Portable Electrical Generator
Service Manual
HW3000/L
HW4000/L
HW5500/L
HW5500E/L
HW6200/L
HW7000E/L
HW7500E/L
Read and Save These Instructions
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CONTENTS
IMPORTANT SAFETY INSTRUCTIONS ....................................................................... 1-1
WARRANTIES ............................................................................................................... 2-1
NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY ............................................2-1
NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY ..........................................2-2
NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY .........................2-4
SPECIFICATIONS AND WIRING DIAGRAMS .............................................................. 3-1
SPECIFICATIONS ....................................................................................................................................3-1
BOLT AND FASTENER TORQUE INFORMATION .................................................................................3-2
WIRING DIAGRAMS ................................................................................................................................3-3
COMPONENTS .............................................................................................................. 4-1
PREPARING FOR SERVICE ......................................................................................... 5-1
REQUIRED TOOLS .................................................................................................................................5-1
TRANSPORTING GENERATOR .............................................................................................................5-1
SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE ............................... 6-1
MAINTENANCE ............................................................................................................. 7-1
CONSUMER MAINTENANCE SCHEDULE .............................................................................................7-1
AIR FILTER MAINTENANCE ...................................................................................................................7-3
CLEANING FUEL SEDIMENT CUP .........................................................................................................7-5
SPARK PLUG SERVICE ..........................................................................................................................7-5
CLEANING SPARK ARRESTOR SCREEN .............................................................................................7-6
VALVE LASH ...........................................................................................................................................7-7
GOVERNOR ADJUSTMENT ...................................................................................................................7-7
GOVERNOR RANGE ADJUSTMENT ......................................................................................................7-7
BATTERY SERVICE ................................................................................................................................7-8
TROUBLESHOOTING ................................................................................................... 8-1
ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) .............................................................................8-2
ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) ......................................................8-6
ENGINE DIAGNOSTICS (ALL MODELS) ..............................................................................................8-10
SERVICE AND DISASSEMBLY .................................................................................... 9-1
CONTROL PANEL ...................................................................................................................................9-1
ENGINE AND ALTERNATOR ..................................................................................................................9-2
ALTERNATOR .........................................................................................................................................9-3
FUEL TANK SYSTEM ..............................................................................................................................9-4
EVAPORATIVE EMISSIONS CONTROL SYSTEM .................................................................................9-5
MUFFLER .................................................................................................................................................9-6
CARBURETOR ........................................................................................................................................9-7
STARTING SYSTEM ................................................................................................................................9-8
RECOIL STARTER ..................................................................................................................................9-9
FAN COVER ...........................................................................................................................................9-10
WHEEL, LEG, & HANDLE ASSEMBLY (HW3000/L MODELS) .............................................................9-11
WHEEL, LEG, & HANDLE ASSEMBLY (ALL MODELS EXCEPT HW3000/L) ......................................9-12
INDEX .......................................................................................................................... 10-1
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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 injury, and property damage.
Hazard Symbols and Meanings
NOTE:
Since there are many variations in the circumstances sur-
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.
In addition to the signal words, the following symbols may
be used to draw your attention to specific types of haz-
ards.
1.1 SAFETY MESSAGES
Fire
Toxic fumes
Explosion
Signal Words
Safety messages are provided throughout this manual to
help prevent personal injury and equipment damage. All
safety messages are introduced by a signal word indicat-
ing the hazard level.
Chemical burn
Hot surface
Electrical shock
Indicates an imminently hazard-
ous situation which, if not
avoided, will result in death or
DANGER
serious injury to the operator or to
bystanders.
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
WARNING
injury to the operator or to
bystanders.
Indicates a potentially hazardous
situation which, if not avoided,
Only use OUTSIDE and
far away from windows,
doors, and vents.
NEVER use inside a home
or garage, EVEN IF doors
and windows are open.
may result in moderate or minor
CAUTION
injury to the operator or to
bystanders.
Indicates a situation which, if not
SAFETY PRECAUTIONS
avoided, may result in damage to
NOTICE
the generator components.
• Wear appropriate protective safety equipment, such as
safety shoes and safety glasses.
• Comply 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.
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SAFETY MESSAGES
Electric Shock Hazards
The muffler becomes very hot during operation and
remains hot for a while after stopping the engine.
Generators produce powerful voltage that can cause
• NEVER touch hot surfaces and avoid hot gases.
• Let engine cool before storing the generator indoors.
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 qualified elec-
trician.
Battery gases are explosive.
• 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.
• NEVER allow open flames, lit cigarettes, sparks, or
spark-producing equipment near the battery.
Battery electrolyte fluid is comprised of sulfuric acid,
which can be very dangerous and cause severe
burns.
• NEVER allow battery fluid to contact eyes, skin, or
clothing. If contact or spillage occurs, immediately flush
the area with water.
• Exposed terminals, even on disconnected batteries,
can cause electric shock.
• NEVER touch both battery terminals with bare hands
at the same time.
Medical and Life Support Uses
• 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.
• 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 a loss of
power would cause you or anyone in your household to
experience a medical emergency.
• NEVER lay tools or other metal objects on top of bat-
tery.
Fire and Burn Hazards
Generator Damage Hazards
Fuel and its vapors are extremely flammable and
explosive under certain conditions.
NOTICE
Improper treatment or misuse of generator can cause per-
manent damage.
• Refuel generator only outdoors, in a well-ventilated
area.
• NEVER enclose the generator in any structure.
• Keep generator at least 6 feet (2 meters) away from
buildings, other equipment, and combustible materials
during operation.
• NEVER fill fuel tank while the engine is running. Turn
generator OFF and allow to cool before filling with fuel.
• NEVER smoke or allow flames or sparks near the gen-
erator or where gasoline is stored.
• Damage to generator caused by misuse or modifica-
tion is not covered under warranty.
California Proposition 65
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.
• NEVER overfill the fuel tank (there should be no fuel in
the filler neck). After refueling, tighten the fuel cap
securely.
• Be careful not to spill fuel when refueling. Spilled fuel
or fuel vapor may ignite. If any fuel is spilled, the area
must be dry before starting the engine.
• Avoid repeated or prolonged contact with skin or
breathing of vapor.
1-2
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2: WARRANTIES
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.
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 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 & exclusions as
stated below. For warranty service, customer should locate
wellgenerators.com or by calling 1-888-HWHELP1 (494-
3571).
LIMITED WARRANTY PERIODS
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; (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.
Consumer Use: 3 Years Limited. 1st year, parts and labor.
2nd & 3rd years, parts only.
Commercial Use: 1 Year Limited. No warranty for rental use.
Commencement and Definitions.The limited warranty period
begins on the date of retail purchase by the original 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.
REGISTRATION
DISCLAIMERS, LIMITATIONS OF REMEDIES &
EXCLUSIONS
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
Warranty registration with the Company is required on all
products. You may send in the enclosed Product Registration,
tors.com.
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.
Warranty is also available by keeping and showing your origi-
nal receipt from date of purchase to an authorized Honeywell
Generator Dealer.
GENERATOR SERVICE
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 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.
Do not return your generator to place of purchase for service.
For all customer service inquiries, call 1-888-HWHELP1
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
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WARRANTIES
EMISSIONS CONTROL SYSTEMS PARTS
Coverage under this warranty extends only to the emissions
control parts listed below.
NORTHSHORE POWER SYSTEMS
EMISSIONS CONTROL WARRANTY
Honeywell Portable Generator
1. Fuel Metering System
A. Carburetor gaskets
WARRANTY STATEMENT
The U.S. Environmental Protection Agency (EPA) and Califor-
nia Air Resources Board (CARB) require manufacturers of
small off-road engines (SORE) to warranty their products with
a 2-year warranty for those components that are specified as
being part of the emission control system. Northshore Power
Systems, LLC, CARB, and EPA offer the following explana-
tion of the Emission Control Warranty.
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)
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.
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
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.
A. Catalytic converter (if equipped)
B. Exhaust manifold
C. Muffler gasket
5. Crankcase Breather Assembly
A. Breather connection tube
6. Air Injection System
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
A. Pulse valve
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.
