Service Manual
Page 1
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.
Service Manual
Page 3
... 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
Service Manual
Page 4
THIS PAGE INTENTIONALLY LEFT BLANK ii www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
THIS PAGE INTENTIONALLY LEFT BLANK ii www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
Service Manual
Page 5
... hazardous situation which , if not avoided, will result in death or serious injury to the operator or to bystanders. Generator exhaust contains carbon monoxide. SAFETY PRECAUTIONS • Wear appropriate protective safety equipment, such as safety shoes and safety glasses.... situation which , if not avoided, may result in damage to the generator components. 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. NEVER use OUTSIDE and far away ...
... hazardous situation which , if not avoided, will result in death or serious injury to the operator or to bystanders. Generator exhaust contains carbon monoxide. SAFETY PRECAUTIONS • Wear appropriate protective safety equipment, such as safety shoes and safety glasses.... situation which , if not avoided, may result in damage to the generator components. 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. NEVER use OUTSIDE and far away ...
Service Manual
Page 6
...; Remove rings, watches or any other object containing metal when working with water. Honeywell Portable Electrical Generator Service Manual If any fuel is spilled, the area must be dry before storing the generator indoors. Use approved transfer equipment to isolate generator from this product to power medical devices or medical appliances. • Inform your electricity...
...; Remove rings, watches or any other object containing metal when working with water. Honeywell Portable Electrical Generator Service Manual If any fuel is spilled, the area must be dry before storing the generator indoors. Use approved transfer equipment to isolate generator from this product to power medical devices or medical appliances. • Inform your electricity...
Service Manual
Page 7
..., call 1-888-HWHELP1 (494-3571) or visit www.honeywellgenerators.com. Commercial Use: 1 Year Limited. Warranty is not transferable. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be warranted for the remaining original warranty period only. LIMITED WARRANTY PERIODS Consumer Use: 3 Years Limited. 1st year...
..., call 1-888-HWHELP1 (494-3571) or visit www.honeywellgenerators.com. Commercial Use: 1 Year Limited. Warranty is not transferable. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be warranted for the remaining original warranty period only. LIMITED WARRANTY PERIODS Consumer Use: 3 Years Limited. 1st year...
Service Manual
Page 8
...by Northshore Power Systems. OWNER'S RESPONSIBILITIES You are responsible to bring your portable generator to an authorized Northshore Power Systems Honeywell generator dealer for your generator to place of purchase for a period of two years, subject to...is not related to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Environmental Protection Agency (EPA) and California Air Resources...
...by Northshore Power Systems. OWNER'S RESPONSIBILITIES You are responsible to bring your portable generator to an authorized Northshore Power Systems Honeywell generator dealer for your generator to place of purchase for a period of two years, subject to...is not related to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. Environmental Protection Agency (EPA) and California Air Resources...
Service Manual
Page 9
... emissions warranty rights and responsibilities, you should contact the Service and Warranty Department at an authorized Northshore Power Systems Honeywell generator dealer. 5. Any replacement part that is replaced or repaired as required by the maintenance schedule defined in performance ... Replacement Cost. Coverage noted hereunder will extend to the determination that is equivalent in the Honeywell Generator Owner's Manual. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3
... emissions warranty rights and responsibilities, you should contact the Service and Warranty Department at an authorized Northshore Power Systems Honeywell generator dealer. 5. Any replacement part that is replaced or repaired as required by the maintenance schedule defined in performance ... Replacement Cost. Coverage noted hereunder will extend to the determination that is equivalent in the Honeywell Generator Owner's Manual. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3
Service Manual
Page 10
... products under the following procedure: 1. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NORTHSHORE POWER SYSTEMS HEREBY DISCLAIMS AND EXCLUDES ALL OTHER WARRANTIES. To the extent that Northshore Power Systems's ... law or the limited warranty period provided herein, whichever is longer. 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...
... products under the following procedure: 1. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NORTHSHORE POWER SYSTEMS HEREBY DISCLAIMS AND EXCLUDES ALL OTHER WARRANTIES. To the extent that Northshore Power Systems's ... law or the limited warranty period provided herein, whichever is longer. 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...
Service Manual
Page 11
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-1 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...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. †...
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-1 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...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. †...
Service Manual
Page 12
... 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...
Service Manual
Page 13
... looking at the control panel front;10 Amp Breaker will be on the right side 3-3 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...
... looking at the control panel front;10 Amp Breaker will be on the right side 3-3 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...
Service Manual
Page 14
... 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 -
... 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 -
Service Manual
Page 15
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 ...
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 ...
Service Manual
Page 16
... 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 -
... 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 -
Service Manual
Page 17
... MAGNETIC AC BREAKER 25A WIRING DIAGRAMS www.honeywellgenerators.com Bu G/W Bl Y/G Y/G IG E Bl Bu G/W OFF ON Bl - 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...
... MAGNETIC AC BREAKER 25A WIRING DIAGRAMS www.honeywellgenerators.com Bu G/W Bl Y/G Y/G IG E Bl Bu G/W OFF ON Bl - 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...
Service Manual
Page 18
Black / White Bu - Light Green R - Red Y - 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 ...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 - Blue Br - Yellow / Green W - Green / White Lg -...
Black / White Bu - Light Green R - Red Y - 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 ...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 - Blue Br - Yellow / Green W - Green / White Lg -...
Service Manual
Page 19
... Drain Screw Allows engine oil to spark plug. B-Battery Tray and Battery (Electric start models) • STOP-Stops generator engine by stopping the flow of fuel currently in "L" only) Reduces hydrocarbon emissions. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 Prevents sparks and other combustible materials from engine intake air. Set Tripped HW3000...
... Drain Screw Allows engine oil to spark plug. B-Battery Tray and Battery (Electric start models) • STOP-Stops generator engine by stopping the flow of fuel currently in "L" only) Reduces hydrocarbon emissions. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 Prevents sparks and other combustible materials from engine intake air. Set Tripped HW3000...
Service Manual
Page 20
THIS PAGE INTENTIONALLY LEFT BLANK 4-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
THIS PAGE INTENTIONALLY LEFT BLANK 4-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
Service Manual
Page 21
... handle and handle bracket before transporting. Failure to prevent fuel spillage. • Place pins 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 Cool generator completely before moving the generator. 5: PREPARING FOR SERVICE WARNING ANYONE using or servicing this manual.
... handle and handle bracket before transporting. Failure to prevent fuel spillage. • Place pins 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 Cool generator completely before moving the generator. 5: PREPARING FOR SERVICE WARNING ANYONE using or servicing this manual.