Honeywell HW4000 Service Manual
Portable gasoline generator
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Also See for HW4000:
- Owner's manual (86 pages) ,
- Specification sheet (1 page) ,
- Owner's manual (47 pages)
Table of Contents
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Table of Contents
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Summary of Contents for Honeywell HW4000
- Page 1 Portable Gasoline Generator Service Manual HW4000 HW5500 HW5500E HW6200 HW7500E 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. DRAFT - 07/30/08...
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Page 3: Table Of Contents
MUFFLER ..............................9-3 GENERATOR ............................9-4 GENERATOR REAR HOUSING ....................... 9-5 ALTERNATOR ............................9-6 CONTROL PANEL ............................ 9-8 STARTING SYSTEM ..........................9-9 RECOIL STARTER ..........................9-10 FAN COVER ............................9-11 FRAME ..............................9-12 INDEX ..........................10-1 Honeywell Portable Generator Service Manual www.honeywellgenerators.com... - Page 4 THIS PAGE INTENTIONALLY LEFT BLANK www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
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Page 5: Important Safety Rules
NEVER use inside a home or to bystanders. away from windows, doors, and or garage, EVEN IF doors vents. and windows are open. Indicates a situation which, if not avoided, may result in damage to generator com- ponents. Honeywell Portable Generator Service Manual www.honeywellgenerators.com... - Page 6 • Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, be sure the area is dry before starting the engine. • Avoid repeated or prolonged contact with skin or breathing of vapor. www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
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Page 7: Warranties
Warranty is also available by keeping and showing your origi- warranty period, and any repaired product shall be warranted nal receipt from date of purchase to an authorized Honeywell for the remaining original warranty period only. Generator Dealer. -
Page 8: Northshore Power Systems Emissions Control Warranty
You may be denied warranty coverage if a part an emissions control part is defective, if the diagnostic has failed due to abuse, neglect, improper maintenance or work is performed at an authorized NSP Honeywell gen- unapproved modifications. erator dealer. - Page 9 Service department at NSP. By phone: 1-414-332-2375 Via web: www.honeywellgenerators.com By US mail: Northshore Power Systems, LLC Attention: Product Warranty and Service Dept. 4425 N Port Washington Road Suite 105 Milwaukee WI 53212-1082 Honeywell Portable Generator Service Manual www.honeywellgenerators.com...
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Page 10: Northshore Power Systems Replacement Parts Limited Warranty
CONSEQUENTIAL DAMAGE 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) www.honeywellgenerators.com Honeywell Portable Generator Service Manual... -
Page 11: Specifications And Wiring Diagrams
Spark Plug Type 0.028-0.031 / 0.028-0.031 / 0.028-0.031 / 0.028-0.031 / Spark Plug Gap [in /mm] 0.7-0.8 0.7-0.8 0.7-0.8 0.7-0.8 *Equivalent spark plug replacements: Bosch W20EPR, Champion RN9YC, Denso WR7DC TABLE 3-1. Honeywell Portable Generator Specifications Honeywell Portable Generator Service Manual www.honeywellgenerators.com... -
Page 12: Bolt And Fastener Torque Information
.8 - 1.2 Standard Torque Values 8 mm bolt, nut 22 - 28 16.2 - 20.7 2.2 - 2.9 10 mm bolt, nut 24 - 32 17.7 - 23.6 2.4 - 3.3 TABLE 3-2. Torque Values www.honeywellgenerators.com Honeywell Portable Generator Service Manual... -
Page 13: Wiring Diagrams
WIRING DIAGRAMS 3.2 WIRING DIAGRAMS HW4000 FIGURE 3-1: HW4000 Wiring Diagram Honeywell Portable Generator Service Manual www.honeywellgenerators.com... - Page 14 WIRING DIAGRAMS HW5500 FIGURE 3-2: HW5500 Wiring Diagram www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
- Page 15 WIRING DIAGRAMS HW5500E FIGURE 3-3: HW5500E Wiring Diagram Honeywell Portable Generator Service Manual www.honeywellgenerators.com...
- Page 16 WIRING DIAGRAMS HW6200 FIGURE 3-4: HW6200 Wiring Diagram www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
- Page 17 WIRING DIAGRAMS HW7500E FIGURE 3-5: HW7500E Wiring Diagram Honeywell Portable Generator Service Manual www.honeywellgenerators.com...
