Service Manual
Page 3
......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...9-5 MUFFLER ...9-6 CARBURETOR ...9-7 STARTING SYSTEM ...9-8 RECOIL STARTER ...9-9 FAN COVER ...9-10 WHEEL, LEG, & 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....
......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...9-5 MUFFLER ...9-6 CARBURETOR ...9-7 STARTING SYSTEM ...9-8 RECOIL STARTER ...9-9 FAN COVER ...9-10 WHEEL, LEG, & 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....
Service Manual
Page 8
...carburetor and internal components (if equipped) 2. Ignition coil B. Exhaust System A. Purge valves 8. Miscellaneous Items used in materials and workmanship for a period of the emission control system. Length of the Emission Control Warranty. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator...claims based on the engine are responsible to bring your portable generator to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Your emission control system may include parts such...
...carburetor and internal components (if equipped) 2. Ignition coil B. Exhaust System A. Purge valves 8. Miscellaneous Items used in materials and workmanship for a period of the emission control system. Length of the Emission Control Warranty. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator...claims based on the engine are responsible to bring your portable generator to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Your emission control system may include parts such...
Service Manual
Page 19
G-Recoil Starter Handle Provides means to carburetor. Choke Control Controls choke valve. L-Muffler Equipped with select models) or connect a transfer switch (not included) to a building's main electrical system for ...engine to start (manual start feature. NEVER touch hot surfaces. C-Oil Fill Dipstick Seals off Valve Controls flow of electricity from the generator to drain from generator. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 M-Spark Plug Cap (Wire) Delivers voltage to all outlets. When spark plug needs service, cap must...
G-Recoil Starter Handle Provides means to carburetor. Choke Control Controls choke valve. L-Muffler Equipped with select models) or connect a transfer switch (not included) to a building's main electrical system for ...engine to start (manual start feature. NEVER touch hot surfaces. C-Oil Fill Dipstick Seals off Valve Controls flow of electricity from the generator to drain from generator. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 M-Spark Plug Cap (Wire) Delivers voltage to all outlets. When spark plug needs service, cap must...
Service Manual
Page 23
...Receptacles / Ports Recoil Starter Assembly Spark Plug Electric Starter Starter Solenoid Voltage Regulator ENGINE Air Filter Air Cleaner Carburetor Choke Converter (Model Numbers Ending in "L") Cylinder Head Cover Cylinder Head Gasket Engine Complete Governor Assembly Head...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... 40 40 40 30 30 30 30 30 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 6-1
...Receptacles / Ports Recoil Starter Assembly Spark Plug Electric Starter Starter Solenoid Voltage Regulator ENGINE Air Filter Air Cleaner Carburetor Choke Converter (Model Numbers Ending in "L") Cylinder Head Cover Cylinder Head Gasket Engine Complete Governor Assembly Head...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... 40 40 40 30 30 30 30 30 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 6-1
Service Manual
Page 27
... NOTICE A dirty air filter will not start until sufficient oil is within the indicated range. Stop engine if it is added. Honeywell Portable Electrical Generator Service Manual FIGURE 7-2: Air Cleaner Cover-Model Numbers Ending in good running . 2. AIR FILTER MAINTENANCE ENGINE OIL RECOMMENDATIONS NOTICE Engine...Ending in extremely dusty areas, clean air filter more frequently. Low Oil Protection The generator engine is protected from low lubrication failure by your area is added to carburetor, which may be used motor oil according to guidelines established by an oil shutdown...
... NOTICE A dirty air filter will not start until sufficient oil is within the indicated range. Stop engine if it is added. Honeywell Portable Electrical Generator Service Manual FIGURE 7-2: Air Cleaner Cover-Model Numbers Ending in good running . 2. AIR FILTER MAINTENANCE ENGINE OIL RECOMMENDATIONS NOTICE Engine...Ending in extremely dusty areas, clean air filter more frequently. Low Oil Protection The generator engine is protected from low lubrication failure by your area is added to carburetor, which may be used motor oil according to guidelines established by an oil shutdown...
Service Manual
Page 29
... leaks. 7.4 SPARK PLUG SERVICE To ensure proper engine operation, the spark plug must be securely tightened. Torque spark plug to 100842A Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-5 Use only recommended spark plugs or equivalent. Stop the engine if it is running , the spark...damage the engine. Gap should be: 0.028-0.031 in. (0.70-0.80 mm). .028 - .031 in the fuel tank from entering the carburetor. ft.). Measure the spark plug gap with a wire feeler gauge. If necessary, adjust gap by carefully bending side electrode. 3. Spark Plug ...
... leaks. 7.4 SPARK PLUG SERVICE To ensure proper engine operation, the spark plug must be securely tightened. Torque spark plug to 100842A Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-5 Use only recommended spark plugs or equivalent. Stop the engine if it is running , the spark...damage the engine. Gap should be: 0.028-0.031 in. (0.70-0.80 mm). .028 - .031 in the fuel tank from entering the carburetor. ft.). Measure the spark plug gap with a wire feeler gauge. If necessary, adjust gap by carefully bending side electrode. 3. Spark Plug ...
Service Manual
Page 36
.../L MODELS) Rated Power Check (Low Power Output) NOTE: At high-altitudes, standard carburetor air-fuel mixture will be at room temperature when resistance is measured. ./4%4HEALTERNATORDIAGNOSTICSREQUIREMEASUREMENTS OFLOWRESISTANCEVALUESWHICHAREBEYONDTHE ...)F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE Replace Alternator Refer to Illustrations on Page 8-5. 8-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NOTE: At this time, a high-altitude carburetor kit is Out of the Following Occurs: s0OWER/UTPUTat the NEMA 5-20R 120V Duplex Outlet ...
