HW4000 Portable Generator Owner’s Manual Portable Gasoline Generator Read and Save These Instructions For product inquiries or support, please visit www.honeywellgenerators.com or call toll-free at 1-888-494-3571.
Congratulations on owning a Honeywell portable generator 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. Please use spaces provided below to write down important information about your generator.
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.
3 – DEMOGRAPHIC INFORMATION GENDER: MALE HOUSEHOLD INCOME LESS THAN $15,000 FEMALE MARITAL STATUS: MARRIED SINGLE / / DD $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: DATE OF BIRTH: MM $100,000 - $124,999 $15,000 - $29,999 IN-STORE YYYY ONLINE TV INCLUDING YOUR SELF, HOW MANY PEOPLE LIVE IN YOUR HOUSEHOLD? MAIL ORDER TYPES OF CREDIT CARDS HELD BY HOUSEHOLD MEM
CONTENTS IMPORTANT SAFETY RULES............................................................................................ 1 Safety Messages ............................................................................................................................................1 Location of Important Labels ..........................................................................................................................3 GETTING STARTED ..........................................................
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SAVE THESE INSTRUCTIONS IMPORTANT SAFETY RULES ANYONE using or servicing generator must read, understand, and follow all safety and operation instructions provided in product manual. Failure to closely follow these instructions can result in circumstances leading to death, serious injury, and property damage.
Safety Messages Electric Shock 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 electrician. Generator Damage Hazards Improper treatment or misuse of generator can cause permanent damage.
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 1-888-4943571 to request replacements.
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GETTING STARTED Use the information in this section to get your generator ready for operation. ANYONE using the generator must read, understand, and follow all safety and operation instructions provided in the product manual. Failure to closely follow these instructions can result in circumstances leading to death, serious injury, and property damage. Unpacking Guidelines Generator is heavy! Lifting generator can cause back or other bodily injury. NEVER lift generator without assistance. 1.
Record Generator Information Record Generator Information It is recommended that you take a moment to write down the identification information specific to your generator in the spaces provided on the inside cover of this Owner’s Manual. You can find this information on generator’s name plate, located on rear side of generator (see illustration below). FIGURE 1: Generator Name Plate Location 6 www.honeywellgenerators.
Assembly Assembly Generator must be empty of engine oil and fuel. Drain engine oil and fuel, if necessary. Generator is heavy! Lifting generator can cause back or other bodily injury. NEVER lift generator without assistance. Wheel Kit FIGURE 2: Wheel Assembly Components i NOTE: In order to install support legs and wheel assembly, you will need to either tilt generator on its side or elevate generator by placing solid wood pieces underneath unit. • NEVER USE wheel kit on-road.
Assembly Step 1: Install Support Legs 5. To install support legs, you will need: 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. 25 mm full-thread hex bolts (2) 5/16" washers (2) 13 mm flange serrated nuts (6) 16 mm full-thread hex bolts (4) Socket Wrench with 10 mm Socket* * Not included FIGURE 4: Rubber Stopper Attachment to Support Leg 6. Generator must be empty of engine oil and fuel.
Assembly 4. Slide second 9/16" washer onto axle. To install wheel assembly, you will need: 5. Slide cotter pin into pre-drilled hole until fully seated. Socket wrench with 10 mm socket* 6. Using needlenose pliers, bend each end of cotter pin in opposing directions to secure wheel to axle.
Grounding the Generator Step 3: Install Handle Assembly To install handle assembly, you will need: Once properly installed, the handles can be collapsed, if desired. Handle Brackets (2) Hands and fingers can be pinched from collapsible handles. 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 1. Hold handle bracket over pre-drilled holes on frame as shown in Figure 9.
Using Generator for Backup Power Using Generator for Backup Power Before connecting to building’s electrical system, consult your local utility company or a qualified electrician. Improper connections to a building's electrical system can be deadly. Electrical current from generator to feedback into 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.
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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 section (page 15) for instructions on operating generator. J I K A D L H G F B E C FIGURE 12: HW4000 Portable Generator A—Power Control Center Household Outlets 120V 20 Amp Duplex outlets to connect 120V appliances to generator for power. D—Engine Control Switch Control used to run and stop the engine.
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OPERATION Preparing for Operation Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home Only use OUTSIDE and far or garage, EVEN IF doors away from windows, doors, and vents. and windows are open.
