HW5500/HW5500E Portable Generator
Owner’s Manual
Portable Gasoline Generator
Electric Start
Read and Save These Instructions
For product inquiries or support, please visit www.honeywellgenerators.com
or call toll-free at 1-888-494-3571.
Congratulations on owning a Honeywell portable generator
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 spaces provided below to write down 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 generator’s
nameplate.
Date of Purchase:
Store/Dealer Purchased From:
Generator Model Number:
Generator Serial Number:
Northshore Power Systems, LLC
4425 N. Port Washington Rd., Suite 105
Milwaukee, WI 53212-1082 USA
TEL 1-888-494-3571
honeywellgenerators.com
© 2008 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
To register your product, please complete the information below and mail to the mailing address at the end of form,
or register online at www.honeywellgenerators.com
1 – PERSONAL INFORMATION
FIRST NAME INITIAL
LAST NAME
CHECK HERE TO RECEIVE PRODUCT REMINDERS AND OFFERS VIA EMAIL
CHECK HERE TO RECEIVE INFORMATION FROM OTHER COMPANIES VIA EMAIL, UNDERSTANDING YOUR
EMAIL ADDRESS MAY BE SHARED OR COMBINED WITH INFORMATION FROM OTHER SOURCES
2 – PRODUCT INFORMATION
DATE OF PURCHASE
/
MM DD YYYY
/
MODEL NUMBER*:
SERIAL NUMBER*:
*Found on nameplate of generator
OTHER BRANDS CONSIDERED WHEN SHOPPING
FOR THIS PRODUCT:
PRIMARY USE FOR PRODUCT:
TOOL POWER
RECREATION POWER
PURCHASE LOCATION:
EMERGENCY POWER
IN-STORE
ONLINE
STORE
NAME______________________________
PRIMARY LOCATION FOR PRODUCT USE:
HOME
WORK
PURCHASE PRICE
$__________.00
FEATURES INFLUENCING
PRODUCT PURCHASE
BRAND
REPUTATION
PORTABILITY
POWER RATING
PRICE
HOW DID YOU BECOME AWARE OF THIS
PRODUCT?
IN-STORE
INTERNET
PRINT
EASE OF USE
SIZE/WEIGHT
STYLE/APPEARANCE
WARRANTY
RADIO/TV
STORE CIRCULAR
WORD OF MOUTH
TYPE OF WORK, IF PRODUCT BEING USED FOR
PROFESSION:
WHAT OTHER TYPE OF POWER EQUIPMENT ARE
INTERESTED IN PURCHASING IN THE FUTURE?
WHO DECIDED TO PURCHASE THIS PRODUCT?
3 – DEMOGRAPHIC INFORMATION
GENDER:
MALE
FEMALE
MARITAL STATUS:
MARRIED
SINGLE
DATE OF BIRTH:
/
MM DD YYYY
/
INCLUDING YOUR SELF, HOW MANY PEOPLE LIVE IN
YOUR HOUSEHOLD?
NUMBER OF CHILDREN UNDER 18 LIVING IN YOUR
HOUSEHOLD:
PRIMARY RESIDENCE:
OWN
RENT
HOUSEHOLD INCOME
LESS THAN $15,000 $100,000 - $124,999
$15,000 - $29,999
$30,000 - $49,999
$50,000 - $79,999
$80,000 - $99,999
PRIMARY METHOD OF PURCHASING HOUSEHOLD
ITEMS:
$125,000 - $149,000
$150,000 – $174,999
$175,000 – $199,999
$200,000 OR OVER
IN-STORE
ONLINE
TV
MAIL ORDER
TYPES OF CREDIT CARDS HELD BY HOUSEHOLD
MEMBERS:
VISA/MASTER CARD
DISCOVER
AMERICAN EXPRESS
GAS/RETAIL
OTHER
NONE
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.
HOUSEHOLD INTERESTS:
HOME IMPROVEMENT
AUTOMOTIVE WORK
CAMPING
OTHER:
_________________________________________
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.
CONTENTS
IMPORTANT SAFETY RULES............................................................................................ 1
Safety Messages ............................................................................................................................................1
Location of Important Labels ..........................................................................................................................3
GETTING STARTED ............................................................................................................5
Unpacking Guidelines .....................................................................................................................................5
Record Generator Information ........................................................................................................................6
Assembly ........................................................................................................................................................7
Grounding the Generator ..............................................................................................................................11
Using Generator for Backup Power ..............................................................................................................12
COMPONENTS .................................................................................................................. 13
OPERATION ......................................................................................................................15
Preparing for Operation ................................................................................................................................15
Generator Location .......................................................................................................................................15
Starting Generator ........................................................................................................................................15
Stopping Generator ......................................................................................................................................17
High Altitude Operation ................................................................................................................................17
Powering Appliances ....................................................................................................................................17
MAINTENANCE .................................................................................................................19
Maintenance Schedule .................................................................................................................................19
Engine Oil .....................................................................................................................................................20
Adding Fuel ..................................................................................................................................................22
Air Filter Maintenance ...................................................................................................................................23
Cleaning Fuel Sediment Cup ........................................................................................................................24
Spark Plug Service .......................................................................................................................................24
Cleaning Spark Arrestor Screen ...................................................................................................................25
Transporting Generator ................................................................................................................................26
Storing Generator .........................................................................................................................................26
TROUBLESHOOTING .......................................................................................................29
SPECIFICATIONS .............................................................................................................31
WARRANTIES ................................................................................................................... 33
NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY ..............................................33
NORTHSHORE POWER SYSTEMS LIMITED WARRANTY ......................................................................35
INDEX .................................................................................................................................37
HW5500/5500E MAINTENANCE PARTS .........................................................................39
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SAVE THESE INSTRUCTIONS
NOTE:
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IMPORTANT SAFETY RULES
ANYONE using or servicing generator must read, understand, and follow all safety and operation instructions provided in 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, and maintenance of
this generator unit, we cannot possibly anticipate or provide advice or safety messages to cover every situation.
