Honeywell hw400, HW3000 User Manual

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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.



IMPORTANT SAFETY INSTRUCTIONS ....................................................................... 1-1

WARRANTIES ............................................................................................................... 2-1

NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY ............................................2-1

NORTHSHORE POWER 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 MAINTENANCE SCHEDULE .............................................................................................7-1

AIR FILTER MAINTENANCE ...................................................................................................................7-3

CLEANING FUEL SEDIMENT CUP .........................................................................................................7-5

SPARK PLUG SERVICE ..........................................................................................................................7-5

CLEANING SPARK ARRESTOR SCREEN .............................................................................................7-6

VALVE LASH ...........................................................................................................................................7-7

GOVERNOR ADJUSTMENT ...................................................................................................................7-7

GOVERNOR RANGE ADJUSTMENT ......................................................................................................7-7

BATTERY SERVICE ................................................................................................................................7-8

TROUBLESHOOTING ................................................................................................... 8-1

ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) .............................................................................8-2

ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) ......................................................8-6

ENGINE DIAGNOSTICS (ALL MODELS) ..............................................................................................8-10

SERVICE AND DISASSEMBLY .................................................................................... 9-1

CONTROL PANEL ...................................................................................................................................9-1

ENGINE AND ALTERNATOR ..................................................................................................................9-2

ALTERNATOR .........................................................................................................................................9-3

FUEL TANK SYSTEM ..............................................................................................................................9-4

EVAPORATIVE EMISSIONS CONTROL SYSTEM .................................................................................9-5

MUFFLER .................................................................................................................................................9-6

CARBURETOR ........................................................................................................................................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

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ii www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

SAVE THESE INSTRUCTIONS

NOTE:

WARNING

DANGER

WARNING

CAUTION

NOTICE

DANGER

1: IMPORTANT SAFETY INSTRUCTIONS

ANYONE using or servicing this generator must read, understand, and follow all safety and operation instructions provided in the product manual. Failure to closely follow these instructions can result in circumstances leading to death, serious injury, and property damage.

Hazard Symbols and Meanings

Since there are many variations in the circumstances surrounding the installation, operation, service, and maintenance of this generator, we cannot possibly anticipate or provide advice or safety messages to cover every situation.

In addition to the signal words, the following symbols may be used to draw your attention to specific types of haz-

ards.

1.1 SAFETY MESSAGES

Signal Words

Safety messages are provided throughout this manual to help prevent personal injury and equipment damage. All safety messages are introduced by a signal word indicating the hazard level.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury to the operator or to bystanders.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to the operator or to bystanders.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury to the operator or to bystanders.

Indicates a situation which, if not avoided, may result in damage to the generator components.

Explosion

Chemical burn

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home

or garage, EVEN IF doors

and windows are open.

Tox i c f u m es

Electrical shock

Only use OUTSIDE and

far away from windows,

doors, and vents.

Fire

Hot surface

SAFETY PRECAUTIONS

• Wear appropriate protective safety equipment, such as safety shoes and safety glasses.

• Comply with the warnings in this manual and take special precautions when working around electrical equipment.

• NEVER wear loose or damp clothing that might get caught in equipment or conduct electricity.

• Keep service area organized and free of unnecessary clutter to reduce hazard potential.

• Keep guards and shields in place on machinery and maintain equipment in good working condition.

• Store flammable liquids in approved containers and away from fire, flame, spark, pilot light, switches, arcproducing equipment and other ignition sources.

• 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 1-1

SAFETY MESSAGES

WARNING

Electric Shock Hazards

Generators produce powerful voltage that can cause death or great physical harm.

• Notify the utility company when using generator for backup power. Use approved transfer equipment to isolate generator from electric utility.

• NEVER connect to a building’s electrical system unless a transfer switch has been installed by a qualified electrician.

• NEVER touch bare wires or receptacles.

• NEVER use generator with electrical cords that are worn, frayed, bare, or otherwise damaged.

• NEVER operate generator in rain or snow, or when the generator is set on wet surface.

• Generator repairs should only be performed by a trained service technician.

• Keep the generator out of reach of children, pets, and untrained people.

• Exposed terminals, even on disconnected batteries, can cause electric shock.

• NEVER touch both battery terminals with bare hands at the same time.

• Remove rings, watches or any other object containing metal when working with battery. If metal comes into contact with battery terminals, electric shock and serious burns can result.

• Only use insulated/non-conducting tools when working with or near battery.

• NEVER lay tools or other metal objects on top of battery.

Fire and Burn Hazards

The muffler becomes very hot during operation and remains hot for a while after stopping the engine.

• NEVER touch hot surfaces and avoid hot gases.

• Let engine cool before storing the generator indoors.

Battery gases are explosive.

• NEVER allow open flames, lit cigarettes, sparks, or spark-producing equipment near the battery.

Battery electrolyte fluid is comprised of sulfuric acid, which can be very dangerous and cause severe burns.

• NEVER allow battery fluid to contact eyes, skin, or clothing. If contact or spillage occurs, immediately flush the area with water.

Medical and Life Support Uses

• In case of emergency, call 911 immediately.

• NEVER use this product to power life support devices or life support appliances.

• NEVER use this product to power medical devices or medical appliances.

• Inform your electricity provider immediately if you or anyone in your household depends on electrical equipment to live.

• Inform your electrical provider immediately if a loss of power would cause you or anyone in your household to experience a medical emergency.

• Refuel generator only outdoors, in a well-ventilated area.

• NEVER enclose the generator in any structure.

• Keep generator at least 6 feet (2 meters) away from buildings, other equipment, and combustible materials during operation.

• NEVER fill fuel tank while the engine is running. Turn generator OFF and allow to cool before filling with fuel.

• NEVER smoke or allow flames or sparks near the generator or where gasoline is stored.

• NEVER overfill the fuel tank (there should be no fuel in the filler neck). After refueling, tighten the fuel cap securely.

• Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. 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.

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Fuel and its vapors are extremely flammable and explosive under certain conditions.

Generator Damage Hazards

NOTICE

Improper treatment or misuse of generator can cause permanent damage.

• Damage to generator caused by misuse or modification is not covered under warranty.

California Proposition 65

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

2: WARRANTIES

NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY

Honeywell Portable Generator

LIMITED WARRANTY

Northshore Power Systems, LLC, will repair or replace, free of charge, to the original retail customer, in North America, any parts of the portable generator found by Northshore Power Systems or an authorized service center to be defective in material or workmanship. This limited warranty covers the cost of the replacement parts and labor for defects. Transportation charges are the responsibility of the customer. This limited warranty has time period conditions, operating conditions and disclaimers, limitations of remedies & exclusions as stated below. For warranty service, customer should locate an authorized Honeywell Generator Dealer from www.honeywellgenerators.com or by calling 1-888-HWHELP1 (494-

3571).

LIMITED WARRANTY PERIODS

Consumer Use: 3 Years Limited. 1st year, parts and labor. 2nd & 3rd years, parts only.

Commercial Use: 1 Year Limited. No warranty for rental use.

Commencement and Definitions.The limited warranty period begins on the date of retail purchase by the original purchaser. The limited warranty is not transferable. "Consumer use" is personal use by a retail customer. "Commercial use" is any usage for income producing, business related use.

No Extension of Warranty. Repair or replacement pursuant to this limited warranty shall not renew or extend the original warranty period, and any repaired product shall be warranted for the remaining original warranty period only.

DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

MEDICAL AND LIFE SUPPORT USES. This warranty excludes any use of this product intended to power life support devices, life support appliances, medical devices, or medical appliances.

DISCLAIMER OF OTHER WARRANTIES. TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, THIS LIMITED WARRANTY IS EXCLUSIVE AND EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER IMPLIED WARRANTIES THAT MAY ARISE FROM A COURSE OF DEALING OR USAGE OF TRADE. NORTHSHORE POWER SYSTEMS HEREBY DISCLAIMS AND EXCLUDES ALL OTHER WARRANTIES. To the extent that Northshore Power Systems's products are consumer products under applicable federal or state law with respect to any customer, the duration of any implied warranties (including, but not limited to, implied warranties of merchantability or fitness for a particular purpose) are limited to the shortest duration permitted by applicable law or the limited warranty period provided herein, whichever is longer.

LIMITATIONS OF REMEDIES. NORTHSHORE POWER SYSTEMS SHALL NOT BE LIABLE TO CUSTOMER, OR TO ANYONE CLAIMING UNDER CUSTOMER, FOR ANY OTHER OBLIGATIONS OR LIABILITIES, INCLUDING, BUT NOT LIMITED TO, OBLIGATIONS OR LIABILITIES ARISING OUT OF BREACH OF CONTRACT OR WARRANTY, NEGLIGENCE OR OTHER TORT OR ANY THEORY OF STRICT LIABILITY, WITH RESPECT TO THE GENERATOR OR NORTHSHORE POWER SYSTEMS'S ACTS OR OMISSIONS OR OTHERWISE. TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, NORTHSHORE POWER SYSTEMS SHALL NOT, IN ANY EVENT, BE LIABLE FOR INCIDENTAL, COMPENSATORY, PUNITIVE, CONSEQUENTIAL, INDIRECT, SPECIAL OR OTHER DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF USE, LOSS 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 DAMAGE OR ECONOMIC LOSS.

EXCLUSIONS. In addition to the foregoing disclaimers, limitations and terms, this limited warranty shall not apply to and does not cover accessories, nor does it cover products that are in any way subjected to: (i) improper setup, installation or storage; (ii) lack of proper maintenance and service; (iii) accident, damage, abuse or misuse; (iv) abnormal operating conditions or applications; (v) repair or modification by customer or any third party without prior written consent of Northshore Power Systems; (vi) use under operating conditions or in applications not made known to or contemplated by Northshore Power Systems; or (viii) acts of God. The application of these exclusions will be determined at Northshore Power Systems's sole discretion.

REGISTRATION

Warranty registration with the Company is required on all products. You may send in the enclosed Product Registration, or register your product on-line at www.honeywellgenerators.com.

Warranty is also available by keeping and showing your original receipt from date of purchase to an authorized Honeywell Generator Dealer.

GENERATOR SERVICE

Do not return your generator to place of purchase for service. For all customer service inquiries, call 1-888-HWHELP1 (494-3571) or visit www.honeywellgenerators.com.

Warranty inquiries can be addressed to:

Northshore Power Systems, LLC Attention: Service and Warranty Dept. 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1

WARRANTIES

NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY

Honeywell Portable Generator

WARRANTY STATEMENT

The U.S. Environmental Protection Agency (EPA) and California Air Resources Board (CARB) require manufacturers of small off-road engines (SORE) to warranty their products with a 2-year warranty for those components that are specified as being part of the emission control system. Northshore Power Systems, LLC, CARB, and EPA offer the following explanation of the Emission Control Warranty.

In the United States and California, new small off-road engines must be designed, built, and equipped to meet stringent anti-smog standards. Northshore Power Systems must warrant the emission control system on your 2010 small offroad engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your small off-road engine. The emissions warranty is a defects warranty and is not related to an in-use emissions test.

Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and the catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Northshore Power Systems will repair your small off-road engine at no cost to you, including diagnosis, parts, and labor.

COVERAGE

Emissions control parts on the engine are warranted for a period of two years, subject to provisions set below. If any covered part on your engine is defective, the part will be repaired or replaced by Northshore Power Systems.

OWNER’S RESPONSIBILITIES

You are responsible to maintain the engine as defined in your Honeywell Generator Owner's Manual. Northshore Power Systems recommends that you retain all records/receipts covering maintenance on your engine, but Northshore Power Systems cannot deny warranty claims based on the lack of receipts or for your failure to perform all scheduled maintenance. You may be denied warranty coverage if a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

You are responsible to bring your portable generator to an authorized Northshore Power Systems Honeywell generator dealer for repairs as soon as a problem exists. Do not return your generator to place of purchase for service. For emissions warranty service, contact your nearest dealer; a listing

is available at www.honeywellgenerators.com or by calling 1-877-HWTECHS (498-3247).

2.1 WARRANTIES

EMISSIONS CONTROL SYSTEMS PARTS

Coverage under this warranty extends only to the emissions control parts listed below.

1. Fuel Metering System A. Carburetor gaskets B. Choke system C. Clamps D. Fuel filter (if equipped) and screen E. Fuel line, control valve, and fittings F. Fuel pump (if equipped) G. Gasoline carburetor and internal components

(if equipped)

2. Air Induction System

A. Air cleaner B. Intake manifold C. Vent lines

3. Ignition System

A. Ignition coil B. Spark plug

4. Exhaust System

A. Catalytic converter (if equipped) B. Exhaust manifold C. Muffler gasket

5. Crankcase Breather Assembly

A. Breather connection tube

6. Air Injection System

A. Pulse valve

7. Fuel Tank Evaporative Emissions Control System

A. Carbon canister and mounting brackets B. Fuel cap C. Fuel tank D. Purge valves

8. Miscellaneous Items used in above systems

A. Hoses, belts, connectors, valves, and assemblies B. Switches

WARRANTY PROVISIONS

1. Claims. Warranty claims shall be filed in accordance

with provisions of the Northshore Power Systems warranty and policies established with the authorized dealer network.

2. Exclusions. Warranty coverage shall be denied for failure of an emissions control part caused by abuse, neglect, improper maintenance as described in the Honeywell Generator Owner's Manual, use of add-on parts, modified parts, or parts that are not equivalent to original Honeywell generator parts in performance and durability.

3. Length of Coverage. Northshore Power Systems warrants to the original retail purchaser and each subsequent owner that the emissions control part shall be free from defects in materials and workmanship for a period of two years from the date the generator is delivered to the original retail customer.

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4. Repair or Replacement Cost. Repair or Replacement Cost. Repair or replacement of any emissions control part will be performed at no charge to the owner, including diagnostic labor which leads to the determination that an emissions control part is defective, if the diagnostic work is performed at an authorized Northshore Power Systems Honeywell generator dealer.

5. Consequential Coverage. Coverage noted hereunder will extend to the failure of any engine components caused by the failure of any emissions control part still under warranty.

6. Maintenance. The emissions control parts are warranted only for defects during the warranty period. The warranty does not cover an emission control part that is replaced or repaired as required by the maintenance schedule defined in the Honeywell Generator Owner's Manual. Any replacement part that is equivalent in performance and durability may be used for maintenance or repairs.

QUESTIONS

If you have questions regarding your emissions warranty rights and responsibilities, you should contact the Service and Warranty Department at Northshore Power Systems.

By phone: 1-877-HWTECHS (498-3247)

By email: service@nspsystems.com

By US mail:

Northshore Power Systems, 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

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, Northshore Power Systems will, at its option and sole discretion, repair or replace the part if it is found to be defective in material or workmanship after inspection by Northshore Power Systems.

Any parts which the buyer claims to be defective must be examined by the nearest Authorized Northshore Power Systems Warranty Service Facility. All shipping costs under this limited warranty are to be borne and prepaid by the buyer.

DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

EXCLUSIONS. In addition to the foregoing disclaimers, limitations and terms, this limited warranty shall not apply to and does not cover products that are in any way subjected to: (i) improper setup, installation or storage; (ii) lack of proper maintenance and service; (iii) accident, damage, abuse or misuse; (iv) abnormal operating conditions or applications; (v) repair or modification by customer or any third party without prior written consent of Northshore Power Systems; (vi) use under operating conditions or in applications not made known to or contemplated by Northshore Power Systems; or (vii) acts of God. The application of these exclusions will be determined at Northshore Power Systems's sole discretion.

NORTHSHORE POWER SYSTEMS PARTS LIMITED WARRANTY CLAIMS PROCEDURES

DEFECTIVE NEW PARTS. Parts which are defective from

new stock, or immediately upon installation must be filed under limited warranty. The defective part must be returned to Northshore Power Systems’s Service and Warranty Department under the following procedure:

1. Fill out a Warranty Claim Form listing the part number and write “New Defective” in the description.

2. List invoice number that the part was purchased on and/ or provide receipt.

NOTE: Freight damaged parts are not valid as warranty claims.

FAILURE WITHIN 90 DAYS. Parts which have been installed and have failed within 90 days will be handled by the Northshore Power Systems Service and Warranty Department. A Warranty Claim Form must accompany each part for which coverage under the limited warranty is sought. Claims will not be processed without the model and serial numbers of the unit and the purchase and failure dates for the part. Attach a copy of the original proof-of-purchase (for the part) to the Warranty Claim Form.

WARRANTY CLAIMS

For all customer service inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com.

Warranty claim forms and inquiries can be addressed to:

Northshore Power Systems, LLC Attention: Service and Warranty Dept. 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082

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3: SPECIFICATIONS AND WIRING DIAGRAMS

3.1 SPECIFICATIONS

HW5500

HW5500E

HW5500EL

HW5500L

POWER

GENERATOR

HW3000

HW3000L

HW4000

HW4000L

HW6200

HW6200L

HW7000E

HW7000EL

HW7500E

HW7500EL

Rated [watts]

(+/-10% under load)

Maximum [watts]

(+/-10% under load)

Frequency [hertz]

(+/-5% under load)

Voltage [volts]

(+/-5% under load)

OPERATING TEMPERATURE

Maximum [F / C]

Minimum [F / C]

ENGINE

Speed [rpm]

Type OHV 4-cycle

Displacement [cc]

Valve Lash [in /mm]

Fuel

Fuel Tank Capacity [gal / L]

(Non-L Models)

3000 4000 5500 6200 7000 7500

3750 5000 6875 7750 8750 9375

120 120 / 240 120 / 240 120 / 240 120 / 240 120 / 240

104 / 40

14 / -10

3600

196 242 337 389 420 420

IN: 0.005±0.001 / 0.125±0.025

EX: 0.007±0.001 / 0.175±0.025

87 or higher unleaded

4.2 / 16 6.5 / 24.6 6.5 / 24.6 6.5 / 24.6 6.6 / 25 6.5 / 24.6

(Model Numbers Ending in “L”)

Engine Oil

Engine Oil Capacity [qt / L] 0.6 / 0.6

Spark Plug

Spark Plug Gap [in /mm]

Air Filter

(Non-L Models)

(Model Numbers Ending in “L”)

Battery

(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.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-1

3.2 / 12 6.5 / 24.6 6.5 / 24.6 6.5 / 24.6 6.1 / 23 6.5 / 24.6

SAE 10W-30

1.2 / 1.1 1.2 / 1.1 1.2 / 1.1 1.2 / 1.1 1.2 / 1.1

102557A

†

100842A

†

100842A

†

100842A

†

100842A

†

100842A

0.028-0.031 / 0.7-0.8

102555A 100833A 100833A 100833A 100833A 100833A

102556A 101865A 101865A 101865A 101865A 101865A

-- -- 101536A -- 101536A 101536A

†

BOLT AND FASTENER TORQUE INFORMATION

3.2 BOLT AND FASTENER TORQUE INFORMATION

Component-Specific Fastener Fastener Size

Alternator End Cover Bolts M5 x 0.75 x 12 4 3

Alternator Housing Bolts M10 x 1.25 x 80 48 35

Axle Bracket Bolts M8 x 1.0 x 16 25 18

Brush Assembly Bolt M5 x 0.75 x 16 2 2

Carbon Canister Bracket Bolts M6 x 1.0 x 10 2 2

Connecting Rod Bolts M8 x 1.25 15 11

Control Panel Bolts M6 x 1.0 x 15 4 3

Cooling Fan Flange Nut

Crankcase Cover Bolts M8 x 1.25 x 40 28 21

Cylinder Head Bolts M10 x 1.25 x 80 48 35

Exhaust Pipe Bolts M8 x 32 18 13

Fuel Shut-off Valve Hex Fitting M10 x 1.25 24 17

Fuel Tank Mounting Bolts M6 x 1.0 x 25 10 7

Ignition Coil Bolts M6 x 1.0 x 25 10 7

Muffler Cover Bolts M6 x 1.0 x 14 4 3

M18 x 1.5

Torque Values

N•m lb. ft.

105 77

Muffler Rear Mounting Bracket Bolts M8 x 1.0 x 16 18 13

Muffler Side Guard Bolts M6 x 1.0 x 14 4 3

Oil Drain Screw M12 x 1.5 32 24

Pivot Adjusting Nuts M6 x 0.75 12 9

Pivot Bolts M8 x 1.25 30 22

Rotor Bolt -- 48 35

Spark Arrestor Clamp Screw M4 x 0.75 x 16 1 1

Spark Arrestor Screw M3.5 x 0.75 x 10 1 1

Spark Plug 13/16” 28 21

Starter Solenoid Terminal Nut M6 x 1.0 6 4

Support Leg to Frame Bolts M8 x 1.0 x 16 25 18

Support Leg to Rubber Stopper Bolts M8 x 1.0 x 25 25 18

Wheel Handle Pivot Bracket Bolts M6 x 1.0 x 40 10 7

TABLE 3-3: Torque Values

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3.3 WIRING DIAGRAMS

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

ENGINE

CONTROL

SWITCH

Bl Y/G

Y/G

EIG

GROUND

TERMINAL

DUPLEX

5-20R

Y/G 2.5 mm

THERMAL

AC BREAKER

15A

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

YBu BuBr Y Y

120 VAC

Bl 4 mm

W 4 mm

WBl

ALTERNATOR

Bl - Black

Bu - Blue

Br - Brown

Y - Yellow

Y/G - Yellow / Green

W - White

THERMAL

AC BREAKER

10A

NOTE:

Alternator is mechanically

connected to the engine

block providing ground

connection between the

engine block and the

alternator frame.

