Generac Power Systems 3500XL Manuale utente

Model No. 9441–5 (3500 Watt AC Generator) Manual No. 99112 Revision 4 (9/8/2000)

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call the generator

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3500XL

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Portable Generator Owner’s Manual

Generac Portable Products 3,500 Watt Generator

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

• 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

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

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 pre-

lubricated 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

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

Generac Portable Products 3,500 Watt Generator

Stopping the Engine

• Unplug all electrical loads from generator panel

receptacles. Never start or stop engine with electrical

devices plugged in and turned on.

• Put the idle control switch in the “Off” position.

• Let engine run at no-load for 30 seconds to stabilize the

internal temperatures of engine and generator.

• Move run/stop switch to “Stop.”

• Close the fuel shut–off valve.

Operating Automatic Idle Control

This switch is designed to greatly improve fuel economy.

When this switch is turned ON, the engine will only

run at its normal high governed engine speed when an

electrical load is connected. When an electrical load is

removed, the engine will run at a reduced speed. With

the switch off, the engine will run at the normal high

engine speed. Always have the switch off when

starting and stopping the engine.

Charging a Battery

DANGER! Storage batteries give off explosive

hydrogen gas while recharging. This explosive

mixture will remain around the battery for a long

time after it has been charged. The slightest spark

can ignite the hydrogen and cause an explosion. Such

an explosion can shatter the battery and cause

blindness or other serious injury.

DANGER! Do Not permit smoking, open flame,

sparks or any other source of heat around a battery.

Wear protective goggles, rubber apron and rubber

gloves when working around a battery. Battery

electrolyte fluid is an extremely caustic sulfuric acid

solution that can cause severe burns. If spill occurs,

flush area with clear water immediately.

Your generator has the capability of recharging a discharged

12 Volt automotive or utility style storage battery. Do Not

use the unit to charge any 6 Volt batteries. Do Not use

the unit to crank an engine having a discharged battery.

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.

• If the battery is equipped with vent caps, make sure they

are installed and are tight.

• If necessary, clean battery terminals.

• Connect battery charge cable connector plug to panel

receptacle identified by the words “12-VOLT D.C.”

• Connect battery charge cable clamp with red handle to

the positive (+) battery terminal (Figure 5).

• Connect battery charge cable clamp with black handle

to the negative (–) battery terminal (Figure 5).

• Start engine. Let the engine run while battery recharges.

• When battery has charged, shut down engine

NOTE: Use an automotive hydrometer to test battery

state of charge and condition. Follow the hydrometer

manufacturer’s instructions carefully. Generally, a battery is

considered to be at 100% state of charge when specific

gravity of its fluid (as measured by hydrometer) is 1.260 or

higher.

Figure 5 — Battery Connections

Generac Portable Products 3,500 Watt Generator

COLD WEATHER

OPERATION

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.

In an emergency, use the original shipping box as a

temporary shelter:

• Cut off all flaps.

• Cut out one of the long sides of the box to expose

exhaust side of unit. Ensure a minimum of two feet

clearance between open side of box and nearest object.

• Cut appropriate slots to access receptacles of unit. You

may also need to cut a clearance slot for the handle.

• Start unit, then place box over it.

IMPORTANT: Remove shelter when temperature is

above 40°F [4°C].

For a more permanent shelter, build a structure that will

enclose three sides and the top of the generator:

• Make sure entire muffler-side of generator is exposed. A

typical shelter is shown in Figure 6.

• Ensure a minimum of two feet clearance between open

side of box and nearest object.

• Face exposed end away from wind and elements.

• Enclosure should hold enough heat created by the

generator to prevent icing problems.

CAUTION! Never run unit indoors; Do Not

enclose generator any more than shown. Remove

shelter when temperatures are above 40°F [4°C].

RECEPTACLES

120 Volt AC, 15 Amp Receptacles

Each of these outlets is protected against overload by

15 Amp push-to-reset circuit breakers (Figure 7).

Use each outlet to operate 120 Volt AC, 60 Hz, single

phase loads requiring 1,800 (1.8 kW) watts at 15 Amps of

current.

Wind

Figure 6 — Temporary Cold Weather Shelter

Figure 7 — 120 Volt, 15 Amp Receptacles

Generac Portable Products 3,500 Watt Generator

120/240 Volt AC, 20 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.

This receptacle powers 120/240 Volt AC, 60 Hz, single

phase loads requiring up to 2,400 watts of power at

20 Amps for 120 Volts OR 3,500 watts of power (3.5 kW)

at 14.6 Amps for 240 Volts. The outlet is protected by a

push-to-reset circuit breaker.

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5-30 plug with this receptacle. Connect a 3-

wire cord set rated for 125 Volts AC at 30 Amps to the

plug (Figure 9).

Use this receptacle to operate 120 Volt AC, 60 Hz, single

phase loads requiring up to 3,500 watts (3.5 kW) of power

at 29.2 Amps. The outlet is protected by a push-to-reset

circuit breaker.

CAUTION! Although this outlet states it has a

120 Volt, 30 Amp rating (up to 3,600 watts), the

generator is only rated for 3,500 watts. Powering

loads that exceed the wattage/amperage capacity of

the generator can damage it or cause serious

injuries. Loads of 120 Volts powered through this

outlet should not exceed 29.2 Amps of current.

Figure 8 — 120/240 Volt, 20 Amp Locking Receptacle

Figure 9 — 120 Volt, 30 Amp Locking Receptacle

Generac Portable Products 3,500 Watt Generator

DON’T OVERLOAD THE

GENERATOR

Overloading a generator in excess of its rated wattage

capacity can result in damage to the generator and/or

connected electrical devices. Observe the following, to

prevent overloading the unit:

• Add up the total wattage of all electrical devices to be

connected at one time. This total should NOT be

greater than the generator’s wattage capacity.

• The rated wattage of lights can be taken from light bulbs.

The rated wattage of tools, appliances and motors can

usually be found on a data plate or decal affixed to the

device.

• 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. Be sure you allow

for this high starting wattage when selecting electrical

devices to connect to your generator. First figure the

watts needed to start the largest motor. Add to that

figure the running watts of all other connected loads.

• Items in the wattage reference guide (Figure 10) are

provided to help you to determine how many items the

generator can operate at one time.

Recreational/Home Uses

Tool/Appliance....................................................Watts

AM/FM clock radio.....................................................................50

Light bulb....................................................................................100

Fan................................................................................................200

20" color TV..............................................................................400

*Deep freezer............................................................................500

Personal computer and 15" monitor...................................800

*1/3 hp furnace fan blower.....................................................800

Microwave oven........................................................................800

*18 cu ft refrigerator...............................................................800

Sump pump..............................................................................1000

Electric skillet..........................................................................1250

*½ hp water well pump........................................................1400

*12,000 Btu window air conditioner.................................1400

Space heater............................................................................1800

Electric water heater.............................................................4000

Professional/Contractor Uses

Tool/Appliance....................................................Watts

*1/3 hp airless sprayer.............................................................600

3/8" hammer drill .....................................................................600

Variable speed Sawzall®..........................................................960

½" power drill.........................................................................1000

Quartz-halogen work light...................................................1000

Belt sander...............................................................................1200

7 ¼" circular saw ...................................................................1500

7 ¼" worm drive saw............................................................1600

*1½ hp air compressor ........................................................1800

*10" power miter saw...........................................................1800

6" bench grinder.....................................................................1800

*6" table planer.......................................................................1800

*10" table/radial arm saw .....................................................2000

Wire feed welder...................................................................2400

* allow 3 times listed watts for starting this device

Figure 10 — Wattage Reference Guide

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