Home

Honeywell HW3000 User's Manual

1. 7 1 CONSUMER MAINTENANCE SCHEDULE asvnnsvnnnnvnnnnnnnnnnnnnnnnnenannennnvennnennnnnnnvnnnnvnnnnnnnnnennnennnnnnnnennnvenneennnr 7 1 AIR FILTER MAINTENANCE t 7 3 CLEANING FUEL SEDIMENT CUP tain enum ttum inc caasa suse ndm nao imam aia nnm nac dieu dne 7 5 SPARK PLUG SERVICE c nenn 7 5 CLEANING SPARK ARRESTOR SCREEN asvnnvvnnnvnnsnnnnnnnnnnnnnnennnnennnvennvennnennnvnnnnvnnnnnnnnnennnennnnnnnnennnvennnennr 7 6 7 7 GOVERNOR ADJUSTMENT 7 7 GOVERNOR RANGE ADJUSTMENT ausvnnnvensvennnvnnnnvnnnvnnnnnnnnnennnvnnnnnnnnennnvennnennneennnvennvnnnnnnnnnennnnnnnnenunenunnenner 7 7 BATTERY SERVICE Hu 7 8 TROUBLESHOOTING eisen 8 1 ELECTRICAL DIAGNOSTICS HW3000 L MODELS asennsvnnnnvnnnnnnnnnennnnnnnnnnnnennnvennnennnvnnnnnnnnvnnnnvnnnnennnvnnnner 8 2 ELECTRICAL DIAGNOSTICS ALL MODELS EXCEPT HW3000 L 8 6 ENGINE DIAGNOSTICS ALL MODELS usvennvnnvvnnnnvnnnnnnnnvnnnnvnnnnnnnnennnennnnennnnennennnnvnnnnvnnnvnnnnvnnnnennnevunenuner 8 10 SERVICE AND DISASSEMBLY aan 9 1 ie ueMJz 9 1 ENGINE ALTERNATOR e 9 2 ALTERNATOR veden 9 3 FUEL TANK SYSTEM
2. 110 d d HOLIMS SNIGNIM OVAOZL 9 NMOGLNHE SNIGNIM SNIGNIM 100100 NISN A Td GION310S LNOLNO ovaoer SNINIA amaa qana NIYIN 1 pue SEDE i 00 q y uonoeuuoo ay Adal va si 4109 LON HW7500E amp HW7500EL Wiring Diagram 6 HW7000E HW7000EL FIGURE 3 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 8 4 COMPONENTS FIGURE 4 1 Honeywell Portable Electrical Generator Controls and Components HW5500EL Model Illustrated A Power Control Center Electrical Outlets 125 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 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 appli ance Master circuit breaker controls power to all outlets If there is no power at outlets see TROUBLESHOOTING page 8 1 HW3
3. pue ONIGNIM uonoeuuoo 5 qui Bulpinoid 110 eui 1 SI v HOLIMS 310N NMOGLNHS 1 HW3000 amp HW3000L Wiring Diagram FIGURE 3 1 3 3 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual o lt HW4000 amp HW4000L TANVd JOYLNOO TANVd HOLIMS 440 NO D A Yost H MOOTLSIML VSL OV IVINH3HL VSL Ov OLL3NDVIN BENE lua Np OV TYWNYIHL HOLIMS 7031409 SHUM M NOII A D A peH H u 19 JUG 61 WD umolg yoelg ig HOIVNHALIV M pa pa HAV vl OOOO na 61 M m ba pa Hn U HUGA i H ONIANIM 6 OVAOZL NIVIN ONIGNIM ONIGNIM 100119 ONIGNIM ana ONIANIM OWA 021 NIVN 10jeuJey e oui pue ueewjeq uonoeuuoo puno16 eui peioeuuoo Ajjesiueyoau SI 3LON uad NMOGLNHS 3208 la 1109 M
4. JojeuJej e eu PU NMOGLNHS y uee eq uono uuoo 110 puno16 oojq eui Ajjes ueysau SI VVVV GIONSTOS LON LNOLNO 1913 NIS i INIONA FIGURE 3 3 HW5500 amp HW5500L Wiring Diagram Honeywell Portable Electrical Generator Service Manual o lt HW5500E amp HW5500EL 1 IVNIINH3 L 905 71 OV TYWHIHL DIA HOLIMS TOHLNOO 3NION3 o ODA 1 ng OV TYWNYIHL T3NVd HOLIMS SHUM M D A MOII9A 4 161 61 u9919 WD umolg ng SHUM X1 Ig ve OLAV viz ov asnd OLL3NDVN vs ZU 39018 3NION3 PL HH NOLLINDI 1 RE IE F oma ng 67 gt lt a Hr b 1 H3aNas mps ps E un d N 147v 10 dh rh HOLIMS ONIGNIM OVAOZL o 9 NMOGLNHE ONIGNIM ONIGNIM 1NOLNO ONIGNIM Jans GION31OS qii Meri ov og jani NIV eureJj pue YOLOW xoo q ay u m q
5. It is recommended that this maintenance task be performed by service dealer Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 7 1 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 Fuel and fuel vapors are extremely flammable and explosive under certain conditions Refuel generator only outdoors in well ventilated area NEVER fill fuel tank while engine is running Turn gen erator OFF and allow to cool before filling with fuel NEVER smoke or allow flames or sparks near genera tor 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 fu
6. 10 Reinstall remaining spark arrestor components Spark arrestor screen cap and screw m Clamp and screw 5 gt Muffler cover FIGURE 7 14 Remove Muffler Cover 7 6 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual VALVE LASH 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 com pression 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 FIGURE 7 17 Lock Nut Location IN 0 005 0 001 in 0 125 0 025 mm Standard valve lash EX 0 007 0 001 in 0 175 0 025 mm TABLE 7 5 Standard Valve Lash A ROCKER ARM B LOCK NUT 12 Nem 9 Ib ft To increase valve lash screw pivot nut out To decrease valve lash screw pivot nut in C PIVOT BOLT 30 Nem 22 Ib ft 5 Hold the rocker arm pivot and loosen the lock nut see Bin illustration 6 Turn the rocker arm pivot see C in illustration to obtain specified valve lash Retighten the lock nut while holding rocker arm pi
7. d Muvds 5 1431Y HOLIMS GION3IOS 3NION3 FIGURE 3 2 HW4000 amp HW4000L Wiring Diagram Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 4 lt M D A 5 JR BERE SEERE RER FERNER ET HERE BEE GERE SEE SER FT EE NEE SSG TANVd 1OH LNOO 13NVd HOLIMS 440 NO 67 SUM uaa mo m TWNIAHSL 7 IR ng a V 18 5 HOLIMS aM JOHLNOD o 0 17 00718IML uoz s PI wooh FIT GID ng D A GOD xD IV L 11 EN voz voz OV uaxvaudg OV TVINH3H L 9 TWWYSHL 3 5 www honeywellgenerators com HW5500 amp HW5500L _ YOIWNHALTV Vile ov OLLINDVIN joo Ec S m MCN gt 22 ND 1 1 32018 3NION3 1 x 1 p di 8 1109 OAOA PL HH NOLLINDI OOOO Im 67 M Ein 5 ARMAN H HH il n TIT ona MUVdS ONIGNIM ONIGNIM LNOLND SNIGNIM ana m 1437Y 110 JOPEUJSYE pue
8. HW3000 HW4000 HW5500 HW5500E HW6200 HW7000E HW7500E 2 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 Nem 3 Ib ft 9 6 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual CARBURETOR 9 7 CARBURETOR Fuel and its vapors are extremely flammable and explosive under certain conditions Refuel generator only outdoors in 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 oper ation 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
9. 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 Fuel 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 war ranty and policies established with the authorized dealer network 2 Exclusions Warranty coverage shall be denied for fail ure of an emissions control part caused by abuse neglect improper maintenance as described in the Hon eywell 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 war rants to the original retail purchaser and each subse quent 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 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 inc
