Service Manual
Contents
1. 3 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual WIRING DIAGRAM 3 3 WIRING DIAGRAM OF Jeep NOH i GN ov MEE dois joyeelg s oyeaug na AOPZ VOE VOZ g ed ema 9 MOCPLIVWSN MOCSVW3N MOZSVWSN x O M ues 3u014 quiessy eued E21089 3 r j 109 ond 1109 NOUIND WHVdS 921498 Ayal ya 9 M 4 4 3 2 3 WINDING MAIN WINDIM TUL 120719 WOLVHSNSO yoojg HW7000EH Wiring Diagram FIGURE 3 1 3 3 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual THIS PAGE INTENTIONALLY LEFT BLANK 3 4 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 4 COMPONENTS psp GENI lt De 9 um id FIGURE 4 2 Honeywell Portable Electrical Generator Controls and Components A Power Control Center Household Outlets 125VAC 20 Amp Duplex NEMA 5 20R outlets to connect 120V appliances to generator for power Generator Cord 125 250VAC 30 Amp Twist Lock NEMA L14 30R outlet2. RUBBER STOPPER 25 Nem 18 Ib ft H WHEEL NOTICE Wheel kit is intended to be used specifically with this generator NEVER use wheel kit for any other purpose NEVER use wheel kit on road Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 9 9 THIS PAGE INTENTIONALLY LEFT BLANK 9 10 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 10 INDEX A Alternator 9 4 9 5 exciter winding connector 9 6 ground cable 9 6 main winding terminal block 9 7 rotor winding connection 9 7 slip rings 9 7 voltage regulator 9 6 B Battery 7 4 Brush Assembly 9 5 Components breakers 4 1 choke control 4 1 engine control switch 4 1 fuel shut off valve 4 1 hour meter 4 1 outlets household 4 1 recoil starter grip 4 1 spark plug cap 4 1 Control Panel 9 8 Electrical Diagnostics 8 2 Emissions Control System 9 2 Engine 7 2 9 4 Engine Control Switch 4 1 Fuel Gauge 9 1 Fuel Recommendations 7 2 Fuel Sediment Cup 7 3 9 1 Fuel Shut off Valve 4 1 9 1 Fuel Strainer 9 1 Fuel Tank 9 1 Ground Terminal 4 1 Hour Meter 4 1 9 8 Maintenance 7 1 battery service 7 4 fuel sediment cup 7 3 schedule 7 1 spark arrestor screen 7 3 Muffler 9 3 Oil Recommendations 7 2 Outlets 4 1 9 8 household 4 1 Power Control Center 4 1 ground terminal 4 1 household outlets 4 1 Rotor 9 5 Safety Important Instructions 1 1 Service
3. can be used to Power 120V appliances using 4 in 1 power cord not included Power 240V appliances using appropriate NEMA L14 30P power cord not included Breakers Protects circuits from damage caused by overload or short circuit by stopping the flow of electricity from the generator to the appliance Master circuit breaker controls power to all outlets If there is no power at outlets see TROUBLESHOOTING Hour Meter Shows the total unit run time for maintenance purposes Ground Terminal Connects generator to ground wire for grounding protec tion Generator must be grounded to prevent electrical w shock from faulty appliances Tray and Battery Provides power for electric start feature C Oil Fill Dipstick Seals off engine oil fill hole and provides indicator for engine oil level D Oil Drain Screw Allows engine oil to drain from generator E Engine Control Switch Control used to start and stop the engine ignition system e START Starts generator engine e RUN Prepares engine to start manual start Indicates engine is currently running electric start STOP Stops generator engine by inhibiting ignition F Fuel Shut off Valve Controls flow of fuel from fuel tank to carburetor G Recoil Starter Grip Handle Provides means to manually start engine if needed H Air Cleaner Assembly Removes dust from engine intake air I Choke Control Controls choke val
4. AND WIRING DIAGRAM 3 1 SPECIFICATIONS GENERATOR HW7000EH POWER 7000 Frequency hertz 60 5 under load 5 under load 120 240 OPERATING TEMPERATURE Maximum F C 104 40 Minimum F C 14 10 ENGINE Speed rpm 3600 Type OHV 4 Cycle Displacement cc 389 Fuel Tank Capacity gal I 6 5 24 6 Engine Oil Capacity qt 1 2 1 1 See Honda Owner s Manual for Additional Engine Information TABLE 3 2 Honeywell Portable Generator Specifications Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com BOLT AND FASTENER TORQUE INFORMATION 3 2 BOLT AND FASTENER TORQUE INFORMATION Component Specific Fastener Fastener Size El Nem Ib ft Alternator End Cover Bolts M5 x 12 4 3 Alternator Housing Bolts M10 x 1 25 x 80 48 35 Axle Bracket Bolts M8 x 16 25 18 Brush Assembly Bolt M5 x 16 2 1 5 Carbon Canister Bracket Bolts M6 x 1 0 x 10 2 1 5 Control Panel Bolts M6 x 1 0 x 15 4 3 Exhaust Pipe Nuts M8 x 1 25 24 17 Fuel Tank Mounting Bolts M6 x 1 0 10 7 Fuel Shut off Valve Hex Fitting M10 x 1 25 24 17 Muffler to Engine Bolts M8 x 1 25 29 22 Spark Arrestor Bolts M6 x 0 8 x 10 2 1 5 Support Leg to Frame Bolts M8 x 16 25 18 Support Leg to Rubber Stopper Bolts M8 x 25 25 18 Wheel Handle Pivot Bracket Bolts M6 x 40 10 7 See Honda Owner s Manual TABLE 3 4 Torque Values
5. OR TO ANYONE CLAIMING UNDER CUSTOMER FOR ANY OTHER OBLIGATIONS OR LIABILITIES INCLUDING BUT NOT LIMITED TO OBLIGATIONS OR LIABILITIES ARISING OUT OF BREACH OF CONTRACT OR WARRANTY NEGLI GENCE OR OTHER TORT OR ANY THEORY OF STRICT LIABILITY WITH RESPECT TO THE GENERATOR OR NORTHSHORE POWER SYSTEMS S ACTS OR OMIS SIONS OR OTHERWISE TO THE FULLEST EXTENT PER MITTED BY APPLICABLE LAW NORTHSHORE 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 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 improper setup installation or storage ii lack of proper maintenance and service iii accident damage abuse or misuse iv abnormal operating conditions or applications v repair or modification by customer or any third party with out prior written consent of Northshore Power Systems vi use under operating conditions or in applications not made known to or contemplated by Northshore Power Systems or vii acts of God The application of these exclusions will be
