Honeywell Portable Generator Hw3000 Users Manual PortablesServiceManual

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HW3000/L

HW4000/L

HW5500/L

HW5500E/L

HW6200/L

HW7000E/L

HW7500E/L

For technical support and parts, contact your Regional Master Parts Distributor

toll-free at 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com.

Service Manual

Portable Electrical Generator

Read and Save These Instructions



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

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

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

THIS PAGE INTENTIONALLY LEFT BLANK

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

SAVE THESE INSTRUCTIONS

1: IMPORTANT SAFETY INSTRUCTIONS

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.

1.1 SAFETY MESSAGES

Signal Words

Safety messages are provided throughout this manual to

help prevent personal injury and equipment damage. All

safety messages are introduced by a signal word indicat-

ing the hazard level.

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-

ards.

SAFETY PRECAUTIONS

• 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.

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.

WARNING

Indicates an imminently hazard-

ous situation which, if not

avoided, will result in death or

serious injury to the operator or to

bystanders.

Indicates a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury to the operator or to

bystanders.

Indicates a potentially hazardous

situation which, if not avoided,

may result in moderate or minor

injury to the operator or to

bystanders.

Indicates a situation which, if not

avoided, may result in damage to

the generator components.

DANGER

WARNING

CAUTION

NOTICE

Explosion Toxic fume s Fire

Chemical burn

Electrical shock

Hot surface

Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is a

poison you cannot see or smell.

NEVER use inside a home

or garage, EVEN IF doors

and windows are open.

Only use OUTSIDE and

far away from windows,

doors, and vents.

+

DANGER

SAFETY MESSAGES

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

Electric Shock Hazards

Fire and Burn Hazards

Medical and Life Support Uses

Generator Damage Hazards

California Proposition 65

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 qualified 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

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.

Fuel and its vapors are extremely flammable and

explosive under certain conditions.

• Refuel generator only outdoors, in a well-ventilated

area.

• NEVER enclose the generator in any structure.

• Keep generator at least 6 feet (2 meters) away from

buildings, other equipment, and combustible materials

during operation.

• NEVER fill fuel tank while the engine is running. Turn

generator OFF and allow to cool before filling with fuel.

• 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.

• Avoid repeated or prolonged contact with skin or

breathing of vapor.

WARNING

WARNING

The muffler becomes very hot during operation and

remains hot for a while after stopping the engine.

• NEVER touch hot surfaces and avoid hot gases.

• Let engine cool before storing the generator indoors.

Battery gases are explosive.

• NEVER allow open flames, lit cigarettes, sparks, or

spark-producing equipment near the battery.

Battery electrolyte fluid is comprised of sulfuric acid,

which can be very dangerous and cause severe

burns.

• NEVER allow battery fluid to contact eyes, skin, or

clothing. If contact or spillage occurs, immediately flush

the area with water.

• 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.

NOTICE

Improper treatment or misuse of generator can cause per-

manent damage.

• 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.

WARNING

WARNING

WARNING

WARNING

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

2: WARRANTIES

NORTHSHORE POWER SYSTEMS

CONSUMER LIMITED WARRANTY

Honeywell Portable Generator

LIMITED WARRANTY

Northshore Power Systems, LLC, will repair or replace, free

of charge, to the original retail customer, in North America,

any parts of the portable generator found by Northshore

Power Systems or an authorized service center to be 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

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 & 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.

DISCLAIMERS, LIMITATIONS OF REMEDIES &

EXCLUSIONS

This warranty gives you specific legal rights, and you may

also have other rights which vary from state to state.

MEDICAL AND LIFE SUPPORT USES. This warranty

excludes any use of this product intended to power life 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 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; (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

WARRANTIES

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

NORTHSHORE POWER SYSTEMS

EMISSIONS CONTROL WARRANTY

Honeywell Portable Generator

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.

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 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.

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).

2.1 WARRANTIES

EMISSIONS CONTROL SYSTEMS PARTS

Coverage under this warranty extends only to the emissions

control parts listed below.

1. Fuel Metering System

A. Carburetor gaskets

B. Choke system

C. Clamps

D. Fuel filter (if equipped) and screen

E. Fuel line, control valve, and fittings

F. Fuel pump (if equipped)

G. Gasoline carburetor and internal components

(if equipped)

2. Air Induction System

A. Air cleaner

B. Intake manifold

C. Vent lines

3. Ignition System

A. Ignition coil

B. Spark plug

4. Exhaust System

A. Catalytic converter (if equipped)

B. Exhaust manifold

C. Muffler gasket

5. Crankcase Breather Assembly

A. Breather connection tube

6. Air Injection System

A. Pulse valve

7. Fuel Tank Evaporative Emissions Control System

A. Carbon canister and mounting brackets

B. Fuel cap

C. Fuel tank

D. Purge valves

8. Miscellaneous Items used in above systems

A. Hoses, belts, connectors, valves, and assemblies

B. Switches

WARRANTY PROVISIONS

1. Claims. Warranty claims shall be filed in accordance

with provisions of the Northshore Power Systems 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.

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

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: service@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

WARRANTIES

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

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.

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.

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;

(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 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 a

copy of the original proof-of-purchase (for the part) to the

Warranty Claim Form.

WARRANTY CLAIMS

For all customer service inquiries, call 1-877-HWTECHS

(498-3247) or visit www.honeywellgenerators.com.

Warranty claim forms and inquiries can be addressed to:

Northshore Power Systems, LLC

Attention: Service and Warranty Dept.

4425 N. Port Washington Road

Suite 105

Milwaukee, WI 53212-1082

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-1

3: SPECIFICATIONS AND WIRING DIAGRAMS

3.1 SPECIFICATIONS

GENERATOR HW3000

HW3000L

HW4000

HW4000L

HW5500

HW5500E

HW5500EL

HW5500L

HW6200

HW6200L

HW7000E

HW7000EL

HW7500E

HW7500EL

POWER

Rated [watts]

(+/-10% under load) 3000 4000 5500 6200 7000 7500

Maximum [watts]

(+/-10% under load) 3750 5000 6875 7750 8750 9375

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] 104 / 40

Minimum [F / C] 14 / -10

ENGINE

Speed [rpm] 3600

Type OHV 4-cycle

Displacement [cc] 196 242 337 389 420 420

Valve Lash [in /mm] IN: 0.005±0.001 / 0.125±0.025

EX: 0.007±0.001 / 0.175±0.025

Fuel 87 or higher unleaded

Fuel Tank Capacity [gal / L]

(Non-L Models) 4.2 / 16 6.5 / 24.6 6.5 / 24.6 6.5 / 24.6 6.6 / 25 6.5 / 24.6

(Model Numbers Ending in “L”) 3.2 / 12 6.5 / 24.6 6.5 / 24.6 6.5 / 24.6 6.1 / 23 6.5 / 24.6

Engine Oil SAE 10W-30*

*See ENGINE OIL RECOMMENDATIONS, page 7-3 for other engine oil types outside general temperature use.

