Owners Manual
Page 5
... Stopping Generator ...17 High Altitude Operation ...17 Powering Appliances ...17 MAINTENANCE ...19 Maintenance Schedule ...19 Engine Oil ...20 Adding Fuel ...22 Air Filter Maintenance ...23 Cleaning Fuel Sediment Cup ...24 Spark Plug Service ...24 Cleaning Spark Arrestor Screen ...25 Transporting Generator ...26 Storing Generator ...26 TROUBLESHOOTING ...29 SPECIFICATIONS ...31 WARRANTIES ...33 NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY 33 NORTHSHORE POWER SYSTEMS LIMITED WARRANTY 35 INDEX ...37 HW5500/5500E MAINTENANCE PARTS 39 HW5500/5500E Portable Generator Owner's Manual www...
... Stopping Generator ...17 High Altitude Operation ...17 Powering Appliances ...17 MAINTENANCE ...19 Maintenance Schedule ...19 Engine Oil ...20 Adding Fuel ...22 Air Filter Maintenance ...23 Cleaning Fuel Sediment Cup ...24 Spark Plug Service ...24 Cleaning Spark Arrestor Screen ...25 Transporting Generator ...26 Storing Generator ...26 TROUBLESHOOTING ...29 SPECIFICATIONS ...31 WARRANTIES ...33 NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY 33 NORTHSHORE POWER SYSTEMS LIMITED WARRANTY 35 INDEX ...37 HW5500/5500E MAINTENANCE PARTS 39 HW5500/5500E Portable Generator Owner's Manual www...
Owners Manual
Page 8
... gases. • Let engine cool before filling with governed speed. plies correct rated frequency and voltage when running . Turn generator OFF and allow to cool before storing the generator indoors. 2 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner's Manual Use approved transfer equipment to isolate generator from buildings and other equipment during operation and remains hot for backup power, notify utility company. Fuel and its vapors are...
... gases. • Let engine cool before filling with governed speed. plies correct rated frequency and voltage when running . Turn generator OFF and allow to cool before storing the generator indoors. 2 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner's Manual Use approved transfer equipment to isolate generator from buildings and other equipment during operation and remains hot for backup power, notify utility company. Fuel and its vapors are...
Owners Manual
Page 11
... by using the generator must read and understand 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...
... by using the generator must read and understand 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...
Owners Manual
Page 17
... faulty appliances. • Before using a receptacle tester, it will not show same ground circuit condition as for local codes or ordinances that apply to AC neutral wire. Grounding the Generator Generator must be connected to prevent electrical shock from illustration provided. iNOTE: While engine is running, a small "trickle" charge is not connected to the intended use of generator. HW5500/5500E Portable Generator Owner's Manual www.honeywellgenerators.com 11 fasten...
... faulty appliances. • Before using a receptacle tester, it will not show same ground circuit condition as for local codes or ordinances that apply to AC neutral wire. Grounding the Generator Generator must be connected to prevent electrical shock from illustration provided. iNOTE: While engine is running, a small "trickle" charge is not connected to the intended use of generator. HW5500/5500E Portable Generator Owner's Manual www.honeywellgenerators.com 11 fasten...
Owners Manual
Page 19
Set Tripped Ground Terminal Connects generator to ground wire for engine oil level. Choke control must be removed. K-Fuel Tank Cap Provides a secure seal on operating generator. See page 11. HW5500/5500E Portable Generator Owner's Manual www.honeywellgenerators.com 13 COMPONENTS Use information provided in this section to become familiar with HW5500E models) A-Power Control Center Household Outlets 120V 20 Amp Duplex outlets to connect 120V appliances to generator for power. Breakers Protects circuits from damage caused by overload or short...
Set Tripped Ground Terminal Connects generator to ground wire for engine oil level. Choke control must be removed. K-Fuel Tank Cap Provides a secure seal on operating generator. See page 11. HW5500/5500E Portable Generator Owner's Manual www.honeywellgenerators.com 13 COMPONENTS Use information provided in this section to become familiar with HW5500E models) A-Power Control Center Household Outlets 120V 20 Amp Duplex outlets to connect 120V appliances to generator for power. Breakers Protects circuits from damage caused by overload or short...
