Honeywell HW3000/L Service Manual Download Page 2

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Summary of Contents for HW3000/L

Page 1: ...W7000E 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 ...

Page 2: ... ...

Page 3: ...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 DIAGNOST...

Page 4: ...ii www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 5: ...tion 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...

Page 6: ... 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 f...

Page 7: ...onsumer 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 POWE...

Page 8: ...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 con...

Page 9: ...ons 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 ma...

Page 10: ...SHORE 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 additi...

Page 11: ... 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...

Page 12: ... 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 Adjustin...

Page 13: ...AC BREAKER 15A G W X FIELD WINDING MAIN WINDING EXCITER WINDING AVR Y Bu Bu Br Y Y 120 VAC Bl 4 mm 2 W 4 mm 2 W Bl 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 W X G W X G W X LEFT RIGHT 15...

Page 14: ...5A G W X FIELD WINDING MAIN WINDING EXCITER WINDING AVR W R W Lg 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 W X DUPLEX 5 20R G W Y G W Y MAIN WI...

Page 15: ...0A G W X FIELD WINDING MAIN WINDING EXCITER WINDING AVR W R W Lg 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 W X DUPLEX 5 20R G W Y G W Y...

Page 16: ... WINDING EXCITER WINDING AVR W R W Lg 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 W X DUPLEX 5 20R G W Y G W Y MAIN WINDING Br W R Bu Br W R Bu FUEL CUTOUT WINDING 5A FUSE G W G W TWIST LOCK L14 30R Bl g g Br Br MAGNETIC AC BREAKER 21A 120 VAC Br CHARGE COIL BATTERY STARTER MOTOR...

Page 17: ... 20A G W X FIELD WINDING MAIN WINDING EXCITER WINDING AVR W R W Lg 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 W X DUPLEX 5 20R G W Y G W Y MAIN ...

Page 18: ...ER WINDING AVR W R W Lg 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 W X DUPLEX 5 20R G W Y G W Y MAIN WINDING Br W R Bu Br W R Bu 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 CUT...

Page 19: ...or 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 Provi...

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Page 21: ...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 re...

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Page 23: ...Receptacles Ports 50 50 50 50 50 50 50 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 Choke 45 45 45 45 45 45 45 Converter Model Numbers Ending in L 60 60 60 60 60 60 60 Cylin...

Page 24: ...Ending in L 30 30 30 30 30 30 30 Fuel Tank 60 60 60 60 60 60 60 Fuel Shut off Valve 40 40 40 40 40 40 40 Muffler 50 50 50 50 60 60 60 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 Asse...

Page 25: ...ou 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 ...

Page 26: ...el 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 ...

Page 27: ...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 deterge...

Page 28: ... 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 ...

Page 29: ...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...

Page 30: ...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 Reins...

Page 31: ...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 p...

Page 32: ...ttery 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 ne...

Page 33: ...ollow 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 o...

Page 34: ...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...

Page 35: ...OSTICS 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 W X G W X G W Y G W Y Duplex Outlet 2 NEMA 5 20R 120V ...

Page 36: ...ator 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 4H...

Page 37: ...rown 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 ...

Page 38: ...k 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...

Page 39: ...oltage 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...

Page 40: ...L 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...

Page 41: ...wn 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 W...

Page 42: ...tion 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...

Page 43: ... 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...

Page 44: ...ND 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...

Page 45: ... 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...

Page 46: ...l 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...

Page 47: ...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 ...

Page 48: ...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...

Page 49: ...reful 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 a...

Page 50: ... 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 CHAR...

Page 51: ...k 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 glove...

Page 52: ...ly 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 positio...

Page 53: ... 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 E G 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 ...

Page 54: ...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...

Page 55: ...l 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 alt...

Page 56: ...98 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 ...

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