3500XL
Model No. 9441–5 (3500 Watt AC Generator) Manual No. 99112 Revision 4 (9/8/2000)
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3500XL
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Portable Generator Owner’s Manual
Generac Portable Products 3,500 Watt Generator
2
EQUIPMENT
DESCRIPTION
This generator is an engine-driven, revolving field,
alternating current (AC) generator. It was designed to
supply electrical power for operating compatible electrical
lighting, appliances, tools and motor loads. This manual
contains information for a generator that operates 120
and/or 240 Volt, single phase, 60 Hz devices that require up
to 3,500 watts (3.5 kW) of power that pull up to
29.2 Amps at 120 Volts or 14.6 Amps at 240 Volts.
CAUTION! Do Not exceed the generator’s
wattage/amperage capacity. Add up the rated watts
of all devices you are connecting to generator
receptacles at one time. This total should not be
greater than 3,500 watts. In most cases rated watts
of the electrical device can be found on the device
nameplate. If the device nameplate gives only volts
and amps, multiply volts times amps to obtain watts
(volts X amps = watts).
The 3,500 watt generator has the following features:
• 120/240 Volt, 20 Amp locking type receptacle and a
120 Volt, 30 Amp locking type receptacle.
• 120 Volt, 15 Amp receptacles.
• Low Oil Shutdown: Automatically shuts down the engine
if oil drops below safe operation level.
• Four gallon overhead fuel tank with fuel gauge.
• The generator’s revolving field is driven at about
3,600 rpm by a Generac Power Systems 6.5 h.p. engine.
WARNING! Do Not tamper with engine
governed speed. High operating speeds are
dangerous and increase risk of personal injury or
damage to equipment. The generator supplies
correct rated frequency and voltage only when
running at proper governed speed. Incorrect
frequency and/or voltage can damage some
connected electrical loads. Operating at excessively
low speeds imposes a heavy load. When adequate
engine power is not available engine life may be
shortened.
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.
The manufacturer could not possibly anticipate every
circumstance that might involve a hazard. For that reason
warnings in the manual and warnings on tags or decals
affixed to the unit are not all–inclusive. If you intend to
handle, operate or service the unit by a procedure or
method not specifically recommended by the manufacturer,
first make sure that such a procedure or method will not
render this equipment unsafe or pose a threat to you and
others.
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
DANGER! You must isolate the generator from
the electric utility by opening the electrical system’s
main circuit breaker or main switch if this unit is
used for backup power. Failure to isolate the
generator from the power utility may result
in injury or death to electric utility workers
and damage to the generator due to a backfeed
of electrical energy. Whenever unit is providing
backup power, the electric utility must be notified.
DANGER
! Generator exhaust gases contain
DEADLY carbon monoxide gas. Carbon
monoxide, if breathed in sufficient
concentrations, can cause unconsciousness or
death. Operate this equipment outdoors where
adequate ventilation is available.
The Emission Control System for this generator is
warranted for standards set by the Environmental
Protection Agency. For warranty information refer to the
engine owner’s manual.
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other
reproductive harm.
WARNING:
Generac Portable Products 3,500 Watt Generator
3
• 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.
• Never handle any kind of electrical cord or device while
standing in water, while barefoot or while hands or feet
are wet. Death or serious injury from electrocution may
result.
• Use a ground fault circuit interrupter (GFCI) in any damp
or highly conductive area (such as metal decking or steel
work).
• Never use worn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damage from electrical shock may result.
• Gasoline is highly FLAMMABLE and its vapors
are EXPLOSIVE. Never allow smoking, open
flames, sparks or heat in the vicinity while
handling gasoline. Avoid spilling gasoline on a hot
engine. Comply with all laws regulating storage and
handling of gasoline.
• Do Not overfill the fuel tank. Always allow room for
fuel expansion. If tank is overfilled, fuel can overflow
onto a hot engine and cause a FIRE or an
EXPLOSION.
• Never store a generator with fuel in the tank where
gasoline vapors might reach an open flame, spark or pilot
light (as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.
• The unit requires an adequate flow of cooling air for its
continued proper operation. Never operate the unit
inside any room or enclosure where the free flow of
cooling air into and out of the unit might be obstructed.
Allow at least 2 feet of clearance on all sides of generator,
even while operating unit outdoors, or you could damage
the unit.
• Never start, or stop the unit with electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting any electrical loads. Disconnect all electrical
loads before shutting down the generator.
• Do Not insert any object through cooling slots of the
engine. You could damage the unit or injure yourself.
• Never operate the generator:
in rain; in any enclosed compartment; when connected
electrical devices overheat; if electrical output is lost; if
engine or generator sparks; if flame or smoke is
observed while unit is running; if unit vibrates
excessively.
GROUNDING THE
GENERATOR
The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of the
unit. For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure 1).
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth-driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, local codes
may vary widely. Consult with a local electrician for
grounding requirements in your area.
Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
Figure 1 — Grounding Wing Nut
Grounding Wing Nut
Generac Portable Products 3,500 Watt Generator
4
12 Volt DC, 10 Amp Receptacle — Use this receptacle
with battery charge cables to charge a 12 Volt battery.
120 Volt AC, 15 Amp Receptacles — May be used to
supply electrical power for the operation of 120 Volt AC,
15 Amp, single phase, 60 Hz electrical lighting, appliance,
tool and motor loads.
120 Volt AC, 30 Amp Locking Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, 30 Amp, single phase, 60 Hz electrical
lighting, appliance, tool and motor loads.
120/240 Volt AC, 20 Amp Locking Receptacle —
May be used to supply electrical power for the operation
of 120 and/or 240 Volt AC, 20 Amp, single phase, 60 Hz
AC electrical lighting, appliance, tool and motor loads.
Circuit Breakers (AC) — Each receptacle is provided
with a circuit breaker to protect the generator against
electrical overload. Breakers are "push to reset" type.
Fuel Shut Off Valve — Controls fuel supply to engine.
Fuel Tank — Capacity of 4 U.S. gallons.
Grounding Wing Nut — Provides a tie-point for
connecting the generator frame to earth ground.
Idle Control Switch — The idle control runs the engine
at normal (high) speeds when there is a load present and
runs the engine at idle (low) speeds when a load is not
present. This feature greatly improves fuel economy,
extends the life of the engine, and reduces engine noise.
Run/Stop Switch — Must be in “Run” position to start
engine. Set to “Stop” to stop a running engine.
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.
Circuit Breakers (AC)
Fuel Tank
120 Volt AC, 30 Amp
Locking Receptacle
Run/Stop Switch
120/240 Volt AC, 20 Amp
Locking Receptacle
12 Volt DC, 10 Amp
Receptacle
120 Volt AC, 15 Amp
Receptacles
Idle Control Switch
Grounding Wing Nut
Fuel Shut–Off Valve
Generac Portable Products 3,500 Watt Generator
5
BEFORE STARTING THE
ENGINE
Add Oil
WARNING! Any attempt to crank or start the
engine before it has been properly filled with the
recommended oil may result in an engine failure.
To fill your engine with oil:
• Place generator on a level surface.
• Clean area around oil fill and remove oil fill cap.
• Select the oil's viscosity grade and fill engine with oil
following the instructions given in the engine owner’s
manual. Do Not overfill!
• Install oil fill cap.
NOTE: The generator’s revolving field rides on a prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
Add Gasoline
DANGER! Explosion Hazard! Never fill fuel tank
indoors. Never fill fuel tank when engine is running
or hot. Do Not light a cigarette or smoke when
filling the fuel tank.
WARNING! Do Not overfill the fuel tank.
Always allow room for fuel expansion.
• 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 unleaded regular gasoline, slowly to fuel tank. Be
careful not to overfill. Allow about 1/2" of tank space for
fuel expansion (Figure 2).
• Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in essential fuel system parts such as the
carburetor, fuel filter, fuel hose or tank during storage.
Also, experience indicates that alcohol-blended fuels (called
gasohol, ethanol or methanol) can attract moisture which
leads to separation and formation of acids during storage.
Acidic gas can damage the fuel system of an engine while in
storage.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See “Storage”
on page 11. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
Figure 2 — Fill Tank with Fuel
Generac Portable Products 3,500 Watt Generator
6
OPERATING THE
GENERATOR
CAUTION! Never start or stop, the engine with
electrical loads connected to the unit and with the
connected devices turned ON.
Starting the Engine
Disconnect all electrical loads from the generator. Use the
following start instruction steps by numerical order:
1. Make sure the Idle Control switch is in “Off” position.
2. Turn the fuel valve to the “On” position.
3. Set the Run/Stop switch to “Run” position (Figure 3).
4. Place the choke lever in the “Full” choke position
(Figure 4).
5. Grasp the recoil handle and pull slowly until slight
resistance is felt. Then pull rapidly one time only to
start engine.
• If engine starts, proceed to step 7.
• If engine fails to start, proceed to step 6.
6. Move the choke lever to “Half” choke position, and
pull recoil handle twice.
• If engine fails to start, repeat steps 4 thru 6.
7. Move choke lever to “Run” position. If engine falters,
move choke lever to “Half” choke position until the
engine runs smoothly and then to “Run” position.
NOTE: If engine still fails to start after 3 pulls, check for
proper oil level in crankcase. This unit is equipped with a
Low Oil Shutdown System. See engine manual.
Refer to the engine owner’s manual for complete
starting instructions.
• Grasp starter grip and pull slowly until you feel slight
resistance, then pull quickly. Ease the starter rope back
into the engine.
• When engine starts, move choke lever to “Run”
position” by sliding it all the way to the right (away from
the valve cover and under the arrow).
NOTE: If engine fails to start after 3 pulls, move the choke
lever to “Half” choke position and pull starter rope again 2
times.
NOTE: If the engine still fails to start, check for proper oil
level in crankcase. Unit is equipped with a low oil
shutdown system. See engine owner’s manual for
information regarding the low oil shutdown system.
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes after
starting.
• Plug in and turn on the desired 120 and/or 240 Volt AC,
single phase, 60 Hertz electrical loads.
• Do Not connect 240 Volt loads to 120 Volt receptacles.
• Do Not connect 3–phase loads to the generator.
• Do Not connect 50Hz loads to the generator.
• DO NOT OVERLOAD THE GENERATOR. Add up
the rated watts (or amps) of all loads to be connected at
one time. This total should not be greater than the rated
wattage/amperage capacity of the generator. See “Don’t
Overload the Generator” on page 10.
Figure 3 — Run/Stop Switch
Full Choke
Position
Figure 4 — Choke Lever
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