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Portable Electrical Generator Service Manual HW4000/L HW5500/L HW5500E/L HW5600C HW6200/L HW6850EC 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. CONTENTS IMPORTANT SAFETY INSTRUCTIONS SAFETY MESSAGES . 1-1 1-1 WARRANTIES . NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY SPECIFICATIONS AND WIRING DIAGRAMS SPECIFICATIONS WIRING DIAGRAMS BOLT AND FASTENER TORQUE INFORMATION 3-1 3-1 .3-2 3-3 COMPONENTS 4-1 .
5-1 .5-1 .5-1 PREPARING FOR SERVICE REQUIRED TOOLS TRANSPORTING GENERATOR SERVICE REPAIR TIME ANALYSIS & FLAT RATE SCHEDULE MAINTENANCE CONSUMER MAINTENANCE SCHEDULE AIR FILTER MAINTENANCE SPARK PLUG SERVICE VALVE CLEARANCE CLEANING FUEL SEDIMENT CUP . CLEANING SPARK ARRESTOR SCREEN GOVERNOR ADJUSTMENT BATTERY SERVICE .GOVERNOR RANGE ADJUSTMENT 7-8 TROUBLESHOOTING ENGINE DIAGNOSTICS . 8-1 8-2 8-3 ELECTRICAL DIAGNOSTICS SERVICE AND DISASSEMBLY FUEL TANK SYSTEM CARBURETOR MUFFLER 9-1 9-1 .9-3 9-2 EMISSIONS CONTROL SYSTEM ENGINE AND ALTERNATOR ALTERNATOR CONTROL PANEL STARTING SYSTEM RECOIL STARTER FAN COVER WHEEL, LEG, & HANDLE ASSEMBLY INDEX 10-1 www.honeywellgenerators.com i Honeywell Portable Electrical Generator Service Manual THIS PAGE INTENTIONALLY LEFT BLANK ii www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual SAVE THESE INSTRUCTIONS 1: IMPORTANT SAFETY INSTRUCTIONS WARNING ANYONE using or servicing this generator must read, understand, and follow all safety and operation instructions provided in the product manual. Failure to closely follow these instructions can result in circumstances leading to death, serious injury, and property damage. NOTE: Hazard Symbols and Meanings In addition to the signal words, the following symbols may be used to draw your attention to specific types of hazards. + Since there are many variations in the circumstances surrounding the installation, operation, service, and maintenance of this generator, we cannot possibly anticipate or provide advice or safety messages to cover every situation. 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 indicating the hazard level. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury to the operator or to bystanders. 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. Explosion Toxic fumes Fire Chemical burn Electrical shock Hot surface DANGER DANGER Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. WARNING CAUTION NOTICE NEVER use inside a home Only use OUTSIDE and far or garage, EVEN IF doors away from windows, doors, and vents. 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 special precautions when working around electrical equipment. · 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, arcproducing 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.
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