Service Manual
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...FILTER MAINTENANCE ...7-3 CLEANING FUEL SEDIMENT CUP ...7-5 SPARK PLUG SERVICE ...7-5 CLEANING SPARK ARRESTOR SCREEN 7-6 VALVE LASH ...7-7 GOVERNOR ADJUSTMENT ...7-7 GOVERNOR RANGE ADJUSTMENT ...7-7 BATTERY SERVICE ...7-8 TROUBLESHOOTING 8-1 ELECTRICAL DIAGNOSTICS (HW3000/L MODELS 8-2 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L 8-6 ENGINE DIAGNOSTICS (ALL MODELS 8-10 SERVICE AND ... 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
...FILTER MAINTENANCE ...7-3 CLEANING FUEL SEDIMENT CUP ...7-5 SPARK PLUG SERVICE ...7-5 CLEANING SPARK ARRESTOR SCREEN 7-6 VALVE LASH ...7-7 GOVERNOR ADJUSTMENT ...7-7 GOVERNOR RANGE ADJUSTMENT ...7-7 BATTERY SERVICE ...7-8 TROUBLESHOOTING 8-1 ELECTRICAL DIAGNOSTICS (HW3000/L MODELS 8-2 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L 8-6 ENGINE DIAGNOSTICS (ALL MODELS 8-10 SERVICE AND ... 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
Service Manual
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... appliances. • NEVER use insulated/non-conducting tools when working with water. Honeywell Portable Electrical Generator Service Manual Spilled fuel or fuel vapor may ignite. If metal comes into contact with battery terminals, electric shock and serious burns can result. • Only use this ... during operation. • NEVER fill fuel tank while the engine is set on disconnected batteries, can cause death or great physical harm. • Notify the utility company when using generator for a while after stopping the engine. • NEVER touch hot surfaces and avoid hot...
... appliances. • NEVER use insulated/non-conducting tools when working with water. Honeywell Portable Electrical Generator Service Manual Spilled fuel or fuel vapor may ignite. If metal comes into contact with battery terminals, electric shock and serious burns can result. • Only use this ... during operation. • NEVER fill fuel tank while the engine is set on disconnected batteries, can cause death or great physical harm. • Notify the utility company when using generator for a while after stopping the engine. • NEVER touch hot surfaces and avoid hot...
Service Manual
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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... 100833A 100833A 100833A 100833A 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 general temperature ...
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... 100833A 100833A 100833A 100833A 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 general temperature ...
Service Manual
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...-30R G GROUND TERMINAL Black / White Bu - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL 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 Bl Y IGNITION COIL Bl Bl ENGINE BLOCK Br W G/W...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 -...
...-30R G GROUND TERMINAL Black / White Bu - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL 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 Bl Y IGNITION COIL Bl Bl ENGINE BLOCK Br W G/W...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 -...
Service Manual
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... White Lg - Blue Br - Black Bl / W - Brown G/W - 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 Bl Y IGNITION COIL Bl ...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 -
... White Lg - Blue Br - Black Bl / W - Brown G/W - 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 Bl Y IGNITION COIL Bl ...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 -
Service Manual
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... power. N-Carbon Canister (Model numbers ending in fuel tank. Master circuit breaker controls power to spark plug. B-Battery Tray and Battery (Electric start models only) Provides power for electric start engine, if needed. Set Tripped HW3000 / HW3000L models only...flow of fuel from faulty appliances. H-Air Cleaner Assembly Removes dust from escaping generator. Prevents sparks and other combustible materials from engine intake air. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 J-Fuel Cap Provides a secure seal on select...
... power. N-Carbon Canister (Model numbers ending in fuel tank. Master circuit breaker controls power to spark plug. B-Battery Tray and Battery (Electric start models only) Provides power for electric start engine, if needed. Set Tripped HW3000 / HW3000L models only...flow of fuel from faulty appliances. H-Air Cleaner Assembly Removes dust from escaping generator. Prevents sparks and other combustible materials from engine intake air. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 J-Fuel Cap Provides a secure seal on select...