7. Fuel Tank Evaporative Emissions Control System
A. Carbon canister and mounting brackets
B. Fuel cap
C. Fuel tank
OWNER’S RESPONSIBILITIES
D. Purge valves
You are responsible to maintain the engine as defined in your
Honeywell Generator Owner's Manual. Northshore Power
Systems recommends that you retain all records/receipts
covering maintenance on your engine, but Northshore Power
Systems cannot deny warranty claims based on the lack of
receipts or for your failure to perform all scheduled mainte-
nance. You may be denied warranty coverage if a part has
failed due to abuse, neglect, improper maintenance or unap-
proved modifications.
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.
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
1-877-HWTECHS (498-3247).
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.
2.1 WARRANTIES
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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, includ-
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: [email protected]
By US mail:
Northshore Power Systems, LLC
Attention: Service and Warranty Dept.
4425 N. Port Washington Road
Suite 105
Milwaukee, WI 53212-1082
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WARRANTIES
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;
(v) 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 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
REPLACEMENT PARTS LIMITED WARRANTY
Honeywell Portable Generator
For a period of 90 days from the date of sale or installation of
a Northshore Power Systems, LLC supplied part, Northshore
Power Systems will, at its option and sole discretion, repair or
replace the part if it is found to be defective in material or
workmanship after inspection by Northshore Power Systems.
Any parts which the buyer claims to be defective must be
examined by the nearest Authorized Northshore Power Sys-
tems Warranty Service Facility. All shipping costs under this
limited warranty are to be borne and prepaid by the buyer.
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:
DISCLAIMERS, LIMITATIONS OF REMEDIES &
EXCLUSIONS
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
DISCLAIMER OF OTHER WARRANTIES. TO THE 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 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.
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 a
copy of the original proof-of-purchase (for the part) to the
Warranty Claim Form.
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.
WARRANTY CLAIMS
For all customer service inquiries, call 1-877-HWTECHS
Warranty claim forms and inquiries can be addressed to:
Northshore Power Systems, LLC
Attention: Service and Warranty Dept.
4425 N. Port Washington Road
Suite 105
Milwaukee, WI 53212-1082
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3: SPECIFICATIONS AND WIRING DIAGRAMS
3.1 SPECIFICATIONS
HW5500
HW3000
HW4000
HW5500E
HW5500EL
HW5500L
HW6200
HW7000E
HW7500E
GENERATOR
HW3000L
HW4000L
HW6200L
HW7000EL HW7500EL
POWER
Rated [watts]
(+/-10% under load)
3000
3750
4000
5000
5500
6875
6200
7750
7000
8750
7500
9375
Maximum [watts]
(+/-10% under load)
Frequency [hertz]
(+/-5% under load)
60
Voltage [volts]
(+/-5% under load)
120
120 / 240
120 / 240
120 / 240
120 / 240
120 / 240
OPERATING TEMPERATURE
Maximum [F / C]
Minimum [F / C]
ENGINE
104ꢀ / 40ꢀ
14ꢀ / -10ꢀ
Speed [rpm]
3600
Type
OHV 4-cycle
Displacement [cc]
196
242
337
389
420
420
IN: 0.005 0.001 / 0.125 0.025
EX: 0.007 0.001 / 0.175 0.025
Valve Lash [in /mm]
Fuel
87 or higher unleaded
Fuel Tank Capacity [gal / L]
(Non-L Models)
4.2 / 16
3.2 / 12
6.5 / 24.6
6.5 / 24.6
6.5 / 24.6
6.5 / 24.6
6.5 / 24.6
6.5 / 24.6
6.6 / 25
6.1 / 23
6.5 / 24.6
6.5 / 24.6
(Model Numbers Ending in “L”)
Engine Oil
SAE 10W-30*
Engine Oil Capacity [qt / L]
Spark Plug
0.6 / 0.6
1.2 / 1.1
1.2 / 1.1
1.2 / 1.1
1.2 / 1.1
1.2 / 1.1
102557A
100842A†
100842A†
100842A†
100842A†
100842A†
†
Spark Plug Gap [in /mm]
0.028-0.031 / 0.7-0.8
Air Filter
(Non-L Models)
102555A
102556A
--
100833A
101865A
--
100833A
101865A
101536A
100833A
101865A
--
100833A
101865A
101536A
100833A
101865A
101536A
(Model Numbers Ending in “L”)
Battery
(Electric Start Models Only)
TABLE 3-1: Honeywell Portable Generator Specifications
*
See ENGINE OIL RECOMMENDATIONS, page 7-3 for other engine oil types outside general temperature use.
† See SPARK PLUG SERVICE, page 7-5 for other recommended spark plug replacements.
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BOLT AND FASTENER TORQUE INFORMATION
3.2 BOLT AND FASTENER TORQUE INFORMATION
Torque Values
lb. ft.
Component-Specific Fastener
Fastener Size
N•m
4
Alternator End Cover Bolts
Alternator Housing Bolts
Axle Bracket Bolts
M5 x 0.75 x 12
M10 x 1.25 x 80
M8 x 1.0 x 16
M5 x 0.75 x 16
M6 x 1.0 x 10
M8 x 1.25
3
35
18
2
48
25
2
Brush Assembly Bolt
Carbon Canister Bracket Bolts
Connecting Rod Bolts
Control Panel Bolts
2
2
15
4
11
3
M6 x 1.0 x 15
M18 x 1.5
Cooling Fan Flange Nut
Crankcase Cover Bolts
Cylinder Head Bolts
105
28
48
18
24
10
10
4
77
21
35
13
17
7
M8 x 1.25 x 40
M10 x 1.25 x 80
M8 x 32
Exhaust Pipe Bolts
Fuel Shut-off Valve Hex Fitting
Fuel Tank Mounting Bolts
Ignition Coil Bolts
M10 x 1.25
M6 x 1.0 x 25
M6 x 1.0 x 25
M6 x 1.0 x 14
M8 x 1.0 x 16
M6 x 1.0 x 14
M12 x 1.5
7
Muffler Cover Bolts
3
Muffler Rear Mounting Bracket Bolts
Muffler Side Guard Bolts
Oil Drain Screw
18
4
13
3
32
12
30
48
1
24
9
Pivot Adjusting Nuts
M6 x 0.75
Pivot Bolts
M8 x 1.25
22
35
1
Rotor Bolt
--
Spark Arrestor Clamp Screw
Spark Arrestor Screw
Spark Plug
M4 x 0.75 x 16
M3.5 x 0.75 x 10
13/16”
1
1
28
6
21
4
Starter Solenoid Terminal Nut
Support Leg to Frame Bolts
Support Leg to Rubber Stopper Bolts
M6 x 1.0
M8 x 1.0 x 16
M8 x 1.0 x 25
M6 x 1.0 x 40
25
25
10
18
18
7
Wheel Handle Pivot Bracket Bolts
TABLE 3-3: Torque Values
3-2
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WIRING DIAGRAMS
3.3 WIRING DIAGRAMS
HW3000 & HW3000L
FIGURE 3-1: HW3000 & HW3000L Wiring Diagram
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WIRING DIAGRAMS
HW4000 & HW4000L
FIGURE 3-2: HW4000 & HW4000L Wiring Diagram
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WIRING DIAGRAMS
HW5500 & HW5500L
FIGURE 3-3: HW5500 & HW5500L Wiring Diagram
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WIRING DIAGRAMS
HW5500E & HW5500EL
FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram
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WIRING DIAGRAMS
HW6200 & HW6200L
FIGURE 3-5: HW6200 & HW6200L Wiring Diagram
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WIRING DIAGRAMS
HW7000E, HW7000EL, HW7500E, & HW7500EL
FIGURE 3-6: HW7000E, HW7000EL, HW7500E & HW7500EL Wiring Diagram
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4: COMPONENTS
K
J
L
A
E
M
I
B
H
N
F
C
G
D
FIGURE 4-1: Honeywell Portable Electrical Generator Controls and Components (HW5500EL Model Illustrated)
A—Power Control Center
Electrical Outlets
E—Engine Control Switch
Control used to start and stop the engine ignition system.
•
•
START—Starts generator engine (electric start models)
•
125VAC 20 Amp Duplex (NEMA 5-20R) outlets to connect
120V appliances to generator for power.
