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Portable Electrical Generator
Service Manual
HW3000/L
HW4000/L
HW5500/L
HW5500E/L
HW6200/L
HW7000E/L
HW7500E/L
Read and Save These Instructions
For technical support and parts, contact your Regional Master Parts Distributor
toll-free at 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com.
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CONTENTS IMPORTANT SAFETY INSTRUCTIONS ....................................................................... 1-1 WARRANTIES ............................................................................................................... 2-1 NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY ............................................2-1 NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY ..........................................2-2 NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY .
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THIS PAGE INTENTIONALLY LEFT BLANK ii www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
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+ SAVE THESE INSTRUCTIONS 1: IMPORTANT SAFETY INSTRUCTIONS WARNING ANYONE using or servicing this generator must read, understand, and follow all safety and operation instruc- tions provided in the product manual. Failure to closely follow these instructions can result in circumstances leading to death, serious injury, and property damage. Hazard Symbols and Meanings NOTE: Since there are many variations in the circumstances sur- In addition to the signal words, the following symbols may roun
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SAFETY MESSAGES Electric Shock Hazards WARNING WARNING The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Generators produce powerful voltage that can cause death or great physical harm. • NEVER touch hot surfaces and avoid hot gases. • Let engine cool before storing the generator indoors. • Notify the utility company when using generator for backup power. Use approved transfer equipment to iso- late generator from electric utility. WARNING
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2: WARRANTIES LIMITATIONS OF REMEDIES. NORTHSHORE POWER NORTHSHORE POWER SYSTEMS SYSTEMS SHALL NOT BE LIABLE TO CUSTOMER, OR TO CONSUMER LIMITED WARRANTY ANYONE CLAIMING UNDER CUSTOMER, FOR ANY Honeywell Portable Generator OTHER OBLIGATIONS OR LIABILITIES, INCLUDING, BUT NOT LIMITED TO, OBLIGATIONS OR LIABILITIES ARISING LIMITED WARRANTY OUT OF BREACH OF CONTRACT OR WARRANTY, NEGLI- Northshore Power Systems, LLC, will repair or replace, free GENCE OR OTHER TORT OR ANY THEORY OF STRICT o
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WARRANTIES EMISSIONS CONTROL SYSTEMS PARTS NORTHSHORE POWER SYSTEMS Coverage under this warranty extends only to the emissions EMISSIONS CONTROL WARRANTY control parts listed below. Honeywell Portable Generator 1. Fuel Metering System WARRANTY STATEMENT A. Carburetor gaskets The U.S. Environmental Protection Agency (EPA) and Califor- B. Choke system nia Air Resources Board (CARB) require manufacturers of C. Clamps small off-road engines (SORE) to warranty their products with D. Fuel filter
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WARRANTIES 4. Repair or Replacement Cost. Repair or Replacement Cost. Repair or replacement of any emissions control part will be performed at no charge to the owner, includ- ing diagnostic labor which leads to the determination that an emissions control part is defective, if the diagnostic work is performed at an authorized Northshore Power Systems Honeywell generator dealer. 5. Consequential Coverage. Coverage noted hereunder will extend to the failure of any engine components caused by
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WARRANTIES EXCLUSIONS. In addition to the foregoing disclaimers, limi- NORTHSHORE POWER SYSTEMS tations and terms, this limited warranty shall not apply to and REPLACEMENT PARTS LIMITED WARRANTY does not cover products that are in any way subjected to: (i) Honeywell Portable Generator improper setup, installation or storage; (ii) lack of proper maintenance and service; (iii) accident, damage, abuse or For a period of 90 days from the date of sale or installation of misuse; (iv) abnormal o
