HW5500
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Portable Electrical Generator
Owner’s Manual
Manual del Propietario
HW5500
HW5500L
HW5500E
HW5500EL
For product inquiries or support, visit www.honeywellgenerators.com or call
toll-free at 1-888-HWHELP1 (494-3571).
Si tiene preguntas acerca de los productos o requiere de asistencia, visite
www.honeywellgenerators.com o llame gratis al 1-888-HWHELP1 (494-3571).
Congratulations on owning a Honeywell portable generator!
WARNING
Model Number Phase
Part Number
AC Voltage
Serial Number
Fuel
Frequency
Power Output
Engine RPM
This manual contains important instructions for operating this generator. For your safety and the
safety of others, be sure to read this manual thoroughly before operating the generator. Failure to
properly follow all instructions and precautions can cause you and others to be seriously hurt or
killed.
Please use the spaces provided below to record important information about your generator. You may be asked to
provide this information should you require product service or support.
Identification information specific to your generator (model number and serial number) can be found on the generator nameplate.
HW5500L & 5500EL Models
FIGURE 1: Generator Nameplate Location
Date of Purchase:
Store/Dealer Purchased From:
HW5500 & HW5500E Models
Generator Model Number:
Generator Serial Number:
Northshore Power Systems, LLC
4425 N. Port Washington Rd., Suite 105
Milwaukee, WI 53212-1082 USA
TEL 1-888-HWHELP1 (494-3571)
www.honeywellgenerators.com
© 2009 Northshore Power Systems, LLC
The Honeywell Trademark is used under license from
Honeywell International Inc.
Honeywell International Inc. makes no representations or
warranties with respect to this product.
PRODUCT REGISTRATION
1 - PERSONAL INFORMATION
2 - PRODUCT INFORMATION
FIRST NAME
LAST NAME
CHECK HERE TO RECEIVE ANNUAL MAINTENANCE REMINDERS AND SPECIAL OFFERS FROM HONEYWELL
GENERATORS
CHECK HERE TO RECEIVE INFORMATION FROM OTHER COMPANIES VIA EMAIL, UNDERSTANDING YOUR
EMAIL ADDRESS MAY BE SHARED OR COMBINED WITH INFORMATION FROM OTHER SOURCES
DATE OF PURCHASE:
MM DD YYYY
//
*MODEL NUMBER:
*SERIAL NUMBER (18-digits):
PURCHASE LOCATION:
IN-STORE
ONLINE
STORE NAME:
PURCHASE PRICE: $___________.00
FEATURES INFLUENCING PRODUCT PURCHASE:
BRAND REPUTATION EASE OF USE
PORTABILITY SIZE / WEIGHT
POWER RATING STYLE/APPEARANCE
PRICE WARRANTY
HOW DID YOU BECOME AWARE OF THIS PRODUCT?
IN-STORE RADIO/TV
INTERNET STORE CIRCULAR
PRINT WORD OF MOUTH
OTHER BRANDS CONSIDERED WHEN SHOPPING
FOR THIS PRODUCT:
PRIMARY USE FOR PRODUCT:
TOOL POWER
RECREATION POWER
EMERGENCY POWER
PRIMARY LOCATION FOR PRODUCT USE:
HOME
WORK
TYPE OF WORK, IF PRODUCT BEING USED FOR
PROFESSION:
WHAT OTHER TYPE OF POWER EQUIPMENT ARE
YOU INTERESTED IN PURCHASING IN THE FUTURE?
WHO DECIDED TO PURCHASE THIS PRODUCT?
STREET ADDRESS
CITY, STATE, ZIP
COUNTRY
PHONE
EMAIL
*Found on nameplate of generator
To register your product, please complete the information below and mail to the address at the end of the form or register
online at www.honeywellgenerators.com. 18-digit serial number must be completed in order for warranty to be acti-
vated.
3 - DEMOGRAPHIC INFORMATION
GENDER:
MALE
FEMALE
MARITAL STATUS:
MARRIED
SINGLE
DATE OF BIRTH:
MM DD YYYY
//
INCLUDING YOURSELF, HOW MANY PEOPLE LIVE IN
YOUR HOUSEHOLD:
NUMBER OF CHILDREN UNDER 18 LIVING IN YOUR
HOUSEHOLD:
PRIMARY RESIDENCE:
OWN
RENT
EDUCATION:
SOME HIGH SCHOOL
HIGH SCHOOL DIPLOMA
COLLEGE DEGREE
GRADUATE DEGREE
THANK YOU FOR REGISTERING YOUR PRODUCT. THE INFORMATION YOU PROVIDED MAY BE USED
FOR MARKETING PURPOSES IN ORDER TO OFFER YOU VARIOUS PRODUCT INFORMATION AND
OFFERS.
CHECK HERE IF YOU DO NOT WISH TO BE CONTACTED ABOUT SPECIAL OFFERS.
PLEASE RETURN THIS FORM TO THE FOLLOWING ADDRESS:
Northshore Power Systems, LLC
4425 N Port Washington Road
Suite 105
Milwaukee, WI 53212-1082
PLEASE MAIL THIS FORM IN A SEALED ENVELOPE. DO NOT STAPLE.