.../L MODELS) Rated Power Check (Low Power Output) NOTE: At high-altitudes, standard carburetor air-fuel mixture will be at room temperature when resistance is measured. ./4%4HEALTERNATORDIAGNOSTICSREQUIREMEASUREMENTS OFLOWRESISTANCEVALUESWHICHAREBEYONDTHE ...)F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE Replace Alternator Refer to Illustrations on Page 8-5. 8-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NOTE: At this time, a high-altitude carburetor kit is Out of the Following Occurs: s0OWER/UTPUTat the NEMA 5-20R 120V Duplex Outlet ...
Service Manual
Page 40
..."ROWN .O#ONTINUITY )F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE Replace Alternator Refer to Illustrations on Page 8-9. 8-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) Rated Power Check (Low Power Output) NOTE: At high-altitudes, standard carburetor air-fuel mixture will be at room temperature when resistance is measured. ./4%4HEALTERNATORDIAGNOSTICSREQUIREMEASUREMENTSOFLOWRESISTANCE VALUESWHICHAREBEYONDTHECAPABILITYOFATYPICALMULTI METER...
..."ROWN .O#ONTINUITY )F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE Replace Alternator Refer to Illustrations on Page 8-9. 8-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) Rated Power Check (Low Power Output) NOTE: At high-altitudes, standard carburetor air-fuel mixture will be at room temperature when resistance is measured. ./4%4HEALTERNATORDIAGNOSTICSREQUIREMEASUREMENTSOFLOWRESISTANCE VALUESWHICHAREBEYONDTHECAPABILITYOFATYPICALMULTI METER...
Service Manual
Page 42
... Check Engine Control Switch Voltage Drop in Off Position Check Air Cleaner Check Ignition for Spark Check Spark Plug & Gap Check Fuel Line & Blockage Check Carburetor Check Spark Arrestor Check Muffler Blockage Check Valve Adjustment Perform Engine Compression Test Recoil Not Operating Recoil Locked = Disassemble and Repair Recoil (see Manual Section... Plug Check Ignition for Mechanical Binding Rope 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
... Check Engine Control Switch Voltage Drop in Off Position Check Air Cleaner Check Ignition for Spark Check Spark Plug & Gap Check Fuel Line & Blockage Check Carburetor Check Spark Arrestor Check Muffler Blockage Check Valve Adjustment Perform Engine Compression Test Recoil Not Operating Recoil Locked = Disassemble and Repair Recoil (see Manual Section... Plug Check Ignition for Mechanical Binding Rope 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
Service Manual
Page 44
... lb. E-ROTOR See ROTOR, page 9-5. Refer to illustration for engine maintenance and repairs. ft.) D-REAR BEARING CARRIER AND STATOR See CARBURETOR, page 9-7. ft.) G-VIBRATION ISOLATORS Insert tabs into holes. NOTE: On some models there are only 4 vibration isolators instead of 6...., hardened, or worn. H-FRAME See WHEEL, LEG, & HANDLE ASSEMBLY, page 9-11. C A B F E D I - ft.) H G 9-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual F-ENGINE Contact an authorized service dealer for proper positioning. Cylinder Head Bolts - 48 N•m (35 lb.
... lb. E-ROTOR See ROTOR, page 9-5. Refer to illustration for engine maintenance and repairs. ft.) D-REAR BEARING CARRIER AND STATOR See CARBURETOR, page 9-7. ft.) G-VIBRATION ISOLATORS Insert tabs into holes. NOTE: On some models there are only 4 vibration isolators instead of 6...., hardened, or worn. H-FRAME See WHEEL, LEG, & HANDLE ASSEMBLY, page 9-11. C A B F E D I - ft.) H G 9-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual F-ENGINE Contact an authorized service dealer for proper positioning. Cylinder Head Bolts - 48 N•m (35 lb.
Service Manual
Page 49
.... F-MAIN JET Clean with compressed air before installation. CARBURETOR 9.7 CARBURETOR WARNING Fuel and its vapors are extremely flammable and explosive under certain conditions. • Refuel generator only outdoors, in a well-ventilated area. • NEVER enclose the generator in the filler neck). If any fuel is running. I H A B G F C D E Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-7 B-FLOAT Check...
.... F-MAIN JET Clean with compressed air before installation. CARBURETOR 9.7 CARBURETOR WARNING Fuel and its vapors are extremely flammable and explosive under certain conditions. • Refuel generator only outdoors, in a well-ventilated area. • NEVER enclose the generator in the filler neck). If any fuel is running. I H A B G F C D E Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-7 B-FLOAT Check...
Service Manual
Page 55
... outlets 4-1, 9-1 ground terminal 4-1 R Rotor 9-2, 9-3 S Safety, Important Instructions 1-1 Service and Disassembly 9-1 alternator 9-3 carburetor 9-7 control panel 9-1 engine and alternator 9-2 evaporative emissions control system 9-5 fan cover 9-10 fuel tank system 9-4 muffler ...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...
... outlets 4-1, 9-1 ground terminal 4-1 R Rotor 9-2, 9-3 S Safety, Important Instructions 1-1 Service and Disassembly 9-1 alternator 9-3 carburetor 9-7 control panel 9-1 engine and alternator 9-2 evaporative emissions control system 9-5 fan cover 9-10 fuel tank system 9-4 muffler ...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...