Owners Manual
Page 21
... utility lines during a power outage. Check/add engine oil- It is placed on an uneven or flexible surface, generator could ignite. • Place generator on firm, level surface and avoid loose sand or snow. Starting generator with generator. Check/add fuel*-See "Adding Fuel" on page 22. Be sure ground terminal is properly connected to each use generator inside a home Only use and match amp and voltage ratings of generator outlet...
... utility lines during a power outage. Check/add engine oil- It is placed on an uneven or flexible surface, generator could ignite. • Place generator on firm, level surface and avoid loose sand or snow. Starting generator with generator. Check/add fuel*-See "Adding Fuel" on page 22. Be sure ground terminal is properly connected to each use generator inside a home Only use and match amp and voltage ratings of generator outlet...
Owners Manual
Page 23
... a "tripped" breaker. If this manual, the term "appliance" refers to add power rating (watts) of appliance, refer to generator for appliance you will increase. Typical Appliance Running Wattages HW5500/5500E Portable Generator Owner's Manual www.honeywellgenerators.com 17 High Altitude Operation At high altitudes, standard carburetor air-fuel mixture will be connected to appliance operating manuals, or contact appliance manufacturer. Performance will decrease and fuel consumption will need to run appliances using generator to power appliances...
... a "tripped" breaker. If this manual, the term "appliance" refers to add power rating (watts) of appliance, refer to generator for appliance you will increase. Typical Appliance Running Wattages HW5500/5500E Portable Generator Owner's Manual www.honeywellgenerators.com 17 High Altitude Operation At high altitudes, standard carburetor air-fuel mixture will be connected to appliance operating manuals, or contact appliance manufacturer. Performance will decrease and fuel consumption will need to run appliances using generator to power appliances...
Owners Manual
Page 35
...). 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) Engine suddenly stops. 1 No fuel. 2 No engine oil. 1 Add fuel (page 22). 2 Add engine oil (page 20). Have appliance serviced by qualified repair facility. 1 Recharge battery. * Master circuit breaker controls power to death, serious injury, and property damage. TROUBLESHOOTING ANYONE using or servicing generator must read, understand, and follow these instructions can...
...). 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) Engine suddenly stops. 1 No fuel. 2 No engine oil. 1 Add fuel (page 22). 2 Add engine oil (page 20). Have appliance serviced by qualified repair facility. 1 Recharge battery. * Master circuit breaker controls power to death, serious injury, and property damage. TROUBLESHOOTING ANYONE using or servicing generator must read, understand, and follow these instructions can...
Owners Manual
Page 39
... in the Honeywell Generator Owner's Manual, use emissions test. Carburetor C. Exhaust manifold C. Choke system B. The warranty does not cover an emission control part that are not equivalent to original Honeywell generator parts in above systems A. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT US Environmental Protection Agency (EPA) requires manufacturers of small off-road engines (SORE) to warranty their products with the authorized dealer network. 2. In the United States and California, new small off-road...
... in the Honeywell Generator Owner's Manual, use emissions test. Carburetor C. Exhaust manifold C. Choke system B. The warranty does not cover an emission control part that are not equivalent to original Honeywell generator parts in above systems A. WARRANTIES NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator WARRANTY STATEMENT US Environmental Protection Agency (EPA) requires manufacturers of small off-road engines (SORE) to warranty their products with the authorized dealer network. 2. In the United States and California, new small off-road...
Owners Manual
Page 41
... of the customer. For warranty service, customer should locate an authorized Honeywell Generator Dealer from state to an authorized Honeywell Generator Dealer. Repair or replacement pursuant to : Northshore Power Systems, LLC Attention: Product Warranty and Service Dept. 4425 N Port Washington Road Suite 105 Milwaukee WI 53212-1082 HW5500/5500E Portable Generator Owner's Manual www.honeywellgenerators.com 35 DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS This warranty gives you specific legal rights, and you...
