Honeywell HW4000 - Portable Generator NOT User manual

HW4000
HW4000L
Owner’s Manual
Portable Electrical Generator
Manual del Propietario
For product inquiries or support, visit www.honeywellgenerators.com or call
toll-free at 1-888-HWHELP1 (494-3571).
Si tiene preguntas acerca de los productos o requiere de asistencia, visite
www.honeywellgenerators.com o llame gratis al 1-888-HWHELP1 (494-3571).

Congratulations on owning a Honeywell portable generator!
Please use the spaces provided below to record important information about your generator. You may be asked to
provide this information should you require product service or support.
Identification information specific to your generator (model number and serial number) can be found on the genera-
tor nameplate.
This manual contains important instructions for operating this generator. For your safety and the
safety of others, be sure to read this manual thoroughly before operating the generator. Failure to
properly follow all instructions and precautions can cause you and others to be seriously hurt or
killed.
FIGURE 1: Generator Nameplate Location
Date of Purchase:
Store/Dealer Purchased From:
Generator Model Number:
Generator Serial Number:
WARNING
Model Number Phase
Part Number
AC Voltage
Serial Number
Fuel Frequency
Power Output Engine RPM
HW4000L Model HW4000 Model
Northshore Power Systems, LLC
4425 N. Port Washington Rd., Suite 105
Milwaukee, WI 53212-1082 USA
TEL 1-888-HWHELP1 (494-3571)
www.honeywellgenerators.com
© 2009 Northshore Power Systems, LLC
The Honeywell Trademark is used under license from
Honeywell International Inc.
Honeywell International Inc. makes no representations or
warranties with respect to this product.

PRODUCT REGISTRATION
To register your product, please complete the information below and mail to the address at the end of the form or register
online at www.honeywellgenerators.com. 18-digit serial number must be completed in order for warranty to be acti-
vated.
1 - PERSONAL INFORMATION
2 - PRODUCT INFORMATION
FIRST NAME
LAST NAME
CHECK HERE TO RECEIVE ANNUAL MAINTENANCE REMINDERS AND SPECIAL OFFERS FROM HONEYWELL
GENERATORS
CHECK HERE TO RECEIVE INFORMATION FROM OTHER COMPANIES VIA EMAIL, UNDERSTANDING YOUR
EMAIL ADDRESS MAY BE SHARED OR COMBINED WITH INFORMATION FROM OTHER SOURCES
DATE OF PURCHASE:
MM DD YYYY
//
*MODEL NUMBER:
*SERIAL NUMBER (18-digits):
PURCHASE LOCATION:
IN-STORE
ONLINE
STORE NAME:
PURCHASE PRICE: $___________.00
FEATURES INFLUENCING PRODUCT PURCHASE:
BRAND REPUTATION EASE OF USE
PORTABILITY SIZE / WEIGHT
POWER RATING STYLE/APPEARANCE
PRICE WARRANTY
HOW DID YOU BECOME AWARE OF THIS PRODUCT?
IN-STORE RADIO/TV
INTERNET STORE CIRCULAR
PRINT WORD OF MOUTH
OTHER BRANDS CONSIDERED WHEN SHOPPING
FOR THIS PRODUCT:
PRIMARY USE FOR PRODUCT:
TOOL POWER
RECREATION POWER
EMERGENCY POWER
PRIMARY LOCATION FOR PRODUCT USE:
HOME
WORK
TYPE OF WORK, IF PRODUCT BEING USED FOR
PROFESSION:
WHAT OTHER TYPE OF POWER EQUIPMENT ARE
YOU INTERESTED IN PURCHASING IN THE FUTURE?
WHO DECIDED TO PURCHASE THIS PRODUCT?
STREET ADDRESS
CITY, STATE, ZIP
COUNTRY
PHONE
EMAIL
*Found on nameplate of generator