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 102557A†100842A†

† See SPARK PLUG SERVICE, page 7-5 for other recommended spark plug replacements.

100842A†100842A†100842A†100842A†

Spark Plug Gap [in /mm] 0.028-0.031 / 0.7-0.8

Air Filter

(Non-L Models) 102555A 100833A 100833A 100833A 100833A 100833A

(Model Numbers Ending in “L”) 102556A 101865A 101865A 101865A 101865A 101865A

Battery

(Electric Start Models Only) -- -- 101536A -- 101536A 101536A

TABLE 3-1: Honeywell Portable Generator Specifications

BOLT AND FASTENER TORQUE INFORMATION

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

3.2 BOLT AND FASTENER TORQUE INFORMATION

Component-Specific Fastener Fastener Size Torque Values

N•m lb. ft.

Alternator End Cover Bolts M5 x 0.75 x 12 4 3

Alternator Housing Bolts M10 x 1.25 x 80 48 35

Axle Bracket Bolts M8 x 1.0 x 16 25 18

Brush Assembly Bolt M5 x 0.75 x 16 2 2

Carbon Canister Bracket Bolts M6 x 1.0 x 10 2 2

Connecting Rod Bolts M8 x 1.25 15 11

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 1.0 x 14 4 3

Muffler Rear Mounting Bracket Bolts M8 x 1.0 x 16 18 13

Muffler Side Guard Bolts M6 x 1.0 x 14 4 3

Oil Drain Screw M12 x 1.5 32 24

Pivot Adjusting Nuts M6 x 0.75 12 9

Pivot Bolts M8 x 1.25 30 22

Rotor Bolt -- 48 35

Spark Arrestor Clamp Screw M4 x 0.75 x 16 1 1

Spark Arrestor Screw M3.5 x 0.75 x 10 1 1

Spark Plug 13/16” 28 21

Starter Solenoid Terminal Nut M6 x 1.0 6 4

Support Leg to Frame Bolts M8 x 1.0 x 16 25 18

Support Leg to Rubber Stopper Bolts M8 x 1.0 x 25 25 18

Wheel Handle Pivot Bracket Bolts M6 x 1.0 x 40 10 7

TABLE 3-3: Torque Values

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

WIRING DIAGRAMS

3.3 WIRING DIAGRAMS

HW3000 & HW3000L

FIGURE 3-1: HW3000 & HW3000L Wiring Diagram

ALTERNATOR

CONTROL PANEL

ENGINE

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

YY

Bl Bl

Bl Bl

ENGINE

CONTROL

SWITCH

Bl Y/G

Y/G

EIG

GROUND

TERMINAL

DUPLEX

5-20R

Y/G 2.5 mm2

THERMAL

AC BREAKER

15A

G

WX

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

YBu BuBr Y Y

120 VAC

Bl 4 mm2

W 4 mm2

WBl

ALTERNATOR

Bl - Black

Bu - Blue

Br - Brown

Y - Yellow

Y/G - Yellow / Green

W - White

THERMAL

AC BREAKER

10A

NOTE:

Alternator is mechanically

connected to the engine

block providing ground

connection between the

engine block and the

alternator frame.

ON/OFF SWITCH PANEL

G

WX

G

WX

G

WX

LEFT* RIGHT*

*15 Amp Breaker will be on the left side when looking at the control panel front;10 Amp Breaker will be on the right side

W 2.5 mm2

Bl 2.5 mm2

Bl 2.5 mm2 Bl 2.5 mm2

DUPLEX

5-20R

OFF

ON

Bl Y/G

WIRING DIAGRAMS

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

HW4000 & HW4000L

FIGURE 3-2: HW4000 & HW4000L Wiring Diagram

G

Y

W

X

ALTERNATOR

CONTROL PANEL

ENGINE

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

YY

Bl Y

Bl Bl

ENGINE

CONTROL

SWITCH

Bl

Bu

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

15A

G

WX

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

WR WLg Bu Bu

ALTERNATOR

Bl - Black

Bu - Blue

Br - Brown

G/W - Green / White

Lg - Light Green

R - Red

Y - Yellow

Y/G - Yellow / Green

W - White

THERMAL

AC BREAKER

15A

NOTE:

Alternator is mechanically connected

to the engine block providing ground

connection between the engine block

and the alternator frame.

ON/OFF SWITCH PANEL

G

WX

DUPLEX 5-20R

G

WY

G

WY

MAIN

WINDING

Br WRBu

Br WRBu

FUEL

CUTOUT

WINDING

5A FUSE

G/W

G/W TWIST-LOCK

L14-30R

Y/G

gg

Br Br

MAGNETIC

AC BREAKER

15A

120 VAC

120 VAC

OFF

ON

Bu BlG/W Y/G

FUEL CUTOUT

SOLENOID

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-5

WIRING DIAGRAMS

HW5500 & HW5500L

FIGURE 3-3: HW5500 & HW5500L Wiring Diagram

G

Y

W

X

ALTERNATOR

CONTROL PANEL

ENGINE

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

YY

Bl Y

Bl Bl

ENGINE

CONTROL

SWITCH

Bl

Bu

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

20A

G

WX

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

WR WLg Bu Bu

120 VAC

ALTERNATOR

Bl - Black

Bu - Blue

Br - Brown

G/W - Green / White

Lg - Light Green

R - Red

Y - Yellow

Y/G - Yellow / Green

W - White

THERMAL

AC BREAKER

20A

NOTE:

Alternator is mechanically connected

to the engine block providing ground

connection between the engine block

and the alternator frame.