Safety Messages
Hazard Symbols and Meanings
In addition to the signal words described above, the following symbols may be used to draw your attention to
specific types of hazards.
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 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.
To xic f umes
Electrical shock
Only use OUTSIDE and far
away from windows, doors, and
vents.
Fire
Hot surface
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 1
Safety Messages
Electric Shock Hazards
Generator produces powerful voltage that can cause
death or great physical harm.
• When using generator for backup power, notify 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.
Generator Damage Hazards
Improper treatment or misuse of generator can cause permanent damage.
• NEVER tamper with governed speed. Generator supplies correct rated frequency and voltage when running
at governed speed.
• NEVER modify generator in any way.
• Damage to generator caused by misuse or modification
is not covered under Warranty.
• Refuel generator only outdoors, in a well-ventilated
area.
• NEVER enclose the generator in any structure.
• Keep generator at least 3 feet (1 meter) away from
buildings and other equipment 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.
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
Location of Important Labels
Your generator is packaged with 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, contact Customer Hotline at 1-888-4943571 to request replacements. NOTE: Illustration below shows battery, which is available only with HW5500E models.
PRODUCT LABEL PART NUMBER
A 100884A
B 100886A
C 100887A
D 100883A
E 100879A
F 100882A
G 100885A
H 100881A
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GETTING STARTED
Use the information in this section to get your generator ready for operation.
ANYONE using the 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
Generator is heavy! Lifting generator can cause back or other bodily injury. NEVER lift generator without assistance.
1. Set carton on a rigid, flat surface.
2. Remove all contents, except generator unit.
3. Open carton completely by using a utility knife to cut each corner (from top to bottom).
Package Checklist
Verify that all of the following items are included in the generator package:
HW5500/5500E Portable Generator
Wheel Kit (including handle assembly and assembly hardware)
Battery (HW5500E models only)
20’ 30 amp 4-in-1 Power Cord
1 L Engine Oil
Paper Funnel
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 hurt or killed.
Owner’s Manual
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 Customer Hotline at 1-888-494-3571.
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 5
Record Generator Information
Record Generator Information
It is recommended that you take a moment to write down the identification information specific to your generator in the
spaces provided on the inside cover of this Owner’s Manual. You can find this information on generator’s name plate,
located on rear side of generator (see illustration below).
FIGURE 1: Generator Name Plate Location
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Assembly
NOTE:
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Wheel Kit
Assembly
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 2: Wheel Assembly Components
Illustration above shows battery, which is available only with HW5500E 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.
• 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.
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 7
Assembly
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
* 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. Be sure generator is set on 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 bottom of each support leg
using a 25 mm full-thread hex bolt and 13 mm flange
serrated nut; tighten until securely seated.
FIGURE 4: 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 3: Tip onto Generator Recoil Side
3. Gently set generator onto recoil side.
4. Place 5/16" washer in center of each rubber stopper.
FIGURE 5: Support Leg Attachment to Generator
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Assembly
Step 2: Install Wheel Axle and Wheels
To install wheel assembly, you will need:
Socket wrench with 10 mm socket
Needlenose Pliers
*
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)
* Not included.
† 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.
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.
*
4. Slide second 9/16" washer onto axle.
5. Slide cotter pin into pre-drilled hole until fully seated.
6. Using needlenose pliers, bend each end of cotter pin
in opposing directions to secure wheel to axle.
FIGURE 8: Cotter Pin Installation
7. Return generator in upright position (so that wheels
and leg supports are touching ground).
FIGURE 6: 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 7: Slide Wheel onto Wheel Axle
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Assembly
NOTE:
i
Step 3: Install Handle Assembly
To install handle assembly, you will need:
Handle Brackets (2)
Handle Bars (2)
Rubber Handle Grips (2)
40 mm Washer Style Hex Bolts (6)
10 mm flange serrated nuts (6)
Socket wrench with 8mm socket
* Not included
1. Hold handle bracket over pre-drilled holes on frame
as shown in Figure 9.
FIGURE 9: Handle Bracket to Frame
2. Attach bracket to frame using 40 mm washer style
hex bolts and 10 mm flange serrated nuts; tighten
until securely seated.
3. Slide handle bar through center of each bracket and
line up bolt holes.
*
Once properly installed, the handles can be collapsed, if
desired.
Hands and fingers can be pinched from collapsible
handles.
• Keep hands and fingers clear from hinges when collapsing generator handles.
• To collapse handles, push firmly down on handle
until it rests vertically against generator frame.
• To return handles to horizontal position, pull up on
handle.
Battery
To use electric start feature, 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.
FIGURE 10: Insert Handle Bar to Bracket
4. Attach handle to each bracket using 40 mm washer
style hex bolt and 10 mm flange serrated nut; tighten
until securely seated.
Handle should stick straight out after tightening bolts and
nuts. If handle seems to hang down, tighten bolts and
nuts further.
5. Slide rubber handle grip onto each handle bar and
push to achieve snug fit.
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. Generator is packaged with the negative (-) battery
lead attached to top of alternator with a plastic cable
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Grounding the Generator
NOTE:
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NOTE:
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NOTE:
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+
–
strap. Carefully cut cable strap to disengage battery
lead.
FIGURE 11: Negative Battery Lead Attached to Alternator for Shipping
To avoid electric arcing, which can result in electric
shock, follow these instructions exactly.
When connecting or disconnecting battery leads:
• ALWAYS connect negative (-) battery lead
last.
• ALWAYS disconnect negative (-) battery lead
first.
• NEVER connect negative (-) battery lead to
red positive (+) post on battery.
• NEVER connect positive (+) battery lead to
black negative (-) post on battery.
2. Connect red positive (+) battery lead to red positive
(+) post on battery; fasten with nut and bolt provided.
3. Connect black negative (-) battery lead to black nega-
tive (-) post on battery; fasten with nut and bolt provided.
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.
Before using generator, a ground wire must be connected
to the ground terminal (Figure 13).
FIGURE 13: Ground Terminal
The system ground is not connected to AC neutral wire. If
using a receptacle tester, it will not show 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.
