HW5500/HW5500E Portable Generator
Owner’s Manual
Portable Gasoline Generator
Electric Start
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
IMPORTANT SAFETY RULES............................................................................................ 1
Location of Important Labels ..........................................................................................................................3
COMPONENTS .................................................................................................................. 13
OPERATION ...................................................................................................................... 15
Stopping Generator ......................................................................................................................................17
High Altitude Operation ................................................................................................................................17
MAINTENANCE ................................................................................................................. 19
Adding Fuel ..................................................................................................................................................22
TROUBLESHOOTING ....................................................................................................... 29
SPECIFICATIONS ............................................................................................................. 31
WARRANTIES ................................................................................................................... 33
NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY ..............................................33
NORTHSHORE POWER SYSTEMS LIMITED WARRANTY ......................................................................35
HW5500/5500E MAINTENANCE PARTS ......................................................................... 39
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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. NOTE: Illustration below shows battery, which is available only with HW5500E models.
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:
‰
‰
‰
‰
‰
‰
‰
HW5500/5500E Portable Generator
Wheel Kit (including handle assembly and assembly hardware)
Battery (HW5500E models only)
20’ 30 amp 4-in-1 Power Cord
1 L Engine Oil
Paper Funnel
Smart Start Instruction Card
The Smart Start instruction card is NOT intended to replace information provided in this Owner’s Manual. Be sure to
thoroughly read and understand all information provided in Owner’s Manual before operating generator. Failure to
properly follow all instructions and precautions can cause you and others to be seriously hurt or killed.
‰
Owner’s Manual
Inspect for Damage
Carefully inspect generator for any damage that may have occurred during shipment. If loss or damage is noted after
delivery, separate damaged materials and call Customer Hotline at 1-888-494-3571.
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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:
Illustration above shows battery, which is available only with HW5500E models.
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.
8
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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*
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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Assembly
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
Battery
To use electric start feature, battery (included) must be
connected to generator’s electric starter.
Battery gases are explosive.
• NEVER allow open flames, lit cigarettes, sparks, or
spark-producing equipment near the battery.
FIGURE 9: Handle Bracket to Frame
Battery electrolyte fluid is comprised of sulfuric acid,
which can be very dangerous and cause severe
burns.
2. Attach bracket to frame using 40 mm washer style
hex bolts and 10 mm flange serrated nuts; tighten
until securely seated.
• NEVER allow battery fluid to contact eyes, skin, or
clothing. If contact or spillage occurs, immediately flush
the area with water.
3. Slide handle bar through center of each bracket and
line up bolt holes.
Exposed terminals, even on disconnected batter-
ies, 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 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.
1. Generator is packaged with the negative (-) battery
i
NOTE:
lead attached to top of alternator with a plastic cable
Handle should stick straight out after tightening bolts and
nuts. If handle seems to hang down, tighten bolts and
nuts further.
5. Slide rubber handle grip onto each handle bar and
push to achieve snug fit.
10
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Grounding the Generator
strap. Carefully cut cable strap to disengage battery
lead.
Grounding the Generator
Generator must be grounded to prevent electrical
shock from faulty appliances.
• Before using generator, consult a qualified electrician,
electrical inspector, or local agency having jurisdiction
for local codes or ordinances that apply to the intended
use of generator.
Before using generator, a ground wire must be connected
FIGURE 11: Negative Battery Lead Attached to Alternator for Shipping
To avoid electric arcing, which can result in electric
shock, follow these instructions exactly.
When connecting or disconnecting battery leads:
• ALWAYS connect negative (-) battery lead
last.
FIGURE 13: Ground Terminal
• ALWAYS disconnect negative (-) battery lead
first.
i
NOTE:
• NEVER connect negative (-) battery lead to
red positive (+) post on battery.
• NEVER connect positive (+) battery lead to
black negative (-) post on battery.
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.
Special Requirements
2. Connect red positive (+) battery lead to red positive
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.
(+) post on battery; fasten with nut and bolt provided.
3. Connect black negative (-) battery lead to black nega-
tive (-) post on battery; fasten with nut and bolt pro-
vided.
•
In some areas, generators are required to be regis-
tered with local utility companies.