6. Problem to Ensure Safe Operation After Electrical Load Resolved Push to Reset Breaker If Cannot Reset Replace Breaker Check for Tripped Duplex Circuit Breaker s Outlets Above the Breaker Indicate the Excess Load Source Resolve Overload Problem to Ensure Safe Operation After Electrical Load Resolved Wait Several Minutes for Thermal Breaker to Cool Push to Reset Breaker If Cannot Reset Replace Breaker Start Engine and Run at No Load Check Engine Frequency 62 5 Hz 0 5 Adjust Governor if necessary see Honda Shop Manual If Frequency Still Out of Range see Honda Shop Manual for Engine Troubleshooting Check Voltage Output at NEMA L14 30R 240V Receptacle 246 252V 123 126V If Voltage Out of Range see 240V Circuit Check Check Voltage Output at NEMA 5 20R 120V Duplex Outlet 1 If Voltage Out of Range see 120 Circuit Check Check Voltage Output at NEMA 5 20R 120V Duplex Outlet 2 126V If Voltage Out of Range see 120V Circuit Check 240V Circuit Check Out of Spec Voltage Conduct This Check Only When Directed by General Eletrical Check Check Master Breaker Continuity If Out of Range Replace Breaker Check Continuity from NEMA L14 30R 240V Receptacle For Each Connection X Y W G to Corresponding Alternator Terminal If No Continuity Check for Tight Connections at the Receptacle amp Alternator If Connections Did Not Correct Continuity Replace E
7. and Disassembly 9 1 alternator 9 5 control panel 9 8 emissions control system 9 2 engine and alternator 9 4 fuel tank 9 1 muffler 9 3 preparing for 5 1 wheel leg amp handle assembly 9 9 Service Repair Time 6 1 Spark Arrestor 7 3 9 3 Specifications 3 1 Tools Service 5 1 Torque Information 3 2 Transporting Generator 5 1 Troubleshooting 8 1 Voltage Regulator 9 5 9 6 Warranty emissions control 2 2 limited 2 1 replacement parts 2 4 Wheel Leg amp Handle Assembly 9 9 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 10 1 THIS PAGE INTENTIONALLY LEFT BLANK 10 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual Northshore Power Systems LLC 4425 N Port Washington Rd Suite 105 Milwaukee WI 53212 1082 USA TEL 1 888 494 3571 www honeywellgenerators com HW7000EH P N 102141B August 2009 2009 Northshore Power Systems LLC The Honeywell Trademark is used under license Honeywell from Honeywell International Inc Honeywell International Inc makes no representation or warranties with respect to this product
8. and measure resistance between slip rings If specified resistance is not obtained at slip rings replace alternator The alternator must be at room temperature when resis tance is measured E MAIN WINDING TERMINAL BLOCK Resistance Specifications 0 3 0 5 Q Using an ohmmeter measure resistance between the red and white wires If specified resistance is not obtained replace alternator The alternator must be at room temperature when resis tance is measured Red 2 wires Brown 1 wire Blue 2 wires White 2 wires Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 9 7 CONTROL PANEL 9 6 CONTROL PANEL A CONTROL PANEL ASSEMBLY FRONT 4 Nem Ib ft B CONTROL PANEL ASSEMBLY BACK C MAIN CONTROL PANEL FRONT 125VAC 20 Amp Duplex NEMA 5 20R 125 250VAC 30 Amp Twist Lock NEMA L14 30R Master Circuit Breaker Magnetic Circuit Breaker Thermal Hour Meter D MAIN CONTROL PANEL BACK E SWITCH PLATE FRONT F START STOP RUN SWITCH G SWITCH PLATE BACK 9 8 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual WHEEL LEG amp HANDLE ASSEMBLY 9 7 WHEEL LEG amp HANDLE ASSEMBLY A WHEEL HANDLE PIVOT BRACKET 10 Nem 7 Ib ft B PIN AND CHAIN C HANDLE BAR D RUBBER HANDLE GRIP E AXLE 25 Nem 18 Ib ft F SUPPORT LEG 25 Nem 18 Ib ft G
9. 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 GAGE After reassembly check float for proper operation B FUEL CAP Be sure air vent hole is clean and free of obstruction Blow with compressed air if necessary C FUEL STRAINER Before reassembly be sure fuel strainer is clean and undamaged D FUEL TANK MOUNTING HARDWARE 10 Nem 7 Ib ft E FUEL TANK Before reassembly clean fuel tank to remove any sediment and dry thor oughly F FUEL SCREEN See CLEANING FUEL SEDIMENT CUP page 7 3 G FUEL SHUT OFF VALVE Clear passages if clogged After reinstalling check for fuel leak age Hex fitting 24 Nem 17 Ib ft H FUEL SEDIMENT CUP See CLEANING FUEL SEDIMENT CUP page 7 3 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 9 1 EMISSIONS CONTROL SYSTEM 9 2 EMISSIONS CONTROL SYSTEM A CARBON CANISTER B CARBON CANISTER TUBE Secure with hose clamps C VAPOR LINE Secure with hose clamps D CARBON CANISTER BRACKET 2 Nem 1 5 Ib ft 9 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual MUFFLER 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 b
10. EPAIR TIME ANALYSIS amp FLAT RATE SCHEDULE 6 1 MAINTENANCE 7 1 CONSUMER MAINTENANCE SCHEDULE asvnnsvnnnnvnnnnnnnnnnnnnennnennnnnnnnvennvennnnnnnvnnnnvnnnnnnnnnennnenunnnunnenunvennevnnne 7 1 CLEANING FUEL SEDIMENT CUP nuo suum inue caasa inna nim nai da arai m aoa nim nac qn nien 7 3 CLEANING SPARK ARRESTOR SCREEN 7 3 BATERY SERVICES p 7 4 TROUBLESHOOTING au sva EU I GRE ded Ead gba dic EK EE 8 1 ELECTRICAL DIAGNOSTICS musvnnnnvnnnnvnnnvnnnnvnnnnnnnnennnennnvennnennnvnnnnnennnvnnnnnnnnennnennnnennnenuneennnvennennnnvennnennnevunner 8 2 SERVICE AND DISASSEMBLY 9 1 FUEL ecc c 9 1 EMISSIONS CONTROL SYSTEM 9 2 MUFFLERS ee 9 3 ENGINE AND ALTERNATOR 9 4 ALTERNATOR pe 9 5 GONIROLPANEL c 9 8 WHEEL LEG amp HANDLE ASSEMBLY eade nnno im nunca cum tn ande inan deua annet ne enn 9 9 INDEX ecce 10 1 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com THIS PAGE INTENTIONALLY LEFT BLANK www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual SAVE THESE INSTRUCTIONS 1 IMPORTANT SAFETY INSTRUCTION