... of the customer. For warranty service, customer should locate an authorized Honeywell Generator Dealer from state to an authorized Honeywell Generator Dealer. Repair or replacement pursuant to : Northshore Power Systems, LLC Attention: Product Warranty and Service Dept. 4425 N Port Washington Road Suite 105 Milwaukee WI 53212-1082 HW5500/5500E Portable Generator Owner's Manual www.honeywellgenerators.com 35 DISCLAIMERS, LIMITATIONS OF REMEDIES & EXCLUSIONS This warranty gives you specific legal rights, and you...
Service Manual
Page 8
... of an emissions control part caused by Northshore Power Systems. OWNER'S RESPONSIBILITIES You are warranted for a period of purchase for repairs as soon as being part of add-on your nearest dealer; a listing is not related to original Honeywell generator parts in the Honeywell Generator Owner's Manual, use emissions test. Fuel Metering System A. Choke system C. Clamps D. Fuel pump (if equipped) G. Intake manifold C. Ignition System A. Air Injection System A. Fuel cap C. Hoses, belts, connectors, valves, and assemblies B. Claims. Warranty claims shall be...
... of an emissions control part caused by Northshore Power Systems. OWNER'S RESPONSIBILITIES You are warranted for a period of purchase for repairs as soon as being part of add-on your nearest dealer; a listing is not related to original Honeywell generator parts in the Honeywell Generator Owner's Manual, use emissions test. Fuel Metering System A. Choke system C. Clamps D. Fuel pump (if equipped) G. Intake manifold C. Ignition System A. Air Injection System A. Fuel cap C. Hoses, belts, connectors, valves, and assemblies B. Claims. Warranty claims shall be...
Service Manual
Page 10
.... WARRANTIES NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY Honeywell Portable Generator For a period of 90 days from the date of sale or installation of a Northshore Power Systems, LLC supplied part, Northshore Power Systems will, at Northshore Power Systems's sole discretion. TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, NORTHSHORE POWER SYSTEMS SHALL NOT, IN ANY EVENT, BE LIABLE FOR INCIDENTAL, COMPENSATORY, PUNITIVE, CONSEQUENTIAL, INDIRECT, SPECIAL OR OTHER DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF USE, LOSS...
.... WARRANTIES NORTHSHORE POWER SYSTEMS REPLACEMENT PARTS LIMITED WARRANTY Honeywell Portable Generator For a period of 90 days from the date of sale or installation of a Northshore Power Systems, LLC supplied part, Northshore Power Systems will, at Northshore Power Systems's sole discretion. TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, NORTHSHORE POWER SYSTEMS SHALL NOT, IN ANY EVENT, BE LIABLE FOR INCIDENTAL, COMPENSATORY, PUNITIVE, CONSEQUENTIAL, INDIRECT, SPECIAL OR OTHER DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF USE, LOSS...
Service Manual
Page 16
... Honeywell Portable Electrical Generator Service Manual OFF Bu G/W Bl Y/G Bl/W Bl IG E Bu Y/G G/W ON START Bl - White Bl/W ENGINE CONTROL SWITCH ON/OFF SWITCH PANEL CONTROL PANEL THERMAL AC BREAKER 20A THERMAL AC BREAKER 20A W X W Y G DUPLEX 5-20R G DUPLEX 5-20R W X W Y G G Y/G W X Y TWIST-LOCK L14-30R G GROUND TERMINAL Green / White Lg - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www.honeywellgenerators.com ENGINE CHARGE COIL BATTERY STARTER MOTOR FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG...
... Honeywell Portable Electrical Generator Service Manual OFF Bu G/W Bl Y/G Bl/W Bl IG E Bu Y/G G/W ON START Bl - White Bl/W ENGINE CONTROL SWITCH ON/OFF SWITCH PANEL CONTROL PANEL THERMAL AC BREAKER 20A THERMAL AC BREAKER 20A W X W Y G DUPLEX 5-20R G DUPLEX 5-20R W X W Y G G Y/G W X Y TWIST-LOCK L14-30R G GROUND TERMINAL Green / White Lg - WIRING DIAGRAMS HW5500E & HW5500EL 3-6 FIGURE 3-4: HW5500E & HW5500EL Wiring Diagram www.honeywellgenerators.com ENGINE CHARGE COIL BATTERY STARTER MOTOR FUEL CUTOUT SOLENOID OIL SHUTDOWN SWITCH OIL ALERT SENDER SPARK PLUG...
