Honeywell HW7500E Service Manual

Honeywell HW7500E - Portable Generator NOT Manual

Get Honeywell HW7500E - Portable Generator NOT PDF manuals and user guides
UPC - 894190002049
View all Honeywell HW7500E manuals
Add to My Manuals
Save this manual to your list of manuals

Honeywell HW7500E manual content summary:

  • Honeywell HW7500E | Service Manual - 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.
  • Honeywell HW7500E | Service Manual - Page 2
  • Honeywell HW7500E | Service Manual - Page 3
    SYSTEM 9-5 MUFFLER ...9-6 CARBURETOR ...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
  • Honeywell HW7500E | Service Manual - Page 4
    THIS PAGE INTENTIONALLY LEFT BLANK ii www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 5
    Honeywell Portable Electrical Generator Service Manual Explosion Toxic fumes Fire Chemical burn Electrical shock Hot surface DANGER 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
  • Honeywell HW7500E | Service Manual - Page 6
    by misuse or modifica- tion is not covered under warranty. California Proposition 65 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 7
    or visit www.honeywellgenerators.com. Warranty inquiries can be addressed to: Northshore Power Systems, LLC Attention: Service and Warranty Dept. 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-1
  • Honeywell HW7500E | Service Manual - Page 8
    each subsequent owner that the emissions control part shall be free from defects in materials and workmanship for a period of two years from the date the generator is delivered to the original retail customer. 2-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 9
    -HWTECHS (498-3247) By email: [email protected] By US mail: Northshore Power Systems, LLC Attention: Service and Warranty Dept. 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 WARRANTIES Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 2-3
  • Honeywell HW7500E | Service Manual - Page 10
    .com. Warranty claim forms and inquiries can be addressed to: Northshore Power Systems, LLC Attention: Service and Warranty Dept. 4425 N. Port Washington Road Suite 105 Milwaukee, WI 53212-1082 2-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 11
    101865A 101865A 101865A Battery (Electric Start Models Only) -- -- 101536A -- 101536A 101536A 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
  • Honeywell HW7500E | Service Manual - Page 12
    18 13 24 17 10 7 10 7 4 3 18 13 4 3 32 24 12 9 30 22 48 35 1 1 1 1 28 21 6 4 25 18 25 18 10 7 3-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 13
    DIAGRAMS HW3000 & HW3000L FIGURE 3-1: HW3000 & HW3000L Wiring Diagram Honeywell Portable Electrical Generator Service Manual ENGINE OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG Y Y Bl Bl IGNITION COIL Bl Bl Y/G ENGINE BLOCK ALTERNATOR NOTE: Alternator is mechanically connected to the
  • Honeywell HW7500E | Service Manual - Page 14
    Bu Br W R Bu Br W ALTERNATOR Honeywell Portable Electrical Generator Service Manual 5A FUSE Bu G/W Bl Y/G OFF ON Bl - Black Bu - Blue Br - Brown G/W - Green / White Lg - Light Green R - Red Y - Yellow Y/G - Yellow / Green W - White Y/G IG E Bl Bu G/W ENGINE CONTROL SWITCH ON/OFF SWITCH PANEL
  • Honeywell HW7500E | Service Manual - Page 15
    HW5500 & HW5500L FIGURE 3-3: HW5500 & HW5500L Wiring Diagram Honeywell Portable Electrical Generator Service Manual ENGINE FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG G/W Y Y Bl Y IGNITION COIL Bl Bl ENGINE BLOCK gg ALTERNATOR NOTE: Alternator is mechanically
  • Honeywell HW7500E | Service Manual - Page 16
    AC BREAKER 21A Honeywell Portable Electrical Generator Service Manual OFF Bu G/W Bl Y/G Bl/W Bl IG E Bu Y/G G/W ON START 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 Bl/W ENGINE CONTROL SWITCH ON
  • Honeywell HW7500E | Service Manual - Page 17
    & HW6200L FIGURE 3-5: HW6200 & HW6200L Wiring Diagram Honeywell Portable Electrical Generator Service Manual ENGINE FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG G/W Y Y Bl Y IGNITION COIL Bl Bl ENGINE BLOCK ALTERNATOR NOTE: Alternator is mechanically connected to
  • Honeywell HW7500E | Service Manual - Page 18
    BREAKER 240V 30A Honeywell Portable Electrical Generator Service Manual OFF Bu G/W Bl Y/G Bl/W Bl IG E Bu Y/G G/W ON START 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 Bl/W ENGINE CONTROL SWITCH
  • Honeywell HW7500E | Service Manual - Page 19
    -Starts generator engine (electric start models) • RUN-Prepares engine to start (manual start models); Indicates engine is currently running (electric start models) • STOP-Stops generator engine by inhibiting ignition F-Fuel Shut-off Valve Controls flow of fuel from fuel tank to carburetor. G-Recoil
  • Honeywell HW7500E | Service Manual - Page 20
    THIS PAGE INTENTIONALLY LEFT BLANK 4-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 21
    -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. NOTICE NEVER drop, strike, or place heavy objects on generator when transporting. Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 22
    THIS PAGE INTENTIONALLY LEFT BLANK 5-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 23
    30 30 --30 30 40 50 45 60 45 40 180 50 40 45 30 40 30 HW5500 HW5500L (min.) HW5500E HW5500EL (min.) HW6200 HW6200L (min.) HW7000E HW7000EL (min.) HW7500E HW7500EL (min.) 120 120 120 120 30 30 30 30 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 6-1
  • Honeywell HW7500E | Service Manual - Page 24
    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 6-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 25
    . 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
  • Honeywell HW7500E | Service Manual - Page 26
    the fuel tank. Use fresh gasoline with a pump octane rating of 87 or higher. NOTICE Running the engine with persistent spark knock or pinging can cause engine damage. Warranty does not cover parts damaged by misuse. 7-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service
  • Honeywell HW7500E | Service Manual - Page 27
    dipstick. Crankcase pressure can cause hot engine oil to spray out of engine fill hole. Hot engine oil can cause severe burns. Honeywell Portable Electrical Generator Service Manual FIGURE 7-2: Air Cleaner Cover-Model Numbers Ending in "L" For Non-L Models: • Turn thumbscrew counterclock wise to
  • Honeywell HW7500E | Service Manual - Page 28
    cleaner cover. FIGURE 7-8: Excess Oil Removal CAUTION 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. 7-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 29
    Plug Equivalents to 102557A All Other Models: Recommended Spark Plug Replacement: 100842A AutoLite 63 Bosch WR7DC Champion RN9YC Denso W20EPR NGK BPR6ES TABLE 7-4. Spark Plug Equivalents to 100842A Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-5
  • Honeywell HW7500E | Service Manual - Page 30
    Stop the engine if it is running. Allow to completely cool. 2. Place generator on a flat, level surface. 3. Using a socket models). 4. Remove muffler cover. B FIGURE 7-15: Spark Arrestor Assembly 6. Slide off spark arrestor clamp. 7. Using Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 31
    lb. ft.). 8. Check valve lash again after tightening lock nut. 9. Repeat steps 4 through 7, as needed, until valve lash is within specifications. 10. Reassemble the spark plug, cylinder head cover, and gasket. Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 7-7
  • Honeywell HW7500E | Service Manual - Page 32
    . 4. Disconnect the black negative (-) battery lead remov- ing the bolt and nut. FIGURE 7-21: Electric Start Battery-Lead Connection 5. Disconnect the red positive (+) battery lead removing the bolt and nut. 7-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 33
    NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. NOTE: For all dealer service inquiries, call 1-877-HWTECHS (498-3247) or visit www.honeywellgenerators.com. Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 34
    Adjust Voltage Regulator, if Necessary by Turning the Potentiometer on the Rear of the Voltage Regulator If Voltage Still Out of Range Replace Voltage Regulator Refer to Illustrations on Pages 8-3 and 8-5. 8-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 35
    Duplex Outlet #1 NEMA 5-20R 120V Duplex Outlet #2 NEMA 5-20R 120V W XW G W XW G Y G Y G 3000 RATED WATTS • 3750 MAXIMUM WATTS White Wire = W Black Wire = X Yellow / Green Wire = G To Alternator Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-3
  • Honeywell HW7500E | Service Manual - Page 36
    ELECTRICAL DIAGNOSTICS (HW3000/L MODELS) Rated Power Check (Low Power 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 high-altitude carburetor kit is not available
  • Honeywell HW7500E | Service Manual - Page 37
    ROTOR SLIP RINGS POTENTIOMETER TO ADJUST VOLTAGE EXCITER & AVR TAP CONNECTOR* AVR TAP Blue Brown WINDING EXCITER Yellow Yellow WINDING *view looking into female connector from alternator SLIP RING TERMINALS Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-5
  • Honeywell HW7500E | Service Manual - Page 38
    (X to Y) of the 240V Receptacle = 246-252V Adjust Voltage Regulator, if Necessary by Turning the Potentiometer on the Rear of the Voltage Regulator If Voltage Still Out of Range Replace Voltage Regulator 8-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 39
    Receptacle NEMA 14-30R White Wire = Y Yellow / Green Wire = G Red Wire = X Blue Wire = W on Duplex Outlet #1 Brown Wire = W on Duplex Outlet #2 To Alternator Fuel Cutout Winding Connector Brown Wires (2) Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 8-7
  • Honeywell HW7500E | Service Manual - Page 40
    ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) Rated Power Check (Low Power 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 high-altitude carburetor kit is
  • Honeywell HW7500E | Service Manual - Page 41
    ELECTRICAL DIAGNOSTICS (ALL MODELS EXCEPT HW3000/L) BRUSH ASSEMBLY Red Wire White Wire ADJUST VOLTAGE FUEL CUTOUT WINDING CONNECTOR* Brown Brown Black *view looking into female connector from alternator ROTOR SLIP RINGS SLIP RING TERMINALS Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 42
    for Spark Check Spark Plug & Gap Check Fuel Line & Blockage Check Carburetor Check Spark Arrestor Check Muffler Blockage Check Valve Adjustment Perform Engine Compression Test Recoil Not Operating Recoil Locked = Disassemble and Repair Recoil (see Manual Section "Recoil Starter") Check Recoil for
  • Honeywell HW7500E | Service Manual - Page 43
    ) B D Control panels vary between models. POWER CONTROL CENTER HOUSEHOLD OUTLETS 120 VOLTS AC 120/240 VOLTS AC C BREAKER BREAKER MASTER BREAKER A ENGINE START E1 RUN STOP ENGINE RUN E2 F STOP G Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-1
  • Honeywell HW7500E | Service Manual - Page 44
    to illustration for proper positioning. 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.) H G 9-2 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 45
    or goggles when using a hammer. 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. Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 46
    fitting - 24 N•m (17 lb. ft.) G-FUEL SEDIMENT CUP See CLEANING FUEL SEDIMENT CUP, page 7-5. H-FUEL LINE Check for cracks or damage. Secure with hose clamps. A B E 1 C D E 2 F H G HW7500E Model Illustrated 9-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 47
    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 A C D B2 B1 E1 E2 Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 48
    , HW7000EL, 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.) G E1 E2 F 9-6 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 49
    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 installation. I H A B G F C D E Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-7
  • Honeywell HW7500E | Service Manual - Page 50
    STARTING SYSTEM 9.8 STARTING SYSTEM A-ELECTRIC STARTER Attempt to crank engine by switching the engine control switch to the START position. Starter Solenoid COIL ASSEMBLY Check for continuity. A G F C D E 9-8 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 51
    on the starter case tab. CAUTION Return spring is under tension. Use extreme caution and wear safety glasses and gloves when disassembling to prevent injury COVER BOLT I H G F E D RECOIL STARTER C B A Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-9
  • Honeywell HW7500E | Service Manual - Page 52
    COVER Remove and install with the recoil starter assembly. E-RECOIL STARTER ASSEMBLY Install with the recoil starter handle position as shown. A B C D E 9-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 53
    N•m (18 lb. ft.) G-WHEEL A B 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. D E G F Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-11
  • Honeywell HW7500E | Service Manual - Page 54
    H-WHEEL E 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. F H G HW5500E Model Illustrated 9-12 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual
  • Honeywell HW7500E | Service Manual - Page 55
    Transporting Generator 5-1 Troubleshooting 8-1 V Valve Lash 7-7 Voltage Regulator 8-5, 8-9, 9-3 W Warranty emissions control 2-2 limited 2-1 replacement parts 2-4 Wheel, Leg, & Handle Assembly 9-11 Wiring Diagrams 3-3 Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators
  • Honeywell HW7500E | Service Manual - Page 56
    .com P/N 101290D c 2010 Northshore Power Systems, LLC The Honeywell Trademark is used under license from Honeywell International Inc. Honeywell International Inc. makes no representation or warranties with respect to this product. Manufactured exclusively for Northshore Power Systems.
  • 1
  • 2
  • 3
  • 4
  • 5
  • 6
  • 7
  • 8
  • 9
  • 10
  • 11
  • 12
  • 13
  • 14
  • 15
  • 16
  • 17
  • 18
  • 19
  • 20
  • 21
  • 22
  • 23
  • 24
  • 25
  • 26
  • 27
  • 28
  • 29
  • 30
  • 31
  • 32
  • 33
  • 34
  • 35
  • 36
  • 37
  • 38
  • 39
  • 40
  • 41
  • 42
  • 43
  • 44
  • 45
  • 46
  • 47
  • 48
  • 49
  • 50
  • 51
  • 52
  • 53
  • 54
  • 55
  • 56
HW3000/L
HW4000/L
HW5500/L
HW5500E/L
HW6200/L
HW7000E/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