10. FIGURE 7 6 Dry Air Filter 7 Coat the air filter with clean engine oil FIGURE 7 10 Air Filter Plate Installation Non L Models air filter plate shape varies by model 9B Reinstall air filter 9 Reinstall the air cleaner cover FIGURE 7 7 Oil Air Filter 8 Squeeze out excess oil o 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 7 4 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual CLEANING FUEL SEDIMENT CUP 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 Place generator on a flat level surface 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 sedi ment cup assembly sediment cup o ring and fuel screen using 10 mm box wrench FIGURE 7 12 Fuel Sediment Cup Assembly 5 Clean the fuel screen A o ring B and se
11. poison you cannot see or smell NEVER use inside home Only use OUTSIDE and or garage EVEN IF doors far away from windows and windows are open doors and vents SAFETY PRECAUTIONS Wear appropriate protective safety equipment such as safety shoes and safety glasses with the warnings in this manual and take spe cial precautions when working around electrical equip ment 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 arc producing 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 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 iso late generator from electric utility NEVER connect to a building s electrical system unless a transfer switch has been installed by a qu
12. 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 WIRING DIAGRAMS 3 3 WIRING DIAGRAMS HW3000 amp HW3000L epis 1uBu eui uo eq dwy 0 jeued epis Yo eui uo eq Jeyea g GL D EEA REE PE rn UA ER me amp TANVd 1081 00 1 TYNINYIL 90 D A 1 305 5 402 9 1 92 18 LI var 1 OV yuu sea TYNYIHL I LHDIY 1331 L Jr uw v Ig u8819 D A NOII A umolg ng eld 18 TANVd HOLIMS 44O NO HOLIMS TJOHLNOD ANIONS YOLVNYALIV MOOTE ANIONA 1100 NOILINDI 1 on Td 5 B ONIGNIM JojeuJej e
13. Wood block for rotor support 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 amp FLAT RATE SCHEDULE HW3000 HW4000 HW5500 HW5500E HW6200 HW7000E HW7500E Operation HW3000L HWA000L HW5500L HW5500EL HW6200L HW7000EL HW7500EL min min min min min min 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 Breakers 45 45 45 45 45 45 45 Oil Shutdown Switch 40 40 40 40 40 40 40 Oil Alert Sender 40 40 40 40 40 40 40 Receptacles Ports 50 50 50 50 50 50 50 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 3
14. 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 Depart ment 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 North shore 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 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 t
15. at room temperature when resistance is measured NOTE The alternator diagnostics require measurements of low resistance values which are beyond the capability of a typical multi meter Use only for directional indication of resistance For best results use an ohmmeter capable of measuring low resistance values Refer to Illustrations on Page 8 5 Resolution 10 milliohms Accuracy 1 Check Brush Assembly for Excessive Wear or Defect NOTE Use Caution When Removing and Installing Brush Holder to Avoid Damaging Brushes If Length Less than 5 mm Replace Brush Assembly If Length Greater than 5 mm Verify Resistance Between Each Brush Tip and Corresponding Terminal is Less than 0 1 Q If Resistance Out of Spec Replace Brush Assembly Check Alternator Winding Resistances Disconnect the Exciter Connector Disconnect the Wires at the Alternator Terminal Block NOTE Each Terminal Contains Nut Lock Washer and Flat Washer Measure Winding Resistances as Specified Below Resistance Range Winding Specification Q 20 35 of AVR Tap Brown Blue Stator X Resistance Slip Rings or Slip Ring Terminals If Using an Ohmmeter with Kelvin Bridge Clips Measure Resistance at the Slip Ring Wire Terminals for Best Results Measure Resistance Between Wires If a Winding Resistance is Out of Spec Replace Alternator Check for Cross Shorted Windings in the Stator Assembly Check for Continuity Between Windings as Specified Belo
16. 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 Refer to Illustrations on Pages 8 7 and 8 9 8 6 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual ELECTRICAL DIAGNOSTICS ALL MODELS EXCEPT HW3000 L See Specifications Page For Rated Power Voltage amp Frequency Specs Under Load and No Load Conditions Duplex Outlet 1 POWER CONTROL CENTER Duplex Outlet 2 NEMA 5 20R 120V NEMA 5 20R 120V HOUSEHOLD POWER CORD or OUTLETS TRANSFER SW tl 120 VOLTS AC 120 7 VOLTS AC 240 Rece ptacle NEMA 14 30R BREAKER BREAKER 1 1 9 O PORTABLE GENERATOR 7000 RATED WATTS 8750 MAXIMUM WATTS White Wire Y Yellow Green Wire G Red Wire X OP Blue Wire W on Duplex Outlet 1 Op Brown Wire W on Duplex Outlet 2 To Fuel Cutout Winding Connector Brown Wires 2 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 8 7 ELECTRICAL DIAGNOSTICS ALL MODELS EXCEPT HW3000 L Rated Power Check Low Power Output NOTE At high altitudes standard carburetor air fuel mixture will be rich causing dec
17. 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 5 20R 120V Duplex Outlet 1 126V G If Voltage Out of Range Perform 120V Circuit 1 Check Check Voltage Output at NEMA 5 20R 120V Duplex Outlet 2 If Voltage Out of Range Perform 120V Circuit 2 Check Remove Alternator End Cover 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 Wires and Connections for the Exciter amp 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 L
18. iii acci dent damage abuse or misuse iv abnormal operating con ditions 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 North shore 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 honeywellgenera tors com Warranty is also available by keeping and showing your origi nal 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 Califor nia Air Reso
19. 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 installa tion 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 Nem 4 Ib 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 Nem 7 Ib ft E FLYWHEEL F CLAMP G CHARGING COIL ASSEMBLY Check for continuity 9 8 www honeywellgenerators com Honeywell Port
