Honeywell Portable Generator HW4000 User Manual

HW4000 Portable Generator  
Owner’s Manual  
Portable Gasoline Generator  
Read and Save These Instructions  
or call toll-free at 1-888-494-3571.  
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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  
/
/
OTHER BRANDS CONSIDERED WHEN SHOPPING  
FOR THIS PRODUCT:  
MM  
DD  
YYYY  
MODEL NUMBER*:  
PRIMARY USE FOR PRODUCT:  
TOOL POWER  
SERIAL NUMBER*:  
*Found on nameplate of generator  
RECREATION POWER  
EMERGENCY POWER  
PURCHASE LOCATION:  
IN-STORE  
PRIMARY LOCATION FOR PRODUCT USE:  
ONLINE  
STORE  
NAME______________________________  
HOME  
WORK  
PURCHASE PRICE  
TYPE OF WORK, IF PRODUCT BEING USED FOR  
PROFESSION:  
$__________.00  
FEATURES INFLUENCING  
PRODUCT PURCHASE  
BRAND  
REPUTATION  
EASE OF USE  
WHAT OTHER TYPE OF POWER EQUIPMENT ARE  
INTERESTED IN PURCHASING IN THE FUTURE?  
PORTABILITY  
POWER RATING  
PRICE  
SIZE/WEIGHT  
STYLE/APPEARANCE  
WARRANTY  
WHO DECIDED TO PURCHASE THIS PRODUCT?  
HOW DID YOU BECOME AWARE OF THIS  
PRODUCT?  
IN-STORE  
INTERNET  
PRINT  
RADIO/TV  
STORE CIRCULAR  
WORD OF MOUTH  
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3 – DEMOGRAPHIC INFORMATION  
GENDER:  
HOUSEHOLD INCOME  
MALE  
LESS THAN $15,000  
$100,000 - $124,999  
$125,000 - $149,000  
$150,000 – $174,999  
$175,000 – $199,999  
$200,000 OR OVER  
FEMALE  
$15,000 - $29,999  
$30,000 - $49,999  
$50,000 - $79,999  
$80,000 - $99,999  
MARITAL STATUS:  
MARRIED  
SINGLE  
PRIMARY METHOD OF PURCHASING HOUSEHOLD  
ITEMS:  
DATE OF BIRTH:  
/
/
IN-STORE  
ONLINE  
TV  
MM  
DD  
YYYY  
MAIL ORDER  
INCLUDING YOUR SELF, HOW MANY PEOPLE LIVE IN  
YOUR HOUSEHOLD?  
TYPES OF CREDIT CARDS HELD BY HOUSEHOLD  
MEMBERS:  
NUMBER OF CHILDREN UNDER 18 LIVING IN YOUR  
HOUSEHOLD:  
VISA/MASTER CARD  
DISCOVER  
AMERICAN EXPRESS  
GAS/RETAIL  
OTHER  
PRIMARY RESIDENCE:  
OWN  
RENT  
NONE  
EDUCATION  
HOUSEHOLD INTERESTS:  
HOME IMPROVEMENT  
AUTOMOTIVE WORK  
CAMPING  
SOME HIGH SCHOOL  
HIGH SCHOOL DIPLOMA  
COLLEGE DEGREE  
GRADUATE DEGREE  
OTHER:  
_________________________________________  
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.  
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CONTENTS  
HW4000 Portable Generator Owner’s Manual  
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SAVE THESE INSTRUCTIONS  
IMPORTANT SAFETY RULES  
ANYONE using or servicing generator must read, understand, and follow all safety and operation instructions pro-  
vided in product manual. Failure to closely follow these instructions can result in circumstances leading to death, seri-  
ous injury, and property damage.  
Hazard Symbols and Meanings  
i
NOTE:  
Since there are many variations in the circumstances sur-  
rounding the installation, operation, and maintenance of  
this generator unit, we cannot possibly anticipate or pro-  
vide advice or safety messages to cover every situation.  
In addition to the signal words described above, the fol-  
lowing symbols may be used to draw your attention to  
specific types of hazards.  
Safety Messages  
Fire  
Toxic fumes  
Explosion  
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.  
Chemical burn  
Hot surface  
Indicates an imminently hazardous situa-  
tion which, if not avoided, will result in  
death or serious injury to the operator or  
to bystanders.  
Electrical shock  
Indicates a potentially hazardous situa-  
tion which, if not avoided, could result in  
death or serious injury to the operator or  
to bystanders.  
Using a generator indoors CAN KILL YOU IN MINUTES.  
Generator exhaust contains carbon monoxide. This is a poi-  
son you cannot see or smell.  
Indicates a potentially hazardous situa-  
tion which, if not avoided, may result in  
moderate or minor injury to the operator  
or to bystanders.  
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.  
Indicates a situation which, if not avoided,  
may result in damage to generator com-  
ponents.  