ON/OFF SWITCH PANEL

G

WX

DUPLEX 5-20R

G

WY

G

WY

MAIN

WINDING

Br WRBu

Br WRBu

FUEL

CUTOUT

WINDING

5A FUSE

G/W

G/W TWIST-LOCK

L14-30R

Y/G

gg

Br Br

MAGNETIC

AC BREAKER

21A

120 VAC

OFF

ON

Bu BlG/W Y/G

FUEL CUTOUT

SOLENOID

WIRING DIAGRAMS

3-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

HW5500E & HW5500EL

FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram

ALTERNATOR

CONTROL PANEL

ENGINE

ON/OFF SWITCH PANEL

G

Y

W

X

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

YY

Bl Y

Bl Bl

ENGINE

CONTROL

SWITCH

Y/G

Bu

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

20A

G

WX

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

WR WLg Bu Bu

120 VAC

ALTERNATOR

Bl - Black

Bl/W - Black / White

Bu - Blue

Br - Brown

G/W - Green / White

Lg - Light Green

R - Red

Y - Yellow

Y/G - Yellow / Green

W - White

THERMAL

AC BREAKER

20A

G

WX

DUPLEX 5-20R

G

WY

G

WY

MAIN

WINDING

Br WRBu

Br WRBu

FUEL

CUTOUT

WINDING

5A

FUSE

G/W

G/W TWIST-LOCK

L14-30R

Bl

gg

Br Br

MAGNETIC

AC BREAKER

21A

120 VAC

Br

CHARGE

COIL

BATTERY

STARTER

MOTOR M

Gr

W

FUEL

CUTOUT

SOLENOID

AUTO

PROTECTOR

3A

Bl/W

Bl/W

OFF

START

Bu BlG/W Y/G

ON

Bl/W

NOTE:

Alternator is mechanically connected

to the engine block providing ground

connection between the engine block

and the alternator frame.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-7

WIRING DIAGRAMS

HW6200 & HW6200L

FIGURE 3-5: HW6200 & HW6200L Wiring Diagram

G

Y

W

X

ALTERNATOR

CONTROL PANEL

ENGINE

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

YY

Bl Y

Bl Bl

ENGINE

CONTROL

SWITCH

Bl

Bu

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

THERMAL

AC BREAKER

20A

G

WX

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

WR WLg Bu Bu

ALTERNATOR

Bl - Black

Bu - Blue

Br - Brown

G/W - Green / White

Lg - Light Green

R - Red

Y - Yellow

Y/G - Yellow / Green

W - White

THERMAL

AC BREAKER

20A

NOTE:

Alternator is mechanically connected

to the engine block providing ground

connection between the engine block

and the alternator frame.

ON/OFF SWITCH PANEL

G

WX

DUPLEX 5-20R

G

WY

G

WY

MAIN

WINDING

Br WRBu

Br WRBu

FUEL

CUTOUT

WINDING

5A FUSE

G/W

G/W TWIST-LOCK

L14-30R

Y/G

Br Br

MAGNETIC

AC BREAKER

25A

120 VAC

120 VAC

OFF

ON

Bu BlG/W Y/G

FUEL CUTOUT

SOLENOID

WIRING DIAGRAMS

3-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

HW7000E, HW7000EL, HW7500E, & HW7500EL

FIGURE 3-6: HW7000E, HW7000EL, HW7500E & HW7500EL Wiring Diagram

ALTERNATOR

CONTROL PANEL

ENGINE

ON/OFF SWITCH PANEL

G

Y

W

X

OIL ALERT

SENDER

SPARK

PLUG

OIL

SHUTDOWN

SWITCH

IGNITION

COIL

ENGINE BLOCK

YY

Bl Y

Bl Bl

ENGINE

CONTROL

SWITCH

Y/G

Bu

EIG

GROUND

TERMINAL

DUPLEX 5-20R

Y/G

SINGLE POLE

THERMAL

AC BREAKER

120V 20A

G

WX

FIELD

WINDING

MAIN

WINDING

EXCITER

WINDING

AVR

WR WLg Bu Bu

120 VAC

ALTERNATOR

Bl - Black

Bl / W - Black / White

Bu - Blue

Br - Brown

G/W - Green / White

Lg - Light Green

R - Red

Y - Yellow

Y/G - Yellow / Green

W - White

SINGLE POLE

THERMAL

AC BREAKER

120V 20A

G

WX

DUPLEX 5-20R

G

WY

G

WY

MAIN

WINDING

Br WRBu

Br WRBu

5A

FUSE

G/W TWIST-LOCK

L14-30R

Bl

DUAL POLE

MAGNETIC

AC BREAKER

240V 30A

120 VAC

Br

CHARGE

COIL

BATTERY

STARTER

MOTOR M

Gr

W

FUEL

CUTOUT

SOLENOID

Bl/W

OFF

START

Bu BlG/W Y/G

ON

Bl/W

FUEL

CUTOUT

WINDING

Br Br

AUTO

PROTECTOR

3A

Bl/W

NOTE:

Alternator is mechanically connected

to the engine block providing ground

connection between the engine block

and the alternator frame.

G/W

LEFT* RIGHT*

*When looking at the control panel front

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 4-1

4: COMPONENTS

A—Power Control Center

Electrical Outlets

•125VAC 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 a 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.

HW3000 / HW3000L models only:

•15-amp circuit breaker (left outlet)

•10-amp circuit breaker (right outlet)

Ground Terminal

Connects generator to ground wire for grounding protec-

tion.

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);

Indicates 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 materials from escaping generator.

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.

FIGURE 4-1: Honeywell Portable Electrical Generator Controls and Components (HW5500EL Model Illustrated)

K

G

B

I

H

J

E

C

D

A

F

M

L

N

Generator must be grounded to prevent electrical

shock from faulty appliances.

Tripped

Set

CAUTION

Muffler reaches temperatures that can cause serious

burns if touched. NEVER touch hot surfaces.

WARNING

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

THIS PAGE INTENTIONALLY LEFT BLANK

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 5-1

5: PREPARING FOR SERVICE

5.1 REQUIRED TOOLS

A complete set of standard and metric shop tools are

required to service the generator. Also needed are:

•Hammer

•Torque wrench

•Volt-ohm meter

•Frequency meter

•Resistive load - such as a load bank, heaters, light

bulbs, etc.

•Alternator removal tool

•Wood block (for rotor support)

5.2 TRANSPORTING GENERATOR

When moving or transporting the generator:

•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.

•Place pins in the handle and handle bracket before

moving the generator.

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.

WARNING

Hot engine or exhaust system can cause serious

burns or fires. Cool generator completely before

transporting.

NOTICE

NEVER drop, strike, or place heavy objects on generator

when transporting.

