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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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...potentially hazardous situation which , if not avoided, may result in this generator, we cannot possibly anticipate or provide advice or safety messages to cover every situation. 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. Failure to closely follow ...
...potentially hazardous situation which , if not avoided, may result in this generator, we cannot possibly anticipate or provide advice or safety messages to cover every situation. 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. Failure to closely follow ...
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... buildings, other object containing metal when working with water. Honeywell Portable Electrical Generator Service Manual Generator Damage Hazards NOTICE Improper treatment or misuse of generator can cause permanent damage. • Damage to generator caused by a qualified electrician. • NEVER touch bare wires or receptacles. • NEVER use generator with electrical cords that can result. • Only use...
... buildings, other object containing metal when working with water. Honeywell Portable Electrical Generator Service Manual Generator Damage Hazards NOTICE Improper treatment or misuse of generator can cause permanent damage. • Damage to generator caused by a qualified electrician. • NEVER touch bare wires or receptacles. • NEVER use generator with electrical cords that can result. • Only use...
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... required on all customer service inquiries, call 1-888-HWHELP1 (494-3571) or visit www.honeywellgenerators.com. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 "Commercial use" is personal use . No Extension of purchase for a particular purpose) are the responsibility of merchantability or fitness...
... required on all customer service inquiries, call 1-888-HWHELP1 (494-3571) or visit www.honeywellgenerators.com. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 "Commercial use" is personal use . No Extension of purchase for a particular purpose) are the responsibility of merchantability or fitness...
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...provisions of time listed below provided there has been no cost to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Fuel pump (if equipped) G. Air Induction System A. Muffler gasket 5. Air Injection System A. Pulse...Power Systems cannot deny warranty claims based on your nearest dealer; WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Northshore Power Systems recommends that are responsible to place of receipts or for service...
...provisions of time listed below provided there has been no cost to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Fuel pump (if equipped) G. Air Induction System A. Muffler gasket 5. Air Injection System A. Pulse...Power Systems cannot deny warranty claims based on your nearest dealer; WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Northshore Power Systems recommends that are responsible to place of receipts or for service...
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... part that an emissions control part is defective, if the diagnostic work is performed at an authorized Northshore Power Systems Honeywell generator dealer. 5. Coverage noted hereunder will be used for defects during the warranty period. The emissions control parts are warranted...Repair or Replacement Cost. Repair or replacement of any emissions control part will extend to the determination that is equivalent in the Honeywell Generator Owner's Manual. 4. Any replacement part that is replaced or repaired as required by the failure of any emissions control part ...
... part that an emissions control part is defective, if the diagnostic work is performed at an authorized Northshore Power Systems Honeywell generator dealer. 5. Coverage noted hereunder will be used for defects during the warranty period. The emissions control parts are warranted...Repair or Replacement Cost. Repair or replacement of any emissions control part will extend to the determination that is equivalent in the Honeywell Generator Owner's Manual. 4. Any replacement part that is replaced or repaired as required by the failure of any emissions control part ...
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... of the original proof-of God. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual DISCLAIMER OF OTHER WARRANTIES. To the extent that Northshore Power Systems's products are consumer products under applicable federal...to or contemplated by the Northshore Power Systems Service and Warranty Department. WARRANTIES NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY Honeywell Portable Generator For a period of 90 days from state to and does not cover products that the part was purchased on ...
... of the original proof-of God. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual DISCLAIMER OF OTHER WARRANTIES. To the extent that Northshore Power Systems's products are consumer products under applicable federal...to or contemplated by the Northshore Power Systems Service and Warranty Department. WARRANTIES NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY Honeywell Portable Generator For a period of 90 days from state to and does not cover products that the part was purchased on ...
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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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... 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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... control panel front;10 Amp Breaker will be on the right side 3-3 Black Bu - Yellow Y/G - 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...
... control panel front;10 Amp Breaker will be on the right side 3-3 Black Bu - Yellow Y/G - 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 - Brown G/W - WIRING DIAGRAMS HW4000 & HW4000L 3-4 FIGURE 3-2: HW4000 & HW4000L Wiring Diagram www.honeywellgenerators...
... 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 - Brown G/W - WIRING DIAGRAMS HW4000 & HW4000L 3-4 FIGURE 3-2: HW4000 & HW4000L Wiring Diagram www.honeywellgenerators...
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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 3-5 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...
... 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 3-5 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 - Blue Br - Yellow Y/G - Yellow / Green W - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL...
... 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 - Blue Br - Yellow Y/G - Yellow / Green W - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL...
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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 3-7 Brown G/W - Light Green R - 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...
... 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 - Light Green R - 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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...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 - Yellow / Green W - Black / White Bu - ...Blue Br - Light Green R - Yellow Y/G - Black Bl / W - Green / White Lg - WIRING DIAGRAMS HW7000E, HW7000EL, HW7500E, & HW7500EL 3-8 FIGURE 3-6: HW7000E, HW7000EL, HW7500E &...
...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 - Yellow / Green W - Black / White Bu - ...Blue Br - Light Green R - Yellow Y/G - Black Bl / W - Green / White Lg - WIRING DIAGRAMS HW7000E, HW7000EL, HW7500E, & HW7500EL 3-8 FIGURE 3-6: HW7000E, HW7000EL, HW7500E &...
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... fill hole and provides indicator for grounding protec- Choke control must be moved to manually start models); Prevents sparks and other combustible materials 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...
... fill hole and provides indicator for grounding protec- Choke control must be moved to manually start models); Prevents sparks and other combustible materials 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...
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...and metric shop tools are : • Hammer • Torque wrench • Volt-ohm meter • Frequency meter • Resistive load - Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 such as a load bank, heaters, light bulbs, etc. • Alternator removal tool • Wood block (for...to the STOP position. • Turn the fuel shut-off valve to the OFF position. • Keep the generator level to service the generator. Also needed are required to prevent fuel spillage. • Place pins in this manual. 5: PREPARING FOR SERVICE WARNING...
...and metric shop tools are : • Hammer • Torque wrench • Volt-ohm meter • Frequency meter • Resistive load - Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 such as a load bank, heaters, light bulbs, etc. • Alternator removal tool • Wood block (for...to the STOP position. • Turn the fuel shut-off valve to the OFF position. • Keep the generator level to service the generator. Also needed are required to prevent fuel spillage. • Place pins in this manual. 5: PREPARING FOR SERVICE WARNING...