HOUSEHOLD INCOME:
LESS THAN $15,000 $100,000 - $124,999
$15,000 - $29,999 $125,000 - $149,999
$30,000 - $49,999 $150,000 - $174,999
$50,000 - $79,999 $175,000 - $199,999
$80,000 - $99,999 $200,000 OR OVER
PRIMARY METHOD OF PURCHASING HOUSEHOLD
ITEMS:
IN-STORE
ONLINE
TV
MAIL ORDER
TYPES OF CREDIT CARDS HELD BY HOUSEHOLD
MEMBERS:
VISA / MASTERCARD
DISCOVER
AMERICAN EXPRESS
GAS / RETAIL
OTHER
NONE
HOUSEHOLD INTERESTS:
HOME IMPROVEMENT
AUTOMOTIVE WORK
CAMPING
OTHER
CONTENTS
IMPORTANT SAFETY RULES ............................................................................................ 1
Safety Messages .........................................................................................................................................1
Location of Important Labels .......................................................................................................................3
GETTING STARTED ......................................................................................................... 5
Unpacking Guidelines ..................................................................................................................................5
Record Generator Information .....................................................................................................................5
Assembly .....................................................................................................................................................6
Grounding the Generator ........................................................................................................................... 11
Using Generator for Back-up Power ..........................................................................................................11
COMPONENTS ............................................................................................................... 13
OPERATION ................................................................................................................... 15
Generator Location ....................................................................................................................................15
Preparing for Operation .............................................................................................................................15
Stopping Generator ...................................................................................................................................18
High-Altitude Operation ............................................................................................................................. 18
Powering Appliances .................................................................................................................................18
MAINTENANCE .............................................................................................................. 21
Maintenance Schedule .............................................................................................................................. 21
Engine Oil ..................................................................................................................................................22
Engine Fuel ............................................................................................................................................... 24
Air Filter Maintenance ................................................................................................................................25
Battery Service ..........................................................................................................................................27
Cleaning Fuel Sediment Cup ..................................................................................................................... 27
Spark Plug Service ....................................................................................................................................28
Cleaning Spark Arrestor Screen ................................................................................................................29
Transporting Generator ............................................................................................................................. 29
Storing Generator ...................................................................................................................................... 30
TROUBLESHOOTING .................................................................................................... 31
SPECIFICATIONS ........................................................................................................... 33
WARRANTIES ................................................................................................................ 35
NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY .............................................35
NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY ...........................................36
INDEX .............................................................................................................................. 39
MAINTENANCE PARTS ................................................................................................. 41
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SAVE THESE INSTRUCTIONS
NOTE:
WARNING
DANGER
WARNING
CAUTION
NOTICE
+
DANGER
IMPORTANT SAFETY RULES
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.
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.
Hazard Symbols and Meanings
In addition to the signal words, the following symbols may
be used to draw your attention to specific types of haz-
ards.
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
Chemical burn
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 open.
Tox i c fum e s
Electrical shock
Only use OUTSIDE and far
away from windows, doors, and
vents.
Fire
Hot surface
HW5500/HW5500E/HW5500EL/HW5500L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 1
Safety Messages
WARNING
WARNING
WARNING
WARNING
Electric Shock Hazards
Generator produces powerful voltage that can cause
death or great physical harm.
• When using generator for back-up power, notify the
utility company. Use approved transfer equipment to
isolate generator from electric utility.
• NEVER connect to a building's electrical system
unless a transfer switch has been installed by a qualified electrician.
• 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.
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
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 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.
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
equipment 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 permanent damage.
• NEVER modify generator in any way.
• NEVER tamper with governed speed. Generator
supplies correct rated frequency and voltage when
running at governed speed.
• Damage to generator caused by misuse or modifica-
tion is not covered under Warranty.
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.
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Location of Important Labels
A
C
B
D
E
F
A
G
H
NEVER FUEL UNIT WITH ENGINE RUNNING.
ALWAYS FUEL UNIT IN WELL VENTILATED AREA.
ALWAYS CLEAN FUEL SPILLS.
ALWAYS ALLOW UNIT TO COOL BEFORE FUELING.
FUEL
CUTOUT
NUNCA LLENE LA UNIDAD DE COMBUSTIBLE
CON EL MOTOR PRENDIDO.
SIEMPRE LLENE LA UNIDAD EN UN ÁREA
BIEN VENTILADA.
SIEMPRE LIMPIE CUALQUIER DERRAME
DE COMBUSTIBLE.
SIEMPRE DEJE QUE LA UNIDAD SE ENFRÍE
ANTES DE LLENARLA DE COMBUSTIBLE.
WARNING
ADVERTENCIA
NEVER FUEL UNIT WITH ENGINE RUNNING.
ALWAYS FUEL UNIT IN WELL VENTILATED AREA.
ALWAYS CLEAN FUEL SPILLS.
ALWAYS ALLOW UNIT TO COOL BEFORE FUELING.
WARNING
NUNCA LLENE LA UNIDAD DE COMBUSTIBLE
CON EL MOTOR PRENDIDO.
SIEMPRE LLENE LA UNIDAD EN UN ÁREA BIEN VENTILADA.
SIEMPRE LIMPIE CUALQUIER DERRAME DE COMBUSTIBLE.
SIEMPRE DEJE QUE LA UNIDAD SE ENFRÍE ANTES
DE LLENARLA DE COMBUSTIBLE.
ADVERTENCIA
CUTOUT
p/n 101796A
USAR EL GENERATOR EN INTERIORES
LO PUEDE MATAR EN MINUTOS.
EL ESCAPE DEL GENERATOR CONTIENE
MONÓXIDO DE CARBONO.