Stopping Generator 2. Turn fuel valve to ON position. 7. As engine warms up, and RPM stabilizes, gradually push in choke control to OFF position. To prevent damage to generator, do not allow starter grip to snap back against engine. Stopping Generator FIGURE 13: Fuel Valve Lever — ON/OFF position 3. Pull choke control to ON position. In an emergency: Press and hold engine control switch to STOP position until engine stops. In normal use: 1.
Powering Appliances Appliance Faulty appliances and power cords can result in electrical shock. • Before attempting to power an appliance, be sure generator has been properly grounded, and that appliance and power cord are in good working order. Plan carefully: Before using generator to power appliances, take time to add power rating (watts) of each appliance and verify that total wattage does not exceed rated output of generator.
Powering Appliances Appliance Typical Running Watts Toaster oven 1225 VCR/DVD 17-21 / 20-25 Vacuum cleaner* 1000-1440 Water heater (40 gal) 4500-5500 Water pump* (deep well) 250-1100 TABLE 1. Typical Appliance Running Wattages * Allow up to three times normal running watts for starting or cycling compressor of this appliance. Starting appliances that have motors requires more power. Examples of motorized appliances include refrigerators, water pumps, and furnace blowers.
MAINTENANCE Maintenance Schedule Periodic maintenance and adjustment is necessary to keep generator in good operating condition. Perform service and inspection at intervals shown in Generator Maintenance Schedule (Table 2). Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. Accidental starting of generator can cause severe injury or death. Before performing maintenance, disconnect spark plug cap from spark plug.
Engine Oil Oil level should be at “H” or somewhere between the “L” and “H”. Engine Oil Engine oil is a major factor affecting engine performance and service life. Non-detergent and 2-stroke engine oils will damage engine and are not recommended. • Be sure to use engine oils specified under “Engine Oil Recommendations.” It is very important to maintain proper level of engine oil to keep engine in good running condition. • Check engine oil level prior to each use. Refill engine oil if oil level is too low.
Engine Oil Changing Engine Oil 6. Using a socket wrench with 12 mm socket, loosen drain plug bolt; remove drain bolt and sealing washer. Frequent or prolonged contact with engine oil may cause skin cancer. • Immediately after handling engine oil, thoroughly wash hands and any areas of skin exposed to engine oil, with soap and water.
Adding Fuel 14. Reinstall oil fill cap and tighten until fully seated. • i NOTE: Dispose of used motor oil according to guidelines established by your local or state government. Some states (and provinces in Canada) require this information to be posted on the fuel pump. If you notice undesirable operating symptoms, switch to a conventional unleaded gasoline. Adding Fuel Before each use, check fuel gauge on fuel tank. If fuel level is low, refill tank with recommended fuel. NEVER OVERFILL.
Air Filter Maintenance 4. Slowly pour gasoline into fuel tank. Be careful not to overfill. 2. Remove air cleaner cover. FIGURE 26: Fuel Level 5. Reinstall fuel tank cap and fully tighten. i NOTE: Occasional, light spark knock, "pinging", or rattling noise is normal while operating under heavy loads. If spark knock, pinging, or rattling occurs at a steady engine speed, under normal load, drain fuel (page 27) and refill with fresh gasoline. If noise persists, see an authorized generator dealer.
Cleaning Fuel Sediment Cup Soak air filter in clean engine oil and squeeze out excess oil. 7. A Frequent or prolonged contact with engine oil may cause skin cancer. • Thoroughly wash hands and any areas of skin exposed to used oil with soap and water. i NOTE: Engine will smoke during initial start-up if too much oil is left in filter. B C FIGURE 31: Fuel Sediment Cup Assembly Pieces 5. Clean fuel screen (A), o-ring (B), and sediment cup (C), with soap and water. 8. Reinstall air filter. 6.
Cleaning Spark Arrestor Screen 3. Remove spark plug cap. 11. Inspect spark plug washer and verify it is in good con- dition. 12. Reinstall spark plug by hand to prevent cross-thread- ing. 13. After spark plug is seated, tighten with spark plug wrench to compress washer. If installing a new spark plug, tighten l/2 turn after the spark plug seats to compress the washer. If reinstalling a used spark plug, tighten l/8 - l/4 turn after the spark plug seats to compress the washer.
Transporting Generator 4. Pull off enclosure panel. C A Storing Generator Follow service procedures for preparing generator for storage. Inadequate or improper care of generator can result in damage to generator components and will void limited warranty. Before storing generator for extended period of time: B FIGURE 36: Spark Arrestor Assembly 5. Using a screwdriver, loosen and remove screw holding spark arrestor clamp (A). 6. Slide off spark arrestor clamp. 7.
Storing Generator Draining Fuel 1. Turn fuel lever to OFF position. 2. Run engine until it stops due to lack of fuel. 3. Place suitable container underneath drain hole to catch fuel. 4. Loosen bolt (underneath fuel sediment cup). FIGURE 37: Loosen Bolt to Drain Fuel 5. Turn fuel lever to ON position. FIGURE 38: Fuel Valve Lever — ON/OFF position 6. Allow fuel to drain into container. 7.
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TROUBLESHOOTING ANYONE using or servicing 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. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.
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SPECIFICATIONS GENERATOR Dimensions* Length 27 inches (685.8 mm) Width 21.5 inches (546.1 mm) Height 21.5 inches (546.1 mm) Dry Weight 155 pounds (70.3 kg) AC Output Continuous (Rated) Power) 4000 Watts Maximum Power 5000 Watts Surge Power 6000 Watts Frequency 60 Hz Voltage 120/240 Volts Operating Temperature Maximum 104° F (40° C) Minimum -10° F (-23° C) ENGINE Speed (RPM) 3600 Type OHV 4-Cycle Displacement 242 cc Fuel Tank Capacity 6.5 Gallons (24.
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WARRANTIES E. Fuel tank, cap and screen F. Carbon Canister (if equipped) NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY Honeywell Portable Generator 2. A. Air cleaner B. Vent lines C. Intake manifold WARRANTY STATEMENT US Environmental Protection Agency (EPA) requires manufacturers of small off-road engines (SORE) to warranty their products with a 2 year warranty for those components that are specified as being part of the emission control system.
NORTHSHORE POWER SYSTEMS EMISSIONS CONTROL WARRANTY QUESTIONS If you have questions regarding your emissions warranty rights and responsibilities, you should contact the Warranty and Service department at NSP. By phone: (414) 332-2375 Via web: www.honeywellgenerators.com By US mail: Northshore Power Systems, LLC Attention: Product Warranty and Service Dept. 4425 N Port Washington Road Suite 105 Milwaukee WI 53212-1082 34 www.honeywellgenerators.
NORTHSHORE POWER SYSTEMS LIMITED WARRANTY NORTHSHORE POWER SYSTEMS LIMITED WARRANTY Honeywell Portable Generator Effective April 1, 2008 LIMITED WARRANTY Northshore Power Systems, LLC, (NSP) will repair or replace, free of charge, to the original retail customer, in North America, any parts of the portable generator found by NSP or an authorized service center to be defective in material or workmanship. This limited warranty covers the cost of the replacement parts and labor for defects.
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INDEX INDEX unpacking guidelines 5 warranty 35 Ground 10 special requirements 10 terminal 13 A Air Filter maintenance 23 Appliances powering 16 rules for powering 16 wattage information 17 Assembly handle 10 wheels 9 H Handles installing 10 High Altitude operation 16 C Checklist generator shipment 5 Components and Controls breakers 13 choke control 13 engine switch 13 fuel valve 13 outlets Household 13 recoil starter grip 13 spark plug cap 13 M Maintenance 19 air filter 23 changing engine oil 21 cleani
INDEX W Warranty emissions control 33 limited product 35 Wattage typical appliance 17 Wheels installing 9 38 www.honeywellgenerators.
HW4000 MAINTENANCE PARTS To order maintenance parts, visit www.honeywellgenerators.com or call Customer Hotline at 1-888-494-3571.
Northshore Power Systems, LLC 4425 N. Port Washington Rd., Suite 105 Milwaukee, WI 53212-1082 USA HW4000 – P/N: 100901A March 2008 © 2008 Northshore Power Systems, LLC TEL 1-888-494-3571 The Honeywell Trademark is used under license from Honeywell International Inc. www.honeywellgenerators.com Honeywell International Inc.
