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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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... hazardous situation which , if not avoided, may result in approved containers and away from windows, doors, and vents. 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...
... hazardous situation which , if not avoided, may result in approved containers and away from windows, doors, and vents. 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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...to contact eyes, skin, or clothing. SAFETY MESSAGES Electric Shock Hazards WARNING Generators produce powerful voltage that are extremely flammable and explosive under warranty. Honeywell Portable Electrical Generator Service Manual Fire and Burn Hazards WARNING Fuel and its vapors are worn, frayed, ...bare, or otherwise damaged. • NEVER operate generator in your household to live. • Inform...
...to contact eyes, skin, or clothing. SAFETY MESSAGES Electric Shock Hazards WARNING Generators produce powerful voltage that are extremely flammable and explosive under warranty. Honeywell Portable Electrical Generator Service Manual Fire and Burn Hazards WARNING Fuel and its vapors are worn, frayed, ...bare, or otherwise damaged. • NEVER operate generator in your household to live. • Inform...
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...: 1 Year Limited. MEDICAL AND LIFE SUPPORT USES. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 No Extension of God. TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, NORTHSHORE POWER ...LIMITATIONS OF REMEDIES. This warranty excludes any way subjected to state. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be defective in material or workmanship. Transportation charges are in any...
...: 1 Year Limited. MEDICAL AND LIFE SUPPORT USES. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 No Extension of God. TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, NORTHSHORE POWER ...LIMITATIONS OF REMEDIES. This warranty excludes any way subjected to state. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be defective in material or workmanship. Transportation charges are in any...
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... at no abuse, neglect or improper maintenance of your portable generator to you retain all scheduled maintenance. Vent lines 3. Ignition System A. Northshore Power Systems must be denied warranty coverage if a part has failed due to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Length of the Emission Control Warranty. Carburetor gaskets...
... at no abuse, neglect or improper maintenance of your portable generator to you retain all scheduled maintenance. Vent lines 3. Ignition System A. Northshore Power Systems must be denied warranty coverage if a part has failed due to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Length of the Emission Control Warranty. Carburetor gaskets...
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... any emissions control part still under warranty. 6. 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 will extend to the failure of any ...which leads to the determination that an emissions control part is defective, if the diagnostic work is equivalent in the Honeywell Generator Owner's Manual. Consequential Coverage. Coverage noted hereunder will be used for defects during the warranty period. Repair or Replacement Cost....
... any emissions control part still under warranty. 6. 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 will extend to the failure of any ...which leads to the determination that an emissions control part is defective, if the diagnostic work is equivalent in the Honeywell Generator Owner's Manual. Consequential Coverage. Coverage noted hereunder will be used for defects during the warranty period. Repair or Replacement Cost....
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... inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com. 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,... provided herein, whichever is sought. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Fill out a Warranty Claim Form listing the part number and write "New Defective" in applications not made known...
... inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com. 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,... provided herein, whichever is sought. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Fill out a Warranty Claim Form listing the part number and write "New Defective" in applications not made known...
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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 Brush...
... 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 Brush...
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... 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 to...
... 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 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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Light Green R - Brown G/W - 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 is mechanically ...
Light Green R - Brown G/W - 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 is mechanically ...
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... 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.com ENGINE...
... 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.com ENGINE...
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... 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 Black Bu - Green / White Lg - 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...
... 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 Black Bu - Green / White Lg - 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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...Blue Br - Light Green R - Red Y - Black / White Bu - Green / White Lg - Yellow Y/G - 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 ... 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 - Brown G/W -
...Blue Br - Light Green R - Red Y - Black / White Bu - Green / White Lg - Yellow Y/G - 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 ... 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 - Brown G/W -
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... Twist-Lock (NEMA L14-30R) outlet (on fuel tank. 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...in "L" only) Reduces hydrocarbon emissions. When spark plug needs service, cap must be grounded to the appliance. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 Set Tripped HW3000 / HW3000L models only: • 15-amp circuit breaker (left outlet...
... Twist-Lock (NEMA L14-30R) outlet (on fuel tank. 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...in "L" only) Reduces hydrocarbon emissions. When spark plug needs service, cap must be grounded to the appliance. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 Set Tripped HW3000 / HW3000L models only: • 15-amp circuit breaker (left outlet...
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... meter • Resistive load - 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 Cool generator completely before moving or transporting the generator: • Press the engine control switch to the STOP position. • Turn...
... meter • Resistive load - 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 Cool generator completely before moving or transporting the generator: • Press the engine control switch to the STOP position. • Turn...