–
+
•
If generator is used at a construction site, there may
be additional regulations which must be observed.
FIGURE 12: Electric Starter Battery
i
NOTE:
Actual battery appearance may vary from illustration pro-
vided.
i
NOTE:
While engine is running, a small “trickle” charge is applied
to starting battery.This keeps an adequate battery
charge.
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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.
12
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COMPONENTS
Use information provided in this section to become familiar with your generator’s components.
Information below is provided for reference only. Refer to Operation section (page 15) for instructions on operat-
ing generator.
K
J
L
A
E
M
I
B
H
G
C
F
D
FIGURE 14: HW5500/5500E Portable Generator (Illustration shows battery, which is available only with HW5500E models)
A—Power Control Center
E—Engine Control Switch
Control used to run and stop the engine.
Household Outlets
120V 20 Amp Duplex outlets to connect
120V appliances to generator for power.
•
•
START—Starts generator engine (HW5500E)
RUN—Prepares engine for starting (HW5500);
Indicates engine is currently running (HW5500E)
STOP—Stops generator engine
Power Cord/ Transfer Switch
120/240V 30 Amp Twist-Lok outlet can
be used to:
•
F—Recoil Starter Grip Handle
Starts engine (HW5500).
•
•
•
Power 120V appliances using 4-in-1
power cord (included with generator).
Power 240V appliances using appropriate (L14-30) power
cord (not included).
Connect a transfer switch to building’s main electrical sys-
tem for backup power (see page 12).
Provides means to manually start engine, if needed
(HW5500E).
G—Fuel Valve
Controls flow of fuel from fuel tank to carburetor.
H—Air Cleaner Assembly
Removes dust from engine intake air.
Breakers
Protects circuits from damage caused by over-
load or short-circuit by stopping flow of electricity
between generator and appliance. Master circuit
breaker controls power to all outlets. If there is
no power at outlets, see Troubleshooting.
I— Choke Control
Controls choke valve. Choke control must be pulled out to
ON position when starting a cold engine.
Set Tripped
J—Fuel Gauge
Indicates level of fuel currently in fuel tank.
Ground Terminal
Connects generator to ground wire for grounding protection.
K—Fuel Tank Cap
Provides a secure seal on fuel tank.
L—Muffler Equipped with Spark Arrester
Provides outlet for engine exhaust. Prevents sparks and
other combustible materials from escaping generator.
Generator must be grounded to prevent electrical
B—Battery Tray and Battery (HW5500E Only)
Provides power for electric start feature.
Muffler reaches temperatures that can cause serious
burns if touched. NEVER touch hot surfaces.
C—Engine Oil Fill Cap/Dipstick
Seals off engine oil fill hole and provides indicator for engine
oil level.
M—Spark Plug Cap (Wire)
Delivers volts to spark plug. When spark plug needs service,
cap must be removed.
D—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
ventilated area. See “Generator Location”.
• 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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Starting Generator
2. Turn fuel valve to ON position.
When engine starts, the engine control switch gradu-
ally settles at RUN (center) position.
i
NOTE:
While engine is running, a small “trickle” charge is applied
to starting battery.This keeps an adequate battery
charge.
Manual (Recoil) Start:
„ Press engine control switch to RUN position.
FIGURE 15: Fuel Valve Lever — ON/OFF position
3. Pull choke control to ON position.
FIGURE 18: Engine Control Switch
„ Grip recoil starter handle and pull slowly until you
feel slight resistance.
Kickback (rapid retraction) of starter cord will pull hand and
arm toward engine faster than you can let go.
FIGURE 16: Choke Rod
Broken bones, fractures, bruises, or sprains could result.
• When using recoil starter, pull cord firmly and slowly until
you feel resistance and then pull rapidly to avoid kick-
back.
4. Proceed according to method you want to use to start
engine (see Electric Start or Manual Start).
Electric Start (HW5500E Model Only):
„ Press and hold engine control switch in START
position for 5 seconds or until engine starts.
FIGURE 17: Engine Control Switch
FIGURE 19: Recoil Starter Handle
„ Apply a swift, single pull to start engine. Carefully
• Holding engine control switch for more than 5 seconds
can damage starter motor. If engine fails to start after 5
seconds, release engine start switch and wait 10 seconds
before attempting to start engine again.
return recoil starter handle to its original position.
