HW7500EL
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HW7500E
HW7500EL
Owner’s Manual
Portable Electrical Generator
Manual del Propietario
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!
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 genera-
tor nameplate.
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.
FIGURE 1: Generator Nameplate Location
Date of Purchase:
Store/Dealer Purchased From:
Generator Model Number:
Generator Serial Number:
WARNING
Model Number Phase
Part Number
AC Voltage
Serial Number
Fuel
Frequency
Power Output
Engine RPM
HW7500EL Model
HW7500E Model
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
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.
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
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
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com i
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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ii www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 1
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY RULES
NOTE:
Since there are many variations in the circumstances sur-
rounding the installation, operation, service, and mainte-
nance of this generator, we cannot possibly anticipate or
provide advice or safety messages to cover every situa-
tion.
Safety Messages
Signal Words
Safety messages are provided throughout this manual to
help prevent personal injury and equipment damage. All
safety messages are introduced by a signal word indicat-
ing the hazard level.
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.
ANYONE using or servicing this generator must read, understand, and follow all safety and operation instructions pro-
vided in the product manual. Failure to closely follow these instructions can result in circumstances leading to death,
serious injury, and property damage.
WARNING
Indicates an imminently hazardous situa-
tion which, if not avoided, will result in
death or serious injury to the operator or
to bystanders.
Indicates a potentially hazardous situa-
tion which, if not avoided, could result in
death or serious injury to the operator or
to bystanders.
Indicates a potentially hazardous situa-
tion 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.
DANGER
WARNING
CAUTION
NOTICE
Explosion
Tox i c fum e s
Fire
Chemical burn
Electrical shock
Hot surface
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a poi-
son 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.
+
DANGER
Safety Messages
2 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
Electric Shock Hazards
Fire and Burn Hazards
Medical and Life Support Uses
Generator Damage 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 qual-
ified 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.
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 materi-
als 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.
WARNING
WARNING
WARNING
• 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 house-
hold to experience a medical emergency.
NOTICE
Improper treatment or misuse of generator can cause per-
manent 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.
WARNING
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 3
Location of Important Labels
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.
FIGURE 2: Label Locations
PRODUCT LABEL PART NUMBER
A
100884A (HW7500E Model)
101796A (HW75000EL Model)
B 100886A
C 100887A
D 101406B
E 100879B
F 100882A
G 100885A
H 100881A
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
FUEL
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
USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES.
GENERATOR EXHAUST CONTAINS CARBON MONOXIDE.
THIS IS A POISON YOU CANNOT SEE OR SMELL.
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.
HOT
SURFACES
SUPERFICIES
CALIENTES
WARNING
ADVERTENCIA
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4 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 5
GETTING STARTED
Use the information in this section to get your generator ready for operation.
Unpacking Guidelines
1. Set carton on a rigid, flat surface.
2. Remove carton contents.
3. Verify all of the following items are included in the generator package:
HW7500E/HW7500EL Portable Electrical Generator
Wheel Kit (including handle assembly and assembly hardware)
Battery
20’ 30 amp 4-in-1 Power Cord
1 L Engine Oil
Funnel
Owner’s Manual
Smart Start Instruction Card
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).
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.
Generator is heavy! Lifting generator can cause back or other bodily injury. NEVER lift generator without assistance.
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 prop-
erly follow all instructions and precautions can cause you and others to be seriously injured or killed.
FIGURE 3: Generator Nameplate Location
WARNING
CAUTION
WARNING
Model Number Phase
Part Number
AC Voltage
Serial Number
Fuel
Frequency
Power Output
Engine RPM
HW7500EL Model
HW7500E Model
Assembly
6 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
Assembly
Wheel Kit
NOTE:
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.
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 4: Wheel Assembly Components
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.
CAUTION
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 7
Assembly
Step 1: Install Support Legs
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.
3. Gently set generator onto the recoil side.
4. Place 5/16" washer in the center of each rubber stop-
per.
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.
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.
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
Brackets (2)
Rubber stopper (2)
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 6: Tip onto Generator Recoil Side
CAUTION
FIGURE 7: Rubber Stopper Attachment to Support Leg
FIGURE 8: Support Leg Attachment to Generator
Assembly
8 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
Step 2: Install Wheel Axle and Wheels
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.