Service Manual
Page 19
... Canister (Model numbers ending in fuel tank. Master circuit breaker controls power to ground wire for electric start models) • STOP-Stops generator engine by stopping the flow of electricity from fuel tank to the appliance. Muffler reaches temperatures that can be moved to manually start models); Indicates engine is no power at outlets, see TROUBLESHOOTING, page 8-1. K-Fuel Gage Indicates level of fuel from the generator to carburetor. B-Battery Tray and Battery (Electric start models only) Provides power for grounding protec- C-Oil Fill...
... Canister (Model numbers ending in fuel tank. Master circuit breaker controls power to ground wire for electric start models) • STOP-Stops generator engine by stopping the flow of electricity from fuel tank to the appliance. Muffler reaches temperatures that can be moved to manually start models); Indicates engine is no power at outlets, see TROUBLESHOOTING, page 8-1. K-Fuel Gage Indicates level of fuel from the generator to carburetor. B-Battery Tray and Battery (Electric start models only) Provides power for grounding protec- C-Oil Fill...
Service Manual
Page 25
... servicing dealer for /clean debris X Check engine oil level X Change engine oil X X Check air filter X Clean air filter X† Run engine Clean/change spark plug X‡ X Clean fuel sediment cup X Clean spark arrestor X Clean cylinder cooling fins X** Check/adjust valve lash X** Check fuel line TABLE 7-1. NOTICE Maintenance, replacement, or repair of generator can be sure the area is run , be seriously hurt or killed. Also disconnect both starting of the emission control devices and systems...
... servicing dealer for /clean debris X Check engine oil level X Change engine oil X X Check air filter X Clean air filter X† Run engine Clean/change spark plug X‡ X Clean fuel sediment cup X Clean spark arrestor X Clean cylinder cooling fins X** Check/adjust valve lash X** Check fuel line TABLE 7-1. NOTICE Maintenance, replacement, or repair of generator can be sure the area is run , be seriously hurt or killed. Also disconnect both starting of the emission control devices and systems...
Service Manual
Page 27
... system until the required amount of engine fill hole. The engine control switch will not start until sufficient oil is very important to maintain proper level of used motor oil according to guidelines established by an oil shutdown switch. Crankcase pressure can cause hot engine oil to release plastic tabs. Honeywell Portable Electrical Generator Service Manual FIGURE 7-2: Air Cleaner Cover-Model Numbers Ending in good running . 2. AIR FILTER MAINTENANCE ENGINE OIL RECOMMENDATIONS NOTICE Engine oil is too low...
... system until the required amount of engine fill hole. The engine control switch will not start until sufficient oil is very important to maintain proper level of used motor oil according to guidelines established by an oil shutdown switch. Crankcase pressure can cause hot engine oil to release plastic tabs. Honeywell Portable Electrical Generator Service Manual FIGURE 7-2: Air Cleaner Cover-Model Numbers Ending in good running . 2. AIR FILTER MAINTENANCE ENGINE OIL RECOMMENDATIONS NOTICE Engine oil is too low...
Service Manual
Page 28
...: Air Filter Plate Installation-Non-L Models (air filter plate shape varies by model) For Non-L Models: 9A. FIGURE 7-7: Oil Air Filter 8. Remove foam air filter(s). FIGURE 7-8: Excess Oil Removal CAUTION Frequent or prolonged contact with soap and water. 7-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NOTE: Engine will smoke during initial start-up if too much oil is left in the support brackets if it fell out during air filter removal. FIGURE 7-6: Dry Air Filter...
...: Air Filter Plate Installation-Non-L Models (air filter plate shape varies by model) For Non-L Models: 9A. FIGURE 7-7: Oil Air Filter 8. Remove foam air filter(s). FIGURE 7-8: Excess Oil Removal CAUTION Frequent or prolonged contact with soap and water. 7-4 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual NOTE: Engine will smoke during initial start-up if too much oil is left in the support brackets if it fell out during air filter removal. FIGURE 7-6: Dry Air Filter...
