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Honeywell L manual

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Table of contents for the manual

  • Page 1

    HW3000/L HW4000/L HW5500/L HW5500E/L HW6200/L HW7000E/L HW7500E/L F or technical suppor t and par ts, contact y our Regional Master P ar ts Distrib utor toll-free at 1-877-HWTECHS (498-3247) or visit www .hone ywellgenerators .com. Ser vice Manual P or tab le Electrical Generator Read and Save These Instructions[...]

  • Page 2

    [...]

  • Page 3

    Honeywell P ortable Electrical Generator Ser vice Man ual www .honeywellgenerators.com i CONTENTS IMPORTANT SAFETY INSTRUCTIONS ....................................................................... 1-1 WARRANTIES ........................................................... .................................................... 2-1 NORTHSHORE POWER S[...]

  • Page 4

    ii www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual THIS P A GE INTENTIONALL Y LEFT BLANK[...]

  • Page 5

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 1-1 SA VE THESE INSTR UCTIONS 1: IMPORT ANT SAFETY INSTR UCTIONS NO TE: Since there are many v ariations in the circumstances sur- rounding the installation, operation, service, and mainte- nance of this generator , we cannot possibly anticipate or provide advice [...]

  • Page 6

    SAFETY MESSA GES 1-2 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual Electric Shoc k Hazards Fire and Burn Hazards Medical and Life Support Uses Generator Damage Hazar ds California Pr oposition 65 Generators produce powerful v oltage that can cause death or great physical harm. • Notify the utility company w[...]

  • Page 7

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 2-1 2: W ARRANTIES NORTHSHORE PO WER SYSTEMS CONSUMER LIMITED W ARRANTY Honeywell P or table Generator LIMITED W ARRANTY Nor thshore P ower Systems , LLC, will repair or replace, free of charge, to the original retail customer , in Nor th Amer ica, any parts of th[...]

  • Page 8

    W ARRANTIES 2-2 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual NORTHSHORE PO WER SYSTEMS EMISSIONS CONTROL W ARRANTY Honeywell P or table Generator W ARRANTY STATEMENT The U .S. En vironmental Protection Agency (EP A) an d Califor- nia Air Resources Board (CARB) require manuf acture rs of small off-road engine[...]

  • Page 9

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 2-3 W ARRANTIES 4. Repair or Replacement Cost . Repair or Replacement Cost. Repair or replacement of any emissions control par t will be performed at no charge to the owner , includ- ing diagnostic labo r which leads to the deter mination that an emissions control[...]

  • Page 10

    W ARRANTIES 2-4 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual NORTHSHORE PO WER SYSTEMS REPLA CEMENT P ARTS LIMITED W ARRANTY Honeywell P or table Generator F or a per iod of 90 days from the date of sale or installatio n of a Nor thshore P ower Systems , LLC supplied par t, Nor thshore P owe r Systems w ill,[...]

  • Page 11

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 3-1 3: SPECIFICA TIONS AND WIRING DIA GRAMS 3.1 SPECIFICA TIONS GENERA T OR 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[...]

  • Page 12

    BOL T AND F ASTENER T ORQUE INFORMA TION 3-2 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 3.2 BOL T AND F ASTENER T ORQUE INFORMA TION Component-Specific F astener F astener Siz e T orque V alues N•m lb . ft. Alter nator End Cov er Bolts M5 x 0.75 x 12 4 3 Alter nator Housing Bolts M10 x 1.25 x 80 48 35 Ax[...]

  • Page 13

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 3-3 WIRING DIA GRAMS 3.3 WIRING DIA GRAMS HW3000 & HW3000L FIGURE 3-1: HW3000 & HW3000 L Wir ing Diagr am AL TERNA T OR CONTROL P ANEL ENGINE OIL ALERT SENDER SP ARK PLUG OIL SHUTDOWN SWITCH IGNITION COIL ENGINE BLOCK Y Y Bl Bl Bl Bl ENGINE CONTROL SWITCH [...]

  • Page 14

    WIRING DIA GRAMS 3-4 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual HW4000 & HW4000L FIGURE 3-2: HW4000 & HW4000L Wiring Diagra m G Y W X AL TERNA T OR CONTROL P ANEL ENGINE OIL ALERT SENDER SP ARK PLUG OIL SHUTDOWN SWITCH IGNITION COIL ENGINE BLOCK Y Y Bl Y Bl Bl ENGINE CONTROL SWITCH Bl Bu E IG GROUN[...]

