Honeywell HW3000/L Service Manual
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Honeywell HW3000/L Service Manual

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See also: Owner's Manual
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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HW3000/L
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Summary of Contents for Honeywell HW3000/L

  • Page 1 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. Downloaded from www.Manualslib.com manuals search engine...
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  • Page 3: Table Of Contents

    ............................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 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com...
  • Page 4 THIS PAGE INTENTIONALLY LEFT BLANK www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 5: Important Safety Instructions

    • Use the correct tool for the job and check its condition before starting. • Keep fire extinguishers and safety equipment nearby. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...

  • Page 6: Safety Messages

    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. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 7: Warranties

    Warranty is also available by keeping and showing your origi- excludes any use of this product intended to power life sup- nal receipt from date of purchase to an authorized Honeywell port devices, life support appliances, medical devices, or Generator Dealer.

  • Page 8: Northshore Power Systems Emissions Control Warranty

    Honeywell generator parts in performance and durability. 1-877-HWTECHS (498-3247). Length of Coverage. Northshore Power Systems war- rants to the original retail purchaser and each subse- 2.1 WARRANTIES...
  • Page 9 Honeywell Generator Owner's Manual. Any replacement part that is equivalent in per- formance and durability may be used for maintenance or repairs.

  • Page 10: Northshore Power Systems Replacement Parts Limited Warranty

    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. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 11: Specifications And Wiring Diagrams

    101536A 101536A (Electric Start Models Only) TABLE 3-1: Honeywell Portable Generator Specifications See ENGINE OIL RECOMMENDATIONS, page 7-3 for other engine oil types outside general temperature use. † See SPARK PLUG SERVICE, page 7-5 for other recommended spark plug replacements.

  • Page 12: Bolt And Fastener Torque Information

    M8 x 1.0 x 16 Support Leg to Rubber Stopper Bolts M8 x 1.0 x 25 Wheel Handle Pivot Bracket Bolts M6 x 1.0 x 40 TABLE 3-3: Torque Values www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 13: Wiring Diagrams

    WIRING DIAGRAMS 3.3 WIRING DIAGRAMS HW3000 & HW3000L FIGURE 3-1: HW3000 & HW3000L Wiring Diagram Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
  • Page 14 WIRING DIAGRAMS HW4000 & HW4000L FIGURE 3-2: HW4000 & HW4000L Wiring Diagram www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
  • Page 15 WIRING DIAGRAMS HW5500 & HW5500L FIGURE 3-3: HW5500 & HW5500L Wiring Diagram Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
  • Page 16 WIRING DIAGRAMS HW5500E & HW5500EL FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
  • Page 17 WIRING DIAGRAMS HW6200 & HW6200L FIGURE 3-5: HW6200 & HW6200L Wiring Diagram Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
  • Page 18 WIRING DIAGRAMS HW7000E, HW7000EL, HW7500E, & HW7500EL FIGURE 3-6: HW7000E, HW7000EL, HW7500E & HW7500EL Wiring Diagram www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 19: Components

    4: COMPONENTS 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 •...
  • Page 20 THIS PAGE INTENTIONALLY LEFT BLANK www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 21: Preparing For Service

    Keep the generator level to prevent fuel spillage. • Place pins in the handle and handle bracket before moving the generator. NOTICE NEVER drop, strike, or place heavy objects on generator when transporting. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
  • Page 22 THIS PAGE INTENTIONALLY LEFT BLANK www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 23: Service Repair Time Analysis & Flat Rate Schedule

    FUEL & EXHAUST Carbon Canister (with bracket) (Model Numbers Ending in “L”) Carbon Canister Tube (Model Numbers Ending in “L”) Exhaust Pipe (Model Numbers Ending in “L”) Fuel Gage Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
  • Page 24 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 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 25: Maintenance

    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. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com...

  • Page 26: Consumer Maintenance Schedule

    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. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 27: Air Filter Maintenance

    Crankcase pressure can cause hot engine oil to spray out of engine fill hole. Hot engine oil can cause severe burns. FIGURE 7-3: Air Cleaner Cover—Non-L Models Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
  • Page 28 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. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 29: Cleaning Fuel Sediment Cup

    Champion RN9YC Turn the fuel shut-off valve to the ON position. Start generator and check for leaks. Denso W20EPR BPR6ES TABLE 7-4. Spark Plug Equivalents to 100842A Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...

  • Page 30: Cleaning Spark Arrestor Screen

    FIGURE 7-16: Clean Screen Reinstall remaining spark arrestor components. „ Spark arrestor screen cap and screw Clamp and screw „ „ Muffler cover FIGURE 7-14: Remove Muffler Cover www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 31: Valve Lash

    Check valve lash again after tightening lock nut. Repeat steps 4 through 7, as needed, until valve lash is within specifications. Reassemble the spark plug, cylinder head cover, and gasket. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...

  • Page 32: Battery Service

    Disconnect the black negative (-) battery lead remov- ing the bolt and nut. FIGURE 7-21: Electric Start Battery—Lead Connection Disconnect the red positive (+) battery lead removing the bolt and nut. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 33: Troubleshooting

    EVEN IF doors doors, and vents. and windows are open. NOTE: For all dealer service inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...