Service Manual
Page 42
... Replace Battery Check Voltage Across Components Check Battery Connections Check Leads on Side of Spec Components Check Engine Control Switch Voltage Drop in Off Position Check Air Cleaner Check Ignition for Spark Check Spark Plug & Gap Check Fuel Line & Blockage Check Carburetor Check Spark Arrestor Check Muffler Blockage Check Valve Adjustment Perform Engine Compression Test Recoil Not Operating Recoil Locked = Disassemble and Repair Recoil (see Manual Section "Recoil Starter") 8-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual...
... Replace Battery Check Voltage Across Components Check Battery Connections Check Leads on Side of Spec Components Check Engine Control Switch Voltage Drop in Off Position Check Air Cleaner Check Ignition for Spark Check Spark Plug & Gap Check Fuel Line & Blockage Check Carburetor Check Spark Arrestor Check Muffler Blockage Check Valve Adjustment Perform Engine Compression Test Recoil Not Operating Recoil Locked = Disassemble and Repair Recoil (see Manual Section "Recoil Starter") 8-10 www.honeywellgenerators.com Honeywell Portable Electrical Generator Service Manual...
Service Manual
Page 49
... for leaks after installation. C-DRAIN SCREW Clean with compressed air before installation. I H A B G F C D E Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-7 I - D-SET BOLT Check for correct installation. G-MAIN NOZZLE Clean with compressed air before installation. F-MAIN JET Clean with compressed air before installation. E-FUEL CUTOUT SOLENOID Check continuity between the double green wires of vapor. H-O-RING Check for any sign of fuel leakage after installation. CARBURETOR 9.7 CARBURETOR WARNING Fuel and its vapors...
... for leaks after installation. C-DRAIN SCREW Clean with compressed air before installation. I H A B G F C D E Honeywell Portable Electrical Generator Service Manual www.honeywellgenerators.com 9-7 I - D-SET BOLT Check for correct installation. G-MAIN NOZZLE Clean with compressed air before installation. F-MAIN JET Clean with compressed air before installation. E-FUEL CUTOUT SOLENOID Check continuity between the double green wires of vapor. H-O-RING Check for any sign of fuel leakage after installation. CARBURETOR 9.7 CARBURETOR WARNING Fuel and its vapors...
Service Manual
Page 55
... 9-2 evaporative emissions control system 9-5 fan cover 9-10 fuel tank system 9-4 muffler 9-6 preparing for 5-1 recoil starter 9-9 starting system 9-8 wheel, leg, & handle assembly 9-11 Service Repair Time 6-1 Spark Arrestor 4-1, 7-6, 9-6 Spark Plug 4-1, 7-5 Specifications 3-1 T Tools, Service 5-1 Torque Information 3-2 Transporting Generator 5-1 Troubleshooting 8-1 V Valve Lash 7-7 Voltage Regulator 8-5, 8-9, 9-3 W Warranty emissions control 2-2 limited 2-1 replacement parts 2-4 Wheel, Leg, & Handle Assembly 9-11 Wiring Diagrams 3-3 Honeywell Portable Electrical Generator Service Manual www...
... 9-2 evaporative emissions control system 9-5 fan cover 9-10 fuel tank system 9-4 muffler 9-6 preparing for 5-1 recoil starter 9-9 starting system 9-8 wheel, leg, & handle assembly 9-11 Service Repair Time 6-1 Spark Arrestor 4-1, 7-6, 9-6 Spark Plug 4-1, 7-5 Specifications 3-1 T Tools, Service 5-1 Torque Information 3-2 Transporting Generator 5-1 Troubleshooting 8-1 V Valve Lash 7-7 Voltage Regulator 8-5, 8-9, 9-3 W Warranty emissions control 2-2 limited 2-1 replacement parts 2-4 Wheel, Leg, & Handle Assembly 9-11 Wiring Diagrams 3-3 Honeywell Portable Electrical Generator Service Manual www...