3 - DEMOGRAPHIC INFORMATION
GENDER:
MALE
FEMALE
MARITAL STATUS:
MARRIED
SINGLE
DATE OF BIRTH:
MM DD YYYY
//
INCLUDING YOURSELF, HOW MANY PEOPLE LIVE IN
YOUR HOUSEHOLD:
NUMBER OF CHILDREN UNDER 18 LIVING IN YOUR
HOUSEHOLD:
PRIMARY RESIDENCE:
OWN
RENT
EDUCATION:
SOME HIGH SCHOOL
HIGH SCHOOL DIPLOMA
COLLEGE DEGREE
GRADUATE DEGREE
THANK YOU FOR REGISTERING YOUR PRODUCT. THE INFORMATION YOU PROVIDED MAY BE USED
FOR MARKETING PURPOSES IN ORDER TO OFFER YOU VARIOUS PRODUCT INFORMATION AND
OFFERS.
CHECK HERE IF YOU DO NOT WISH TO BE CONTACTED ABOUT SPECIAL OFFERS.
PLEASE RETURN THIS FORM TO THE FOLLOWING ADDRESS:
Northshore Power Systems, LLC
4425 N Port Washington Road
Suite 105
Milwaukee, WI 53212-1082
PLEASE MAIL THIS FORM IN A SEALED ENVELOPE. DO NOT STAPLE.
HOUSEHOLD INCOME:
LESS THAN $15,000 $100,000 - $124,999
$15,000 - $29,999 $125,000 - $149,999
$30,000 - $49,999 $150,000 - $174,999
$50,000 - $79,999 $175,000 - $199,999
$80,000 - $99,999 $200,000 OR OVER
PRIMARY METHOD OF PURCHASING HOUSEHOLD
ITEMS:
IN-STORE
ONLINE
TV
MAIL ORDER
TYPES OF CREDIT CARDS HELD BY HOUSEHOLD
MEMBERS:
VISA / MASTERCARD
DISCOVER
AMERICAN EXPRESS
GAS / RETAIL
OTHER
NONE
HOUSEHOLD INTERESTS:
HOME IMPROVEMENT
AUTOMOTIVE WORK
CAMPING
OTHER

HW4000/HW4000L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com i
CONTENTS
IMPORTANT SAFETY RULES ............................................................................................ 1
Safety Messages .........................................................................................................................................1
Location of Important Labels .......................................................................................................................3
GETTING STARTED ......................................................................................................... 5
Unpacking Guidelines ..................................................................................................................................5
Record Generator Information .....................................................................................................................5
Assembly .....................................................................................................................................................6
Grounding the Generator ...........................................................................................................................10
Using Generator for Back-up Power ..........................................................................................................10
COMPONENTS ............................................................................................................... 11
OPERATION ................................................................................................................... 13
Generator Location ....................................................................................................................................13
Preparing for Operation .............................................................................................................................13
Stopping Generator ...................................................................................................................................15
High-Altitude Operation .............................................................................................................................15
Powering Appliances .................................................................................................................................15
MAINTENANCE .............................................................................................................. 17
Maintenance Schedule ..............................................................................................................................17
Engine Oil ..................................................................................................................................................18
Engine Fuel ...............................................................................................................................................20
Air Filter Maintenance ................................................................................................................................21
Cleaning Fuel Sediment Cup .....................................................................................................................23
Spark Plug Service ....................................................................................................................................23
Cleaning Spark Arrestor Screen ................................................................................................................24
Transporting Generator .............................................................................................................................25
Storing Generator ......................................................................................................................................25
TROUBLESHOOTING .................................................................................................... 27
SPECIFICATIONS ........................................................................................................... 29
WARRANTIES ................................................................................................................ 31
NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY .............................................31
NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY ...........................................32
INDEX .............................................................................................................................. 35
MAINTENANCE PARTS ................................................................................................. 37

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ii www.honeywellgenerators.com HW4000/HW4000L Portable Electrical Generator Owner’s Manual