20. sete 9 4 EVAPORATIVE EMISSIONS CONTROL SYSTEM avunnsvnnsvnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnennnennnvennvnnnnvnnnnvennnennnvennner 9 5 MUFFLER qd cd quc Yd dn das FN Dan OR Re dO Leg P TM RR ERE ER RE bs 9 6 CARBURETOR e IM Merced 9 7 STARTING SYSTEM e 9 8 9 9 FAN COVER 9 10 WHEEL LEG 8 HANDLE ASSEMBLY HW3000 L MODELS 1 u l u u u 9 11 WHEEL LEG amp HANDLE ASSEMBLY ALL MODELS EXCEPT HW3000 L 9 12 INDEX EN 10 1 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com THIS PAGE INTENTIONALLY LEFT BLANK www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual SAVE THESE INSTRUCTIONS 1 IMPORTANT SAFETY INSTRUCTIONS ANYONE using or servicing this generator must read understand and follow all safety and operation instruc tions provided in the product manual Failure to closely follow these instructions can result in circumstances leading to death serious i
21. 0 30 Air Cleaner 40 40 40 40 40 40 40 Carburetor 50 50 50 50 50 50 50 Choke 45 45 45 45 45 45 45 numbers Endre 9 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 amp EXHAUST eme 4 5 Model Numbers EU a 8 An 20 49 ao 30 30 30 30 30 30 30 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 6 1 SERVICE REPAIR TIME ANALYSIS HW3000 HW4000 HW5500 HW5500E HW6200 HW7000E HW7500E Operation HW3000L HW4000L HW5500L HW5500EL HW6200L HW7000EL HW7500EL min min min min min min min Model Numbers Ends des 29 50 gt 98 Fuel Tank 60 60 60 60 60 60 60 Fuel Shut off Valve 40 40 40 40 40 40 40 Muffler 50 50 50 50 60 60 60 Muffler Gasket 50 50 50 50 60 60 60 Secondary Air Intake Valve with gasket 50 50 50 50 50 50 50 Model Numbers Ending in L MISC Model Numbers En 120 120 120 120 120 120 120 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 NOTE Repair times represent generally accepted intervals for conducting a re
22. 000 HW3000L models only 15 circuit breaker left outlet 10 circuit breaker right outlet Ground Terminal Connects generator to ground wire for grounding protec tion OEEC Set Tripped 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 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 22 engine is currently running electric start mod els 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 m
23. 5 MTBE by volume can ether be used NOTICE To avoid damage to the engine NEVER use stale or contam inated 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 or pinging can cause engine damage Warranty does not cover parts damaged by misuse 7 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual AIR FILTER MAINTENANCE 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 automo bile 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 viscosi ties 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 SAE 30 10W 30 Synthetic 5W 30 Temperature Range of
24. 556A 101865A 101865A 101865A 101865A 101865A 102555A 100833A 100833A 100833A 100833A 100833A 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 T See SPARK PLUG SERVICE page 7 5 for other recommended spark plug replacements zx 101536 101536A 101536A Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 3 1 BOLT AND FASTENER TORQUE INFORMATION 3 2 BOLT AND FASTENER TORQUE INFORMATION Component Specific Fastener Fastener Size Torque Values Nem Ib ft Alternator End Cover Bolts M5x0 75x 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 5 0 75 16 2 2 Carbon Canister Bracket Bolts M6 x 1 0 x 10 2 2 Connecting Rod Bolts 8 x 1 25 15 14 Control Panel Bolts M6 x 1 0 x 15 4 3 Cooling Fan Flange Nut M18 x 1 5 105 77 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 0x 14 4 3 Muffler Rear Mounting Bracket Bolts M8 x 1 0 x 16
25. Expected Use FIGURE 7 1 Recommended Oil Viscosity 0 NOTE 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 fail ure 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 dip stick Crankcase pressure can cause hot engine oil to spray out of engine fill hole Hot engine oil can cause severe burns 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 vent to clean air filter element Gasoline and flammable solvents can cause fire or explosion NEVER use gasoline or flammable sol Use only household soap and water to clean air filter element To clean air filter you will need Household soap and water Clean dry
26. F 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 Nem 7 Ib ft E FUEL TANK Before reassembly clean fuel tank to remove any sediment and drain com pletely E1 Model Numbers Ending in L HW3000L HW4000L HW5500L HW5500EL HW6200L HW7000EL HW7500EL E2 Non 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 Nem 17 Ib ft G FUEL SEDIMENT CUP See CLEANING FUEL SEDIMENT HW7500E Model Illustrated CUP page 7 5 H FUEL LINE Check for cracks or damag
27. Honeywell 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 a 1 1 WARRANTIES ea 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 SPEGIFIGAN ONS eem 3 1 BOLT AND FASTENER TORQUE INFORMATION usenuvvennnnnnnvnnnnvnnnnnnnnnnnnnnnnnennnnennnennnvennnvennennnnvnnnnennnveunner 3 2 WIRING DIAGRAMS 3 3 COMPONENTS bobo FO EX unos EDDIE NR KV ER E RU XV ODE ERU RE DR 4 1 PREPARINGFORSERVIGE cin DIDIT 5 1 REQUIRED TOOLS vr 5 1 TRANSPORTING GENERATOR uuu ass Hann ae anne ga nenn anne 5 1 SERVICE REPAIR TIME ANALYSIS amp FLAT RATE SCHEDULE 6 1 MAINTENANGE aan E
28. OMETER TO ADJUST VOLTAGE SLIP RING TERMINALS Brown Black view looking into female connector from alternator Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 8 9 ENGINE DIAGNOSTICS ALL MODELS 8 3 ENGINE DIAGNOSTICS ALL MODELS Engine Fails to Start 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 Reinstall Plug Dull Spark Pull Coil amp 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 Drain Oil and Check Low Oil Switch Connection and Continuity Yellow Wire on Side of Engine Check Flywheel Woodruff Key Repair or Replace Key Perform Engine Compression Test Engine Fails to Crank Using Electric Starter Check Recoil for Mechanical Binding 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 amp Tight Check Voltage Across Components are Within 5V of Battery Voltage Replace