WARNING

5-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

THIS PAGE INTENTIONALLY LEFT BLANK

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 6-1

6: SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE

Operation

HW3000

HW3000L

(min.)

HW4000

HW4000L

(min.)

HW5500

HW5500L

(min.)

HW5500E

HW5500EL

(min.)

HW6200

HW6200L

(min.)

HW7000E

HW7000EL

(min.)

HW7500E

HW7500EL

(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 Breakers45454545454545

Oil Shutdown Switch 40 40 40 40 40 40 40

Oil Alert Sender 40 40 40 40 40 40 40

Receptacles / Ports50505050505050

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 30 30

Air Cleaner 40 40 40 40 40 40 40

Carburetor 50 50 50 50 50 50 50

Choke45454545454545

Converter

(Model Numbers Ending in “L”) 60 60 60 60 60 60 60

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 & EXHAUST

Carbon Canister (with bracket)

(Model Numbers Ending in “L”) 45 45 45 45 45 45 45

Carbon Canister Tube

(Model Numbers Ending in “L”) 30 30 30 30 30 30 30

Exhaust Pipe

(Model Numbers Ending in “L”) 40 40 40 40 40 40 40

Fuel Gage 30 30 30 30 30 30 30

SERVICE REPAIR TIME ANALYSIS

6-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

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

Vapor Line

(Model Numbers Ending in “L”) 30 30 30 30 30 30 30

Fuel Tank 60 60 60 60 60 60 60

Fuel Shut-off Valve40404040404040

Muffler50505050606060

Muffler Gasket 50 50 50 50 60 60 60

Secondary Air Intake Valve

(with gasket)

(Model Numbers Ending in “L”)

50 50 50 50 50 50 50

MISC

Frame

(Model Numbers Ending in “L”) 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

Operation

HW3000

HW3000L

(min.)

HW4000

HW4000L

(min.)

HW5500

HW5500L

(min.)

HW5500E

HW5500EL

(min.)

HW6200

HW6200L

(min.)

HW7000E

HW7000EL

(min.)

HW7500E

HW7500EL

(min.)

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-1

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.

NEVER use inside a home

or garage, EVEN IF doors

and windows are open.

Only use OUTSIDE and

far away from windows,

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.

DANGER

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.

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.

WARNING

WARNING

FREQUENCY*

MAINTENANCE TASK Before each

use

First month

or 20 hours of

use

Every 3

months or 50

hours of use

Every 6

months or 100

hours of use

Every year or

200 hours of

use

Inspect for/clean debris X

Check engine oil level X

Change engine oil X X

Check air filter X

Clean air filter X†

Run engine X‡

Clean/change spark plug X

Clean fuel sediment cup X

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

* 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.

CONSUMER MAINTENANCE SCHEDULE

7-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

FUEL RECOMMENDATIONS

Before each use, check the fuel tank gage. If the fuel level

is low, refill the tank with recommended fuel. NEVER

OVERFILL.

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 fuel 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 a conventional

unleaded gasoline.

Fuel and fuel vapors are extremely flammable and

explosive under certain conditions.

• 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.

DANGER

NOTICE

Oxygenated fuels can damage paint and plastic. Be careful

not to spill fuel when filling fuel tank. Damage caused by

spilled fuel is not covered under warranty.

TABLE 7-2. Oxygenated Fuel Types

Ethanol

(ethyl or grain alcohol)

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".

Methanol

(methyl or wood

alcohol)

Gasoline containing metha-

nol must contain co-solvents

and corrosion inhibitors to

protect fuel system. Gasoline

containing more than 5%

methanol by volume may

cause starting and/or perfor-

mance problems and may

damage metal, rubber and

plastic parts of fuel system.

MTBE

(methyl tertiary butyl

ether)

Gasoline containing up to

15% MTBE by volume can

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.

NOTICE

Running the engine with persistent spark knock or pinging

can cause engine damage. Warranty does not cover parts

damaged by misuse.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-3

AIR FILTER MAINTENANCE

ENGINE OIL RECOMMENDATIONS

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.

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.

7.2 AIR FILTER MAINTENANCE

Clean air filter every 50 hours of generator operation. If

operating generator in extremely dusty areas, clean air fil-

ter more frequently.

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.

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.

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.

FIGURE 7-1: Recommended Oil Viscosity

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.

5W-30

Synthetic 5W-30

SAE 30, 10W-30

WARNING

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.

Gasoline and flammable solvents can cause fire or

explosion. NEVER use gasoline or flammable sol-

vent to clean air filter element.

• 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

Clean engine oil

FIGURE 7-2: Air Cleaner Cover—Model Numbers Ending in “L”

FIGURE 7-3: Air Cleaner Cover—Non-L Models

WARNING

AIR FILTER MAINTENANCE

7-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

3. Remove foam air filter(s).

4. Wash air filter(s) in a solution of household soap and

warm water.

5. Rinse parts thoroughly with water.

6. Using a clean, absorbent cloth, squeeze air filter dry,

being careful not to twist or tear the filter.

7. Coat the air filter with clean engine oil.

8. Squeeze out excess oil.

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.

9B. Reinstall the dark grey foam air filter.

9C. Reinstall the air cleaner cover.

For Non-L Models:

9A. Reinstall the metal air filter plate in the support

brackets if it fell out during air filter removal.

9B. Reinstall air filter.

9C. Reinstall the air cleaner cover.

FIGURE 7-4: Air Filter Removal

FIGURE 7-5: Wash Air Filter

FIGURE 7-6: Dry Air Filter

FIGURE 7-7: Oil Air Filter

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.

CAUTION

FIGURE 7-9: Air Filter Installation—Model Numbers Ending in “L”

(filter shape varies by model)

FIGURE 7-10: Air Filter Plate Installation—Non-L Models

(air filter plate shape varies by model)

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-5

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:

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.

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.

5. Clean the fuel screen (A), o-ring (B), and sediment

cup (C), with soap and water.

6. Rinse parts thoroughly with water.

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.

10. 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.

1. Measure the spark plug gap with a wire feeler gauge.

Gap should be: 0.028-0.031 in. (0.70-0.80 mm).

2. If necessary, adjust gap by carefully bending side

electrode.