FIGURE 12: Electric Starter Battery
Actual battery appearance may vary from illustration provided.
While engine is running, a small “trickle” charge is applied
to starting battery.This keeps an adequate battery
charge.
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 11
Using Generator for Backup Power
Using Generator for Backup Power
Before connecting to 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 to 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.
If you will be using generator for backup power, generator
must be connected to building’s electrical system through
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.
Transfer switch is either a manual switch, an automatic switch or a combination of manual and automatic. During a power outage, transfer switch
isolates emergency circuits from utility line, allowing
for efficient operation of generator without backfeeding onto utility.
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COMPONENTS
K
F
B
I
H
J
E
C
D
A
G
M
L
Set Tripped
Use information provided in this section to become familiar with your generator’s components.
Information below is provided for reference only. Refer to Operation section (page15) for instructions on operat-
ing generator.
FIGURE 14: HW5500/5500E Portable Generator (Illustration shows battery, which is available only with HW5500E models)
A—Power Control Center
Household Outlets
120V 20 Amp Duplex outlets to connect
120V appliances to generator for power.
Power Cord/ Transfer Switch
120/240V 30 Amp Twist-Lok outlet can
be used to:
• Power 120V appliances using 4-in-1
power cord (included with generator).
• Power 240V appliances using appropriate (L14-30) power
cord (not included).
• Connect a transfer switch to building’s main electrical sys-
tem for backup power (see page12).
Breakers
Protects circuits from damage caused by overload or short-circuit by stopping flow of electricity
between generator and 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.
Generator must be grounded to prevent electrical
shock from faulty appliances. See page 11.
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.
E—Engine Control Switch
Control used to run and stop the engine.
• START—Starts generator engine (HW5500E)
• RUN—Prepares engine for starting (HW5500);
Indicates engine is currently running (HW5500E)
• 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 volts to spark plug. When spark plug needs service,
cap must be removed.
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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. See “Generator Location”.
Consult a licensed electrician or utility company if
you will be using your generator for backup
power. The generator must be connected to build-
ing’s electrical system via a transfer switch. See
“Using Generator for Backup Power” on page12.
Only use OUTSIDE and far
away from windows, doors, and
vents.
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.
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.
Check/add engine oil— See “Engine Oil” on
page20. For initial start-up, follow instructions on oil
container provided with generator.
*
Check/add fuel
—See “Adding Fuel” on page22.
Be sure ground terminal is properly connected to
earth ground—See “Grounding the Generator” on
page11.
Check extension cords—be sure cords are:
In good condition.
Rated for outdoor use and match amp and voltage
ratings of generator outlet.
Equipped with proper plugs that contain grounding
blades.
NEVER operate generator in rain or snow, or
when the generator is set on wet surface.
Starting Generator
Before starting generator, be sure to thoroughly read
all information provided in this Owner’s Manual.
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.
To start generator:
1. Be sure generator is placed outside, in well-ventilated
area.
* You must add fuel before using the generator for the first time.
See “Adding Fuel” on page22.
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Starting Generator
NOTE:
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2. Turn fuel valve to ON position.
FIGURE 15: Fuel Valve Lever — ON/OFF position
3. Pull choke control to ON position.
FIGURE 16: Choke Rod
4. Proceed according to method you want to use to start
engine (see Electric Start or Manual Start).
Electric Start (HW5500E Model Only):
Press and hold engine control switch in START
position for 5 seconds or until engine starts.
When engine starts, the engine control switch gradually settles at RUN (center) position.
While engine is running, a small “trickle” charge is applied
to starting battery.This keeps an adequate battery
charge.
Manual (Recoil) Start:
Press engine control switch to RUN position.
FIGURE 18: Engine Control Switch
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.
• When using recoil starter, pull cord firmly and slowly until
you feel resistance and then pull rapidly to avoid kickback.
FIGURE 17: Engine Control Switch
• 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.
5. As engine warms up, and RPM stabilizes, gradually
FIGURE 19: Recoil Starter Handle
Apply a swift, single pull to start engine. Carefully
return recoil starter handle to its original position.
push in choke control to OFF position.
• If you notice engine cranking speed drop after a period of
time, it may be an indication that battery should be
recharged.
To prevent damage to generator, do not allow starter grip to
snap back against engine.
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Stopping Generator
NOTE:
i
Stopping Generator
In an emergency:
Press and hold engine control switch to STOP position
until engine stops.
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 excessively 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
meter) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.
If engine jetted for high altitude is used at lower altitude, lean
air fuel mixture will reduce performance and may over-heat
and seriously damage the engine.
exceed rated output of generator. Power rating information can usually be found on an appliance’s product label, or stamped inside or on back of appliance.
See Table1 for a listing of average appliance wattage
requirements.
• NEVER overload: Circuit breakers will stop flow of
electricity between generator and appliance if 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 to
reset circuit breaker.
• 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.
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
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.
• Plan carefully: Before using generator to power
appliances, take time to add power rating (watts) of
each appliance and verify that total wattage does not
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 17
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
• Window
Aquarium 50-1210
Clock radio 10
Coffee maker 900-1200
Washing machine 350-500
Electric dryer 1800-5000
Iron 1000-1800
TABLE 1. Typical Appliance Running Wattages
3500
500-1440
Powering Appliances
Appliance Typical Running Watts
1200-2400 (using drying feature
Dishwasher*
Dehumidifier* 785
Electric blanket
(Single/Double)
Fans*
• Ceiling
greatly increases energy consumption)
60 / 100
65-175
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.
• Window
Furnace*
Hair dryer 1200-1875
Heater (portable) 750-1500
Microwave oven 750-1100
Personal computer
• CPU - awake /
asleep
• Monitor - awake /
asleep
• Laptop
Radio (stereo) 70-400
Refrigerator*
(frost-free, 16 cubic
feet)
Sump pump*
• 1/2 hp
• 1/3 hp
Television (color)
• 19"
55-250
*
750
120 / 30 or less
150 / 30 or less
50
725
2150
2300
65-110
• 27"
• 36"
• 53"-61" Projection
• Flat screen
Toaster 800-1400
Toaster oven 1225
VCR/DVD 17-21 / 20-25
Vacuum cleaner* 1000-1440
Water heater (40 gal) 4500-5500
Water pump*
(deep well)
TABLE 1. Typical Appliance Running Wattages
* Allow up to three times normal running watts for starting or
cycling compressor of this appliance.
