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...SYSTEMS EMISSIONS CONTROL WARRANTY 2-2 NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY 2-4 SPECIFICATIONS 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... (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
...SYSTEMS EMISSIONS CONTROL WARRANTY 2-2 NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY 2-4 SPECIFICATIONS 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... (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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...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. Only use inside a home or garage, EVEN IF doors and windows are many variations in the circumstances surrounding the installation, operation, service, and maintenance of this generator...result in damage to the generator components. Failure to closely ... extinguishers and safety equipment nearby. Generator exhaust contains carbon monoxide. SAFETY... using or servicing this generator must read, understand,...
...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. Only use inside a home or garage, EVEN IF doors and windows are many variations in the circumstances surrounding the installation, operation, service, and maintenance of this generator...result in damage to the generator components. Failure to closely ... extinguishers and safety equipment nearby. Generator exhaust contains carbon monoxide. SAFETY... using or servicing this generator must read, understand,...
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...consumer products under operating conditions or in material or workmanship. EXCLUSIONS. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be determined at www.honeywellgenerators.com. LIMITED WARRANTY PERIODS Consumer Use:.... DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS This warranty gives you specific legal rights, and you may send in the enclosed Product Registration, or register your generator to power life support devices, life support appliances, medical devices,...
...consumer products under operating conditions or in material or workmanship. EXCLUSIONS. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be determined at www.honeywellgenerators.com. LIMITED WARRANTY PERIODS Consumer Use:.... DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS This warranty gives you specific legal rights, and you may send in the enclosed Product Registration, or register your generator to power life support devices, life support appliances, medical devices,...
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...sole discretion. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 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 God.....com. All shipping costs under the following procedure: 1. DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS This warranty gives you specific legal rights, and you may also have failed within 90 days will not be borne and prepaid by the Northshore Power...
...sole discretion. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual 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 God.....com. All shipping costs under the following procedure: 1. DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS This warranty gives you specific legal rights, and you may also have failed within 90 days will not be borne and prepaid by the Northshore Power...
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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 ...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 ...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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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 Brush Assembly Bolt Carbon Canister Bracket Bolts Connecting Rod Bolts Control Panel Bolts Cooling ... 18 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 Brush Assembly Bolt Carbon Canister Bracket Bolts Connecting Rod Bolts Control Panel Bolts Cooling ... 18 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
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... the lock nut (see C in illustration). 6. Turn the rocker arm pivot (see B in illustration) to maintain position. 5. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-7 Turn the engine crankshaft using the recoil starter, positioning engine at top, dead center, of range,...the engine and run with the engine cold. 1. Stop the engine. 4. If frequency is within specifications. 10. Check valve lash again after tightening lock nut. 9. Remove the generator control panel for re-use. (Inspect and replace gasket, if necessary.) 2. ft.) • ...
... the lock nut (see C in illustration). 6. Turn the rocker arm pivot (see B in illustration) to maintain position. 5. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-7 Turn the engine crankshaft using the recoil starter, positioning engine at top, dead center, of range,...the engine and run with the engine cold. 1. Stop the engine. 4. If frequency is within specifications. 10. Check valve lash again after tightening lock nut. 9. Remove the generator control panel for re-use. (Inspect and replace gasket, if necessary.) 2. ft.) • ...
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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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... "ETWEEN7INDINGS #ONTINUITY Specification 3TATOR 8"LACK AVR Tap"ROWN #ONTINUITY 3TATOR 8"LACK Either Exciter Yellow .O#ONTINUITY )F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE Replace Alternator Refer to Illustrations on Page 8-5. 8-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual ELECTRICAL ...Each Terminal Contains Nut, Lock Washer, and Flat Washer -EASURE7INDING2ESISTANCESAS3PECIFIED"ELOW Winding Measure Resistance "ETWEEN7IRES Resistance Range Specification (Ω) Stator-X "LACK White 0.15 - 0.35 AVR Tap "ROWN "LUE 20-35% of Stator-X...
... "ETWEEN7INDINGS #ONTINUITY Specification 3TATOR 8"LACK AVR Tap"ROWN #ONTINUITY 3TATOR 8"LACK Either Exciter Yellow .O#ONTINUITY )F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE Replace Alternator Refer to Illustrations on Page 8-5. 8-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual ELECTRICAL ...Each Terminal Contains Nut, Lock Washer, and Flat Washer -EASURE7INDING2ESISTANCESAS3PECIFIED"ELOW Winding Measure Resistance "ETWEEN7IRES Resistance Range Specification (Ω) Stator-X "LACK White 0.15 - 0.35 AVR Tap "ROWN "LUE 20-35% of Stator-X...