ON/OFF SWITCH PANEL

LEFT* RIGHT*

*15 Amp Breaker will be on the left side when looking at the control panel front;10 Amp Breaker will be on the right side

W 2.5 mm

Bl 2.5 mm

DUPLEX

5-20R

OFF

Bl Y/G

HW3000 & HW3000L

WIRING DIAGRAMS

ALTERNATOR

CONTROL PANEL

ENGINE

FIGURE 3-1: HW3000 & HW3000L Wiring Diagram

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-3

WIRING DIAGRAMS

ALTERNATOR

CONTROL PANEL

ENGINE

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

ENGINE

CONTROL

SWITCH

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

15A

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

WR WLg Bu Bu

ALTERNATOR

Bl - Black

Bu - Blue

Br - Brown

G/W - Green / White

Lg - Light Green

R - Red

Y - Yellow

Y/G - Yellow / Green

W - White

THERMAL

AC BREAKER

15A

NOTE:

Alternator is mechanically connected

to the engine block providing ground

connection between the engine block

and the alternator frame.

ON/OFF SWITCH PANEL

DUPLEX 5-20R

MAIN

WINDING

Br WRBu

FUEL

CUTOUT

WINDING

5A FUSE

G/W

TWIST-LOCK

L14-30R

Y/G

Br Br

MAGNETIC

AC BREAKER

15A

120 VAC

OFF

Bu BlG/W Y/G

HW4000 & HW4000L

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FIGURE 3-2: HW4000 & HW4000L Wiring Diagram

FUEL CUTOUT

SOLENOID

HW5500 & HW5500L

ALTERNATOR

CONTROL PANEL

ENGINE

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

ENGINE

CONTROL

SWITCH

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

20A

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

WR WLg Bu Bu

120 VAC

ALTERNATOR

Bl - Black

Bu - Blue

Br - Brown

G/W - Green / White

Lg - Light Green

R - Red

Y - Yellow

Y/G - Yellow / Green

W - White

THERMAL

AC BREAKER

20A

NOTE:

Alternator is mechanically connected

to the engine block providing ground

connection between the engine block

and the alternator frame.

ON/OFF SWITCH PANEL

DUPLEX 5-20R

MAIN

WINDING

Br WRBu

FUEL

CUTOUT

WINDING

5A FUSE

G/W

TWIST-LOCK

L14-30R

Y/G

Br Br

MAGNETIC

AC BREAKER

21A

120 VAC

OFF

Bu BlG/W Y/G

WIRING DIAGRAMS

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-5

FIGURE 3-3: HW5500 & HW5500L Wiring Diagram

FUEL CUTOUT

SOLENOID

WIRING DIAGRAMS

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

ENGINE

CONTROL

SWITCH

Y/G

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

20A

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

WR WLg Bu Bu

120 VAC

ALTERNATOR

Bl - Black

Bl/W - Black / White

Bu - Blue

Br - Brown

G/W - Green / White

Lg - Light Green

R - Red

Y - Yellow

Y/G - Yellow / Green

W - White

THERMAL

AC BREAKER

20A

DUPLEX 5-20R

MAIN

WINDING

Br WRBu

FUEL

CUTOUT

WINDING

FUSE

G/W

TWIST-LOCK

L14-30R

Br Br

MAGNETIC

AC BREAKER

21A

120 VAC

CHARGE

COIL

BATTERY

STARTER

MOTOR

FUEL

CUTOUT

SOLENOID

AUTO

PROTECTOR

Bl/W

OFF

START

Bu BlG/W Y/G

Bl/W

NOTE:

Alternator is mechanically connected

to the engine block providing ground

connection between the engine block

and the alternator frame.

HW5500E & HW5500EL

ALTERNATOR

CONTROL PANEL

ENGINE

ON/OFF SWITCH PANEL

FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram

3-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

HW6200 & HW6200L

ALTERNATOR

CONTROL PANEL

ENGINE

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

ENGINE

CONTROL

SWITCH

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

20A

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

WR WLg Bu Bu

ALTERNATOR

Bl - Black

Bu - Blue

Br - Brown

G/W - Green / White

Lg - Light Green

R - Red

Y - Yellow

Y/G - Yellow / Green

W - White

THERMAL

AC BREAKER

20A

NOTE:

Alternator is mechanically connected

to the engine block providing ground

connection between the engine block

and the alternator frame.

ON/OFF SWITCH PANEL

DUPLEX 5-20R

MAIN

WINDING

Br WRBu

FUEL

CUTOUT

WINDING

5A FUSE

G/W

TWIST-LOCK

L14-30R

Y/G

Br Br

MAGNETIC

AC BREAKER

25A

120 VAC

OFF

Bu BlG/W Y/G

WIRING DIAGRAMS

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-7

FIGURE 3-5: HW6200 & HW6200L Wiring Diagram

FUEL CUTOUT

SOLENOID

WIRING DIAGRAMS

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

ENGINE

CONTROL

SWITCH

Y/G

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

SINGLE POLE

THERMAL

AC BREAKER

120V 20A

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

WR WLg Bu Bu

120 VAC

ALTERNATOR

Bl - Black

Bl / W - Black / White

Bu - Blue

Br - Brown

G/W - Green / White

Lg - Light Green

R - Red

Y - Yellow

Y/G - Yellow / Green

W - White

SINGLE POLE

THERMAL

AC BREAKER

120V 20A

DUPLEX 5-20R

MAIN

WINDING

Br WRBu

FUSE

G/W

TWIST-LOCK

L14-30R

DUAL POLE

MAGNETIC

AC BREAKER

240V 30A

120 VAC

CHARGE

COIL

BATTERY

STARTER

MOTOR

FUEL

CUTOUT

SOLENOID

Bl/W

OFF

START

Bu BlG/W Y/G

Bl/W

FUEL

CUTOUT

WINDING

Br Br

AUTO

PROTECTOR

Bl/W

NOTE:

Alternator is mechanically connected

to the engine block providing ground

connection between the engine block

and the alternator frame.

G/W

LEFT* RIGHT*

*When looking at the control panel front

HW7000E, HW7000EL, HW7500E, & HW7500EL

ALTERNATOR

CONTROL PANEL

ENGINE

FIGURE 3-6: HW7000E, HW7000EL, HW7500E & HW7500EL Wiring Diagram

3-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

ON/OFF SWITCH PANEL

4: COMPONENTS

Tripped

Set

CAUTION

WARNING

FIGURE 4-1: Honeywell Portable Electrical Generator Controls and Components (HW5500EL Model Illustrated)

A—Power Control Center

Electrical Outlets

• 125VAC 20 Amp Duplex (NEMA 5-20R) outlets to connect

120V appliances to generator for power.

• 125/250VAC 30 Amp Twist-Lock (NEMA L14-30R) outlet

(on select models) can be used to power appliances using appropriate (NEMA L14-30P) power cord (with select models) or connect a transfer switch (not included) to a building’s main electrical system for backup power.

Breakers

Protects circuits from damage caused by overload or short-circuit by stopping the flow

of electricity from the generator to the appliance. Master circuit breaker controls power to all outlets. If there is no power at outlets,

see TROUBLESHOOTING, page 8-1.

HW3000 / HW3000L models only:

• 15-amp circuit breaker (left outlet)

• 10-amp circuit breaker (right outlet)

Ground Terminal

Connects generator to ground wire for grounding protection.

E—Engine Control Switch

Control used to start and stop the engine ignition system.

• START—Starts generator engine (electric start models)

• RUN—Prepares engine to start (manual start models);

Indicates engine is currently running (electric start models)

• STOP—Stops generator engine by inhibiting ignition

F—Fuel Shut-off Valve

Controls flow of fuel from fuel tank to carburetor.

G—Recoil Starter Handle

Provides means to manually start engine, if needed.

H—Air Cleaner Assembly

Removes dust from engine intake air.

I— Choke Control

Controls choke valve. Choke control must be moved to ON position when starting a cold engine.

J—Fuel Cap

Provides a secure seal on fuel tank.

K—Fuel Gage

Indicates level of fuel currently in fuel tank.

L—Muffler Equipped with Spark Arrestor

Provides outlet for engine exhaust. Prevents sparks and other combustible materials from escaping generator.

Generator must be grounded to prevent electrical shock from faulty appliances.

B—Battery Tray and Battery (Electric start models only)

Provides power for electric start feature.

C—Oil Fill Dipstick

Seals off engine oil fill hole and provides indicator for engine oil level.

D—Oil Drain Screw

Allows engine oil to drain from generator.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1

Muffler reaches temperatures that can cause serious burns if touched. NEVER touch hot surfaces.

M—Spark Plug Cap (Wire)

Delivers voltage to spark plug. When spark plug needs service, cap must be removed.

N—Carbon Canister (Model numbers ending in “L” only)

Reduces hydrocarbon emissions.

THIS PAGE INTENTIONALLY LEFT BLANK

4-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

5: PREPARING FOR SERVICE

WARNING

ANYONE using or servicing this generator must read, understand, and follow all safety and operation instructions provided in this manual. Failure to closely follow these instructions can result in circumstances leading to death, serious injury, and property damage.

5.1 REQUIRED TOOLS

A complete set of standard and metric shop tools are required to service the generator. Also needed are:

• Hammer

• Torque wrench

• Volt-ohm meter

• Frequency meter

• Resistive load - such as a load bank, heaters, light

bulbs, etc.

• Alternator removal tool

• Wood block (for rotor support)

5.2 TRANSPORTING GENERATOR

Hot engine or exhaust system can cause serious burns or fires. Cool generator completely before transporting.

When moving or transporting the generator:

• Press the engine control switch to the STOP position.

• Turn the fuel shut-off valve to the OFF position.

• 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 5-1

THIS PAGE INTENTIONALLY LEFT BLANK

5-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

6: SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE

Operation

HW3000

HW3000L

(min.)

HW4000

HW4000L

(min.)

HW5500

HW5500L

(min.)

HW5500E

HW5500EL

(min.)

HW6200

HW6200L

(min.)

HW7000E

HW7000EL

(min.)

HW7500E

HW7500EL

(min.)

