Honeywell hw400, HW3000 User Manual

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.



CONTENTS

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

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

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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

WARNING

WARNING

WARNING

WARNING

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.

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

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.

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

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: [e-mail]

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.

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 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

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

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

60

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

3-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

3.3 WIRING DIAGRAMS

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

Y

Y

Bl

Bl

Bl

Bl

ENGINE

CONTROL

SWITCH

Bl Y/G

Y/G

EIG

GROUND

TERMINAL

DUPLEX

5-20R

Y/G 2.5 mm

2

THERMAL

AC BREAKER

15A

G

WX

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

YBu BuBr Y Y

120 VAC

Bl 4 mm

2

W 4 mm

2

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

G

WX

G

WX

G

WX

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

2

Bl 2.5 mm

2

Bl 2.5 mm

2

Bl 2.5 mm

2

DUPLEX

5-20R

OFF

ON

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

G

Y

W

X

ALTERNATOR

CONTROL PANEL

ENGINE

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

Y

Y

Bl

Y

Bl

Bl

ENGINE

CONTROL

SWITCH

Bl

Bu

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

15A

G

WX

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

G

WX

DUPLEX 5-20R

G

WY

G

WY

MAIN

WINDING

Br WRBu

Br WRBu

FUEL

CUTOUT

WINDING

5A FUSE

G/W

G/W

TWIST-LOCK

L14-30R

Y/G

Br Br

MAGNETIC

AC BREAKER

15A

120 VAC

120 VAC

OFF

ON

Bu BlG/W Y/G

HW4000 & HW4000L

3-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

FIGURE 3-2: HW4000 & HW4000L Wiring Diagram

FUEL CUTOUT

SOLENOID

HW5500 & HW5500L

G

Y

W

X

ALTERNATOR

CONTROL PANEL

ENGINE

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

Y

Y

Bl

Y

Bl

Bl

ENGINE

CONTROL

SWITCH

Bl

Bu

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

20A

G

WX

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

G

WX

DUPLEX 5-20R

G

WY

G

WY

MAIN

WINDING

Br WRBu

Br WRBu

FUEL

CUTOUT

WINDING

5A FUSE

G/W

G/W

TWIST-LOCK

L14-30R

Y/G

Br Br

MAGNETIC

AC BREAKER

21A

120 VAC

OFF

ON

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

G

Y

W

X

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

Y

Y

Bl

Y

Bl

Bl

ENGINE

CONTROL

SWITCH

Y/G

Bu

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

20A

G

WX

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

G

WX

DUPLEX 5-20R

G

WY

G

WY

MAIN

WINDING

Br WRBu

Br WRBu

FUEL

CUTOUT

WINDING

5A

FUSE

G/W

G/W

TWIST-LOCK

L14-30R

Bl

Br Br

MAGNETIC

AC BREAKER

21A

120 VAC

Br

CHARGE

COIL

BATTERY

STARTER

MOTOR

M

Gr

W

FUEL

CUTOUT

SOLENOID

AUTO

PROTECTOR

3A

Bl/W

Bl/W

OFF

START

Bu BlG/W Y/G

ON

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

G

Y

W

X

ALTERNATOR

CONTROL PANEL

ENGINE

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

Y

Y

Bl

Y

Bl

Bl

ENGINE

CONTROL

SWITCH

Bl

Bu

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

20A

G

WX

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

G

WX

DUPLEX 5-20R

G

WY

G

WY

MAIN

WINDING

Br WRBu

Br WRBu

FUEL

CUTOUT

WINDING

5A FUSE

G/W

G/W

TWIST-LOCK

L14-30R

Y/G

Br Br

MAGNETIC

AC BREAKER

25A

120 VAC

120 VAC

OFF

ON

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