ESTE GAS ES UN VENENO QUE NO SE
PUEDE VER NI OLER.
NUNCA USE EL GENERADOR DENTRO
DEL HOGAR O EL GARAJE, AÚN SI LAS
PUERTAS Y VENTANAS ESTÁN ABIERTAS.
SOLO USELO EN EXTERIORES Y LEJOS
DE VENTILACIONES, PUERTAS Y
VENTANAS ABIERTAS.
DANGER PELIGRO
ONLY USE OUTSIDE AND
FAR AWAY FROM WINDOWS,
DOORS, AND VENTS.
NEVER USE INSIDE A HOME
OR GARAGE, EVEN IF DOORS
AND WINDOWS ARE OPEN.
ON
OFF
Clean up in cleansing solvent and dry up
once every 50 hours (every 10 hours in
unusually dusty circumstances) and then
immerse in clean engine oil until
saturated. Squeeze out excessive oil.
MAINTAIN AIR CLEANER
MANTENGA EL FILTRO DE AIRE
Límpielo segun las instrucciones en el manual del
usuario y séquelo una vez cada 50 horas (o cada 10
horas en condiciones cuando haya mucho polvo)
entonces sumérjalo en aceite de motor limpio hasta
saturarse, exprima el aceite de sobra.
ON
OFF
HOT
SURFACES
SUPERFICIES
CALIENTES
WARNING
ADVERTENCIA
Location of Important Labels
Your generator has several labels which provide important safety and maintenance information. Samples of these labels are
provided below. Should any of these labels become illegible or damaged, call 1-888-HWHELP1 (494-3571) for replacements.
NOTE: Illustration below shows battery, which is available only with HW5500E and HW5500EL models.
FIGURE 2: Label Locations
PRODUCT LABEL PART NUMBER
100884A
FUEL
(HW5500 & HW5500E Models)
A
101796A
(HW5500L & HW5500EL Models)
USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES.
GENERATOR EXHAUST CONTAINS CARBON MONOXIDE.
THIS IS A POISON YOU CANNOT SEE OR SMELL.
B 100886A
C 100887A
D 100883A
E 100879B
F 100882A
G 100885A
H 100881A
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GETTING STARTED
WARNING
CAUTION
WARNING
Model Number Phase
Part Number
AC Voltage
Serial Number
Fuel
Frequency
Power Output
Engine RPM
Use the information in this section to get your generator ready for operation.
ANYONE using 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.
Unpacking Guidelines
1. Set carton on a rigid, flat surface.
2. Remove carton contents.
Generator is heavy! Lifting generator can cause back or other bodily injury. NEVER lift generator without assistance.
3. Verify all of the following items are included in the generator package:
HW5500/HW5500E/HW5500EL/HW5500L Portable Electrical Generator
Wheel Kit (including handle assembly and assembly hardware)
Battery (HW5500E Only)
20’ 30 amp 4-in-1 Power Cord
1 L Engine Oil
Funnel
Owner’s Manual
Smart Start Instruction Card
The Smart Start instruction card is NOT intended to replace information provided in this Owner’s Manual. Be sure to
thoroughly read and understand all information provided in Owner’s Manual before operating generator. Failure to properly follow all instructions and precautions can cause you and others to be seriously injured or killed.
Inspect for Damage
Carefully inspect generator for any damage that may have occurred during shipment. If loss or damage is noted after
delivery, separate damaged materials and call the Customer Hotline at 1-888-HWHELP1 (494-3571).
Record Generator Information
Write down the identification information specific to your generator in the spaces provided on the inside cover of this
Owner’s Manual. This information is located on the generator nameplate (see illustration below).
HW5500L & HW5500EL Models
HW5500 & HW5500E Models
FIGURE 3: Generator Nameplate Location
HW5500/HW5500E/HW5500EL/HW5500L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 5
Assembly
NOTE:
NOTE:
CAUTION
Assembly
Wheel Kit
Generator must be empty of engine oil and fuel. Drain engine oil and fuel, if necessary.
Generator is heavy! Lifting generator can cause back or other bodily injury. NEVER lift generator without
assistance.
FIGURE 5: Wheel Assembly Components
Illustration above shows battery, which is available only with HW5500E and HW5500EL models.
In order to install support legs and wheel assembly, you will need to either tilt generator on its side or elevate generator
by placing solid wood pieces underneath unit.
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.
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Assembly
CAUTION
Step 1: Install Support Legs
To install support legs, you will need:
25 mm full-thread hex bolts (2)
5/16" washers (2)
13 mm flange serrated nuts (6)
16 mm full-thread hex bolts (4)
Socket wrench with 10 mm socket
Brackets (2)
Rubber stopper (2)
* Not included
Generator must be empty of engine oil and fuel.
Drain engine oil and fuel, if necessary.
Generator is heavy! Lifting generator can cause
back or other bodily injury. NEVER lift generator
without assistance.
1. Place the generator on a flat, level surface.
2. Stand at side of generator opposite recoil starter
handle. Grip frame; carefully pull up and push to tilt
generator backward.
*
5. Attach a rubber stopper to the bottom of each support
leg using a 25 mm full-thread hex bolt and a 13 mm
flange serrated nut; tighten until securely seated.
FIGURE 7: Rubber Stopper Attachment to Support Leg
6. Attach each support leg to pre-drilled holes on bottom
of generator frame, using 16 mm full-thread hex bolts
and 13 mm flange serrated nuts; tighten until securely
seated.