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Safety Messages  
Electric Shock Hazards  
Generator Damage Hazards  
Improper treatment or misuse of generator can cause per-  
manent damage.  
Generator produces powerful voltage that can cause  
death or great physical harm.  
• NEVER tamper with governed speed. Generator sup-  
plies correct rated frequency and voltage when running  
at governed speed.  
• When using generator for backup power, notify utility  
company. Use approved transfer equipment to isolate  
generator from electric utility.  
• NEVER modify generator in any way.  
• NEVER connect to a building's electrical system unless  
a transfer switch has been installed by a qualified elec-  
trician.  
• Damage to generator caused by misuse or modification  
is not covered under Warranty.  
• NEVER touch bare wires or receptacles.  
• NEVER use generator with electrical cords that are  
worn, frayed, bare, or otherwise damaged.  
• NEVER operate generator in rain or snow, or when the  
generator is set on wet surface.  
Fire and Burn Hazards  
Fuel and its vapors are extremely flammable and  
explosive under certain conditions.  
• Refuel generator only outdoors, in a well-ventilated  
area.  
• NEVER enclose the generator in any structure.  
• Keep generator at least 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 gen-  
erator 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  
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 1-888-494-  
3571 to request replacements.  
H
A
B
A
C
G
D
E
F
PRODUCT LABEL  
PART NUMBER  
A
100884A  
B
C
100886A  
100887A  
D
E
100883A  
100879A  
F
100882A  
G
H
100885A  
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:  
HW4000 Portable Generator  
Wheel Kit (including handle assembly and assembly hardware)  
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.  
HW4000 Portable Generator Owner’s Manual  
5
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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  
6
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Assembly  
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.  
Wheel Kit  
FIGURE 2: Wheel Assembly Components  
i
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.  
• NEVER USE wheel kit on-road.  
• Wheel kit is intended to be used specifically with this generator. NEVER use wheel kit for any other purpose.  
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Assembly  
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.  
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  
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.  
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.  
FIGURE 5: Support Leg Attachment to Generator  
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.  
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Assembly  
4. Slide second 9/16" washer onto axle.  
Step 2: Install Wheel Axle and Wheels  
5. Slide cotter pin into pre-drilled hole until fully seated.  
To install wheel assembly, you will need:  
6. Using needlenose pliers, bend each end of cotter pin  
Socket wrench with 10 mm socket*  
Needlenose Pliers*  
in opposing directions to secure wheel to axle.  
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.  
FIGURE 8: Cotter Pin Installation  
7. Return generator in upright position (so that wheels  
1. Install wheel axle brackets to frame using 16 mm full-  
and leg supports are touching ground).  
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.  
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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Grounding the Generator  
Once properly installed, the handles can be collapsed, if  
desired.  
Step 3: Install Handle Assembly  
To install handle assembly, you will need:  
Handle Brackets (2)  
Hands and fingers can be pinched from collapsible  
handles.  
Handle Bars (2)  
Rubber Handle Grips (2)  
• Keep hands and fingers clear from hinges when col-  
lapsing generator handles.  
40 mm Washer Style Hex Bolts (6)  
10 mm flange serrated nuts (6)  
To collapse handles, push firmly down on handle  
until it rests vertically against generator frame.  
Socket wrench with 8mm socket*  
*
Not included  
To return handles to horizontal position, pull up on  
handle.  
1. Hold handle bracket over pre-drilled holes on frame  
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.  
FIGURE 9: Handle Bracket to Frame  
Before using generator, a ground wire must be connected  
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.  
FIGURE 11: Ground Terminal  
i
NOTE:  
The system ground is not connected to AC neutral wire. If  
using a receptacle tester, it will not show same ground cir-  
cuit condition as for a home receptacle.  
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.  
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.  
i
NOTE:  
Handle should stick straight out after tightening bolts and  
nuts. If handle seems to hang down, tighten bolts and  
nuts further.  
In some areas, generators are required to be regis-  
tered with local utility companies.  
5. Slide rubber handle grip onto each handle bar and  
push to achieve snug fit.  
If generator is used at a construction site, there may  
be additional regulations which must be observed.  
10  
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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 util-  
ity lines. Such feedback may electrocute utility com-  
pany 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 auto-  
matic switch or a combination of manual and auto-  
matic. During a power outage, transfer switch  
isolates emergency circuits from utility line, allowing  
for efficient operation of generator without back-  
feeding onto utility.  
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COMPONENTS  
Use information provided in this section to become familiar with your generator’s components.  
The information below is provided for reference only. Refer to Operation section (page 15) for instructions on  
operating generator.  
J
I
K
A
D
L
H
G
F
B
E
C
FIGURE 12: HW4000 Portable Generator  
A—Power Control Center House-  
hold Outlets  
120V 20 Amp Duplex outlets to con-  
nect 120V appliances to generator  
for power.  