29. 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 Speed Unstable Check Governor Frequency 60 Hz 3 Check Governor Assembly Adjustment Engine Starts Then Shuts Down 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 erform Engine Compression Test Engine Runs Rough Recoil Not Operating Recoil Locked Disassemble and Repair Recoil see Manual Section Recoil Starter M Check Recoil for Mechanical Binding Rope Not Retracting Disassemble and Repair Broken Ratchets or Springs see Manual Section Recoil Starter 8 10 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 9 SERVICE AND DISASSEMBLY 9 1 CONTROL PANEL A CONTROL PANEL ASSEMBLY FRONT 4 Nem 3 Ib ft B CONTROL PANEL ASSEMBLY BACK C MAIN CONTROL PANEL FRONT 125 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 T
30. 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 Sys tems Warranty Service Facility All shipping costs under this limited warranty are to be borne and prepaid by the buyer DISCLAIMERS LIMITATIONS OF REMEDIES amp 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 FULL EST EXTENT PERMITTED BY APPLICABLE LAW THIS LIMITED WARRANTY IS EXCLUSIVE AND EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES INCLUD ING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER IMPLIED WARRANTIES THAT MAY ARISE FROM 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 warran ties including but not limited to implied warranties of mer chantability or fitness for particular purpose are limited to the shortest duration permitted by applicable law or the lim
31. 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 amp Handle Assembly 9 11 Wiring Diagrams 3 3 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 10 1 Northshore Power Systems LLC 4425 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 II from Honeywell International Inc oneywe Honeywell International Inc makes no representation or warranties with respect to this product Manufactured exclusively for Northshore Power Systems
32. USSMJEQ uonoeuuoo 10 1 ay jeoiueuooeuu SI E 105 100100 ALON NS HOIVNHALIV FIGURE 3 5 HW6200 amp HW6200L Wiring Diagram 3 7 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual o lt HW7000EL HW7500E amp HW7500EL HW7000E TVNIINH3L 905 17 WZ ER Q Io nuoo Buniool USUM JOHLNOO HOLIMS 9 A 2 HOLIMS JOHLNOD My M 3NISN3 JAMIE 2 5 o19 OG TD 1 M ng ig voz m es Us OV JYNYIHL JYNHIHL 310d 3 TONIS 310d 3 TONIS 1 ve HOLOSLOHd OLNV VOE ov OILJNOVN T T N 310d SHUM M NOII A D A MOII8A u 19 67 SUM WD ng M I8 18 MMM YHOIWNYALTV HOIVNH3ITV 30018 gt HH NOLLINDI 1 eq e JE dd d oma HYAS O Ing 81 M lt a i dt en HIANSS M a Ll li
33. WHEEL LEG amp HANDLE ASSEMBLY 9 11 WHEEL LEG amp HANDLE ASSEMBLY HW3000 L MODELS A LOCKING HANDLE BRACKET 10 Nem 7 Ib ft B SPRING LOCKING HANDLE C RUBBER HANDLE GRIP D AXLE 25 Nem 18 Ib ft E SUPPORT LEG 25 Nem 18 Ib ft F RUBBER STOPPER 25 Nem 18 Ib ft G WHEEL Accessory kit is intended to be used specifically with this generator NEVER use accessory kit for any other purpose NEVER use accessory kit on road Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 9 11 WHEEL LEG amp HANDLE ASSEMBLY 9 12 WHEEL LEG amp HANDLE ASSEMBLY ALL MODELS EXCEPT HW3000 L A WHEEL HANDLE PIVOT BRACKET 10 Nem 7 Ib ft B PIN AND CHAIN C HANDLE BAR D RUBBER HANDLE GRIP E AXLE 25 Nem 18 Ib ft F SUPPORT LEGS 25 Nem 18 Ib ft NOTE On some models the leg support nuts are welded to the frame G RUBBER STOPPER 25 Nem 18 Ib ft H WHEEL Accessory kit is intended to be used specifically with this generator NEVER use accessory kit for any other purpose NEVER use accessory kit on road HW5500E Model Illustrated 9 12 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 10 INDEX A 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 Break
34. able Electrical Generator Service Manual 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 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 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 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 fly wheel When disassembling and assem bling 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 Nem 77 Ib 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
35. alents to 100842A Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 7 5 CLEANING SPARK ARRESTOR SCREEN 7 5 CLEANING SPARK ARRESTOR SCREEN Muffler reaches temperatures that can cause serious burns if touched NEVER touch hot surfaces The screen which must be cleaned according to the mainte nance schedule see Table 7 1 to ensure prevention of sparks escaping generator generator muffler is equipped with spark arrestor Using a screwdriver loosen and remove the spark arrestor clamp A screw To clean spark arrestor screen you will need FIGURE 7 15 Spark Arrestor Assembly 1 4 socket wrench Slide off spark arrestor clamp 8 mm socket Using a socket wrench with a 7 32 socket remove 7 32 socket the retaining screw on spark arrestor screen cap B 2 Phillips screwdriver ag ull out spark arrestor screen C Wire brush p Inspect spark arrestor screen 1 Stop the engine if it is running Allow to completely If screen is damaged or excessively worn replace cool with new screen 2 Place generator on a flat level surface a X Usi kot PAR kel If screen is in good condition clean using wire 3 sing a socket wrench with an 8 mm socket remove ameter reirietail the muffler cover bolts muffler cover not present on HW3000 or HW3000L models 4 Remove muffler cover FIGURE 7 16 Clean Screen
36. alified elec trician 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 Medical and Life Support Uses 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 seri ous 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 bat tery 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 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 fl