RUN—Prepares engine to start (manual start models);
Indicates engine is currently running (electric start mod-
els)
•
125/250VAC 30 Amp Twist-Lock (NEMA L14-30R) outlet
(on select models) can be used to power appliances
using appropriate (NEMA L14-30P) power cord (with
select models) or connect a transfer switch (not
included) to a building’s main electrical system for
backup power.
•
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.
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.
H—Air Cleaner Assembly
Removes dust from engine intake air.
Set
Tripped
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.
HW3000 / HW3000L models only:
•
15-amp circuit breaker (left outlet)
10-amp circuit breaker (right outlet)
K—Fuel Gage
Indicates level of fuel currently in fuel tank.
•
Ground Terminal
L—Muffler Equipped with Spark Arrestor
Provides outlet for engine exhaust. Prevents sparks and
other combustible materials from escaping generator.
Connects generator to ground wire for grounding protec-
tion.
Generator must be grounded to prevent electrical
shock from faulty appliances.
Muffler reaches temperatures that can cause serious
burns if touched. NEVER touch hot surfaces.
M—Spark Plug Cap (Wire)
B—Battery Tray and Battery (Electric start models only)
Delivers voltage to spark plug. When spark plug needs
service, cap must be removed.
Provides power for electric start feature.
C—Oil Fill Dipstick
Seals off engine oil fill hole and provides indicator for
engine oil level.
N—Carbon Canister (Model numbers ending in “L” only)
Reduces hydrocarbon emissions.
D—Oil Drain Screw
Allows engine oil to drain from generator.
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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 or exhaust system can cause serious
burns or fires. Cool generator completely before
transporting.
Torque wrench
Volt-ohm meter
Frequency meter
When moving or transporting the generator:
Resistive load - such as a load bank, heaters, light
bulbs, etc.
•
•
•
•
Press the engine control switch to the STOP position.
Turn the fuel shut-off valve to the OFF position.
Keep the generator level to prevent fuel spillage.
•
•
Alternator removal tool
Wood block (for rotor support)
Place pins in the handle and handle bracket before
moving the generator.
NOTICE
NEVER drop, strike, or place heavy objects on generator
when transporting.
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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.)
Operation
ELECTRICAL
Alternator Complete
Battery
120
--
120
--
120
--
120
30
45
45
60
50
45
40
40
50
30
30
45
35
30
120
--
120
30
45
45
60
50
45
40
40
50
30
30
45
35
30
120
30
45
45
60
50
45
40
40
50
30
30
45
35
30
Brush Assembly
45
45
60
50
45
40
40
50
30
30
--
45
45
60
50
45
40
40
50
30
30
--
45
45
60
50
45
40
40
50
30
30
--
45
45
60
50
45
40
40
50
30
30
--
Charging Coil Assembly
Control Panel Assembly
Ignition Coil
Meters / Circuit Breakers
Oil Shutdown Switch
Oil Alert Sender
Receptacles / Ports
Recoil Starter Assembly
Spark Plug
Electric Starter
Starter Solenoid
--
--
--
--
Voltage Regulator
30
30
30
30
ENGINE
Air Filter
Air Cleaner
Carburetor
Choke
30
40
50
45
30
40
50
45
30
40
50
45
30
40
50
45
30
40
50
45
30
40
50
45
30
40
50
45
Converter
(Model Numbers Ending in “L”)
60
60
60
60
60
60
60
Cylinder Head Cover
Cylinder Head Gasket
Engine Complete
45
40
45
40
45
40
45
40
45
40
45
40
45
40
180
50
180
50
180
50
180
50
210
50
210
50
210
50
Governor Assembly
Head Cover Gasket
FUEL & EXHAUST
40
40
40
40
40
40
40
Carbon Canister (with bracket)
(Model Numbers Ending in “L”)
45
30
45
30
45
30
45
30
45
30
45
30
45
30
Carbon Canister Tube
(Model Numbers Ending in “L”)
Exhaust Pipe
(Model Numbers Ending in “L”)
40
30
40
30
40
30
40
30
40
30
40
30
40
30
Fuel Gage
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SERVICE REPAIR TIME ANALYSIS
HW3000
HW3000L
(min.)
HW4000
HW4000L
(min.)
HW5500
HW5500L
(min.)
HW5500E
HW5500EL
(min.)
HW6200
HW6200L
(min.)
HW7000E
HW7000EL
(min.)
HW7500E
HW7500EL
(min.)
Operation
Vapor Line
30
30
30
30
30
30
30
(Model Numbers Ending in “L”)
Fuel Tank
60
40
50
50
60
40
50
50
60
40
50
50
60
40
50
50
60
40
60
60
60
40
60
60
60
40
60
60
Fuel Shut-off Valve
Muffler
Muffler Gasket
Secondary Air Intake Valve
(with gasket)
50
50
50
50
50
50
50
(Model Numbers Ending in “L”)
MISC
Frame
120
120
120
120
120
120
120
(Model Numbers Ending in “L”)
(Non-L Models)
Handle Assembly
Leg Assembly
90
30
30
30
90
30
30
30
90
30
30
30
90
30
30
30
90
30
30
30
90
30
30
30
90
30
30
30
Wheel Assembly
NOTE:
Repair times represent generally accepted intervals for conducting a repair. Service centers are always advised to
provide feedback during the warranty claim process if additional time may be needed due to unforeseen circumstances.
6.1 SERVICE REPAIR TIME ANALYSIS
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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).
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a poi-
son you cannot see or smell.
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 in which you can be seri-
ously hurt or killed. Always follow inspection and mainte-
nance recommendations and schedules in this manual.
Only use OUTSIDE and
far away from windows,
doors, and vents.
NEVER use inside a home
or garage, EVEN IF doors
and windows are open.
• Shut off the engine before performing any maintenance.
If the engine must be run, be sure the area is well venti-
lated.
NOTICE
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.
NOTICE
Maintenance, replacement, or repair of the emission
control devices and systems may be performed by any
non-road engine repair establishment or individual.
*
FREQUENCY
Every year or
200 hours of
use
First month
or 20 hours of
use
Every 3
months or 50
hours of use
Every 6
months or 100
hours of use
Before each
use
MAINTENANCE TASK
Inspect for/clean debris
Check engine oil level
Change engine oil
Check air filter
X
X
X
X
X
†
Clean air filter
X
‡
Run engine
X
Clean/change spark plug
Clean fuel sediment cup
Clean spark arrestor
Clean cylinder cooling fins
X
X
X
**
X
**
Check/adjust valve lash
Check fuel line
X
**
Every 2 years (replace if necessary)
TABLE 7-1. Generator Maintenance Schedule
*
Perform at every indicated month or operating hour interval, whichever comes first.
Clean more often when using generator in dusty areas.
†
‡
It is recommended that the generator is run for 15-30 minutes every three months to ensure the battery remains charged.
If the generator is stored for more than a year without running, a battery charger may required to recharge the generator battery.
** It is recommended that this maintenance task be performed by a service dealer.
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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
NOTICE
OVERFILL.
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.
Gasoline containing more
than 10% ethanol by volume
may cause starting or perfor-
Ethanol
mance problems. Gasoline
(ethyl or grain alcohol)
• Refuel generator only outdoors, in a 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.
containing ethanol may be
marketed under the name
"Gasohol".
Gasoline containing metha-
nol must contain co-solvents
and corrosion inhibitors to
protect fuel system. Gasoline
Methanol
containing more than 5%
(methyl or wood
methanol by volume may
alcohol)
cause starting and/or perfor-
mance problems and may
damage metal, rubber and
plastic parts of fuel system.
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.
MTBE
(methyl tertiary butyl
ether)
Gasoline containing up to
15% MTBE by volume can
be used.
NEVER use stale or contaminated gasoline. Avoid getting
dirt or water in the fuel tank. Always keep the fuel strainer
in place while refueling.
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.
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.
Use fresh gasoline with a pump octane rating of 87 or
higher.
NOTICE
Running the engine with persistent spark knock or pinging
can cause engine damage. Warranty does not cover parts
damaged by misuse.
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 a conventional
unleaded gasoline.
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AIR FILTER MAINTENANCE
ENGINE OIL RECOMMENDATIONS
7.2 AIR FILTER MAINTENANCE
NOTICE
NOTICE
Engine oil is a major factor affecting engine performance
and service life. NEVER use non-detergent or 2-stroke
engine oils.
