Honeywell HW7500E - Portable Generator NOT User manual

HW7500E
HW7500EL
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 in the location
illustrated below.
This manual contains important instructions for operating this generator. For your safety and the
safety of others, 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
Phase
Fuel
1
Gasoline
Model Number
Part Number
HW4000
100805C Frequency
3600Engine RPM
60Hz
AC Voltage
Power Output 4.0 kW
120/240V
p/n XXXXXXX
Northshore Power Systems
Milwaukee, WI 53212 USA
Serial Number
p/n XXXXXXX
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

HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com i
CONTENTS
IMPORTANT SAFETY INSTRUCTIONS ............................................................................. 1
Safety Messages .........................................................................................................................................1
Location of Important Labels .......................................................................................................................3
GETTING STARTED ......................................................................................................... 5
Unpacking Guidelines ..................................................................................................................................5
Record Generator Information .....................................................................................................................5
Assembly .....................................................................................................................................................6
Grounding the Generator ...........................................................................................................................11
Using Generator for Back-up Power ..........................................................................................................11
COMPONENTS ............................................................................................................... 13
OPERATION ................................................................................................................... 15
Generator Location ....................................................................................................................................15
Preparing for Operation .............................................................................................................................15
Starting Generator .....................................................................................................................................16
Stopping Generator ...................................................................................................................................18
Powering Appliances .................................................................................................................................18
MAINTENANCE .............................................................................................................. 21
Maintenance Schedule ..............................................................................................................................21
Engine Oil ..................................................................................................................................................22
Engine Fuel ...............................................................................................................................................24
Air Filter Maintenance ................................................................................................................................25
Battery Service ..........................................................................................................................................27
Cleaning Fuel Sediment Cup .....................................................................................................................27
Spark Plug Service ....................................................................................................................................28
Cleaning Spark Arrestor Screen ................................................................................................................29
Transporting Generator .............................................................................................................................29
Storing Generator ......................................................................................................................................30
TROUBLESHOOTING .................................................................................................... 33
SPECIFICATIONS ........................................................................................................... 35
WARRANTIES ................................................................................................................ 37
NORTHSHORE POWER SYSTEMS CONSUMER LIMITED WARRANTY .............................................37
NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY ...........................................38
INDEX .............................................................................................................................. 41
MAINTENANCE PARTS ................................................................................................. 43

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ii www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual

HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 1
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
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 hazard-
ous situation which, if not avoided,
will result in death or serious injury
to the operator or to bystanders.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury to the operator or to
bystanders.
Indicates a potentially hazardous
situation 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 HW7500E/HW7500EL 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.
WARNING
WARNING
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.
•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
WARNING

HW7500E/HW7500EL 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
A101586A
B100884B (HW7500E Model)
101796B (HW75000EL Model)
C100886C
D100849D
A
E
B
F
G
H
A
D
C
I
J
I
Use regular unleaded gasoline
with a minimum octane
rating of 87
Utilice gasolina sin plomo
con un octanaje
mínimo de 87
p/n 101586A
p/n 100884B
CUTOUT
WARNING
ADVERTENCIA
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.
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
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/n101796B
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.
PELIGRODANGER
USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES.
GENERATOR EXHAUST CONTAINS CARBON MONOXIDE.
THIS IS A POISON 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.
p/n 100886C
p/n 100849D
TODOS LOS USUARIOS DEBEN LEER Y COMPRENDER EL MANUAL DEL PROPIETARIO
ALL USERS MUST READ AND UNDERSTAND OWNER’S MANUAL!

Location of Important Labels
4www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
E100887C
F101986A
G100879D
H100882C
I100885C
J100881B
The Smart Start instruction card (see D on page 3) is NOT intended to replace information provided in this Owner’s
Manual. 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 injured or killed.
p/n 100887C
ON
OFF
MAINTAIN AIR CLEANER MANTENGA EL FILTRO DE AIRE
ON
OFF
p/n 101986A
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.
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.
p/n 100879D
p/n 100882C
p/n 100885C
HOT
SURFACES SUPERFICIES CALIENTES
WARNING ADVERTENCIA
p/n 100881B
WARNING

HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 5
GETTING STARTED
Use the information in this section to prepare your generator for operation.
Unpacking Guidelines
1. Set carton on a rigid, flat surface.
2. Remove carton contents.
3. Remove and discard silica gel packs.
4. Verify all of the following items are included in the generator package:
HW7500E/HW7500EL Portable Electrical Generator
Wheel Kit (including handle assembly and assembly hardware)
Battery
20’ 30 amp 4-in-1 Power Cord
1.1 Liter Engine Oil
Funnel
Owner’s Manual
5. Remove the “No Oil Fill” tag from the generator. See “Adding Engine Oil” on page 22.
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.
FIGURE 3: Generator Nameplate Location
WARNING
CAUTION
CAUTION
OIL HAS BEEN DRAINED FOR SHIPPING
Failure to fill engine with oil before starting
engine will result in permanent damage
and will void engine warranty.
(Please remove tag prior to operating)
p/n101179B
Phase
Fuel
1
Gasoline
Model Number
Part Number
HW4000
100805C Frequency
3600Engine RPM
60Hz
AC Voltage
Power Output 4.0 kW
120/240V
p/n XXXXXXX
Northshore Power Systems
Milwaukee, WI 53212 USA
Serial Number
p/n XXXXXXX

Assembly
6www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
Assembly
Wheel Kit
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 4: Wheel Kit Assembly
NOTICE
• Wheel kit is intended to be used specifically with this generator.
• NEVER use wheel kit for any other purpose.
• NEVER use wheel kit on-road.
CAUTION

HW7500E/HW7500EL 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 or elevate
the generator by placing solid wood pieces under-
neath unit.
4. Place a washer in the center of each rubber stopper.
5. Attach a rubber stopper to the bottom of each support
leg using a 30 mm long hex flange bolt and a serrated
flange nut; tighten until securely seated.
6. Attach each support leg to pre-drilled holes on bottom
of generator frame, using 16 mm long full-thread hex
flange bolts and serrated flange nuts; tighten until
securely seated.
To install support legs, you will need:
M8 x 30 mm long hex flange bolts (2)
M8 x 16 mm OD x 1.5 mm washers (2)
M8 serrated flange nuts (6)
M8 x 16 mm long full-thread hex flange bolts (4)
Brackets (2)
Rubber stoppers (2)
Socket wrench with 13 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 5: Tip onto Generator Recoil Side
CAUTION
FIGURE 6: Rubber Stopper Attached to Support Leg
FIGURE 7: Support Leg Attached to Generator

Assembly
8www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
Step 2: Install Wheel Axle and Wheels
1. Install wheel axle brackets to frame using 16 mm long
full-thread hex flange bolts and serrated flange 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 and push wheel onto axle until it fits snug
against washer.
NOTE:
Axle brackets are offset (one side longer than the other),
place with the short side up during installation.
3. Slide a washer onto axle.
4. Slide cotter pin into pre-drilled hole until fully seated.
5. Using needle-nose pliers, bend each end of cotter pin
in opposing directions to secure wheel to axle.
6. 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)
M8 x 16 mm long full-thread hex flange bolts (4)
M8 serrated flange 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 box.
Wheels (2)
M16 x 30 mm OD x 2 mm washers (2)
Cotter pins (2)
13 mm open end wrench†
Socket wrench with 13 mm socket†
† Not included.
Needle-nose pliers†
FIGURE 8: Wheel Axle Attached to Generator
FIGURE 9: Slide Wheel onto Wheel Axle
FIGURE 10: Cotter Pin Installation

HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 9
Assembly
Step 3: Install Handle Assembly
1. Hold handle pivot bracket over pre-drilled holes on
frame as shown in Figure 11.
2. Attach bracket to frame using 40 mm long hex flange
bolts and serrated flange 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 long
flange-head hex bolt and serrated flange nut to hole
closest to frame and tighten.
NOTE:
Handle should be in a horizontal position 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 pivot brackets (2)
Handle bars (2)
Pin and chain (2)
Rubber handle grips (2)
M6 X 40 mm long hex flange bolts (6)
M6 serrated flange nuts (6)
Socket wrench with 8 mm socket*
* Not included
10 mm open end wrench*
FIGURE 11: Handle Bracket to Frame
FIGURE 12: Insert Handle Bar to Bracket
FIGURE 13: Attach Chain to Handle Bracket
FIGURE 14: Attach Grips to Handle
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

Assembly
10 www.honeywellgenerators.com HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual
Step 4: Install Battery
To use the electric-start feature, the battery (included)
must be connected to generator’s electric starter.
1. To access battery posts, loosen and remove nuts on
retaining plate; slide retaining plate off support rods
and tip battery slightly forward.
2. Remove boot/bolt/nut from each battery post.
3. Confirm red positive (+) battery lead is securely fas-
tened to the positive (+) battery post as it may have
loosened during shipping.
4. The generator is packaged with the negative (-) bat-
tery cable tie wrapped. Carefully cut the tie wrap to
disengage the battery lead and remove the plastic
bag.
5. Connect the black negative (-) battery lead to the neg-
ative (-) battery post; install bolt, nut, and boot.
6. Reinstall retaining plate; tighten bolts and nuts.
NOTE:
Actual battery appearance may vary from illustration pro-
vided.
NOTE:
While the engine is running, a small “trickle” charge is
applied to the battery. This keeps an adequate battery
charge.
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 batteries,
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 15: Electric Start Battery—Remove Retaining Plate
WARNING
WARNING
To avoid electric arcing, which can result in electric
shock, follow these instructions exactly.
When connecting or disconnecting battery leads:
• ALWAYS connect positive (+) battery lead
first.
• ALWAYS disconnect negative (-) battery lead
first.
• NEVER connect negative (-) battery lead to
positive (+) post on battery.
• NEVER connect positive (+) battery lead to
negative (-) post on battery.
FIGURE 16: Electric Start Battery—Lead Connection
WARNING

HW7500E/HW7500EL Portable Electrical Generator Owner’s Manual www.honeywellgenerators.com 11
Grounding the Generator
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 17) 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 17: Ground Terminal
WARNING
Before connecting to a building’s electrical system, consult
your local utility company and/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 generator-powered circuits from the
utility line, allowing for efficient operation of the gen-
erator without back-feeding into utility power.
DANGER

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HW7500E/HW7500EL Portable Electrical 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
125VAC 20 Amp Duplex (NEMA 5-
20R) outlets to connect 120V appli-
ances to generator for power.
Power Cord / Transfer Switch
125/250VAC 30 Amp Twist-Lock
(NEMA L14-30R) outlet can be used
to:
•Power 120V appliances using 4-
in-1 power cord (included with
generator).
•Power 240V appliances using appropriate (NEMA L14-
30P) power cord (not included).
•Connect a transfer switch to building’s main electrical sys-
tem for backup power (see page 11).
Breakers
Protects circuits from
damage caused by
overload or short-cir-
cuit by stopping flow
of electricity from the
generator to the appliance. Master circuit breaker controls
power to all outlets. If there is no power at outlets, see Tr o u -
bleshooting section.
Ground Terminal
Connects generator to ground wire for grounding protection.
B—Battery Tray and Battery
Provides power for electric start feature.
C—Oil Fill Dipstick
Seals off engine oil fill hole and provides indicator for engine
oil level.
D—Engine Oil Plug
Allows engine oil to drain from generator.
E—Engine Control Switch
Control used to start and stop the engine. Engine control
switch has three positions:
•START—Starts generator engine
•RUN—Prepares engine to start (manual start);
Indicates engine is currently running (electric start)
•STOP—Stops generator engine
F—Recoil Starter Grip Handle
Provides means to manually start engine, if needed.
G—Fuel Shut-off 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 Gage
Indicates level of fuel currently in fuel tank.
K—Fuel Tank Cap
Provides a secure seal on fuel tank.
L—Muffler Equipped with Spark Arrestor
Provides outlet for engine exhaust. Prevents sparks and other
combustible materials from escaping generator.
M—Spark Plug Cap (Wire)
Delivers voltage to spark plug. When spark plug needs ser-
vice, cap must be removed.
N—Carbon Canister (HW7500EL model only)
Reduces hydrocarbon emissions.
The information below is provided for reference only. Refer to “OPERATION” on page 15 for instructions
on operating generator.
FIGURE 18: HW7500EL Portable Generator
CAUTION
K
F
B
I
H
E
C
D
A
J
G
M
L
N
Generator must be grounded to prevent electrical
shock from faulty appliances. See page 11.
POWER CONTROL CENTER
HOUSEHOLD
OUTLETS
120/240 VOLTS AC
MASTER
BREAKER
BREAKER BREAKER
120 VOLTS AC
Set Tripped Tripped
Set
CAUTION
Muffler reaches temperatures that can cause serious
burns if touched. NEVER touch hot surfaces.
WARNING

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