HW4000/HW4000L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 1
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY RULES
NOTE:
Since there are many variations in the circumstances sur-
rounding the installation, operation, service, and mainte-
nance of this generator, we cannot possibly anticipate or
provide advice or safety messages to cover every situa-
tion.
Safety Messages
Signal Words
Safety messages are provided throughout this manual to
help prevent personal injury and equipment damage. All
safety messages are introduced by a signal word indicat-
ing the hazard level.
Hazard Symbols and Meanings
In addition to the signal words, the following symbols may
be used to draw your attention to specific types of haz-
ards.
ANYONE using or servicing this generator must read, understand, and follow all safety and operation instructions pro-
vided in the product manual. Failure to closely follow these instructions can result in circumstances leading to death,
serious injury, and property damage.
WARNING
Indicates an imminently hazardous situa-
tion which, if not avoided, will result in
death or serious injury to the operator or
to bystanders.
Indicates a potentially hazardous situa-
tion which, if not avoided, could result in
death or serious injury to the operator or
to bystanders.
Indicates a potentially hazardous situa-
tion which, if not avoided, may result in
moderate or minor injury to the operator
or to bystanders.
Indicates a situation which, if not avoided,
may result in damage to the generator
components.
DANGER
WARNING
CAUTION
NOTICE
Explosion Toxic fumes Fire
Chemical burn
Electrical shock
Hot surface
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a poi-
son you cannot see or smell.
NEVER use inside a home
or garage, EVEN IF doors
and windows are open.
Only use OUTSIDE and far
away from windows, doors, and
vents.
+
DANGER

Safety Messages
2www.honeywellgenerators.com HW4000/HW4000L Portable Electrical Generator Owner’s Manual
Electric Shock Hazards
Fire and Burn Hazards
Medical and Life Support Uses
Generator Damage Hazards
Generator produces powerful voltage that can cause
death or great physical harm.
•When using generator for back-up power, notify the
utility company. Use approved transfer equipment to
isolate generator from electric utility.
•NEVER connect to a building's electrical system
unless a transfer switch has been installed by a qual-
ified electrician.
•NEVER touch bare wires or receptacles.
•NEVER use generator with electrical cords that are
worn, frayed, bare, or otherwise damaged.
•NEVER operate generator in rain or snow, or when
the generator is set on wet surface.
Fuel and its vapors are extremely flammable and
explosive under certain conditions.
•Refuel generator only outdoors, in a well-ventilated
area.
•NEVER enclose the generator in any structure.
•Keep generator at least 6 feet (2 meters) away from
buildings, other equipment, and combustible materi-
als during operation.
•NEVER fill fuel tank while the engine is running. Turn
generator OFF and allow to cool before filling with
fuel.
•NEVER smoke or allow flames or sparks near the
generator or where gasoline is stored.
•NEVER overfill the fuel tank (there should be no fuel
in the filler neck). After refueling, make sure the tank
cap is closed properly and securely.
•Be careful not to spill fuel when refueling. Spilled fuel
or fuel vapor may ignite. If any fuel is spilled, be sure
the area is dry before starting the engine.
•Avoid repeated or prolonged contact with skin or
breathing of vapor.
The muffler becomes very hot during operation and
remains hot for a while after stopping the engine.
•NEVER touch hot surfaces and avoid hot gases.
•Let engine cool before storing the generator indoors.
WARNING
WARNING
WARNING
•In case of emergency, call 911 immediately.
•NEVER use this product to power life support
devices or life support appliances.
•NEVER use this product to power medical devices or
medical appliances.
•Inform your electricity provider immediately if you or
anyone in your household depends on electrical
equipment to live.
•Inform your electrical provider immediately if a loss
of power would cause you or anyone in your house-
hold to experience a medical emergency.
NOTICE
Improper treatment or misuse of generator can cause per-
manent damage.
•NEVER modify generator in any way.
•NEVER tamper with governed speed. Generator
supplies correct rated frequency and voltage when
running at governed speed.
•Damage to generator caused by misuse or modifica-
tion is not covered under Warranty.
WARNING

HW4000/HW4000L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 3
Location of Important Labels
Location of Important Labels
Your generator has several labels which provide important safety and maintenance information. Samples of these labels are
provided below. Should any of these labels become illegible or damaged, call 1-888-HWHELP1 (494-3571) for replacements.
FIGURE 2: Label Locations
PRODUCT LABEL PART NUMBER
A100884A (HW4000 Model)
101796A (HW4000L Model)
B100886A
C100887A
D100883A
E100879B
F100882A
G100885A
H100881A
A
C
B
D
E
F
A
G
H
NEVER FUEL UNIT WITH ENGINE RUNNING.
ALWAYS FUEL UNIT IN WELL VENTILATED AREA.
ALWAYS CLEAN FUEL SPILLS.
ALWAYS ALLOW UNIT TO COOL BEFORE FUELING.
FUEL
CUTOUT NUNCA LLENE LA UNIDAD DE COMBUSTIBLE
CON EL MOTOR PRENDIDO.
SIEMPRE LLENE LA UNIDAD EN UN ÁREA
BIEN VENTILADA.
SIEMPRE LIMPIE CUALQUIER DERRAME
DE COMBUSTIBLE.
SIEMPRE DEJE QUE LA UNIDAD SE ENFRÍE
ANTES DE LLENARLA DE COMBUSTIBLE.
WARNING
ADVERTENCIA
FUEL
NEVER FUEL UNIT WITH ENGINE RUNNING.
ALWAYS FUEL UNIT IN WELL VENTILATED AREA.
ALWAYS CLEAN FUEL SPILLS.
ALWAYS ALLOW UNITTO COOL BEFORE FUELING.
WARNING
NUNCA LLENE LA UNIDAD DE COMBUSTIBLE
CON EL MOTOR PRENDIDO.
SIEMPRE LLENE LA UNIDAD EN UN ÁREA BIEN VENTILADA.
SIEMPRE LIMPIE CUALQUIER DERRAME DE COMBUSTIBLE.
SIEMPRE DEJE QUE LA UNIDAD SE ENFRÍE ANTES
DE LLENARLA DE COMBUSTIBLE.
ADVERTENCIA
CUTOUT
p/n101796A
USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES.
GENERATOR EXHAUST CONTAINS CARBON MONOXIDE.
THIS IS A POISON YOU CANNOT SEE OR SMELL.
USAR EL GENERATOR EN INTERIORES
LO PUEDE MATAR EN MINUTOS.
EL ESCAPE DEL GENERATOR CONTIENE
MONÓXIDO DE CARBONO.
ESTE GAS ES UN VENENO QUE NO SE
PUEDE VER NI OLER.
NUNCA USE EL GENERADOR DENTRO
DEL HOGAR O EL GARAJE, AÚN SI LAS
PUERTAS Y VENTANAS ESTÁN ABIERTAS.
SOLO USELO EN EXTERIORES Y LEJOS
DE VENTILACIONES, PUERTAS Y
VENTANAS ABIERTAS.
DANGER PELIGRO
ONLY USE OUTSIDE AND
FAR AWAY FROM WINDOWS,
DOORS, AND VENTS.
NEVER USE INSIDE A HOME
OR GARAGE, EVEN IF DOORS
AND WINDOWS ARE OPEN.
ON
OFF
Clean up in cleansing solvent and dry up
once every 50 hours (every 10 hours in
unusually dusty circumstances) and then
immerse in clean engine oil until
saturated. Squeeze out excessive oil.
MAINTAIN AIR CLEANER MANTENGA EL FILTRO DE AIRE
Límpielo segun las instrucciones en el manual del
usuario y séquelo una vez cada 50 horas (o cada 10
horas en condiciones cuando haya mucho polvo)
entonces sumérjalo en aceite de motor limpio hasta
saturarse, exprima el aceite de sobra.
ON
OFF
HOT
SURFACES SUPERFICIES CALIENTES
WARNING ADVERTENCIA

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HW4000/HW4000L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 5
GETTING STARTED
Use the information in this section to get your generator ready for operation.
Unpacking Guidelines
1. Set carton on a rigid, flat surface.
2. Remove carton contents.
3. Verify all of the following items are included in the generator package:
HW4000/HW4000L Portable Electrical Generator
Wheel Kit (including handle assembly and assembly hardware)
1 L Engine Oil
Funnel
Owner’s Manual
Smart Start Instruction Card
Inspect for Damage
Carefully inspect generator for any damage that may have occurred during shipment. If loss or damage is noted after
delivery, separate damaged materials and call the Customer Hotline at 1-888-HWHELP1 (494-3571).
Record Generator Information
Write down the identification information specific to your generator in the spaces provided on the inside cover of this
Owner’s Manual. This information is located on the generator nameplate (see illustration below).
ANYONE using this generator must read, understand, and follow all safety and operation instructions provided in the
product manual. Failure to closely follow these instructions can result in circumstances leading to death, serious injury,
and property damage.
Generator is heavy! Lifting generator can cause back or other bodily injury. NEVER lift generator without assistance.
The Smart Start instruction card is NOT intended to replace information provided in this Owner’s Manual. Be sure to
thoroughly read and understand all information provided in Owner’s Manual before operating generator. Failure to prop-
erly follow all instructions and precautions can cause you and others to be seriously injured or killed.
FIGURE 3: Generator Nameplate Location
WARNING
CAUTION
WARNING
Model Number Phase
Part Number
AC Voltage
Serial Number
Fuel Frequency
Power Output Engine RPM
HW4000L Model
HW4000 Model

Assembly
6www.honeywellgenerators.com HW4000/HW4000L Portable Electrical Generator Owner’s Manual
Assembly
Wheel Kit
NOTE:
In order to install support legs and wheel assembly, you will need to either tilt generator on its side or elevate generator
by placing solid wood pieces underneath unit.
Generator must be empty of engine oil and fuel. Drain engine oil and fuel, if necessary.
Generator is heavy! Lifting generator can cause back or other bodily injury. NEVER lift generator without
assistance.
FIGURE 5: Wheel Assembly Components
NOTICE
• NEVER USE wheel kit on-road.
• Wheel kit is intended to be used specifically with this generator. NEVER use wheel kit for any other purpose.
CAUTION

HW4000/HW4000L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 7
Assembly
Step 1: Install Support Legs
1. Place the generator on a flat, level surface.
2. Stand at side of generator opposite recoil starter
handle. Grip frame; carefully pull up and push to tilt
generator backward.
3. Gently set generator onto the recoil side.
4. Place 5/16" washer in the center of each rubber stop-
per.
5. Attach a rubber stopper to the bottom of each support
leg using a 25 mm full-thread hex bolt and a 13 mm
flange serrated nut; tighten until securely seated.
6. Attach each support leg to pre-drilled holes on bottom
of generator frame, using 16 mm full-thread hex bolts
and 13 mm flange serrated nuts; tighten until securely
seated.
To install support legs, you will need:
25 mm full-thread hex bolts (2)
5/16" washers (2)
13 mm flange serrated nuts (6)
16 mm full-thread hex bolts (4)
Socket wrench with 10 mm socket*
* Not included
Brackets (2)
Rubber stopper (2)
Generator must be empty of engine oil and fuel.
Drain engine oil and fuel, if necessary.
Generator is heavy! Lifting generator can cause
back or other bodily injury. NEVER lift generator
without assistance.
FIGURE 6: Tip onto Generator Recoil Side
CAUTION
FIGURE 7: Rubber Stopper Attachment to Support Leg
FIGURE 8: Support Leg Attachment to Generator

Assembly
8www.honeywellgenerators.com HW4000/HW4000L Portable Electrical Generator Owner’s Manual
Step 2: Install Wheel Axle and Wheels
1. Install wheel axle brackets to frame using 16 mm full-
thread hex bolts and 13 mm flange serrated nuts.
1A. Install pre-attached bracket to frame first.
1B. Install other bracket (included in hardware bag) to
frame.
On each end of axle:
2. Slide 9/16" washer onto axle.
3. Slide and push wheel onto axle until it fits snug
against washer.
4. Slide second 9/16" washer onto axle.
5. Slide cotter pin into pre-drilled hole until fully seated.
6. Using needle-nose pliers, bend each end of cotter pin
in opposing directions to secure wheel to axle.
7. Return generator to upright position (so that wheels
and leg supports are touching the ground).
To install wheel assembly, you will need:
Wheel axle (1)
16 mm full-thread hex bolts (4)
13 mm flange serrated nuts (4)
Axle bracket*(1)
* Two brackets are needed to install wheel axle. One bracket
comes already attached to wheel axle; other bracket is included
in wheel kit hardware bag.
Wheels (2)
9/16" washers (4)
Cotter pins (2)
Socket wrench with 10 mm socket†
† Not included.
Needle-nose pliers†
FIGURE 9: Wheel Axle Attached to Generator
FIGURE 10: Slide Wheel onto Wheel Axle
FIGURE 11: Cotter Pin Installation

HW4000/HW4000L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 9
Assembly
Step 3: Install Handle Assembly
1. Hold handle bracket over pre-drilled holes on frame
as shown in Figure 12.
2. Attach bracket to frame using 40 mm flange-head hex
bolts and 10 mm flange serrated nuts and tighten.
3. Slide handle bar through center of each bracket and
line up bolt holes.
4. Attach handle to each bracket using 40 mm flange-
head hex bolt and 10 mm flange serrated nut to hole
closest to handle and tighten.
NOTE:
Handle should stick straight out after tightening bolts and
nuts. If handle seems to hang down, tighten bolts and
nuts further.
5. Attach chain to handle bracket as illustrated below.
Insert pin through bracket and handle.
6. Slide rubber handle grip onto each handle bar and
push to achieve snug fit.
Once properly installed, the handles can be collapsed, if
desired, by removing the pins.
•To collapse handles, remove pins and push firmly
down on handle until it rests vertically against genera-
tor frame.
•To return handles to horizontal position, pull up on
handle and lock with pins.
To install handle assembly, you will need:
Handle brackets (2)
Handle bars (2)
Pin and chain (2)
Rubber handle grips (2)
M6 X 40 X 8 mm flange-head hex bolts (6)
10 mm flange serrated nuts (6)
Socket wrench with 8 mm socket*
* Not included
10 mm open end wrench*
FIGURE 12: Handle Bracket to Frame
FIGURE 13: Insert Handle Bar to Bracket
RUN
STOP
FIGURE 14: Attach pin and chain
Hands and fingers can be pinched from collapsible
handles.
• Keep hands and fingers clear from hinges when
collapsing generator handles.
• Handles should only be used to roll the generator to a
new location. If lifting the generator (i.e. into a vehicle),
never use the handles to support the complete weight
of the generator.
CAUTION

Grounding the Generator
10 www.honeywellgenerators.com HW4000/HW4000L Portable Electrical Generator Owner’s Manual
Grounding the Generator
The National Electric Code (NEC) requires the generator
to be connected to an earth ground. Before using the gen-
erator, connect a copper wire (minimum 10 AWG) from the
ground terminal (see Figure 15) to an earth ground. Con-
sult a licensed electrician for proper grounding methods.
NOTE:
The generator has a floating neutral which means the
ground terminal on the generator is not connected to AC
neutral wire in the generator. If using a receptacle tester, it
will not show the same ground circuit condition as for a
home receptacle.
Special Requirements
There may be Federal or State Occupational Safety and
Health Administration (OSHA) regulations, local codes, or
ordinances that apply to the intended use of generator.
Please consult a qualified electrician, electrical inspector,
or the local agency having jurisdiction.
•In some areas, generators are required to be regis-
tered with local utility companies.
•If generator is used at a construction site, there may
be additional regulations which must be observed.
Using Generator for Back-up Power
The NEC requires any generator connected to a building’s
electrical wiring utilize a transfer switch installed by a
licensed electrician.
Generator must be grounded to prevent electrical
shock from faulty appliances.
• Before using generator, consult a qualified electrician,
electrical inspector, or local agency having jurisdiction
for local codes or ordinances that apply to the intended
use of generator.
FIGURE 15: Ground Terminal
WARNING
Before connecting to a building’s electrical system, consult
your local utility company or a qualified electrician.
Improper connections to a building's electrical system can
be deadly.
Electrical current from generator can feedback into
utility lines. Such feedback may electrocute utility
company workers or others who contact utility lines
during a power outage.
Electrical current can feedback into generator. When
utility power is restored, generator may explode,
burn, or cause fires in building's electrical system.
What is a transfer switch?
A transfer switch is a device that allows switching
from utility power to emergency generator power.
The transfer switch is either a manual switch, an
automatic switch, or a combination of manual and
automatic. During a power outage, the transfer
switch isolates emergency circuits from the utility
line, allowing for efficient operation of the generator
without back-feeding into utility power.
DANGER