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3: SPECIFICATIONS AND WIRING DIAGRAMS 3.1 SPECIFICATIONS HW5500 HW3000 HW4000 HW5500E HW6200 HW7000E HW7500E GENERATOR HW3000L HW4000L HW5500EL HW6200L HW7000EL HW7500EL HW5500L POWER Rated [watts] 3000 4000 5500 6200 7000 7500 (+/-10% under load) Maximum [watts] 3750 5000 6875 7750 8750 9375 (+/-10% under load) Frequency [hertz] 60 (+/-5% under load) Voltage [volts] 120 120 / 240 120 / 240 120 / 240 120 / 240 120 / 240 (+/-5% under load) OPERATING TEMPERATURE Maximum [F / C] 104 / 40 Minimum
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BOLT AND FASTENER TORQUE INFORMATION 3.2 BOLT AND FASTENER TORQUE INFORMATION Torque Values Component-Specific Fastener Fastener Size 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 Bolt
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WIRING DIAGRAMS 3.3 WIRING DIAGRAMS HW3000 & HW3000L FIGURE 3-1: HW3000 & HW3000L Wiring Diagram Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-3 ALTERNATOR ENGINE OIL NOTE: SHUTDOWN Y Y Alternator is mechanically SWITCH MAIN 120 VAC connected to the engine WINDING FIELD block providing ground OIL ALERT WINDING Bl connection between the SENDER Bl EXCITER engine block and the WINDING alternator frame. WBl SPARK PLUG YBu BrBu Y Y IGNITION COIL Bl Bl AVR
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WIRING DIAGRAMS HW4000 & HW4000L FIGURE 3-2: HW4000 & HW4000L Wiring Diagram 3-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual gg ALTERNATOR ENGINE G/W NOTE: FUEL CUTOUT SOLENOID Alternator is mechanically connected to the engine block providing ground OIL connection between the engine block SHUTDOWN Y and the alternator frame. Y SWITCH MAIN 120 VAC WINDING FIELD OIL ALERT WINDING Bl FUEL SENDER Y CUTOUT EXCITER WINDING WINDING MAIN 120 VAC SPARK WINDING
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WIRING DIAGRAMS HW5500 & HW5500L FIGURE 3-3: HW5500 & HW5500L Wiring Diagram Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-5 gg ALTERNATOR ENGINE G/W NOTE: FUEL CUTOUT Alternator is mechanically connected SOLENOID to the engine block providing ground OIL connection between the engine block SHUTDOWN Y and the alternator frame. Y SWITCH MAIN 120 VAC WINDING FIELD OIL ALERT WINDING Bl FUEL SENDER Y CUTOUT EXCITER WINDING WINDING MAIN 120 VAC SPARK WINDING
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WIRING DIAGRAMS HW5500E & HW5500EL FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram 3-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual gg ALTERNATOR ENGINE Gr Br CHARGE NOTE: COIL Alternator is mechanically connected BATTERY to the engine block providing ground connection between the engine block W STARTER M and the alternator frame. MOTOR MAIN 120 VAC FUEL G/W WINDING FIELD CUTOUT WINDING FUEL SOLENOID Bl/W CUTOUT EXCITER OIL WINDING WINDING MAIN 120 VAC SH
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WIRING DIAGRAMS HW6200 & HW6200L FIGURE 3-5: HW6200 & HW6200L Wiring Diagram Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 3-7 ALTERNATOR ENGINE G/W NOTE: FUEL CUTOUT Alternator is mechanically connected SOLENOID to the engine block providing ground OIL connection between the engine block SHUTDOWN and the alternator frame. Y Y SWITCH MAIN 120 VAC WINDING FIELD OIL ALERT WINDING Bl FUEL SENDER Y CUTOUT EXCITER WINDING WINDING MAIN 120 VAC SPARK WINDING PL
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WIRING DIAGRAMS HW7000E, HW7000EL, HW7500E, & HW7500EL FIGURE 3-6: HW7000E, HW7000EL, HW7500E & HW7500EL Wiring Diagram 3-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual ALTERNATOR ENGINE Gr Br CHARGE NOTE: COIL Alternator is mechanically connected to the engine block providing ground BATTERY connection between the engine block W STARTER and the alternator frame. M MOTOR MAIN 120 VAC G/W FUEL WINDING FIELD CUTOUT WINDING FUEL SOLENOID Bl/W CUTOUT EXCITER
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4: COMPONENTS K J L A E M I B H N F C G D FIGURE 4-1: Honeywell Portable Electrical Generator Controls and Components (HW5500EL Model Illustrated) A—Power Control Center E—Engine Control Switch Control used to start and stop the engine ignition system. Electrical Outlets • START—Starts generator engine (electric start models) • 125VAC 20 Amp Duplex (NEMA 5-20R) outlets to connect • RUN—Prepares engine to start (manual start models); 120V appliances to generator for power. Indicates engine is
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