37. aterials from escaping generator 79 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 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 4 1 THIS PAGE INTENTIONALLY LEFT BLANK 4 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 5 PREPARING FOR SERVICE 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 prop erty damage 5 1 REQUIRED TOOLS 5 2 TRANSPORTING GENERATOR A complete set of standard and metric shop tools are required to service the generator Also needed are Hammer Hot engine exhaust system can cause serious Torque wrench burns or fires Cool generator completely before transporting Volt ohm meter Frequency meter e Resistive load such as a load bank heaters light When moving or transporting the generator bulbs etc Press the engine control switch to the STOP position Alternator removal tool Turn the fuel shut off valve to the OFF position
38. cloth Clean engine oil 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 1 FIGURE 7 3 Air Cleaner Cover Non L Models Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 7 3 AIR FILTER MAINTENANCE 3 Remove foam air filter s l 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 9C Reinstall the air cleaner cover 9B Reinstall the dark grey foam air filter FIGURE 7 5 Wash Air Filter 5 Rinse parts thoroughly with water FIGURE 7 9 Air Filter Installation Model Numbers Ending in L aur filter shape varies by model 6 Using aclean absorbent cloth squeeze air filter dry P en being careful not to twist or tear the filter For Non L Models 9 Reinstall the metal air filter plate in the support brackets if it fell out during air filter removal
39. com mended that the generator is started every three months If the generator is stored for more than year without run ning battery charger may be required to recharge the generator battery Recommended Battery Replacement 101536A XTAX14AHL BS 12N14 3A TABLE 7 6 Replacement Battery Equivalents to 101536A Xtreme Yuasa To replace battery 1 Remove spark plug cap gt Q FIGURE 7 19 Spark Plug Cap Removal 2 Loosen and remove nuts on retaining plate slide retaining plate off support rods 4 4 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 6 Remove the battery l NOTE Dispose of used battery according to guidelines estab lished by your local or state government 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 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 o 7 8 www honeywellgenerators com Honeywell Portable Electrical Generator Serv
40. diment cup C with soap and water Rinse parts thoroughly with water Wipe the pieces clean with clean dry cloth Reinstall the sediment cup o ring and fuel screen Turn the fuel shut off valve to the ON position o 99 No 0 Start generator and check for leaks 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 028 031 in 70 80 FIGURE 7 13 Correct Spark Plug Gap 2 If necessary adjust gap by carefully bending side electrode 3 Torque spark plug to 28 Nem 21 Ib ft The spark plug must be securely tightened 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 amp 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 Equiv
41. duration of any implied warran ties including but not limited to implied warranties of mer chantability or fitness for a particular purpose are limited to the shortest duration permitted by applicable law or the lim ited 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 NEGLI GENCE OR OTHER TORT OR ANY THEORY OF STRICT LIABILITY WITH RESPECT TO THE GENERATOR OR NORTHSHORE POWER SYSTEMS S ACTS OR OMIS SIONS OR OTHERWISE TO THE FULLEST EXTENT PER MITTED BY APPLICABLE LAW NORTHSHORE POWER SYSTEMS SHALL NOT IN ANY EVENT BE LIABLE FOR INCIDENTAL COMPENSATORY PUNITIVE CONSEQUEN TIAL 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 DAM AGE OR ECONOMIC LOSS EXCLUSIONS In addition to the foregoing disclaimers limi tations 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
42. e Secure with hose clamps 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 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 Nem 1 5 Ib ft E1 HW3000L Model Only E2 All Other Models x at 3 ul Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 9 5 MUFFLER 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 Nem 3 Ib ft NOTE Not present on HW3000 or HW3000L models C SPARK ARRESTOR Clamp 1 Nem 1 Ib ft Screen 1 Nem 1 Ib 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 Nem 13 Ib ft E EXHAUST PIPE 18 Nem 13 Ib ft 1 L Models
43. el 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 emis sions Some areas of the United States use oxygenated fuels to help meet clean air standards Before using an oxygenated fuel ensure pump octane rat ing is 87 or higher Some states and provinces in Canada require this infor mation to be posted on the fuel pump If you notice unde sirable operating symptoms switch to conventional unleaded gasoline Oxygenated fuels damage paint 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 Gasoline containing more than 10 ethanol by volume may cause starting or perfor mance problems Gasoline containing ethanol may be marketed under the name Gasohol Ethanol ethyl or grain alcohol Gasoline containing metha nol must contain co solvents and corrosion inhibitors to protect fuel system Gasoline Methanol methyl or wood containing more than 5 alcohol methanol by volume may cause starting and or perfor mance problems and may damage metal rubber and plastic parts of fuel system MTBE Gasoline containing up to methyl tertiary butyl 1
44. emoving rotor and stator remove brush assembly 2 1 5 Ib 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 Nem 35 Ib ft NOTICE Rotor can become damaged if not properly supported Place wooden block and rag underneath rotor for support 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 Alternator Illustrated Matches All Models Except HW3000 amp HW3000L Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 9 3 FUEL TANK SYSTEM 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 oper ation NEVER fill the fuel tank while the engine is running Turn the generator OF
45. ers 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 Oil Fill Dipstick 4 1 Oil Recommendations 7 3 Outlets 4 1 9 1 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 1 1 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 amp 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 Tools Service 5 1 Torque Information 3 2 Transporting Generator 5 1