HW4000/HW4000L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 11
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” on page 13 for instructions on
operating the generator.
FIGURE 16: HW4000L Portable Generator
CAUTION
J
E
H
G
D
B
C
A
I
F
L
K
M
A—Power Control Center
Household Outlets
120V 20 Amp Duplex (NEMA 5-20R)
outlets to connect 120V appliances
to generator for power.
Generator Cord/ Transfer Switch
120V 20 Amp Twist-Lock outlet can
be used to:
•Power 240V appliances using
appropriate (NEMA L14-20R)
power cord (not included).
•Connect a transfer switch to building’s main electrical sys-
tem for back-up power (see page 10).
Breakers
Protects circuits from damage caused by
overload or short-circuit by stopping the flow
of electricity from the generator to the appli-
ance. Master circuit breaker controls power
to all outlets. If there is no power at outlets,
see Troubleshooting section.
Ground Terminal
Connects generator to ground wire for grounding protection.
B—Engine Oil Fill Cap/Dipstick
Seals off engine oil fill hole and provides indicator for engine
oil level.
C—Engine Oil Plug
When loosened, allows engine oil to drain from generator.
D—Engine Control Switch
Control used to run and stop the engine. Engine switch has
two positions:
•RUN—Prepares engine to start
•STOP—Stops generator engine
E—Recoil Starter Grip Handle
Starts engine.
F—Fuel Valve
Controls flow of fuel from fuel tank to carburetor.
G—Air Cleaner Assembly
Removes dust from engine intake air.
H—Choke Control
Controls choke valve. Choke control must be pulled out to ON
position when starting a cold engine.
I— Fuel Gauge
Indicates level of fuel currently in fuel tank.
J—Fuel Tank Cap
Provides a secure seal on fuel tank.
K—Muffler Equipped with Spark Arrester
Provides outlet for engine exhaust. Prevents sparks and other
combustible materials from escaping generator.
L—Spark Plug Cap (Wire)
Delivers voltage to spark plug. When spark plug needs ser-
vice, cap must be removed.
M—Carbon Canister (HW4000L model only)
Reduces hydrocarbon emissions.
Generator must be grounded to prevent electrical
shock from faulty appliances. See page 10.
POWER CONTROL CENTER
HOUSEHOLD
OUTLETS
4-IN-1POWER CORD OF
TRANSFER SWITCH
120 VOLTS AC 120/240 VOLTS AC
BREAKER
PORTABLE GENERATOR
5500 CONTINUOUS WATTS • 9375MAXIMUM WATTS
4000 242cc
BREAKER
MASTER
BREAKER
Set Tripped
CAUTION
Muffler reaches temperatures that can cause serious
burns if touched. NEVER touch hot surfaces.
WARNING