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.
• Use engine oils specified below.
It is very important to maintain proper level of engine oil to
keep engine in good running condition.
Clean air filter every 50 hours of generator operation. If
operating generator in extremely dusty areas, clean air fil-
ter more frequently.
• 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.
Gasoline and flammable solvents can cause fire or
explosion. NEVER use gasoline or flammable sol-
vent to clean air filter element.
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.
• Use only household soap and water to clean air filter
element.
To clean air filter, you will need:
% Household soap and water
% Clean, dry cloth
SAE 30, 10W-30
Synthetic 5W-30
% Clean engine oil
5W-30
1. Stop engine if it is running.
2. Remove air cleaner cover.
For Model Numbers Ending in “L”:
FIGURE 7-1: Recommended Oil Viscosity
•
Unlock the latches at the top and bottom of the air cleaner
cover.
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.
FIGURE 7-2: Air Cleaner Cover—Model Numbers Ending in “L”
For Non-L Models:
•
•
Turn thumbscrew counterclock wise to loosen and
remove.
When engine shuts down due to low oil level:
1. The engine control switch will remain in the RUN posi-
Pull bottom of air cleaner cover out and lift up to release
plastic tabs.
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.
FIGURE 7-3: Air Cleaner Cover—Non-L Models
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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
9B. Reinstall the dark grey foam air filter.
9C. Reinstall the air cleaner cover.
4. Wash air filter(s) in a solution of household soap and
warm water.
FIGURE 7-5: Wash Air Filter
5. Rinse parts thoroughly with water.
FIGURE 7-9: Air Filter Installation—Model Numbers Ending in “L”
(filter shape varies by model)
6. Using a clean, absorbent cloth, squeeze air filter dry,
For Non-L Models:
being careful not to twist or tear the filter.
9A. Reinstall the metal air filter plate in the support
brackets if it fell out during air filter removal.
FIGURE 7-6: Dry Air Filter
7. Coat the air filter with clean engine oil.
FIGURE 7-10: Air Filter Plate Installation—Non-L Models
(air filter plate shape varies by model)
9B. Reinstall air filter.
9C. Reinstall the air cleaner cover.
FIGURE 7-7: Oil Air Filter
8. Squeeze out excess oil.
FIGURE 7-8: Excess Oil Removal
Frequent or prolonged contact with engine oil may cause
skin cancer.
• Thoroughly wash hands and any areas of skin exposed
to used oil with soap and water.
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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.
If the engine has been running, the spark plug will
reach temperatures that could cause severe burns.
Do not touch.
To clean fuel sediment cup, you will need:
% 10 mm box wrench
% 22 mm open end wrench
% Household soap and water
% Clean, dry cloth
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 mm)
To clean fuel sediment cup:
1. Stop the engine if it is running. Allow to completely
cool.
2. Place generator on a flat, level surface.
3. Turn the fuel shut-off valve to the OFF position.
FIGURE 7-13: Correct Spark Plug Gap
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 a 10 mm box wrench.
2. If necessary, adjust gap by carefully bending side
electrode.
3. Torque spark plug to 28 N•m (21 lb. ft.).
NOTICE
The spark plug must be securely tightened. An improperly
tightened spark plug can become very hot and damage the
engine. NEVER use spark plugs that have an improper heat
range. Use only recommended spark plugs or equivalent.
HW3000 & HW3000L Models:
FIGURE 7-11: Fuel Sediment Cup Assembly Removal
Recommended Spark Plug Replacement: 102557A
A
AutoLite
Bosch
62
WR5DC
B
Champion RN6YC
Denso
NGK
W22EPR-U
BPR7ES
C
TABLE 7-3. Spark Plug Equivalents to 102557A
FIGURE 7-12: Fuel Sediment Cup Assembly
All Other Models:
Recommended Spark Plug Replacement: 100842A
5. Clean the fuel screen (A), o-ring (B), and sediment
cup (C), with soap and water.
6. Rinse parts thoroughly with water.
AutoLite
Bosch
63
7. Wipe the pieces clean with a clean, dry cloth.
8. Reinstall the sediment cup, o-ring, and fuel screen.
9. Turn the fuel shut-off valve to the ON position.
WR7DC
Champion RN9YC
Denso
NGK
W20EPR
BPR6ES
10. Start generator and check for leaks.
TABLE 7-4. Spark Plug Equivalents to 100842A
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CLEANING SPARK ARRESTOR SCREEN
5. Using a screwdriver, loosen and remove the spark
7.5 CLEANING SPARK ARRESTOR
SCREEN
arrestor clamp (A) screw.
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 mainte-
nance schedule (see Table 7-1) to ensure prevention of
sparks escaping generator.
B
FIGURE 7-15: Spark Arrestor Assembly
6. Slide off spark arrestor clamp.
To clean spark arrestor screen, you will need:
% 1/4” socket wrench
% 8 mm socket
7. Using a socket wrench with a 7/32” socket, remove
the retaining screw on spark arrestor screen cap (B);
pull off cap.
% 7/32” socket
% #2 Phillips screwdriver
% Wire brush
8. Pull out spark arrestor screen (C).
9. 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.
If screen is in good condition, clean using wire
3. Using a socket wrench with an 8 mm socket, remove
the muffler cover bolts (muffler cover not present on
HW3000 or HW3000L models).
brush and then reinstall.
4. Remove muffler cover.
FIGURE 7-16: Clean Screen
10. Reinstall remaining spark arrestor components.
Spark arrestor screen cap and screw
Clamp and screw
Muffler cover
FIGURE 7-14: Remove Muffler Cover
7-6
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VALVE LASH
7.6 VALVE LASH
7.7 GOVERNOR ADJUSTMENT
1. Start the engine and run with no load.
2. Attach a frequency meter and adjust the limiting
Valve lash inspection and adjustment must be performed
with the engine cold.
screw on the governor stop to 62.5 Hz 0.5.
3. Stop the engine.
1. Remove the cylinder head cover and carefully remove
the gasket for re-use. (Inspect and replace gasket, if
necessary.)
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
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.
7.8 GOVERNOR RANGE ADJUSTMENT
1. Remove the generator control panel for access.
4. Insert a feeler gauge between the rocker arm and
valve spring to measure valve lash.
2. Loosen the nut on the governor arm pinch bolt (see
illustration).
NUT
GOVERNOR ARM SHAFT
GOVERNOR ARM
PINCH BOLT
LOCK NUT
GOVERNOR
SPRING
GOVERNOR ARM
FIGURE 7-17: Lock Nut Location
LIMITING
SCREW
0.005 0.001 in
IN.
(0.125 0.025 mm)
Standard valve lash
ANTI-SURGE SPRING
0.007 0.001 in
EX.
(0.175 0.025 mm)
THROTTLE
TABLE 7-5. Standard Valve Lash
FIGURE 7-18: Governor Arm Assembly
A—ROCKER ARM
B—LOCK NUT
12 N•m (9 lb. ft.)
A
3. Rotate the governor arm shaft counter-clockwise until
the throttle is completely open and hold in position.
B
4. Tighten the nut on the governor arm pinch bolt to
• To increase valve lash,
maintain position.
screw pivot nut out.
5. Confirm the governor arm and throttle move smoothly
• To decrease valve lash,
and do not bind.
screw pivot nut in.
6. Reinstall the generator control panel.
C—PIVOT BOLT
30 N•m (22 lb. ft.)
C
5. Hold the rocker arm pivot and loosen the lock nut (see
B in illustration).
6. Turn the rocker arm pivot (see C in illustration) to
obtain specified valve lash.
7. Retighten the lock nut while holding rocker arm pivot
and torque to 12 N•m (9 lb. ft.).
8. Check valve lash again after tightening lock nut.
9. Repeat steps 4 through 7, as needed, until valve lash
is within specifications.
10. Reassemble the spark plug, cylinder head cover, and
gasket.
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BATTERY SERVICE
6. Remove the battery.
7.9 BATTERY SERVICE
NOTE:
To ensure the battery remains charged, it is recom-
mended that the generator is started every three months.
If the generator is stored for more than a year without run-
ning, a battery charger may be required to recharge the
generator battery.
Dispose of used battery according to guidelines estab-
lished by your local or state government.