ELECTRICAL

Alternator Complete 120 120 120 120 120 120 120

Battery -- -- -- 30 -- 30 30

Brush Assembly 45 45 45 45 45 45 45

Charging Coil Assembly 45 45 45 45 45 45 45

Control Panel Assembly 60 60 60 60 60 60 60

Ignition Coil 50 50 50 50 50 50 50

Meters / Circuit Breakers45454545454545

Oil Shutdown Switch 40 40 40 40 40 40 40

Oil Alert Sender 40 40 40 40 40 40 40

Receptacles / Ports50505050505050

Recoil Starter Assembly 30 30 30 30 30 30 30

Spark Plug 30 30 30 30 30 30 30

Electric Starter -- -- -- 45 -- 45 45

Starter Solenoid -- -- -- 35 -- 35 35

Voltage Regulator 30 30 30 30 30 30 30

ENGINE

Air Filter 30 30 30 30 30 30 30

Air Cleaner 40 40 40 40 40 40 40

Carburetor 50 50 50 50 50 50 50

Choke45454545454545

Converter

(Model Numbers Ending in “L”)

Cylinder Head Cover 45 45 45 45 45 45 45

Cylinder Head Gasket 40 40 40 40 40 40 40

Engine Complete 180 180 180 180 210 210 210

Governor Assembly 50 50 50 50 50 50 50

Head Cover Gasket 40 40 40 40 40 40 40

FUEL & EXHAUST

Carbon Canister (with bracket) (Model Numbers Ending in “L”)

Carbon Canister Tube

(Model Numbers Ending in “L”)

60 60 60 60 60 60 60

45 45 45 45 45 45 45

30 30 30 30 30 30 30

Exhaust Pipe

(Model Numbers Ending in “L”)

40 40 40 40 40 40 40

Fuel Gage 30 30 30 30 30 30 30

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 6-1

SERVICE REPAIR TIME ANALYSIS

NOTE:

Operation

Vapor Line

(Model Numbers Ending in “L”)

Fuel Tank 60 60 60 60 60 60 60

Fuel Shut-off Valve40404040404040

Muffler50505050606060

Muffler Gasket 50 50 50 50 60 60 60

Secondary Air Intake Valve

(with gasket)

(Model Numbers Ending in “L”)

MISC

Frame

(Model Numbers Ending in “L”)

(Non-L Models) 90 90 90 90 90 90 90

Handle Assembly 30 30 30 30 30 30 30

Leg Assembly 30 30 30 30 30 30 30

Wheel Assembly 30 30 30 30 30 30 30

HW3000

HW3000L

(min.)

HW4000

HW4000L

(min.)

HW5500

HW5500L

(min.)

HW5500E

HW5500EL

(min.)

HW6200

HW6200L

(min.)

HW7000E

HW7000EL

(min.)

HW7500EL

30 30 30 30 30 30 30

50 50 50 50 50 50 50

120 120 120 120 120 120 120

HW7500E

(min.)

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

6-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

7: MAINTENANCE

DANGER

WARNING

7.1 CONSUMER MAINTENANCE SCHEDULE

Periodic maintenance and adjustment are necessary to keep the generator in good operating condition. Perform service and inspection at intervals shown in the Generator Maintenance Schedule (Table 7-1).

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home

or garage, EVEN IF doors

and windows are open.

• Shut off the engine before performing any maintenance. If the engine must be run, be sure the area is well ventilated.

Only use OUTSIDE and

far away from windows,

doors, and vents.

NOTICE

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any non-road engine repair establishment or individual.

MAINTENANCE TASK

Inspect for/clean debris X

Check engine oil level X

Change engine oil X X

Check air filter X

Clean air filter

Run engine

Clean/change spark plug X

Clean fuel sediment cup X

Clean spark arrestor X

Clean cylinder cooling fins

Check/adjust valve lash

Check fuel line

TABLE 7-1. Generator Maintenance Schedule

* Perform at every indicated month or operating hour interval, whichever comes first. † Clean more often when using generator in dusty areas. ‡ It is recommended that the generator is run for 15-30 minutes every three months to ensure the battery remains charged.

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.

Before each

use

First month

or 20 hours of

Accidental starting of generator can cause severe injury or death. Before performing maintenance, disconnect spark plug cap from spark plug. Also disconnect both starting battery cables. Remove the negative (-) cable first to reduce the risk of arcing.

Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow inspection and maintenance recommendations and schedules in this manual.

NOTICE

The maintenance schedule applies to normal operating conditions. If you operate generator under severe conditions, such as sustained high-load or high-temperature, or use it in unusually wet or dusty conditions, consult your servicing dealer for recommendations applicable to your individual needs and use.

FREQUENCY

Every 3

months or 50

use

Every 2 years (replace if necessary)

hours of use

Every 6

months or 100

hours of use

†

‡

Every year or

200 hours of

use

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-1

CONSUMER MAINTENANCE SCHEDULE

DANGER

FUEL RECOMMENDATIONS

Before each use, check the fuel tank gage. If the fuel level is low, refill the tank with recommended fuel. NEVER OVERFILL.

Fuel and fuel vapors are extremely flammable and explosive under certain conditions.

• Refuel generator only outdoors, in a well-ventilated area.

• NEVER fill fuel tank while engine is running. Turn generator OFF and allow to cool before filling with fuel.

• NEVER smoke or allow flames or sparks near generator or where gasoline is stored.

• NEVER overfill fuel tank (no fuel should be in filler neck). After refueling, tighten the fuel cap securely.

• Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. 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.

General Fuel Information

Check the fuel gage located on the top of the generator near the fuel tank and refill the tank if fuel level is low. Refuel carefully to avoid spilling fuel. Do not fill above the shoulder of fuel strainer. Use unleaded gasoline with a pump octane rating of 87 or higher.

NEVER use stale or contaminated gasoline. Avoid getting dirt or water in the fuel tank. Always keep the fuel strainer in place while refueling.

Oxygenated Fuels

At certain times of the year, some U.S. locations may have only oxygenated fuel available. Oxygenated fuel is blended with alcohol or ether additives to increase octane quality, enhance combustion, and reduce exhaust emissions.

Some areas of the United States use oxygenated fuels to help meet clean air standards.

Before using an oxygenated fuel, ensure pump octane rating is 87 or higher.

Some states (and provinces in Canada) require this information to be posted on the fuel pump. If you notice undesirable operating symptoms, switch to a conventional unleaded gasoline.

Oxygenated fuels can damage paint and plastic. Be careful not to spill fuel when filling fuel tank. Damage caused by spilled fuel is not covered under warranty.

TABLE 7-2. Oxygenated Fuel Types

Ethanol (ethyl or grain alcohol)

Methanol (methyl or wood alcohol)

MTBE (methyl tertiary butyl ether)

To avoid damage to the engine, NEVER use stale or contaminated gasoline or oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.

Use fresh gasoline with a pump octane rating of 87 or higher.

Running the engine with persistent spark knock or pinging can cause engine damage. Warranty does not cover parts damaged by misuse.

NOTICE

Gasoline containing more than 10% ethanol by volume may cause starting or performance problems. Gasoline containing ethanol may be marketed under the name "Gasohol".

Gasoline containing methanol must contain co-solvents and corrosion inhibitors to protect fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems and may damage metal, rubber and plastic parts of fuel system.

Gasoline containing up to 15% MTBE by volume can be used.

NOTICE

7-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

AIR FILTER MAINTENANCE

NOTE:

5W-30

Synthetic 5W-30

SAE 30, 10W-30

WARNING

ENGINE OIL RECOMMENDATIONS

NOTICE

Engine oil is a major factor affecting engine performance and service life. NEVER use non-detergent or 2-stroke engine oils.

• Use engine oils specified below.

It is very important to maintain proper level of engine oil to keep engine in good running condition.

• Check engine oil level prior to each use. Refill engine oil if oil level is too low.

Use 4-stroke oil, or equivalent high detergent, premium quality motor oil certified to meet or exceed U.S. automobile manufacturer's requirements for API Performance Class SL, SJ, or better.

SAE 10W-30 is recommended for general temperature use. Refer to Figure 7-1 for information on other viscosities that may be used. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range.

7.2 AIR FILTER MAINTENANCE

NOTICE

A dirty air filter will restrict air flow to carburetor, which may cause poor engine performance or damage. NEVER run the generator without the air cleaner assembly properly attached.

Clean air filter every 50 hours of generator operation. If operating generator in extremely dusty areas, clean air fil-

ter more frequently.

Gasoline and flammable solvents can cause fire or explosion. NEVER use gasoline or flammable solvent to clean air filter element.

• Use only household soap and water to clean air filter element.

To clean air filter, you will need:

 Household soap and water

 Clean, dry cloth

 Clean engine oil

FIGURE 7-1: Recommended Oil Viscosity

Dispose of used motor oil according to guidelines established by your local or state government.

Low Oil Protection

The generator engine is protected from low lubrication failure by an oil shutdown switch. This switch prevents the operation of the ignition system until sufficient oil is added to the crankcase for proper engine lubrication.

When engine shuts down due to low oil level:

1. The engine control switch will remain in the RUN posi-

tion.

2. The engine will not start until the required amount of

engine oil is added.

ALWAYS stop engine before removing oil fill dipstick.

1. Stop engine if it is running.

2. Remove air cleaner cover.

For Model Numbers Ending in “L”:

• Unlock the latches at the top and bottom of the air cleaner

cover.

FIGURE 7-2: Air Cleaner Cover—Model Numbers Ending in “L”

For Non-L Models:

• Turn thumbscrew counterclock wise to loosen and

remove.

• Pull bottom of air cleaner cover out and lift up to release

plastic tabs.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-3

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

AIR FILTER MAINTENANCE

NOTE:

CAUTION

3. Remove foam air filter(s).

FIGURE 7-4: Air Filter Removal

4. Wash air filter(s) in a solution of household soap and

warm water.

FIGURE 7-5: Wash Air Filter

5. Rinse parts thoroughly with water.

6. Using a clean, absorbent cloth, squeeze air filter dry,

being careful not to twist or tear the filter.

Engine will smoke during initial start-up if too much oil is left in filter.

9. Reassemble the air cleaner assembly.

For Model Numbers Ending in “L”: 9A. Reinstall the light grey foam air filter.

9B. Reinstall the dark grey foam air filter.

9C. Reinstall the air cleaner cover.

FIGURE 7-9: Air Filter Installation—Model Numbers Ending in “L”

(filter shape varies by model)

For Non-L Models: 9A. Reinstall the metal air filter plate in the support

brackets if it fell out during air filter removal.

FIGURE 7-6: Dry Air Filter

7. Coat the air filter with clean engine oil.

FIGURE 7-7: Oil Air Filter

8. Squeeze out excess oil.

FIGURE 7-8: Excess Oil Removal

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.

FIGURE 7-10: Air Filter Plate Installation—Non-L Models (air filter plate shape varies by model)

9B. Reinstall air filter.

9C. Reinstall the air cleaner cover.

7-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

CLEANING FUEL SEDIMENT CUP

WARNING

.028 - .031 in.

(.70 - .80 mm)

7.3 CLEANING FUEL SEDIMENT CUP

The sediment cup prevents any dirt or water that may be in the fuel tank from entering the carburetor.

Clean fuel sediment cup at the intervals specified in Table 7-1.

To clean fuel sediment cup, you will need:

 10 mm box wrench

 22 mm open end wrench

 Household soap and water

 Clean, dry cloth

To clean fuel sediment cup:

1. Stop the engine if it is running. Allow to completely

cool.

2. Place generator on a flat, level surface.

3. Turn the fuel shut-off valve to the OFF position.

4. While holding the fitting above the fuel shut-off valve

with a 22 mm open end wrench, remove the fuel sediment cup assembly (sediment cup, o-ring, and fuel screen) using a 10 mm box wrench.

7.4 SPARK PLUG SERVICE

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

If the engine has been running, the spark plug will reach temperatures that could cause severe burns. Do not touch.