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.
4. Slide second 9/16" washer onto axle.
5. Slide cotter pin into pre-drilled hole until fully seated.
6. Using needle-nose pliers, bend each end of cotter pin
in opposing directions to secure wheel to axle.
7. Return generator to upright position (so that wheels
and leg supports are touching the ground).
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)
* 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.
Wheels (2)
9/16" washers (4)
Cotter pins (2)
Socket wrench with 10 mm socket
†
† Not included.
Needle-nose pliers
†
FIGURE 9: Wheel Axle Attached to Generator
FIGURE 10: Slide Wheel onto Wheel Axle
FIGURE 11: Cotter Pin Installation
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 9
Assembly
Step 3: Install Handle Assembly
1. Hold handle bracket over pre-drilled holes on frame
as shown in Figure 12.
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.
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.
NOTE:
Handle should stick straight out after tightening bolts and
nuts. If handle seems to hang down, tighten bolts and
nuts further.
5. Attach chain to handle bracket as illustrated below.
Insert pin through bracket and handle.
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.
• To collapse handles, remove pins and push firmly
down on handle until it rests vertically against genera-
tor frame.
• To return handles to horizontal position, pull up on
handle and lock with pins.
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
*
* Not included
10 mm open end wrench*
FIGURE 12: Handle Bracket to Frame
FIGURE 13: Insert Handle Bar to Bracket
RUN
STOP
FIGURE 14: Attach pin and chain
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.
CAUTION
Assembly
10 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
Step 4: Install Battery
To use the electric-start feature, the battery (included)
must be connected to generator’s electric starter.
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.
2. To access battery posts:
2A. Loosen and remove nuts on retaining plate; slide
retaining plate off support rods.
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.
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.
NOTE:
Actual battery appearance may vary from illustration pro-
vided.
NOTE:
While the engine is running, a small “trickle” charge is
applied to the battery. This keeps an adequate battery
charge.
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 termi-
nals, 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.
FIGURE 15: Positive Battery Lead Attached to Alternator for Shipping
WARNING
WARNING
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.
FIGURE 17: Electric Starter Battery—Remove Retaining Plate
FIGURE 18: Electric Starter Battery—Lead Connection
WARNING
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 11
Grounding the Generator
Grounding the Generator
The National Electric Code (NEC) requires the generator
to be connected to an earth ground. Before using the gen-
erator, connect a copper wire (minimum 10 AWG) from the
ground terminal (see Figure 19) to an earth ground. Con-
sult a licensed electrician for proper grounding methods.
NOTE:
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.
Using Generator for Back-up Power
The NEC requires any generator connected to a building’s
electrical wiring utilize a transfer switch installed by a
licensed electrician.
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.
FIGURE 19: Ground Terminal
WARNING
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.
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.
DANGER
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12 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 13
COMPONENTS
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 backup 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 appli-
ance. Master circuit breaker controls power
to all outlets. If there is no power at outlets,
see Troubleshooting section.
Ground Terminal
Connects generator to ground wire for grounding protection.
B—Battery Tray and Battery
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. Engine switch has
three positions:
• START—Starts generator engine
• RUN—Prepares engine to start (manual start);
Indicates engine is currently running (electric start)
• STOP—Stops generator engine
F—Recoil Starter Grip Handle
Provides means to manually start engine, if needed.
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 moved 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 Arrestor
Provides outlet for engine exhaust. Prevents sparks and other
combustible materials from escaping generator.
M—Spark Plug Cap (Wire)
Delivers voltage to spark plug. When spark plug needs ser-
vice, cap must be removed.
N—Carbon Canister (HW7500EL model only)
Reduces hydrocarbon emissions.
The information below is provided for reference only. Refer to “OPERATION” on page 15 for instructions on oper-
ating generator.
FIGURE 20: HW7500EL Portable Generator
CAUTION
K
F
B
I
H
E
C
D
A
J
G
M
L
N
Generator must be grounded to prevent electrical
shock from faulty appliances. See page 11.