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113
133
170
120
250-1100
MAINTENANCE
Maintenance Schedule
Periodic maintenance and adjustment is necessary to keep generator in good operating condition. Perform service and inspec-
tion at intervals shown in Generator Maintenance Schedule (Table2).
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.
Accidental starting of generator can cause severe injury or
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.
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.
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.
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.
*
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 cleaner X
Clean air cleaner
†
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
TABL E 2 . Generator Maintenance Schedule
* Perform at every indicated month or operating hour interval, whichever comes first.
† 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 6
Every year or
200 hours of
use
‡
X
‡
X
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 19
Engine Oil
NOTE:
i
Engine Oil
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 Figure20 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.
Oil level should be at “H” or somewhere between the
“L” and “H”.
FIGURE 22: Engine Oil Level
If oil level is at “L” or below, add recommended oil
(see “Adding Engine Oil”). Do not overfill.
If oil level
is at “H” or somewhere between the “L” and “H”,
reinstall oil fill cap and fully tighten.
6. 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:
FIGURE 20: Recommended Oil Viscosity
Checking Engine Oil Level
To check engine oil level:
1. Stop generator if engine is running.
2. Be sure generator is set on flat, level surface.
3. Remove oil fill cap and wipe off dipstick end with
clean cloth.
4. Insert oil fill cap to oil fill hole but do not screw in (Fig-
ure 21).
5. Pull out to read current oil level indicated on dipstick
end.
• 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.
Adding Engine Oil
For initial start-up, follow instructions provided on engine
oil bottle provided with generator.
1. Stop generator if engine is running.
2. Be sure generator is set on flat, level surface.
3. Remove oil fill cap.
FIGURE 23: Oil Fill Cap Removal
4. Slowly pour oil into oil fill hole.
5. Check oil level.
6. Replace oil fill cap and fully tighten.
FIGURE 21: Engine Oil Level
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Engine Oil
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:
Socket wrench with 12 mm socket
Oil drain pan or other container suitable for holding
engine oil
Clean cloth
Unused engine oil (SAE type indicated in Fig-
ure20)
1. Be sure generator is placed on 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.
6. Using a socket wrench with 12 mm socket, loosen
drain plug bolt; remove drain bolt and sealing washer.
FIGURE 25: Loosen Oil Drain Bolt
7. Allow oil to drain into oil pan or container.
8. Slowly unscrew and remove oil fill cap.
FIGURE 26: Remove Oil Fill Cap
• ALWAYS stop engine before removing oil fill cap.
4. Place oil pan, or other container suitable for holding
engine oil, underneath generator.
FIGURE 24: Oil Drain Bolt
5. Keep oil fill cap on initially to avoid having oil spray
out too fast.
9. Allow oil to completely drain into oil pan or container.
FIGURE 27: 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. (See
Figure20 for recommended oil type). Do not overfill.
13. Check oil level.
FIGURE 28: Engine Oil Dipstick—Oil Level Indicator
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 21
Adding Fuel
NOTE:
i
14. Reinstall oil fill cap and tighten until fully seated.
Dispose of used motor oil according to guidelines established by your local or state government.
Adding Fuel
Before each use, check fuel gauge on fuel tank.
If fuel level is low, refill tank with recommended fuel.
NEVER OVERFILL.
Fuel and fuel vapors are extremely flammable and
explosive under certain conditions.
• Refuel generator only outdoors, in a well-ventilated
area.
• NEVER fill fuel tank while engine is running. Turn generator OFF and allow to cool before filling with fuel.
• NEVER smoke or allow flames or sparks near generator 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.
• Try to confirm contents of fuel.
Some states (and provinces in Canada) require this information to be posted on the fuel pump. If you notice undesirable operating symptoms, switch to a conventional
unleaded gasoline.
Oxygenated fuels can damage paint and plastic. Be careful
not to spill fuel when filling fuel tank. Damage caused by
spilled fuel is not covered under warranty.
TABLE 3. Oxygenated Fuel Types
Gasoline containing more than
10% ethanol by volume may
Ethanol
(ethyl or grain alcohol)
Methanol
(methyl or wood alcohol)
MTBE
(methyl tertiary butyl
ether)
cause starting or performance
problems. Gasoline containing
ethanol may be marketed
under the name "Gasohol".
Gasoline containing methanol
must contain co-solvents and
corrosion inhibitors to protect
fuel system. Gasoline contain-
ing more than 5% methanol by
volume may cause starting
and/or performance problems
and may damage metal, rub-
ber and plastic parts of fuel
system.
You can use gasoline contain-
ing up to 15% MTBE by vol-
ume.
General Fuel Information
Check fuel gauge located on the top of generator near fuel
tank and refill tank if fuel level is low. Refuel carefully to
avoid spilling fuel. Do not fill above the shoulder of fuel
strainer. Use unleaded gasoline with a pump octane rating
of 87 or higher.
Never use stale or contaminated gasoline. Avoid getting
dirt or water in the fuel tank. Always keep fuel strainer in
place while refueling.
Oxygenated Fuels
At certain times of the year, some U.S. locations may
have only oxygenated fuel available. Oxygenated fuel is
blended with alcohol or ether additives to increase octane
quality, enhance combustion, and reduce exhaust emissions.
Some areas of the United States use oxygenated fuels to
help meet clean air standards.
Before using an oxygenated fuel:
• Be sure pump octane rating is 87 or higher.
Fuel Recommendations
To avoid damage to engine, never use stale or contaminated
gasoline or oil/gasoline mixture. Avoid getting dirt or water in
fuel tank.