7. Place the new battery in the generator frame.
8. Connect the red positive (+) battery lead to the posi-
Recommended Battery Replacement: 101536A
tive (+) post on the battery; install bolt, nut, and boot.
Xtreme
Yuasa
XTAX14AHL-BS
12N14-3A
9. Connect the black negative (-) battery lead to the neg-
ative (-) post on the battery; install bolt, nut, and boot.
10. Reinstall retaining plate; tighten bolts and nuts.
11. Reinstall spark plug cap.
TABLE 7-6. Replacement Battery Equivalents to 101536A
To replace battery:
1. Remove spark plug cap.
FIGURE 7-19: Spark Plug Cap Removal
2. Loosen and remove nuts on retaining plate; slide
retaining plate off support rods.
FIGURE 7-20: Electric Start Battery—Remove Retaining Plate
3. Tip battery slightly forward.
4. Disconnect the black negative (-) battery lead remov-
ing the bolt and nut.
FIGURE 7-21: Electric Start Battery—Lead Connection
5. Disconnect the red positive (+) battery lead removing
the bolt and nut.
7-8
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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.
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell.
Only use OUTSIDE and
far away from windows,
doors, and vents.
NEVER use inside a home
or garage, EVEN IF doors
and windows are open.
NOTE:
Honeywell Portable Electrical Generator Service Manual
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ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)
8.1 ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)
120V Circuit #1 Check
(No Output OR
120V Circuit #2 Check
(No Output OR
General Electrical Check
Voltage Out of Spec)
Voltage Out of Spec)
Refer to Illustrations on
Pages 8-3 and 8-5.
Conduct This Check Only When
Directed by General Electrical Check
Conduct This Check Only When
Directed by General Electrical Check
Check for Tripped Duplex Circuit Breaker(s)
Outlets Above the Breaker Indicate
the Excess Load Source
Remove Alternator End Cover
Remove Main Control Panel from
Control Panel Assembly
Resolve Overload Problem to Ensure Safe Operation
Check Wires and Connections
from AVR to Brush Assembly
for Proper Orientation
After Electrical Load Resolved Wait Several Minutes
(for Thermal Breaker to Cool) Push to Reset Breaker
Check Continuity from
Duplex Outlet #1
for Each Connection (X or Y, W, G) to
Duplex Outlet #2
of Wire Connections
If Cannot Reset, Replace Breaker
If a Connection is Loose or
Disconnected, Reestablish
a Tight Connection
If Continuity Not Present
in Any Circuit,
Check Wires and Connections from
Duplex Outlet #1 to Duplex Outlet #2
Start Engine and Run at No Load
If a Wire or Connection is Damaged,
Replace AVR
Check Engine Frequency = 61.5 to 63 Hz
If a Connection is Loose or
Disconnected, Reestablish a
Tight Connection and Recheck
Continuity
Adjust Governor, if necessary
(see Manual Section “Governor Adjustment”)
Check Wires and Connections
for the Exciter & AVR Tap
from AVR to Alternator
If Frequency Still Out of Range,
see Engine Diagnostics Section
If a Wire or Connection
is Damaged,
Replace Electrical Panel
On AVR Side of Connection:
If a Connection is Loose or
Disconnected, Reestablish a
Tight Connection
Check Voltage Output at NEMA 5-20R 120V
Duplex Outlet #1
Check for Continuity in
Duplex Outlet #2 Breaker
from the Line Terminal
to the Load Terminal
If a Wire or Connector is Damaged,
Replace AVR
W
X
123-
126V
G
On Alternator Side of Connection:
If a Connection is Loose or
Disconnected, Reestablish a
Tight Connection
If Voltage Out of Range,
Perform “120V Circuit #1 Check”
If No Continuity,
Replace Duplex Circuit Breaker
Check Voltage Output at NEMA 5-20R 120V
Duplex Outlet #2
If a Wire or Connector
is Damaged,
Replace Alternator
Check for Continuity in Each Circuit of
Duplex Outlet #2
from the Female Socket on the Front
to the Terminal on the Back
W
Y
123-
Check for Continuity from
Duplex Outlet #1
for Each Connection (X, Y, W, G) to
Corresponding Alternator Terminal
126V
G
If No Continuity,
Replace Duplex Receptacle
If Voltage Out of Range,
Perform “120V Circuit #2 Check”
If Continuity Present,
Replace Electrical Panel
If Continuity Not Present
in Any Circuit,
Check Wires and Connections
from Receptacle to Alternator
If a Connection is Loose or
Disconnected, Reestablish a Tight
Connection and Recheck Continuity
If a Wire or Connection is Damaged,
Replace Electrical Panel
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
8-2
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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
W
X
X
W
W
Y
Y
G
G
G
G
3000 RATED WATTS
•
3750 MAXIMUM WATTS
White Wire = W
Black Wire = X
Yellow / Green Wire = G
To
Alternator
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ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)
Rated Power Check
Alternator 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: The alternator must be at room temperature
when resistance is measured.
Refer to Illustrations on
Page 8-5.
./4%ꢃ 4HE ALTERNATOR DIAGNOSTICS REQUIRE MEASUREMENTS
OF LOW RESISTANCE VALUES WHICH ARE BEYOND THE
CAPABILITY OF A TYPICAL MULTIꢈMETERꢅ
NOTE: At this time, a high-altitude
carburetor kit is not available.
5SE ONLY FOR DIRECTIONAL INDICATION OF RESISTANCEꢅ
For best results, use an ohmmeter capable of
measuring low resistance values:
Start Engine and
Add Resistive Loads Until
One of the Following Occurs:
Resolution: 10 milliohms
+
!CCURACYꢃ 1%
s 0OWER /UTPUT at the
NEMA 5-20R 120V Duplex Outlet #1
is Within Rated Power Specification
Range
#HECK "RUSH !SSEMBLY FOR %XCESSIVE 7EAR OR $EFECT
./4%ꢃ 5SE #AUTION 7HEN 2EMOVING AND )NSTALLING "RUSH (OLDER
TO !VOID $AMAGING "RUSHES
s &REQUENCY $ROPS "ELOW ꢀꢁ (Z
)F ,ENGTH ,ESS THAN ꢀ MMꢂ 2EPLACE "RUSH !SSEMBLY
s 6OLTAGE /UTPUT $ROPS "ELOW
Minimum
)F ,ENGTH 'REATER THAN ꢀ MMꢂ6ERIFY 2ESISTANCE "ETWEEN %ACH
"RUSH 4IP AND #ORRESPONDING 4ERMINAL IS ,ESS THAN ꢄꢅꢆ Ω
W
X
)F 2ESISTANCE /UT OF 3PECꢂ 2EPLACE "RUSH !SSEMBLY
123-
126V
G
If Minimum Rated Power
#ANNOT "E !CHIEVEDꢂ
see Engine Diagnostics Section
Check Alternator Winding Resistances
Disconnect the Exciter Connector
$ISCONNECT THE 7IRES AT THE !LTERNATOR 4ERMINAL "LOCK
NOTE: Each Terminal Contains Nut, Lock Washer, and Flat Washer
-EASURE 7INDING 2ESISTANCES AS 3PECIFIED "ELOWꢃ
Resistance
Measure Resistance
Range
"ETWEEN 7IRES
Specification (Ω)
Winding
Stator-X
"LACK
"ROWN
Yellow
White
"LUE
0.15 - 0.35
20-35% of
Stator-X
Resistance
AVR Tap
Exciter
Yellow
ꢉꢅꢉ ꢈ ꢉꢅꢁ
Slip Rings
or
Rotor
45 - 65
Slip Ring Terminals*
ꢇ )F 5SING AN /HMMETER WITH +ELVIN "RIDGE #LIPSꢂ
-EASURE 2ESISTANCE AT THE 3LIP 2ING 7IRE 4ERMINALS FOR "EST 2ESULTS
If a Winding Resistance is Out of Spec, Replace Alternator
#HECK FOR #ROSSꢈ3HORTED 7INDINGS IN THE 3TATOR !SSEMBLY
#HECK FOR #ONTINUITY "ETWEEN 7INDINGS AS 3PECIFIED "ELOWꢃ
#HECK FOR #ONTINUITY
"ETWEEN 7INDINGS
#ONTINUITY
Specification
3TATORꢈ8 "LACK AVR Tap "ROWN
#ONTINUITY
3TATORꢈ8 "LACK Either Exciter Yellow .O #ONTINUITY
)F #ONTINUITY IS $IFFERENT THAN 3PECIFIED !BOVEꢂ
Replace Alternator
8-4
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ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)
BRUSH ASSEMBLY
Blue Wire
Yellow Wire
STATOR-X
WINDING
TERMINAL
BLOCK
5-9 mm
White
Black
STATOR-Y
WINDING
White (2 wires)
Black (2 wires)
ROTOR
VOLTAGE REGULATOR
SLIP
RINGS
SLIP RING
TERMINALS
EXCITER & AVR TAP
CONNECTOR*
POTENTIOMETER
TO ADJUST VOLTAGE
AVR TAP
WINDING
Blue
Brown
EXCITER
WINDING
Yellow Yellow
*view looking into
female connector
from alternator
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ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)
8.2 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)
240V Circuit Check
(No Output OR
120V Circuit Check
(No Output OR
General Electrical Check
Voltage Out of Spec)
Voltage Out of Spec)
Refer to Illustrations on
Pages 8-7 and 8-9.
