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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.
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... AND WIRING DIAGRAMS 3-1 SPECIFICATIONS ...3-1 BOLT AND FASTENER TORQUE INFORMATION 3-2 WIRING DIAGRAMS ...3-3 COMPONENTS ...4-1 PREPARING FOR SERVICE 5-1 REQUIRED TOOLS ...5-1 TRANSPORTING GENERATOR ...5-1 SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE 6-1 MAINTENANCE ...7-1 CONSUMER MAINTENANCE SCHEDULE 7-1 AIR FILTER MAINTENANCE ...7-3 CLEANING FUEL SEDIMENT CUP ...7-5 ...HANDLE ASSEMBLY (HW3000/L MODELS 9-11 WHEEL, LEG, & HANDLE ASSEMBLY (ALL MODELS EXCEPT HW3000/L 9-12 INDEX ...10-1 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com i
... AND WIRING DIAGRAMS 3-1 SPECIFICATIONS ...3-1 BOLT AND FASTENER TORQUE INFORMATION 3-2 WIRING DIAGRAMS ...3-3 COMPONENTS ...4-1 PREPARING FOR SERVICE 5-1 REQUIRED TOOLS ...5-1 TRANSPORTING GENERATOR ...5-1 SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE 6-1 MAINTENANCE ...7-1 CONSUMER MAINTENANCE SCHEDULE 7-1 AIR FILTER MAINTENANCE ...7-3 CLEANING FUEL SEDIMENT CUP ...7-5 ...HANDLE ASSEMBLY (HW3000/L MODELS 9-11 WHEEL, LEG, & HANDLE ASSEMBLY (ALL MODELS EXCEPT HW3000/L 9-12 INDEX ...10-1 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com i
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Honeywell Portable Electrical Generator Service Manual Explosion Toxic fumes Fire Chemical burn Electrical shock Hot surface DANGER Using a generator indoors CAN KILL YOU IN MINUTES. www.honeywellgenerators.com 1-1 Hazard Symbols and Meanings In addition to the signal ... Indicates a potentially hazardous situation which , if not avoided, will result in approved containers and away from windows, doors, and vents. Generator exhaust contains carbon monoxide. Only use inside a home or garage, EVEN IF doors and windows are provided throughout this manual and take special...
Honeywell Portable Electrical Generator Service Manual Explosion Toxic fumes Fire Chemical burn Electrical shock Hot surface DANGER Using a generator indoors CAN KILL YOU IN MINUTES. www.honeywellgenerators.com 1-1 Hazard Symbols and Meanings In addition to the signal ... Indicates a potentially hazardous situation which , if not avoided, will result in approved containers and away from windows, doors, and vents. Generator exhaust contains carbon monoxide. Only use inside a home or garage, EVEN IF doors and windows are provided throughout this manual and take special...
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... transfer switch has been installed by a qualified electrician. • NEVER touch bare wires or receptacles. • NEVER use generator with electrical cords that can result. • Only use insulated/non-conducting tools when working with battery. If metal comes ... battery fluid to experience a medical emergency. Spilled fuel or fuel vapor may ignite. Honeywell Portable Electrical Generator Service Manual SAFETY MESSAGES Electric Shock Hazards WARNING Generators produce powerful voltage that are extremely flammable and explosive under warranty. Medical and Life Support...
... transfer switch has been installed by a qualified electrician. • NEVER touch bare wires or receptacles. • NEVER use generator with electrical cords that can result. • Only use insulated/non-conducting tools when working with battery. If metal comes ... battery fluid to experience a medical emergency. Spilled fuel or fuel vapor may ignite. Honeywell Portable Electrical Generator Service Manual SAFETY MESSAGES Electric Shock Hazards WARNING Generators produce powerful voltage that are extremely flammable and explosive under warranty. Medical and Life Support...
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...products under operating conditions or in material or workmanship. For all products. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be warranted for service. Transportation charges are limited to : (i) improper setup...inquiries can be addressed to state. For warranty service, customer should locate an authorized Honeywell Generator Dealer from date of purchase to place of the portable generator found by a retail customer. No warranty for defects. TO THE FULLEST EXTENT PERMITTED...
...products under operating conditions or in material or workmanship. For all products. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be warranted for service. Transportation charges are limited to : (i) improper setup...inquiries can be addressed to state. For warranty service, customer should locate an authorized Honeywell Generator Dealer from date of purchase to place of the portable generator found by a retail customer. No warranty for defects. TO THE FULLEST EXTENT PERMITTED...