3. Torque spark plug to 28 N•m (21 lb. ft.).

HW3000 & HW3000L Models:

Recommended Spark Plug Replacement: 102557A

All Other Models:

Recommended Spark Plug Replacement: 100842A

To clean fuel sediment cup, you will need:

10 mm box wrench

22 mm open end wrench

Household soap and water

Clean, dry cloth

FIGURE 7-11: Fuel Sediment Cup Assembly Removal

FIGURE 7-12: Fuel Sediment Cup Assembly

A

B

C

If the engine has been running, the spark plug will

reach temperatures that could cause severe burns.

Do not touch.

FIGURE 7-13: Correct Spark Plug Gap

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.

AutoLite 62

Bosch WR5DC

Champion RN6YC

Denso W22EPR-U

NGK BPR7ES

TABLE 7-3. Spark Plug Equivalents to 102557A

AutoLite 63

Bosch WR7DC

Champion RN9YC

Denso W20EPR

NGK BPR6ES

TABLE 7-4. Spark Plug Equivalents to 100842A

WARNING

.028 - .031 in.

(.70 - .80 mm)

CLEANING SPARK ARRESTOR SCREEN

7-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

7.5 CLEANING SPARK ARRESTOR

SCREEN

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.

1. Stop the engine if it is running. Allow to completely

cool.

2. Place generator on a flat, level surface.

3. Using a socket wrench with an 8 mm socket, remove

the muffler cover bolts (muffler cover not present on

HW3000 or HW3000L models).

4. Remove muffler cover.

5. Using a screwdriver, loosen and remove the spark

arrestor clamp (A) screw.

6. Slide off spark arrestor clamp.

7. Using a socket wrench with a 7/32” socket, remove

the retaining screw on spark arrestor screen cap (B);

pull off cap.

8. Pull out spark arrestor screen (C).

9. Inspect spark arrestor screen.

If screen is damaged or excessively worn, replace

with new screen.

If screen is in good condition, clean using wire

brush and then reinstall.

10. Reinstall remaining spark arrestor components.

Spark arrestor screen cap and screw

Clamp and screw

Muffler cover

Muffler reaches temperatures that can cause serious

burns if touched. NEVER touch hot surfaces.

To clean spark arrestor screen, you will need:

1/4” socket wrench

8 mm socket

7/32” socket

#2 Phillips screwdriver

Wire brush

FIGURE 7-14: Remove Muffler Cover

WARNING

FIGURE 7-15: Spark Arrestor Assembly

FIGURE 7-16: Clean Screen

A

B

C

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-7

VALVE LASH

7.6 VALVE LASH

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.

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.

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).

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.

Valve lash inspection and adjustment must be performed

with the engine cold.

FIGURE 7-17: Lock Nut Location

Standard valve lash

IN. 0.005±0.001 in

(0.125±0.025 mm)

EX. 0.007±0.001 in

(0.175±0.025 mm)

TABLE 7-5. Standard Valve Lash

A—ROCKER ARM

B—LOCK NUT

12 N•m (9 lb. ft.)

•To increase valve lash,

screw pivot nut out.

•To decrease valve lash,

screw pivot nut in.

C—PIVOT BOLT

30 N•m (22 lb. ft.)

CAUTION

LOCK NUT

A

B

C

FIGURE 7-18: Governor Arm Assembly

GOVERNOR ARM SHAFT

GOVERNOR ARM

PINCH BOLT

GOVERNOR ARM

ANTI-SURGE SPRING

THROTTLE

NUT

GOVERNOR

SPRING

LIMITING

SCREW

BATTERY SERVICE

7-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

7.9 BATTERY SERVICE

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.

Recommended Battery Replacement: 101536A

To replace battery:

1. Remove spark plug cap.

2. Loosen and remove nuts on retaining plate; slide

retaining plate off support rods.

3. Tip battery slightly forward.

4. Disconnect the black negative (-) battery lead remov-

ing the bolt and nut.

5. Disconnect the red positive (+) battery lead removing

the bolt and nut.

6. Remove the battery.

NOTE:

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-

tive (+) post on the battery; install bolt, nut, and boot.

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.

Xtreme XTAX14AHL-BS

Yuasa 12N14-3A

TABLE 7-6. Replacement Battery Equivalents to 101536A

FIGURE 7-19: Spark Plug Cap Removal

FIGURE 7-20: Electric Start Battery—Remove Retaining Plate

FIGURE 7-21: Electric Start Battery—Lead Connection

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-1

8: TROUBLESHOOTING

NOTE:

For all dealer service inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com.

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.

NEVER use inside a home

or garage, EVEN IF doors

and windows are open.

Only use OUTSIDE and

far away from windows,

doors, and vents.

WARNING

DANGER

ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)

8-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

8.1 ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)

Perform “Alternator Check”

Remove Alternator End Cover

120V Circuit #1 Check

(No Output OR

Voltage Out of Spec)

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 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

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

120V Circuit #2 Check

(No Output OR

Voltage Out of Spec)

General Electrical Check

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

Conduct This Check Only When

Directed by General Electrical Check

Start Engine and Run at No Load

Conduct This Check Only When

Directed by General Electrical Check

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

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 Socket on the Front

to the Terminal on the Back

If No Continuity,

Replace Duplex Receptacle

If Continuity Present,

Replace Electrical Panel

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, if necessary

(see Manual Section “Governor Adjustment”)

If Frequency Still Out of Range,

see Engine Diagnostics Section

W

G

X

123-

126V

Check Voltage Output at NEMA 5-20R 120V

Duplex Outlet #1

If Voltage Out of Range,

Perform “120V Circuit #1 Check”

W

G

Y

123-

126V

Check Voltage Output at NEMA 5-20R 120V

Duplex Outlet #2

If Voltage Out of Range,

Perform “120V Circuit #2 Check”

Remove Main Control Panel from

Control Panel Assembly

Check Wires and Connections

for the Exciter & 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 Loose or

Disconnected, Reestablish a Tight

Connection and Recheck Continuity

If a Wire or Connection is Damaged,

Replace Electrical Panel

Refer to Illustrations on

Pages 8-3 and 8-5.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-3

ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)

To

Alternator

See “Specifications” Page For

Rated Power, Voltage, & Frequency Specs

Under Load and No Load Conditions

Yellow / Green Wire = G

White Wire = W

Black Wire = X

3000 RATED WATTS • 3750 MAXIMUM WATTS

Duplex Outlet #1

NEMA 5-20R 120V

G

WX

G

WX

G

WY

G

WY

Duplex Outlet #2

NEMA 5-20R 120V

ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)

8-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

Rated Power Check

(Low Power Output)

NOTE: At high-altitudes, standard

carburetor air-fuel mixture will be

rich causing a decrease in engine

performance and an increase in

fuel consumption.

