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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...Honeywell Portable Electrical Generator Service Manual If metal comes into contact with battery terminals, electric shock and serious burns can result. • Only use insulated/non-conducting tools when working with or near the generator or where gasoline is comprised of sulfuric acid, which can be no fuel in any structure. • Keep generator...spill fuel when refueling. Medical and Life Support Uses WARNING • In case of battery. Turn generator OFF and allow flames or sparks near battery. • NEVER lay tools or other reproductive harm. After refueling, tighten the ...
...Honeywell Portable Electrical Generator Service Manual If metal comes into contact with battery terminals, electric shock and serious burns can result. • Only use insulated/non-conducting tools when working with or near the generator or where gasoline is comprised of sulfuric acid, which can be no fuel in any structure. • Keep generator...spill fuel when refueling. Medical and Life Support Uses WARNING • In case of battery. Turn generator OFF and allow flames or sparks near battery. • NEVER lay tools or other reproductive harm. After refueling, tighten the ...
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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... - Yellow / Green W - 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...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 - Light Green R - White Bl/W ENGINE...
... - Yellow / Green W - 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...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 - Light Green R - White Bl/W ENGINE...
Service Manual
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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 Bl ENGINE BLOCK Br W G/W Bl/W ALTERNATOR... 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 -
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 Bl ENGINE BLOCK Br W G/W Bl/W ALTERNATOR... 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 -
Service Manual
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... generator. B-Battery Tray and Battery (Electric start models only) Provides power for grounding protec- N-Carbon Canister (Model numbers ending in fuel tank. Master circuit breaker controls power to spark plug. H-Air Cleaner Assembly Removes dust from escaping generator. K-Fuel Gage Indicates level of fuel currently in "L" only) Reduces hydrocarbon emissions. NEVER touch hot surfaces. Honeywell Portable...
... generator. B-Battery Tray and Battery (Electric start models only) Provides power for grounding protec- N-Carbon Canister (Model numbers ending in fuel tank. Master circuit breaker controls power to spark plug. H-Air Cleaner Assembly Removes dust from escaping generator. K-Fuel Gage Indicates level of fuel currently in "L" only) Reduces hydrocarbon emissions. NEVER touch hot surfaces. Honeywell Portable...
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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...WARNING Improper maintenance, or failure to correct a problem before performing any non-road engine repair establishment or individual. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-1 NEVER use inside a home or garage, EVEN IF doors and windows are .../adjust valve lash X** Check fuel line TABLE 7-1. If the generator is stored for 15-30 minutes every three months to recharge the generator battery. ** It is recommended that the generator is well ventilated. Always follow inspection and maintenance recommendations and schedules...
...WARNING Improper maintenance, or failure to correct a problem before performing any non-road engine repair establishment or individual. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-1 NEVER use inside a home or garage, EVEN IF doors and windows are .../adjust valve lash X** Check fuel line TABLE 7-1. If the generator is stored for 15-30 minutes every three months to recharge the generator battery. ** It is recommended that the generator is well ventilated. Always follow inspection and maintenance recommendations and schedules...
Service Manual
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... to the neg- Disconnect the red positive (+) battery lead removing the bolt and nut. 7-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual install bolt, nut, and boot. 9. Tip battery slightly forward. 4. FIGURE 7-21: Electric Start Battery-Lead Connection 5. Remove the battery. Connect the black negative (-) battery lead to 101536A To replace battery: 1. install bolt, nut, and boot. 10...
... to the neg- Disconnect the red positive (+) battery lead removing the bolt and nut. 7-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual install bolt, nut, and boot. 9. Tip battery slightly forward. 4. FIGURE 7-21: Electric Start Battery-Lead Connection 5. Remove the battery. Connect the black negative (-) battery lead to 101536A To replace battery: 1. install bolt, nut, and boot. 10...
Service Manual
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... = 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 ...Governor Assembly Adjustment Engine Starts Then Shuts Down Check Fuel Level Check Fuel Quality 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;
... = 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 ...Governor Assembly Adjustment Engine Starts Then Shuts Down Check Fuel Level Check Fuel Quality 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....