1. Measure the spark plug gap with a wire feeler gauge.

Gap should be: 0.028-0.031 in. (0.70-0.80 mm).

FIGURE 7-13: Correct Spark Plug Gap

2. If necessary, adjust gap by carefully bending side

electrode.

3. Torque spark plug to 28 N•m (21 lb. ft.).

FIGURE 7-11: Fuel Sediment Cup Assembly Removal

FIGURE 7-12: Fuel Sediment Cup Assembly

5. Clean the fuel screen (A), o-ring (B), and sediment

cup (C), with soap and water.

6. Rinse parts thoroughly with water.

7. Wipe the pieces clean with a clean, dry cloth.

8. Reinstall the sediment cup, o-ring, and fuel screen.

9. Turn the fuel shut-off valve to the ON position.

10. Start generator and check for leaks.

NOTICE

The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and damage the engine. NEVER use spark plugs that have an improper heat range. Use only recommended spark plugs or equivalent.

HW3000 & HW3000L Models:

Recommended Spark Plug Replacement: 102557A

AutoLite 62

Bosch WR5DC

Champion RN6YC

Denso W22EPR-U

NGK BPR7ES

TABLE 7-3. Spark Plug Equivalents to 102557A

All Other Models:

Recommended Spark Plug Replacement: 100842A

AutoLite 63

Bosch WR7DC

Champion RN9YC

Denso W20EPR

NGK BPR6ES

TABLE 7-4. Spark Plug Equivalents to 100842A

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-5

CLEANING SPARK ARRESTOR SCREEN

WARNING

7.5 CLEANING SPARK ARRESTOR SCREEN

Muffler reaches temperatures that can cause serious burns if touched. NEVER touch hot surfaces.

The generator muffler is equipped with a spark arrestor screen, which must be cleaned according to the maintenance schedule (see Table 7-1) to ensure prevention of sparks escaping generator.

To clean spark arrestor screen, you will need:

 1/4” socket wrench

 8 mm socket

 7/32” socket

 #2 Phillips screwdriver

 Wire brush

1. Stop the engine if it is running. Allow to completely

cool.

2. Place generator on a flat, level surface.

3. Using a socket wrench with an 8 mm socket, remove

the muffler cover bolts (muffler cover not present on HW3000 or HW3000L models).

4. Remove muffler cover.

5. Using a screwdriver, loosen and remove the spark

arrestor clamp (A) screw.

FIGURE 7-15: Spark Arrestor Assembly

6. Slide off spark arrestor clamp.

7. Using a socket wrench with a 7/32” socket, remove

the retaining screw on spark arrestor screen cap (B); pull off cap.

8. Pull out spark arrestor screen (C).

9. Inspect spark arrestor screen.

 If screen is damaged or excessively worn, replace

with new screen.

 If screen is in good condition, clean using wire

brush and then reinstall.

7-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

FIGURE 7-16: Clean Screen

10. Reinstall remaining spark arrestor components.

 Spark arrestor screen cap and screw

 Clamp and screw

 Muffler cover

FIGURE 7-14: Remove Muffler Cover

VALVE LASH

CAUTION

GOVERNOR ARM SHAFT

GOVERNOR ARM

PINCH BOLT

GOVERNOR ARM

ANTI-SURGE SPRING

THROTTLE

NUT

GOVERNOR SPRING

LIMITING

SCREW

7.6 VALVE LASH

Valve lash inspection and adjustment must be performed with the engine cold.

1. Remove the cylinder head cover and carefully remove

the gasket for re-use. (Inspect and replace gasket, if necessary.)

2. Remove the spark plug to reduce engine compres-

sion resistance.

3. Turn the engine crankshaft using the recoil starter,

positioning engine at top, dead center, of the compression stroke. This can be verified by the piston position in the cylinder.

4. Insert a feeler gauge between the rocker arm and

valve spring to measure valve lash.

LOCK NUT

7.7 GOVERNOR ADJUSTMENT

1. Start the engine and run with no load.

2. Attach a frequency meter and adjust the limiting

screw on the governor stop to 62.5 Hz ± 0.5.

3. Stop the engine.

4. If frequency is out of range, see the “GOVERNOR

RANGE ADJUSTMENT” procedure below.

5. Repeat steps 1 through 3. If frequency still out of

range, see ENGINE DIAGNOSTICS (ALL MODELS), page 8-10

7.8 GOVERNOR RANGE ADJUSTMENT

1. Remove the generator control panel for access.

2. Loosen the nut on the governor arm pinch bolt (see

illustration).

FIGURE 7-17: Lock Nut Location

IN.

0.005±0.001 in (0.125±0.025 mm)

Standard valve lash

EX.

TABLE 7-5. Standard Valve Lash

A—ROCKER ARM B—LOCK NUT

0.007±0.001 in (0.175±0.025 mm)

12 N•m (9 lb. ft.)

• To increase valve lash,

screw pivot nut out.

• To decrease valve lash,

screw pivot nut in.

C—PIVOT BOLT

30 N•m (22 lb. ft.)

5. Hold the rocker arm pivot and loosen the lock nut (see

B in illustration).

6. Turn the rocker arm pivot (see C in illustration) to

obtain specified valve lash.

7. Retighten the lock nut while holding rocker arm pivot

and torque to 12 N•m (9 lb. ft.).

8. Check valve lash again after tightening lock nut.

9. Repeat steps 4 through 7, as needed, until valve lash

is within specifications.

10. Reassemble the spark plug, cylinder head cover, and

gasket.

FIGURE 7-18: Governor Arm Assembly

3. Rotate the governor arm shaft counter-clockwise until

the throttle is completely open and hold in position.

4. Tighten the nut on the governor arm pinch bolt to

maintain position.

5. Confirm the governor arm and throttle move smoothly

and do not bind.

6. Reinstall the generator control panel.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-7

BATTERY SERVICE

NOTE:

7.9 BATTERY SERVICE

To ensure the battery remains charged, it is recommended that the generator is started every three months. If the generator is stored for more than a year without running, a battery charger may be required to recharge the generator battery.

Recommended Battery Replacement: 101536A

Xtreme XTAX14AHL-BS

Yuasa 12N14-3A

TABLE 7-6. Replacement Battery Equivalents to 101536A

To replace battery:

1. Remove spark plug cap.

FIGURE 7-19: Spark Plug Cap Removal

6. Remove the battery.

Dispose of used battery according to guidelines established by your local or state government.

7. Place the new battery in the generator frame.

8. Connect the red positive (+) battery lead to the posi-

tive (+) post on the battery; install bolt, nut, and boot.

9. Connect the black negative (-) battery lead to the neg-

ative (-) post on the battery; install bolt, nut, and boot.

10. Reinstall retaining plate; tighten bolts and nuts.

11. Reinstall spark plug cap.

2. Loosen and remove nuts on retaining plate; slide

retaining plate off support rods.

FIGURE 7-20: Electric Start Battery—Remove Retaining Plate

3. Tip battery slightly forward.

4. Disconnect the black negative (-) battery lead remov-

ing the bolt and nut.

FIGURE 7-21: Electric Start Battery—Lead Connection

5. Disconnect the red positive (+) battery lead removing

the bolt and nut.

7-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

8: TROUBLESHOOTING

NOTE:

WARNING

DANGER

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home

or garage, EVEN IF doors

and windows are open.

For all dealer service inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com.

Only use OUTSIDE and

far away from windows,

doors, and vents.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-1

ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)

Perform “Alternator Check”

Remove Alternator End Cover

120V Circuit #1 Check

(No Output OR

Voltage Out of Spec)

Check Wires and Connections

from AVR to Brush Assembly

for Proper Orientation

of Wire Connections

If a Connection is Loose or

Disconnected, Reestablish

a Tight Connection

If a Wire or Connection is Damaged,

Replace AVR

Check for Continuity in Each Circuit of

Duplex Outlet #1

from the Female Socket on the Front

to the Terminal on the Back

If No Continuity,

Replace Duplex Receptacle

If Continuity Present,

Replace Electrical Panel

120V Circuit #2 Check

(No Output OR

Voltage Out of Spec)

General Electrical Check

Check Output Voltage (X to W) of

Duplex Outlet #1= 123-126V

Adjust Voltage Regulator, if Necessary

by Turning the Potentiometer on

the Rear of the Voltage Regulator

If Voltage Still Out of Range

Replace Voltage Regulator

Conduct This Check Only When

Directed by General Electrical Check

Start Engine and Run at No Load

Conduct This Check Only When

Directed by General Electrical Check

Check for Continuity in

Duplex Outlet #1 Breaker

from the Line Terminal

to the Load Terminal

If No Continuity,

Replace Duplex Circuit Breaker

Check for Continuity in

Duplex Outlet #2 Breaker

from the Line Terminal

to the Load Terminal

If No Continuity,

Replace Duplex Circuit Breaker

Check for Continuity in Each Circuit of

Duplex Outlet #2

from the Female Socket on the Front

to the Terminal on the Back

If No Continuity,

Replace Duplex Receptacle

If Continuity Present,

Replace Electrical Panel

Check for Tripped Duplex Circuit Breaker(s)

Outlets Above the Breaker Indicate

the Excess Load Source

Resolve Overload Problem to Ensure Safe Operation

After Electrical Load Resolved Wait Several Minutes (for Thermal Breaker to Cool) Push to Reset Breaker

If Cannot Reset, Replace Breaker

Start Engine and Run at No Load

Check Engine Frequency = 61.5 to 63 Hz

Adjust Governor, if necessary

(see Manual Section “Governor Adjustment”)

If Frequency Still Out of Range,

see

Engine Diagnostics Section

X 123126V

Check Voltage Output at NEMA 5-20R 120V

Duplex Outlet #1

If Voltage Out of Range,

Perform “120V Circuit #1 Check”

123-

126V

Check Voltage Output at NEMA 5-20R 120V

Duplex Outlet #2

If Voltage Out of Range,

Perform “120V Circuit #2 Check”

Remove Main Control Panel from

Control Panel Assembly

Check Wires and Connections

for the Exciter & AVR Tap

from AVR to Alternator

On AVR Side of Connection:

If a Connection is Loose or

Disconnected, Reestablish a

Tight Connection

If a Wire or Connector is Damaged,

Replace AVR

On Alternator Side of Connection:

If a Connection is Loose or

Disconnected, Reestablish a

Tight Connection

If a Wire or Connector

is Damaged,

Replace Alternator

Check for Continuity from

Duplex Outlet #1

for Each Connection (X, Y, W, G) to

Corresponding Alternator Terminal

If Continuity Not Present

in Any Circuit, Check Wires and Connections from Receptacle to Alternator

If a Connection is Loose or

Disconnected, Reestablish a Tight

Connection and Recheck Continuity

If a Wire or Connection is Damaged,

Replace Electrical Panel

Refer to Illustrations on

Pages 8-3 and 8-5.