D—Engine Control Switch  
Control used to run and stop the engine. Engine switch has  
two positions:  
RUN—Prepares engine for starting  
STOP—Stops generator engine  
Generator Cord/ Transfer Switch  
120V 20 Amp Twist-Lok outlet can  
be used to:  
E—Recoil Starter Grip Handle  
Starts engine.  
F—Fuel Valve  
Controls flow of fuel from fuel tank to carburetor.  
Power 240V appliances using  
appropriate (L14-20) power cord  
(not included).  
G—Air Cleaner Assembly  
Removes dust from engine intake air.  
Connect a transfer switch to building’s main electrical sys-  
tem for backup power (see page 11).  
H—Choke Control  
Breakers  
Controls choke valve. Choke control must be pulled out to  
ON position when starting a cold engine.  
Protects circuits from damage caused by over-  
load or short-circuit by stopping flow of electric-  
ity between generator and appliance. Master  
circuit breaker controls power to all outlets. If  
there is no power at outlets, see Troubleshoot-  
ing section.  
I— Fuel Gauge  
Indicates level of fuel currently in fuel tank.  
Set Tripped  
J—Fuel Tank Cap  
Provides a secure seal on fuel tank.  
K—Muffler Equipped with Spark Arrester  
Ground Terminal  
Provides outlet for engine exhaust. Prevents sparks and  
other combustible materials from escaping generator.  
Connects generator to ground wire for grounding protection.  
Generator must be grounded to prevent electrical  
shock from faulty appliances. See page 10.  
Muffler reaches temperatures that can cause serious  
burns if touched. NEVER touch hot surfaces.  
B—Engine Oil Fill Cap/Dipstick  
Seals off engine oil fill hole and provides indicator for engine  
oil level.  
L—Spark Plug Cap (Wire)  
Delivers volts to spark plug. When spark plug needs service,  
cap must be removed.  
C—Engine Oil Plug  
When loosened, allows engine oil to drain from generator.  
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OPERATION  
Preparing for Operation  
Generator Location  
When deciding on the location to place your generator,  
keep in mind the following safety rules:  
Using a generator indoors CAN KILL YOU IN MINUTES.  
Generator exhaust contains carbon monoxide. This is a poi-  
son you cannot see or smell.  
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.  
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.  
Before starting generator, complete the following prepara-  
tion tasks:  
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.  
Be sure generator is placed outdoors in a well  
• Place generator on firm, level surface and avoid  
loose sand or snow. If generator is tilted or over-  
turned, fuel spillage may result. Also, if generator  
is overturned or sinks into a soft surface, sand,  
dirt, or water may enter generator.  
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  
Before connecting to a building’s electrical system,  
consult utility company or qualified electrician.  
NEVER operate generator in rain or snow, or  
when the generator is set on wet surface.  
• Connecting to a building's electrical system with-  
out 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.  
Starting Generator  
Before starting generator, be sure to thoroughly read  
all information provided in this Owner’s Manual.  
Check/add engine oil— See “Engine Oil” on  
page 20. For initial start-up, follow instructions on oil  
container provided with generator.  
It is very important to maintain proper level of engine oil to  
keep engine in good running condition.  
Check/add fuel*—See “Adding Fuel” on page 22.  
• Check engine oil level prior to each use.  
Starting generator with appliances connected can cause  
permanent damage to appliances.  
Be sure ground terminal is properly connected to  
• NEVER start generator with electrical appliances plugged  
in and turned on.  
Check extension cords—be sure cords are:  
In good condition.  
To start generator:  
1. Be sure generator is placed outside, in well-ventilated  
Rated for outdoor use and match amp and voltage  
area.  
ratings of generator outlet.  
Equipped with proper plugs that contain grounding  
blades.  
*
You must add fuel before using the generator for the first time.  
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Stopping Generator  
2. Turn fuel valve to ON position.  
7. As engine warms up, and RPM stabilizes, gradually  
push in choke control to OFF position.  
To prevent damage to generator, do not allow starter grip to  
snap back against engine.  
Stopping Generator  
In an emergency:  
Press and hold engine control switch to STOP position  
until engine stops.  
FIGURE 13: Fuel Valve Lever — ON/OFF position  
3. Pull choke control to ON 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 excessively rich. Performance will decrease and fuel  
consumption will increase.  
FIGURE 14: Choke Rod  
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.  
4. Press engine control switch to RUN position.  
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 horse-  
power will be greater than this if no carburetor modifica-  
tion is made.  
FIGURE 15: Engine Control Switch  
5. Grip recoil starter handle and pull slowly until you feel  
slight resistance.  
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.  
Powering Appliances  
i
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  
NEVER start generator with electrical appliances plugged in  
and turned on.  
FIGURE 16: Recoil Starter Handle  
6. Apply a swift, single pull to start engine. Carefully  
return recoil starter handle to original position.  
