For Parts Call 606-678-9623 or 606-561-4983
OPERATOR’S MANUAL
PORTABLE GENERATOR
3,500 WATT
HG3550
Your new generator has been engineered and manufactured to a high standard for dependability, ease of operation, and
operator safety. When properly cared for, it will give you years of rugged, trouble-free performance.
DANGER: You WILL be KILLED or SERIOUSLY HURT if you do not follow the instructions in this operator’s
manual.
Thank you for your purchase.
SAVE THIS MANUAL FOR FUTURE REFERENCE
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For Parts Call 606-678-9623 or 606-561-4983
TABLE OF CONTENTS
Introduction .................................................................................................................................................................... 2
General Safety Rules ..................................................................................................................................................... 3
Specific Safety Rules ..................................................................................................................................................... 4
Symbols ......................................................................................................................................................................5-7
Electrical .....................................................................................................................................................................8-9
Features .................................................................................................................................................................10-11
Assembly ..................................................................................................................................................................... 11
Operation ................................................................................................................................................................12-14
Maintenance ...........................................................................................................................................................15-18
Troubleshooting ........................................................................................................................................................... 19
Wiring Diagram ............................................................................................................................................................ 20
Warranty .......................................................................................................................................................................21
Parts Ordering / Service .................................................................................................................................Back Page
INTRODUCTION
This product has many features for making its use more pleasant and enjoyable. Safety, performance, and dependability
have been given top priority in the design of this product, making it easy to maintain and operate.
DANGER
GROUNDING THE GENERATOR
To avoid the risk of shock or electrocution, generator must be properly grounded. The nut and ground terminal on the
frame must always be used to connect the generator to a suitable ground source. The ground path should be made
with #8 size wire. Connect the terminal of the ground wire between the lock washer and the nut, and tighten the nut
fully. Connect the other end of the wire securely to a suitable ground source.
The National Electric Code contains several practical ways in which
to establish a good ground source. If a steel or iron rod is used,
it should be at least 5/8 in. diameter, and if a nonferrous rod is
used, it should be at least 1/2 in. diameter and be listed as
material for grounding. Drive the rod or pipe to a depth of 8
ft. If a rock bottom is encountered less than 4 ft. down, bury
the rod or pipe in a trench.
All electrical tools and appliances operated from this generator must be properly grounded by use of a third wire or be
“Double Insulated.”
It is recommended to:
1. Use electrical devices with 3-prong grounded plugs.
2. Use an extension cord with a 3-pole receptacle and a
3-prong plug at opposite ends to ensure continuity of the
ground protection from the generator to the appliance.
Check and adhere to all applicable federal, state, and local regulations relating to grounding specifications. Consult a
qualified electrician or service personnel if the grounding instructions are not completely understood or if in doubt as
to whether the generator is properly grounded.
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For Parts Call 606-678-9623 or 606-561-4983
IMPORTANT SAFETY INSTRUCTIONS
WARNING:
Read and understand all instructions. Failure to follow
all instructions listed below may result in electrocution,
fire, and/or carbon monoxide poisoning, which will cause
death or serious injury.
WARNING:
National Electric Code requires generator to be grounded
to an approved earth ground. Before using the ground
terminal, consult a qualified electrician, electrical
inspector, or local agency having jurisdiction for local
codes or ordinances that apply to the intended use of
the generator.
SAVE THESE INSTRUCTIONS
This manual contains important instructions for HG3550 that
should be followed during installation and maintenance of
the generator and batteries.
Do not allow children or untrained individuals to use this
unit.
� Never start or run the engine inside a closed or partially
enclosed area. Breathing exhaust fumes will kill you.
� Wear eye protection which is marked to comply with ANSI
Z87.1 as well as hearing protection when operating this
equipment.
� Keep all bystanders, children, and pets at least 10 feet
away.
� Wear sturdy and dry shoes or boots. Do not operate while
barefoot.
� Do not operate generator when you are tired or under the
influence of drugs, alcohol, or medication.
� Keep all parts of your body away from any moving parts
and all hot surfaces of the unit.
� Product users on United States Forest Service land, and
in some states, must comply with fire prevention regulations. This product is not equipped with a spark arrestor.
Check with the federal, state, or local authorities in your
area before use.