Service Manual
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6: SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE Operation ELECTRICAL Alternator Complete Battery Brush Assembly Charging Coil Assembly Control Panel Assembly Ignition Coil Meters / Circuit Breakers Oil Shutdown ... 180 50 40 45 30 40 30 HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW7500EL (min.) 120 120 120 120 120 -- 30 -- 30 30 45 45 45 45 45 45 45 45 45 45 ...30 30 30 30 30 40 40 40 40 40 30 30 30 30 30 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 6-1
6: SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE Operation ELECTRICAL Alternator Complete Battery Brush Assembly Charging Coil Assembly Control Panel Assembly Ignition Coil Meters / Circuit Breakers Oil Shutdown ... 180 50 40 45 30 40 30 HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW7500EL (min.) 120 120 120 120 120 -- 30 -- 30 30 45 45 45 45 45 45 45 45 45 45 ...30 30 30 30 30 40 40 40 40 40 30 30 30 30 30 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 6-1
Service Manual
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... to ensure the battery remains charged. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-1 DANGER Using a generator indoors CAN KILL YOU IN MINUTES. WARNING Improper maintenance, or failure to keep the generator in good operating condition. Generator Maintenance Schedule Every ... for 15-30 minutes every three months to recharge the generator battery. ** It is recommended that the generator is run , be performed by any maintenance. WARNING Accidental starting battery cables. Before performing maintenance, disconnect spark plug cap from ...
... to ensure the battery remains charged. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-1 DANGER Using a generator indoors CAN KILL YOU IN MINUTES. WARNING Improper maintenance, or failure to keep the generator in good operating condition. Generator Maintenance Schedule Every ... for 15-30 minutes every three months to recharge the generator battery. ** It is recommended that the generator is run , be performed by any maintenance. WARNING Accidental starting battery cables. Before performing maintenance, disconnect spark plug cap from ...
Service Manual
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.... 4. ing the bolt and nut. Disconnect the red positive (+) battery lead removing the bolt and nut. 7-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual tive (+) post on the battery; install bolt, nut, and boot. 10. Replacement Battery Equivalents to recharge the generator battery. NOTE: Dispose of used battery according to the posi- Reinstall retaining plate; FIGURE 7-20: Electric...
.... 4. ing the bolt and nut. Disconnect the red positive (+) battery lead removing the bolt and nut. 7-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual tive (+) post on the battery; install bolt, nut, and boot. 10. Replacement Battery Equivalents to recharge the generator battery. NOTE: Dispose of used battery according to the posi- Reinstall retaining plate; FIGURE 7-20: Electric...
Service Manual
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...Not Retracting = Disassemble and Repair Broken Ratchets or Springs (see Manual Section "Recoil Starter") 8-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Replace Coil if Repeated Battery Discharge Engine Speed Unstable Check Spark Plug & Gap Check Ignition for Spark Adjust Coil Air Gap Check Spark Arrestor ... Start Check Oil Level Check Fuel Level Check Fuel Shut-off Valve Open Confirm Choke in Start Position Check Battery Post / Solenoid Voltage Drop Check Battery Post / Starter Lugs Voltage Drop NOTE: Generator has Charging Coil During Operation;
...Not Retracting = Disassemble and Repair Broken Ratchets or Springs (see Manual Section "Recoil Starter") 8-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Replace Coil if Repeated Battery Discharge Engine Speed Unstable Check Spark Plug & Gap Check Ignition for Spark Adjust Coil Air Gap Check Spark Arrestor ... Start Check Oil Level Check Fuel Level Check Fuel Shut-off Valve Open Confirm Choke in Start Position Check Battery Post / Solenoid Voltage Drop Check Battery Post / Starter Lugs Voltage Drop NOTE: Generator has Charging Coil During Operation;
Service Manual
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...Fuel Strainer 9-4 Fuel Tank 9-4, 9-5 Fuel, Oxygenated 7-2 G Governor 7-7 Ground Terminal 4-1 M Maintenance 7-1 air filter 7-3 battery service 7-8 fuel sediment cup 7-5 governor adjustment 7-7 governor range adjustment 7-7 schedule 7-1 spark arrestor screen 7-6 spark plug 7-5 ... Torque Information 3-2 Transporting Generator 5-1 Troubleshooting 8-1 V Valve Lash 7-7 Voltage Regulator 8-5, 8-9, 9-3 W Warranty emissions control 2-2 limited 2-1 replacement parts 2-4 Wheel, Leg, & Handle Assembly 9-11 Wiring Diagrams 3-3 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators....
...Fuel Strainer 9-4 Fuel Tank 9-4, 9-5 Fuel, Oxygenated 7-2 G Governor 7-7 Ground Terminal 4-1 M Maintenance 7-1 air filter 7-3 battery service 7-8 fuel sediment cup 7-5 governor adjustment 7-7 governor range adjustment 7-7 schedule 7-1 spark arrestor screen 7-6 spark plug 7-5 ... Torque Information 3-2 Transporting Generator 5-1 Troubleshooting 8-1 V Valve Lash 7-7 Voltage Regulator 8-5, 8-9, 9-3 W Warranty emissions control 2-2 limited 2-1 replacement parts 2-4 Wheel, Leg, & Handle Assembly 9-11 Wiring Diagrams 3-3 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators....