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 WARRANTIES ....................................................................... 1-1 ............................................................................................................... 2-1 NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY ............................................2-1 NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY ..........................................
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SAVE THESE INSTRUCTIONS 1: IMPORTANT SAFETY INSTRUCTIONS WARNING 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.
SAFETY MESSAGES Electric Shock Hazards WARNING 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.
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.
WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator 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 WARRANTY STATEMENT The U.S.
WARRANTIES 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.
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.
3: SPECIFICATIONS AND WIRING DIAGRAMS 3.
BOLT AND FASTENER TORQUE INFORMATION 3.2 BOLT AND FASTENER TORQUE INFORMATION Component-Specific Fastener Fastener Size Torque Values N•m lb. ft. 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 M8 x 1.25 15 11 M6 x 1.0 x 15 4 3 Cooling Fan Flange Nut M18 x 1.5 105 77 Crankcase Cover Bolts M8 x 1.
Honeywell Portable Electrical Generator Service Manual Bl - Black Bu - Blue Br - Brown Y - Yellow Y/G - Yellow / Green W - White ON OFF Bl Y/G Y/G Bl Y Bl IG E Y/G ENGINE CONTROL SWITCH Bl Bl Bl Y ALTERNATOR NOTE: Alternator is mechanically connected to the engine block providing ground connection between the engine block and the alternator frame.
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Honeywell Portable Electrical Generator Service Manual Bl - Black Bu - Blue Br - Brown G/W - Green / White Lg - Light Green R - Red Y - Yellow Y/G - Yellow / Green W - White ON OFF Bu G/W Bl Y/G IGNITION COIL Bl Bl Y Y ENGINE CONTROL SWITCH IG E G/W Bu G/W Br Br W 5A FUSE FUEL CUTOUT WINDING AVR g W W ALTERNATOR Bu EXCITER WINDING R Lg W Bu FIELD WINDING NOTE: Alternator is mechanically connected to the engine block providing ground connection between the engine block and the altern
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Honeywell Portable Electrical Generator Service Manual Bu G/W Bl Y/G Bl - Black Bu - Blue Br - Brown G/W - Green / White Lg - Light Green R - Red Y - Yellow Y/G - Yellow / Green W - White ON OFF IGNITION COIL Bl Bl Y Y ENGINE CONTROL SWITCH IG E G/W Bu G/W Br Br W 5A FUSE FUEL CUTOUT WINDING AVR W W ALTERNATOR Bu EXCITER WINDING R Lg W Bu FIELD WINDING NOTE: Alternator is mechanically connected to the engine block providing ground connection between the engine block and the alternato
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4: COMPONENTS K J L A E M I B H N F G C D FIGURE 4-1: Honeywell Portable Electrical Generator Controls and Components (HW5500EL Model Illustrated) A—Power Control Center E—Engine Control Switch Electrical Outlets • 125VAC 20 Amp Duplex (NEMA 5-20R) outlets to connect 120V appliances to generator for power.
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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 5.2 TRANSPORTING GENERATOR A complete set of standard and metric shop tools are required to service the generator.
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6: SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE HW3000 HW3000L (min.) HW4000 HW4000L (min.) HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW7500EL (min.
SERVICE REPAIR TIME ANALYSIS Operation HW3000 HW3000L (min.) HW4000 HW4000L (min.) HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW7500EL (min.
7: MAINTENANCE 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). 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. Accidental starting of generator can cause severe injury or death.
CONSUMER MAINTENANCE SCHEDULE FUEL RECOMMENDATIONS Before each use, check the fuel tank gage. If the fuel level is low, refill the tank with recommended fuel. NEVER OVERFILL. DANGER NOTICE 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 Fuel and fuel vapors are extremely flammable and explosive under certain conditions.
AIR FILTER MAINTENANCE ENGINE OIL RECOMMENDATIONS 7.2 AIR FILTER MAINTENANCE 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.
AIR FILTER MAINTENANCE 3. Remove foam air filter(s). NOTE: 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. FIGURE 7-4: Air Filter Removal 4. Wash air filter(s) in a solution of household soap and warm water. 9B. Reinstall the dark grey foam air filter. 9C. Reinstall the air cleaner cover. FIGURE 7-5: Wash Air Filter 5.
CLEANING FUEL SEDIMENT CUP 7.3 CLEANING FUEL SEDIMENT CUP 7.4 SPARK PLUG SERVICE The sediment cup prevents any dirt or water that may be in the fuel tank from entering the carburetor. To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. Clean fuel sediment cup at the intervals specified in Table 7-1. WARNING If the engine has been running, the spark plug will reach temperatures that could cause severe burns. Do not touch.
CLEANING SPARK ARRESTOR SCREEN 7.5 CLEANING SPARK ARRESTOR SCREEN 5. Using a screwdriver, loosen and remove the spark arrestor clamp (A) screw. WARNING C A 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.
VALVE LASH 7.6 VALVE LASH 7.7 GOVERNOR ADJUSTMENT CAUTION Valve lash inspection and adjustment must be performed with the engine cold. 1. 2. 3. 4. Remove the cylinder head cover and carefully remove the gasket for re-use. (Inspect and replace gasket, if necessary.) Remove the spark plug to reduce engine compression resistance. Turn the engine crankshaft using the recoil starter, positioning engine at top, dead center, of the compression stroke.
BATTERY SERVICE 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. 6. Remove the battery.
8: TROUBLESHOOTING WARNING 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. DANGER Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.
ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) 8.
ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) See “Specifications” Page For Rated Power, Voltage, & Frequency Specs Under Load and No Load Conditions Duplex Outlet #1 NEMA 5-20R 120V Duplex Outlet #2 NEMA 5-20R 120V W X W G W Y G X G W Y G 3000 RATED WATTS • 3750 MAXIMUM WATTS White Wire = W Black Wire = X Yellow / Green Wire = G Honeywell Portable Electrical Generator Service Manual To Alternator www.honeywellgenerators.
ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) 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. Alternator Check NOTE: The alternator must be at room temperature when resistance is measured. .
ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) BRUSH ASSEMBLY Blue Wire STATOR-X WINDING Yellow Wire TERMINAL BLOCK 5-9 mm White STATOR-Y WINDING Black White (2 wires) Black (2 wires) ROTOR VOLTAGE REGULATOR SLIP RINGS EXCITER & AVR TAP CONNECTOR* POTENTIOMETER TO ADJUST VOLTAGE AVR TAP WINDING Blue Yellow SLIP RING TERMINALS Brown EXCITER Yellow WINDING *view looking into female connector from alternator Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.
ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) 8.
ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) See “Specifications” Page For Rated Power, Voltage, & Frequency Specs Under Load and No Load Conditions Duplex Outlet #1 NEMA 5-20R 120V Duplex Outlet #2 NEMA 5-20R 120V HOUSEHOLD OUTLETS POWER CORD or TRANSFER SWITCH 120 VOLTS AC 120/240 VOLTS AC W X W G W Y Y Y W 240V Receptacle NEMA 14-30R G G X W G BREAKER X G BREAKER MASTER BREAKER 7000 7000 RATED WATTS • 8750 MAXIMUM WATTS White Wire = Y Yellow / Green Wire = G Red Wire = X Bl
ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) Rated Power Check (Low Power Output) Alternator Check 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: The alternator must be at room temperature when resistance is measured. Refer to Illustrations on Page 8-9. .
ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) EXCITER & AVR TAP CONNECTOR* STATOR-X WINDING BRUSH ASSEMBLY Blue Red Wire Green EXCITER WINDING AVR TAP WINDING Blue White Wire 5-9 mm White *view looking into female connector from alternator TERMINAL BLOCK Blue Red STATOR-Y WINDING White Brown Blue (2 wires) Red (2 wires) White (2 wires) Brown (2 wires) ROTOR VOLTAGE REGULATOR SLIP RINGS POTENTIOMETER TO ADJUST VOLTAGE FUEL CUTOUT WINDING CONNECTOR* SLIP RING TERMINALS Brown Brown
ENGINE DIAGNOSTICS (ALL MODELS) 8.
9: SERVICE AND DISASSEMBLY 9.1 CONTROL PANEL A—CONTROL PANEL ASSEMBLY (FRONT) 4 N•m (3 lb. ft.) B—CONTROL PANEL ASSEMBLY (BACK) B 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) D Circuit Breaker (Thermal) Control panels vary between models.
ENGINE AND ALTERNATOR 9.2 ENGINE AND ALTERNATOR A—END COVER F 4 N•m (3 lb. ft.) E B—ROTOR BOLT Use oil before replacing the rotor bolt. D C A B I C—ALTERNATOR HOUSING BOLTS 48 N•m (35 lb. ft.) D—REAR BEARING CARRIER AND STATOR H See CARBURETOR, page 9-7. E—ROTOR See ROTOR, page 9-5. F—ENGINE Contact an authorized service dealer for engine maintenance and repairs. G Cylinder Head Bolts - 48 N•m (35 lb. ft.) G—VIBRATION ISOLATORS Insert tabs into holes.
ALTERNATOR 9.3 ALTERNATOR A—VOLTAGE REGULATOR G B—BRUSH ASSEMBLY F Before removing rotor and stator, remove brush assembly. 2 N•m (1.5 lb. ft.) E C—REAR BEARING CARRIER D—MAIN WINDING TERMINAL BLOCK C E—STATOR F—ROTOR Install appropriate alternator removal tool (special tool), hold flywheel, and torque tool to 48 N•m (35 lb. ft.). A B D NOTICE Rotor can become damaged if not properly supported. Place wooden block and rag underneath rotor for support.
FUEL TANK SYSTEM 9.4 FUEL TANK SYSTEM WARNING 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.
EVAPORATIVE EMISSIONS CONTROL SYSTEM 9.5 EVAPORATIVE EMISSIONS CONTROL SYSTEM For Model Numbers Ending in “L” only. A—FUEL TANK B—CARBON CANISTER • • A 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 C D B2 B1 E1 Honeywell Portable Electrical Generator Service Manual E2 www.honeywellgenerators.
MUFFLER 9.6 MUFFLER WARNING 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. A B—MUFFLER COVER 4 N•m (3 lb. ft.) NOTE: Not present on HW3000 or HW3000L models. B C—SPARK ARRESTOR Clamp - 1 N•m (1 lb. ft.) Screen - 1 N•m (1 lb. ft.
CARBURETOR 9.7 CARBURETOR WARNING 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.
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 A B 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. G Check for cracked or damaged insulation; replace, if necessary.
RECOIL STARTER 9.9 RECOIL STARTER 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. CAUTION Return spring is under tension. Use extreme caution and wear safety glasses and gloves when disassembling to prevent injury. I H C G F E D B A D—STARTER REEL Install on the starter case after installing the return spring.
FAN COVER 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. A B C D E 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.
WHEEL, LEG, & HANDLE ASSEMBLY 9.11 WHEEL, LEG, & HANDLE ASSEMBLY (HW3000/L MODELS) A—LOCKING HANDLE BRACKET 10 N•m (7 lb. ft.) B—SPRING LOCKING HANDLE A C—RUBBER HANDLE GRIP D—AXLE 25 N•m (18 lb. ft.) B E—SUPPORT LEG C 25 N•m (18 lb. ft.) F—RUBBER STOPPER 25 N•m (18 lb. ft.) G—WHEEL D 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.
WHEEL, LEG, & HANDLE ASSEMBLY 9.12 WHEEL, LEG, & HANDLE ASSEMBLY (ALL MODELS EXCEPT HW3000/L) A—WHEEL HANDLE PIVOT BRACKET 10 N•m (7 lb. ft.) A B—PIN AND CHAIN C—HANDLE BAR D—RUBBER HANDLE GRIP E—AXLE C B D 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 E F H NOTICE • Accessory kit is intended to be used specifically with this generator.
10: INDEX A P Power Control Center 4-1, 9-1 breakers 4-1, 9-1 electrical outlets 4-1, 9-1 ground terminal 4-1 Air Filter Maintenance 7-3 Alternator 9-2, 9-3 Automatic Voltage Regulator (AVR) 8-5, 8-9, 9-3 B Battery 4-1, 7-8 Breakers 4-1 C R Rotor 9-2, 9-3 S 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 Safety, Important Instructions 1-1 Service and Disassembly 9-1 alternator 9-3 carburetor 9-7 c
Northshore Power Systems, LLC 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 USA P/N 101290D c 2010 Northshore Power Systems, LLC The Honeywell Trademark is used under license from Honeywell International Inc. 1-888-HWTECHS (498-3247) Honeywell International Inc. makes no representation or warranties with respect to this product. www.honeywellgenerators.com Manufactured exclusively for Northshore Power Systems.
