Main
Service Manual
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CONTENTS
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SAVE THESE INSTRUCTIONS
1: IMPORTANT SAFETY INSTRUCTIONS
NOTICE
1.1 SAFETY MESSAGES
Signal Words
SAFETY MESSAGES
Electric Shock Hazards
California Proposition 65
Fire and Burn Hazards
Medical and Life Support Uses
2: WARRANTIES
NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator
LIMITED WARRANTY
LIMITED WARRANTY PERIODS
DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS
2.1 WARRANTIES
WARRANTY STATEMENT
COVERAGE
OWNERS RESPONSIBILITIES
EMISSIONS CONTROL SYSTEMS PARTS
QUESTIONS
NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY Honeywell Portable Generator
DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS
NORTHSHORE POWER SYSTEMS PARTS LIMITED WARRANTY CLAIMS PROCEDURES
WARRANTY CLAIMS
3: SPECIFICATIONS AND WIRING DIAGRAMS
3.1 SPECIFICATIONS
BOLT AND FASTENER TORQUE INFORMATION
3.2 BOLT AND FASTENER TORQUE INFORMATION
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-3
3.3 WIRING DIAGRAMS
FIGURE 3-1: HW3000 & HW3000L Wiring Diagram
HW3000 & HW3000L
LEFT* RIGHT*
3-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
HW4000 & HW4000L
FIGURE 3-2: HW4000 & HW4000L Wiring Diagram
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-5
HW5500 & HW5500L
FIGURE 3-3: HW5500 & HW5500L Wiring Diagram
3-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
HW5500E & HW5500EL
FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram
Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-7
HW6200 & HW6200L
FIGURE 3-5: HW6200 & HW6200L Wiring Diagram
3-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
HW7000E, HW7000EL, HW7500E, & HW7500EL
LEFT* RIGHT*
FIGURE 3-6: HW7000E, HW7000EL, HW7500E & HW7500EL Wiring Diagram
4: COMPONENTS
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5: PREPARING FOR SERVICE
5.1 REQUIRED TOOLS
5.2 TRANSPORTING GENERATOR
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6: SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE
SERVICE REPAIR TIME ANALYSIS
6.1 SERVICE REPAIR TIME ANALYSIS
7: MAINTENANCE
7.1 CONSUMER MAINTENANCE SCHEDULE
MAINTENANCE TASK
200
CONSUMER MAINTENANCE SCHEDULE
FUEL RECOMMENDATIONS
General Fuel Information
Oxygenated Fuels
AIR FILTER MAINTENANCE
ENGINE OIL RECOMMENDATIONS
7.2 AIR FILTER MAINTENANCE
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CLEANING FUEL SEDIMENT CUP
7.3 CLEANING FUEL SEDIMENT CUP
7.4 SPARK PLUG SERVICE
CLEANING SPARK ARRESTOR SCREEN
7.5 CLEANING SPARK ARRESTOR SCREEN
VALVE LASH
7.6 VALVE LASH
7.7 GOVERNOR ADJUSTMENT
7.8
BATTERY SERVICE
7.9 BATTERY SERVICE
8: TROUBLESHOOTING
8-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
8.1 ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)
120V Circuit #1 Check (No Output OR Voltage Out of Spec)
120V Circuit #2 Check (No Output OR Voltage Out of Spec)
General Electrical Check
W G
To Alternator
8-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
Rated Power Check (Low Power Output)
Alternator Check
Refer to Illustrations on Page 8-5.
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8-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
8.2 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)
Y
X
246- 252V
X
Alternator
8-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
Rated Power Check (Low Power Output)
Alternator Check
Refer to Illustrations on Page 8-9.
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ENGINE DIAGNOSTICS (ALL MODELS)
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8.3 ENGINE DIAGNOSTICS (ALL MODELS)
Engine Fails to Crank Using Electric Starter
Engine Fails to Start
9: SERVICE AND DISASSEMBLY
9.1 CONTROL PANEL
4 Nm (3 lb. ft.)
NOTE: Not present on HW3000 or HW3000L models.
ENGINE AND ALTERNATOR
9.2 ENGINE AND ALTERNATOR
ALTERNATOR
9.3 ALTERNATOR
FUEL TANK SYSTEM
9.4 FUEL TANK SYSTEM
EVAPORATIVE EMISSIONS CONTROL SYSTEM
9.5 EVAPORATIVE EMISSIONS CONTROL SYSTEM
Secure with hose clamps.
2 Nm (1.5 lb. ft.)
MUFFLER
9.6 MUFFLER
CARBURETOR
9.7 CARBURETOR
STARTING SYSTEM
9.8 STARTING SYSTEM
RECOIL STARTER
9.9 RECOIL STARTER
FAN COVE R
9.10 FAN COVER
WHEEL, LEG, & HANDLE ASSEMBLY
9.11 WHEEL, LEG, & HANDLE ASSEMBLY (HW3000/L MODELS)
10 Nm (7 lb. ft.)
WHEEL, LEG, & HANDLE ASSEMBLY
9.12 WHEEL, LEG, & HANDLE ASSEMBLY (ALL MODELS EXCEPT HW3000/L)
10: INDEX