGINE OIL ALER T SENDER SP ARK PLUG OIL SHUTDO WN SWITCH IGNITION COIL ENGINE BLOCK Y Y ...
Page 19 - Electrical Outlets; CAUTION
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 4: COMPONENTS A—Power Control Center Electrical Outlets • 125VAC 20 Amp Duplex (NEMA 5-20R) outlets to connect 120V appliances to generator for power. • 125/250VAC 30 Amp Twist-Lock (NEMA L14-30R) outlet (on selec...
Page 21 - : PREPARING FOR SERVICE; TRANSPORTING GENERATOR; When moving or transporting the generator:
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 5: PREPARING FOR SERVICE 5.1 REQUIRED TOOLS A complete set of standard and metric shop tools are required to service the generator. Also needed are: • Hammer • Torque wrench • Volt-ohm meter • Frequency meter • Re...
Page 23 - : SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE; ELECTRICAL
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 6-1 6: SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE Operation HW3000 HW3000L (min.) HW4000 HW4000L (min.) HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW...
Page 24 - SERVICE REPAIR TIME ANALYSIS; MISC
SERVICE REPAIR TIME ANALYSIS 6-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NOTE: Repair times represent generally accepted intervals for conducting a repair. Service centers are always advised to provide feedback during the warranty claim process if additiona...
Page 25 - CONSUMER MAINTENANCE SCHEDULE
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-1 7: MAINTENANCE 7.1 CONSUMER MAINTENANCE SCHEDULE Periodic maintenance and adjustment are necessary to keep the generator in good operating condition. Perform service and inspection at intervals shown in the Genera...
Page 26 - CONSUMER MAINTENANCE SCHEDULE; FUEL RECOMMENDATIONS; Oxygenated Fuels
CONSUMER MAINTENANCE SCHEDULE 7-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual FUEL RECOMMENDATIONS Before each use, check the fuel tank gage. If the fuel level is low, refill the tank with recommended fuel. NEVER OVERFILL. General Fuel Information Check the fue...
Page 27 - ENGINE OIL RECOMMENDATIONS; Low Oil Protection; When engine shuts down due to low oil level:; AIR FILTER MAINTENANCE; For Model Numbers Ending in “L”:
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-3 AIR FILTER MAINTENANCE ENGINE OIL RECOMMENDATIONS Use 4-stroke oil, or equivalent high detergent, premium quality motor oil certified to meet or exceed U.S. automo-bile manufacturer's requirements for API Performa...
Page 29 - CLEANING FUEL SEDIMENT CUP; To clean fuel sediment cup:; SPARK PLUG SERVICE; To clean fuel sediment cup, you will need:
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-5 CLEANING FUEL SEDIMENT CUP 7.3 CLEANING FUEL SEDIMENT CUP The sediment cup prevents any dirt or water that may be in the fuel tank from entering the carburetor. Clean fuel sediment cup at the intervals specified i...
Page 30 - CLEANING SPARK ARRESTOR SCREEN; To clean spark arrestor screen, you will need:
CLEANING SPARK ARRESTOR SCREEN 7-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 7.5 CLEANING SPARK ARRESTOR SCREEN The generator muffler is equipped with a spark arrestor screen, which must be cleaned according to the mainte-nance schedule (see Table 7-1) to ens...
Page 31 - VALVE LASH; Check valve lash again after tightening lock nut.; GOVERNOR ADJUSTMENT; Start the engine and run with no load.; GOVERNOR RANGE ADJUSTMENT; Remove the generator control panel for access.; Standard valve lash; A—ROCKER ARM
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-7 VALVE LASH 7.6 VALVE LASH 1. Remove the cylinder head cover and carefully remove the gasket for re-use. (Inspect and replace gasket, if necessary.) 2. Remove the spark plug to reduce engine compres-sion resistance...
Page 32 - BATTERY SERVICE
BATTERY SERVICE 7-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 7.9 BATTERY SERVICE To ensure the battery remains charged, it is recom-mended that the generator is started every three months. If the generator is stored for more than a year without run-ning, a b...
Page 33 - NEVER use inside a home
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-1 8: TROUBLESHOOTING NOTE: For all dealer service inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com. ANYONE using or servicing this generator must read, understand, and follow all safety ...
Page 35 - To
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-3 ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) To Alternator See “Specifications” Page For Rated Power, Voltage, & Frequency Specs Under Load and No Load Conditions Yellow / Green Wire = G White Wire = W Black Wire ...
Page 43 - : SERVICE AND DISASSEMBLY; B—CONTROL PANEL ASSEMBLY
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-1 9: SERVICE AND DISASSEMBLY 9.1 CONTROL PANEL A—CONTROL PANEL ASSEMBLY (FRONT) 4 N•m (3 lb. ft.) B—CONTROL PANEL ASSEMBLY (BACK) C—MAIN CONTROL PANEL (FRONT) • 125VAC 20 Amp Duplex (NEMA 5-20R) • 125/250VAC 30 Amp ...