  • Page 34: Electrical Diagnostics (Hw3000/L Models)

    ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) 8.1 ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) 120V Circuit #1 Check 120V Circuit #2 Check General Electrical Check (No Output OR (No Output OR Voltage Out of Spec) Voltage Out of Spec) Refer to Illustrations on Conduct This Check Only When...
  • Page 35 NEMA 5-20R 120V NEMA 5-20R 120V 3000 RATED WATTS • 3750 MAXIMUM WATTS White Wire = W Black Wire = X Yellow / Green Wire = G Alternator Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...
  • Page 36 Slip Rings Rotor 45 - 65 Slip Ring Terminals* If a Winding Resistance is Out of Spec, Replace Alternator Specification AVR Tap Either Exciter Yellow Replace Alternator www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...
  • Page 37 EXCITER & AVR TAP SLIP RING CONNECTOR* TERMINALS POTENTIOMETER TO ADJUST VOLTAGE AVR TAP Blue Brown WINDING EXCITER Yellow Yellow WINDING *view looking into female connector from alternator Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...

  • Page 38: Electrical Diagnostics (All Models Except Hw3000/L)

    ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) 8.2 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) 120V Circuit Check 240V Circuit Check General Electrical Check (No Output OR (No Output OR Voltage Out of Spec) Voltage Out of Spec) Refer to Illustrations on...
  • Page 39 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) See “Specifications” Page For Rated Power, Voltage, & Frequency Specs Under Load and No Load Conditions Duplex Outlet #1 Duplex Outlet #2 NEMA 5-20R 120V NEMA 5-20R 120V HOUSEHOLD POWER CORD or OUTLETS TRANSFER SWITCH...
  • Page 40 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) Rated Power Check Alternator Check (Low Power Output) NOTE: At high-altitudes, standard NOTE: The alternator must be at room temperature when resistance is measured. Refer to Illustrations on carburetor air-fuel mixture will be rich causing a decrease in engine Page 8-9.
  • Page 41 ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) EXCITER & AVR TAP CONNECTOR* STATOR-X BRUSH ASSEMBLY WINDING Blue Green Red Wire EXCITER AVR TAP WINDING WINDING Blue White White Wire TERMINAL BLOCK Blue *view looking into female connector from alternator 5-9 mm...

  • Page 42: Engine Diagnostics (All Models)

    Frequency = 60 Hz + 3 Disassemble and Repair Check Worn Piston Rings Broken Ratchets or Springs (see Manual Section “Recoil Starter”) Check Governor Assembly Perform Engine Compression Test Adjustment 8-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 43: Service And Disassembly

    HW7500E, HW7500EL) • E2 - Manual Start Models (HW3000, HW3000L, HW4000, HW4000L, HW5500, HW5500L, HW6200, HW6200L) F—ENGINE CONTROL SWITCH G—SWITCH PLATE (BACK) ENGINE START STOP ENGINE STOP Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...

  • Page 44: Engine And Alternator

    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.) www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 45: Alternator

    J—BRUSH ASSEMBLY K—TERMINAL BLOCK L—SLIP RINGS M—FUEL CUTOUT CONNECTOR N—VOLTAGE REGULATOR Also known as Automatic Voltage Regulator or AVR. Alternator Illustrated Matches All Models Except HW3000 & HW3000L Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...

  • Page 46: Fuel Tank System

    Hex fitting - 24 N•m (17 lb. ft.) G—FUEL SEDIMENT CUP See CLEANING FUEL SEDIMENT HW7500E Model Illustrated CUP, page 7-5. H—FUEL LINE Check for cracks or damage. Secure with hose clamps. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 47: Evaporative Emissions Control System

    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 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...

  • Page 48: Muffler

    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.) www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 49: Carburetor

    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. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...

  • Page 50: Starting System

    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. www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 51: Recoil Starter

    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 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com Downloaded from www.Manualslib.com manuals search engine...

  • Page 52: Fan Cover

    105 N•m (77 lb. ft.) D—FAN COVER Remove and install with the recoil starter assembly. E—RECOIL STARTER ASSEMBLY Install with the recoil starter handle position as shown. 9-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 53: Wheel, Leg, & Handle Assembly (Hw3000/L Models)

    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 9-11 Downloaded from www.Manualslib.com manuals search engine...

  • Page 54: Wheel, Leg, & Handle Assembly (All Models Except Hw3000/L)

    • 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. HW5500E Model Illustrated 9-12 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual Downloaded from www.Manualslib.com manuals search engine...

  • Page 55: Index

    7-7 schedule 7-1 spark arrestor screen 7-6 spark plug 7-5 valve lash 7-7 Muffler 4-1 Oil Fill Dipstick 4-1 Oil Recommendations 7-3 Outlets 4-1 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 10-1 Downloaded from www.Manualslib.com manuals search engine...
  • Page 56 Northshore Power Systems, LLC P/N 101290D 2010 Northshore Power Systems, LLC 4425 N. Port Washington Road The Honeywell Trademark is used under license Suite 105 from Honeywell International Inc. Milwaukee, WI 53212-1082 USA Honeywell International Inc. makes no representation 1-888-HWTECHS (498-3247) or warranties with respect to this product.

This manual is also suitable for:

Hw5500/lHw4000/lHw5500e/lHw6200/lHw7000e/lHw7500e/l

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