16  
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Powering Appliances  
Typical Running Watts  
Appliance  
Window  
Faulty appliances and power cords can result in elec-  
trical shock.  
500-1440  
Aquarium  
50-1210  
10  
• Before attempting to power an appliance, be sure genera-  
tor has been properly grounded, and that appliance and  
power cord are in good working order.  
Clock radio  
Coffee maker  
Washing machine  
Electric dryer  
Iron  
900-1200  
350-500  
1800-5000  
1000-1800  
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  
exceed rated output of generator. Power rating infor-  
mation can usually be found on an appliance’s prod-  
uct label, or stamped inside or on back of appliance.  
See Table 1 for a listing of average appliance wattage  
requirements.  
1200-2400 (using drying feature  
greatly increases energy con-  
sumption)  
Dehumidifier*  
785  
Electric blanket  
(Single/Double)  
60 / 100  
NEVER overload: Circuit breakers will stop flow of  
electricity between generator and appliance if genera-  
tor 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.  
65-175  
55-250  
Ceiling  
Window  
*
750  
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.  
Hair dryer  
1200-1875  
750-1500  
750-1100  
Heater (portable)  
Microwave oven  
Personal computer  
CPU - awake /  
Use suitable extension cords: If using an extension  
cord to connect appliance to generator, use only UL-  
listed, three-prong extension cords. Be sure exten-  
sion cord is proper size (wire-gauge) to handle elec-  
tric load that will be plugged into it.  
120 / 30 or less  
150 / 30 or less  
asleep  
Monitor - awake /  
asleep  
50  
Laptop  
Radio (stereo)  
70-400  
Do not run power cords under carpet, rugs, or other materi-  
als where heat might build up or cord damage may go unno-  
ticed.  
Refrigerator*  
(frost-free, 16 cubic  
feet)  
725  
Appliance Wattage Information  
Sump pump*  
Use table below as a guide to determine how much power  
you will need to run appliances using generator.  
2150  
2300  
1/2 hp  
1/3 hp  
Television (color)  
The values provided in following table are estimates only.  
65-110  
113  
19"  
• 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.  
27"  
133  
36"  
170  
53"-61" Projection  
Appliance  
Typical Running Watts  
Air Conditioner*  
120  
Flat screen  
3500  
Toaster  
800-1400  
Central  
TABLE 1. Typical Appliance Running Wattages  
TABLE 1. Typical Appliance Running Wattages  
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Powering Appliances  
Appliance  
Toaster oven  
Typical Running Watts  
1225  
VCR/DVD  
17-21 / 20-25  
1000-1440  
4500-5500  
Vacuum cleaner*  
Water heater (40 gal)  
Water pump*  
(deep well)  
250-1100  
TABLE 1. Typical Appliance Running Wattages  
*
Allow up to three times normal running watts for starting or  
cycling compressor of this appliance.  
Starting appliances that have motors requires more power.  
Examples of motorized appliances include refrigerators,  
water pumps, and furnace blowers. Be sure that power rat-  
ing of appliance does not exceed that of generator.  
18  
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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 (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.  
Accidental starting of generator can cause severe injury or  
death. Before performing maintenance, disconnect spark  
plug cap from spark plug.  
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.  
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.  
• Shut off engine before performing any maintenance. If  
engine must be run, be sure area is well ventilated.  
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.  
*
FREQUENCY  
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  
MAINTENANCE TASK  
Before each  
use  
Check engine oil level  
Inspect for/clean debris  
Check air cleaner  
X
X
X
Clean air cleaner  
X
Change engine oil  
X
X
X
X
X
Clean fuel sediment cup  
Check/clean spark plug  
Clean spark arrestor  
Check/adjust valve clearance  
X
Clean fuel tank and strainer  
Check fuel line  
X
Every 2 years (replace if necessary)  
TABLE 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.  
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Engine Oil  
Oil level should be at “H” or somewhere between the  
“L” and “H”.  
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.  
FIGURE 19: Engine Oil Level  
• Check engine oil level prior to each use. Refill engine  
oil if oil level is too low.  
If oil level is at “L” or below, add recommended oil  
If oil level  
Engine Oil Recommendations  
is at “H” or somewhere between the “L” and “H”,  
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.  
reinstall oil fill cap and fully tighten.  
6. Reinstall oil fill cap and fully tighten.  
Low Oil Protection  
SAE 10W-30 is recommended for general temperature  
that may be used. Other viscosities shown in chart may be  
used when average temperature in your area is within  
indicated range.  
When engine oil level approaches an unsafe level, the low  
oil protection feature prevents equipment damage by  
automatically shutting down engine.  
When engine shuts down due to low oil level:  
The engine start switch will remain in RUN position.  
You will not be able to start engine until you add  
required amount of engine oil.  