  • Page 15

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 3-5 WIRING DIA GRAMS HW5500 & HW5500L FIGURE 3-3: HW5500 & HW5500L Wiring Diagr am G Y W X AL TERNA T OR CONTROL P ANEL ENGINE OIL ALERT SENDER SP ARK PLUG OIL SHUTDOWN SWITCH IGNITION COIL ENGINE BLOCK Y Y Bl Y Bl Bl ENGINE CONTROL SWITCH Bl Bu E IG GROUN[...]

  • Page 16

    WIRING DIA GRAMS 3-6 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual HW5500E & HW5500EL FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram AL TERNA T OR CONTROL P ANEL ENGINE ON/OFF SWITCH P ANEL G Y W X OIL ALERT SENDER SP ARK PLUG OIL SHUTDOWN SWITCH IGNITION COIL ENGINE BLOCK Y Y Bl Y Bl Bl ENGINE CONTROL[...]

  • Page 17

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 3-7 WIRING DIA GRAMS HW6200 & HW6200L FIGURE 3-5: HW6200 & HW6200L Wiring Diagr am G Y W X AL TERNA T OR CONTROL P ANEL ENGINE OIL ALERT SENDER SP ARK PLUG OIL SHUTDOWN SWITCH IGNITION COIL ENGINE BLOCK Y Y Bl Y Bl Bl ENGINE CONTROL SWITCH Bl Bu E IG GROUN[...]

  • Page 18

    WIRING DIA GRAMS 3-8 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual HW7000E, HW7000EL, HW7500E, & HW7 500EL FIGURE 3- 6: HW7000E, HW7000EL, HW7500E & HW7500EL Wiring Diagram AL TERNA T OR CONTROL P ANEL ENGINE ON/OFF SWITCH P ANEL G Y W X OIL ALERT SENDER SP ARK PLUG OIL SHUTDOWN SWITCH IGNITION COIL E[...]

  • Page 19

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 4-1 4: COMPONENTS A—P ower Control Center Electrical Outlets • 125V AC 20 Amp Duplex (NEMA 5-20R) outlets to connect 120V appliances to generator fo r power . • 125/250V AC 30 Amp T wist-Lock (NEMA L14-30R) outlet (on select models) can be used to power appl[...]

  • Page 20

    4-2 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual THIS P A GE INTENTIONALL Y LEFT BLANK[...]

  • Page 21

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 5-1 5: PREP ARING FOR SER VICE 5.1 REQUIRED T OOLS A complete set of standard and metric shop tools are required to ser vice the generator . Also needed are: • Hammer • T orque wrench • V olt-ohm meter • F requency meter • Resistive loa d - such as a loa[...]

  • Page 22

    5-2 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual THIS P A GE INTENTIONALL Y LEFT BLANK[...]

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    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 6-1 6: SER VICE REP AIR TIME ANAL YSIS & FLA T RA TE SCHEDULE Operation HW3000 HW3000L (min.) HW4000 HW4000L (min.) HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW7500EL (min.) ELECTRICAL Alter nator Compl[...]

  • Page 24

    SER VICE REP AIR TIME ANAL YSIS 6-2 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual NO TE: Repair times represent generally accepted intervals f or conducting a repair . Ser vice centers are alwa ys advised to provide f eedback during the warr anty claim process if additional time may be needed due to unf orese[...]

  • Page 25

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 7-1 7: MAINTENANCE 7.1 CONSUMER MAINTENANCE SCHEDULE P eriodic mai ntenance and adjustment a re necessar y to keep the ge nerator in good o perating condition. P erform ser vice and inspection at inter vals sho wn in the Ge nerator Maintenance Schedule (T able 7-1[...]

  • Page 26

    CONSUMER MAINTENANCE SCHEDULE 7-2 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual FUEL RECOMMEND A TIONS Bef ore each use, check the fuel tank gage . If the fuel lev el is low , refill the tank with recommended fuel. NEVER O VERFILL. General Fuel Information Check the fuel gage located on the top of the gener a[...]

  • Page 27

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 7-3 AIR FIL TER MAINTENANCE ENGINE OIL RECOMMEND A TIONS Use 4-stroke oil, or equiv alent high detergent, premium quality motor oil cer tified to meet or e xceed U.S . automo- bile manuf acturer's requirements f or API P erf or mance Class SL, SJ, or better .[...]

  • Page 28

    AIR FIL TER MAINTENANCE 7-4 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 3. Remov e foam air filter(s). 4. W ash air filter(s) in a solution of household soap and war m wat er . 5. Rinse par ts thoroughly with water . 6. Using a clean, absorbent cloth, squeeze air filter dry , being careful not to twist or t[...]