7500 CONTINUOUS WATTS • 9375MAXIMUM WATTS
Set
Tripped
CAUTION
Muffler reaches temperatures that can cause serious
burns if touched. NEVER touch hot surfaces.
WARNING
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14 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 15
OPERATION
Generator Location
When deciding on the location to place your generator,
keep in mind the following safety rules:
Preparing for Operation
Before starting generator, complete the following prepara-
tion 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.
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.
Depressed areas such as construction foundations,
pools, or any low-lying areas, can cause carbon
monoxide to accumulate. Inhalation of carbon mon-
oxide 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 sur-
face, 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 sur-
face, 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.
DANGER
+
WARNING
WARNING
WARNING
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a poi-
son 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.
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 elec-
trical current from generator to feed back into
utility lines, resulting in death or serious injury
to utility company workers or others who con-
tact utility lines during a power outage.
* You must add fuel before using the generator for the first time
See “Adding Fuel” on page 24.
DANGER
DANGER
Preparing for Operation
16 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
Starting Generator
Electric Start
1. Be sure generator is placed outside, in well-ventilated
area.
2. Confirm the circuit breakers are set.
3. Turn fuel valve to ON position.
4. Move choke control to ON position.
5. Press and hold engine control switch in START posi-
tion until engine starts.
6. When the engine starts, release the engine control
switch allowing it to settle to the RUN (center) posi-
tion.
7. As engine warms up, and RPM stabilizes, gradually
push choke control to OFF position.
NOTE:
While engine is running, a small “trickle” charge is applied
to starting battery.This keeps an adequate battery charge.
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.
NOTICE
Keep the generator at a minimum of 6 feet (2 meters) from
any building, object, or wall.
FIGURE 21: Circuit Breaker Position
FIGURE 22: Fuel Valve Lever — ON/OFF position
FIGURE 24: Choke Lever
WARNING
Set Tripped
ON
OFF
FIGURE 25: Engine Control Switch
NOTICE
If engine will not start, move the choke to the OFF posi-
tion 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 sec-
onds 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.
To avoid generator damage, NEVER press the engine con-
trol switch to the START position while generator is running.
START
ENGINE
STOP
RUN
CAUTION
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 17
Preparing for Operation
Manual (Recoil) Start:
1. Be sure generator is placed outside, in well-ventilated
area.
2. Confirm the circuit breakers are set.
3. Turn fuel valve to ON position.
4. Move choke control to ON position.
5. Press engine control switch to RUN position.
6. Grip recoil starter handle and pull slowly until you feel
slight resistance.
7. Apply a swift, single pull to start engine. Carefully
return recoil starter handle to its original position.
8. As engine warms up, and RPM stabilizes, gradually
move choke control to OFF position.
NOTICE
Keep the generator at a minimum of 6 feet (2 meters) from
any building, object, or wall.
FIGURE 26: Circuit Breaker Position
FIGURE 27: Fuel Valve Lever — ON/OFF position
FIGURE 29: Choke Lever
Set Tripped
ON
OFF
FIGURE 30: Engine Control Switch
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.
FIGURE 32: Recoil Starter Handle
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 posi-
tion to reduce fuel to the engine.
START
ENGINE
STOP
RUN
CAUTION
Stopping Generator
18 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
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 per-
form 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 car-
buretor modification is made.
Powering Appliances
NOTE:
In this manual, the term “appliance” refers to any electri-
cal device that can be connected to generator for power.
Rules for Powering Appliances
• Plan carefully: Before using the generator to power
appliances, take time to add power ratings (watt-
age) of each appliance and verify that total wattage
does not exceed rated output of generator. Power
rating information can usually be found on an appli-
ance’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 dis-
connect appliance(s), wait a few minutes, and then
push circuit breaker to reset.
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.
NOTICE
NEVER start generator with electrical appliances plugged in
and turned on.
Faulty appliances and power cords can result in elec-
trical shock.
• Before attempting to power an appliance, be sure gen-
erator 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 equip-
ment to live.
• Inform your electrical provider immediately if a loss of
power would cause you or anyone in your household to
experience a medical emergency.