FIGURE 8: Support Leg Attachment to Generator
FIGURE 6: Tip onto Generator Recoil Side
3. Gently set generator onto the recoil side.
4. Place 5/16" washer in the center of each rubber stop-
per.
HW5500/HW5500E/HW5500EL/HW5500L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 7
Assembly
Step 2: Install Wheel Axle and Wheels
To install wheel assembly, you will need:
Wheel axle (1)
16 mm full-thread hex bolts (4)
13 mm flange serrated nuts (4)
Axle bracket* (1)
Wheels (2)
9/16" washers (4)
Cotter pins (2)
Socket wrench with 10 mm socket
Needle-nose pliers
* Two brackets are needed to install wheel axle. One bracket
comes already attached to wheel axle; other bracket is included
in wheel kit hardware bag.
† Not included.
†
1. Install wheel axle brackets to frame using 16 mm full-
thread hex bolts and 13 mm flange serrated nuts.
1A. Install pre-attached bracket to frame first.
1B. Install other bracket (included in hardware bag) to
frame.
†
6. Using needle-nose pliers, bend each end of cotter pin
in opposing directions to secure wheel to axle.
FIGURE 11: Cotter Pin Installation
7. Return generator to upright position (so that wheels
and leg supports are touching the ground).
FIGURE 9: Wheel Axle Attached to Generator
On each end of axle:
2. Slide 9/16" washer onto axle.
3. Slide and push wheel onto axle until it fits snug
against washer.
FIGURE 10: Slide Wheel onto Wheel Axle
4. Slide second 9/16" washer onto axle.
5. Slide cotter pin into pre-drilled hole until fully seated.
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Assembly
NOTE:
RUN
STOP
CAUTION
Step 3: Install Handle Assembly
To install handle assembly, you will need:
Handle brackets (2)
Handle bars (2)
Pin and chain (2)
Rubber handle grips (2)
M6 X 40 X 8 mm flange-head hex bolts (6)
10 mm flange serrated nuts (6)
Socket wrench with 8 mm socket
10 mm open end wrench*
* Not included
1. Hold handle bracket over pre-drilled holes on frame
as shown in Figure 12.
FIGURE 12: Handle Bracket to Frame
2. Attach bracket to frame using 40 mm flange-head hex
bolts and 10 mm flange serrated nuts and tighten.
3. Slide handle bar through center of each bracket and
line up bolt holes.
*
5. Attach chain to handle bracket as illustrated below.
Insert pin through bracket and handle.
FIGURE 14: Attach pin and chain
6. Slide rubber handle grip onto each handle bar and
push to achieve snug fit.
Once properly installed, the handles can be collapsed, if
desired, by removing the pins.
Hands and fingers can be pinched from collapsible
handles.
• Keep hands and fingers clear from hinges when
collapsing generator handles.
• Handles should only be used to roll the generator to a
new location. If lifting the generator (i.e. into a vehicle),
never use the handles to support the complete weight
of the generator.
• To collapse handles, remove pins and push firmly
down on handle until it rests vertically against generator frame.
• To return handles to horizontal position, pull up on
handle and lock with pins.
FIGURE 13: Insert Handle Bar to Bracket
4. Attach handle to each bracket using 40 mm flange-
head hex bolt and 10 mm flange serrated nut to hole
closest to handle and tighten.
Handle should stick straight out after tightening bolts and
nuts. If handle seems to hang down, tighten bolts and
nuts further.
HW5500/HW5500E/HW5500EL/HW5500L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 9
Assembly
NOTE:
NOTE:
WARNING
WARNING
WARNING
Step 4: Install Battery
(HW5500E and HW5500EL Only)
To use the electric-start feature, the battery (included)
must be connected to generator’s electric starter.
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.
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 serious 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 battery.
1. The generator is packaged with the positive (+) bat-
tery lead attached to the top of the alternator with a
plastic tie wrap. Carefully cut the tie wrap to disen-
gage the battery lead and remove the plastic bag.
To avoid electric arcing, which can result in electric
shock, follow these instructions exactly.
When connecting or disconnecting battery leads:
• ALWAYS connect positive (+) battery lead
first.
• ALWAYS disconnect negative (-) battery lead
first.
• NEVER connect negative (-) battery lead to
positive (+) post on battery.
• NEVER connect positive (+) battery lead to
negative (-) post on battery.
2. To access battery posts:
2A. Loosen and remove nuts on retaining plate; slide
retaining plate off support rods.
FIGURE 17: Electric Starter Battery—Remove Retaining Plate
2B. Tip battery slightly forward.
3. Remove bolt/nut from each battery post.
4. Connect red positive (+) battery lead to positive (+)
post on battery; fasten with bolt and nut.
FIGURE 18: Electric Starter Battery—Lead Connection
5. Confirm the black negative (-) battery lead is securely
fastened to the negative (-) battery post as it may
have loosened during shipping.
6. Reinstall retaining plate; tighten bolts and nuts.
FIGURE 16: Positive Battery Lead Attached to Alternator for Shipping
Actual battery appearance may vary from illustration provided.
While the engine is running, a small “trickle” charge is
applied to the battery. This keeps an adequate battery
charge.
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Grounding the Generator
NOTE:
WARNING
DANGER
Grounding the Generator
Generator must be grounded to prevent electrical
shock from faulty appliances.