5. As engine warms up, and RPM stabilizes, gradually
push in choke control to OFF position.
• If you notice engine cranking speed drop after a period of
time, it may be an indication that battery should be
recharged.
To prevent damage to generator, do not allow starter grip to
snap back against engine.
16
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Stopping Generator
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.
Stopping Generator
In an emergency:
Press and hold engine control switch to STOP position
until engine stops.
In normal use:
•
•
•
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.
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.
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.
High Altitude Operation
At high altitudes, standard carburetor air-fuel mixture will
be excessively rich. Performance will decrease and fuel
consumption will increase.
High altitude performance can be improved by installing a
smaller diameter main fuel jet in the carburetor and then
readjusting the pilot screw. If you always operate the
engine at altitudes higher than 5000 feet (1500 meters)
above sea level, have an authorized generator dealer per-
form this carburetor modification.
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.
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.
Do not run power cords under carpet, rugs, or other materi-
als where heat might build up or cord damage may go unno-
ticed.
Appliance Wattage Information
Use table below as a guide to determine how much power
you will need to run appliances using generator.
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.
The values provided in following table are estimates only.
Powering Appliances
• 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.
i
NOTE:
In this manual, the term “appliance” refers to any electri-
cal device that can be connected to generator for power.
Appliance
Typical Running Watts
Rules for Powering Appliances
Air Conditioner*
3500
• Central
NEVER start generator with electrical appliances plugged in
and turned on.
500-1440
• Window
Aquarium
50-1210
10
Faulty appliances and power cords can result in elec-
trical shock.
Clock radio
Coffee maker
Washing machine
Electric dryer
Iron
900-1200
350-500
1800-5000
1000-1800
• 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.
•
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
TABLE 1. Typical Appliance Running Wattages
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Powering Appliances
Appliance
Dishwasher*
Typical Running Watts
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.
1200-2400 (using drying feature
greatly increases energy con-
sumption)
Dehumidifier*
785
Electric blanket
(Single/Double)
60 / 100
Fans*
65-175
55-250
• Ceiling
• Window
*
Furnace*
750
Hair dryer
1200-1875
750-1500
750-1100
Heater (portable)
Microwave oven
Personal computer
• CPU - awake /
120 / 30 or less
150 / 30 or less
asleep
• Monitor - awake /
asleep
50
• Laptop
Radio (stereo)
70-400
Refrigerator*
(frost-free, 16 cubic
feet)
725
2150
2300
• 1/2 hp
• 1/3 hp
Television (color)
65-110
113
• 19"
• 27"
133
• 36"
170
• 53"-61" Projection
120
• Flat screen
Toaster
800-1400
1225
Toaster oven
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.
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-
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. 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.
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 22: 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
use. Refer to Figure 20 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.
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 20: 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 23: Oil Fill Cap Removal
4. Slowly pour oil into oil fill hole.
5. Check oil level.
6. Replace oil fill cap and fully tighten.
FIGURE 21: Engine Oil Level
20
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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 25: 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 26: 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 27: Oil Draining from Generator
10. Using clean cloth, wipe around oil fill and drain plug
areas to clean any dirt and debris.
11. Reinstall sealing washer and drain plug bolt.
FIGURE 24: Oil Drain Bolt
12. Pour new (unused) engine oil into oil fill hole. (See
Figure 20 for recommended oil type). Do not overfill.
5. Keep oil fill cap on initially to avoid having oil spray
13. Check oil level.
out too fast.
FIGURE 28: 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.
22
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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 29: Fuel Level
5. Reinstall fuel tank cap and fully tighten.
FIGURE 30: 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
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 31: 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 32: 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 34: 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 33: 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 35: 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 36: Spark Plug Removal
7. Inspect spark plug.
„ If spark plug is damaged or excessively worn, or if
insulator is cracked or chipped use a new spark
plug.
‰ 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 37: Correct Spark Plug Gap
10. If necessary, adjust gap by carefully bending side
electrode.
FIGURE 38: 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 39: 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.