  • Page 29

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 7-5 CLEANING FUEL SEDIMENT CUP 7.3 CLEANING FUEL SEDIMENT CUP The sediment cup pre vents any dirt or water that ma y be in the fuel tank from entering the carburetor . Clean fuel sediment cup at the intervals specified in T able 7-1. T o clean fuel sediment cup: 1[...]

  • Page 30

    CLEANING SP ARK ARREST OR SCREEN 7-6 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 7.5 CLEANING SP ARK ARREST OR SCREEN The generator muffler is equipped with a spark arrestor screen, which must be cleaned according to the mainte- nance schedule (see T able 7-1) to ensure pre v ention of sparks escaping gener[...]

  • Page 31

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 7-7 V AL VE LASH 7.6 V AL VE LASH 1. Remov e the cylinder head cov er and carefully remov e the gasket f or re-use. (Inspect and replace gask et, if necessar y .) 2. Remov e the spark plug to reduce engine compres- sion resistance. 3. T ur n the engine crankshaft [...]

  • Page 32

    B A TTER Y SER VICE 7-8 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 7.9 B ATTER Y SER VICE T o ensure the batter y remains charged, it is recom- mended that the generator is started ev er y three months. If the generator is stored f or more than a year with out r un- ning, a batter y charger ma y be require[...]

  • Page 33

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 8-1 8: TR OUBLESHOO TING NO TE: For all dealer service inquiries, call 1-877-HWTECHS (498-3247) or visit www .hone ywellgenerators.com. ANY ONE using or ser vi cing this generator must read, un derstand, and follow all saf ety and operation instr uctions pro- vide[...]

  • Page 34

    ELECTRICAL DIA GNOSTICS (HW3000/L MODELS) 8-2 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 8.1 ELECTRICAL DIA GNOSTICS (HW3000/L MODELS) P erform “Alter nator Check” Remove Alternator End Cov er 120V Circuit #1 Check (No Output OR V oltage Out of Spec) Check Wires and Connections from A VR to Brush Assem[...]

  • Page 35

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 8-3 ELECTRICAL DIA GNOSTICS (HW3000/L MODELS) To Alternator See “Specifications” P age For Rated P ower , V oltage, & Frequency Specs Under Load and No Load Conditions Y ellow / Green Wire = G White Wire = W Black Wire = X 3000 RATED WATTS • 3750 MAXIMUM[...]

  • Page 36

    ELECTRICAL DIA GNOSTICS (HW3000/L MODELS) 8-4 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual Rated P ower Chec k (Low P ow er 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 hi[...]

  • Page 37

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 8-5 ELECTRICAL DIA GNOSTICS (HW3000/L MODELS) Blue Y ellow Brown Y ellow EXCITER WINDING A VR T AP WINDING EXCITER & A VR T AP CONNECTOR* *view looking into female connector from alternator ROTOR SLIP RINGS SLIP RING TERMINALS VOL T AGE REGULA T OR POTENTIOMET[...]

  • Page 38

    ELECTRICAL DIA GNOSTICS (ALL MODELS EXCEPT HW3000/L) 8-6 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 8.2 ELECTRICAL DIA GNOSTICS (ALL MODELS EXCEPT HW3000/L) P erform “Alter nator Check” Check f or T ripped Master Breaker Resolve Ov erload Problem to Ensure Safe Operation After Electrical Load Resolved [...]

  • Page 39

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 8-7 ELECTRICAL DIA GNOSTICS (ALL MODELS EXCEPT HW3000/L) Y ellow / Green Wire = G White Wire = Y Red Wire = X To Alternator See “Specifications” P age For Rated P ower , V oltage, & Frequency Specs Under Load and No Load Conditions Brown Wire = W on Duplex[...]

  • Page 40

    ELECTRICAL DIA GNOSTICS (ALL MODELS EXCEPT HW3000/L) 8-8 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual Rated P ower Check (Low P ower 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 t[...]

  • Page 41

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 8-9 ELECTRICAL DIA GNOSTICS (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 VOL T AGE REGULA T OR POTENTIOMETER TO A[...]

  • Page 42

    ENGINE DIA GNOSTICS (ALL MODELS) 8-10 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 8.3 ENGINE DIA GNOSTICS (ALL MODELS) Engine F ails to Crank Using Electric Star ter Check Battery V oltage Higher than 12.5 V olts = Check V oltage Across Components Less than 12.5 V olts = Charge or Replace Battery Check V ol[...]

  • Page 43

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 9-1 9: SER VICE AND DISASSEMBL Y 9.1 CONTROL P ANEL A—CONTROL P ANEL ASSEMBL Y (FR ONT) 4 N•m (3 lb . ft.) B—CONTROL P ANEL ASSEMBL Y (BA CK) C—MAIN CONTROL P ANEL (FRO NT) • 125V AC 20 Amp Duple x (NEMA 5-20R) • 125/250V AC 30 Amp T wi st-Lock (NEMA L[...]