WARNING
WARNING
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 19
Powering Appliances
• 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 appli-
ance, 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 UL-
listed, three-prong extension cords. Be sure extension
cord is proper size (wire-gauge) to handle electric
load that will be plugged into it.
Appliance Wattage Information
Use table below as a guide to determine how much power
you will need to run appliances using generator.
Do not run power cords under carpet, rugs, or other materi-
als where heat might build up or cord damage may go unno-
ticed.
The values provided in following table are estimates only.
• ALWAYS verify actual wattage requirements for appli-
ance 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
120 / 30 or less
Computer, Monitor -
Awake / Asleep
150 / 30 or less
Computer, Laptop 50
Dehumidifier* 785
Dishwasher*
1200-2400 (using drying
feature greatly increases
energy consumption)
Dryer, Electric 1800-5000
Electric Blanket
(Single/Double)
60 / 100
Fan, Ceiling* 65-175
Fan, Window* 55-250
Furnace*
750
*
Hair Dryer 1200-1875
Heater, Portable 750-1500
TABLE 1. Typical Appliance Running Wattages
CAUTION
CAUTION
Iron 1000-1800
Microwave Oven 750-1100
Radio, Stereo 70-400
Refrigerator, Frost-free, 16
Cubic Feet*
725
Sump Pump, 1/2 hp* 2150
Sump Pump, 1/3 hp* 2300
Television
• 19"
65-110
• 27"
113
• 36"
133
• 53"-61" Projection
170
• Flat Screen
120
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
* Allow up to three times normal running watts for starting this
appliance.
NOTICE
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.
Appliance Typical Running Watts
TABLE 1. Typical Appliance Running Wattages
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HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 21
MAINTENANCE
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).
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a poi-
son 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.
DANGER
Accidental starting of generator can cause severe injury or
death. Before performing maintenance, disconnect spark
plug cap from spark plug.Also disconnect both starting bat-
tery 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 seri-
ously hurt or killed. Always follow inspection and mainte-
nance recommendations and schedules in this owner's
manual.
NOTICE
The maintenance schedule applies to normal operating con-
ditions. 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.
WARNING
WARNING
MAINTENANCE TASK
FREQUENCY
*
Before each
use
First month or
20 hours of
use
Every 3
months or 50
hours of use
Every 6
months or 100
hours of use
Every year or
200 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
X
‡
Clean fuel tank and strainer
X
‡
Check fuel line
Every 2 years (replace if necessary)‡
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.
Engine Oil
22 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
Engine Oil
Engine Oil Recommendations
Use 4-stroke oil, or equivalent high detergent, premium
quality motor oil certified to meet or exceed U.S. automo-
bile 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.
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.
6. Oil should be filled to the “H” level or somewhere
between the “L” and “H”.
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 auto-
matically 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.
Adding Engine Oil
1. Stop generator if engine is running.
2. Place the generator on a flat, level surface.
3. Remove oil fill cap.
4. Slowly pour oil into oil fill hole using funnel.
5. Check oil level.
6. Replace oil fill cap and fully tighten.
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.
FIGURE 33: Recommended Oil Viscosity
FIGURE 34: Engine Oil Level
5W-30
Synthetic 5W-30
SAE 30, 10W-30
FIGURE 35: Engine Oil Level
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.
FIGURE 36: Oil Fill Cap Removal
WARNING
HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 23
Engine Oil
Changing Engine Oil
1. Place the generator on a flat, level surface.
2. Start engine and run until warm.
3. Stop engine.
4. Place oil pan, or other container suitable for holding
engine oil, underneath generator.
5. Using a socket wrench with 12 mm socket and exten-
sion, loosen drain plug bolt partially to allow oil to flow
slowly.
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.
9. Allow oil to completely drain into oil pan or container.
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.
14. Reinstall oil fill cap and tighten until fully seated.
NOTE:
Dispose of used motor oil according to guidelines estab-
lished by your local or state government.
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)
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.
FIGURE 37: Oil Drain Bolt
FIGURE 38: Loosen Oil Drain Bolt
WARNING
WARNING
FIGURE 39: Remove Oil Fill Cap
FIGURE 40: Oil Draining from Generator
FIGURE 41: Engine Oil Dipstick—Oil Level Indicator
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