46. esistances as Specified Below Resistance Range Specification Measure Resistance HW5500 L HW7000E L Winding Between Wires HW4000 L HW5500E L HW6200 L HW7500E L mes 0 5 0 7 0 25 0 45 0 2 0 35 0 15 0 25 Bue Bue 18 25 17 23 1 8 2 5 1 3 1 8 0 4 0 6 0 3 0 5 03 05 0 3 0 5 Slip Rings Rotor or 30 55 40 60 37 68 45 70 Slip Ring Terminals If Using an Ohmmeter with Kelvin Bridge Clips Measure Resistance at the Slip Ring Wire Terminals for Best Results 20 35 of Stator X Resistance If a Winding Resistance is Out of Spec Replace Alternator Check for Cross Shorted Windings in the Stator Assembly Check for Continuity Between Windings as Specified Below Between Windings Specification Stator Y White Either Fuel Cutout Brown Either Exciter Blue Either Fuel Cutout Brown If Continuity is Different than Specified Above Replace Alternator Refer to Illustrations on Page 8 9 8 8 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual ELECTRICAL DIAGNOSTICS ALL MODELS EXCEPT HW3000 L EXCITER amp AVR TAP CONNECTOR STATOR X WINDING BRUSH ASSEMBLY EXCITE WINDIN view looking into female connector from alternator L White STATOR Y Brown WINDING Blue 2 wires Red 2 wires White 2 wires Brown 2 wires FUEL CUTOUT WINDING CONNECTOR POTENTI
47. f 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 f 123 126 V 126V If Voltage Out of Range Perform 240V Circuit Check Check Voltage Output at NEMA 5 20R 120V Duplex Outlet 1 X 123 126V G If Voltage Out of Range Perform 120V Circuit Check Check Voltage Output at NEMA 5 20R 120V Duplex Outlet 2 n 123 126V G If Voltage Out of Range Perform 120V Circuit Check 240V Circuit Check No Output OR Voltage Out of Spec Conduct This Check Only When Directed by General Electrical Check Remove Alternator End Cover 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 Wire or Connection is Damaged Replace AVR Check Wires and Connections for the Exciter amp AVR Tap from AVR to Alternator On AVR Side of Connection If Connection is Loose or Disconnected Reestablish Tight Connection If a Wire or Connector is Damaged Replace AVR On Alternator Side of Connection If Connection is Loose or Disconnected Reestablish 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 P
48. hermal D MAIN CONTROL PANEL BACK E SWITCH PLATE FRONT e 1 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 Control panels vary between models POWER CONTROL CENTER START amp Lo ENGINE RUN Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 9 1 ENGINE AND ALTERNATOR 9 2 ENGINE AND ALTERNATOR A END COVER 4 Nem 3 Ib ft B ROTOR BOLT Use oil before replacing the rotor bolt C ALTERNATOR HOUSING BOLTS 48 Nem 35 Ib 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 35 Ib 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 amp HANDLE ASSEMBLY page 9 11 I CRANKCASE COVER 28 Nem 21 Ib ft 9 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual ALTERNATOR 9 3 ALTERNATOR A VOLTAGE REGULATOR B BRUSH ASSEMBLY Before r
49. ice Manual 8 TROUBLESHOOTING ANYONE using or servicing this generator must read understand and follow all safety and operation instructions pro vided in the product manual Failure to closely follow these instructions can result in circumstances leading to death serious injury and property damage DANGER Using generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is poison you cannot see or smell Fle NEVER use inside home Only use OUTSIDE and or garage EVEN IF doors far away from windows and windows are open doors and vents NOTE For all dealer service inquiries call 1 877 HWTECHS 498 3247 or visit www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 8 1 ELECTRICAL DIAGNOSTICS HW3000 L MODELS 8 1 ELECTRICAL DIAGNOSTICS HW3000 L MODELS 120V Circuit 1 Check 120V Circuit 42 Check No Output OR No Output OR General Electrical Check Voltage Out of Spec Conduct This Check Only When Directed by General Electrical Check Voltage Out of Spec Refer to Illustrations on Conduct This Check Only When Pages 8 3 and 8 5 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
50. in which you can be seri ously hurt or killed Always follow inspection and mainte nance recommendations and schedules in this manual The maintenance schedule applies to normal operating con ditions 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 Before ouch First month Every 3 Every 6 Every year or MAINTENANCE TASK or 20 hours of months or 50 months or 100 200 hours of use hours of use hours of use use Inspect for clean debris Check engine oil level X Change engine oil X x Check air filter x Clean air filter xt Run engine xt Clean change spark plug x Clean fuel sediment cup Clean spark arrestor x Clean cylinder cooling fins x Check adjust valve lash x Check fuel line Every 2 years replace if necessary TABLE 7 1 Generator Maintenance Schedule 1 Clean more often when using generator in dusty areas Perform at every indicated month or operating hour interval whichever comes first Itis 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
51. initions The limited warranty period begins on the date of retail purchase by the original pur chaser 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 amp 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 sup port devices life support appliances medical devices or medical appliances DISCLAIMER OF OTHER WARRANTIES TO THE FULL EST EXTENT PERMITTED BY APPLICABLE LAW THIS LIMITED WARRANTY IS EXCLUSIVE AND EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES INCLUD ING 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
52. ited 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 NEGLI GENCE OR OTHER TORT OR ANY THEORY OF STRICT LIABILITY WITH RESPECT TO THE GENERATOR OR NORTHSHORE POWER SYSTEMS S ACTS OR OMIS SIONS OR OTHERWISE TO THE FULLEST EXTENT PER MITTED BY APPLICABLE LAW NORTHSHORE POWER SYSTEMS SHALL NOT IN ANY EVENT BE LIABLE FOR INCIDENTAL COMPENSATORY PUNITIVE CONSEQUEN TIAL 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 DAM AGE OR ECONOMIC LOSS EXCLUSIONS In addition to the foregoing disclaimers limi tations 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 repair or modification by customer or any third party with out prior written consent of Northshore Power Systems vi use under operating conditions or in
