Honeywell HW4000 - Portable Generator NOT Service Manual Download Page 1

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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

Service Manual

Portable Gasoline Generator

Summary of Contents for HW4000 - Portable Generator NOT

Page 1: ...ad 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 Service Manual Portable Gasoline Generator ...

Page 2: ......

Page 3: ...OLS AND COMPONENTS 4 1 PREPARING FOR SERVICE 5 1 REQUIRED TOOLS 5 1 TRANSPORTING GENERATOR 5 1 SERVICE REPAIR TIME ANALYSIS FLAT RATE SCHEDULE 6 1 MAINTENANCE 7 1 CONSUMER MAINTENANCE SCHEDULE 7 1 CLEANING FUEL SEDIMENT CUP 7 5 SPARK PLUG SERVICE 7 6 CLEANING SPARK ARRESTOR SCREEN 7 6 VALVE CLEARANCE 7 7 GOVERNOR ADJUSTMENT 7 8 TROUBLESHOOTING 8 1 ENGINE DIAGNOSTICS 8 2 ALTERNATOR DIAGNOSTICS 8 3 ...

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

Page 5: ... tions provided in the product manual Failure to closely follow these instructions can result in circumstances leading to death serious injury and property damage Indicates an imminently hazardous situa tion which if not avoided will result in death or serious injury to the operator or to bystanders Indicates a potentially hazardous situa tion which if not avoided could result in death or serious ...

Page 6: ...battery terminals electric shock and seri ous burns can result Only use insulated non conducting tools when working with or near battery NEVER lay tools or other metal objects on top of bat tery Fuel and its vapors are extremely flammable and explosive under certain conditions Refuel generator only outdoors in a well ventilated area NEVER enclose the generator in any structure Keep generator at le...

Page 7: ...tate law with respect to any customer the duration of any implied warranties including but not limited to implied warranties of merchantability 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 NSP SHALL NOT BE LIABLE TO CUSTOMER OR TO ANYONE CLAIMING UNDER...

Page 8: ...For emissions warranty ser vice contact your nearest dealer a listing is available at www honeywellgenerators com or by calling 1 888 494 3571 EMISSIONS CONTROL SYSTEMS PARTS Coverage under this warranty extends only to the emissions control parts listed below 1 Fuel Metering System A Choke system B Carburetor C Fuel Pump if equipped D Fuel line clamps control valve E Fuel tank cap and screen F Ca...

Page 9: ... have questions regarding your emissions warranty rights and responsibilities you should contact the Warranty and 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 ...

Page 10: ...OMISSIONS OR OTH ERWISE TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW NSP SHALL NOT IN ANY EVENT BE LIABLE FOR INCIDENTAL COMPENSATORY PUNITIVE CONSEQUENTIAL INDIRECT SPECIAL OR OTHER DAM AGES INCLUDING BUT NOT LIMITED TO LOSS OF USE LOSS OF INCOME LOSS OF TIME LOSS OF SALES INJURY TO PERSONAL PROPERTY OR LIABILITY CUS TOMER INCURS WITH RESPECT TO ANY OTHER PER SON OR ANY OTHER TYPE OR FORM OF...

Page 11: ...C 14 10 14 10 14 10 14 10 ENGINE Speed rpm 3600 3600 3600 3600 Type OHV 4 cycle OHV 4 cycle OHV 4 cycle OHV 4 cycle Displacement cc 242 337 389 420 Fuel Tank Capacity gal L 6 5 24 6 6 5 24 6 6 5 24 6 6 5 24 6 Engine Oil Capacity qt L 1 2 1 1 1 2 1 1 1 2 1 1 1 2 1 1 Spark Plug Type 100842A 100842A 100842A 100842A Spark Plug Gap in mm 0 028 0 031 0 7 0 8 0 028 0 031 0 7 0 8 0 028 0 031 0 7 0 8 0 028...

Page 12: ... mm 14 16 10 3 11 8 1 4 1 6 Air Cleaner Wing Nut 6 1 0 mm 2 4 1 5 3 0 2 4 Muffler Mounting Bolt 8 1 25 mm 27 30 19 9 22 1 2 8 3 1 Oil Drain Bolt 12 1 5 mm 30 35 22 1 25 8 3 1 3 6 Fuel Tank Mounting Bolt 6 1 0 mm 8 12 5 9 8 9 8 1 2 Fuel Valve Joint Nut 10 1 25 mm 22 26 16 2 19 2 2 2 2 7 Flywheel Mounting Nut 16 1 5 mm 90 100 66 4 73 8 9 2 10 2 Spark Plug 13 16 27 30 19 9 22 1 2 8 3 1 Ignition Coil ...