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Page 19: Controls And Components
Seals off engine oil fill hole and provides indicator for Delivers volts to spark plug. When spark plug needs ser- engine oil level. vice, cap must be removed. D—Engine Oil Plug When loosened, allows engine oil to drain from generator. Honeywell Portable Generator Service Manual www.honeywellgenerators.com... - Page 20 THIS PAGE INTENTIONALLY LEFT BLANK www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
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Page 21: Preparing For Service
To avoid damage to generator, take care not to drop or strike • Jumper wires generator when transporting. Do not place heavy objects on generator. • Rotor Puller • Wood block (for rotor support) Honeywell Portable Generator Service Manual www.honeywellgenerators.com... - Page 22 THIS PAGE INTENTIONALLY LEFT BLANK www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
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Page 23: Service Repair Time Analysis & Flat Rate Schedule
Repair times represent generally accepted intervals for conducting a repair. Service centers are always advised to pro- vide feedback during the warranty claim process if additional time may be needed due to unforseen circumstances. Honeywell Portable Generator Service Manual www.honeywellgenerators.com... - Page 24 THIS PAGE INTENTIONALLY LEFT BLANK www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
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Page 25: Maintenance
Every 2 years (replace if necessary)† TABLE 7-1. Generator Maintenance Schedule * Clean more often when using generator in dusty areas. † It is recommended that this maintenance task be performed by a service dealer. Honeywell Portable Generator Service Manual www.honeywellgenerators.com... - Page 26 If the oil level is insuffi- cient, the switch opens, thus creating an open circuit in the ignition system, stopping the engine. www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
- Page 27 Be sure pump octane rating is 87 or higher. • Try to confirm contents of fuel. Some states (and provinces in Canada) require this infor- mation to be posted on the fuel pump. If you notice unde- Honeywell Portable Generator Service Manual www.honeywellgenerators.com...
- Page 28 FIGURE 7-5: Wash Air Filter Using a clean, absorbent cloth, squeeze air cleaner element dry, being careful not to twist or tear the filter. FIGURE 7-2: Air Cleaner Cover FIGURE 7-6: Dry Air Filter www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
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Page 29: Cleaning Fuel Sediment Cup
(C), with soap and water. Wipe the pieces clean with a clean, dry cloth. Reinstall the sediment cup, o-ring, and fuel filter. Turn the fuel valve to the ON position and check for leaks. Honeywell Portable Generator Service Manual www.honeywellgenerators.com... -
Page 30: Spark Plug Service
FIGURE 7-12: Remove Spark Arrestor Enclosure Panel TABLE 7-3. Spark Plug Equivalents to 100842A Pull off enclosure panel. FIGURE 7-13: Spark Arrestor Assembly Using a screwdriver, loosen and remove screw hold- ing spark arrestor clamp (A). www.honeywellgenerators.com Honeywell Portable Generator Service Manual... -
Page 31: Valve Clearance
To decrease valve clearance, screw pivot nut in. C—PIVOT Hold the rocker arm pivot and loosen the lock nut (see B in illustration). Turn the rocker arm pivot (see C in illustration) to obtain specified clearance. Honeywell Portable Generator Service Manual www.honeywellgenerators.com... -
Page 32: Governor Adjustment
3600 ± 150 rpm 57-62 hz Loaded Speed 3600 ± 100 rpm 58-61 hz TABLE 7-5. Engine Speed GOVERNOR ARM SHAFT GOVERNOR ARM PINCH BOLT GOVERNOR SPRING GOVERNOR ARM ANTI-SURGE SPRING THROTTLE FIGURE 7-16: Governor Arm Assembly www.honeywellgenerators.com Honeywell Portable Generator Service Manual... -
Page 33: Troubleshooting
Only use OUTSIDE and far NEVER use inside a home away from windows, doors, and or garage, EVEN IF doors vents. and windows are open. NOTE: For all dealer service inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com. Honeywell Portable Generator Service Manual www.honeywellgenerators.com... -
Page 34: Engine Diagnostics
Check Oil in Fuel Check Oil Overfilled Check Worn Piston Rings Check Governor Assembly Rope Not Retracting = Adjustment Disassemble and Repair Broken Ratchets or Springs Perform Engine Compression Test (see Manual Section “Recoil Starter”) Honeywell Portable Generator Service Manual www.honeywellgenerators.com... -
Page 35: Alternator Diagnostics