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...Power Systems. OWNER'S RESPONSIBILITIES You are responsible to bring your portable generator to original Honeywell generator parts in your Honeywell Generator Owner's Manual. For emissions warranty service, contact your generator to meet stringent anti-smog standards. Carburetor gaskets B. Breather connection...parts such as a problem exists. You are responsible to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Air Induction System A. Ignition System A. Choke system C. Fuel pump (if equipped) G. ...
...Power Systems. OWNER'S RESPONSIBILITIES You are responsible to bring your portable generator to original Honeywell generator parts in your Honeywell Generator Owner's Manual. For emissions warranty service, contact your generator to meet stringent anti-smog standards. Carburetor gaskets B. Breather connection...parts such as a problem exists. You are responsible to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Air Induction System A. Ignition System A. Choke system C. Fuel pump (if equipped) G. ...
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... warranty rights and responsibilities, you should contact the Service and Warranty Department at an authorized Northshore Power Systems Honeywell generator dealer. 5. The warranty does not cover an emission control part that is equivalent in performance and durability may be... control parts are warranted only for maintenance or repairs. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3 Consequential Coverage. Repair or replacement of any emissions control part will extend to the...
... warranty rights and responsibilities, you should contact the Service and Warranty Department at an authorized Northshore Power Systems Honeywell generator dealer. 5. The warranty does not cover an emission control part that is equivalent in performance and durability may be... control parts are warranted only for maintenance or repairs. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3 Consequential Coverage. Repair or replacement of any emissions control part will extend to the...
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...to Northshore Power Systems's Service and Warranty Department under the following procedure: 1. WARRANTIES 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...each part for the part. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, THIS LIMITED WARRANTY IS EXCLUSIVE AND EXPRESSLY IN LIEU...
...to Northshore Power Systems's Service and Warranty Department under the following procedure: 1. WARRANTIES 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...each part for the part. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, THIS LIMITED WARRANTY IS EXCLUSIVE AND EXPRESSLY IN LIEU...
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3: 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 ...Numbers Ending in "L") 102556A 101865A 101865A 101865A 101865A 101865A Battery (Electric Start Models Only) -- -- 101536A -- 101536A 101536A 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,...
3: 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 ...Numbers Ending in "L") 102556A 101865A 101865A 101865A 101865A 101865A Battery (Electric Start Models Only) -- -- 101536A -- 101536A 101536A 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,...
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... 13 24 17 10 7 10 7 4 3 18 13 4 3 32 24 12 9 30 22 48 35 1 1 1 1 28 21 6 4 25 18 25 18 10 7 3-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual BOLT AND FASTENER TORQUE INFORMATION 3.2 BOLT AND FASTENER TORQUE INFORMATION Component-Specific Fastener Alternator End Cover Bolts Alternator Housing Bolts Axle Bracket Bolts...
... 13 24 17 10 7 10 7 4 3 18 13 4 3 32 24 12 9 30 22 48 35 1 1 1 1 28 21 6 4 25 18 25 18 10 7 3-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual BOLT AND FASTENER TORQUE INFORMATION 3.2 BOLT AND FASTENER TORQUE INFORMATION Component-Specific Fastener Alternator End Cover Bolts Alternator Housing Bolts Axle Bracket Bolts...
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Black Bu - 3.3 WIRING DIAGRAMS HW3000 & HW3000L FIGURE 3-1: HW3000 & HW3000L Wiring Diagram Honeywell Portable Electrical Generator Service Manual ENGINE OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG Y Y Bl Bl IGNITION COIL Bl Bl Y/G ENGINE BLOCK ALTERNATOR NOTE: Alternator is mechanically connected ...
Black Bu - 3.3 WIRING DIAGRAMS HW3000 & HW3000L FIGURE 3-1: HW3000 & HW3000L Wiring Diagram Honeywell Portable Electrical Generator Service Manual ENGINE OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG Y Y Bl Bl IGNITION COIL Bl Bl Y/G ENGINE BLOCK ALTERNATOR NOTE: Alternator is mechanically connected ...
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... CUTOUT WINDING FIELD WINDING EXCITER WINDING MAIN WINDING 120 VAC MAIN 120 VAC WINDING Br Br W R Lg W Bu Bu AVR R Bu Br W R Bu Br W ALTERNATOR Honeywell Portable Electrical Generator Service Manual 5A FUSE Bu G/W Bl Y/G OFF ON Bl - Brown G/W - WIRING DIAGRAMS HW4000 & HW4000L 3-4 FIGURE 3-2: HW4000 & HW4000L Wiring Diagram www.honeywellgenerators.com ENGINE FUEL...