Use fresh gasoline with a pump octane rating of 87 or
higher.
To add fuel to generator:
1.
Stop generator if engine is running. Allow to completely cool.
2. Be sure generator is set on flat, level surface.
3. Remove fuel tank cap.
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4.
NOTE:
i
Slowly pour gasoline into fuel tank. Be careful not to
overfill.
FIGURE 29: Fuel Level
5. Reinstall fuel tank cap and fully tighten.
Occasional, light spark knock, "pinging", or rattling noise
is normal while operating under heavy loads. If spark
knock, pinging, or rattling occurs at a steady engine
speed, under normal load, drain fuel (page 27) and refill
with fresh gasoline. If noise persists, see an authorized
generator dealer.
Air Filter Maintenance
2. Remove air cleaner cover.
FIGURE 30: Air Cleaner Cover
2A. Turn thumbscrew counterclock wise to loosen and
remove.
2B. Push upward at bottom of cover to release plastic
tabs.
Running engine with persistent spark knock or pinging can
cause engine damage. Warranty does not cover parts
damaged by misuse.
Air Filter Maintenance
A dirty air filter will restrict air flow to carburetor, which may
cause poor engine performance or damage.
Never run the generator without air cleaner assembly properly attached.
Clean air cleaner filter every 50 hours of generator operation. If operating generator in extremely dusty areas, clean
air filter more frequently.
Gasoline and flammable solvents can cause fire or
explosion. NEVER use gasoline or flammable solvent to clean air cleaner element.
• Use only household soap and water to clean air
cleaner element.
To clean air filter, you will need:
Household soap and water
Clean, dry cloth
Clean engine oil
FIGURE 31: Air Cleaner Cover—Release Tabs
3. Pull out foam air filter.
FIGURE 32: Air Filter Removal
4. Wash air filter in a solution of household soap and
warm water.
5. Rinse air filter thoroughly.
6. Using a clean, absorbent cloth, squeeze air cleaner
element dry, being careful not to twist or tear the filter.
1. Stop engine if it is running.
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 23
Cleaning Fuel Sediment Cup
NOTE:
i
A
B
C
7. Soak air filter in clean engine oil and squeeze out
excess oil.
Frequent or prolonged contact with engine oil may cause
skin cancer.
• Thoroughly wash hands and any areas of skin exposed
to used oil with soap and water.
Engine will smoke during initial start-up if too much oil is
left in filter.
8. Reinstall air filter.
9. Reinstall air cleaner cover and tighten thumbscrew.
Cleaning Fuel Sediment Cup
The sediment cup prevents any dirt or water that may be
in the fuel tank from entering the carburetor.
Clean fuel sediment cup at the intervals specified in
Table2.
To clean fuel sediment cup, you will need:
Socket wrench with 10 mm socket
Household soap and water
Clean, dry cloth
To clean fuel sediment cup:
1. Stop engine if it is running.
2. Be sure generator is set on flat, level surface.
3. Turn fuel valve to OFF position.
4. Using a socket wrench with 10 mm socket, remove
fuel sediment cup assembly (sediment cup, o-ring,
and fuel screen).
FIGURE 34: Fuel Sediment Cup Assembly Pieces
5. Clean fuel screen (A), o-ring (B), and sediment cup
(C), with soap and water.
6. Wipe pieces clean with clean, dry cloth.
7. Reinstall sediment cup, o-ring, and fuel filter.
8. Turn fuel valve to ON position and check for leaks.
Spark Plug Service
To ensure proper engine operation, spark plug must be
properly gapped and free of deposits.
If engine has been running, muffler will reach temperatures that could cause severe burns. Do not
touch.
Recommended Spark Plug Replacement: 100842A
Bosch W20EPR
Champion RN9YC
Denso WR7DC
TABLE 4. Spark Plug Equivalents to 100842A
To service spark plug, you will need:
Clean cloth
13/16” Spark plug socket wrench
New spark plug (if existing spark plug is exces-
sively worn or damaged)
Wire brush
Wire feeler gauge (for setting spark plug gap to cor-
rect size)
*
1. Stop engine if it is running.
FIGURE 33: Fuel Sediment Cup Assembly Removal
24 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
2. Be sure generator is set on flat, level surface.
* See Maintenance Parts at end of this manual.
3.
Remove spark plug cap.
FIGURE 35: Spark Plug Cap Removal
4. Clean any dirt from around spark plug base.
5. Carefully pull off spark plug cap.
6. Using a 13/16” spark plug socket wrench, loosen and
remove spark plug.
Cleaning Spark Arrestor Screen
11. Inspect spark plug washer and verify it is in good con-
dition.
12. Reinstall spark plug by hand to prevent cross-thread-
ing.
13. After spark plug is seated, tighten with spark plug
wrench to compress washer.
If installing a new spark plug, tighten l/2 turn after
the spark plug seats to compress the washer.
If reinstalling a used spark plug, tighten l/8 - l/4 turn
after the spark plug seats to compress the washer.
Spark plug must be securely tightened. An improperly tightened spark plug can become very hot and could damage
engine. Never use spark plugs that have an improper heat
range. Use only recommended spark plugs or equivalent.
Cleaning Spark Arrestor Screen
Muffler reaches temperatures that can cause serious
burns if touched. NEVER touch hot surfaces.
FIGURE 36: Spark Plug Removal
7. Inspect spark plug.
If spark plug is damaged or excessively worn, or if
insulator is cracked or chipped use a new spark
plug.
If spark plug is in good condition, reuse existing
spark plug.
8. If reusing spark plug, clean spark plug with wire
brush.
9. Measure spark plug gap with wire feeler gauge.
Gap should be: (0.028-0.031 in) (0.70-0.80 mm).
Generator muffler is equipped with spark arrestor screen,
which must be cleaned according to maintenance schedule (Table2) to ensure prevention of sparks escaping
generator.
To clean spark arrestor screen, you will need:
Socket wrench with 8 mm socket
Phillips head screwdriver
Wire brush
1. Stop generator if engine is running. Allow to com-
pletely cool.
