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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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... 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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... cover every situation. This is a poison you cannot see or smell. 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. All safety messages are provided throughout this generator, we cannot possibly anticipate or provide advice or safety messages to death...
... cover every situation. This is a poison you cannot see or smell. 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. All safety messages are provided throughout this generator, we cannot possibly anticipate or provide advice or safety messages to death...
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.... Battery electrolyte fluid is not covered under certain conditions. • Refuel generator only outdoors, in a well-ventilated area. • NEVER enclose the generator in rain or snow, or when the generator is running. Spilled fuel or fuel vapor may ignite. Honeywell Portable Electrical Generator Service Manual tion is comprised of California to cause cancer, birth defects or...
.... Battery electrolyte fluid is not covered under certain conditions. • Refuel generator only outdoors, in a well-ventilated area. • NEVER enclose the generator in rain or snow, or when the generator is running. Spilled fuel or fuel vapor may ignite. Honeywell Portable Electrical Generator Service Manual tion is comprised of California to cause cancer, birth defects or...
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...) or visit www.honeywellgenerators.com. "Commercial use . LIMITATIONS OF REMEDIES. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 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 be determined at www.honeywellgenerators.com. This limited warranty covers the cost...
...) or visit www.honeywellgenerators.com. "Commercial use . LIMITATIONS OF REMEDIES. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 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 be determined at www.honeywellgenerators.com. This limited warranty covers the cost...
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... warranty coverage if a part has failed due to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Exclusions. In the United States and California, new small off-road engines must warrant the emission control... a defects warranty and is defective, the part will repair your portable generator to an in above systems A. Exhaust manifold C. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Ignition coil B. Northshore Power Systems warrants to...
... warranty coverage if a part has failed due to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Exclusions. In the United States and California, new small off-road engines must warrant the emission control... a defects warranty and is defective, the part will repair your portable generator to an in above systems A. Exhaust manifold C. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Ignition coil B. Northshore Power Systems warrants to...
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... US mail: Northshore Power Systems, LLC Attention: Service and Warranty Dept. 4425 N. Consequential Coverage. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3 Repair or replacement of any emissions control part still under warranty. 6. Repair or Replacement Cost. Coverage noted hereunder will be used...
... US mail: Northshore Power Systems, LLC Attention: Service and Warranty Dept. 4425 N. Consequential Coverage. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3 Repair or replacement of any emissions control part still under warranty. 6. Repair or Replacement Cost. Coverage noted hereunder will be used...
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... herein, whichever is longer. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Parts which the buyer claims to be defective must be filed under this limited warranty shall not apply to... or modification by the nearest Authorized Northshore Power Systems Warranty Service Facility. 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...
... herein, whichever is longer. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Parts which the buyer claims to be defective must be filed under this limited warranty shall not apply to... or modification by the nearest Authorized Northshore Power Systems Warranty Service Facility. 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...
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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 HW7500E HW7000EL HW7500EL POWER Rated [watts] (+/-10% ...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. † ...
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 HW7500E HW7000EL HW7500EL POWER Rated [watts] (+/-10% ...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. † ...
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... 18 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
... 18 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
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... the control panel front;10 Amp Breaker will be on the right side 3-3 Yellow / Green W - 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 to...
... the control panel front;10 Amp Breaker will be on the right side 3-3 Yellow / Green W - 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 to...
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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 -
... 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 -
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... THERMAL AC BREAKER 20A W X W Y G DUPLEX 5-20R G DUPLEX 5-20R W X W Y G G Y/G W X Y TWIST-LOCK L14-30R G GROUND TERMINAL 3-5 Blue Br - Brown G/W - 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 is...
... THERMAL AC BREAKER 20A W X W Y G DUPLEX 5-20R G DUPLEX 5-20R W X W Y G G Y/G W X Y TWIST-LOCK L14-30R G GROUND TERMINAL 3-5 Blue Br - Brown G/W - 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 is...
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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 - Red Y - Yellow / Green W - Blue Br - Green / White Lg...
... 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 - Red Y - Yellow / Green W - Blue Br - Green / White Lg...
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... Bu G/W Bl Y/G Y/G IG E Bl Bu G/W OFF ON Bl - Green / White Lg - Light Green R - Black Bu - Yellow Y/G - Brown G/W - 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 mechanically...
... Bu G/W Bl Y/G Y/G IG E Bl Bu G/W OFF ON Bl - Green / White Lg - Light Green R - Black Bu - Yellow Y/G - Brown G/W - 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 mechanically...
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... Yellow Y/G - Black Bl / W - Red Y - Green / White Lg - 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 ... 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 - Blue Br - Light Green R - Yellow / Green W ...
... Yellow Y/G - Black Bl / W - Red Y - Green / White Lg - 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 ... 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 - Blue Br - Light Green R - Yellow / Green W ...
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... power cord (with Spark Arrestor Provides outlet for grounding protec- 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 120V... fuel tank. When spark plug needs service, cap must be moved to drain from faulty appliances. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 Master circuit breaker controls power to spark plug. K-Fuel Gage Indicates level of...
... power cord (with Spark Arrestor Provides outlet for grounding protec- 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 120V... fuel tank. When spark plug needs service, cap must be moved to drain from faulty appliances. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 Master circuit breaker controls power to spark plug. K-Fuel Gage Indicates level of...
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... shut-off valve to the OFF position. • Keep the generator level to service the generator. When moving the generator. 5: PREPARING FOR SERVICE WARNING ANYONE using or servicing this generator must read, understand, and follow these instructions can cause serious burns or fires. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 such as a load bank, heaters, light...
... shut-off valve to the OFF position. • Keep the generator level to service the generator. When moving the generator. 5: PREPARING FOR SERVICE WARNING ANYONE using or servicing this generator must read, understand, and follow these instructions can cause serious burns or fires. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 such as a load bank, heaters, light...