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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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... result in death or serious injury to the operator or to the generator components. NOTE: Since there are introduced by a signal word indicating the hazard level. 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. Only use inside a home or...
... result in death or serious injury to the operator or to the generator components. NOTE: Since there are introduced by a signal word indicating the hazard level. 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. Only use inside a home or...
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... or other equipment, and combustible materials during operation. • NEVER fill fuel tank while the engine is comprised of generator can cause permanent damage. • Damage to spill fuel when refueling. Honeywell Portable Electrical Generator Service Manual Spilled fuel or fuel vapor may ignite. WARNING Battery gases are worn, frayed, bare, or otherwise damaged...
... or other equipment, and combustible materials during operation. • NEVER fill fuel tank while the engine is comprised of generator can cause permanent damage. • Damage to spill fuel when refueling. Honeywell Portable Electrical Generator Service Manual Spilled fuel or fuel vapor may ignite. WARNING Battery gases are worn, frayed, bare, or otherwise damaged...
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...vary from www.honeywellgenerators.com or by a retail customer. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 LIMITED WARRANTY PERIODS Consumer Use: 3 Years Limited. 1st year, parts and ...defective in material or workmanship. LIMITATIONS OF REMEDIES. For all products. 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 Warranty...
...vary from www.honeywellgenerators.com or by a retail customer. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 LIMITED WARRANTY PERIODS Consumer Use: 3 Years Limited. 1st year, parts and ...defective in material or workmanship. LIMITATIONS OF REMEDIES. For all products. 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 Warranty...
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... A. Fuel Tank Evaporative Emissions Control System A. Purge valves 8. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Environmental Protection Agency (EPA) and California Air Resources Board (CARB) require manufacturers of two years from the ...be designed, built, and equipped to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual The emissions warranty is a defects warranty and is available at no abuse, neglect or improper ...
... A. Fuel Tank Evaporative Emissions Control System A. Purge valves 8. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Environmental Protection Agency (EPA) and California Air Resources Board (CARB) require manufacturers of two years from the ...be designed, built, and equipped to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual The emissions warranty is a defects warranty and is available at no abuse, neglect or improper ...
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...your emissions warranty rights and responsibilities, you should contact the Service and Warranty Department at an authorized Northshore Power Systems Honeywell generator dealer. 5. Repair or Replacement Cost. Any replacement part that is replaced or repaired as required by the failure... of 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 4. Repair or replacement of any emissions control part will be used for defects during...
...your emissions warranty rights and responsibilities, you should contact the Service and Warranty Department at an authorized Northshore Power Systems Honeywell generator dealer. 5. Repair or Replacement Cost. Any replacement part that is replaced or repaired as required by the failure... of 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 4. Repair or replacement of any emissions control part will be used for defects during...
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...and sole discretion, repair or replace the part if it is longer. WARRANTIES NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY Honeywell Portable Generator For a period of 90 days from new stock, or immediately upon installation must be filed under limited warranty. In... (498-3247) or visit www.honeywellgenerators.com. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual All shipping costs under the following procedure: 1. or (vii) acts of Northshore Power Systems; (vi) use ...
...and sole discretion, repair or replace the part if it is longer. WARRANTIES NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY Honeywell Portable Generator For a period of 90 days from new stock, or immediately upon installation must be filed under limited warranty. In... (498-3247) or visit www.honeywellgenerators.com. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual All shipping costs under the following procedure: 1. or (vii) acts of Northshore Power Systems; (vi) use ...
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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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... 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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... WIRING DIAGRAMS www.honeywellgenerators.com Bl Y/G IG E ENGINE CONTROL SWITCH Bl Y/G OFF ON Bl - Brown Y - 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...
... WIRING DIAGRAMS www.honeywellgenerators.com Bl Y/G IG E ENGINE CONTROL SWITCH Bl Y/G OFF ON Bl - Brown Y - 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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... 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 - White Y/G IG E Bl Bu G/W ENGINE CONTROL SWITCH ON/OFF SWITCH PANEL CONTROL PANEL MAGNETIC AC BREAKER...
... 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 - White Y/G IG E Bl Bu G/W ENGINE CONTROL SWITCH ON/OFF SWITCH PANEL CONTROL PANEL MAGNETIC AC BREAKER...
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... 21A WIRING DIAGRAMS www.honeywellgenerators.com Bu G/W Bl Y/G Y/G IG E Bl Bu G/W OFF ON Bl - Green / White Lg - 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...
... 21A WIRING DIAGRAMS www.honeywellgenerators.com Bu G/W Bl Y/G Y/G IG E Bl Bu G/W OFF ON Bl - Green / White Lg - 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 - Light Green R - White Bl/W ENGINE CONTROL SWITCH ON/OFF SWITCH PANEL CONTROL...
... 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 - Light Green R - White Bl/W ENGINE CONTROL SWITCH ON/OFF SWITCH PANEL CONTROL...
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... www.honeywellgenerators.com Bu G/W Bl Y/G Y/G IG E Bl Bu G/W OFF ON Bl - Green / White Lg - Black Bu - 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...
... www.honeywellgenerators.com Bu G/W Bl Y/G Y/G IG E Bl Bu G/W OFF ON Bl - Green / White Lg - Black Bu - 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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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 ... 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 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 - Green / White Lg - Red Y - Yellow Y/G - Blue ...
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 ... 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 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 - Green / White Lg - Red Y - Yellow Y/G - Blue ...
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...Fuel Shut-off engine oil fill hole and provides indicator for grounding protec- tion. 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...the appliance. M-Spark Plug Cap (Wire) Delivers voltage to ground wire for engine oil level. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 When spark plug needs service, cap must be removed.
...Fuel Shut-off engine oil fill hole and provides indicator for grounding protec- tion. 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...the appliance. M-Spark Plug Cap (Wire) Delivers voltage to ground wire for engine oil level. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 When spark plug needs service, cap must be removed.
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...• Place pins in the handle and handle bracket before transporting. NOTICE NEVER drop, strike, or place heavy objects on generator when transporting. 5: PREPARING FOR SERVICE WARNING ANYONE using or servicing this manual. such as a load bank, heaters, light ...; Wood block (for rotor support) 5.2 TRANSPORTING GENERATOR WARNING Hot engine or exhaust system can result in 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 Failure to closely...
...• Place pins in the handle and handle bracket before transporting. NOTICE NEVER drop, strike, or place heavy objects on generator when transporting. 5: PREPARING FOR SERVICE WARNING ANYONE using or servicing this manual. such as a load bank, heaters, light ...; Wood block (for rotor support) 5.2 TRANSPORTING GENERATOR WARNING Hot engine or exhaust system can result in 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 Failure to closely...