Adding Engine Oil  
i
NOTE:  
For initial start-up, follow instructions provided on engine  
oil bottle provided with generator.  
FIGURE 17: Recommended Oil Viscosity  
Checking 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.  
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.  
5. Pull out to read current oil level indicated on dipstick  
end.  
FIGURE 20: 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 18: Engine Oil Level  
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Engine Oil  
6. Using a socket wrench with 12 mm socket, loosen  
Changing Engine Oil  
drain plug bolt; remove drain bolt and sealing washer.  
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  
FIGURE 22: Loosen Oil Drain Bolt  
Clean cloth  
7. Allow oil to drain into oil pan or container.  
8. Slowly unscrew and remove oil fill cap.  
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.  
FIGURE 23: Remove Oil Fill Cap  
9. Allow oil to completely drain into oil pan or container.  
• 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 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.  
FIGURE 21: Oil Drain Bolt  
12. Pour new (unused) engine oil into oil fill hole. (See  
5. Keep oil fill cap on initially to avoid having oil spray  
13. Check oil level.  
out too fast.  
FIGURE 25: Engine Oil Dipstick—Oil Level Indicator  
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Adding Fuel  
14. Reinstall oil fill cap and tighten until fully seated.  
Try to confirm contents of fuel.  
Some states (and provinces in Canada) require this infor-  
mation to be posted on the fuel pump. If you notice unde-  
sirable operating symptoms, switch to a conventional  
unleaded gasoline.  
i
NOTE:  
Dispose of used motor oil according to guidelines estab-  
lished by your local or state government.  
Adding Fuel  
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.  
Before each use, check fuel gauge on fuel tank.  
If fuel level is low, refill tank with recommended fuel.  
NEVER OVERFILL.  
TABLE 3. Oxygenated Fuel Types  
Gasoline containing more than  
10% ethanol by volume may  
Ethanol  
(ethyl or grain alcohol)  
cause starting or performance  
problems. Gasoline containing  
ethanol may be marketed  
Fuel and fuel vapors are extremely flammable and  
explosive under certain conditions.  
under the name "Gasohol".  
• Refuel generator only outdoors, in a well-ventilated  
area.  
• NEVER fill fuel tank while engine is running. Turn gen-  
erator OFF and allow to cool before filling with fuel.  
• NEVER smoke or allow flames or sparks near genera-  
tor 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.  
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.  
Methanol  
(methyl or wood alco-  
hol)  
MTBE  
(methyl tertiary butyl  
ether)  
You can use gasoline contain-  
ing up to 15% MTBE by vol-  
ume.  
• Avoid repeated or prolonged contact with skin or  
breathing of vapor.  
Fuel Recommendations  
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.  
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.  
Never use stale or contaminated gasoline. Avoid getting  
dirt or water in the fuel tank. Always keep fuel strainer in  
place while refueling.  
To add fuel to generator:  
Oxygenated Fuels  
1. Stop generator if engine is running. Allow to com-  
pletely cool.  
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 emis-  
sions.  
2. Be sure generator is set on flat, level surface.  
3. Remove fuel tank cap.  
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.  
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Air Filter Maintenance  
4. Slowly pour gasoline into fuel tank. Be careful not to  
2. Remove air cleaner cover.  
overfill.  
FIGURE 26: Fuel Level  
5. Reinstall fuel tank cap and fully tighten.  
FIGURE 27: Air Cleaner Cover  
i
NOTE:  
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.  
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  
FIGURE 28: Air Cleaner Cover—Release Tabs  
3. Pull out foam air filter.  
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 prop-  
erly attached.  
Clean air cleaner filter every 50 hours of generator opera-  
tion. 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 sol-  
vent to clean air cleaner element.  
FIGURE 29: Air Filter Removal  
• Use only household soap and water to clean air  
cleaner element.  
4. Wash air filter in a solution of household soap and  
warm water.  
To clean air filter, you will need:  
Household soap and water  
Clean, dry cloth  
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.  
Clean engine oil  
1. Stop engine if it is running.  
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Cleaning Fuel Sediment Cup  
7. Soak air filter in clean engine oil and squeeze out  
A
excess oil.  
B
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.  
C
i
NOTE:  
FIGURE 31: Fuel Sediment Cup Assembly Pieces  
Engine will smoke during initial start-up if too much oil is  
left in filter.  
5. Clean fuel screen (A), o-ring (B), and sediment cup  
(C), with soap and water.  
8. Reinstall air filter.  
6. Wipe pieces clean with clean, dry cloth.  
9. Reinstall air cleaner cover and tighten thumbscrew.  
7. Reinstall sediment cup, o-ring, and fuel filter.  
8. Turn fuel valve to ON position and check for leaks.  
Cleaning Fuel Sediment Cup  
Spark Plug Service  
The sediment cup prevents any dirt or water that may be  
in the fuel tank from entering the carburetor.  
