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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. Downloaded from www.Manualslib.com manuals search engine...
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............................9-7 STARTING SYSTEM ..........................9-8 RECOIL STARTER ..........................9-9 FAN COVER ............................9-10 WHEEL, LEG, & 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 Downloaded from www.Manualslib.com...
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THIS PAGE INTENTIONALLY LEFT BLANK www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
• Use the correct tool for the job and check its condition before starting. • Keep fire extinguishers and safety equipment nearby. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
If any fuel is spilled, the area must be dry before starting the engine. • Avoid repeated or prolonged contact with skin or breathing of vapor. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
Warranty is also available by keeping and showing your origi- excludes any use of this product intended to power life sup- nal receipt from date of purchase to an authorized Honeywell port devices, life support appliances, medical devices, or Generator Dealer.
Honeywell generator parts in performance and durability. 1-877-HWTECHS (498-3247). Length of Coverage. Northshore Power Systems war- rants to the original retail purchaser and each subse- 2.1 WARRANTIES...
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Honeywell Generator Owner's Manual. Any replacement part that is equivalent in per- formance and durability may be used for maintenance or repairs.
OF INCOME, LOSS OF TIME, LOSS OF SALES, INJURY TO PERSONAL PROPERTY, OR LIABILITY CUSTOMER INCURS WITH RESPECT TO ANY OTHER PERSON, OR ANY OTHER TYPE OR FORM OF CONSEQUENTIAL DAM- AGE OR ECONOMIC LOSS. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
101536A 101536A (Electric Start Models Only) 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, page 7-5 for other recommended spark plug replacements.
M8 x 1.0 x 16 Support Leg to Rubber Stopper Bolts M8 x 1.0 x 25 Wheel Handle Pivot Bracket Bolts M6 x 1.0 x 40 TABLE 3-3: Torque Values www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
4: COMPONENTS FIGURE 4-1: Honeywell Portable Electrical Generator Controls and Components (HW5500EL Model Illustrated) A—Power Control Center E—Engine Control Switch Control used to start and stop the engine ignition system. Electrical Outlets • • START—Starts generator engine (electric start models) 125VAC 20 Amp Duplex (NEMA 5-20R) outlets to connect •...
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Keep the generator level to prevent fuel spillage. • Place pins in the handle and handle bracket before moving the generator. NOTICE NEVER drop, strike, or place heavy objects on generator when transporting. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
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FUEL & EXHAUST Carbon Canister (with bracket) (Model Numbers Ending in “L”) Carbon Canister Tube (Model Numbers Ending in “L”) Exhaust Pipe (Model Numbers Ending in “L”) Fuel Gage Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
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Repair times represent generally accepted intervals for conducting a repair. Service centers are always advised to provide feedback during the warranty claim process if additional time may be needed due to unforeseen circumstances. 6.1 SERVICE REPAIR TIME ANALYSIS www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
If the generator is stored for more than a year without running, a battery charger may required to recharge the generator battery. ** It is recommended that this maintenance task be performed by a service dealer. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com...
Some states (and provinces in Canada) require this infor- mation to be posted on the fuel pump. If you notice unde- sirable operating symptoms, switch to a conventional unleaded gasoline. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
Crankcase pressure can cause hot engine oil to spray out of engine fill hole. Hot engine oil can cause severe burns. FIGURE 7-3: Air Cleaner Cover—Non-L Models Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
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Frequent or prolonged contact with engine oil may cause skin cancer. • Thoroughly wash hands and any areas of skin exposed to used oil with soap and water. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
Champion RN9YC Turn the fuel shut-off valve to the ON position. Start generator and check for leaks. Denso W20EPR BPR6ES TABLE 7-4. Spark Plug Equivalents to 100842A Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
Check valve lash again after tightening lock nut. Repeat steps 4 through 7, as needed, until valve lash is within specifications. Reassemble the spark plug, cylinder head cover, and gasket. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
Disconnect the black negative (-) battery lead remov- ing the bolt and nut. FIGURE 7-21: Electric Start Battery—Lead Connection Disconnect the red positive (+) battery lead removing the bolt and nut. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
EVEN IF doors doors, and vents. and windows are open. NOTE: For all dealer service inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) 8.1 ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) 120V Circuit #1 Check 120V Circuit #2 Check General Electrical Check (No Output OR (No Output OR Voltage Out of Spec) Voltage Out of Spec) Refer to Illustrations on Conduct This Check Only When...
