Owners Manual
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... a cold engine. B-Battery Tray and Battery (HW5500E Only) Provides power for reference only. HW5500/5500E Portable Generator Owner's Manual www.honeywellgenerators.com 13 Information below is available only with your generator's components. Refer to ON position when starting (HW5500); K J I - H-Air Cleaner Assembly Removes... ground wire for power. When spark plug needs service, cap must be removed. If there is currently running (HW5500E) • STOP-Stops generator engine F-Recoil Starter Grip Handle Starts engine (HW5500). G-Fuel Valve Controls flow of fuel currently in...
... a cold engine. B-Battery Tray and Battery (HW5500E Only) Provides power for reference only. HW5500/5500E Portable Generator Owner's Manual www.honeywellgenerators.com 13 Information below is available only with your generator's components. Refer to ON position when starting (HW5500); K J I - H-Air Cleaner Assembly Removes... ground wire for power. When spark plug needs service, cap must be removed. If there is currently running (HW5500E) • STOP-Stops generator engine F-Recoil Starter Grip Handle Starts engine (HW5500). G-Fuel Valve Controls flow of fuel currently in...
Service Manual
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Portable Electrical Generator Service Manual HW3000/L HW4000/L HW5500/L HW5500E/L HW6200/L HW7000E/L HW7500E/L Read and Save These Instructions For technical support and parts, contact your Regional Master Parts Distributor toll-free at 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com.
Portable Electrical Generator Service Manual HW3000/L HW4000/L HW5500/L HW5500E/L HW6200/L HW7000E/L HW7500E/L Read and Save These Instructions For technical support and parts, contact your Regional Master Parts Distributor toll-free at 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com.
Service Manual
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... SPECIFICATIONS AND WIRING DIAGRAMS 3.1 SPECIFICATIONS GENERATOR HW3000 HW3000L HW4000 HW4000L HW5500 HW5500E HW5500EL HW5500L HW6200 HW6200L HW7000E HW7500E HW7000EL HW7500EL POWER Rated [watts] (+/-10% under load) 3000 4000 5500 6200 7000 7500 Maximum [watts] ...TABLE 3-1: Honeywell Portable Generator Specifications * See ENGINE OIL RECOMMENDATIONS, page 7-3 for other engine oil types outside general temperature use. † See SPARK PLUG SERVICE, page 7-5 for other recommended spark plug replacements. Honeywell Portable Electrical Generator Service Manual www....
... SPECIFICATIONS AND WIRING DIAGRAMS 3.1 SPECIFICATIONS GENERATOR HW3000 HW3000L HW4000 HW4000L HW5500 HW5500E HW5500EL HW5500L HW6200 HW6200L HW7000E HW7500E HW7000EL HW7500EL POWER Rated [watts] (+/-10% under load) 3000 4000 5500 6200 7000 7500 Maximum [watts] ...TABLE 3-1: Honeywell Portable Generator Specifications * See ENGINE OIL RECOMMENDATIONS, page 7-3 for other engine oil types outside general temperature use. † See SPARK PLUG SERVICE, page 7-5 for other recommended spark plug replacements. Honeywell Portable Electrical Generator Service Manual www....
Service Manual
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...R Lg W Bu Bu AVR R Bu Br W R Bu Br W ALTERNATOR 5A FUSE AUTO PROTECTOR 3A MAGNETIC AC BREAKER 21A Honeywell Portable Electrical Generator Service Manual OFF Bu G/W Bl Y/G Bl/W Bl IG E Bu Y/G G/W ON START Bl - Black / White Bu - Brown G/W ...X Y TWIST-LOCK L14-30R G GROUND TERMINAL Blue Br - Light Green R - Green / White Lg - Black Bl/W - Yellow Y/G - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www.honeywellgenerators.com ENGINE CHARGE COIL BATTERY STARTER MOTOR FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG Gr...
...R Lg W Bu Bu AVR R Bu Br W R Bu Br W ALTERNATOR 5A FUSE AUTO PROTECTOR 3A MAGNETIC AC BREAKER 21A Honeywell Portable Electrical Generator Service Manual OFF Bu G/W Bl Y/G Bl/W Bl IG E Bu Y/G G/W ON START Bl - Black / White Bu - Brown G/W ...X Y TWIST-LOCK L14-30R G GROUND TERMINAL Blue Br - Light Green R - Green / White Lg - Black Bl/W - Yellow Y/G - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www.honeywellgenerators.com ENGINE CHARGE COIL BATTERY STARTER MOTOR FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG Gr...