11. Honeywell POWERED by HONDA Portable Electrical Generator Service Manual HW7000EH For technical support and parts contact your Regional Master Parts Distributor toll free at 1 877 HWTECHS 498 3247 or visit www honeywellgenerators com IMPORTANT SAFETY INSTRUCTIONS a 1 1 SAFETY MESSAGES iiec edidisse med tuia ie LUI 1 1 WARRANTIES e 2 1 NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY eerte 2 1 NORTHSHORE POWER SYSTEMS EVAPORATIVE EMISSIONS CONTROL WARRANTY 2 2 NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY 2 4 SPECIFICATIONS AND WIRING DIAGRAM 3 1 sidsieideued 3 1 BOLT AND FASTENER TORQUE INFORMATION usennvvennvnnnnvnnnnvnnnnnnnnnnnnnennnennnnennnennnvennnvennennnnvennnennnveunner 3 2 WIRING DIAGRAM 3 3 COMPONENTS c M 4 1 PREPARING FOR SERVICE pU ERROR Ven ROUX FINDS OUI RR RR CRAB RR RUD EN 5 1 REQUIRED TOOLS ren 5 1 TRANSPORTING GENERATOR nindun ainnean aaeain aaia 5 1 SERVICE R
12. OTE 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 unforeseen circumstances Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 6 1 THIS PAGE INTENTIONALLY LEFT BLANK 6 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 7 MAINTENANCE 7 4 CONSUMER MAINTENANCE SCHEDULE Periodic maintenance and adjustment are necessary to keep the generator in good operating condition Perform service and inspection at intervals shown in the Generator Maintenance Schedule Table 7 1 DANGER Using a generator indoors CAN KILL YOU IN MINUTES Accidental starting of generator can cause severe injury or Generator exhaust contains carbon monoxide This is a poi death Before performing maintenance disconnect spark son you cannot see or smell plug cap from spark plug Also disconnect both starting bat tery cables Remove the negative cable first to reduce the risk of arcing NEVER use inside a home Only use OUTSIDE and far Improper maintenance or failure to correct a problem before way from windows doors an operation can cause a malfunction in which you can be seri ne mom Vents ously hurt or killed Always follow inspection and mainte nance recommendations and sc
13. S ANYONE using or servicing this generator must read understand and follow 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 NOTE Since there are many variations in the circumstances sur rounding the installation operation service and mainte nance of this generator we cannot possibly anticipate or provide advice or safety messages to cover every situa tion 1 1 SAFETY MESSAGES Signal Words Safety messages are provided throughout this manual to help prevent personal injury and equipment damage All safety messages are introduced by a signal word indicat ing the hazard level Indicates an imminently hazard ous situation which if not avoided will result in death or serious injury to the operator or to bystanders DANGER Indicates a potentially hazardous situation which if not avoided could result in death or serious injury to the operator or to bystanders Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury to the operator or to bystanders Indicates a situation which if not avoided may result in damage to the generator components NOTICE Hazard Symbols and Meanings In addition to the signal words the following symbols may be used to draw your attention to
14. at no charge to the owner The portable generator owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective emission related warranted part provided that such diagnostic work is performed at a warranty sta tion Northshore Power Systems is liable for damages to other engine or equipment components proximately caused by a failure under warranty of any warranted part Throughout the portable generator warranty period stated above Northshore Power Systems will maintain a supply of warranted parts sufficient to meet the expected demand for such parts Any replacement part may be used in the performance of any warranty maintenance or repairs and must be pro vided without charge to the owner Such use will not reduce the warranty obligations of Northshore Power Systems Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claims Northshore Power Systems will not be liable to warrant failures of warranted parts caused by the use of a non exempted add on or modified part 2 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual WARRANTED PARTS The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverag
15. crew Start Engine and Add Resistive Loads Until One of the Following Occurs Power Output is Within Rated Power Specification Range Frequency Drops Below 57 Hz Voltage Output at the NEMA L14 30R 240V Receptacle Drops Below Minimum If Minimum Rated Power Cannot Be Achieved see Honda Shop Manual for Engine Troubleshooting See Specifications Page For Rated Power Voltage amp Frequency Specs Under Load and No Load Conditions NEMA 5 20R 120v Duplex Outlet 2 NEMA 14 30R Receptacie Duplex Outlet 1 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 8 2 FUEL TANK SYSTEM 9 SERVICE AND DISASSEMBLY 9 1 FUEL TANK SYSTEM Fuel and its vapors are extremely flammable and explosive under certain conditions Refuel the generator only outdoors in a well ventilated area NEVER enclose the generator in any structure Keep generator at least 6 feet 2 meters away from buildings other equipment and combustible materials during oper ation NEVER fill the fuel tank while the engine is running Turn the generator OFF and allow it to cool before filling with fuel NEVER smoke or allow flames or sparks near the generator or where gasoline is stored NEVER overfill the fuel tank there should be no fuel in the filler neck 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
16. d to be defective in material or workmanship after inspection by Northshore Power Systems Any parts which the buyer claims to be defective must be examined by the nearest Authorized Northshore Power Sys tems Warranty Service Facility All shipping costs under this limited warranty are to be borne and prepaid by the buyer DISCLAIMERS LIMITATIONS OF REMEDIES amp EXCLUSIONS This warranty gives you specific legal rights and you may also have other rights which vary from state to state DISCLAIMER OF OTHER WARRANTIES TO THE FULL EST EXTENT PERMITTED BY APPLICABLE LAW THIS LIMITED WARRANTY IS EXCLUSIVE AND EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES INCLUD ING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER IMPLIED WARRANTIES THAT MAY ARISE FROM A COURSE OF DEALING OR USAGE OF TRADE NORTHSHORE POWER SYSTEMS HEREBY DISCLAIMS AND EXCLUDES ALL OTHER WARRANTIES To the extent that Northshore Power Systems s products are consumer 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 POWER SYSTEMS SHALL NOT BE LIABLE TO CUSTOMER
17. determined at Northshore Power Systems s sole discretion NORTHSHORE POWER SYSTEMS PARTS LIMITED WARRANTY CLAIMS PROCEDURES DEFECTIVE NEW PARTS Parts which are defective from new stock or immediately upon installation must be filed under limited warranty The defective part must be returned to Northshore Power Systems s Service and Warranty Depart ment under the following procedure 1 Fillout a Warranty Claim Form listing the part number and write New Defective in the description 2 List invoice number that the part was purchased on and or provide receipt NOTE Freight damaged parts are not valid as warranty claims FAILURE WITHIN 90 DAYS Parts which have been installed and have failed within 90 days will be handled by the North shore Power Systems Service and Warranty Department A Warranty Claim Form must accompany each part for which coverage under the limited warranty is sought Claims will not be processed without the model and serial numbers of the unit and the purchase and failure dates for the part Attach a copy of the original proof of purchase for the part to the Warranty Claim Form WARRANTY CLAIMS 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 3 SPECIFICATIONS
18. e if Northshore Power Systems demon strates that the portable generator has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part That notwithstand ing any adjustment of a component that has a factory installed and properly operating adjustment limiting device is still eligible for warranty coverage The following emission warranty parts are covered Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps Vapor Hoses Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector QUESTIONS If you have questions regarding your emissions warranty rights and responsibilities you should contact the Service and Warranty Department at Northshore Power Systems By phone 1 414 332 2375 Via web www honeywellgenerators com By US mail Northshore Power Systems LLC Attention Service and Warranty Dept 4425 N Port Washington Road Suite 105 Milwaukee WI 53212 1082 zeommpoon Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 2 3 WARRANTIES NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY Honeywell Portable Generator For a period of 90 days from the date of sale or installation of a Northshore Power Systems LLC supplied part Northshore Power Systems will at its option and sole discretion repair or replace the part if it is foun
19. efore storing the generator indoors A EXHAUST PIPE Exhaust pipe nuts 24 Nem 17 Ib ft B MUFFLER 29 Nem 22 Ib ft C SPARK ARRESTOR SCREEN ar 2 Nem 1 5 Ib ft R A Raw G III 9 U AC E 9 9 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 9 3 ENGINE AND ALTERNATOR 9 4 ENGINE AND ALTERNATOR A END COVER 4 Nem Ib ft B ROTOR BOLT Use oil before replacing the rotor bolt C ALTERNATOR HOUSING BOLTS 48 Nem 35 Ib ft D ALTERNATOR REAR HOUSING AND STATOR See ALTERNATOR page 9 5 E ROTOR See ROTOR page 9 4 F ENGINE Contact an authorized Honda service dealer for engine maintenance and repairs G VIBRATION ISOLATOR Insert tabs into holes Be sure rubber is not chipped hardened or worn Refer to illustration for proper positioning H FRAME See WHEEL LEG amp HANDLE ASSEMBLY page 9 9 9 4 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual ALTERNATOR 9 5 ALTERNATOR A ALTERNATOR ENGINE ADAPTER B ROTOR Use appropriate tool to remove rotor NOTICE Rotor can become damaged if not properly sup ported Place wooden block and rag under neath rotor for support C STATOR D MAIN WINDING TERMINAL BLOCK E ALTERNATOR REAR HOUSING F BRUSH ASSEMBLY Before removing rotor and stator remove brush assembl
20. ell Portable Generator WARRANTY STATEMENT The California Air Resources Board and Northshore Power Systems LLC are pleased to explain the evaporative emis sion control system EECS warranty on your 2009 portable generator In California new portable generators must be designed built and equipped to meet the State s stringent anti smog standards Northshore Power Systems must war rant the EECS on your portable generator for the period of time listed below provided there has been no abuse neglect or improper maintenance of your portable generator Your EECS may include parts such as the carburetor fuel lines fuel caps valves canisters filters vapor hoses clamps and other associated emission related components Where a war rantable condition exists Northshore Power Systems will repair your portable generator at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This evaporative emission control system is warranted for two years If any evaporative emission related part on your equip ment is defective the part will be repaired or replaced by Northshore Power Systems OWNER S WARRANTY RESPONSIBILITIES As the portable generator owner you are responsible for per formance of the required maintenance listed in your owner s manual Northshore Power Systems recommends that you retain all receipts covering maintenance on your portable generator but Northshore Power Systems cannot deny war ra
21. fuel sediment cup at the intervals specified in Table 7 1 To clean fuel sediment cup you will need 10 mm box wrench 22 mm open end wrench Household soap and water Clean dry cloth To clean fuel sediment cup 1 Stop the engine if it is running Allow to completely cool 2 Place generator on a flat level surface 3 Turn the fuel shut off valve to the OFF position 4 While holding the fitting above the fuel shut off valve with a 22 mm open end wrench remove the fuel sedi ment cup assembly sediment cup o ring and fuel Screen using a 10 mm box wrench FIGURE 7 2 Fuel Sediment Cup Assembly 5 Clean the fuel screen A o ring B and sediment cup C with soap and water Rinse parts thoroughly with water Wipe the pieces clean with a clean dry cloth Reinstall the sediment cup o ring and fuel screen Turn the fuel shut off valve to the ON position o 2 2 0 Start generator and check for leaks 7 3 CLEANING SPARK ARRESTOR SCREEN Muffler reaches temperatures that can cause serious burns if touched NEVER touch hot surfaces Generator muffler is equipped with spark arrestor screen which must be cleaned according to maintenance sched ule Table 7 1 To clean spark arrestor screen you will need 2 Phillips screwdriver C Wire brush 1 Stop generator if engine is running Allow to com pletely cool 2 Place generator on a flat level
22. harm NEVER touch bare wires or receptacles NEVER use generator with electrical cords that are worn frayed bare or otherwise damaged NEVER operate generator in rain or snow or when the generator is set on wet surface Exposed terminals even on disconnected batteries can cause electric shock NEVER touch both battery terminals with bare hands at the same time Remove rings watches or any other object containing metal when working with battery If metal comes into contact with 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 Fire and Burn Hazards 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 least 6 feet 2 meters away from buildings other equipment and combustible materials during operation NEVER 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 make sure the tank cap is closed properly and securely Be careful not to spill fuel when refueling Spilled fuel or fuel
23. hedules in this manual Shut off the engine before performing any mainte nance If the engine must be run be sure the area is well ventilated NOTICE The maintenance schedule applies to normal operating con NOTICE such as sustained high load or high temperature o use tin Maintenance replacement or repair of the emission unusually wet or dusty conditions consult your servicing control devices and systems may be performed by any dealer for recommendations applicable to your individual non road engine repair establishment or individual needs and use FREQUENCY Before cach First month Every 3 6 MAINTENANCE TASK or 20 hours of months or 50 monthsor100 or300 hours of use hours of use hours of use use Inspect for clean debris X Check engine oil level X Change engine oil X X Check air filter X Clean air filter xt Replace air filter X Run engine xt Check adjust spark plug X Replace spark plug X Clean fuel sediment cup X Clean spark arrestor X Clean cylinder cooling fins x Check adjust idle speed x Check adjust valve clearance x Clean fuel tank and filter X Clean combustion chamber Every 500 hours Check fuel tube Every 2 years replace if necessary TABLE 7 1 Generator Maintenance Schedule Perform at every indicated month or operating hour interval whichever comes first T Clean more often when us
24. ing generator in dusty areas Itis recommended that the generator is run for 30 60 minutes every three months to ensure the battery remains charged If the unit is stored for more than a year without running a battery charger may required to recharge the generator battery These items should be serviced by a Honda service dealer unless you have the proper tools and are mechanically proficient Refer to the Honda shop manual for service procedures Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 7 1 CONSUMER MAINTENANCE SCHEDULE ENGINE OIL RECOMMENDATIONS NOTICE It is very important to maintain proper level of engine oil to FUEL RECOMMENDATIONS DANGER Fuel and fuel vapors are extremely flammable and explosive under certain conditions Refuel generator only outdoors in well ventilated area NEVER fill 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 is spilled be sure area is dry before starting engine Avoid repeated or prolonged contact with skin or breathing of vapor NOTICE To avoid damage to the engine never use sta
25. ing to guidelines estab lished by your local or state government 6 Place the new battery in the generator frame 7 Connect the red positive battery lead to the posi tive post on the battery install bolt nut and boot 8 Connectthe black negative battery lead to the neg ative post on the battery install bolt nut and boot 9 Reinstall retaining plate tighten bolts and nuts 7 4 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 8 TROUBLESHOOTING NOTE ANYONE using or servicing this generator must read understand and follow all safety and operation instruc tions provided in the product manual Failure to closely follow these instructions can result in circumstances AE leading to death serious injury and property damage DANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poi Son you cannot see or smell g NEVER use inside a home Only use OUTSIDE and far or garage EVEN IF doors away from windows doors and and windows are open vents OI NOTE For all dealer service inquiries call 1 877 HWTECHS 498 3247 or visit www honeywellgenerators com www honeywellgenerators com 8 1 Honeywell Portable Electrical Generator Service Manual 8 1 ELECTRICAL DIAGNOSTICS General Electrical Check Check for Tripped Master Breaker Resolve Overload
26. le or contami nated gasoline or oil gasoline mixture Avoid getting dirt or water in the fuel tank Use fresh gasoline with a pump octane rating of 86 or higher keep engine in good running condition Check engine oil level prior to each use Refill engine oil if oil level is too low See the Honda Owner s Manual for instructions on how to properly maintain the engine Contact an authorized Honda service dealer for engine maintenance and repairs In some locations authorized Honeywell service dealers are also Honda service dealers Contact your local dealer before transporting your generator for service ALWAYS stop engine before removing oil fill dip stick Crankcase pressure can cause hot engine oil to spray out of engine fill hole Hot engine oil can cause severe burns Gasoline and flammable solvents can cause fire or explosion NEVER use gasoline or flammable sol vent to clean air filter element Use only household soap and water to clean air filter element Frequent or prolonged contact with engine oil may cause skin cancer e Thoroughly wash hands and any areas of skin exposed to used oil with soap and water 7 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual CLEANING FUEL SEDIMENT CUP 7 2 CLEANING FUEL SEDIMENT CUP The sediment cup prevents any dirt or water that may be in the fuel tank from entering the carburetor Clean
27. lectrical Panel Check Alternator Brushes for Residue or Defect see Manual Section Alternator Carbon Brushes Check Rotor Winding see Manual Section Alternator Rotor Winding Connection Check Main Winding see Manual Section Alternator Main Winding Terminal Block Check Exciter Winding see Manual Section Alternator Exciter Winding Connector Start Engine and Run at No Load Check Output Voltage 246 252V Adjust Voltage Regulator if necessary If Voltage Still Out of Range Replace Voltage Regulator ELECTRICAL DIAGNOSTICS 120V Circuit Check Out of Spec Voltage Conduct This Check Only When Directed by General Eletrical Check Check Duplex Outlet Breaker Continuity If Out of Range Replace Breaker Check Continuity from NEMA 5 20R 120V Duplex Outlet For Each Connection X or Y W G to NEMA L14 30R 240V Receptacle If No Continuity Check for Tight Connections at the Receptacle amp Alternator If Connections Did Not Correct Continuity Replace Electrical Panel Rated Power Check Low Power Output Conduct This Check Only When Directed by General Eletrical Check NOTE At high altitudes standard carburetor air fuel mixture will be rich causing a decrease in engine performance and an increase in fuel consumption If generator will always operate in altitudes higher than 5000 feet 1500 meters install smaller carburetor main fuel jet and readjust pilot s
28. nty solely for the lack of receipts As the portable generator owner you should however be aware that Northshore Power Systems may deny you warranty coverage if your portable generator or a part has failed due to abuse neglect or improper maintenance or unapproved modifications You are responsible for presenting your portable generator to North shore Power Systems s distribution center or service center as soon as the problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have a question regarding your warranty cov erage you should contact www honeywellgenerators com or by calling 1 888 HWHELP1 494 3571 GENERAL EVAPORATIVE EMISSIONS WARRANTY COVERAGE Northshore Power Systems warrants to the ultimate pur chaser and each subsequent purchaser that the portable generator is Designed built and equipped so as to conform with all applicable regulations and free from defects in mate rials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in the application for certification The warranty period begins on the date the portable generator is delivered to an ultimate purchaser or first placed into service The war ranty period is two years Subject to certain conditions and exclusions as stated below the warranty on emission related parts is as follows 10 Any warranted part that is n
29. ohm meter Frequency meter e Resistive load such as a load bank heaters light When transporting the generator bulbs etc Press engine control switch to STOP position Wood block for rotor support Turn fuel shut off valve to OFF position Keep generator level to prevent fuel spillage NOTICE NEVER drop strike or place heavy objects on generator when transporting Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 5 1 THIS PAGE INTENTIONALLY LEFT BLANK 5 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 6 SERVICE REPAIR TIME ANALYSIS amp FLAT RATE SCHEDULE Operation OLDE min ELECTRICAL Alternator Complete 120 Battery 30 Brush Assembly 45 Charging Coil Assembly 45 Flash the Field 45 Front Panel Assembly 60 Ignition Coil 50 Meters Circuit Breakers 45 Oil Shutdown Switch 40 Oil Alert Sender 40 Receptacles Ports 50 Recoil Assembly 30 Spark Plug 30 Electric Starter 45 Starter Solenoid 35 Voltage Regulator 60 ENGINE Refer to the Honda Shop Manual FUEL amp EXHAUST Carbon Canister with bracket 45 Carbon Canister Tube 30 Fuel Gauge 30 Fuel Line 30 Fuel Tank 60 Fuel Shut off Valve 40 Muffler 60 Muffler Gasket 60 MISC Frame 120 Handle Assembly 30 Leg Assembly 30 Wheel Assembly 30 9 N
30. orrect rated frequency and voltage when run ning at governed speed Damage to generator caused by misuse or modifica tion is not covered under warranty www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 2 WARRANTIES NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY Honeywell Portable Generator Effective March 1 2009 LIMITED WARRANTY Northshore Power Systems LLC will repair or replace free of charge to the original retail customer in North America any parts of the portable generator found by Northshore Power Systems or an authorized service center to be defec tive in material or workmanship This limited warranty covers the cost of the replacement parts and labor for defects Trans portation charges are the responsibility of the customer This limited warranty has time period conditions operating condi tions and disclaimers limitations of remedies amp exclusions as stated below For warranty service customer should locate an authorized Honeywell Generator Dealer from www honey wellgenerators com or by calling 1 888 HWHELP1 494 3571 LIMITED WARRANTY PERIODS Consumer Use 3 Years Limited 1st year parts and labor 2nd amp 3rd years parts only Commercial Use 1 Year Limited No warranty for rental use Commencement and Definitions The limited warranty period begins on the date of retail purchase by the original pur chaser The limited warranty is not tran
31. ot scheduled for replacement as required maintenance in the written instructions sup plied is warranted for the warranty period stated above If the part fails during the period of warranty coverage the part will be repaired or replaced by Northshore Power Systems according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period Any warranted part that is scheduled only for regular inspection in the written instructions supplied is war ranted for the warranty period stated above Any such part repaired or replaced under warranty will be war ranted for the remaining warranty period Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first sched uled replacement date for that part If the part fails before the first scheduled replacement the part will be repaired or replaced by Northshore Power Systems according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part Repair or replacement of any warranted part under the warranty provisions herein must be performed at an authorized Honeywell Service Center Notwithstanding the provisions herein warranty services or repairs will be provided at an authorized Honeywell Service Center
32. 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 POWER SYSTEMS SHALL NOT BE LIABLE TO CUSTOMER OR TO ANYONE CLAIMING UNDER CUSTOMER FOR ANY OTHER OBLIGATIONS OR LIABILITIES INCLUDING BUT NOT LIMITED TO OBLIGATIONS OR LIABILITIES ARISING OUT OF BREACH OF CONTRACT OR WARRANTY NEGLI GENCE OR OTHER TORT OR ANY THEORY OF STRICT LIABILITY WITH RESPECT TO THE GENERATOR OR NORTHSHORE POWER SYSTEMS S ACTS OR OMIS SIONS OR OTHERWISE TO THE FULLEST EXTENT PER MITTED BY APPLICABLE LAW NORTHSHORE 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 addition to the foregoing disclaimers limi tations and terms this limited warranty shall not apply to and does not cover accessories nor does it cover products that are in any way subjected to i improper setup installation or storage ii lack of proper maintenance and service iii acci dent damage abuse or misuse iv abnormal operating con ditions or applications v repair or modification by customer o
33. r any third party without prior written consent of Northshore Power Systems vi use under operating conditions or in applications not made known to or contemplated by North shore Power Systems or viii acts of God The application of these exclusions will be determined at Northshore Power Systems s sole discretion This generator is equipped with an engine that is covered exclusively by a separate warranty from the engine manufac turer Please refer to the engine documentation included with the generator for warranty information related to the engine REGISTRATION Warranty registration with the Company is required on all products You may send in the enclosed Product Registration or register your product on line at www honeywellgenera tors com Warranty is also available by keeping and showing your origi nal receipt from date of purchase to an authorized Honeywell Generator Dealer GENERATOR SERVICE Do not return your generator to place of purchase for service For all customer service inquiries call 1 888 HWHELP1 494 3571 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 WARRANTIES NORTHSHORE POWER SYSTEMS EVAPORA TIVE EMISSIONS CONTROL WARRANTY Honeyw
34. sferable Consumer use is personal use by a retail customer Commercial use is any usage for income producing business related use No Extension of Warranty Repair or replacement pursuant to this limited warranty shall not renew or extend the original warranty period and any repaired product shall be warranted for the remaining original warranty period only DISCLAIMERS LIMITATIONS OF REMEDIES amp EXCLUSIONS This warranty gives you specific legal rights and you may also have other rights which vary from state to state MEDICAL AND LIFE SUPPORT USES This warranty excludes any use of this product intended to power life sup port devices life support appliances medical devices or medical appliances DISCLAIMER OF OTHER WARRANTIES TO THE FULL EST EXTENT PERMITTED BY APPLICABLE LAW THIS LIMITED WARRANTY IS EXCLUSIVE AND EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES INCLUD ING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER IMPLIED WARRANTIES THAT MAY ARISE FROM A COURSE OF DEALING OR USAGE OF TRADE NORTHSHORE POWER SYSTEMS HEREBY DISCLAIMS AND EXCLUDES ALL OTHER WARRANTIES To the extent that Northshore Power Systems s products are consumer 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
35. specific types of haz 8 Explosion Toxic fumes Fire Wy 7 7 Hot surface Electrical shock Chemical burn DANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poi Son you cannot see or smell ar NEVER use inside a home Only use OUTSIDE and far away from windows doors and vents or garage EVEN IF doors and windows are open SAFETY PRECAUTIONS Wear appropriate protective safety equipment such as safety shoes and safety glasses Comply with the warnings in this manual and take spe cial precautions when working around electrical equip ment Never wear loose or damp clothing that might get caught in equipment or conduct electricity Keep service area organized and free of unnecessary clutter to reduce hazard potential Keep guards and shields in place on machinery and maintain equipment in good working condition 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 Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 1 1 SAFETY MESSAGES Electric Shock Hazards Generators produce powerful voltage that can cause death or great physical
36. surface 3 Usea Phillips screwdriver to remove the spark arres tor screws and washers 4 Remove the spark arrestor FIGURE 8 Spark Arrestor Assembly 5 Inspect the spark arrestor screen m If the screen is damaged or excessively worn replace the spark arrestor m f the screen is in good condition clean using a wire brush FIGURE 9 Clean Screen 6 Reinstall spark arrestor carefully aligning screw holes Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 7 3 BATTERY SERVICE 7 4 BATTERY SERVICE To ensure the battery remains charged it is recom mended that the generator is started every three months If the unit is stored for more than a year without running a battery charger may be required to recharge the generator battery Recommended Battery Replacement Xtreme XTAX14AHL BS Yuasa 12N14 3A TABLE 8 Replacement Batteries To replace battery 1 Loosen and remove nuts on retaining plate slide retaining plate off support rods 1 FIGURE 10 Electric Start Battery Remove Retaining Plate 2 Tip battery slightly forward 3 Disconnect the black negative battery lead remov ing the boot bolt and nut I FIGURE 12 Electric Start Battery Lead Connection 4 Disconnect the red positive battery lead removing the boot bolt and nut 5 Remove the battery NOTE Dispose of used battery accord
37. 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 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 Battery gases are explosive NEVER allow open flames lit cigarettes sparks or spark producing equipment near the battery Battery electrolyte fluid is comprised of sulfuric acid which can be very dangerous and cause severe burns NEVER allow battery fluid to contact eyes skin or clothing If contact or spillage occurs immediately flush the area with water Medical and Life Support Uses In case of emergency call 911 immediately NEVER use this product to power life support devices or life support appliances NEVER use this product to power medical devices or medical appliances Inform your electricity provider immediately if you or anyone in your household depends on electrical equip ment to live Inform your electrical provider immediately if a loss of power would cause you or anyone in your household to experience a medical emergency Generator Damage Hazards NOTICE Improper treatment or misuse of generator can cause per manent damage NEVER modify generator in any way NEVER tamper with governed speed Generator sup plies c
38. ve Choke control must be moved to ON position when starting a cold engine J Fuel Tank Cap Provides a secure seal on fuel tank K Fuel Gage Indicates level of fuel currently in fuel tank L Muffler Equipped with Spark Arrester Provides outlet for engine exhaust Prevents sparks and other combustible materials from escaping generator Muffler reaches temperatures that can cause serious wil burns if touched NEVER touch hot surfaces M Spark Plug Cap Wire Delivers voltage to spark plug When spark plug needs service cap must be removed N Carbon Canister Reduces hydrocarbon emissions Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 4 1 THIS PAGE INTENTIONALLY LEFT BLANK 4 2 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual 5 PREPARING FOR SERVICE 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 5 1 REQUIRED TOOLS 5 2 TRANSPORTING GENERATOR A complete set of standard and metric shop tools are required to service the generator Also needed are e Hammer Hot engine or exhaust system can cause serious Torque wrench burns or fires Cool generator completely before transporting or storing e Volt
39. y 2 Nem 1 5 Ib ft G VOLTAGE REGULATOR Honeywell Portable Electrical Generator Service Manual www honeywellgenerators com 9 5 ALTERNATOR A GROUND CABLE B VOLTAGE REGULATOR Voltage can be adjusted via potentiometer on rear of voltage regulator 120 240 volts 35956 Replace voltage regulator if adjustment does not correct the problem C EXCITER WINDING CONNECTOR Resistance Specifications 1 0 1 5 Q Using an ohmmeter measure resistance between the two blue wires If specified resistance is not obtained replace alterna tor The alternator must be at room tempera ture when resistance is measured 9 6 www honeywellgenerators com Honeywell Portable Electrical Generator Service Manual ALTERNATOR D ROTOR WIRING BRUSH ASSEMBLY Remove carbon brushes from brush assembly Inspect brushes for excessive wear or any other defect Replace if length is less than 5 mm 2 in Using an ohmmeter verify resistance is less than 0 1 Q between the tip of each brush and the terminal If resis tance is out of range replace brushes Take care not to damage brushes when removing and installing the brush holder SLIP RINGS 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 ROTOR WINDING CONNECTION Resistance Specifications 45 70 Q Remove brushes
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