26
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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 40: Loosen Bolt to Drain Fuel
5. Turn fuel lever to ON position.
FIGURE 41: Fuel Valve Lever — ON/OFF position
6. Allow fuel to drain into container.
7. To ensure all fuel is drained, carefully tip generator by
pulling up on frame at side opposite of recoil starter
handle.
FIGURE 42: Tip Generator to Completely Drain Fuel
8. Allow fuel to completely drain into container.
9. When ready to put generator back into operation, refill
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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
2 Stale fuel.
2 Drain fuel tank; fill with fresh fuel
3 No engine oil.
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.
8 Dirty spark arrestor screen.
1 No fuel.
Engine suddenly stops.
2 No engine oil.
*
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.
Speed of starter motor
drops after period of time.
1 Battery is losing charge.
1
Recharge battery.
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
HW5500
HW5500E
GENERATOR
*
Dimensions
Length
Width
27 inches (685.8 mm)
21.5 inches (546.1 mm)
21.5 inches (546.1 mm)
185 lb (83.9 kg)
27 inches (685.8 mm)
21.5 inches (546.1 mm)
21.5 inches (546.1 mm)
195 lb (88.4 kg)
Height
Dry Weight
AC Output
Continuous (Rated) Power
5500 Watts
6875 Watts
8250 Watts
60 Hz
5500 Watts
6875 Watts
8250 Watts
60 Hz
Maximum Power
Surge Power
Frequency
Voltage
120/240 Volts
120/240 Volts
Operating Temperature
Maximum
Minimum
104° F (40° C)
-10° F (-23° C)
104° F (40° C)
-10° F (-23° C)
ENGINE
Engine Speed (RPM)
Type
3600
OHV 4-Cycle
337 cc
3600
OHV 4-Cycle
337 cc
Displacement
Fuel Tank Capacity
Engine Oil Capacity
Spark Plug Type
6.5 Gallons (24.6 L)
1.2 qt (1.1 L)
100842A
6.5 Gallons (24.6 L)
1.2 qt (1.1 L)
100842A
0.028-0.031 inches
(0.70-0.80 millimeters)
0.028-0.031 inches
(0.70-0.80 millimeters)
Spark Plug Gap
TABLE 7. HW5500/5500E 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
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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
stopping 17
storing 26
Air Filter
transporting 26
warranty 35
Ground 11
terminal 13
maintenance 23
Appliances
powering 17
wattage information 17
Assembly
battery 10
handle 10
H
wheels 9
Handles
installing 10
High Altitude
operation 17
C
Checklist
generator shipment 5
Components and Controls
breakers 13
M
Maintenance 19
fuel valve 13
cleaning spark arrestor 25
parts listing 39
outlets
Household 13
schedule 19
spark plug 24
Manual (Recoil) Start 16
O
D
E
Operation
Damage
Outlets
Household 13
Engine Oil
P
S
changing 21
Engine Switch 13
F
Fuel
adding 22
draining 27
oxygenated
types 22
recommendations 22
Fuel Sediment Cup
cleaning 24
Safety
labels 3
Spark Arrestor
cleaning 25
Spark Plug
servicing 24
Specifications 31
Storage
G
Generator
location 15
recommendations 26
operation 15
outlets 13
specifications 31
starting 15
T
Transfer Switch
outlet 13
Troubleshooting 29
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HW5500/5500E MAINTENANCE PARTS
To order maintenance parts, visit www.honeywellgenerators.com or call Customer Hotline at 1-888-494-3571.
Part Name
Part Number
Air Cleaner Assembly
Air Filter
100832A
100833A
100834A
100835A
100836A
100838A
100839A
100840A
100841A
100842A
100843A
100844A
100845A
100852A
100846A
100847A
Fuel Cap
Fuel Shut-Off Valve
Fuel Strainer
Ignition Coil
Recoil Assembly
Recoil Rope and Handle
Oil Fill Cap/Dipstick
Spark Plug
Spark Arrestor
Wheel
Wheel Handle Pivot Bracket
Wheel Kit Hardware
Handle Bar
Rubber Handle Grip
100848A (HW5500)
100849A (HW5500E)
Smart Start Card
HW5500/5500E Maintenance Parts List
For part numbers of replacement product labels, see page 3.
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HW5500/5500E – P/N: 100900A
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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