Conduct This Check Only When
Directed by General Electrical Check
Conduct This Check Only When
Directed by 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
Remove Alternator End Cover
Remove Main Control Panel from
Control Panel Assembly
Check Wires and Connections
from AVR to Brush Assembly
for Proper Orientation
Check Continuity from the
120V Duplex Receptacle
for Each Connection (X or Y, W, G)
to the 240V Receptacle
Check for Tripped Duplex Circuit Breaker(s)
of Wire Connections
Outlets Above the Breaker Indicate
the Excess Load Source
If a Connection is Loose or
Disconnected, Reestablish
a Tight Connection
If Continuity Not Present
in Any Circuit,
Check Wires and Connections from
120V Duplex to 240V Receptacle
Resolve Overload Problem to Ensure Safe Operation
If a Wire or Connection is Damaged,
Replace AVR
After Electrical Load Resolved Wait Several Minutes
(for Thermal Breaker to Cool) Push to Reset Breaker
If a Connection is Loose or
Disconnected, Reestablish a
Tight Connection and Recheck
Continuity
If Cannot Reset, Replace Breaker
Check Wires and Connections
for the Exciter & AVR Tap
from AVR to Alternator
Start Engine and Run at No Load
If a Wire or Connection
is Damaged,
Replace Electrical Panel
On AVR Side of Connection:
If a Connection is Loose or
Disconnected, Reestablish a
Tight Connection
Check Engine Frequency = 61.5 to 63 Hz
Adjust Governor, if necessary
(see Manual Section “Governor Adjustment”)
If a Wire or Connector is Damaged,
Replace AVR
Check for Continuity in
Duplex Breaker
from the Line Terminal
to the Load Terminal
If Frequency Still Out of Range,
see Engine Diagnostics Section
On Alternator Side of Connection:
If a Connection is Loose or
Disconnected, Reestablish a
Tight Connection
If No Continuity,
Replace Duplex Circuit Breaker
Check Voltage Output at
NEMA L14-30R 240V Receptacle
246-
G
If a Wire or Connector
is Damaged,
Replace Alternator
252V
Check for Continuity in
Each Circuit of the
120V Duplex Receptacle from
the Female Socket on the Front
to the Terminal on the Back
X
Y
Check for Continuity from
the 240V Receptacle
for Each Connection (X, Y, W, G) to
Corresponding Alternator Terminal
123-
126V
123-
126V
W
If No Continuity,
Replace Duplex Receptacle
If Voltage Out of Range, Perform “240V Circuit Check”
If Continuity Not Present
in Any Circuit,
Check Wires and Connections
from Receptacle to Alternator
If Continuity Present,
Replace Electrical Panel
Check Voltage Output at NEMA 5-20R 120V
Duplex Outlet #1
W
X
If a Connection is Loose or
Disconnected, Reestablish a Tight
Connection and Recheck Continuity
123-
126V
G
If Voltage Out of Range, Perform “120V Circuit Check”
If a Wire or Connection is Damaged,
Replace Electrical Panel
Check Voltage Output at NEMA 5-20R 120V
Duplex Outlet #2
Check for Continuity in
Each Leg of Master Breaker
from the Line Terminal
to the Load Terminal
W
Y
123-
126V
G
If Voltage Out of Range, Perform “120V Circuit Check”
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
8-6
Honeywell Portable Electrical Generator Service Manual
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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
240V Receptacle
NEMA 14-30R
W
W
X
X
W
W
Y
Y
Y
G
G
G
W
X
G
G
MASTER
BREAKER
BREAKER
BREAKER
7000
8750 MAXIMUM WATTS
7000 RATED WATTS
•
White Wire = Y
Yellow / Green Wire = G
Red Wire = X
Blue Wire = W on Duplex Outlet #1
Brown Wire = W on Duplex Outlet #2
To
Alternator
Fuel Cutout Winding Connector
Brown Wires (2)
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ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)
Rated Power Check
Alternator 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: The alternator must be at room temperature when resistance is measured.
Refer to Illustrations on
Page 8-9.
./4%ꢃ 4HE ALTERNATOR DIAGNOSTICS REQUIRE MEASUREMENTS OF LOW RESISTANCE
VALUES WHICH ARE BEYOND THE CAPABILITY OF A TYPICAL MULTIꢈMETERꢅ
5SE ONLY FOR DIRECTIONAL INDICATION OF RESISTANCEꢅ
NOTE: At this time, a high-altitude
carburetor kit is not available.
For best results, use an ohmmeter capable of measuring low resistance values:
Resolution: 10 milliohms
+
!CCURACYꢃ 1%
Start Engine and
Add Resistive Loads Until
One of the Following Occurs:
#HECK "RUSH !SSEMBLY FOR %XCESSIVE 7EAR OR $EFECT
./4%ꢃ 5SE #AUTION 7HEN 2EMOVING AND )NSTALLING "RUSH (OLDER TO !VOID $AMAGING "RUSHES
)F ,ENGTH ,ESS THAN ꢀ MMꢂ 2EPLACE "RUSH !SSEMBLY
s 0OWER /UTPUT at the
NEMA L14-30R 240V Receptacle
is Within Rated Power
Specification Range
)F ,ENGTH 'REATER THAN ꢀ MMꢂ6ERIFY 2ESISTANCE "ETWEEN %ACH
"RUSH 4IP AND #ORRESPONDING 4ERMINAL IS ,ESS THAN ꢄꢅꢆ Ω
s &REQUENCY $ROPS "ELOW ꢀꢁ (Z
s 6OLTAGE /UTPUT $ROPS "ELOW
)F 2ESISTANCE /UT OF 3PECꢂ 2EPLACE "RUSH !SSEMBLY
Minimum
228-
252V
G
Check Alternator Winding Resistances
$ISCONNECT THE %XCITER #ONNECTOR
X
Y
$ISCONNECT THE &UEL #UTOUT 7INDING #ONNECTOR
W
114-
126V
114-
126V
$ISCONNECT THE 7IRES AT THE !LTERNATOR 4ERMINAL "LOCK
NOTE: Each Terminal Contains Nut, Lock Washer, and Flat Washer
If Minimum Rated Power
#ANNOT "E !CHIEVEDꢂ
-EASURE 7INDING 2ESISTANCES AS 3PECIFIED "ELOWꢃ
SEE %NGINE $IAGNOSTICS 3ECTION
Resistance Range Specification (Ω)
Measure Resistance
"ETWEEN 7IRES
(7ꢀꢀꢄꢄꢎ,
(7ꢀꢀꢄꢄ%ꢎ,
(7ꢁꢄꢄꢄ%ꢎ,
(7ꢁꢀꢄꢄ%ꢎ,
Winding
Stator-X
Stator-Y
(7ꢍꢄꢄꢄꢎ,
ꢄꢅꢀ ꢈ ꢄꢅꢁ
(7ꢏꢉꢄꢄꢎ,
ꢄꢅꢉ ꢈ ꢄꢅꢊꢀ
Red
"LUE
ꢄꢅꢉꢀ ꢈ ꢄꢅꢍꢀ
ꢄꢅꢆꢀ ꢈ ꢄꢅꢉꢀ
White
"ROWN
ꢉꢄꢈꢊꢀꢋ OF 3TATORꢈ8 2ESISTANCE
AVR Tap
Green
White
Exciter
"LUE
"LUE
ꢆꢅꢌ ꢈ ꢉꢅꢀ
ꢄꢅꢍ ꢈ ꢄꢅꢏ
ꢆꢅꢁ ꢈ ꢉꢅꢊ
ꢄꢅꢊ ꢈ ꢄꢅꢀ
ꢆꢅꢌ ꢈ ꢉꢅꢀ
ꢄꢅꢊ ꢈ ꢄꢅꢀ
1.3 - 1.8
Fuel Cutout
"ROWN
"ROWN
ꢄꢅꢊ ꢈ ꢄꢅꢀ
Slip Rings
Rotor
or
ꢊꢄ ꢈ ꢀꢀ
ꢍꢄ ꢈ ꢏꢄ
ꢊꢁ ꢈ ꢏꢌ
ꢍꢀ ꢈ ꢁꢄ
Slip Ring Terminals*
ꢇ )F 5SING AN /HMMETER WITH +ELVIN "RIDGE #LIPSꢂ