2. Be sure generator is set on flat, level surface.
3. Using a socket wrench with 8 mm socket, remove
spark arrestor enclosure panel bolts.
FIGURE 37: Correct Spark Plug Gap
10. If necessary, adjust gap by carefully bending side
electrode.
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 25
FIGURE 38: Remove Spark Arrestor Enclosure Panel
Transporting Generator
A
B
C
4. Pull off enclosure panel.
FIGURE 39: Spark Arrestor Assembly
5. Using a screwdriver, loosen and remove screw hold-
ing spark arrestor clamp (A).
6. Slide off spark arrestor clamp.
7. Using a screwdriver, loosen and remove retaining
screw on park arrestor screen cap (B); pull off cap.
8. Pull out spark arrestor screen (C).
9. Inspect spark arrestor screen.
If screen is damaged or excessively worn, replace
with new screen.
If screen is in good condition, clean using wire
brush and then reinstall.
10. Reinstall remaining spark arrestor components.
Spark arrestor cap
Retaining screw
Clamp and screw
Spark arrestor enclosure panel
Transporting Generator
Storing Generator
Follow service procedures for preparing generator for storage. Inadequate or improper care of generator can result in
damage to generator components and will void limited warranty.
Before storing generator for extended period of time:
• Be sure storage area is free of excessive humidity
and dust.
• Refer to Table5 for recommended preparation proce-
dures.
Storage Time Recommended Preparation
Less than 1
month
1 to 2 months
2 months to 1
year or more
TABLE 5. Recommended Service Procedures Based on Storage
Time
* Use gasoline conditioners formulated to extend storage life.
Contact authorized generator dealer for conditioner recommendations.
To prepare generator for long-term storage:.
Fuel and its vapors are extremely flammable and
explosive under certain conditions.
No preparation required.
Fill fuel tank with fresh gasoline and
add gasoline conditioner
See procedure below.
*
.
• Refuel generator only outdoors, in well-ventilated area.
Hot engine or exhaust system can cause serious
burns or fires. Cool generator completely before
transporting or storing.
When transporting the generator:
• Press engine control switch to OFF position.
• Turn fuel valve lever to OFF position.
• Keep generator level to prevent fuel spillage.
• NEVER fill fuel tank while the engine is running. Shut
engine OFF and allow to cool before filling with fuel.
• NEVER smoke or allow flames or sparks near generator or where gasoline is stored.
1. Drain fuel into suitable container (see page27).
2. Change engine oil (see page21).
3. Remove spark plug. Add a tablespoon of clean
engine oil into spark plug hole.
4. Place rag over spark plug hole and pull recoil starter
handle slowly to turn engine and distribute oil. Reinstall spark plug.
To avoid damage to generator, take care not to drop or strike
generator when transporting. Do not place heavy objects on
generator.
26 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
At this point, the piston is coming up on its compression stroke and both intake and exhaust valves are
closed. Storing engine in this position will help to protect it from internal corrosion.
Draining Fuel
1. Turn fuel lever to OFF position.
2. Run engine until it stops due to lack of fuel.
3. Place suitable container underneath drain hole to
catch fuel.
4. Loosen bolt (underneath fuel sediment cup).
FIGURE 40: Loosen Bolt to Drain Fuel
5. Turn fuel lever to ON position.
Storing Generator
FIGURE 41: Fuel Valve Lever — ON/OFF position
6. Allow fuel to drain into container.
7. To ensure all fuel is drained, carefully tip generator by
pulling up on frame at side opposite of recoil starter
handle.
FIGURE 42: Tip Generator to Completely Drain Fuel
8. Allow fuel to completely drain into container.
9. When ready to put generator back into operation, refill
with fresh fuel (see page22).
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TROUBLESHOOTING
NOTE:
i
Set Tripped
ANYONE using or servicing 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.
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.
For all customer service inquiries, call 1-888-494-3571 or visit www.honeywellgenerators.com.
PROBLEM PROBABLE CAUSE SOLUTION
1 No fuel.
2 Stale fuel.
3 No engine oil.
Engine will not start or starts
and runs rough.
4 Spark plug wire (cap) disconnected.
5 Faulty/bad spark plug.
6 Fuel not reaching carburetor.
7 Dirty air cleaner.
8 Dirty spark arrestor screen.
Only use OUTSIDE and far
away from windows, doors, and
vents.
1 Add fuel (page 22).
2 Drain fuel tank; fill with fresh fuel
(page27).
3 Add engine oil (page 20).
4 Install spark plug cap over spark plug.
5 Check/replace spark plug (page24).
6 Clean fuel sediment cup (page24).
7 Clean or replace air cleaner (page23).
8 Clean spark arrestor screen (page 25)
Engine suddenly stops.
No power at AC receptacle
1 No fuel.
2 No engine oil.
1 Electrical overload on generator.
2 Poor connection or defective cord
set.
3 Connected electrical appliance/
equipment is defective.
1 Add fuel (page 22).
2 Add engine oil (page 20).
1 Check all circuit breakers
for “tripped’ position.
Reduce electrical load on
circuit, wait 3 minutes,
and then push to reset circuit breaker.
*
2 Check cord connection. Replace defective
cord set.
3 Check electrical appliance/equipment for
defects. Disconnect defective appliance/
equipment from the generator. Have appliance serviced by qualified repair facility.
Speed of starter motor
drops after period of time.
TABLE 6. Troubleshooting — Probable Causes and Solutions
* Master circuit breaker controls power to all receptacles. Be sure to check master breaker even if you are trying to power from a duplex out-
let.
