Honeywell HW5500 - 5500 Portable Generator User manual

Owner’s Manual
For product inquiries or support, please visit www.honeywellgenerators.com
or call toll-free at 1-888-494-3571.
Portable Gasoline Generator
Electric Start
Read and Save These Instructions
HW5500/HW5500E Portable Generator

Congratulations on owning a Honeywell portable generator
Please use spaces provided below to write down 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 generator’s
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.
Date of Purchase:
Store/Dealer Purchased From:
Generator Model Number:
Generator Serial Number:
Northshore Power Systems, LLC
4425 N. Port Washington Rd., Suite 105
Milwaukee, WI 53212-1082 USA
TEL [phone]
honeywellgenerators.com
© 2008 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 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
/ /
MM DD YYYY
MODEL NUMBER*:
SERIAL NUMBER*:
*Found on nameplate of generator
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
INTERESTED IN PURCHASING IN THE FUTURE?

WHO DECIDED TO PURCHASE THIS PRODUCT?

3 – DEMOGRAPHIC INFORMATION
GENDER:
MALE
FEMALE
MARITAL STATUS:
MARRIED
SINGLE
DATE OF BIRTH:
/ /
MM DD YYYY

INCLUDING YOUR SELF, 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
HOUSEHOLD INCOME
LESS THAN $15,000 $100,000 - $124,999
$15,000 - $29,999 $125,000 - $149,000
$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/MASTER CARD
DISCOVER
AMERICAN EXPRESS
GAS/RETAIL
OTHER
NONE
HOUSEHOLD INTERESTS:
HOME IMPROVEMENT
AUTOMOTIVE WORK
CAMPING
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.

HW5500/5500E Portable 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 ........................................................................................................................6
Assembly ........................................................................................................................................................7
Grounding the Generator ..............................................................................................................................11
Using Generator for Backup Power ..............................................................................................................12
COMPONENTS ..................................................................................................................13
OPERATION ......................................................................................................................15
Preparing for Operation ................................................................................................................................15
Generator Location .......................................................................................................................................15
Starting Generator ........................................................................................................................................15
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

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HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 1
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY RULES
NOTE:
i
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.
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 described above, the fol-
lowing symbols may be used to draw your attention to
specific types of hazards.
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.
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 generator com-
ponents.
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.

Safety Messages
2www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
Electric Shock Hazards
Fire and Burn Hazards
Generator Damage Hazards
Generator produces powerful voltage that can cause
death or great physical harm.
• When using generator for backup power, notify 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 qualified elec-
trician.
• 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 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.
Improper treatment or misuse of generator can cause per-
manent damage.
• NEVER tamper with governed speed. Generator sup-
plies correct rated frequency and voltage when running
at governed speed.
• NEVER modify generator in any way.
• Damage to generator caused by misuse or modification
is not covered under Warranty.

HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 3
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.
PRODUCT LABEL PART NUMBER
A100884A
B100886A
C100887A
D100883A
E100879A
F100882A
G100885A
H100881A
A
C
B
D
E
F
A
G
H

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HW5500/5500E Portable 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 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
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.
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.
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
properly follow all instructions and precautions can cause you and others to be seriously hurt or killed.

Record Generator Information
6www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
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

HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 7
Assembly
Assembly
Wheel Kit
NOTE:
i
Illustration above shows battery, which is available only with HW5500E models.
NOTE:
i
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 2: Wheel Assembly Components
• 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.

Assembly
8www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
Step 1: Install Support Legs
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.
3. Gently set generator onto recoil side.
4. Place 5/16" washer in center of each rubber stopper.
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.
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
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 3: Tip onto Generator Recoil Side
FIGURE 4: Rubber Stopper Attachment to Support Leg
FIGURE 5: Support Leg Attachment to Generator

HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 9
Assembly
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 needlenose pliers, bend each end of cotter pin
in opposing directions to secure wheel to axle.
7. Return generator in upright position (so that wheels
and leg supports are touching ground).
To install wheel assembly, you will need:
Socket wrench with 10 mm socket*
* Not included.
Needlenose Pliers*
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)
FIGURE 6: Wheel Axle Attached to Generator
FIGURE 7: Slide Wheel onto Wheel Axle
FIGURE 8: Cotter Pin Installation

Assembly
10 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
Step 3: Install Handle Assembly
1. Hold handle bracket over pre-drilled holes on frame
as shown in Figure 9.
2. Attach bracket to frame using 40 mm washer style
hex bolts and 10 mm flange serrated nuts; tighten
until securely seated.
3. Slide handle bar through center of each bracket and
line up bolt holes.
4. Attach handle to each bracket using 40 mm washer
style hex bolt and 10 mm flange serrated nut; tighten
until securely seated.
NOTE:
i
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.
Once properly installed, the handles can be collapsed, if
desired.
•To collapse handles, push firmly down on handle
until it rests vertically against generator frame.
•To return handles to horizontal position, pull up on
handle.
Battery
To use electric start feature, battery (included) must be
connected to generator’s electric starter.
1. Generator is packaged with the negative (-) battery
lead attached to top of alternator with a plastic cable
To install handle assembly, you will need:
Handle Brackets (2)
Handle Bars (2)
Rubber Handle Grips (2)
40 mm Washer Style Hex Bolts (6)
10 mm flange serrated nuts (6)
Socket wrench with 8mm socket*
* Not included
FIGURE 9: Handle Bracket to Frame
FIGURE 10: Insert Handle Bar to Bracket
Hands and fingers can be pinched from collapsible
handles.
• Keep hands and fingers clear from hinges when col-
lapsing generator handles.
Battery gases are explosive.
• NEVER allow open flames, lit cigarettes, sparks, or
spark-producing equipment near the battery.
Battery electrolyte fluid is comprised of sulfuric acid,
which can be very dangerous and cause severe
burns.
• NEVER allow battery fluid to contact eyes, skin, or
clothing. If contact or spillage occurs, immediately flush
the area with water.
Exposed terminals, even on disconnected 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.

HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 11
Grounding the Generator
strap. Carefully cut cable strap to disengage battery
lead.
2. Connect red positive (+) battery lead to red positive
(+) 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.
NOTE:
i
Actual battery appearance may vary from illustration pro-
vided.
NOTE:
i
While engine is running, a small “trickle” charge is applied
to starting battery.This keeps an adequate battery
charge.
Grounding the Generator
Before using generator, a ground wire must be connected
to the ground terminal (Figure 13).
NOTE:
i
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
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.
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.
• ALWAYS disconnect negative (-) battery lead
first.
• NEVER connect negative (-) battery lead to
red positive (+) post on battery.
• NEVER connect positive (+) battery lead to
black negative (-) post on battery.
FIGURE 12: Electric Starter Battery
+
–
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 13: Ground Terminal

Using Generator for Backup Power
12 www.honeywellgenerators.com HW5500/5500E Portable Generator Owner’s Manual
Using Generator for Backup Power
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.
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.
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.

HW5500/5500E Portable Generator Owner’s Manual www.honeywellgenerators.com 13
COMPONENTS
Use information provided in this section to become familiar with your generator’s components.
A—Power Control Center
Household Outlets
120V 20 Amp Duplex outlets to connect
120V appliances to generator for power.
Power Cord/ Transfer Switch
120/240V 30 Amp Twist-Lok outlet can
be used to:
•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).
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.
Ground Terminal
Connects generator to ground wire for grounding protection.
B—Battery Tray and Battery (HW5500E Only)
Provides power for electric start feature.
C—Engine Oil Fill Cap/Dipstick
Seals off engine oil fill hole and provides indicator for engine
oil level.
D—Engine Oil Plug
When loosened, allows engine oil to drain from generator.
E—Engine Control Switch
Control used to run and stop the engine.
•START—Starts generator engine (HW5500E)
•RUN—Prepares engine for starting (HW5500);
Indicates engine is currently running (HW5500E)
•STOP—Stops generator engine
F—Recoil Starter Grip Handle
Starts engine (HW5500).
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.
I— Choke Control
Controls choke valve. Choke control must be pulled out to
ON position when starting a cold engine.
J—Fuel Gauge
Indicates level of fuel currently in fuel tank.
K—Fuel Tank Cap
Provides a secure seal on fuel tank.
L—Muffler Equipped with Spark Arrester
Provides outlet for engine exhaust. Prevents sparks and
other combustible materials from escaping generator.
M—Spark Plug Cap (Wire)
Delivers volts to spark plug. When spark plug needs service,
cap must be removed.
Information below is provided for reference only. Refer to Operation section (page15) for instructions on operat-
ing generator.
FIGURE 14: HW5500/5500E Portable Generator (Illustration shows battery, which is available only with HW5500E models)
K
F
B
I
H
JE
C
D
A
G
M
L
Generator must be grounded to prevent electrical
shock from faulty appliances. See page 11.
Set Tripped
Muffler reaches temperatures that can cause serious
burns if touched. NEVER touch hot surfaces.

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