NOTE: At this time, a high-altitude

carburetor kit is not available.

Start Engine and

Add Resistive Loads Until

One of the Following Occurs:

s0OWER/UTPUTat the

NEMA 5-20R 120V Duplex Outlet #1

is Within Rated Power Specification

Range

s&REQUENCY$ROPS"ELOW(Z

s6OLTAGE/UTPUT$ROPS"ELOW

Minimum

If Minimum Rated Power

#ANNOT"E!CHIEVED

see Engine Diagnostics Section

NOTE: The alternator must be at room temperature

when resistance is measured.

#HECK"RUSH!SSEMBLYFOR%XCESSIVE7EAROR$EFECT

./4%5SE#AUTION7HEN2EMOVINGAND)NSTALLING"RUSH(OLDER

TO!VOID$AMAGING"RUSHES

)F,ENGTH,ESSTHANMM2EPLACE"RUSH!SSEMBLY

)F,ENGTH'REATERTHANMM6ERIFY2ESISTANCE"ETWEEN%ACH

"RUSH4IPAND#ORRESPONDING4ERMINALIS,ESSTHANΩ

)F2ESISTANCE/UTOF3PEC2EPLACE"RUSH!SSEMBLY

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"ELOW

)F5SINGAN/HMMETERWITH+ELVIN"RIDGE#LIPS

-EASURE2ESISTANCEATTHE3LIP2ING7IRE4ERMINALSFOR"EST2ESULTS

If a Winding Resistance is Out of Spec, Replace Alternator

Alternator Check

./4%4HEALTERNATORDIAGNOSTICSREQUIREMEASUREMENTS

OFLOWRESISTANCEVALUESWHICHAREBEYONDTHE

CAPABILITYOFATYPICALMULTIMETER

5SEONLYFORDIRECTIONALINDICATIONOFRESISTANCE

For best results, use an ohmmeter capable of

measuring low resistance values:

Resolution: 10 milliohms

!CCURACY+ 1%

Measure Resistance

"ETWEEN7IRES

Resistance

Range

Specification (Ω)

Winding

Stator-X "LACK White 0.15 - 0.35

AVR Tap "ROWN "LUE

20-35% of

Stator-X

Resistance

Exciter Yellow Yellow 

Rotor

Slip Rings

or

Slip Ring Terminals* 45 - 65

#HECKFOR#ONTINUITY

"ETWEEN7INDINGS

#ONTINUITY

Specification

3TATOR8"LACK AVR Tap"ROWN #ONTINUITY

3TATOR8"LACK Either Exciter Yellow .O#ONTINUITY

#HECKFOR#ROSS3HORTED7INDINGSINTHE3TATOR!SSEMBLY

#HECKFOR#ONTINUITY"ETWEEN7INDINGSAS3PECIFIED"ELOW

)F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE

Replace Alternator

Refer to Illustrations on

Page 8-5.

W

G

X

123-

126V

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-5

ELECTRICAL DIAGNOSTICS (HW3000/L MODELS)

Blue

Yellow

Brown

Yellow EXCITER

WINDING

AVR TAP

WINDING

EXCITER & AVR TAP

CONNECTOR*

*view looking into

female connector

from alternator

ROTOR

SLIP

RINGS

SLIP RING

TERMINALS

VOLTAGE REGULATOR

POTENTIOMETER

TO ADJUST VOLTAGE

White (2 wires)

Black (2 wires)

BRUSH ASSEMBLY

Yellow Wire

Blue Wire

5-9 mm

STATOR-X

WINDING

STATOR-Y

WINDING

Black

White

TERMINAL

BLOCK

ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)

8-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

8.2 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)

Perform “Alternator 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, if 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

G

Y

W

X

123-

126V

246-

252V

123-

126V

If Voltage Out of Range, Perform “240V Circuit Check”

W

G

X

123-

126V

Check Voltage Output at NEMA 5-20R 120V

Duplex Outlet #1

If Voltage Out of Range, Perform “120V Circuit Check”

W

G

Y

123-

126V

Check Voltage Output at NEMA 5-20R 120V

Duplex Outlet #2

Remove Alternator End Cover

240V Circuit Check

(No Output OR

Voltage Out of Spec)

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 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

Check Continuity from the

120V Duplex Receptacle

for Each Connection (X or Y, W, G)

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

120V Circuit Check

(No Output OR

Voltage Out of Spec)

General Electrical Check

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

If Voltage Out of Range, Perform “120V Circuit Check”

Conduct This Check Only When

Directed by General Electrical Check

Start Engine and Run at No Load

Conduct This Check Only When

Directed by General Electrical Check

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

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

Remove Main Control Panel from

Control Panel Assembly

Check Wires and Connections

for the Exciter & 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

the 240V Receptacle

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 Loose or

Disconnected, Reestablish a Tight

Connection and Recheck Continuity

If a Wire or Connection is Damaged,

Replace Electrical Panel

Refer to Illustrations on

Pages 8-7 and 8-9.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-7

ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)

Yellow / Green Wire = G

White Wire = Y

Red Wire = X To

Alternator

See “Specifications” Page For

Rated Power, Voltage, & Frequency Specs

Under Load and No Load Conditions

Brown Wire = W on Duplex Outlet #2

Blue Wire = W on Duplex Outlet #1

Fuel Cutout Winding Connector

Brown Wires (2)

240V Receptacle

NEMA 14-30R

7000 RATED WATTS • 8750 MAXIMUM WATTS

7000

120 VOLTS AC 120/240 VOLTS AC

POWER CORD or

TRANSFER SWITCH

HOUSEHOLD

OUTLETS

BREAKER BREAKER

MASTER

BREAKER

Duplex Outlet #1

NEMA 5-20R 120V

Duplex Outlet #2

NEMA 5-20R 120V

G

WX

G

WX

G

WY

G

WY

G

Y

WX

ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)

8-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

Rated Power Check

(Low Power Output)

NOTE: At high-altitudes, standard

carburetor air-fuel mixture will be

rich causing a decrease in engine

performance and an increase in

fuel consumption.

NOTE: At this time, a high-altitude

carburetor kit is not available.