Page 44 - ENGINE AND ALTERNATOR; Use oil before replacing the rotor bolt.
ENGINE AND ALTERNATOR 9-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 9.2 ENGINE AND ALTERNATOR A—END COVER 4 N•m (3 lb. ft.) B—ROTOR BOLT Use oil before replacing the rotor bolt. C—ALTERNATOR HOUSING BOLTS 48 N•m (35 lb. ft.) D—REAR BEARING CARRIER AND STATOR ...
Page 45 - ALTERNATOR
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-3 ALTERNATOR 9.3 ALTERNATOR A—VOLTAGE REGULATOR Alternator Illustrated Matches All Models Except HW3000 & HW3000L B—BRUSH ASSEMBLY Before removing rotor and stator, remove brush assembly. 2 N•m (1.5 lb. ft.) C—R...
Page 46 - FUEL TANK SYSTEM; dr y before star ting the engine.
FUEL TANK SYSTEM 9-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 9.4 FUEL TANK SYSTEM Fuel and its vapors are extremely flammable and explosive under certain conditions. • Refuel the generator only outdoors, in a well-ventilated area.• NEVER enclose the generat...
Page 47 - EVAPORATIVE EMISSIONS CONTROL SYSTEM; For Model Numbers Ending in “L” only.; A—FUEL TANK; B2 - All Other Models; C—VAPOR LINE; Secure with hose clamps.; Secure with hose clamps.; E—CARBON CANISTER BRACKET; E2 - All Other Models
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-5 EVAPORATIVE EMISSIONS CONTROL SYSTEM 9.5 EVAPORATIVE EMISSIONS CONTROL SYSTEM For Model Numbers Ending in “L” only. A—FUEL TANK B—CARBON CANISTER • B1 - HW3000L Model Only • B2 - All Other Models C—VAPOR LINE Secu...
Page 48 - MUFFLER
MUFFLER 9-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 9.6 MUFFLER The muffler becomes very hot during operation and remains hot for a while after stopping the engine. • NEVER touch hot surfaces and avoid hot gases.• Let engine cool before storing the generato...
Page 49 - CARBURETOR
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-7 CARBURETOR 9.7 CARBURETOR Fuel and its vapors are extremely flammable and explosive under certain conditions. • Refuel generator only outdoors, in a well-ventilated area.• NEVER enclose the generator in any struct...
Page 50 - STARTING SYSTEM; Check for continuity.
STARTING SYSTEM 9-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 9.8 STARTING SYSTEM A—ELECTRIC STARTER Attempt to crank engine by switching the engine control switch to the START position. Starter Solenoid Terminal Nut - 6 N•m (4 lb. ft.) B—WOODRUFF KEY After i...
Page 51 - RECOIL STARTER; Check for wear or damage.
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-9 RECOIL STARTER 9.9 RECOIL STARTER A—STARTER CASE B—ROPE AND HANDLE Install with recoil starter handle position as shown. C—RETURN SPRING Connect the outer hook in the groove of the starter reel and inner hook on t...
Page 52 - FAN COVER; A—COOLING FAN
FAN COVER 9-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 9.10 FAN COVER A—COOLING FAN Install by aligning the three lugs on the rear side of the fan with the small hole in the fly-wheel. When disassembling and assem-bling, take care not to damage the fan blad...
Page 53 - • Accessor y kit is intended to be used specifically
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-11 WHEEL, LEG, & HANDLE ASSEMBLY 9.11 WHEEL, LEG, & HANDLE ASSEMBLY (HW3000/L MODELS) A—LOCKING HANDLE BRACKET 10 N•m (7 lb. ft.) B—SPRING LOCKING HANDLE C—RUBBER HANDLE GRIP D—AXLE 25 N•m (18 lb. ft.) E—SUP...
Page 54 - On some models the leg
WHEEL, LEG, & HANDLE ASSEMBLY 9-12 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 9.12 WHEEL, LEG, & HANDLE ASSEMBLY (ALL MODELS EXCEPT HW3000/L) A—WHEEL HANDLE PIVOT BRACKET 10 N•m (7 lb. ft.) B—PIN AND CHAIN C—HANDLE BAR D—RUBBER HANDLE GRIP E—AXLE 25 N•...
Page 56 - Northshore Power Systems, LLC; 425 N. Port Washington Road
Northshore Power Systems, LLC 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 USA 1-888-HWTECHS (498-3247) www.honeywellgenerators.com P/N 101290D 2010 Northshore Power Systems, LLC c Honeywell International Inc. makes no representationor warranties with respect to this product. The ...
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