8.1 ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)

Check Continuity from

for Each Connection (X or Y, W, G) to

If Continuity Not Present

Check Wires and Connections from

Duplex Outlet #1 to Duplex Outlet #2

If a Connection is Loose or

Disconnected, Reestablish a

Tight Connection and Recheck

If a Wire or Connection

Replace Electrical Panel

Duplex Outlet #1

Duplex Outlet #2

in Any Circuit,

Continuity

is Damaged,

8-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)

Alternator

See “Specifications” Page For

Rated Power, Voltage, & Frequency Specs

Under Load and No Load Conditions

Yellow / Green Wire = G

White Wire = W

Black Wire = X

3000 RATED WATTS • 3750 MAXIMUM WATTS

Duplex Outlet #1 NEMA 5-20R 120V

Duplex Outlet #2

NEMA 5-20R 120V

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-3

ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)

Start Engine and

Add Resistive Loads Until

One of the Following Occurs:

s0OWER/UTPUTat the

NEMA 5-20R 120V Duplex Outlet #1

is Within Rated Power Specification

Range

s&REQUENCY$ROPS"ELOW(Z

s6OLTAGE/UTPUT$ROPS"ELOW

Minimum

If Minimum Rated Power

#ANNOT"E!CHIEVED

see Engine Diagnostics Section

NOTE: The alternator must be at room temperature

when resistance is measured.

#HECK"RUSH!SSEMBLYFOR%XCESSIVE7EAROR$EFECT

./4%5SE#AUTION7HEN2EMOVINGAND)NSTALLING"RUSH(OLDER

TO!VOID$AMAGING"RUSHES

)F,ENGTH,ESSTHANMM2EPLACE"RUSH!SSEMBLY

)F,ENGTH'REATERTHANMM6ERIFY2ESISTANCE"ETWEEN%ACH

"RUSH4IPAND#ORRESPONDING4ER MINALIS,ESSTHANΩ

)F2ESISTANCE/UTOF3PEC2EPLACE"RUSH!SSEMBLY

Check Alternator Winding Resistances

Disconnect the Exciter Connector

$ISCONNECTTHE7IRESATTHE!LTERNATOR4ERMINAL"LOCK

NOTE: Each Terminal Contains Nut, Lock Washer, and Flat Washer

-EASURE7INDING2ESISTANCESAS3PECIFIED"ELOW

)F5SINGAN/HMMETERWITH+ELVIN"RIDGE#LIPS

-EASURE2ESISTANCEATTHE3LIP2ING7IRE4ER MINALSFOR"EST2ESULTS

If a Winding Resistance is Out of Spec, Replace Alternator

Alternator Check

./4%4HEALTERNATORDIAGNOSTICSREQUIREMEASUREMENTS

OFLOWRESISTANCEVALUESWHICHAREBEYONDTHE

CAPABILITYOFATYPICALMULTIMETER

5SEONLYFORDIRECTIONALINDICATIONOFRESISTANCE

For best results, use an ohmmeter capable of

measuring low resistance values:

Resolution: 10 milliohms

!CCURACY+ 1%

Measure Resistance

"ETWEEN7IRES

Resistance

Range

Specification (Ω)

Winding

Stator-X "LACK White 0.15 - 0.35

AVR Tap "ROWN "LUE

20-35% of

Stator-X

Resistance

Exciter Yellow Yellow 

Rotor

Slip Rings

Slip Ring Terminals*

45 - 65

#HECKFOR#ONTINUITY

"ETWEEN7INDINGS

#ONTINUITY

Specification

3TATOR8"LACK AVR Tap"ROWN #ONTINUITY

3TATOR8"LACK Either Exciter Yellow .O#ONTINUITY

#HECKFOR#ROSS3HORTED7INDINGSINTHE3TATOR!SSEMBLY

#HECKFOR#ONTINUITY"ETWEEN7INDINGSAS3PECIFIED"ELOW

)F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE

Replace Alternator

Refer to Illustrations on

Page 8-5.

123-

126V

Rated Power Check (Low Power Output)

NOTE: At high-altitudes, standard

carburetor air-fuel mixture will be

rich causing a decrease in engine

performance and an increase in

fuel consumption.

NOTE: At this time, a high-altitude

carburetor kit is not available.

8-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

Blue

Yellow

Brown

Yellow

EXCITER WINDING

AVR TAP

WINDING

EXCITER & AVR TAP

CONNECTOR*

*view looking into

female connector

from alternator

ROTOR

SLIP

RINGS

SLIP RING

TERMINALS

VOLTAGE REGULATOR

POTENTIOMETER

TO ADJUST VOLTAGE

White (2 wires)

Black (2 wires)

BRUSH ASSEMBLY

Yellow Wire

Blue Wire

5-9 mm

STATOR-X

WINDING

STATOR-Y

WINDING

Black

White

TERMINAL

BLOCK

ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-5

ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)

Perform “Alternator Check”

Check for Tripped Master Breaker

Resolve Overload Problem to Ensure Safe Operation

After Electrical Load Resolved Push to Reset Breaker

If Cannot Reset, Replace Breaker

Check for Tripped Duplex Circuit Breaker(s)

Outlets Above the Breaker Indicate

the Excess Load Source

Resolve Overload Problem to Ensure Safe Operation

After Electrical Load Resolved Wait Several Minutes (for Thermal Breaker to Cool) Push to Reset Breaker

If Cannot Reset, Replace Breaker

Start Engine and Run at No Load

Check Engine Frequency = 61.5 to 63 Hz

Adjust Governor, if necessary

(see Manual Section “Governor Adjustment”)

If Frequency Still Out of Range,

see

Engine Diagnostics Section

Check Voltage Output at

NEMA L14-30R 240V Receptacle

123126V

246-

252V

123-

126V

If Voltage Out of Range, Perform “240V Circuit Check”

123-

126V

Check Voltage Output at NEMA 5-20R 120V

Duplex Outlet #1

If Voltage Out of Range, Perform “120V Circuit Check”

123-

126V

Check Voltage Output at NEMA 5-20R 120V

Duplex Outlet #2

Remove Alternator End Cover

240V Circuit Check

(No Output OR

Voltage Out of Spec)

Check Wires and Connections

from AVR to Brush Assembly

for Proper Orientation

of Wire Connections

If a Connection is Loose or

Disconnected, Reestablish

a Tight Connection

If a Wire or Connection is Damaged,

Replace AVR

Check for Continuity in Each Circuit

of the 240V Receptacle

from the Female Socket on the Front

to the Terminal on the Back

If No Continuity,

Replace Duplex Receptacle

If Continuity Present,

Replace Electrical Panel

Check Continuity from the

120V Duplex Receptacle

for Each Connection (X or Y, W, G)

to the 240V Receptacle

If Continuity Not Present

in Any Circuit,

Check Wires and Connections from

120V Duplex to 240V Receptacle

If a Connection is Loose or

Disconnected, Reestablish a

Tight Connection and Recheck

Continuity

If a Wire or Connection

is Damaged,

Replace Electrical Panel

120V Circuit Check

(No Output OR

Voltage Out of Spec)

General Electrical Check

Check Output Voltage (X to Y) of the

240V Receptacle = 246-252V

Adjust Voltage Regulator, if Necessary

by Turning the Potentiometer on

the Rear of the Voltage Regulator

If Voltage Still Out of Range

Replace Voltage Regulator

If Voltage Out of Range, Perform “120V Circuit Check”

Conduct This Check Only When

Directed by General Electrical Check

Start Engine and Run at No Load

Conduct This Check Only When

Directed by General Electrical Check

Check for Continuity in

Each Leg of Master Breaker

from the Line Terminal

to the Load Terminal

If No Continuity,

Replace Master Circuit Breaker

Check for Continuity in

Duplex Breaker

from the Line Terminal

to the Load Terminal

If No Continuity,

Replace Duplex Circuit Breaker

Check for Continuity in

Each Circuit of the

120V Duplex Receptacle from

the Female Socket on the Front

to the Terminal on the Back

If No Continuity,

Replace Duplex Receptacle

If Continuity Present,

Replace Electrical Panel

Remove Main Control Panel from

Control Panel Assembly

Check Wires and Connections

for the Exciter & AVR Tap

from AVR to Alternator

On AVR Side of Connection:

If a Connection is Loose or

Disconnected, Reestablish a

Tight Connection

If a Wire or Connector is Damaged,

Replace AVR

On Alternator Side of Connection:

If a Connection is Loose or

Disconnected, Reestablish a

Tight Connection

If a Wire or Connector

is Damaged,

Replace Alternator

Check for Continuity from

the 240V Receptacle for Each Connection (X, Y, W, G) to Corresponding Alternator Terminal

If Continuity Not Present

in Any Circuit,

Check Wires and Connections

from Receptacle to Alternator

If a Connection is Loose or

Disconnected, Reestablish a Tight

Connection and Recheck Continuity

If a Wire or Connection is Damaged,

Replace Electrical Panel

Refer to Illustrations on

Pages 8-7 and 8-9.

8.2 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)

8-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)

Yellow / Green Wire = G

White Wire = Y

Red Wire = X

Alternator

See “Specifications” Page For

Rated Power, Voltage, & Frequency Specs

Under Load and No Load Conditions

Brown Wire = W on Duplex Outlet #2

Blue Wire = W on Duplex Outlet #1

Fuel Cutout Winding Connector

Brown Wires (2)

240V Receptacle

NEMA 14-30R

7000 RATED WATTS • 8750 MAXIMUM WATTS

7000

120 VOLTS AC

120/240 VOLTS AC

POWER CORD or

TRANSFER SWITCH

HOUSEHOLD

OUTLETS

BREAKER BREAKER

MASTER

BREAKER

Duplex Outlet #1 NEMA 5-20R 120V

Duplex Outlet #2

NEMA 5-20R 120V

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-7

ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)

Start Engine and

Add Resistive Loads Until

One of the Following Occurs:

s0OWER/UTPUTat the

NEMA L14-30R 240V Receptacle

is Within Rated Power

Specification Range

s&REQUENCY$ROPS"ELOW(Z

s6OLTAGE/UTPUT$ROPS"ELOW

Minimum

114-

126V

228-

252V

114-

126V

If Minimum Rated Power

#ANNOT"E!CHIEVED

SEE%NGINE$IAGNOSTICS3ECTION

NOTE: The alternator must be at room temperature when resistance is measured.

