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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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... the operator or to bystanders. SAVE THESE INSTRUCTIONS 1: IMPORTANT SAFETY INSTRUCTIONS WARNING ANYONE using or servicing this generator must read, understand, and follow these instructions can result in circumstances leading to bystanders. Failure to closely ...injury and equipment damage. www.honeywellgenerators.com 1-1 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. Generator exhaust contains carbon monoxide. NEVER use OUTSIDE and...
... the operator or to bystanders. SAVE THESE INSTRUCTIONS 1: IMPORTANT SAFETY INSTRUCTIONS WARNING ANYONE using or servicing this generator must read, understand, and follow these instructions can result in circumstances leading to bystanders. Failure to closely ...injury and equipment damage. www.honeywellgenerators.com 1-1 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. Generator exhaust contains carbon monoxide. NEVER use OUTSIDE and...
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...battery. Spilled fuel or fuel vapor may ignite. If any other object containing metal when working with or near the battery. Honeywell Portable Electrical Generator Service Manual If metal comes into contact with fuel. • NEVER smoke or allow battery fluid to cause cancer, birth ...electrical equipment to live. • Inform your electrical provider immediately if a loss of California to contact eyes, skin, or clothing. Turn generator OFF and allow open flames, lit cigarettes, sparks, or spark-producing equipment near battery. • NEVER lay tools or other reproductive harm...
...battery. Spilled fuel or fuel vapor may ignite. If any other object containing metal when working with or near the battery. Honeywell Portable Electrical Generator Service Manual If metal comes into contact with fuel. • NEVER smoke or allow battery fluid to cause cancer, birth ...electrical equipment to live. • Inform your electrical provider immediately if a loss of California to contact eyes, skin, or clothing. Turn generator OFF and allow open flames, lit cigarettes, sparks, or spark-producing equipment near battery. • NEVER lay tools or other reproductive harm...
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...limitations of retail purchase by calling 1-888-HWHELP1 (4943571). For warranty service, customer should locate an authorized Honeywell Generator Dealer from date of purchase for income producing, business related use . TO THE FULLEST EXTENT PERMITTED BY...Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 Commercial Use: 1 Year Limited. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be ...
...limitations of retail purchase by calling 1-888-HWHELP1 (4943571). For warranty service, customer should locate an authorized Honeywell Generator Dealer from date of purchase for income producing, business related use . TO THE FULLEST EXTENT PERMITTED BY...Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1 Commercial Use: 1 Year Limited. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be ...
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...smog standards. Clamps D. Fuel pump (if equipped) G. Purge valves 8. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Northshore Power Systems, LLC, CARB, and EPA offer the following explanation of Coverage. Air cleaner..., contact your small off -road engines (SORE) to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Air Injection System A. Environmental Protection Agency (EPA) and California Air Resources Board (CARB) require...
...smog standards. Clamps D. Fuel pump (if equipped) G. Purge valves 8. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Northshore Power Systems, LLC, CARB, and EPA offer the following explanation of Coverage. Air cleaner..., contact your small off -road engines (SORE) to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Air Injection System A. Environmental Protection Agency (EPA) and California Air Resources Board (CARB) require...
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...warranty rights and responsibilities, you should contact the Service and Warranty Department at an authorized Northshore Power Systems Honeywell generator dealer. 5. 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 Cost. Repair or replacement of any emissions ... LLC Attention: Service and Warranty Dept. 4425 N. The warranty does not cover an emission control part that is equivalent in the Honeywell Generator Owner's Manual. Repair or Replacement Cost.
...warranty rights and responsibilities, you should contact the Service and Warranty Department at an authorized Northshore Power Systems Honeywell generator dealer. 5. 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 Cost. Repair or replacement of any emissions ... LLC Attention: Service and Warranty Dept. 4425 N. The warranty does not cover an emission control part that is equivalent in the Honeywell Generator Owner's Manual. Repair or Replacement Cost.
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...Form. Warranty claim forms and inquiries can be defective in the description. 2. 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,... claims. FAILURE WITHIN 90 DAYS. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Parts which have been installed and have other rights which are to Northshore Power Systems's Service and Warranty...
...Form. Warranty claim forms and inquiries can be defective in the description. 2. 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,... claims. FAILURE WITHIN 90 DAYS. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Parts which have been installed and have other rights which are to Northshore Power Systems's Service and Warranty...
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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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... 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...
... 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...
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... 4 mm2 WIRING DIAGRAMS www.honeywellgenerators.com Bl Y/G IG E ENGINE CONTROL SWITCH Bl Y/G OFF ON Bl - 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...
... 4 mm2 WIRING DIAGRAMS www.honeywellgenerators.com Bl Y/G IG E ENGINE CONTROL SWITCH Bl Y/G OFF ON Bl - 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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... 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 - WIRING DIAGRAMS HW4000 & HW4000L 3-4 FIGURE 3-2: HW4000 & HW4000L Wiring Diagram www.honeywellgenerators.com ENGINE FUEL CUTOUT...
... 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 - WIRING DIAGRAMS HW4000 & HW4000L 3-4 FIGURE 3-2: HW4000 & HW4000L Wiring Diagram www.honeywellgenerators.com ENGINE FUEL CUTOUT...
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... DIAGRAMS www.honeywellgenerators.com Bu G/W Bl Y/G Y/G IG E Bl Bu G/W OFF ON Bl - Blue Br - Yellow Y/G - Light Green R - 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...
... DIAGRAMS www.honeywellgenerators.com Bu G/W Bl Y/G Y/G IG E Bl Bu G/W OFF ON Bl - Blue Br - Yellow Y/G - Light Green R - 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 - Brown G/W - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www.honeywellgenerators...
... 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 - Brown G/W - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www.honeywellgenerators...
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Black Bu - Red Y - 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 ...
Black Bu - Red Y - 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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... 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...
... 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...
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... hydrocarbon emissions. C-Oil Fill Dipstick Seals off Valve Controls flow of electricity from engine intake air. M-Spark Plug Cap (Wire) Delivers voltage to all outlets. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 E-Engine Control Switch Control used to manually start models) • STOP-Stops...
... hydrocarbon emissions. C-Oil Fill Dipstick Seals off Valve Controls flow of electricity from engine intake air. M-Spark Plug Cap (Wire) Delivers voltage to all outlets. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 E-Engine Control Switch Control used to manually start models) • STOP-Stops...
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... position. • Turn the fuel shut-off valve to the OFF position. • Keep the generator level to service the generator. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 NOTICE NEVER drop, strike, or place heavy objects on generator when transporting. Failure to closely follow all safety and operation instructions provided in the handle and...
... position. • Turn the fuel shut-off valve to the OFF position. • Keep the generator level to service the generator. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 NOTICE NEVER drop, strike, or place heavy objects on generator when transporting. Failure to closely follow all safety and operation instructions provided in the handle and...