Do not touch bare wire or receptacles.
Do not use generator with electrical cords which are
worn, frayed, bare, or otherwise damaged.
Before storing, allow the engine to cool.
Do not operate generator in rain, snow, or wet weather.
Empty fuel tank, close fuel valve, and restrain the unit
from moving before transporting in a vehicle.
Allow engine to cool for five minutes before refueling.
To reduce the risk of fire and burn injury, handle fuel with
care. It is highly flammable.
Do not smoke while handling fuel.
Store fuel in a container approved for gasoline.
Position the unit on level ground, stop engine, and allow
to cool before refueling.
Loosen fuel cap slowly to release pressure and to keep
fuel from escaping around the cap.
Tighten the fuel cap securely after refueling.
Wipe spilled fuel from the unit.
Never attempt to burn off spilled fuel under any circum-
stances.
Use only authorized replacement parts and accessories
and follow instructions in the Maintenance section of this
manual. Use of unauthorized parts or failure to follow
Maintenance instructions may create a risk of shock or
injury.
Maintain the unit per maintenance instructions in this
Operator’s Manual.
Inspect the unit before each use for loose fasteners, fuel
leaks, etc. Replace damaged parts.
Generators vibrate in normal use. During and after the
use of the generator, inspect the generator as well as
extension cords and power supply cords connected to
it for damage resulting from vibration. Have damaged
items repaired or replaced as necessary. Do not use plugs
or cords that show signs of damage such as broken or
cracked insulation or damaged blades.
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Page 3
For Parts Call 606-678-9623 or 606-561-4983
SPECIFIC SAFETY RULES
WARNING:
When this generator is used to supply a building wiring
system: generator must be installed by a qualified electrician and connected to a transfer switch as a separately
derived system in accordance with NFPA 70, National
Electrical Code. The generator shall be connected
through a transfer switch that switches all conductors
other than the equipment grounding conductor. Failure
to isolate the generator from power utility can result in
death or injury to electric utility workers.
Exhaust contains poisonous carbon monoxide, a color
less, odorless gas. Breathing exhaust can cause loss
of consciousness and can lead to death. If running in a
confined or partially-enclosed area, the air may contain a
dangerous amount of carbon monoxide. To keep exhaust
fumes from building up, always provide adequate ventilation.
Always use a battery-powered carbon monoxide detec-
tor when running the generator. If you begin to feel sick,
dizzy, or weak while using the generator, shut it off and
get to fresh air immediately. See a doctor. You may have
carbon monoxide poisoning.
Place the generator on a flat, stable surface with a slope
of no more than 4°.
Operate in a well-ventilated, well-lit area isolated from
working areas to avoid noise interference.
Operating the generator in wet conditions could result in
electrocution. Keep the unit dry.
Keep the generator a minimum of 3 feet away from all
types of combustible material.
Do not operate generator near hazardous material.
Do not operate generator at a gas or natural gas filling
station.
Do not touch the muffler or cylinder during or immediately
after use; they are HOT and will cause burn injury.
Do not connect to a building’s electrical system unless a
transfer switch has been properly installed by a qualified
electrician.
Do not allow the generator’s gas tank to overflow when
filling. Fill to 1 in. below the top neck of the gasoline tank to
allow for fuel expansion. Check the ventilation hole inside
-
the fuel tank cap for debris. Do not block the vent.
Do not smoke when filling the generator with gasoline.
Allow the engine to remain in a shut-down condition for
at least five minutes before adding gasoline or oil.
Do not remove the oil dipstick or the fuel tank cap when
the engine is running.
Pay close attention to all safety labels located on the
generator.
Keep children a minimum of 10 feet away from the gen-
erator at all times.
The unit operates best in temperatures between 23°F and
104°F with a relative humidity of 90% or less.
Specific modifications for high-altitude performance
are needed if the generator will always be operated at
altitudes above 5,000 feet. Contact your nearest Baja
authorized service center for more information and to
have these modifications performed.
Save these instructions. Refer to them frequently and use
them to instruct others who may use this tool. If you loan
someone this tool, loan them these instructions also.
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For Parts Call 606-678-9623 or 606-561-4983
SYMBOLS
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper
interpretation of these symbols will allow you to operate the product better and safer.