Start Engine and

Add Resistive Loads Until

One of the Following Occurs:

s0OWER/UTPUTat the

NEMA L14-30R 240V Receptacle

is Within Rated Power

Specification Range

s&REQUENCY$ROPS"ELOW(Z

s6OLTAGE/UTPUT$ROPS"ELOW

Minimum

G

Y

W

X

114-

126V

228-

252V

114-

126V

If Minimum Rated Power

#ANNOT"E!CHIEVED

SEE%NGINE$IAGNOSTICS3ECTION

NOTE: The alternator must be at room temperature when resistance is measured.

#HECK"RUSH!SSEMBLYFOR%XCESSIVE7EAROR$EFECT

./4%5SE#AUTION7HEN2EMOVINGAND)NSTALLING"RUSH(OLDERTO!VOID$AMAGING"RUSHES

)F,ENGTH,ESSTHANMM2EPLACE"RUSH!SSEMBLY

)F,ENGTH'REATERTHANMM6ERIFY2ESISTANCE"ETWEEN%ACH

"RUSH4IPAND#ORRESPONDING4ERMINALIS,ESSTHANΩ

)F2ESISTANCE/UTOF3PEC2EPLACE"RUSH!SSEMBLY

Check Alternator Winding Resistances

$ISCONNECTTHE%XCITER#ONNECTOR

$ISCONNECTTHE&UEL#UTOUT7INDING#ONNECTOR

$ISCONNECTTHE7IRESATTHE!LTERNATOR4ERMINAL"LOCK

NOTE: Each Terminal Contains Nut, Lock Washer, and Flat Washer

-EASURE7INDING2ESISTANCESAS3PECIFIED"ELOW

Alternator Check

./4%4HEALTERNATORDIAGNOSTICSREQUIREMEASUREMENTSOFLOWRESISTANCE

VALUESWHICHAREBEYONDTHECAPABILITYOFATYPICALMULTIMETER

5SEONLYFORDIRECTIONALINDICATIONOFRESISTANCE

For best results, use an ohmmeter capable of measuring low resistance values:

Resolution: 10 milliohms

!CCURACY+ 1%

#HECKFOR#ROSS3HORTED7INDINGSINTHE3TATOR!SSEMBLY

#HECKFOR#ONTINUITY"ETWEEN7INDINGSAS3PECIFIED"ELOW

)F#ONTINUITYIS$IFFERENTTHAN3PECIFIED!BOVE

Replace Alternator

Refer to Illustrations on

Page 8-9.

#HECKFOR#ONTINUITY

"ETWEEN7INDINGS

#ONTINUITY

Specification

Stator-X Red Stator-Y White .O#ONTINUITY

Stator-Y White AVR Tap Green .O#ONTINUITY

Stator-X Red AVR Tap Green #ONTINUITY

Stator-X Red %ITHER%XCITER"LUE .O#ONTINUITY

Stator-Y White .O#ONTINUITY%ITHER%XCITER"LUE

Stator-X Red %ITHER&UEL#UTOUT"ROWN .O#ONTINUITY

Stator-Y White %ITHER&UEL#UTOUT"ROWN .O#ONTINUITY

%ITHER%XCITER"LUE .O#ONTINUITY%ITHER&UEL#UTOUT"ROWN

Measure Resistance

"ETWEEN7IRES

Resistance Range Specification (Ω)

Winding

Stator-X Red "LUE

AVR Tap Green White OF3TATOR82ESISTANCE

Stator-Y White "ROWN

Exciter "LUE "LUE 

Rotor

Slip Rings

or

Slip Ring Terminals*



(7,

(7,

(7%, (7,

(7%,

(7%,

Fuel Cutout

  1.3 - 1.8

"ROWN "ROWN    

  

   

)F5SINGAN/HMMETERWITH+ELVIN"RIDGE#LIPS

-EASURE2ESISTANCEATTHE3LIP2ING7IRE4ERMINALSFOR"EST2ESULTS

If a Winding Resistance is Out of Spec, Replace Alternator

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-9

ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L)

ROTOR

SLIP

RINGS

SLIP RING

TERMINALS

Blue (2 wires)

Red (2 wires)

Brown

Brown Black

FUEL CUTOUT WINDING

CONNECTOR*

*view looking into

female connector

from alternator

VOLTAGE REGULATOR

POTENTIOMETER

TO ADJUST VOLTAGE

STATOR-X

WINDING

STATOR-Y

WINDING

Blue

Red

White

Brown

TERMINAL

BLOCK

White (2 wires)

Brown (2 wires)

Blue

Blue

Green

White

EXCITER

WINDING

AVR TAP

WINDING

EXCITER & AVR TAP

CONNECTOR*

*view looking into

female connector

from alternator

BRUSH ASSEMBLY

White Wire

Red Wire

5-9 mm

ENGINE DIAGNOSTICS (ALL MODELS)

8-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

8.3 ENGINE DIAGNOSTICS (ALL MODELS)

Engine Fails to Crank

Using Electric Starter

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 & Tight

Check Recoil for

Mechanical Binding

Check Voltage Across Components

are Within .5V of Battery Voltage

Replace 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 Fails to Start

Check Flywheel Woodruff Key

Repair or Replace Key

Drain Oil and

Check Low Oil Switch

Connection and Continuity

(Yellow Wire on Side of Engine)

Perform Engine Compression Test

Check Oil Level

Confirm Choke in On Position

Check Spark Plug

Dry Spark Plug =

Check Carburetor

Fuel Cutout Solenoid

Wet Spark Plug =

Check Ignition System

Check Fuel Level

Check Fuel Shut-off Valve Open

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 & 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

Recoil Not Operating

Recoil Locked =

Disassemble and Repair Recoil

(see Manual Section

“Recoil Starter”)

Check Recoil for

Mechanical Binding

Rope Not Retracting =

Disassemble and Repair

Broken Ratchets or Springs

(see Manual Section

“Recoil Starter”)

Engine Starts

Then Shuts Down

Check Fuel Level

Check Fuel Quality

Check Oil Level

Confirm Choke in Off Position

Check Ignition for Spark

Check Spark Plug & Gap

Adjust Coil Air Gap

Check Fuel Line & Blockage

Check Carburetor

Check Spark Arrestor

Check Muffler Blockage

Engine Runs Rough

Check Fuel Level

Check Fuel Quality

Confirm Choke in Off Position

Check Air Cleaner

Check Fuel Line & Blockage

Check Valve Adjustment

Perform Engine Compression Test

Check Ignition for Spark

Check Spark Plug & Gap

Check Carburetor

Check Spark Arrestor

Check Muffler Blockage

Engine Speed Unstable

Check Governor

Frequency = 60 Hz + 3

Check Governor Assembly

Adjustment

Check Spark Plug & Gap

Check Ignition for Spark

Adjust Coil Air Gap

Check Spark Arrestor

Check Muffler Blockage

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

Perform Engine Compression Test

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-1

9: SERVICE AND DISASSEMBLY

9.1 CONTROL PANEL

A—CONTROL PANEL ASSEMBLY

(FRONT)

4 N•m (3 lb. ft.)

B—CONTROL PANEL ASSEMBLY

(BACK)

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—MAIN CONTROL PANEL (BACK)

E—SWITCH PLATE (FRONT)

•E1 - 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)

START

ENGINE

STOP

RUN

RUN

ENGINE

STOP

Control panels vary between models.