  • Page 44

    ENGINE AND AL TERNA T OR 9-2 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 9.2 ENGINE AND AL TERNA T OR A—END CO VER 4 N•m (3 lb . ft.) B—RO T OR BOL T Use oil bef ore replacing the rotor bolt. C—AL TERNA T OR HOUSING BOL TS 48 N•m (35 lb . ft.) D—REAR BEARING CARRIER AND ST A TOR See CARBURET OR,[...]

  • Page 45

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 9-3 AL TERNA T OR 9.3 AL TERNA T OR A—V OL T A GE REGULA TOR Alternator Illustrated Matches All Models Except HW3000 & HW3000L B—BRUS H ASSEMBL Y Bef ore removing rotor and stator , remov e brush assembly . 2 N•m (1.5 lb . ft.) C—REAR BEARING CARRIER D[...]

  • Page 46

    FUEL T ANK SYSTEM 9-4 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 9.4 FUEL TANK SYSTEM Fuel and its v apors are e xtremely fl ammable and e xplosive under cer tain co nditions. • Refuel the generator only outd oors, in a well-v entilated ar ea. • NEVER enclose the generator in an y structure. • K eep [...]

  • Page 47

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 9-5 EV APORA TIVE EMISSIONS CONTR OL SYSTEM 9.5 EV APORA TIVE EMISSIONS CONTROL SYSTEM F or Mo del Numbers Ending in “L ” only . A—FUEL T ANK B—CARBON CANISTER • B1 - HW3000L Model Only • B2 - All Other Models C—V APOR LINE Secure with hose clamps. D[...]

  • Page 48

    MUFFLER 9-6 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 9.6 MUFFLER The muffler becomes very hot dur ing operation and remains hot for a while after stopping the engine. • NEVER touch hot surf aces and av oid hot gases. • Let engine cool before storing the generator indoors. A—MUFFLER GU ARD NO TE: No[...]

  • Page 49

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 9-7 CARBURET OR 9.7 CARBURET OR Fuel and its v apors are e xtremely fl ammable and e xplosive under cer tain co nditions. • Refuel generator only o utdoors, in a well-ventilated area. • NEVER enclose the generator in an y structure. • K eep generator at leas[...]

  • Page 50

    ST AR TING SYSTEM 9-8 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 9.8 ST ARTING SYSTEM A—ELECTRIC ST ARTER Attempt to crank engine b y switching the engine control s witch to the ST AR T position. Star ter Solenoid T er minal Nut - 6 N•m (4 lb . ft.) B—WOODR UFF KEY After installing the flywheel, chec[...]

  • Page 51

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 9-9 RECOIL ST AR TER 9.9 RECOIL ST ARTER A—ST ARTER CASE B—ROPE AND HANDLE Install with recoil star ter handle position as shown. C—RETURN SPRING Connect the outer hook in the groo ve of the star ter reel and inner hook on the star ter case tab . D—ST ARTE[...]

  • Page 52

    FA N C O V E R 9-10 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 9.10 F AN CO VER A—COOLING F AN Install by aligning the three lugs on the rear side of the f an with the small hole in the fly- wheel. When disassembling and assem- bling, tak e care not to damage the f an blades . B—ST ARTER PULLEY Install[...]

  • Page 53

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 9-11 WHEEL, LEG, & HANDLE ASSEMBL Y 9.11 WHEEL, LEG, & HANDLE ASSEMBL Y (HW3000/L MODELS) A—LOCKING HANDLE BRA CKET 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 . f[...]

  • Page 54

    WHEEL, LEG, & HANDLE ASSEMBL Y 9-12 www .honeywellgenerators.com Honeywell P or table Electrical Generator Service Manual 9.12 WHEEL, LEG, & HANDLE ASSEMBL Y (ALL MODELS EXCEPT HW3000/L) A—WHEEL HANDLE PIV O T BRA CKET 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—SUPPOR [...]

  • Page 55

    Honeywell P ortable Electrical Generator Ser vice Manual www .honeywellgenerators.com 10-1 A Air Filter Maintenance 7-3 Alternator 9-2 , 9-3 A utomatic V oltage Regulator (A VR) 8-5 , 8-9 , 9-3 B Batter y 4-1 , 7-8 Breakers 4-1 C Components breakers 4-1 chok e control 4-1 engine control s witch 4-1 fuel shut-off va lve 4-1 recoil star t[...]

  • Page 56

    Northshore Po wer 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 pr oduct. The Honeywell T rademark is used under license fro[...]