1 Battery is losing charge. 1 Recharge battery.
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30 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
SPECIFICATIONS
GENERATOR
Dimensions
AC Output
Operating Temperature
*
Length 27 inches (685.8 mm) 27 inches (685.8 mm)
Width 21.5 inches (546.1 mm) 21.5 inches (546.1 mm)
Height 21.5 inches (546.1 mm) 21.5 inches (546.1 mm)
Dry Weight 185 lb (83.9 kg) 195 lb (88.4 kg)
Continuous (Rated) Power 5500 Watts 5500 Watts
Maximum Power 6875 Watts 6875 Watts
Surge Power 8250 Watts 8250 Watts
Frequency 60 Hz 60 Hz
Voltage 120/240 Volts 120/240 Volts
HW5500 HW5500E
Maximum
Minimum
ENGINE
Engine Speed (RPM) 3600 3600
Type OHV 4-Cycle OHV 4-Cycle
Displacement 337 cc 337 cc
Fuel Tank Capacity 6.5 Gallons (24.6 L) 6.5 Gallons (24.6 L)
Engine Oil Capacity 1.2 qt (1.1 L) 1.2 qt (1.1 L)
Spark Plug Type 100842A 100842A
Spark Plug Gap
TABLE 7. HW5500/5500E Portable Generator Specifications
* Measurements given do not reflect dimensions with wheel kit installed to generator.
104° F (40° C) 104° F (40° C)
-10° F (-23° C) -10° F (-23° C)
0.028-0.031 inches
(0.70-0.80 millimeters)
0.028-0.031 inches
(0.70-0.80 millimeters)
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32 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
WARRANTIES
NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY
Honeywell Portable Generator
WARRANTY STATEMENT
US Environmental Protection Agency (EPA) requires manufacturers of small off-road engines (SORE) to warranty their
products with a 2 year warranty for those components that
are specified as being part of the emission control system.
Northshore Power Systems, LLC (NSP), the California Air
Resources Board (CARB) and the EPA offer the following
explanation of the Emission Control Warranty.
In the United States and California, new small off-road
engines must be designed, built, and equipped to meet stringent anti-smog standards. NSP must warrant the emission
control system on your small off-road engine for the periods
of time listed below provided there has been no abuse,
neglect or improper maintenance of your small off-road
engine. The emissions warranty is a defects warranty and is
not related to an in-use emissions test.
Your emission control system may include parts such as the
carburetor or fuel injection system, the ignition system, and
the catalytic converter. Also included may be hoses, belts,
connectors and other emission-related assemblies.
Where a warrantable condition exists, NSP will repair your
small off-road engine at no cost to you, including diagnosis,
parts, and labor.
COVERAGE
Emissions control parts on the engine are warranted for a
period of two years, subject to provisions set below. If any
covered part on your engine is defective, the part will be
repaired or replaced by NSP.
OWNER’S RESPONSIBILITIES
You are responsible to maintain the engine as defined in your
Honeywell Generator Owner's Manual. NSP recommends
that you retain all records/receipts covering maintenance on
your engine, but NSP cannot deny warranty claims based on
the lack of receipts or for your failure to perform all scheduled
maintenance. You may be denied warranty coverage if a part
has failed due to abuse, neglect, improper maintenance or
unapproved modifications.
You are responsible to bring your portable generator to an
authorized NSP Honeywell generator dealer for repairs as
soon as a problem exists. Do not return your generator to
place of purchase for service. For emissions warranty service, contact your nearest dealer; a listing is available at
www.honeywellgenerators.com or by calling 1-888-494-3571.
EMISSIONS CONTROL SYSTEMS PARTS
Coverage under this warranty extends only to the emissions
control parts listed below.
1. Fuel metering system
A. Choke system
B. Carburetor
C. Fuel Pump (if equipped)
D. Fuel line, clamps, control valve
E. Fuel tank, cap and screen
F. Carbon Canister (if equipped)
2. Air Induction System
A. Air cleaner
B. Vent lines
C. Intake manifold
3. Ignition System
A. Spark Plug
B. Ignition coil
4. Exhaust System
A. Catalytic converter (if equipped)
B. Exhaust manifold
C. Air injection system (if equipped)
5. Miscellaneous Items used in above systems
A. Connectors and assemblies
B. Regulating valves and switches for vacuum, temper-
ature, or position sensing (if equipped)
WARRANTY PROVISIONS
1. Claims. Warranty claims shall be filed in accordance
with provisions of the NSP warranty and policies established with the authorized dealer network.
2. Exclusions. Warranty coverage shall be denied for failure of an emissions control part caused by abuse,
neglect, improper maintenance as described in the Honeywell Generator Owner's Manual, use of add-on parts,
modified parts, or parts that are not equivalent to original
Honeywell generator parts in performance and durability.
3. Length of Coverage. NSP warrants to the original retail
purchaser and each subsequent owner that the emissions control part shall be free from defects in materials
and workmanship for a period of two years from the date
the generator is delivered to the original retail customer.
4. Repair or Replacement Cost. Repair or Replacement
Cost. Repair or replacement of any emissions control
part will be performed at no charge to the owner, including diagnostic labor which leads to the determination that
an emissions control part is defective, if the diagnostic
work is performed at an authorized NSP Honeywell generator dealer.
5. Consequential Coverage. Coverage noted hereunder
will extend to the failure of any engine components
caused by the failure of any emissions control part still
under warranty.
6. Maintenance. The emissions control parts are warranted only for defects during the warranty period. The
warranty does not cover an emission control part that is
replaced or repaired as required by the maintenance
schedule defined in the Honeywell Generator Owner's
Manual. Any replacement part that is equivalent in performance and durability may be used for maintenance or
repairs.
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 33
NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY
QUESTIONS
If you have questions regarding your emissions warranty
rights and responsibilities, you should contact the Warranty
and Service department at NSP.
By phone: (414) 332-2375
Via web: www.honeywellgenerators.com
By US mail:
Northshore Power Systems, LLC
Attention: Product Warranty and Service Dept.
4425 N Port Washington Road
Suite 105
Milwaukee WI 53212-1082
34 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
NORTHSHORE POWER SYSTEMS LIMITED WARRANTY
NORTHSHORE POWER SYSTEMS
LIMITED WARRANTY
Honeywell Portable Generator
Effective April 1, 2008
LIMITED WARRANTY
Northshore Power Systems, LLC, (NSP) will repair or
replace, free of charge, to the original retail customer, in
North America, any parts of the portable generator found by
NSP or an authorized service center to be defective in material or workmanship. This limited warranty covers the cost of
the replacement parts and labor for defects. Transportation
charges are the responsibility of the customer. This limited
warranty has time period conditions, operating conditions and
disclaimers, limitations of remedies & exclusions as stated
below. For warranty service, customer should locate an
authorized Honeywell Generator Dealer from www.honeywellgenerators.com or by calling 1-888-494-3571.