Service Manual
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6: SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE Operation ELECTRICAL Alternator Complete Battery Brush Assembly Charging Coil Assembly Control Panel Assembly Ignition Coil Meters... 45 60 50 45 40 40 50 30 30 --30 30 40 50 45 60 45 40 180 50 40 45 30 40 30 HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW7500EL (min.) 120 120 120 120 120 -- 30 -- 30 30 ...40 45 45 45 45 45 30 30 30 30 30 40 40 40 40 40 30 30 30 30 30 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 6-1
6: SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE Operation ELECTRICAL Alternator Complete Battery Brush Assembly Charging Coil Assembly Control Panel Assembly Ignition Coil Meters... 45 60 50 45 40 40 50 30 30 --30 30 40 50 45 60 45 40 180 50 40 45 30 40 30 HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW7500EL (min.) 120 120 120 120 120 -- 30 -- 30 30 ...40 45 45 45 45 45 30 30 30 30 30 40 40 40 40 40 30 30 30 30 30 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 6-1
Service Manual
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... 50 50 120 90 30 30 30 HW4000 HW4000L (min.) 30 60 40 50 50 50 120 90 30 30 30 HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW7500EL (min.) 30 30 30 30 30 60 60... 30 30 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 additional time may be needed due to unforeseen circumstances. 6.1 SERVICE REPAIR TIME ANALYSIS 6-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
... 50 50 120 90 30 30 30 HW4000 HW4000L (min.) 30 60 40 50 50 50 120 90 30 30 30 HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW7500EL (min.) 30 30 30 30 30 60 60... 30 30 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 additional time may be needed due to unforeseen circumstances. 6.1 SERVICE REPAIR TIME ANALYSIS 6-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
Service Manual
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...HW5500, HW5500L, HW6200, HW6200L) F-ENGINE CONTROL SWITCH G-SWITCH PLATE (BACK) B D Control panels vary between models. 9: SERVICE AND DISASSEMBLY 9.1 CONTROL PANEL A-CONTROL PANEL ASSEMBLY (FRONT) 4 N•m (3 lb. POWER CONTROL CENTER HOUSEHOLD OUTLETS 120 VOLTS AC 120/240 VOLTS AC C BREAKER BREAKER MASTER BREAKER A ENGINE START E1 RUN STOP ENGINE RUN E2 F STOP G Honeywell Portable Electrical Generator Service Manual... www.honeywellgenerators.com 9-1 Electric Start Models (HW5500E, HW5500EL, HW7000E, ...
...HW5500, HW5500L, HW6200, HW6200L) F-ENGINE CONTROL SWITCH G-SWITCH PLATE (BACK) B D Control panels vary between models. 9: SERVICE AND DISASSEMBLY 9.1 CONTROL PANEL A-CONTROL PANEL ASSEMBLY (FRONT) 4 N•m (3 lb. POWER CONTROL CENTER HOUSEHOLD OUTLETS 120 VOLTS AC 120/240 VOLTS AC C BREAKER BREAKER MASTER BREAKER A ENGINE START E1 RUN STOP ENGINE RUN E2 F STOP G Honeywell Portable Electrical Generator Service Manual... www.honeywellgenerators.com 9-1 Electric Start Models (HW5500E, HW5500EL, HW7000E, ...
Service Manual
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...reassembly, clean fuel tank to cool before filling with fuel. • NEVER smoke or allow flames or sparks near the generator or where gasoline is stored. • NEVER overfill the fuel tank (there should be no fuel in "L", the fuel...(HW3000, HW4000, HW5500, HW5500E, HW6200, HW7000E, HW7500E) F-FUEL SHUT-OFF VALVE Clear passages if clogged. H-FUEL LINE Check for cracks or damage. If any fuel is clean and free of vapor. A B E 1 C D E 2 F H G HW7500E Model Illustrated 9-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Spilled fuel or fuel...
...reassembly, clean fuel tank to cool before filling with fuel. • NEVER smoke or allow flames or sparks near the generator or where gasoline is stored. • NEVER overfill the fuel tank (there should be no fuel in "L", the fuel...(HW3000, HW4000, HW5500, HW5500E, HW6200, HW7000E, HW7500E) F-FUEL SHUT-OFF VALVE Clear passages if clogged. H-FUEL LINE Check for cracks or damage. If any fuel is clean and free of vapor. A B E 1 C D E 2 F H G HW7500E Model Illustrated 9-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Spilled fuel or fuel...
Service Manual
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... and remains hot for a while after stopping the engine. • NEVER touch hot surfaces and avoid hot gases. • Let engine cool before storing the generator indoors. C-SPARK ARRESTOR Clamp - 1 N•m (1 lb. ft.) G E1 E2 F 9-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Non "L" Models (HW3000, HW4000, HW5500, HW5500E, HW6200, HW7000E, HW7500E) • E2 -
... and remains hot for a while after stopping the engine. • NEVER touch hot surfaces and avoid hot gases. • Let engine cool before storing the generator indoors. C-SPARK ARRESTOR Clamp - 1 N•m (1 lb. ft.) G E1 E2 F 9-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Non "L" Models (HW3000, HW4000, HW5500, HW5500E, HW6200, HW7000E, HW7500E) • E2 -
Service Manual
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ft.) B C D F-SUPPORT LEGS 25 N•m (18 lb. F H G HW5500E Model Illustrated 9-12 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual G-RUBBER STOPPER 25 N•m (18 lb. ft.) NOTE: On some models the leg support nuts are welded to be used specifically with this generator. • NEVER use accessory kit for any other purpose. • NEVER use accessory kit...
ft.) B C D F-SUPPORT LEGS 25 N•m (18 lb. F H G HW5500E Model Illustrated 9-12 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual G-RUBBER STOPPER 25 N•m (18 lb. ft.) NOTE: On some models the leg support nuts are welded to be used specifically with this generator. • NEVER use accessory kit for any other purpose. • NEVER use accessory kit...