53. ket on the Front to the Terminal on the Back If No Continuity Replace Duplex Receptacle If Continuity Present Replace Electrical Panel 8 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual ELECTRICAL DIAGNOSTICS HW3000 L MODELS See Specifications Page For Rated Power Voltage amp Frequency Specs Under Load and No Load Conditions POWER CONTROL Duplex Outlet 1 CENTER Duplex Outlet 2 NEMA 5 20R 120V NEMA 5 20R 120V HOUSEHOLD OUTLETS 120 VOLTS AC PORTABLE GENERATOR RATED WATTS 3750 MAXIMUM WATTS White Wire w Opel Black Wire X f Yellow Green Wire n Alternator Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 8 3 ELECTRICAL DIAGNOSTICS HW3000 L MODELS Rated Power Check Low Power Output NOTE At high altitudes standard carburetor air fuel mixture will be rich causing decrease in engine performance and an increase in fuel consumption NOTE At this time a high altitude carburetor kit is not available Start Engine and Add Resistive Loads Until One of the Following Occurs Power Output at the NEMA 5 20R 120V Duplex Outlet 1 is Within Rated Power Specification Range Frequency Drops Below 57 Hz Voltage Output Drops Below Minimum 126V If Minimum Rated Power Cannot Be Achieved see Engine Diagnostics Section Alternator Check NOTE The alternator must be
54. lud ing 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 war ranted 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 per formance 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 9 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 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 2 3 WARRANTIES NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY Honeywell Portable Generator For period of 90 days from the date of sale or installation of a Northshore
55. njury and property damage NOTE Since there are many variations in the circumstances 5 rounding the installation operation service and mainte nance of this generator we cannot possibly anticipate or provide advice or safety messages to cover every situa tion 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 signal word indicat ing the hazard level Indicates an imminently hazard ous situation which if not DANGER 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 Hazard Symbols and Meanings In addition to the signal words the following symbols may be used to draw your attention to specific types of haz Explosion Toxic fumes Fire y Chemical burn gt wae Electrical shock ADANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a
56. o 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 HW3000 HW400 HW5500E HW6200 HW7000E HW7500E HW3000L HWA4000L HWS5500EL HW6200L HW7000EL HW7500EL HW5500L POWER nite 2 3000 4000 5500 6200 7000 7500 3750 5000 6875 7750 8750 9375 Frequency hertz 60 5 under load 120 120 240 120 240 120 240 120 240 120 240 OPERATING TEMPERATURE Maximum F C 104 40 Minimum F 14 10 ENGINE Speed rpm 3600 Type OHV 4 cycle Displacement cc 196 242 337 389 420 420 IN 0 005 0 001 0 125 0 025 er 0 007 0 001 0 175 0 025 Fuel 87 or higher unleaded Fuel Tank Capacity gal L Non L Models Model Numbers Ending in L 3 2 12 6 5 24 6 6 5 24 6 6 5 24 6 6 1 23 6 5 24 6 4 2 16 6 5 24 6 6 5 24 6 6 5 24 6 6 6 25 6 5 24 6 Engine Oil SAE 10W 30 Engine Oil Capacity qt L 0 6 0 6 1 2 1 1 1 2 1 1 1 2 1 1 1 2 1 1 1 2 1 1 Spark Plug 10255741 100842At 100842 100842 100842 100842 Spark Plug Gap in mm 0 028 0 031 0 7 0 8 Air Filter Non L Models Model Numbers Ending in L 102
57. oose or Disconnected Reestablish a Tight Connection and Recheck Continuity If a Wire or Connection is Damaged Replace Electrical Panel 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 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 Perform Alternator Check Start Engine and Run at No Load 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 Remove Main Control Panel from Control Panel Assembly Check Continuity from Duplex Outlet 1 for Each Connection X or Y W G to Duplex Outlet 2 If Continuity Not Present in Any Circuit 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 Continuity If a Wire or Connection is Damaged Replace Electrical Panel 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 Soc
58. pair Service centers are always advised to provide feedback during the warranty claim process if additional time may be needed due to unforeseen circumstances 6 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 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 A DANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poi Son you cannot see or smell 2 Only use OUTSIDE NEVER use inside home garage EVEN IF doors far away from windows and windows are open doors and vents Shut off the engine before performing any maintenance If the engine must be run be sure the area is well venti lated NOTICE Maintenance replacement or repair of the emission control devices and systems may be performed by any non road engine repair establishment or individual Accidental starting of generator can cause severe injury or death Before performing maintenance disconnect spark plug cap from spark plug Also disconnect both starting bat tery 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
59. re 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 mainte nance You may be denied warranty coverage if a part has failed due to abuse neglect improper maintenance or unap proved 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 emis sions warranty service contact your nearest dealer a listing is available at www honeywellgenerators com or by calling 1 877 HWTECHS 498 3247 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