Page 13: ...Honeywell Portable Generator Service Manual www honeywellgenerators com 3 3 WIRING DIAGRAMS 3 2 WIRING DIAGRAMS HW4000 FIGURE 3 1 HW4000 Wiring Diagram ...

Page 14: ...WIRING DIAGRAMS 3 4 www honeywellgenerators com Honeywell Portable Generator Service Manual HW5500 FIGURE 3 2 HW5500 Wiring Diagram ...

Page 15: ...Honeywell Portable Generator Service Manual www honeywellgenerators com 3 5 WIRING DIAGRAMS HW5500E FIGURE 3 3 HW5500E Wiring Diagram ...

Page 16: ...WIRING DIAGRAMS 3 6 www honeywellgenerators com Honeywell Portable Generator Service Manual HW6200 FIGURE 3 4 HW6200 Wiring Diagram ...

Page 17: ...Honeywell Portable Generator Service Manual www honeywellgenerators com 3 7 WIRING DIAGRAMS HW7500E FIGURE 3 5 HW7500E Wiring Diagram ...

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Page 19: ...il Plug When loosened allows engine oil to drain from generator E Engine Control Switch Control used to run and stop the engine ignition system START Starts generator engine electric start models RUN Prepares engine for starting manual start mod els Indicates engine is currently running electric start models STOP Stops generator engine by inhibiting ignition F Recoil Starter Grip Handle Starts eng...

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Page 21: ...nerator Press engine control switch to STOP position Turn fuel valve lever to OFF position Keep generator level to prevent fuel spillage 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 result in circumstances leading to death serious injury and prop erty damage Ho...

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Page 23: ...0 60 60 60 Capacitor 30 30 30 30 30 Flash the Field 30 30 30 30 30 Ignition Coil 50 50 50 50 50 Isolator 40 40 40 40 40 Oil Alert 30 30 30 30 30 Pull Start Assembly 30 30 30 30 30 Receptacles Ports Switches Breakers 30 30 30 30 30 Starter electric start models only 40 40 Starter Solenoid 30 30 ENGINE Air Filter Assembly 30 30 30 30 30 Carburetor 30 30 30 30 30 Choke Assembly 50 50 50 60 60 Crankca...

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Page 25: ...roblem before operation can cause a malfunction in which you 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 the generator under severe conditions such as sustained high load or high temperature or use it in unusually wet or dusty conditions...

Page 26: ...lubrication This switch operates by a float level design as the switch is immersed in oil the resistance measurement of the switch goes from zero to infinity If the oil level is insuffi cient the switch opens thus creating an open circuit in the ignition system stopping the engine When engine shuts down due to low oil level 1 The engine start switch will remain in the RUN posi tion 2 The engine wi...

Page 27: ...fuel 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 be sure fuel tank cap is closed properly and securely Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel...

Page 28: ...5 Using a clean absorbent cloth squeeze air cleaner element dry being careful not to twist or tear the filter NOTICE A dirty air filter will restrict air flow to carburetor which may cause poor engine performance or damage Never run the generator without air cleaner assembly prop erly attached Gasoline and flammable solvents can cause fire or explosion NEVER use gasoline or flammable sol vent to c...

Page 29: ...ace 3 Turn the fuel valve to the OFF position 4 Using a socket wrench with a 10 mm socket remove the fuel sediment cup assembly sediment cup o ring and fuel screen 5 Clean the fuel screen A o ring B and sediment cup C with soap and water 6 Wipe the pieces clean with a clean dry cloth 7 Reinstall the sediment cup o ring and fuel filter 8 Turn the fuel valve to the ON position and check for leaks FI...

Page 30: ...urface 3 Using a socket wrench with an 8 mm socket remove the spark arrestor enclosure panel bolts 4 Pull off enclosure panel 5 Using a screwdriver loosen and remove screw hold ing spark arrestor clamp A If the engine has been running the plug will reach temperatures that could cause severe burns Do not touch FIGURE 7 11 Correct Spark Plug Gap NOTICE The spark plug must be securely tightened An im...

Page 31: ...o reduce engine compres sion resistance 3 Turn the engine crankshaft using the recoil starter positioning engine at top dead center of the com pression stroke This can be verified by the piston position in the cylinder 4 Insert a feeler gauge between the rocker arm and valve spring to measure valve clearance 5 Hold the rocker arm pivot and loosen the lock nut see B in illustration 6 Turn the rocke...

Page 32: ...ise until the throttle is completely open and hold in position 4 Tighten the governor arm pinch bolt on the governor arm to maintain position 5 Confirm the governor arm and throttle move smoothly and do not bind 6 Re install the fuel tank 7 Start the engine attach a tachometer and adjust the limiting screw on the governor stop to achieve 3600 rpm 150 rpm at idle 8 To ensure the governor adjustment...