-EASURE 2ESISTANCE AT THE 3LIP 2ING 7IRE 4ERMINALS FOR "EST 2ESULTS
If a Winding Resistance is Out of Spec, Replace Alternator
#HECK FOR #ROSSꢈ3HORTED 7INDINGS IN THE 3TATOR !SSEMBLY
#HECK FOR #ONTINUITY "ETWEEN 7INDINGS AS 3PECIFIED "ELOWꢃ
#HECK FOR #ONTINUITY
"ETWEEN 7INDINGS
#ONTINUITY
Specification
Stator-X Red
Stator-Y White
.O #ONTINUITY
#ONTINUITY
Stator-X Red
Stator-Y White
Stator-X Red
Stator-Y White
Stator-X Red
Stator-Y White
AVR Tap Green
AVR Tap Green
%ITHER %XCITER "LUE
%ITHER %XCITER "LUE
.O #ONTINUITY
.O #ONTINUITY
.O #ONTINUITY
%ITHER &UEL #UTOUT "ROWN .O #ONTINUITY
%ITHER &UEL #UTOUT "ROWN .O #ONTINUITY
%ITHER %XCITER "LUE %ITHER &UEL #UTOUT "ROWN .O #ONTINUITY
)F #ONTINUITY IS $IFFERENT THAN 3PECIFIED !BOVEꢂ
Replace Alternator
8-8
Honeywell Portable Electrical Generator Service Manual
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ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)
EXCITER & AVR TAP
CONNECTOR*
STATOR-X
WINDING
BRUSH ASSEMBLY
Blue
Blue
Green
White
Red Wire
EXCITER
WINDING
AVR TAP
WINDING
White Wire
TERMINAL
BLOCK
Blue
Red
*view looking into
female connector
from alternator
5-9 mm
White
Brown
STATOR-Y
WINDING
Blue (2 wires)
Red (2 wires)
White (2 wires)
Brown (2 wires)
ROTOR
VOLTAGE REGULATOR
SLIP
RINGS
SLIP RING
TERMINALS
FUEL CUTOUT WINDING
CONNECTOR*
POTENTIOMETER
TO ADJUST VOLTAGE
Brown
Brown Black
*view looking into
female connector
from alternator
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ENGINE DIAGNOSTICS (ALL MODELS)
8.3 ENGINE DIAGNOSTICS (ALL MODELS)
Engine Starts
Then Shuts Down
Engine Fails to Crank
Using Electric Starter
Engine Fails to Start
Engine Runs Rough
Check Recoil for
Mechanical Binding
Check Oil Level
Check Fuel Level
Check Fuel Level
Check Fuel Level
Check Fuel Quality
Check Fuel Quality
Confirm Choke in Off Position
Check Air Cleaner
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
Confirm Choke in Off Position
Check Fuel Shut-off Valve Open
Check Oil Level
Confirm Choke in On Position
Check Spark Plug
Check Battery Connections
Check Ignition for Spark
Check Spark Plug & Gap
Check Fuel Line & Blockage
Check Carburetor
Check Ignition for Spark
Check Spark Plug & Gap
Adjust Coil Air Gap
Check Leads on Proper Post
Check Leads are Clean & Tight
Dry Spark Plug =
Check Carburetor
Fuel Cutout Solenoid
Wet Spark Plug =
Check Voltage Across Components
are Within .5V of Battery Voltage
Replace Out of Spec Components
Check Ignition System
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
Check Spark Plug Gap
Plug Condition Good =
Re-Gap Spark Plug
Plug Condition Dirty or Worn =
Replace Spark Plug
Check Fuel Line & Blockage
Check Carburetor
Check Spark Arrestor
Check Ignition for Spark
Check Muffler Blockage
Check Valve Adjustment
Perform Engine Compression Test
Check Spark Arrestor
Check Muffler Blockage
Bright Blue Spark =
Reinstall Plug
Dull Spark =
Engine Speed Unstable
Pull Coil & Check Resistance
Primary Coil = 0.8-1.0 Ohms
Secondary Coil = 5.9-7.1 Ohms
(measure at spark plug lead)
Replace Coil, if Necessary
Reinstall Coil with Proper
Coil / Flywheel Air Gap
Check Spark Plug & Gap
Engine Smokes
Reinstall Plug
Check Ignition for Spark
Adjust Coil Air Gap
Recoil Not Operating
Drain Oil and
Check Low Oil Switch
Connection and Continuity
(Yellow Wire on Side of Engine)
Start Engine
Warm to Operating Temperature
Observe Smoke Color
Recoil Locked =
Disassemble and Repair Recoil
(see Manual Section
White Smoke =
Poor Fuel Quality
Check Spark Arrestor
Check Muffler Blockage
Check Flywheel Woodruff Key
Repair or Replace Key
“Recoil Starter”)
Black Smoke =
Check Choke Operation
Check Ignition System
Check Recoil for
Mechanical Binding
Perform Engine Compression Test
Blue Smoke =
Check Oil in Fuel
Check Oil Overfilled
Check Worn Piston Rings
Check Governor
Frequency = 60 Hz + 3
Rope Not Retracting =
Disassemble and Repair
Broken Ratchets or Springs
(see Manual Section
“Recoil Starter”)
Check Governor Assembly
Adjustment
Perform Engine Compression Test
8-10
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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)
Circuit Breaker (Thermal)
D
Control panels vary between models.
D—MAIN CONTROL PANEL (BACK)
POWER CONTROL CENTER
HOUSEHOLD
OUTLETS
E—SWITCH PLATE (FRONT)
120 VOLTS AC
120/240 VOLTS AC
C
•
•
E1 - Electric Start Models
(HW5500E, HW5500EL,
HW7000E, HW7000EL,
HW7500E, HW7500EL)
MASTER
BREAKER
BREAKER
BREAKER
E2 - Manual Start Models
(HW3000, HW3000L, HW4000,
HW4000L, HW5500, HW5500L,
HW6200, HW6200L)
F—ENGINE CONTROL SWITCH
G—SWITCH PLATE (BACK)
A
ENGINE
START
E1
E2
STOP
ENGINE
RUN
F
STOP
G
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9-1
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ENGINE AND ALTERNATOR
9.2 ENGINE AND ALTERNATOR
A—END COVER
4 N•m (3 lb. ft.)
F
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.
Check rubber is not chipped,
hardened, or worn.
Refer to illustration for proper
positioning.
NOTE: On some models there are only
4 vibration isolators instead of 6.
H—FRAME
See WHEEL, LEG, & HANDLE
ASSEMBLY, page 9-11.
I— CRANKCASE COVER
28 N•m (21 lb. ft.)
9-2
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ALTERNATOR
9.3 ALTERNATOR
A—VOLTAGE REGULATOR
G
B—BRUSH ASSEMBLY
Before removing rotor and stator, remove
brush assembly.
F
2 N•m (1.5 lb. ft.)
E
C—REAR BEARING CARRIER
D—MAIN WINDING TERMINAL BLOCK
E—STATOR
C
F—ROTOR
B
D
A
Install appropriate alternator removal tool
(special tool), hold flywheel, and torque tool to
48 N•m (35 lb. ft.).
NOTICE
Rotor can become damaged if not properly
supported. Place wooden block and rag
underneath rotor for support.