60. rease in engine performance and an increase in fuel consumption NOTE At this time a high altitude carburetor kit is not available Start Engine and Add Resistive Loads Until One of the Following Occurs Power Output at the NEMA L14 30R 240V Receptacle is Within Rated Power Specification Range Frequency Drops Below 57 Hz Voltage Output Drops Below If Minimum Rated Power Cannot Be Achieved see Engine Diagnostics Section Alternator Check NOTE The alternator must be at room temperature when resistance is measured NOTE The alternator diagnostics require measurements of low resistance values which are beyond the capability of a typical multi meter Use only for directional indication of resistance For best results use an ohmmeter capable of measuring low resistance values Resolution 10 millionms Accuracy 1 Check Brush Assembly for Excessive Wear or Defect NOTE Use Caution When Removing and Installing Brush Holder to Avoid Damaging Brushes If Length Less than 5 mm Replace Brush Assembly If Length Greater than 5 mm Verify Resistance Between Each Brush Tip and Corresponding Terminal is Less than 0 1 0 If Resistance Out of Spec Replace Brush Assembly Check Alternator Winding Resistances Disconnect the Exciter Connector Disconnect the Fuel Cutout Winding Connector Disconnect the Wires at the Alternator Terminal Block NOTE Each Terminal Contains Nut Lock Washer and Flat Washer Measure Winding R
61. resent in Any Circuit Check Wires and Connections from Receptacle to Alternator If Connection is Loose or Disconnected Reestablish a Tight Connection and Recheck Continuity If Wire or Connection is Damaged Replace Electrical Panel 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 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 Perform Alternator Check Start Engine and Run at No Load 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 Voltage Out of Spec Conduct This Check Only When Directed by General Electrical Check Remove Main Control Panel from Control Panel Assembly Check Continuity from the 120V Duplex Receptacle for Each Connection X or Y W 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 Check
62. uonoeuuoo 991515 puno16 eui Ad3LIV8 Ajjes ueyaau SI 1109 x 1 31ON J3NION3 YOLVNYSLIV L 4 HW5500E amp HW5500EL Wiring Diagram FIGURE 3 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 6 o lt lt A HW6200 amp HW6200L T7ANVd THNVd HOLIMS 440 NO TWNINHAL 5 HOE b L1 MOOT LSIML C s voc OV H3Mv3HYE OV TYWHIHL TYWNHIHL D A 1 NJ 1 M DI GIANT MUM D A NOII A H ueeio UB 67 9IIUM U6819 WS 4g ng yoelg I HOLIMS JOHLNOO 3NION3 u34v3ugov OLL3NDVN 5 fee eh J HOIVNH3ITV 32018 1 M pa pa ng Ina m 64 NOLLINDI L T m 1 D dH id I ooge o a 0 Orid ONIGNIM 6 gt lt MUVAS OVAOCL ONIGNIM LNOLND 13n4 HIANSS ONIGNIM ONIGNIM ids awed JojeuJe e pue pe NMOGLNHS 00 q y
63. urces 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 explana tion of the Emission Control Warranty In the United States and California new small off road engines must be designed built and equipped to meet strin gent anti smog standards Northshore Power Systems must warrant the emission control system on your 2010 small off road 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 Sys tems 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 a
64. ush the area with water 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 equip ment to live Inform your electrical provider immediately if loss of power would cause you or anyone in your household to experience medical emergency Fire and Burn Hazards Fuel and its vapors are extremely flammable and Generator Damage Hazards explosive under certain conditions NOTICE Improper treatment or misuse of generator can cause per Refuel generator only outdoors in a well ventilated manent damage 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 California Proposition 65 generator OFF and allow to cool before filling with fuel NEVER smoke or allow flames or sparks near the gen erator 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 A
65. void repeated or prolonged contact with skin or breathing of vapor Damage to generator caused by misuse or modifica tion is not covered under warranty The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 2 WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator LIMITED WARRANTY Northshore Power Systems LLG 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 defec tive in material or workmanship This limited warranty covers the cost of the replacement parts and labor for defects Trans portation charges are the responsibility of the customer This limited warranty has time period conditions operating condi tions and disclaimers limitations of remedies amp exclusions as stated below For warranty service customer should locate an authorized Honeywell Generator Dealer from www honey wellgenerators com or by calling 1 888 HWHELP1 494 3571 LIMITED WARRANTY PERIODS Consumer Use 3 Years Limited 1st year parts and labor 2nd amp 3rd years parts only Commercial Use 1 Year Limited No warranty for rental use Commencement and Def
66. vot and torque to 12 Nem 9 Ib 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 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 NOT GOVERNOR ARM SHAFT GOVERNOR ARM PINCH BOLT GOVERNOR SPRING LIMITING SCREW ANTI SURGE SPRING ha FIGURE 7 18 Governor Arm Assembly THROTTLE 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 7 9 BATTERY SERVICE To ensure the battery remains charged it is re
67. w Check for Continuity Continuity Between Windings Specification Stator X Black AVR Tap Brown Stator X Black Either Exciter Yellow If Continuity is Different than Specified Above Replace Alternator 8 4 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual ELECTRICAL DIAGNOSTICS HW3000 L MODELS BRUSH ASSEMBLY STATOR X WINDING White 2 wires Black 2 wires EXCITER amp AVR TAP CONNECTOR POTENTIOMETER TO ADJUST VOLTAGE SLIP RING TERMINALS 7 S view looking into female connector from alternator Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 8 5 ELECTRICAL DIAGNOSTICS ALL MODELS EXCEPT HW3000 L 8 2 ELECTRICAL DIAGNOSTICS ALL MODELS EXCEPT HW3000 L 120V Circuit Check 9 No Output OR General Electrical 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 i

Honeywell HW3000 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents