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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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...with the warnings in moderate or minor injury to the operator or to bystanders. 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, ...• NEVER wear loose or damp clothing that might get caught in approved containers and away from windows, doors, and vents. Generator exhaust contains carbon monoxide. NEVER use OUTSIDE and far away from fire, flame, spark, pilot light, switches, arcproducing equipment and ...
...with the warnings in moderate or minor injury to the operator or to bystanders. 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, ...• NEVER wear loose or damp clothing that might get caught in approved containers and away from windows, doors, and vents. Generator exhaust contains carbon monoxide. NEVER use OUTSIDE and far away from fire, flame, spark, pilot light, switches, arcproducing equipment and ...
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...• Exposed terminals, even on disconnected batteries, can cause death or great physical harm. • Notify the utility company when using generator for a while after stopping the engine. • NEVER touch hot surfaces and avoid hot gases. • Let engine cool before filling...during operation and remains hot for backup power. California Proposition 65 WARNING The engine exhaust from buildings, other reproductive harm. Honeywell Portable Electrical Generator Service Manual If any other metal objects on top of California to contact eyes, skin, or clothing. If contact ...
...• Exposed terminals, even on disconnected batteries, can cause death or great physical harm. • Notify the utility company when using generator for a while after stopping the engine. • NEVER touch hot surfaces and avoid hot gases. • Let engine cool before filling...during operation and remains hot for backup power. California Proposition 65 WARNING The engine exhaust from buildings, other reproductive harm. Honeywell Portable Electrical Generator Service Manual If any other metal objects on top of California to contact eyes, skin, or clothing. If contact ...
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... of Northshore Power Systems; (vi) use . or (viii) acts of remedies & exclusions as stated below. For all products. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be warranted for defects. Commercial Use: 1 Year Limited. No warranty for income producing, business related use under applicable...
... of Northshore Power Systems; (vi) use . or (viii) acts of remedies & exclusions as stated below. For all products. 2: WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems, LLC, will be warranted for defects. Commercial Use: 1 Year Limited. No warranty for income producing, business related use under applicable...
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... must be denied warranty coverage if a part has failed due to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Also included may be designed, built, and equipped to the emissions control parts listed below. 1. You may...return your nearest dealer; Ignition System A. Length of the Emission Control Warranty. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. In the United States and California, new small off -road engines (SORE) to place of...
... must be denied warranty coverage if a part has failed due to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Also included may be designed, built, and equipped to the emissions control parts listed below. 1. You may...return your nearest dealer; Ignition System A. Length of the Emission Control Warranty. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT The U.S. In the United States and California, new small off -road engines (SORE) to place of...
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..., LLC Attention: Service and Warranty Dept. 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3 Repair or replacement of any emissions control part will extend to the determination that ...your emissions warranty rights and responsibilities, you should contact the Service and Warranty Department at an authorized Northshore Power Systems Honeywell generator dealer. 5. Repair or Replacement Cost. Repair or Replacement Cost. Any replacement part that an emissions control part is...
..., LLC Attention: Service and Warranty Dept. 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3 Repair or replacement of any emissions control part will extend to the determination that ...your emissions warranty rights and responsibilities, you should contact the Service and Warranty Department at an authorized Northshore Power Systems Honeywell generator dealer. 5. Repair or Replacement Cost. Repair or Replacement Cost. Any replacement part that an emissions control part is...
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... inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com. 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,... WARRANTY CLAIMS PROCEDURES DEFECTIVE NEW PARTS. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NORTHSHORE POWER SYSTEMS SHALL NOT BE LIABLE TO CUSTOMER, OR TO ANYONE CLAIMING UNDER CUSTOMER, FOR ANY ...
... inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com. 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,... WARRANTY CLAIMS PROCEDURES DEFECTIVE NEW PARTS. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NORTHSHORE POWER SYSTEMS SHALL NOT BE LIABLE TO CUSTOMER, OR TO ANYONE CLAIMING UNDER CUSTOMER, FOR ANY ...
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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 - Blue Br - Green / White Lg - White Y/G IG E Bl Bu G/W ENGINE CONTROL SWITCH ON/OFF SWITCH...
... 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 - Blue Br - Green / White Lg - White Y/G IG E Bl Bu G/W ENGINE CONTROL SWITCH ON/OFF SWITCH...
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Red Y - Brown G/W - Yellow Y/G - 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 ...
Red Y - Brown G/W - Yellow Y/G - 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 - Light Green R - Black Bl/W - Blue Br - Red Y - Yellow...
... 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 - Black Bl/W - Blue Br - Red Y - Yellow...
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... G/W OFF ON Bl - Green / White Lg - Light Green R - Yellow Y/G - Blue Br - Yellow / Green W - Red Y - Black Bu - Brown G/W - 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...
... G/W OFF ON Bl - Green / White Lg - Light Green R - Yellow Y/G - Blue Br - Yellow / Green W - Red Y - Black Bu - Brown G/W - 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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...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 - Red Y - Yellow / Green W... TWIST-LOCK X L14-30R G GROUND TERMINAL Green / White Lg - Brown G/W - 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...
...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 - Red Y - Yellow / Green W... TWIST-LOCK X L14-30R G GROUND TERMINAL Green / White Lg - Brown G/W - 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...
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... shock from faulty appliances. M-Spark Plug Cap (Wire) Delivers voltage to ON position when starting a cold engine. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 4: COMPONENTS K J I - K-Fuel Gage Indicates level of electricity from the generator to drain from damage caused by overload or short-circuit by inhibiting ignition F-Fuel Shut-off engine oil...
... shock from faulty appliances. M-Spark Plug Cap (Wire) Delivers voltage to ON position when starting a cold engine. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1 4: COMPONENTS K J I - K-Fuel Gage Indicates level of electricity from the generator to drain from damage caused by overload or short-circuit by inhibiting ignition F-Fuel Shut-off engine oil...
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...valve to the OFF position. • Keep the generator level to closely follow all safety and operation instructions provided in the handle and handle bracket before transporting. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 Also needed are required... to service the generator. Failure to prevent fuel spillage. • Place pins in this generator must read, understand, and follow these...
...valve to the OFF position. • Keep the generator level to closely follow all safety and operation instructions provided in the handle and handle bracket before transporting. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1 Also needed are required... to service the generator. Failure to prevent fuel spillage. • Place pins in this generator must read, understand, and follow these...