... CUTOUT WINDING FIELD WINDING EXCITER WINDING MAIN WINDING 120 VAC MAIN 120 VAC WINDING Br Br W R Lg W Bu Bu AVR R Bu Br W R Bu Br W ALTERNATOR Honeywell Portable Electrical Generator Service Manual 5A FUSE Bu G/W Bl Y/G OFF ON Bl - Brown G/W - WIRING DIAGRAMS HW4000 & HW4000L 3-4 FIGURE 3-2: HW4000 & HW4000L Wiring Diagram www.honeywellgenerators.com ENGINE FUEL...
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HW5500 & HW5500L FIGURE 3-3: HW5500 & HW5500L Wiring Diagram Honeywell Portable Electrical Generator Service Manual ENGINE FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG G/W Y Y Bl Y IGNITION COIL Bl Bl ENGINE BLOCK gg ALTERNATOR NOTE: Alternator ...
HW5500 & HW5500L FIGURE 3-3: HW5500 & HW5500L Wiring Diagram Honeywell Portable Electrical Generator Service Manual ENGINE FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG G/W Y Y Bl Y IGNITION COIL Bl Bl ENGINE BLOCK gg ALTERNATOR NOTE: Alternator ...
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... WINDING MAIN 120 VAC WINDING Br Br W 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 - Brown G/W - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www.honeywellgenerators...
... WINDING MAIN 120 VAC WINDING Br Br W 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 - Brown G/W - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www.honeywellgenerators...
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HW6200 & HW6200L FIGURE 3-5: HW6200 & HW6200L Wiring Diagram Honeywell Portable Electrical Generator Service Manual ENGINE FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG G/W Y Y Bl Y IGNITION COIL Bl Bl ENGINE BLOCK ALTERNATOR NOTE: Alternator is ...
HW6200 & HW6200L FIGURE 3-5: HW6200 & HW6200L Wiring Diagram Honeywell Portable Electrical Generator Service Manual ENGINE FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG G/W Y Y Bl Y IGNITION COIL Bl Bl ENGINE BLOCK ALTERNATOR NOTE: Alternator is ...
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WIRING DIAGRAMS HW7000E, HW7000EL, HW7500E, & HW7500EL 3-8 FIGURE 3-6: HW7000E, HW7000EL, HW7500E & HW7500EL Wiring Diagram www.honeywellgenerators.com ENGINE CHARGE COIL BATTERY STARTER MOTOR FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG Gr M Y Y Bl... WINDING Br Br W R Lg W Bu Bu AVR R Bu Br W R Bu Br W ALTERNATOR 5A FUSE AUTO PROTECTOR 3A DUAL POLE MAGNETIC AC BREAKER 240V 30A 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 - Black Bl / W - Light Green R -
WIRING DIAGRAMS HW7000E, HW7000EL, HW7500E, & HW7500EL 3-8 FIGURE 3-6: HW7000E, HW7000EL, HW7500E & HW7500EL Wiring Diagram www.honeywellgenerators.com ENGINE CHARGE COIL BATTERY STARTER MOTOR FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG Gr M Y Y Bl... WINDING Br Br W R Lg W Bu Bu AVR R Bu Br W R Bu Br W ALTERNATOR 5A FUSE AUTO PROTECTOR 3A DUAL POLE MAGNETIC AC BREAKER 240V 30A 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 - Black Bl / W - Light Green R -
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...protec- D-Oil Drain Screw Allows engine oil to spark plug. I H F E A B L M N G C D FIGURE 4-1: Honeywell Portable Electrical Generator Controls and Components (HW5500EL Model Illustrated) A-Power Control Center Electrical Outlets • 125VAC 20 Amp Duplex (NEMA 5-20R) outlets to connect ...sparks and other combustible materials from engine intake air. Choke control must be moved to all outlets. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 Breakers Protects circuits from faulty appliances. E-Engine Control Switch Control ...
...protec- D-Oil Drain Screw Allows engine oil to spark plug. I H F E A B L M N G C D FIGURE 4-1: Honeywell Portable Electrical Generator Controls and Components (HW5500EL Model Illustrated) A-Power Control Center Electrical Outlets • 125VAC 20 Amp Duplex (NEMA 5-20R) outlets to connect ...sparks and other combustible materials from engine intake air. Choke control must be moved to all outlets. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 Breakers Protects circuits from faulty appliances. E-Engine Control Switch Control ...
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.... Failure to closely follow all safety and operation instructions provided in the handle and handle bracket before transporting. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 Also needed are required to prevent fuel spillage. • Place pins in this generator must read, understand, and follow these instructions can cause serious burns or fires.
.... Failure to closely follow all safety and operation instructions provided in the handle and handle bracket before transporting. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 Also needed are required to prevent fuel spillage. • Place pins in this generator must read, understand, and follow these instructions can cause serious burns or fires.