Page 33: ...w 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 Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poi son you cannot see or smell NEVER use inside a home or garage EVEN IF doors and windows are open...

Page 34: ...plug lead Replace Coil if Necessary Reinstall Coil with Proper Coil Flywheel Air Gap Reinstall Plug Recoil Not Operating For Models 3000 4000 5500 6200 Recoil Locked Disassemble and Repair Recoil see Manual Section Recoil Starter Then Check Recoil for Mechanical Binding Rope Not Retracting Disassemble and Repair Broken Ratchets or Springs see Manual Section Recoil Starter Engine Starts Then Shuts ...

Page 35: ...ge Regulator Poor Alternator Performance Check Rotor Winding see Manual Section Alternator Rotor Winding Connector Check Main Winding see Manual Section Alternator Main Winding Terminal Block Check Exciter Winding see Manual Section Alternator Exciter Winding Connector AC Power Voltage or Frequency Low Check Engine RPM at Spec Idle Speed 63 hz Adjust Governor if necessary Evaluate Generator Load I...

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Page 37: ...k After refueling make sure the tank cap is closed properly and securely 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 A FUEL GAUGE After reassembly check float for proper operation B FUEL TANK CAP Be sure air vent hole is...

Page 38: ...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 A PILOT SCREW Check the screw head for wear or damage before installation Initial opening 1 5 8 turns out B FLOAT VALVE Check for worn valve or weak spring before installation C FLOAT Check for smooth movement after inst...

Page 39: ...UFFLER 9 3 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 A B C WARNING ...

Page 40: ...emoving rotor and stator remove brusher holder B ROTOR BOLT 43 47 N m 31 7 34 7 lb ft 4 4 4 8 kg m C ROTOR 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 C D F E A B ...

Page 41: ...all appropriate rotor puller special tool hold flywheel and torque puller to 45 50 N m 33 2 36 9 lb ft 4 6 5 1 kg m 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 A B C D E I H G F NOTICE Rotor can become damaged if not properly supported Place wooden block and rag underneath rotor for support To prevent ey...

Page 42: ... applications and may not be applica ble to the unit C CARBON BRUSH SLIP RING Remove carbon brushes from brush holder Inspect brush for excessive wear or any other defect Replace if length is less than 5 mm 25 in Check brush tip for continuity with ohm meter Probe between brush tip and wire terminal If open infinity replace brush assembly Inspect slip rings for dust rust or other damage If rings a...

Page 43: ...00 Model 0 85 1 0 Ω HW5500E Model 0 85 1 0 Ω HW6200 Model 0 6 0 9 Ω HW7500E Model 0 5 0 6 Ω Using an ohmmeter measure resistance between the brown and blue wires If specified resistance is not obtained replace stator F ROTOR WINDING CONNECTOR Resistance Specifications HW4000 Model 38 43 Ω HW5500 Model 50 55 Ω HW5500E Model 50 55 Ω HW6200 Model 51 56 Ω HW7500E Model 55 60Ω Remove brushes and measur...

Page 44: ... 7 CONTROL PANEL A GENERATOR REAR HOUSING 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 RUN ENGINE STOP RUN B C A D C1 C2 ...

Page 45: ...YSTEM 9 8 STARTING SYSTEM A WOODRUFF KEY After installing the flywheel check to ensure the woodruff key is still in its slot on the crankshaft 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 B2 A B1 ...

Page 46: ...e ratchet with the reel cover notch B RATCHET Check for wear or damage C STARTER REEL Install on the starter case after installing the return spring 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 B C D E A ...

Page 47: ... FAN Install by aligning the three lugs on the rear side of the fan with the small hole in the fly wheel When disassembling and assem bling take care not to damage the fan blades 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 B C D...

Page 48: ...ellgenerators com 9 12 FRAME 9 11FRAME WHEEL AND HANDLE ASSEMBLY 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 ...

Page 49: ... 5 transporting 5 1 Ground terminal 4 1 M Maintenance 7 1 air filter 7 4 cleaning spark arrestor 7 6 fuel sediment cup 7 5 schedule 7 1 spark plug 7 6 valve clearance 7 7 Muffler 9 3 O Outlets household 4 1 transfer switch 4 1 P Power Control Center 4 1 ground terminal 4 1 household outlets 4 1 power cord transfer switch 4 1 R Rear Housing 9 5 Rotor 9 4 9 5 S Safety Important Rules 1 1 Service and...

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Page 52: ... 53212 1082 USA TEL 1 888 494 3571 www honeywellgenerators com P N 101290A June 2008 2008 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 ...

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