POWER CONTROL CENTER

HOUSEHOLD

OUTLETS

120/240 VOLTS AC

MASTER

BREAKER

BREAKER BREAKER

120 VOLTS AC

B

C

A

D

E1

E2

F

G

ENGINE AND ALTERNATOR

9-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

9.2 ENGINE AND ALTERNATOR

A—END COVER

4 N•m (3 lb. ft.)

B—ROTOR BOLT

Use oil before replacing the rotor bolt.

C—ALTERNATOR HOUSING BOLTS

48 N•m (35 lb. 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 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.)

C

D

F

E

AB

H

G

I

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-3

ALTERNATOR

9.3 ALTERNATOR

A—VOLTAGE REGULATOR

Alternator Illustrated Matches All Models Except HW3000 & HW3000L

B—BRUSH ASSEMBLY

Before removing rotor and stator, remove

brush assembly.

2 N•m (1.5 lb. 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 N•m (35 lb. ft.).

If torquing alternator removal tool does not

free rotor from crankshaft, tap end of tool with

brass hammer to loosen rotor.

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.

A

B

C

D

F

E

G

M

K

J

I

H

L

N

NOTICE

Rotor can become damaged if not properly

supported. Place wooden block and rag

underneath rotor for support.

To prevent eye injury, always wear

safety glasses or goggles when

using a hammer.

CAUTION

FUEL TANK SYSTEM

9-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

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.

HW7500E Model Illustrated

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 N•m (7 lb. 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 “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.

H—FUEL LINE

Check for cracks or damage.

Secure with hose clamps.

WARNING

A

B

C

D

E 2

F

G

H

E 1

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-5

EVAPORATIVE EMISSIONS CONTROL SYSTEM

9.5 EVAPORATIVE EMISSIONS CONTROL SYSTEM

For Model Numbers Ending in “L” only.

A—FUEL TANK

B—CARBON CANISTER

•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

B2

E1

C

A

D

B1

E2

MUFFLER

9-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

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 N•m (3 lb. ft.)

NOTE: Not present on HW3000 or

HW3000L models.

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”.

(HW3000L, HW4000L, HW5500L,

HW5500EL, HW6200L, HW7000EL,

HW7500EL)

Muffler rear mounting bracket -

18 N•m (13 lb. ft.)

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)

G—MUFFLER SIDE GUARD

4 N•m (3 lb. ft.)

WARNING

E1

A

E2

C

B

D

F

G

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-7

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.

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.

WARNING

A

C

D

E

I

H

F

G

B

STARTING SYSTEM

9-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

9.8 STARTING SYSTEM

A—ELECTRIC STARTER

Attempt to crank engine by switching the

engine control switch to the START position.

Starter Solenoid Terminal Nut -

6 N•m (4 lb. ft.)

B—WOODRUFF KEY

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 N•m (7 lb. ft.)

E—FLYWHEEL

F—CLAMP

G—CHARGING COIL ASSEMBLY

Check for continuity.

D

B

C

A

E

F

G

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-9

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.

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

B

C

D

E

A

F

G

H

I

Return spring is under tension.

Use extreme caution and wear

safety glasses and gloves when

disassembling to prevent injury.

CAUTION

FAN COVER

9-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

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 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.

B

C

D

A

E

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-11

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

D—AXLE

25 N•m (18 lb. ft.)

E—SUPPORT LEG

25 N•m (18 lb. ft.)

F—RUBBER STOPPER

25 N•m (18 lb. ft.)

G—WHEEL

B

C

A

D

EG

F

NOTICE

• Accessory kit is intended to be used specifically

with this generator.

• NEVER use accessory kit for any other purpose.

• NEVER use accessory kit on-road.

WHEEL, LEG, & HANDLE ASSEMBLY

9-12 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual

9.12 WHEEL, LEG, & HANDLE ASSEMBLY

(ALL MODELS EXCEPT HW3000/L)

A—WHEEL HANDLE PIVOT

BRACKET

10 N•m (7 lb. ft.)

B—PIN AND CHAIN

C—HANDLE BAR

D—RUBBER HANDLE GRIP

E—AXLE

25 N•m (18 lb. ft.)

F—SUPPORT LEGS

25 N•m (18 lb. ft.)

NOTE: On some models the leg

support nuts are welded to the

frame.

G—RUBBER STOPPER

25 N•m (18 lb. ft.)

H—WHEEL

HW5500E Model Illustrated

B

C

D

A

E

F

G

H

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.

Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 10-1

A

Air Filter Maintenance 7-3

Alternator 9-2,9-3

Automatic Voltage Regulator (AVR) 8-5,8-9,9-3

B

Battery 4-1,7-8

Breakers 4-1

C

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

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

F

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

G

Governor 7-7

Ground Terminal 4-1

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

P

Power Control Center 4-1,9-1

breakers 4-1,9-1

electrical outlets 4-1,9-1

ground terminal 4-1

R

Rotor 9-2,9-3

S

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, & 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

T

Tool s, S er vic e 5-1

Torque Information 3-2

Transporting Generator 5-1

Troubleshooting 8-1

V

Valve Lash 7-7

Voltage Regulator 8-5,8-9,9-3

W

Warranty

emissions control 2-2

limited 2-1

replacement parts 2-4

Wheel, Leg, & Handle Assembly 9-11

Wiring Diagrams 3-3

10: INDEX

Northshore Power Systems, LLC

4425 N. 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

c

Honeywell International Inc. makes no representation

or warranties with respect to this product.

The Honeywell Trademark is used under license

from Honeywell International Inc.

Manufactured exclusively for Northshore Power Systems.