SYMBOL NAME DESIGNATION/EXPLANATION
V Volts Voltage
A Amperes Current
Hz Hertz Frequency (cycles per second)
W Watt Power
hrs Hours Time
gal Gallon Volume
qt Quart Volume
Wet Conditions Alert Do not expose to rain or use in damp locations.
Read The Operator’s Manual
Eye Protection
Safety Alert Precautions that involve your safety.
Electric Shock
Toxic Fumes
Fire/Explosion
To reduce the risk of injury, user must read and understand
operator’s manual before using this product.
Always wear safety goggles or safety glasses with side shields and,
as necessary, a full face shield when operating this product.
Failure to use in dry conditions and to observe safe practices can
result in electric shock.
Running generator gives off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide can cause nausea,
fainting, or death.
Fuel and its vapors are extremely flammable and explosive. Fire
or explosion can cause severe burns or death.
Hot Surface
Lifting Hazard
Ground
Electrocution
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To reduce the risk of injury or damage, avoid contact with any hot
surface.
To reduce the risk of serious injury, avoid attempting to lift the
generator alone.
Consult with local electrician to determine grounding requirements
before operation.
Failure to properly ground generator can result in electrocution,
especially if the generator is equipped with a wheel kit.
Page 5
For Parts Call 606-678-9623 or 606-561-4983
SYMBOLS
The following signal words and meanings are intended to explain the levels of risk associated with this product.
SYMBOL SIGNAL MEANING
DANGER:
WARNING:
CAUTION:
CAUTION:
Indicates an imminently hazardous situation, which, if not avoided, will result
in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided, could result
in death or serious injury.
Indicates a potentially hazardous situation, which, if not avoided, may result in
minor or moderate injury.
(Without Safety Alert Symbol) Indicates a situation that may result in property
damage.
SERVICE
Servicing requires extreme care and knowledge and should
be performed only by a qualified service technician. For
service, contact Baja Motorsports at 1-866-260-8280. When
servicing, use only identical replacement parts.
WARNING:
Observe all normal safety precautions related to avoid
electrical shock.
DANGER:
To avoid death or serious personal injury, do not attempt
to operate this product until you read thoroughly and
understand completely the operator’s manual. If you
do not understand the warnings and instructions in the
operator’s manual, do not use this product. Call Baja
customer service for assistance.
WARNING:
The operation of any products can result in foreign objects being thrown into your eyes, which can result in
severe eye damage. Before beginning power tool operation, always wear safety goggles or safety glasses
with side shields and, when needed, a full face shield.
over eyeglasses or standard safety glasses with side shields. Always wear eye protection which is marked
to comply with ANSI Z87.1.
We recommend Wide Vision Safety Mask for use
SAVE THESE INSTRUCTIONS
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Page 6
This engine is equipped with an oil sensor.
Fill oil to upper level if failure to start.
Check for any fuel
overflow or leaking.
Stop the engine
before refueling.
WARNING
HOT
SURFACE
For Parts Call 606-678-9623 or 606-561-4983
SYMBOLS
SAFETY LABELS
The information below can be found on the generator. For
your safety, please study and understand all of the labels
before starting the generator.
If any of the labels come off the unit or become hard to read,
contact a Baja authorized service center for replacement.
FUEL WARNING
No smoking when filling with gasoline. Do not overfill. Full
level is 1 in. below the top of the fuel neck. Stop the engine
for five minutes before refueling to avoid the heat from the
muffler igniting fuel vapors.
ENGINE OIL WARNING
You must add oil before first operating the generator. The oil
reservoir capacity is 0.6 qt. Always check the oil level before
each operation. The oil level should always register within
the hatched area on the dipstick. The unit is equipped with
an oil sensor which will automatically shut off the engine if
oil level falls below a safe limit.
HOT SURFACE WARNING
Do not touch the muffler or aluminum cylinder of the engine.
They are very HOT and will cause severe burns. Don’t put
any flammable or combustible materials in the direct path
of the exhaust.
GROUNDING
WARNING
National Electric
Code requires
generator to be
grounded to an
approved earth
ground.
VENTILATION WARNING
Do not use the generator in an enclosed area or near open
windows, vents, or doors. Fumes from the unit can kill.
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