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HW4000/HW4000L Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 13
OPERATION
Generator Location
When deciding on the location to place your generator,
keep in mind the following safety rules:
Preparing for Operation
Before starting generator, complete the following prepara-
tion tasks:
Be sure generator is placed outdoors in a well
ventilated area.
Consult a licensed electrician or utility company if
you will be using your generator for back-up
power. The generator must be connected to build-
ing’s electrical system via a transfer switch. See
“Using Generator for Back-up Power” on page 10.
Check/add engine oil— See “Engine Oil” on
page 18. For initial start-up, follow instructions on oil
container provided with generator.
Check/add fuel*—See “Adding Fuel” on page 20.
Be sure ground terminal is properly connected to
earth ground—See “Grounding the Generator” on
page 10.
Check extension cords—be sure cords are:
In good condition.
Rated for outdoor use and match amperage and
voltage ratings of generator outlet.
Equipped with proper plugs that contain grounding
blades.
Depressed areas such as construction foundations,
pools, or any low-lying areas, can cause carbon
monoxide to accumulate. Inhalation of carbon mon-
oxide can kill you in minutes.
• NEVER use generator inside homes, garages,
crawl spaces, sheds, or similar enclosed
spaces. Use generator only outdoors and far
away from windows, doors, and vents.
If generator is placed on an uneven or flexible sur-
face, generator could tilt or overturn, causing fuel to
spill from gas tank. Spilled fuel could ignite.
• Place generator on firm, level surface and avoid
loose sand or snow. If generator is tilted or
overturned, fuel spillage may result. Also, if
generator is overturned or sinks into a soft sur-
face, sand, dirt, or water may enter generator.
NEVER operate generator in rain or snow, or
when the generator is set on wet surface.
Keep generator at least 6 feet (2 meters) away
from buildings, other equipment, and combustible
materials during operation.
DANGER
+
WARNING
WARNING
WARNING
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a poi-
son you cannot see or smell.
NEVER use inside a home
or garage, EVEN IF doors
and windows are open.
Only use OUTSIDE and far
away from windows, doors, and
vents.
Before connecting to a building’s electrical system,
consult utility company or qualified electrician.
• Connecting to a building's electrical system
without using a transfer switch can cause elec-
trical current from generator to feed back into
utility lines, resulting in death or serious injury
to utility company workers or others who con-
tact utility lines during a power outage.
* You must add fuel before using the generator for the first time
See “Adding Fuel” on page 20.
DANGER
DANGER

Preparing for Operation
14 www.honeywellgenerators.com HW4000/HW4000L Portable Electrical Generator Owner’s Manual
Starting Generator
1. Be sure generator is placed outside, in well-ventilated
area.
2. Confirm the circuit breakers are set.
3. Turn fuel valve to ON position.
4. Pull choke control to ON position.
5. Press engine control switch to RUN position.
6. Grip recoil starter handle and pull slowly until you feel
slight resistance.
7. Apply a swift, single pull to start engine. Carefully
return recoil starter handle to its original position.
8. As engine warms up, and RPM stabilizes, gradually
push in choke control to OFF position.
Before starting generator, be sure to thoroughly read
all information provided in this Owner’s Manual.
NOTICE
It is very important to maintain proper level of engine oil to
keep engine in good running condition.
• Check engine oil level prior to each use.
Starting generator with appliances connected can cause
permanent damage to appliances.
• NEVER start generator with electrical appliances
plugged in and turned on.
NOTICE
Keep the generator at a minimum of 6 feet (2 meters) from
any building, object, or wall.
FIGURE 17: Circuit Breaker Position
FIGURE 18: Fuel Valve Lever — ON/OFF position
FIGURE 19: Choke Rod
WARNING
Set Tripped
ON
OFF
FIGURE 22: Engine Control Switch
Kickback (rapid retraction) of starter cord will pull hand and
arm toward engine faster than you can let go.
Broken bones, fractures, bruises, or sprains could result.
FIGURE 23: Recoil Starter Handle
NOTICE
To prevent damage to generator, do not allow recoil starter
handle to snap back against engine.
NOTICE
If engine will not start, move the choke to the OFF posi-
tion to reduce fuel to the engine.
RUN
ENGINE
STOP
CAUTION