To ensure proper engine operation, spark plug must be  
properly gapped and free of deposits.  
Clean fuel sediment cup at the intervals specified in  
To clean fuel sediment cup, you will need:  
Socket wrench with 10 mm socket  
Household soap and water  
Clean, dry cloth  
If engine has been running, muffler will reach tem-  
peratures that could cause severe burns. Do not  
touch.  
Recommended Spark Plug Replacement: 100842A*  
Bosch  
W20EPR  
RN9YC  
WR7DC  
To clean fuel sediment cup:  
1. Stop engine if it is running.  
Champion  
Denso  
2. Be sure generator is set on flat, level surface.  
3. Turn fuel valve to OFF position.  
TABLE 4. Spark Plug Equivalents to 100842A  
4. Using a socket wrench with 10 mm socket, remove  
fuel sediment cup assembly (sediment cup, o-ring,  
and fuel screen).  
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.  
2. Be sure generator is set on flat, level surface.  
FIGURE 30: Fuel Sediment Cup Assembly Removal  
*
See Maintenance Parts at end of this manual.  
24  
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Cleaning Spark Arrestor Screen  
3. Remove spark plug cap.  
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.  
FIGURE 32: Spark Plug Cap Removal  
Spark plug must be securely tightened. An improperly tight-  
ened 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.  
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  
Muffler reaches temperatures that can cause serious  
burns if touched. NEVER touch hot surfaces.  
Generator muffler is equipped with spark arrestor screen,  
which must be cleaned according to maintenance sched-  
generator.  
To clean spark arrestor screen, you will need:  
Socket wrench with 8 mm socket  
Phillips head screwdriver  
FIGURE 33: 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.  
Wire brush  
1. Stop generator if engine is running. Allow to com-  
pletely cool.  
If spark plug is in good condition, reuse existing  
spark plug.  
2. Be sure generator is set on flat, level surface.  
8. If reusing spark plug, clean spark plug with wire  
3. Using a socket wrench with 8 mm socket, remove  
brush.  
spark arrestor enclosure panel bolts.  
9. Measure spark plug gap with wire feeler gauge.  
Gap should be: (0.028-0.031 in) (0.70-0.80 mm).  
FIGURE 34: Correct Spark Plug Gap  
10. If necessary, adjust gap by carefully bending side  
electrode.  
FIGURE 35: Remove Spark Arrestor Enclosure Panel  
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Transporting Generator  
4. Pull off enclosure panel.  
Storing Generator  
C
Follow service procedures for preparing generator for stor-  
age. Inadequate or improper care of generator can result in  
damage to generator components and will void limited war-  
ranty.  
A
Before storing generator for extended period of time:  
Be sure storage area is free of excessive humidity  
and dust.  
B
FIGURE 36: Spark Arrestor Assembly  
dures.  
5. Using a screwdriver, loosen and remove screw hold-  
ing spark arrestor clamp (A).  
Storage Time  
Recommended Preparation  
No preparation required.  
6. Slide off spark arrestor clamp.  
Less than 1  
month  
7. Using a screwdriver, loosen and remove retaining  
screw on park arrestor screen cap (B); pull off cap.  
Fill fuel tank with fresh gasoline and  
8. Pull out spark arrestor screen (C).  
9. Inspect spark arrestor screen.  
1 to 2 months  
*
add gasoline conditioner .  
2 months to 1  
year or more  
If screen is damaged or excessively worn, replace  
See procedure below.  
with new screen.  
TABLE 5. Recommended Service Procedures Based on Storage  
Time  
If screen is in good condition, clean using wire  
brush and then reinstall.  
*
Use gasoline conditioners formulated to extend storage life.  
Contact authorized generator dealer for conditioner recommen-  
dations.  
10. Reinstall remaining spark arrestor components.  
Spark arrestor cap  
Retaining screw  
To prepare generator for long-term storage:.  
Clamp and screw  
Spark arrestor enclosure panel  
Fuel and its vapors are extremely flammable and  
explosive under certain conditions.  
Transporting Generator  
• Refuel generator only outdoors, in well-ventilated area.  
• 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 genera-  
tor or where gasoline is stored.  
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.  
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. Rein-  
stall spark plug.  
Keep generator level to prevent fuel spillage.  
At this point, the piston is coming up on its compres-  
sion stroke and both intake and exhaust valves are  
closed. Storing engine in this position will help to pro-  
tect it from internal corrosion.  
To avoid damage to generator, take care not to drop or strike  
generator when transporting. Do not place heavy objects on  
generator.  
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Storing Generator  
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 37: Loosen Bolt to Drain Fuel  
5. Turn fuel lever to ON position.  
FIGURE 38: 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 39: Tip Generator to Completely Drain Fuel  
8. Allow fuel to completely drain into container.  
9. When ready to put generator back into operation, refill  
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TROUBLESHOOTING  
ANYONE using or servicing 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.  