H
If torquing alternator removal tool does not
free rotor from crankshaft, tap end of tool with
brass hammer to loosen rotor.
I
J
To prevent eye injury, always wear
safety glasses or goggles when
using a hammer.
K
L
G—ALTERNATOR ENGINE ADAPTER
H—GROUND CABLE
N
I— EXCITER WINDING CONNECTOR
J—BRUSH ASSEMBLY
M
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 & HW3000L
Honeywell Portable Electrical Generator Service Manual
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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 OFF and allow it to cool before filling with fuel.
• NEVER smoke or allow flames or sparks near the generator or where gasoline is stored.
• NEVER overfill the fuel tank (there should be no fuel in the filler neck). After refueling, tighten the fuel cap securely.
• Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, the area must be
dry before starting the engine.
• Avoid repeated or prolonged contact with skin or breathing of vapor.
A—FUEL GAGE
After reassembly, check float for proper
operation.
A
B
B—FUEL CAP
Check air vent hole is clean and free of
obstruction. Blow with compressed air if
necessary.
E 1
C
NOTE: For model numbers ending in
“L”, the fuel cap will be attached to the
fuel tank with a chain.
D
E 2
C—FUEL STRAINER
Before reassembly, check fuel strainer
is clean and undamaged.
D—FUEL TANK MOUNTING HARDWARE
10 N•m (7 lb. ft.)
F
E—FUEL TANK
H
Before reassembly, clean fuel tank to
remove any sediment and drain com-
pletely.
G
•
E1 - Model Numbers Ending in “L”
(HW3000L, HW4000L, HW5500L,
HW5500EL, HW6200L, HW7000EL,
HW7500EL)
•
E2 - Non “L” Models
(HW3000, HW4000, HW5500,
HW5500E, HW6200, HW7000E,
HW7500E)
F—FUEL SHUT-OFF VALVE
Clear passages if clogged.
After reinstalling, check for fuel leakage.
Hex fitting - 24 N•m (17 lb. ft.)
G—FUEL SEDIMENT CUP
See CLEANING FUEL SEDIMENT
CUP, page 7-5.
HW7500E Model Illustrated
H—FUEL LINE
Check for cracks or damage.
Secure with hose clamps.
9-4
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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
E2
Honeywell Portable Electrical Generator Service Manual
9-5
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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.
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.)
D—MUFFLER
Cutaway view shows the catalyst
located inside mufflers on model
numbers ending in “L”.
D
(HW3000L, HW4000L, HW5500L,
HW5500EL, HW6200L, HW7000EL,
HW7500EL)
C
G
Muffler rear mounting bracket -
18 N•m (13 lb. ft.)
E1
E2
E—EXHAUST PIPE
18 N•m (13 lb. ft.)
•
•
E1 - Non “L” Models
(HW3000, HW4000, HW5500,
HW5500E, HW6200, HW7000E,
HW7500E)
E2 - Model Numbers Ending in “L”
(HW3000L, HW4000L, HW5500L,
HW5500EL, HW6200L, HW7000EL,
HW7500EL)
F—SECONDARY AIR INTAKE VALVE
For model numbers ending in “L” only
(HW3000L, HW4000L, HW5500L,
HW5500EL, HW6200L, HW7000EL,
HW7500EL)
F
G—MUFFLER SIDE GUARD
4 N•m (3 lb. ft.)
9-6
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CARBURETOR
9.7 CARBURETOR
Fuel and its vapors are extremely flammable and explosive under certain conditions.
• Refuel generator only outdoors, in a well-ventilated area.
• NEVER enclose the generator in any structure.
• Keep generator at least 6 feet (2 meters) away from buildings, other equipment, and combustible materials during 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
installation.
C—DRAIN SCREW
Clean with compressed air and check
for leaks after installation.
I
D—SET BOLT
Check for any sign of fuel leakage
after installation.
E—FUEL CUTOUT SOLENOID
H
Check continuity between the double
green wires of the solenoid valve. If
there no continuity, replace solenoid.
A
NOTE: Not present on HW3000 or
HW3000L models.
B
F—MAIN JET
Clean with compressed air before
installation.
G
F
G—MAIN NOZZLE
Clean with compressed air before
installation.
H—O-RING
Check for correct installation.
C
D
I— CARBURETOR BODY
Clean internal passages and orifices
with compressed air before installa-
tion.
E
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STARTING SYSTEM
9.8 STARTING SYSTEM
A—ELECTRIC STARTER
Attempt to crank engine by switching the
engine control switch to the START position.
A
Starter Solenoid Terminal Nut -
6 N•m (4 lb. ft.)
B
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.
G
Check for cracked or damaged insulation;
replace, if necessary.
F
D—IGNITION COIL
Pull spark plug lead and connect to spare.
Check ignition for spark to ground.
10 N•m (7 lb. ft.)
E—FLYWHEEL
F—CLAMP
C
D
G—CHARGING COIL ASSEMBLY
Check for continuity.
E
9-8
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RECOIL STARTER
9.9 RECOIL STARTER
A—STARTER CASE
B—ROPE AND HANDLE
Install with recoil starter handle position as
shown.
I
C—RETURN SPRING
C
H
Connect the outer hook in the groove of the
starter reel and inner hook on the starter
case tab.
G
F
E
D
Return spring is under tension.
Use extreme caution and wear
safety glasses and gloves when
disassembling to prevent injury.
B
A
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
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9-9
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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.
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.
E—RECOIL STARTER ASSEMBLY
Install with the recoil starter handle position
as shown.
9-10
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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
C—RUBBER HANDLE GRIP
A
D—AXLE
25 N•m (18 lb. ft.)
B
E—SUPPORT LEG
25 N•m (18 lb. ft.)
C
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.
G
E
F
Honeywell Portable Electrical Generator Service Manual
9-11
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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
B
D—RUBBER HANDLE GRIP
C
E—AXLE
25 N•m (18 lb. ft.)
D
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.
G
• NEVER use accessory kit for any other purpose.
• NEVER use accessory kit on-road.
HW5500E Model Illustrated
9-12
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10: INDEX
A
P
Air Filter Maintenance 7-3
Alternator 9-2,ꢀ9-3
Power Control Center 4-1,ꢀ9-1
breakers 4-1,ꢀ9-1
Automatic Voltage Regulator (AVR) 8-5,ꢀ8-9,ꢀ9-3
electrical outlets 4-1,ꢀ9-1
ground terminal 4-1
B
R
S
Battery 4-1,ꢀ7-8
Breakers 4-1
Rotor 9-2,ꢀ9-3
C
Components
breakers 4-1
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
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
fuel tank system 9-4
muffler 9-6
preparing for 5-1
recoil starter 9-9
starting system 9-8
wheel, leg, & handle assembly 9-11
Service Repair Time 6-1
Spark Arrestor 4-1,ꢀ7-6,ꢀ9-6
Spark Plug 4-1,ꢀ7-5
E
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
Specifications 3-1
F
T
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
Tools, Service 5-1
Torque Information 3-2
Transporting Generator 5-1
Troubleshooting 8-1
Fuel Tank 9-4,ꢀ9-5
Fuel, Oxygenated 7-2
V
Valve Lash 7-7
Voltage Regulator 8-5,ꢀ8-9,ꢀ9-3
G
Governor 7-7
Ground Terminal 4-1
W
Warranty
emissions control 2-2
limited 2-1
replacement parts 2-4
Wheel, Leg, & Handle Assembly 9-11
Wiring Diagrams 3-3
M
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
O
Oil Fill Dipstick 4-1
Oil Recommendations 7-3
Outlets 4-1,ꢀ9-1
Honeywell Portable Electrical Generator Service Manual
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P/N 101290D
2010 Northshore Power Systems, LLC
Northshore Power Systems, LLC
4425 N. Port Washington Road
Suite 105
c
The Honeywell Trademark is used under license
from Honeywell International Inc.
Milwaukee, WI 53212-1082 USA
1-888-HWTECHS (498-3247)
Honeywell International Inc. makes no representation
or warranties with respect to this product.
Manufactured exclusively for Northshore Power Systems.
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