Service Manual
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... 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 SPARK PLUG SERVICE ...7-5 CLEANING ...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
... 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 SPARK PLUG SERVICE ...7-5 CLEANING ...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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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 7500 Maximum [watts... 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...
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 7500 Maximum [watts... 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 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 ... 45 40 180 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 60 60... 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 ... 45 40 180 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 60 60... 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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...) Gasoline containing more than 10% ethanol by misuse. 7-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Methanol (methyl or wood alcohol) Gasoline containing methanol must be used. NEVER OVERFILL. Avoid getting dirt or water in place while refueling. Use fresh gasoline with a pump octane rating of vapor. Use unleaded gasoline with a pump octane...
...) Gasoline containing more than 10% ethanol by misuse. 7-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Methanol (methyl or wood alcohol) Gasoline containing methanol must be used. NEVER OVERFILL. Avoid getting dirt or water in place while refueling. Use fresh gasoline with a pump octane rating of vapor. Use unleaded gasoline with a pump octane...
Service Manual
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ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) See "Specifications" Page For Rated Power, Voltage, & Frequency Specs Under Load and No Load Conditions Duplex Outlet #1 NEMA 5-20R 120V Duplex Outlet #2 NEMA 5-20R 120V W XW G W XW G Y G Y G 3000 RATED WATTS • 3750 MAXIMUM WATTS White Wire = W Black Wire = X Yellow / Green Wire = G To Alternator Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-3
ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) See "Specifications" Page For Rated Power, Voltage, & Frequency Specs Under Load and No Load Conditions Duplex Outlet #1 NEMA 5-20R 120V Duplex Outlet #2 NEMA 5-20R 120V W XW G W XW G Y G Y G 3000 RATED WATTS • 3750 MAXIMUM WATTS White Wire = W Black Wire = X Yellow / Green Wire = G To Alternator Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-3
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...LACK Either Exciter Yellow .O#ONTINUITY )F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE Replace Alternator Refer to Illustrations on Page 8-5. 8-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Start Engine and Add Resistive Loads Until One of the Following Occurs: s0OWER/UTPUTat the NEMA 5-20R 120V... must be rich causing a decrease in engine performance and an increase in fuel consumption. ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) Rated Power Check (Low Power Output) NOTE: At high-altitudes, standard carburetor air-fuel mixture will be at room temperature ...
...LACK Either Exciter Yellow .O#ONTINUITY )F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE Replace Alternator Refer to Illustrations on Page 8-5. 8-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Start Engine and Add Resistive Loads Until One of the Following Occurs: s0OWER/UTPUTat the NEMA 5-20R 120V... must be rich causing a decrease in engine performance and an increase in fuel consumption. ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) Rated Power Check (Low Power Output) NOTE: At high-altitudes, standard carburetor air-fuel mixture will be at room temperature ...
Service Manual
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... Y G W X MASTER BREAKER 7000 7000 RATED WATTS • 8750 MAXIMUM WATTS Duplex Outlet #2 NEMA 5-20R 120V 240V Receptacle NEMA 14-30R White Wire = Y Yellow / Green Wire = G Red Wire = X Blue Wire = W on Duplex Outlet #1 Brown Wire = W on Duplex Outlet #2 To Alternator Fuel Cutout Winding Connector Brown Wires (2) Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-7
... Y G W X MASTER BREAKER 7000 7000 RATED WATTS • 8750 MAXIMUM WATTS Duplex Outlet #2 NEMA 5-20R 120V 240V Receptacle NEMA 14-30R White Wire = Y Yellow / Green Wire = G Red Wire = X Blue Wire = W on Duplex Outlet #1 Brown Wire = W on Duplex Outlet #2 To Alternator Fuel Cutout Winding Connector Brown Wires (2) Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-7
Service Manual
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.../HMMETERWITH+ELVIN"RIDGE#LIPS -EASURE2ESISTANCEATTHE3LIP2ING7IRE4ERMINALSFOR"EST2ESULTS If a Winding Resistance is Within Rated Power Specification Range s&REQUENCY$ROPS"ELOW(Z s6OLTAGE/UTPUT$ROPS"ELOW Minimum 228- ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) Rated Power Check (Low Power Output) NOTE: At high-altitudes, standard carburetor ...!BOVE Replace Alternator Refer to Illustrations on Page 8-9. 8-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NOTE: At this time, a high-altitude carburetor kit is not available.
.../HMMETERWITH+ELVIN"RIDGE#LIPS -EASURE2ESISTANCEATTHE3LIP2ING7IRE4ERMINALSFOR"EST2ESULTS If a Winding Resistance is Within Rated Power Specification Range s&REQUENCY$ROPS"ELOW(Z s6OLTAGE/UTPUT$ROPS"ELOW Minimum 228- ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) Rated Power Check (Low Power Output) NOTE: At high-altitudes, standard carburetor ...!BOVE Replace Alternator Refer to Illustrations on Page 8-9. 8-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NOTE: At this time, a high-altitude carburetor kit is not available.