Using a generator indoors CAN KILL YOU IN MINUTES.  
Generator exhaust contains carbon monoxide. This is a poi-  
son you cannot see or smell.  
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.  
i
NOTE:  
PROBLEM  
PROBABLE CAUSE  
1 No fuel.  
SOLUTION  
1 Add fuel (page 22).  
2 Stale fuel.  
2 Drain fuel tank; fill with fresh fuel  
3 No engine oil.  
3 Add engine oil (page 20).  
4 Spark plug wire (cap) disconnected.  
5 Faulty/bad spark plug.  
6 Fuel not reaching carburetor.  
7 Dirty air cleaner.  
Engine will not start or starts  
and runs rough.  
4 Install spark plug cap over spark plug.  
5 Check/replace spark plug (page 24).  
6 Clean fuel sediment cup (page 24).  
7 Clean or replace air cleaner (page 23).  
8 Clean spark arrestor screen (page 25)  
8 Dirty spark arrestor screen.  
1 No fuel.  
1 Add fuel (page 22).  
Engine suddenly stops.  
2 No engine oil.  
2 Add engine oil (page 20).  
*
1 Electrical overload on generator.  
1 Check all circuit breakers  
for “tripped’ position.  
Reduce electrical load on  
circuit, wait 3 minutes,  
and then push to reset cir-  
cuit breaker.  
2 Poor connection or defective cord  
set.  
Set  
Tripped  
3 Connected electrical appliance/  
equipment is defective.  
No power at AC receptacle  
2 Check cord connection. Replace defective  
cord set.  
3 Check electrical appliance/equipment for  
defects. Disconnect defective appliance/  
equipment from the generator. Have appli-  
ance serviced by qualified repair facility.  
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.  
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SPECIFICATIONS  
GENERATOR  
*
Dimensions  
Length  
Width  
27 inches (685.8 mm)  
21.5 inches (546.1 mm)  
21.5 inches (546.1 mm)  
155 pounds (70.3 kg)  
Height  
Dry Weight  
AC Output  
Continuous (Rated) Power)  
4000 Watts  
5000 Watts  
6000 Watts  
60 Hz  
Maximum Power  
Surge Power  
Frequency  
Voltage  
120/240 Volts  
Operating Temperature  
Maximum  
Minimum  
104° F (40° C)  
-10° F (-23° C)  
ENGINE  
Speed (RPM)  
Type  
3600  
OHV 4-Cycle  
Displacement  
Fuel Tank Capacity  
Engine Oil Capacity  
Spark Plug Type  
Spark Plug Gap  
242 cc  
6.5 Gallons (24.6 L)  
1.1 qt (1.1 L)  
100842A  
0.028-0.031 inches (0.70-0.80 millimeters)  
TABLE 7. HW4000 Portable Generator Specifications  
*
Measurements given do not reflect dimensions with wheel kit installed to generator.  
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WARRANTIES  
E. Fuel tank, cap and screen  
F. Carbon Canister (if equipped)  
NORTHSHORE POWER SYSTEMS  
EMISSIONS CONTROL WARRANTY  
2. Air Induction System  
Honeywell Portable Generator  
A. Air cleaner  
B. Vent lines  
WARRANTY STATEMENT  
US Environmental Protection Agency (EPA) requires manu-  
facturers 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.  
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)  
In the United States and California, new small off-road  
engines must be designed, built, and equipped to meet strin-  
gent 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.  
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  
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.  
1. Claims. Warranty claims shall be filed in accordance  
with provisions of the NSP warranty and policies estab-  
lished with the authorized dealer network.  
2. Exclusions. Warranty coverage shall be denied for fail-  
ure of an emissions control part caused by abuse,  
Where a warrantable condition exists, NSP will repair your  
small off-road engine at no cost to you, including diagnosis,  
parts, and labor.  
neglect, improper maintenance as described in the Hon-  
eywell 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.  
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.  
3. Length of Coverage. NSP warrants to the original retail  
purchaser and each subsequent owner that the emis-  
sions 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.  
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.  
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, includ-  
ing 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 gen-  
erator 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.  
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 ser-  
vice, contact your nearest dealer; a listing is available at  
6. Maintenance. The emissions control parts are war-  
ranted 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 per-  
formance and durability may be used for maintenance or  
repairs.  
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  
HW4000 Portable Generator Owner’s Manual  
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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  
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  
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NORTHSHORE POWER SYSTEMS LIMITED WARRANTY  
CUSTOMER, FOR ANY OTHER OBLIGATIONS OR LIABIL-  
ITIES, INCLUDING, BUT NOT LIMITED TO, OBLIGATIONS  
OR LIABILITIES ARISING OUT OF BREACH OF CON-  
TRACT 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, PUNI-  
TIVE, 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 LIABIL-  
ITY CUSTOMER INCURS WITH RESPECT TO ANY  
OTHER PERSON, OR ANY OTHER TYPE OR FORM OF  
CONSEQUENTIAL DAMAGE OR ECONOMIC LOSS.  
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 mate-  
rial 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  
wellgenerators.com or by calling 1-888-494-3571.  
EXCLUSIONS. In addition to the foregoing disclaimers, limi-  
tations 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) acci-  
dent, damage, abuse or misuse; (iv) abnormal operating con-  
ditions 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.  
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 pur-  
chaser. 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.  
REGISTRATION  
Warranty registration with the Company is required on all  
products. You may send in the enclosed warranty card, or  
tors.com.  
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.  
Warranty is also available by keeping and showing your origi-  
nal receipt from date of purchase to an authorized Honeywell  
Generator Dealer.  
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.  
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  
DISCLAIMER OF OTHER WARRANTIES. TO THE FULL-  
EST EXTENT PERMITTED BY APPLICABLE LAW, THIS  
LIMITED WARRANTY IS EXCLUSIVE AND EXPRESSLY IN  
LIEU OF ANY AND ALL OTHER WARRANTIES, INCLUD-  
ING, WITHOUT LIMITATION, ANY IMPLIED WARRANTIES  
OF MERCHANTABILITY OR FITNESS FOR A PARTICU-  
LAR 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 fed-  
eral 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 pur-  
pose) are limited to the shortest duration permitted by appli-  
cable law or the limited warranty period provided herein,  
whichever is longer.  
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  
LIMITATIONS OF REMEDIES. NSP SHALL NOT BE LIA-  
BLE TO CUSTOMER, OR TO ANYONE CLAIMING UNDER  
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INDEX  
INDEX  
A
unpacking guidelines 5  
warranty 35  
Ground 10  
special requirements 10  
terminal 13  
Air Filter  
maintenance 23  
Appliances  
powering 16  
rules for powering 16  
wattage information 17  
Assembly  
handle 10  
wheels 9  
H
Handles  
installing 10  
High Altitude  
operation 16  
C
Checklist  
M
generator shipment 5  
Components and Controls  
breakers 13  
choke control 13  
engine switch 13  
fuel valve 13  
Maintenance 19  
air filter 23  
changing engine oil 21  
cleaning spark arrestor 25  
fuel sediment cup 24  
parts listing 39  
outlets  
schedule 19  
spark plug 24  
Household 13  
recoil starter grip 13  
spark plug cap 13  
O
Operation  
D
E
F
high altitude 16  
preparing for 15  
Outlets  
Generator Cord/Transfer Switch 13  
Household 13  
Damage  
inspecting for 5  
Draining Fuel 27  
P
S
Engine Oil  
changing 21  
Engine Switch 13  
Power Control Center 13  
ground terminal 13  
Household Outlets 13  
Fuel  
adding 22  
Safety  
labels 3  
Spark Arrestor  
cleaning 25  
draining 27  
oxygenated  
types 22  
Spark Plug  
recommendations 22  
Fuel Sediment Cup  
cleaning 24  
Fuel Valve 13  
servicing 24  
Specifications 31  
Stopping Generator 16  
Storage  
recommendations 26  
G
Generator  
location 15  
T
Transfer Switch  
for backup power 11  
outlet 13  
nameplate information 6  
operation 15  
outlets 13  
safety labels 3  
specifications 31  
starting 15  
Troubleshooting 29  
U
stopping 16  
storing 26  
Unpacking guidelines 5  
transporting 26  
HW4000 Portable Generator Owner’s Manual  
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INDEX  
W
Warranty  
emissions control 33  
limited product 35  
Wattage  
typical appliance 17  
Wheels  
installing 9  
38  
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HW4000 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  
Air Filter  
100832A  
100833A  
100834A  
100835A  
100836A  
100846A  
100837A  
100841A  
100839A  
100840A  
100847A  
100848A  
100843A  
100842A  
100844A  
100845A  
Fuel Cap  
Fuel Shut-Off Valve  
Fuel Strainer  
Handle Bar  
Ignition Coil  
Oil Fill Cap/Dipstick  
Recoil Assembly  
Recoil Rope and Handle  
Rubber Handle Grip  
Smart Start Card  
Spark Arrestor  
Spark Plug  
Wheel  
Wheel Handle Pivot Bracket  
HW4000 Maintenance Parts List  
For part numbers of replacement product labels, see page 3  
HW4000 Portable Generator Owner’s Manual  
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HW4000 – P/N: 100901A  
March 2008  
© 2008 Northshore Power Systems, LLC  
Northshore Power Systems, LLC  
4425 N. Port Washington Rd., Suite 105  
Milwaukee, WI 53212-1082 USA  
TEL 1-888-494-3571  
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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