• Before using generator, consult a qualified electrician,
electrical inspector, or local agency having jurisdiction
for local codes or ordinances that apply to the intended
use of generator.
The National Electric Code (NEC) requires the generator
to be connected to an earth ground. Before using the generator, connect a copper wire (minimum 10 AWG) from the
ground terminal (see Figure 19) to an earth ground. Consult a licensed electrician for proper grounding methods.
FIGURE 19: Ground Terminal
Using Generator for Back-up Power
Before connecting to a building’s electrical system, consult
your local utility company or a qualified electrician.
Improper connections to a building's electrical system can
be deadly.
Electrical current from generator can feedback into
utility lines. Such feedback may electrocute utility
company workers or others who contact utility lines
during a power outage.
Electrical current can feedback into generator. When
utility power is restored, generator may explode,
burn, or cause fires in building's electrical system.
The NEC requires any generator connected to a building’s
electrical wiring utilize a transfer switch installed by a
licensed electrician.
What is a transfer switch?
A transfer switch is a device that allows switching
from utility power to emergency generator power.
The transfer switch is either a manual switch, an
automatic switch, or a combination of manual and
automatic. During a power outage, the transfer
switch isolates emergency circuits from the utility
line, allowing for efficient operation of the generator
without back-feeding into utility power.
The generator has a floating neutral which means the
ground terminal on the generator is not connected to AC
neutral wire in the generator. If using a receptacle tester, it
will not show the same ground circuit condition as for a
home receptacle.
Special Requirements
There may be Federal or State Occupational Safety and
Health Administration (OSHA) regulations, local codes, or
ordinances that apply to the intended use of generator.
Please consult a qualified electrician, electrical inspector,
or the local agency having jurisdiction.
• In some areas, generators are required to be regis-
tered with local utility companies.
• If generator is used at a construction site, there may
be additional regulations which must be observed.
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COMPONENTS
CAUTION
K
F
B
I
H
E
C
D
A
G
J
L
M
N
POWER CONTROL CENTER
HOUSEHOLD
OUTLETS
4-IN-1POWER CORD OF
TRANSFER SWITCH
120 VOLTS AC 120/240 VOLTS AC
BREAKER
PORTABLE GENERATOR
5500 CONTINUOUS WATTS • 9375MAXIMUM WATTS
5500
337cc
BREAKER
MASTER
BREAKER
Set
Tripped
CAUTION
WARNING
Use information provided in this section to become familiar with your generator’s components.
A—Power Control Center
Household Outlets
120V 20 Amp Duplex (NEMA 5-20R)
outlets to connect 120V appliances to
generator for power.
Power Cord/ Transfer Switch
120/240V 30 Amp Twist-Lock outlet
can be used to:
• Power 120V appliances using 4-
in-1 power cord (included with generator).
• Power 240V appliances using appropriate (NEMA L14-
30R) power cord (not included).
• Connect a transfer switch to building’s main electrical sys-
tem for back-up power (see page 11).
Breakers
Protects circuits from damage caused by
overload or short-circuit by stopping 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.
Ground Terminal
Connects generator to ground wire for grounding protection.
B—Battery Tray and Battery (HW5500E Only)
Provides power for electric start feature.
C—Engine Oil Fill Cap/Dipstick
Seals off engine oil fill hole and provides indicator for engine
oil level.
D—Engine Oil Plug
When loosened, allows engine oil to drain from generator.
Information below is provided for reference only. Refer to “OPERATION” on page 15 for instructions on operating
the generator.
FIGURE 20: HW5500EL Portable Generator (battery with HW5500E & HW5500EL models only)
Generator must be grounded to prevent electrical
shock from faulty appliances. See page 11.
E—Engine Control Switch
Control used to run and stop the engine.
• START—Starts generator engine (HW5500E only)
• RUN—Prepares engine to start (HW5500 only);
Indicates engine is currently running (HW5500E only)
• STOP—Stops generator engine
F—Recoil Starter Grip Handle
Starts engine (HW5500).
Provides means to manually start engine, if needed
(HW5500E).
G—Fuel Valve
Controls flow of fuel from fuel tank to carburetor.
H—Air Cleaner Assembly
Removes dust from engine intake air.
I— Choke Control
Controls choke valve. Choke control must be pulled out to ON
position when starting a cold engine.
J—Fuel Gauge
Indicates level of fuel currently in fuel tank.
K—Fuel Tank Cap
Provides a secure seal on 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
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 (HW5500L & EL models only)
Reduces hydrocarbon emissions.
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14 www.honeywellgenerators.com HW5500/HW5500E/HW5500EL/HW5500L Portable Electrical Generator Owner’s Manual
OPERATION
DANGER
+
WARNING
WARNING
WARNING
DANGER
DANGER
Generator Location
When deciding on the location to place your generator,
keep in mind the following safety rules:
Depressed areas such as construction foundations,
pools, or any low-lying areas, can cause carbon
monoxide to accumulate. Inhalation of carbon monoxide can kill you in minutes.
• NEVER use generator inside homes, garages,
crawl spaces, sheds, or similar enclosed
spaces. Use generator only outdoors and far
away from windows, doors, and vents.
If generator is placed on an uneven or flexible surface, generator could tilt or overturn, causing fuel to
spill from gas tank. Spilled fuel could ignite.
