3500XL Portable Generator Owner’s Manual Pro blem Q u Bef e sti s? ore bac takin ons? g k call to th your u e the gen store, nit h 1-80 elpline erator 0-2 at M-F 70-1 8-5 408 CT Model No. 9441–5 (3500 Watt AC Generator) Manual No. 99112 Revision 4 (9/8/2000) Visit our Generac website: www.generac–portables.com This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Generac Portable Products 3,500 Watt Generator EQUIPMENT DESCRIPTION SAFETY RULES This generator set was designed and manufactured for specific applications. Do Not attempt to modify the unit or use it for any application it was not designed for. If you have any questions about your generator’s application, ask your dealer/distributor or consult the factory. This generator is an engine-driven, revolving field, alternating current (AC) generator.
Generac Portable Products 3,500 Watt Generator • The generator produces a very powerful voltage that can cause serious injury or death by electrocution. Never touch bare wires or receptacles. Never permit a child or any unqualified person to operate the generator.
Generac Portable Products 3,500 Watt Generator KNOW YOUR GENERATOR Read this owner’s manual and safety rules before operating your generator. Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference.
Generac Portable Products 3,500 Watt Generator BEFORE STARTING THE ENGINE • Use regular UNLEADED gasoline with the Generator engine. Do Not use premium gasoline. Do Not mix oil with gasoline. • Clean area around fuel fill cap, remove cap. Add Oil • Add unleaded regular gasoline, slowly to fuel tank. Be careful not to overfill. Allow about 1/2" of tank space for fuel expansion (Figure 2).
Generac Portable Products 3,500 Watt Generator OPERATING THE GENERATOR 6. • If engine fails to start, repeat steps 4 thru 6. 7. CAUTION! Never start or stop, the engine with electrical loads connected to the unit and with the connected devices turned ON. Disconnect all electrical loads from the generator. Use the following start instruction steps by numerical order: Make sure the Idle Control switch is in “Off” position. 2. Turn the fuel valve to the “On” position. 3.
Generac Portable Products 3,500 Watt Generator To recharge 12 Volt batteries, proceed as follows: • Check fluid level in all battery cells. If necessary, add ONLY distilled water to cover separators in battery cells. Do Not use tap water. Stopping the Engine • Unplug all electrical loads from generator panel receptacles. Never start or stop engine with electrical devices plugged in and turned on. • If the battery is equipped with vent caps, make sure they are installed and are tight.
Generac Portable Products 3,500 Watt Generator COLD WEATHER OPERATION • Ensure a minimum of two feet clearance between open side of box and nearest object. Under certain weather conditions (temperatures below 40°F [4°C] and a high dew point), your Generac generator may experience icing of the carburetor and/or the crankcase breather system. • Enclosure should hold enough heat created by the generator to prevent icing problems. • Face exposed end away from wind and elements.
Generac Portable Products 3,500 Watt Generator 120/240 Volt AC, 20 Amp Locking Receptacle 120 Volt AC, 30 Amp Locking Receptacle Use a NEMA L14-20 plug with this receptacle. Connect a 4-wire cord set rated for 250 Volts AC at 30 Amps (or greater) (Figure 8). You can use the same 4-wire cord if you plan to run a 120 Volt load. Use a NEMA L5-30 plug with this receptacle. Connect a 3wire cord set rated for 125 Volts AC at 30 Amps to the plug (Figure 9).
Generac Portable Products 3,500 Watt Generator DON’T OVERLOAD THE GENERATOR • If the appliance, tool or motor does not give wattage, multiply 120 Volts times ampere rating to determine watts (volts x amps = watts). • Some electric motors, such as induction types, require about three times more watts of power for starting than for running. This surge of power lasts for only a few seconds when starting such motors.
Generac Portable Products 3,500 Watt Generator SPECIFICATIONS To Clean the Generator Maximum Surge Watts . . . . . . . . . Continuous Wattage Capacity . . . Power Factor . . . . . . . . . . . . . . . . Rated Maximum Continuous Load At 120 Volts . . . . . . . . . . . . . . At 240 Volts . . . . . . . . . . . . . . Phase . . . . . . . . . . . . . . . . . . . . . . Rated Frequency . . . . . . . . . . . . . Fuel Tank Capacity . . . . . . . . . . . . • Use a damp cloth to wipe exterior surfaces clean. . . .
Generac Portable Products 3,500 Watt Generator TROUBLESHOOTING Problem Engine is running, but no AC output is available. Engine runs good but bogs down when loads are connected. Engine will not start; or starts and runs rough. Engine shuts down during operation. Engine lacks power. Engine "hunts" or falters. Cause Solution 1. 2. 1. 2. Reset circuit breaker. Check and repair. 3. Circuit breaker is open. Poor connection or defective cord set. Connected device is bad. 3. 4. 1. 2.
Generac Portable Products 3,500 Watt Generator NOTES 13
Generac Portable Products 3,500 Watt Generator SCHEMATIC DIAGRAM 14
Generac Portable Products 3,500 Watt Generator WIRING DIAGRAM 15
Generac Portable Products 3,500 Watt Generator EXPLODED VIEW – MAIN UNIT 16
Generac Portable Products 3,500 Watt Generator PARTS LIST – MAIN UNIT Item 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 30 32 33 34 35 36 37 Part # 93199 84021 NSP 66365 84141 83540 65791 67451 86307 47480 84508 52858 83208 B4986 66476 89476 70644 84346 40976 83083 83071 81917 66825B 85652 67989 74908 86308 65795 66849A 67022 84132 66386 Qty. 1 1 1 1 1 1 1 1 4 1 2 8 1 1 2 1 1 3 2 1 1 1 1 2 2 4 4 1 1 1 1 1 Description CRADLE, XL SUPPORT, Engine ENGINE, 6.
Generac Portable Products 3,500 Watt Generator EXPLODED VIEW/PARTS LIST – CONTROL PANEL Item 1 2 3 4 5 Part # 83976 83975 66818 66821 68867C Qty.
Generac Portable Products 3,500 Watt Generator NOTES 19
LIMITED WARRANTY FOR "GN" ENGINE DRIVEN PORTABLE GENERATORS GENERAC PORTABLE PRODUCTS (hereafter referred to as the COMPANY) warrants to the original purchaser that the alternator and control panel for its portable generator will be free from defects in materials or workmanship for the items and period set forth below from the date of original purchase. This warranty is not transferable and applies only to portable generators driven by a GN-Series engine.