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NEMA 5-20R 120V NEMA 5-20R 120V 3000 RATED WATTS • 3750 MAXIMUM WATTS White Wire = W Black Wire = X Yellow / Green Wire = G Alternator Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
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Slip Rings Rotor 45 - 65 Slip Ring Terminals* If a Winding Resistance is Out of Spec, Replace Alternator Specification AVR Tap Either Exciter Yellow Replace Alternator www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
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EXCITER & AVR TAP SLIP RING CONNECTOR* TERMINALS POTENTIOMETER TO ADJUST VOLTAGE AVR TAP Blue Brown WINDING EXCITER Yellow Yellow WINDING *view looking into female connector from alternator Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) 8.2 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) 120V Circuit Check 240V Circuit Check General Electrical Check (No Output OR (No Output OR Voltage Out of Spec) Voltage Out of Spec) Refer to Illustrations on...
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ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) See “Specifications” Page For Rated Power, Voltage, & Frequency Specs Under Load and No Load Conditions Duplex Outlet #1 Duplex Outlet #2 NEMA 5-20R 120V NEMA 5-20R 120V HOUSEHOLD POWER CORD or OUTLETS TRANSFER SWITCH...
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ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) Rated Power Check Alternator Check (Low Power Output) NOTE: At high-altitudes, standard NOTE: The alternator must be at room temperature when resistance is measured. Refer to Illustrations on carburetor air-fuel mixture will be rich causing a decrease in engine Page 8-9.
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ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) EXCITER & AVR TAP CONNECTOR* STATOR-X BRUSH ASSEMBLY WINDING Blue Green Red Wire EXCITER AVR TAP WINDING WINDING Blue White White Wire TERMINAL BLOCK Blue *view looking into female connector from alternator 5-9 mm...
NOTE: On some models there are only 4 vibration isolators instead of 6. H—FRAME See WHEEL, LEG, & HANDLE ASSEMBLY, page 9-11. I— CRANKCASE COVER 28 N•m (21 lb. ft.) www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
Hex fitting - 24 N•m (17 lb. ft.) G—FUEL SEDIMENT CUP See CLEANING FUEL SEDIMENT HW7500E Model Illustrated CUP, page 7-5. H—FUEL LINE Check for cracks or damage. Secure with hose clamps. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
HW7500EL) F—SECONDARY AIR INTAKE VALVE For model numbers ending in “L” only (HW3000L, HW4000L, HW5500L, HW5500EL, HW6200L, HW7000EL, HW7500EL) G—MUFFLER SIDE GUARD 4 N•m (3 lb. ft.) www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
G—MAIN NOZZLE Clean with compressed air before installation. H—O-RING Check for correct installation. I— CARBURETOR BODY Clean internal passages and orifices with compressed air before installa- tion. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
Pull spark plug lead and connect to spare. Check ignition for spark to ground. 10 N•m (7 lb. ft.) E—FLYWHEEL F—CLAMP G—CHARGING COIL ASSEMBLY Check for continuity. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
Install on the starter case after installing the return spring. E—RATCHET SPRING F—RATCHET Check for wear or damage. G—FRICTION SPRING H—REEL COVER Align the ratchet with the reel cover notch. I— REEL COVER BOLT Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
105 N•m (77 lb. ft.) D—FAN COVER Remove and install with the recoil starter assembly. E—RECOIL STARTER ASSEMBLY Install with the recoil starter handle position as shown. 9-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
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. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-11 Downloaded from www.Manualslib.com manuals search engine...
• 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. HW5500E Model Illustrated 9-12 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
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Northshore Power Systems, LLC P/N 101290D 2010 Northshore Power Systems, LLC 4425 N. Port Washington Road The Honeywell Trademark is used under license Suite 105 from Honeywell International Inc. Milwaukee, WI 53212-1082 USA Honeywell International Inc. makes no representation 1-888-HWTECHS (498-3247) or warranties with respect to this product.