Adjust Throttle Position to Increase Engine Power POWER CONTROL CENTER HOUSEHOLD 4-IN-1 POWER CORD OF OUTLETS TRANSFER SWITCH 120 VOLTS AC 120/240 VOLTS AC MASTER BREAKER BREAKER BREAKER PORTABLE GENERATOR 5500 CONTINUOUS WATTS - 9375 MAXIMUM WATTS Honeywell Portable Generator Service Manual www.honeywellgenerators.com... - Page 36 THIS PAGE INTENTIONALLY LEFT BLANK www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
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Page 37: Service And Disassembly
F—FUEL FILTER See Chapter 7, “CLEANING FUEL SEDIMENT CUP”. G—FUEL VALVE Clear passages if clogged. After reinstalling, check for fuel leak- age. H—FUEL SEDIMENT CUP See Chapter 7, “CLEANING FUEL SEDIMENT CUP”. Honeywell Portable Generator Service Manual www.honeywellgenerators.com... -
Page 38: Carburetor
G—CARBURETOR BODY Clean internal passages and orifices with compressed air before installa- tion. H—O-RING Check for correct installation. I— MAIN NOZZLE Clean with compressed air before installation. J—MAIN JET Clean with compressed air before installation. www.honeywellgenerators.com Honeywell Portable Generator Service Manual... -
Page 39: 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—EXHAUST PIPE B—MUFFLER C—SPARK ARRESTOR SCREEN Honeywell Portable Generator Service Manual www.honeywellgenerators.com... -
Page 40: Generator
See Chapter 9, “ROTOR” D—CRANKCASE GROMMET Be sure grommet is inserted securely. E—RUBBER MOUNT • Insert tabs into holes. • Be sure rubber is not chipped, hardened, or worn. • Refer to illustration for proper positioning. www.honeywellgenerators.com Honeywell Portable Generator Service Manual... -
Page 41: Generator Rear Housing
If torquing rotor puller does not free rotor from crankshaft, tap end of puller with brass ham- mer to loosen rotor. Use oil before replacing. CAUTION To prevent eye injury, always wear safety glasses or goggles when striking end of rotor puller. Honeywell Portable Generator Service Manual www.honeywellgenerators.com... -
Page 42: Alternator
Inspect slip rings for dust, rust, or other damage. If rings are dirty, wipe with clean, lint-free cloth. If rings are rusted or appear damaged, remove rotor and wipe with fine emory cloth. www.honeywellgenerators.com Honeywell Portable Generator Service Manual... - Page 43 ALTERNATOR D—EXCITER WINDING CONNECTOR Resistance Specifications: Ω • HW4000 Model - 3.3-3.8 Blue White Ω • HW5500 Model - 2.3-2.7 Ω • HW5500E Model - 2.3-2.7 Blue Green Ω • HW6200 Model - 2.1-2.5 Ω • HW7500E Model - 1.7-1.8 Using an ohmmeter, measure resistance between the two blue wires.
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Page 44: Control Panel
See Chapter 9, “GENERATOR”. B—CONTROL PANEL C—ENGINE CONTROL SWITCH • C1 - Electric Start Units (HW5500E and HW7500E) • C2 - Manual Start Units (HW4000, HW5500, HW6200) D—FUEL TUBE Check fuel tube for leaks and damage. ENGINE START STOP ENGINE STOP www.honeywellgenerators.com... -
Page 45: Starting System
B—SPARK PLUG LEAD • B1 - Clamp securely to the crankcase with the two clamps. • B2 - Check for cracked or damaged insu- lation; replace, if necessary. Honeywell Portable Generator Service Manual www.honeywellgenerators.com... -
Page 46: Recoil Starter
D—RETURN SPRING Connect the outer hook in the groove of the starter reel and inner hook on the starter case tab. E—STARTER ROPE Install with the starter grip position as shown. 9-10 www.honeywellgenerators.com Honeywell Portable Generator Service Manual... -
Page 47: Fan Cover
C—FLANGE NUT (16 mm) Hold the flywheel by placing a screwdriver into the pulley. D—FAN COVER Remove and install with the recoil starter assembly. E—RECOIL STARTER ASSEMBLY Install with the starter grip position as shown. Honeywell Portable Generator Service Manual www.honeywellgenerators.com 9-11... -
Page 48: Frame
FIGURE 9-1: Wheel and Handle Assembly Components NOTICE • NEVER USE wheel kit on-road. • Wheel kit is intended to be used specifically with this generator. NEVER use wheel kit for any other purpose. Honeywell Portable Generator Service Manual www.honeywellgenerators.com 9-12... -
Page 49: Index
HW4000 3-3 HW5500 3-4 HW5500E 3-5 Maintenance 7-1 HW6200 3-6 air filter 7-4 HW7500E 3-7 cleaning spark arrestor 7-6 fuel sediment cup 7-5 schedule 7-1 spark plug 7-6 valve clearance 7-7 Muffler 9-3 Honeywell Portable Generator Service Manual www.honeywellgenerators.com 10-1... - Page 50 THIS PAGE INTENTIONALLY LEFT BLANK 10-2 www.honeywellgenerators.com Honeywell Portable Generator Service Manual...
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- Page 52 P/N: 101290A June 2008 4425 N. Port Washington Rd., Suite 105 2008 Northshore Power Systems, LLC Milwaukee, WI 53212-1082 USA The Honeywell Trademark is used under license TEL 1-888-494-3571 from Honeywell International Inc. Honeywell International Inc. makes no representation www.honeywellgenerators.com...