LIMITED WARRANTY PERIODS
Consumer Use: 3 Years Limited. 1st year, parts and labor.
2nd & 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 purchaser. The limited warranty is not transferable. "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 &
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 FULLEST EXTENT PERMITTED BY APPLICABLE LAW, THIS
LIMITED WARRANTY IS EXCLUSIVE AND EXPRESSLY IN
LIEU OF ANY AND ALL OTHER WARRANTIES, INCLUDING, 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. NSP HEREBY DISCLAIMS AND
EXCLUDES ALL OTHER WARRANTIES. To the extent that
NSP's products are consumer products under applicable federal or state law with respect to any customer, the duration of
any implied warranties (including, but not limited to, implied
warranties of merchantability or fitness for a particular purpose) are limited to the shortest duration permitted by applicable law or the limited warranty period provided herein,
whichever is longer.
LIMITATIONS OF REMEDIES. NSP 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, NEGLIGENCE OR OTHER TORT
OR ANY THEORY OF STRICT LIABILITY, WITH RESPECT
TO THE GENERATOR OR NSP'S ACTS OR OMISSIONS
OR OTHERWISE. TO THE FULLEST EXTENT PERMITTED
BY APPLICABLE LAW, NSP SHALL NOT, IN ANY EVENT,
BE LIABLE FOR INCIDENTAL, COMPENSATORY, PUNITIVE, CONSEQUENTIAL, INDIRECT, SPECIAL OR OTHER
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 DAMAGE OR ECONOMIC LOSS.
EXCLUSIONS. In addition to the foregoing disclaimers, limitations 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) accident, damage, abuse or misuse; (iv) abnormal operating conditions or applications; (v) repair or modification by customer
or any third party without prior written consent of NSP; (vi)
use under operating conditions or in applications not made
known to or contemplated by NSP; or (viii) acts of God. The
application of these exclusions will be determined at NSP's
sole discretion.
REGISTRATION
Warranty registration with the Company is required on all
products. You may send in the enclosed warranty card, or
register your product on-line at www.honeywellgenerators.com.
Warranty is also available by keeping and showing your original 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 1-888-494-3571 or visit
www.honeywellgenerators.com.
Warranty inquiries can be addressed to:
Northshore Power Systems, LLC
Attention: Product Warranty and Service Dept.
4425 N Port Washington Road
Suite 105
Milwaukee WI 53212-1082
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 35
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36 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
INDEX
INDEX
A
Air Filter
maintenance
23
Appliances
powering
17
rules for powering 17
wattage information 17
Assembly
battery 10
handle 10
wheels 9
C
Checklist
generator shipment
Components and Controls
breakers 13
choke control 13
engine switch 13
fuel valve 13
outlets
Household
13
Transfer Switch 13
recoil starter grip 13
spark plug cap 13
stopping 17
storing 26
transporting 26
unpacking guidelines 5
warranty 35
Ground 11
special requirements 11
terminal 13
H
Handles
installing
10
High Altitude
operation
5
17
M
Maintenance
19
air filter 23
changing engine oil 21
cleaning spark arrestor 25
fuel sediment cup 24
parts listing 39
schedule 19
spark plug 24
Manual (Recoil) Start 16
D
Damage
inspecting for
Draining Fuel 27
E
Electric Start
Engine Oil
changing
21
Engine Switch 13
F
Fuel
adding
22
draining 27
oxygenated
types
22
recommendations 22
Fuel Sediment Cup
cleaning
24
Fuel Valve 13
G
Generator
location
15
nameplate information 6
operation 15
outlets 13
safety labels 3
specifications 31
starting 15
16
O
Operation
5
high altitude
17
preparing for 15
Outlets
Household
13
Transfer Switch 13
P
Power Control Center
13
ground terminal 13
Household Outlets 13
Power Cord/Transfer Switch 13
S
Safety
labels
3
Spark Arrestor
cleaning
25
Spark Plug
servicing
24
Specifications 31
Stopping Generator 17
Storage
recommendations
26
T
Transfer Switch
for backup power
12
outlet 13
Troubleshooting 29
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 37
INDEX
U
Unpacking guidelines
W
Warranty
emissions control
limited product 35
Wattage
typical appliance
Wheels
installing 9
5
33
17
38 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
HW5500/5500E MAINTENANCE PARTS
To order maintenance parts, visit www.honeywellgenerators.com or call Customer Hotline at 1-888-494-3571.
Part Name Part Number
Air Cleaner Assembly 100832A
Air Filter 100833A
Fuel Cap 100834A
Fuel Shut-Off Valve 100835A
Fuel Strainer 100836A
Ignition Coil 100838A
Recoil Assembly 100839A
Recoil Rope and Handle 100840A
Oil Fill Cap/Dipstick 100841A
Spark Plug 100842A
Spark Arrestor 100843A
Wheel 100844A
Wheel Handle Pivot Bracket 100845A
Wheel Kit Hardware 100852A
Handle Bar 100846A
Rubber Handle Grip 100847A
Smart Start Card
HW5500/5500E Maintenance Parts List
100848A (HW5500)
100849A (HW5500E)
For part numbers of replacement product labels, see page 3.
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 39
Northshore Power Systems, LLC
4425 N. Port Washington Rd., Suite 105
Milwaukee, WI 53212-1082 USA
TEL 1-888-494-3571
www.honeywellgenerators.com
HW5500/5500E – P/N: 100900A
March 2008
© 2008 Northshore Power Systems, LLC
The Honeywell Trademark is used under license
from Honeywell International Inc.
Honeywell International Inc. makes no representation
or warranties with respect to this product
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