• Place generator on firm, level surface and avoid
loose sand or snow. If generator is tilted or
overturned, fuel spillage may result. Also, if
generator is overturned or sinks into a soft surface, sand, dirt, or water may enter generator.
NEVER operate generator in rain or snow, or
when the generator is set on wet surface.
Keep generator at least 6 feet (2 meters) away
from buildings, other equipment, and combustible
materials during operation.
Preparing for Operation
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 open.
Before starting generator, complete the following preparation tasks:
Be sure generator is placed outdoors in a well
ventilated area.
Consult a licensed electrician or utility company if
you will be using your generator for back-up
power. The generator must be connected to build-
ing’s electrical system via a transfer switch. See
“Using Generator for Back-up Power” on page 11.
Before connecting to a building’s electrical system,
consult utility company or qualified electrician.
• Connecting to a building's electrical system
without using a transfer switch can cause electrical current from generator to feed back into
utility lines, resulting in death or serious injury
to utility company workers or others who contact utility lines during a power outage.
Only use OUTSIDE and far
away from windows, doors, and
vents.
Check/add engine oil— See “Engine Oil” on
page 22. For initial start-up, follow instructions on oil
container provided with generator.
*
Check/add fuel
—See “Adding Fuel” on page 24.
Be sure ground terminal is properly connected to
earth ground—See “Grounding the Generator” on
page 11.
Check extension cords—be sure cords are:
In good condition.
Rated for outdoor use and match amperage and
voltage ratings of generator outlet.
Equipped with proper plugs that contain grounding
blades.
* You must add fuel before using the generator for the first time
See “Adding Fuel” on page 24.
HW5500/HW5500E/HW5500EL/HW5500L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 15
Preparing for Operation
NOTE:
WARNING
Set Tripped
CAUTION
Starting Generator
Before starting generator, be sure to thoroughly read
all information provided in this Owner’s Manual.
NOTICE
It is very important to maintain proper level of engine oil to
keep engine in good running condition.
• Check engine oil level prior to each use.
Starting generator with appliances connected can cause
permanent damage to appliances.
• NEVER start generator with electrical appliances
plugged in and turned on.
Electric Start (HW5500E and HW5500EL Models Only)
1. Be sure generator is placed outside, in well-ventilated
area.
NOTICE
Keep the generator at a minimum of 6 feet (2 meters) from
any building, object, or wall.
2. Confirm the circuit breakers are set.
5. Press and hold engine control switch in START posi-
tion until engine starts.
ENGINE
START
RUN
STOP
FIGURE 25: Engine Control Switch
NOTICE
If engine will not start, move the choke to the OFF position to reduce fuel to the engine.
NOTICE
• Holding engine control switch for more than 5 seconds
can damage starter motor. If engine fails to start after 5
seconds, release engine start switch and wait 10 seconds before attempting to start engine again.
• If you notice engine cranking speed drop after a period
of time, it may be an indication that battery should be
recharged.
6. When the engine starts, release the engine control
switch allowing it to settle to the RUN (center) position.
FIGURE 21: Circuit Breaker Position
3. Turn fuel valve to ON position.Pull
FIGURE 22: Fuel Valve Lever — ON/OFF position
4. choke control to ON position.
OFF
ON
To avoid generator damage, NEVER press the engine control switch to the START position while generator is running.
7. As engine warms up, and RPM stabilizes, gradually
push choke control to OFF position.
While engine is running, a small “trickle” charge is applied
to starting battery.This keeps an adequate battery charge.
FIGURE 23: Choke Rod
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Preparing for Operation
Set Tripped
ON
OFF
START
ENGINE
STOP
RUN
RUN
ENGINE
STOP
CAUTION
Manual (Recoil) Start (All Models):
1. Be sure generator is placed outside, in well-ventilated
area.
NOTICE
Keep the generator at a minimum of 6 feet (2 meters) from
any building, object, or wall.
2. Confirm the circuit breakers are set.
FIGURE 26: Circuit Breaker Position
3. Turn fuel valve to ON position.
FIGURE 27: Fuel Valve Lever — ON/OFF position
5. Press engine control switch to RUN position.
FIGURE 30: Engine Control Switch - HW5500E and
HW5500EL Models
FIGURE 31: Engine Control Switch - HW5500 and
HW5500L Models
6. Grip recoil starter handle and pull slowly until you feel
slight resistance.
Kickback (rapid retraction) of starter cord will pull hand and
arm toward engine faster than you can let go.
Broken bones, fractures, bruises, or sprains could result.
4. Pull choke control to ON position.
FIGURE 28: Choke Rod
FIGURE 32: Recoil Starter Handle
7. Apply a swift, single pull to start engine. Carefully
return recoil starter handle to its original position.
NOTICE
To prevent damage to generator, do not allow recoil starter
handle to snap back against engine.
NOTICE
If engine will not start, move the choke to the OFF position to reduce fuel to the engine.
8. As engine warms up, and RPM stabilizes, gradually
push in choke control to OFF position.
HW5500/HW5500E/HW5500EL/HW5500L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 17
Stopping Generator
NOTE:
WARNING
WARNING
Stopping Generator
In an emergency:
Press engine control switch to STOP position.
In normal use:
1. Turn OFF any connected appliances and unplug any
connected power cords.
2. Allow generator to run for 2-3 minutes.
3. Press engine control switch to STOP position.
4. Turn fuel valve to OFF position.
High-Altitude Operation
At high altitudes, standard carburetor air-fuel mixture will
be rich. Performance will decrease and fuel consumption
will increase.
