Honeywell HW5500E, HW5500 User Manual 2
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:
i
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:
i
NOTE:
i
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
HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 9
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