#HECK"RUSH!SSEMBLYFOR%XCESSIVE7EAROR$EFECT

./4%5SE#AUTION7HEN2EMOVINGAND)NSTALLING"RUSH(OLDERTO!VOID$AMAGING"RUSHES

)F,ENGTH,ESSTHANMM2EPLACE"RUSH!SSEMBLY

)F,ENGTH'REATERTHANMM6ERIFY2ESISTANCE"ETWEEN%ACH

"RUSH4IPAND#ORRESPONDING4ERMINALIS,ESSTHANΩ

)F2ESISTANCE/UTOF3PEC2EPLACE"RUSH!SSEMBLY

Check Alternator Winding Resistances

$ISCONNECTTHE%XCITER#ONNECTOR

$ISCONNECTTHE&UEL#UTOUT7INDING#ONNECTOR

$ISCONNECTTHE7IRESATTHE!LTERNATOR4ERMINAL"LOCK

NOTE: Each Terminal Contains Nut, Lock Washer, and Flat Washer

-EASURE7INDING2ESISTANCESAS3PECIFIED"ELOW

Alternator Check

./4%4HEALTERNATORDIAGNOSTICSREQUIREMEASUREMENTSOFLOWRESISTANCE

VALUESWHICHAREBEYONDTHECAPABILITYOFATYPICALMULTIMETER

5SEONLYFORDIRECTIONALINDICATIONOFRESISTANCE

For best results, use an ohmmeter capable of measuring low resistance values:

Resolution: 10 milliohms

!CCURACY+ 1%

#HECKFOR#ROSS3HORTED7INDINGSINTHE3TATOR!SSEMBLY

#HECKFOR#ONTINUITY"ETWEEN7INDINGSAS3PECIFIED"ELOW

)F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE

Replace Alternator

Refer to Illustrations on

Page 8-9.

#HECKFOR#ONTINUITY

"ETWEEN7INDINGS

#ONTINUITY

Specification

Stator-X Red Stator-Y White .O#ONTINUITY

Stator-Y White AVR Tap Green .O#ONTINUITY

Stator-X Red AVR Tap Green #ONTINUITY

Stator-X Red %ITHER%XCITER"LUE .O#ONTINUITY

Stator-Y White .O#ONTINUITY%ITHER%XCITER"LUE

Stator-X Red %ITHER&UEL#UTOUT"ROWN .O#ONTINUITY

Stator-Y White %ITHER&UEL#UTOUT"ROWN .O#ONTINUITY

%ITHER%XCITER"LUE .O#ONTINUITY%ITHER&UEL#UTOUT"ROWN

Measure Resistance

"ETWEEN7IRES

Resistance Range Specification (Ω)

Winding

Stator-X Red "LUE

AVR Tap Green White

OF3TATOR82ESISTANCE

Stator-Y White "ROWN

Exciter "LUE "LUE 

Rotor

Slip Rings

Slip Ring Terminals*



(7,

(7,

(7%, (7,

(7%, (7%,

Fuel Cutout

  1.3 - 1.8

"ROWN "ROWN    

  

   

)F5SINGAN/HMMETERWITH+ELVIN"RIDGE#LIPS

-EASURE2ESISTANCEATTHE3LIP2ING7IRE4ERMINALSFOR"EST2ESULTS

If a Winding Resistance is Out of Spec, Replace Alternator

Rated Power Check (Low Power Output)

NOTE: At high-altitudes, standard

carburetor air-fuel mixture will be

rich causing a decrease in engine

performance and an increase in

fuel consumption.

NOTE: At this time, a high-altitude

carburetor kit is not available.

8-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

ROTOR

SLIP

RINGS

SLIP RING

TERMINALS

Blue (2 wires)

Red (2 wires)

Brown

Brown Black

FUEL CUTOUT WINDING

CONNECTOR*

*view looking into

female connector

from alternator

VOLTAGE REGULATOR

POTENTIOMETER

TO ADJUST VOLTAGE

STATOR-X

WINDING

STATOR-Y

WINDING

Blue

Red

White

Brown

TERMINAL

BLOCK

White (2 wires)

Brown (2 wires)

Blue

Green

White

EXCITER WINDING

AVR TAP

WINDING

EXCITER & AVR TAP

CONNECTOR*

*view looking into

female connector

from alternator

BRUSH ASSEMBLY

White Wire

Red Wire

5-9 mm

ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-9

ENGINE DIAGNOSTICS (ALL MODELS)

Engine Fails to Crank Using Electric Starter

Check Battery Voltage

Higher than 12.5 Volts =

Check Voltage Across Components

Less than 12.5 Volts =

Charge or Replace Battery

Check Voltage Across Components

Check Battery Connections

Check Leads on Proper Post

Check Leads are Clean & Tight

Check Recoil for

Mechanical Binding

Check Voltage Across Components

are Within .5V of Battery Voltage

Replace Out of Spec Components

Check Engine Control Switch

Voltage

Drop in Start Position

Check Battery Post / Solenoid

Voltage Drop

Check Battery Post / Starter Lugs

Voltage Drop

NOTE: Generator has Charging

Coil During Operation; Replace

Coil if Repeated Battery Discharge

Engine Fails to Start

Check Flywheel Woodruff Key

Repair or Replace Key

Drain Oil and

Check Low Oil Switch

Connection and Continuity

(Yellow Wire on Side of Engine)

Perform Engine Compression Test

Check Oil Level

Confirm Choke in On Position

Recoil Not Operating

Recoil Locked =

Disassemble and Repair Recoil

(see Manual Section

“Recoil Starter”)

Check Recoil for

Mechanical Binding

Rope Not Retracting =

Disassemble and Repair

Broken Ratchets or Springs

(see Manual Section

“Recoil Starter”)

Engine Starts

Then Shuts Down

Check Fuel Level

Check Fuel Quality

Check Oil Level

Confirm Choke in Off Position

Check Ignition for Spark

Check Spark Plug & Gap

Adjust Coil Air Gap

Check Fuel Line & Blockage

Check Carburetor

Check Spark Arrestor

Check Muffler Blockage

Engine Runs Rough

Check Fuel Level

Check Fuel Quality

Confirm Choke in Off Position

Check Air Cleaner

Check Fuel Line & Blockage

Check Valve Adjustment

Perform Engine Compression Test

Check Ignition for Spark

Check Spark Plug & Gap

Check Carburetor

Check Spark Arrestor

Check Muffler Blockage

Engine Speed Unstable

Check Governor

Frequency = 60 Hz + 3

Check Governor Assembly

Adjustment

Check Spark Plug & Gap

Check Ignition for Spark

Adjust Coil Air Gap

Check Spark Arrestor

Check Muffler Blockage

Engine Smokes

Start Engine

Warm to Operating Temperature

Observe Smoke Color

White Smoke =

Poor Fuel Quality

Black Smoke =

Check Choke Operation

Check Ignition System

Blue Smoke =

Check Oil in Fuel

Check Oil Overfilled

Check Worn Piston Rings

Perform Engine Compression Test

8.3 ENGINE DIAGNOSTICS (ALL MODELS)

Check Fuel Level

Check Fuel Shut-off Valve Open

Check Spark Plug

Dry Spark Plug =

Check Carburetor

Fuel Cutout Solenoid

Wet Spark Plug =

Check Ignition System

Check Spark Plug Gap

Plug Condition Good =

Re-Gap Spark Plug

Plug Condition Dirty or Worn =

Replace Spark Plug

Check Ignition for Spark

Bright Blue Spark =

Pull Coil & Check Resistance

Primary Coil = 0.8-1.0 Ohms

Secondary Coil = 5.9-7.1 Ohms

(measure at spark plug lead)

Replace Coil, if Necessary

Reinstall Coil with Proper

Coil / Flywheel Air Gap

Reinstall Plug

Dull Spark =

Reinstall Plug

8-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

9: SERVICE AND DISASSEMBLY

START

ENGINE

STOP

RUN

ENGINE

STOP

Control panels vary between models.

POWER CONTROL CENTER

HOUSEHOLD

OUTLETS

120/240 VOLTS AC

MASTER BREAKER

BREAKER BREAKER

120 VOLTS AC

9.1 CONTROL PANEL

A—CONTROL PANEL ASSEMBLY (FRONT)

4 N•m (3 lb. ft.)

B—CONTROL PANEL ASSEMBLY

(BACK)

C—MAIN CONTROL PANEL

(FRONT)

• 125VAC 20 Amp Duplex

(NEMA 5-20R)

• 125/250VAC 30 Amp Twist-Lock

(NEMA L14-30R)

NOTE: Not present on HW3000 or HW3000L models.

• Master Circuit Breaker (Magnetic)

• Circuit Breaker (Thermal)

D—MAIN CONTROL PANEL (BACK)

E—SWITCH PLATE (FRONT)

• E1 - Electric Start Models

(HW5500E, HW5500EL, HW7000E, HW7000EL, HW7500E, HW7500EL)

• E2 - Manual Start Models

(HW3000, HW3000L, HW4000, HW4000L, HW5500, HW5500L, HW6200, HW6200L)

F—ENGINE CONTROL SWITCH

G—SWITCH PLATE (BACK)

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-1

ENGINE AND ALTERNATOR

9.2 ENGINE AND ALTERNATOR

A—END COVER

4 N•m (3 lb. ft.)

B—ROTOR BOLT

Use oil before replacing the rotor bolt.

C—ALTERNATOR HOUSING BOLTS

48 N•m (35 lb. ft.)

D—REAR BEARING CARRIER

AND STATOR

See CARBURETOR, page 9-7.

E—ROTOR

See ROTOR, page 9-5.

F—ENGINE

Contact an authorized service dealer for engine maintenance and repairs.

Cylinder Head Bolts - 48 N•m (35 lb. ft.)

G—VIBRATION ISOLATORS

Insert tabs into holes.

Check rubber is not chipped, hardened, or worn.

Refer to illustration for proper positioning.

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.)

9-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

9.3 ALTERNATOR

NOTICE

Rotor can become damaged if not properly supported. Place wooden block and rag underneath rotor for support.

CAUTION

A—VOLTAGE REGULATOR

B—BRUSH ASSEMBLY

Before removing rotor and stator, remove brush assembly.

2 N•m (1.5 lb. ft.)

C—REAR BEARING CARRIER

D—MAIN WINDING TERMINAL BLOCK

E—STATOR

F—ROTOR

Install appropriate alternator removal tool (special tool), hold flywheel, and torque tool to 48 N•m (35 lb. ft.).

ALTERNATOR

If torquing alternator removal tool does not free rotor from crankshaft, tap end of tool with brass hammer to loosen rotor.

To prevent eye injury, always wear safety glasses or goggles when using a hammer.

G—ALTERNATOR ENGINE ADAPTER

H—GROUND CABLE

I— EXCITER WINDING CONNECTOR

J—BRUSH ASSEMBLY

K—TERMINAL BLOCK

L—SLIP RINGS

M—FUEL CUTOUT CONNECTOR

N—VOLTAGE REGULATOR

Also known as Automatic Voltage Regulator or AVR .

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-3

Alternator Illustrated Matches All Models Except HW3000 & HW3000L

FUEL TANK SYSTEM

WARNING

E 2

E 1

9.4 FUEL TANK SYSTEM

Fuel and its vapors are extremely flammable and explosive under certain conditions.

• Refuel the generator only outdoors, in a well-ventilated area.

• NEVER enclose the generator in any structure.

• Keep generator at least 6 feet (2 meters) away from buildings, other equipment, and combustible materials during operation.

• NEVER fill the fuel tank while the engine is running. Turn the generator OFF and allow it to cool before filling with fuel.