High-altitude performance can be improved by installing a
smaller diameter main fuel jet in the carburetor and then
readjusting the pilot screw. If you always operate the
engine at altitudes higher than 5000 feet (1500 meters)
above sea level, have an authorized generator dealer perform this carburetor modification.
Even with suitable carburetor jetting, engine horsepower
will decrease approximately 3.5% for each 1000 foot (300
meters) increase in altitude above sea level. The effect of
altitude on horsepower will be greater than this if no carburetor modification is made.
NOTICE
If the engine is jetted for high-altitude and is used at a lower
altitude, it will run a lean air-fuel mixture that results in
reduced performance, possible over-heating, and possible
serious engine damage.
Powering Appliances
In this manual, the term “appliance” refers to any electrical device that can be connected to generator for power.
Rules for Powering Appliances
NOTICE
NEVER start generator with electrical appliances plugged in
and turned on.
Faulty appliances and power cords can result in electrical shock.
• Before attempting to power an appliance, be sure generator has been properly grounded, and that appliance
and power cord are in good working order.
• Keep the generator away from other electric cables or
wires including commercial power supply lines.
• Do not use generator for any purpose other than its
intended use.
• Do not parallel connect generators or lengthen the
exhaust pipe.
• Do not connect generator to any household circuit,
otherwise it may destroy generator or home electric
equipment.
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 equipment 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.
• Plan carefully: Before using the generator to power
appliances, take time to add power ratings (wattage) of each appliance and verify that total wattage
does not exceed rated output of generator. Power
rating information can usually be found on an appliance’s product label, stamped inside, or on the
back of the appliance.
See Table 1 for a listing of
average appliance wattage requirements.
• NEVER overload: Circuit breakers will stop the flow
of electricity from the generator to the appliance if the
generator is overloaded. This will be indicated by a
“tripped” breaker. If this happens, power off and disconnect appliance(s), wait a few minutes, and then
push circuit breaker to reset.
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Powering Appliances
CAUTION
CAUTION
• Pay attention to appliance operation: If appliance
begins to operate abnormally, becomes sluggish, or
stops suddenly, turn it OFF immediately. Disconnect
appliance and determine whether problem is appliance, or if rated load capacity of generator has been
exceeded.
• Use suitable extension cords: If using an extension
cord to connect appliance to generator, use only ULlisted, three-prong extension cords. Be sure extension
cord is proper size (wire-gauge) to handle electric
load that will be plugged into it.
Do not run power cords under carpet, rugs, or other materials where heat might build up or cord damage may go unnoticed.
Appliance Wattage Information
Use table below as a guide to determine how much power
you will need to run appliances using generator.
The values provided in following table are estimates only.
• ALWAYS verify actual wattage requirements for appliance you will be powering. Check labels inside or on
the back of appliance, refer to appliance operating
manuals, or contact appliance manufacturer.
Appliance Typical Running Watts
Air Conditioner, Central* 3500
Air Conditioner, Window* 500-1440
Aquarium 50-1210
Clock Radio 10
Coffee Maker 900-1200
Computer, CPU -
Awake / Asleep
Computer, Monitor -
Awake / Asleep
Computer, Laptop 50
Dehumidifier* 785
Dishwasher*
Dryer, Electric 1800-5000
Electric Blanket
(Single/Double)
Fan, Ceiling* 65-175
Fan, Window* 55-250
Furnace*
Hair Dryer 1200-1875
Heater, Portable 750-1500
TABLE 1. Typical Appliance Running Wattages
120 / 30 or less
150 / 30 or less
1200-2400 (using drying
feature greatly increases
energy consumption)
60 / 100
*
750
Appliance Typical Running Watts
Iron 1000-1800
Microwave Oven 750-1100
Radio, Stereo 70-400
Refrigerator, Frost-free, 16
Cubic Feet*
Sump Pump, 1/2 hp* 2150
Sump Pump, 1/3 hp* 2300
Television
• 19"
• 27"
• 36"
• 53"-61" Projection
• Flat Screen
Toaster 800-1400
Toaster Oven 1225
Vacuum Cleaner* 1000-1440
VCR/DVD 17-21 / 20-25
Washing Machine 350-500
Water Heater, 40 gal 4500-5500
Water Pump, Deep Well* 250-1100
TABLE 1. Typical Appliance Running Wattages
* Allow up to three times normal running watts for starting this
appliance.
Starting appliances that have motors requires more power.
Examples of motorized appliances include refrigerators,
water pumps, and furnace blowers. Be sure that power rating
of appliance does not exceed that of generator.
725
65-110
113
133
170
120
NOTICE
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MAINTENANCE
DANGER
WARNING
WARNING
Maintenance Schedule
Periodic maintenance and adjustment is necessary to keep the generator in good operating condition. Perform service and
inspection at intervals shown in Generator Maintenance Schedule (see Table 2).
Accidental starting of generator can cause severe injury or
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 open.
Only use OUTSIDE and far
away from windows, doors, and
vents.
• Shut off engine before performing any maintenance. If
engine must be run, be sure area is well ventilated.
NOTICE
Maintenance, replacement, or repair of the emission
control devices and systems may be performed by any
non-road engine repair establishment or individual.
death. Before performing maintenance, disconnect spark
plug cap from spark plug.Also disconnect both starting battery cables. Remove the negative (-) cable first to reduce the
risk of arcing.
