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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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.... Hazard Symbols and Meanings In addition to the signal words, the following symbols may result in damage to bystanders. 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. SAVE THESE INSTRUCTIONS 1: IMPORTANT SAFETY INSTRUCTIONS WARNING ANYONE using or servicing this...
.... Hazard Symbols and Meanings In addition to the signal words, the following symbols may result in damage to bystanders. 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. SAVE THESE INSTRUCTIONS 1: IMPORTANT SAFETY INSTRUCTIONS WARNING ANYONE using or servicing this...
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... other metal objects on electrical equipment to live. • Inform your electrical provider immediately if a loss of power would cause you or anyone in your household depends on top of battery. tion is running. Honeywell Portable Electrical Generator Service Manual Turn generator OFF and allow to ...cool before filling with or near the battery. WARNING Battery gases are explosive. • NEVER allow flames or sparks near the generator or where gasoline is set on...
... other metal objects on electrical equipment to live. • Inform your electrical provider immediately if a loss of power would cause you or anyone in your household depends on top of battery. tion is running. Honeywell Portable Electrical Generator Service Manual Turn generator OFF and allow to ...cool before filling with or near the battery. WARNING Battery gases are explosive. • NEVER allow flames or sparks near the generator or where gasoline is set on...
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...REMEDIES. Warranty inquiries can be determined at www.honeywellgenerators.com. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be addressed to: Northshore Power Systems, LLC Attention: Service and...CONSEQUENTIAL DAMAGE OR ECONOMIC LOSS. For all products. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 This limited warranty has time period conditions, operating conditions and disclaimers, ...
...REMEDIES. Warranty inquiries can be determined at www.honeywellgenerators.com. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be addressed to: Northshore Power Systems, LLC Attention: Service and...CONSEQUENTIAL DAMAGE OR ECONOMIC LOSS. For all products. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 This limited warranty has time period conditions, operating conditions and disclaimers, ...
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...equipped to meet stringent anti-smog standards. Do not return your generator to place of two years, subject to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual For emissions warranty service, contact your engine, but ...PARTS Coverage under this warranty extends only to perform all records/receipts covering maintenance on your portable generator to an authorized Northshore Power Systems Honeywell generator dealer for those components that are warranted for a period of purchase for service. Environmental...
...equipped to meet stringent anti-smog standards. Do not return your generator to place of two years, subject to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual For emissions warranty service, contact your engine, but ...PARTS Coverage under this warranty extends only to perform all records/receipts covering maintenance on your portable generator to an authorized Northshore Power Systems Honeywell generator dealer for those components that are warranted for a period of purchase for service. Environmental...
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... an emission control part that an emissions control part is defective, if the diagnostic work is equivalent in the Honeywell Generator Owner's Manual. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3 Coverage noted hereunder will be used for defects during the warranty period. 4. Consequential Coverage...
... an emission control part that an emissions control part is defective, if the diagnostic work is equivalent in the Honeywell Generator Owner's Manual. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3 Coverage noted hereunder will be used for defects during the warranty period. 4. Consequential Coverage...
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...: Service and Warranty Dept. 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS This warranty gives you specific legal rights, and you may also have...HWTECHS (498-3247) or visit www.honeywellgenerators.com. LIMITATIONS OF REMEDIES. 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...
...: Service and Warranty Dept. 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS This warranty gives you specific legal rights, and you may also have...HWTECHS (498-3247) or visit www.honeywellgenerators.com. LIMITATIONS OF REMEDIES. 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...
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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... 100833A (Model 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...
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... 100833A (Model 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...
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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 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...
... 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 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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... when looking at the control panel front;10 Amp Breaker will be on the right side 3-3 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...
... when looking at the control panel front;10 Amp Breaker will be on the right side 3-3 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 - Green / White Lg - Red Y - White Y/G IG E Bl Bu G/W ENGINE CONTROL SWITCH ON/OFF SWITCH PANEL CONTROL...
... 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 - Green / White Lg - Red Y - White Y/G IG E Bl Bu G/W ENGINE CONTROL SWITCH ON/OFF SWITCH PANEL CONTROL...
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... 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 Green / White Lg - Light Green R - Yellow / Green 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...
... 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 Green / White Lg - Light Green R - Yellow / Green 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...
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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 - Blue Br - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www...
... 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 - Blue Br - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www...
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... AC BREAKER 20A 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 3-7 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...
... AC BREAKER 20A 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 3-7 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...
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... 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 - Red Y - Brown... looking at the control panel front W Y TWIST-LOCK X L14-30R G GROUND TERMINAL 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...
... 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 - Red Y - Brown... looking at the control panel front W Y TWIST-LOCK X L14-30R G GROUND TERMINAL 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...
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... for engine oil level. D-Oil Drain Screw Allows engine oil to prevent electrical shock from generator. 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 appliances to generator for backup power. Choke Control Controls choke valve. N-Carbon Canister (Model numbers...
... for engine oil level. D-Oil Drain Screw Allows engine oil to prevent electrical shock from generator. 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 appliances to generator for backup power. Choke Control Controls choke valve. N-Carbon Canister (Model numbers...
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... the engine control switch to the STOP position. • Turn the fuel shut-off valve to the OFF position. • Keep the generator level to prevent fuel spillage. • Place pins in circumstances leading to service the generator. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 NOTICE NEVER drop, strike, or place heavy objects on...
... the engine control switch to the STOP position. • Turn the fuel shut-off valve to the OFF position. • Keep the generator level to prevent fuel spillage. • Place pins in circumstances leading to service the generator. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 NOTICE NEVER drop, strike, or place heavy objects on...