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ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) Duplex Outlet #1 NEMA 5-20R 120V See "Specifications" Page For Rated Power, Voltage, & Frequency Specs Under Load and No Load Conditions HOUSEHOLD OUTLETS 120 VOLTS AC POWER CORD or TRANSFER SWITCH 120/240 ... 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
ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) Duplex Outlet #1 NEMA 5-20R 120V See "Specifications" Page For Rated Power, Voltage, & Frequency Specs Under Load and No Load Conditions HOUSEHOLD OUTLETS 120 VOLTS AC POWER CORD or TRANSFER SWITCH 120/240 ... 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
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... 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...&UEL#UTOUT7INDING#ONNECTOR $ISCONNECTTHE7IRESATTHE!LTERNATOR4ERMINAL"LOCK NOTE: Each Terminal Contains Nut, Lock Washer, and Flat Washer -EASURE7INDING2ESISTANCESAS3PECIFIED"ELOW Resistance Range Specification (Ω) Measure Resistance "ETWEEN7IRES (7, (7, (7%, (7%, (7, (7%, Red White "LUE "ROWN AVR Tap Green White ...
... 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...&UEL#UTOUT7INDING#ONNECTOR $ISCONNECTTHE7IRESATTHE!LTERNATOR4ERMINAL"LOCK NOTE: Each Terminal Contains Nut, Lock Washer, and Flat Washer -EASURE7INDING2ESISTANCESAS3PECIFIED"ELOW Resistance Range Specification (Ω) Measure Resistance "ETWEEN7IRES (7, (7, (7%, (7%, (7, (7%, Red White "LUE "ROWN AVR Tap Green White ...
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... 25 N•m (18 lb. ft.) G-WHEEL A B NOTICE • Accessory kit is intended to be used specifically with this generator. • NEVER use accessory kit for any other purpose. • NEVER use accessory kit on-road. D E G F Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-11 WHEEL, LEG, & HANDLE ASSEMBLY 9.11 WHEEL, LEG, & HANDLE ASSEMBLY (HW3000...
... 25 N•m (18 lb. ft.) G-WHEEL A B NOTICE • Accessory kit is intended to be used specifically with this generator. • NEVER use accessory kit for any other purpose. • NEVER use accessory kit on-road. D E G F Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-11 WHEEL, LEG, & HANDLE ASSEMBLY 9.11 WHEEL, LEG, & HANDLE ASSEMBLY (HW3000...
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...18 lb. ft.) NOTE: On some models the leg support nuts are welded to be used specifically with this generator. • NEVER use accessory kit for any other purpose. • NEVER use accessory kit ...on-road. G-RUBBER STOPPER 25 N•m (18 lb. WHEEL, LEG, & HANDLE ASSEMBLY 9.12 WHEEL, LEG, & HANDLE ASSEMBLY (ALL MODELS EXCEPT HW3000/L) A-WHEEL HANDLE PIVOT BRACKET 10 N•m (7 lb. F H G HW5500E Model Illustrated 9-12 www.honeywellgenerators.com Honeywell Portable Electrical Generator...
...18 lb. ft.) NOTE: On some models the leg support nuts are welded to be used specifically with this generator. • NEVER use accessory kit for any other purpose. • NEVER use accessory kit ...on-road. G-RUBBER STOPPER 25 N•m (18 lb. WHEEL, LEG, & HANDLE ASSEMBLY 9.12 WHEEL, LEG, & HANDLE ASSEMBLY (ALL MODELS EXCEPT HW3000/L) A-WHEEL HANDLE PIVOT BRACKET 10 N•m (7 lb. F H G HW5500E Model Illustrated 9-12 www.honeywellgenerators.com Honeywell Portable Electrical Generator...
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... system 9-4 muffler 9-6 preparing for 5-1 recoil starter 9-9 starting system 9-8 wheel, leg, & handle assembly 9-11 Service Repair Time 6-1 Spark Arrestor 4-1, 7-6, 9-6 Spark Plug 4-1, 7-5 Specifications 3-1 T Tools, Service 5-1 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.com 10-1
... system 9-4 muffler 9-6 preparing for 5-1 recoil starter 9-9 starting system 9-8 wheel, leg, & handle assembly 9-11 Service Repair Time 6-1 Spark Arrestor 4-1, 7-6, 9-6 Spark Plug 4-1, 7-5 Specifications 3-1 T Tools, Service 5-1 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.com 10-1