Improper maintenance, or failure to correct a problem before
operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow inspection and maintenance recommendations and schedules in this owner's
manual.
NOTICE
The maintenance schedule applies to normal operating conditions. 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 to your individual
needs and use.
*
Every 6
months or 100
hours of use
MAINTENANCE TASK
Before each
use
First month or
20 hours of
use
FREQUENCY
Every 3
months or 50
hours of use
Check engine oil level X
Inspect for/clean debris X
Check air filter X
Run engine X**
Clean air filter
†
X
Change engine oil X X
Clean fuel sediment cup X
Check/clean spark plug X
Clean spark arrestor X
Check/adjust valve clearance
Clean fuel tank and strainer
Check fuel line
TABLE 2. Generator Maintenance Schedule
* Perform at every indicated month or operating hour interval, whichever comes first.
** It is recommended that the generator is started 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.
† Clean more often when using generator in dusty areas.
‡ It is recommended that this maintenance task be performed by a service dealer.
Every 2 years (replace if necessary)‡
Every year or
200 hours of
use
‡
X
‡
X
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Engine Oil
5W-30
Synthetic 5W-30
SAE 30, 10W-30
WARNING
Engine Oil
NOTICE
Engine oil is a major factor affecting engine performance
and service life. Non-detergent and 2-stroke engine oils will
damage engine and are not recommended.
• Be sure to use engine oils specified under “Engine Oil
Recommendations.”
It is very important to maintain proper level of engine oil to
keep engine in good running condition.
• Check engine oil level prior to each use. Refill engine
oil if oil level is too low.
Engine Oil Recommendations
Use 4-stroke oil, or equivalent high detergent, premium
quality motor oil certified to meet or exceed U.S. automobile manufacturer's requirements for API Performance
Class SL, SJ, or better.
SAE 10W-30 is recommended for general temperature
use. Refer to Figure 33 for information on other viscosities
that may be used. Other viscosities shown in chart may be
used when average temperature in your area is within
indicated range.
6. Oil should be filled to the “H” level or somewhere
between the “L” and “H”.
FIGURE 35: Engine Oil Level
If oil level is at “L” or below, add recommended oil
(see “Adding Engine Oil”). Do not overfill.
7. Reinstall oil fill cap and fully tighten.
Low Oil Protection
When engine oil level approaches an unsafe level, the low
oil protection feature prevents equipment damage by automatically shutting down engine.
When engine shuts down due to low oil level:
• The engine start switch will remain in RUN position.
• You will not be able to start engine until you add
required amount of engine oil.
FIGURE 33: Recommended Oil Viscosity
Checking Engine Oil Level
To check engine oil level:
1. Stop generator if engine is running.
2. Place the generator on a flat, level surface.
3. Remove oil fill cap and wipe off dipstick end with
clean cloth.
4. Insert oil fill cap into oil fill hole but do not screw in
(Figure 34).
5. Pull out to read current oil level indicated on dipstick
end.
Adding Engine Oil
1. Stop generator if engine is running.
Crankcase pressure can cause hot engine oil to
spray out of engine fill hole. Hot engine oil can
cause severe burns.
• ALWAYS stop engine before removing oil fill cap.
2. Place the generator on a flat, level surface.
3. Remove oil fill cap.
FIGURE 36: Oil Fill Cap Removal
4. Slowly pour oil into oil fill hole using funnel.
5. Check oil level.
6. Replace oil fill cap and fully tighten.
FIGURE 34: Engine Oil Level
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Engine Oil
NOTE:
WARNING
WARNING
Changing Engine Oil
Frequent or prolonged contact with engine oil may cause skin
cancer.
• Immediately after handling engine oil, thoroughly wash
hands and any areas of skin exposed to engine oil, with
soap and water.
To change engine oil, you will need:
3/8” socket wrench with 12 mm 6 pt. socket and
3” extension
Oil drain pan or other container suitable for holding
engine oil
Funnel
Clean cloth
Unused engine oil (SAE type indicated in Fig-
ure 33)
1. Place the generator on a flat, level surface.
2. Start engine and run until warm.
3. Stop engine.
Crankcase pressure can cause hot engine oil to
spray out of engine fill hole. Hot engine oil can
cause severe burns.
• ALWAYS stop engine before removing oil fill cap.
4. Place oil pan, or other container suitable for holding
engine oil, underneath generator.
6. Remove drain bolt and sealing washer.
7. Allow oil to drain into oil pan or container.
8. Slowly unscrew and remove oil fill cap.
FIGURE 39: Remove Oil Fill Cap
9. Allow oil to completely drain into oil pan or container.
FIGURE 40: Oil Draining from Generator
10. Using clean cloth, wipe around oil fill and drain plug
areas to clean any dirt and debris.
11. Reinstall sealing washer and drain plug bolt.
12. Pour new (unused) engine oil into oil fill hole using
funnel. (See Figure 33 for recommended oil type).
Do not overfill.
13. Check oil level.
FIGURE 41: Engine Oil Dipstick—Oil Level Indicator
14. Reinstall oil fill cap and tighten until fully seated.
FIGURE 37: Oil Drain Bolt
Dispose of used motor oil according to guidelines established by your local or state government.
5. Using a socket wrench with 12 mm socket and exten-
sion, loosen drain plug bolt partially to allow oil to flow
slowly.
FIGURE 38: Loosen Oil Drain Bolt
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