• NEVER smoke or allow flames or sparks near the generator or where gasoline is stored.

• NEVER overfill the fuel tank (there should be no fuel in the filler neck). After refueling, tighten the fuel cap securely.

• Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. 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.

A—FUEL GAGE

After reassembly, check float for proper operation.

B—FUEL CAP

Check air vent hole is clean and free of obstruction. Blow with compressed air if necessary. NOTE: For model numbers ending in “L”, the fuel cap will be attached to the fuel tank with a chain.

C—FUEL STRAINER

Before reassembly, check fuel strainer is clean and undamaged.

D—FUEL TANK MOUNTING HARDWARE

10 N•m (7 lb. ft.)

E—FUEL TANK

Before reassembly, clean fuel tank to remove any sediment and drain completely.

• E1 - Model Numbers Ending in “L”

(HW3000L, HW4000L, HW5500L, HW5500EL, HW6200L, HW7000EL, HW7500EL)

• E2 - Non “L” Models

(HW3000, HW4000, HW5500, HW5500E, HW6200, HW7000E, HW7500E)

F—FUEL SHUT-OFF VALVE

Clear passages if clogged. After reinstalling, check for fuel leakage. Hex fitting - 24 N•m (17 lb. ft.)

G—FUEL SEDIMENT CUP

See CLEANING FUEL SEDIMENT CUP, page 7-5.

H—FUEL LINE

Check for cracks or damage.

Secure with hose clamps.

HW7500E Model Illustrated

9-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

EVAPORATIVE EMISSIONS CONTROL SYSTEM

9.5 EVAPORATIVE EMISSIONS CONTROL SYSTEM

For Model Numbers Ending in “L” only.

A—FUEL TANK

B—CARBON CANISTER

• B1 - HW3000L Model Only

• B2 - All Other Models

C—VAPOR LINE

Secure with hose clamps.

D—CARBON CANISTER TUBE

Secure with hose clamps.

E—CARBON CANISTER BRACKET

2 N•m (1.5 lb. ft.)

• E1 - HW3000L Model Only

• E2 - All Other Models

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-5

MUFFLER

WARNING

9.6 MUFFLER

The muffler becomes very hot during operation and remains hot for a while after stopping the engine.

• NEVER touch hot surfaces and avoid hot gases.

• Let engine cool before storing the generator indoors.

A—MUFFLER GUARD

NOTE: Not present on HW3000 or

HW3000L models.

B—MUFFLER COVER

4 N•m (3 lb. ft.) NOTE: Not present on HW3000 or HW3000L models.

C—SPARK ARRESTOR

Clamp - 1 N•m (1 lb. ft.)

Screen - 1 N•m (1 lb. ft.)

D—MUFFLER

Cutaway view shows the catalyst located inside mufflers on model numbers ending in “L”.

(HW3000L, HW4000L, HW5500L, HW5500EL, HW6200L, HW7000EL, HW7500EL)

Muffler rear mounting bracket 18 N•m (13 lb. ft.)

E—EXHAUST PIPE

18 N•m (13 lb. ft.)

• E1 - Non “L” Models

(HW3000, HW4000, HW5500, HW5500E, HW6200, HW7000E, HW7500E)

• E2 - Model Numbers Ending in “L”

(HW3000L, HW4000L, HW5500L, HW5500EL, HW6200L, HW7000EL, 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.)

9-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

CARBURETOR

WARNING

9.7 CARBURETOR

Fuel and its vapors are extremely flammable and explosive under certain conditions.

• Refuel generator only outdoors, in a well-ventilated area.

• NEVER enclose the generator in any structure.

• Keep generator at least 6 feet (2 meters) away from buildings, other equipment, and combustible materials during operation.

• NEVER fill fuel tank while the engine is running. Turn generator OFF and allow to cool before filling with fuel.

• NEVER smoke or allow flames or sparks near the generator or where gasoline is stored.

• NEVER overfill the fuel tank (there should be no fuel in the filler neck). After refueling, tighten the fuel cap securely.

• Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. 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.

A—FLOAT VALVE

Check for worn valve or weak spring before installation.

B—FLOAT

Check for smooth movement after installation.

C—DRAIN SCREW

Clean with compressed air and check for leaks after installation.

D—SET BOLT

Check for any sign of fuel leakage after installation.

E—FUEL CUTOUT SOLENOID

Check continuity between the double green wires of the solenoid valve. If there no continuity, replace solenoid.

NOTE: Not present on HW3000 or HW3000L models.

F—MAIN JET

Clean with compressed air before installation.

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 installation.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-7

STARTING SYSTEM

9.8 STARTING SYSTEM

A—ELECTRIC STARTER

Attempt to crank engine by switching the engine control switch to the START position.

Starter Solenoid Terminal Nut 6 N•m (4 lb. ft.)

B—WOODRUFF KEY

After installing the flywheel, check to ensure the woodruff key is still in its slot on the crankshaft.

C—SPARK PLUG LEAD

Clamp securely to the crankcase with the two clamps.

Check for cracked or damaged insulation; replace, if necessary.

D—IGNITION COIL

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.

9-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

9.9 RECOIL STARTER

CAUTION

A—STARTER CASE

B—ROPE AND HANDLE

Install with recoil starter handle position as shown.

C—RETURN SPRING

Connect the outer hook in the groove of the starter reel and inner hook on the starter case tab.

Return spring is under tension. Use extreme caution and wear safety glasses and gloves when disassembling to prevent injury.

D—STARTER REEL

Install on the starter case after installing the return spring.

RECOIL STARTER

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 9-9

FAN COV ER

9.10 FAN COVER

A—COOLING FAN

Install by aligning the three lugs on the rear side of the fan with the small hole in the flywheel. When disassembling and assembling, take care not to damage the fan blades.

B—STARTER PULLEY

Install by aligning the hole in the pulley with the lug on the cooling fan.

C—FLANGE NUT

Hold the flywheel by placing a screwdriver into the pulley.

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

WHEEL, LEG, & HANDLE ASSEMBLY

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.

9.11 WHEEL, LEG, & HANDLE ASSEMBLY

(HW3000/L MODELS)

A—LOCKING HANDLE BRACKET

10 N•m (7 lb. ft.)

B—SPRING LOCKING HANDLE

C—RUBBER HANDLE GRIP

D—AXLE

25 N•m (18 lb. ft.)

E—SUPPORT LEG

25 N•m (18 lb. ft.)

F—RUBBER STOPPER

25 N•m (18 lb. ft.)

G—WHEEL

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-11

WHEEL, LEG, & HANDLE ASSEMBLY

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.

9.12 WHEEL, LEG, & HANDLE ASSEMBLY

(ALL MODELS EXCEPT HW3000/L)

A—WHEEL HANDLE PIVOT BRACKET

10 N•m (7 lb. ft.)

B—PIN AND CHAIN

C—HANDLE BAR

D—RUBBER HANDLE GRIP

E—AXLE

25 N•m (18 lb. ft.)

F—SUPPORT LEGS

25 N•m (18 lb. ft.)

NOTE: On some models the leg support nuts are welded to the frame.

G—RUBBER STOPPER

25 N•m (18 lb. ft.)

H—WHEEL

HW5500E Model Illustrated

9-12 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

10: INDEX

Air Filter Maintenance

7-3

Alternator 9-2,9-3 Automatic Voltage Regulator (AVR) 8-5,8-9,9-3

Battery

4-1,7-8

Breakers 4-1

Components

breakers

4-1

choke control 4-1 engine control switch 4-1 fuel shut-off valve 4-1 recoil starter handle 4-1 spark plug cap 4-1

Control Panel 9-1

Electrical Diagnostics

8-2

all other models 8-6,9-12

HW3000/L models 8-2 Engine 7-3,9-2 Engine Control Switch 4-1,9-1 Engine Diagnostics 8-10 Evaporative Emissions Control System 9-5

Fuel Gage

4-1,9-4

Fuel Recommendations 7-2 Fuel Sediment Cup 7-5,9-4 Fuel Shut-off Valve 4-1,9-4 Fuel Strainer 9-4 Fuel Tank 9-4,9-5 Fuel, Oxygenated 7-2

Governor

7-7

Ground Terminal 4-1

Maintenance

7-1

air filter 7-3

battery service 7-8

fuel sediment cup 7-5

governor adjustment 7-7

governor range adjustment 7-7

schedule 7-1

spark arrestor screen 7-6

spark plug 7-5

valve lash 7-7 Muffler 4-1,9-6

Power Control Center

4-1,9-1

breakers 4-1,9-1 electrical outlets 4-1,9-1 ground terminal 4-1

Rotor

9-2,9-3

Safety, Important Instructions Service and Disassembly 9-1

alternator 9-3 carburetor 9-7 control panel 9-1 engine and alternator 9-2 evaporative emissions control system 9-5 fan cover 9-10 fuel tank 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

Too ls , S er v ic e

5-1

Torque Information 3-2 Transporting Generator 5-1 Troubleshooting 8-1

Valve Lash

7-7

Voltage Regulator 8-5,8-9,9-3

Warranty

emissions control

2-2

limited 2-1

replacement parts 2-4 Wheel, Leg, & Handle Assembly 9-11 Wiring Diagrams 3-3

1-1

Oil Fill Dipstick

4-1

Oil Recommendations 7-3 Outlets 4-1,9-1

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 10-1

Northshore Power Systems, LLC

4425 N. Port Washington Road

Suite 105

Milwaukee, WI 53212-1082 USA

1-888-HWTECHS (498-3247)

www.honeywellgenerators.com

P/N 101290D

2010 Northshore Power Systems, LLC

The Honeywell Trademark is used under license from Honeywell International Inc.

Honeywell International Inc. makes no representation or warranties with respect to this product.

Manufactured exclusively for Northshore Power Systems.

Honeywell hw400, HW3000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS

3.1 SPECIFICATIONS

HW3000 & HW3000L

WIRING DIAGRAMS

HW4000 & HW4000L

HW5500 & HW5500L

HW5500E & HW5500EL

HW6200 & HW6200L

HW7000E, HW7000EL, HW7500E, & HW7500EL

5.1 REQUIRED TOOLS

5.2 TRANSPORTING GENERATOR

7.1 CONSUMER MAINTENANCE SCHEDULE

FUEL RECOMMENDATIONS

AIR FILTER MAINTENANCE

ENGINE OIL RECOMMENDATIONS

CLEANING FUEL SEDIMENT CUP

CLEANING SPARK ARRESTOR SCREEN

VALVE LASH

7.8 GOVERNOR RANGE ADJUSTMENT

BATTERY SERVICE

ENGINE DIAGNOSTICS (ALL MODELS)

ENGINE AND ALTERNATOR

ALTERNATOR

FUEL TANK SYSTEM

EVAPORATIVE EMISSIONS CONTROL SYSTEM

MUFFLER

CARBURETOR

STARTING SYSTEM

RECOIL STARTER

FAN COV ER

WHEEL, LEG, & HANDLE ASSEMBLY