3500XL Portable Generator Owner’s Manual

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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.

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 Generac Portable Products 3,500 Watt Generator

EQUIPMENT SAFETY RULES

DESCRIPTION This generator set was designed and manufactured for
specific applications. Do Not attempt to modify the unit
This generator is an engine-driven, revolving field, or use it for any application it was not designed for. If you
alternating current (AC) generator. It was designed to have any questions about your generator’s application, ask
supply electrical power for operating compatible electrical your dealer/distributor or consult the factory.
lighting, appliances, tools and motor loads. This manual
The manufacturer could not possibly anticipate every
contains information for a generator that operates 120
circumstance that might involve a hazard. For that reason
and/or 240 Volt, single phase, 60 Hz devices that require up
warnings in the manual and warnings on tags or decals
to 3,500 watts (3.5 kW) of power that pull up to
affixed to the unit are not all–inclusive. If you intend to
29.2 Amps at 120 Volts or 14.6 Amps at 240 Volts.
handle, operate or service the unit by a procedure or
CAUTION! Do Not exceed the generator’s method not specifically recommended by the manufacturer,
wattage/amperage capacity. Add up the rated watts first make sure that such a procedure or method will not
of all devices you are connecting to generator render this equipment unsafe or pose a threat to you and
receptacles at one time. This total should not be others.
greater than 3,500 watts. In most cases rated watts Read this manual carefully and become familiar
of the electrical device can be found on the device with your generator set. Know its applications, its
nameplate. If the device nameplate gives only volts limitations and any hazards involved.
and amps, multiply volts times amps to obtain watts
(volts X amps = watts). WARNING:
The 3,500 watt generator has the following features: The engine exhaust from this product contains
chemicals known to the State of California to
• 120/240 Volt, 20 Amp locking type receptacle and a cause cancer, birth defects, or other
120 Volt, 30 Amp locking type receptacle. reproductive harm.
• 120 Volt, 15 Amp receptacles.
• Low Oil Shutdown: Automatically shuts down the engine DANGER! You must isolate the generator from
if oil drops below safe operation level. the electric utility by opening the electrical system’s
main circuit breaker or main switch if this unit is
• Four gallon overhead fuel tank with fuel gauge. used for backup power. Failure to isolate the
• The generator’s revolving field is driven at about generator from the power utility may result
3,600 rpm by a Generac Power Systems 6.5 h.p. engine. in injury or death to electric utility workers
and damage to the generator due to a backfeed
WARNING! Do Not tamper with engine of electrical energy. Whenever unit is providing
governed speed. High operating speeds are backup power, the electric utility must be notified.
dangerous and increase risk of personal injury or
damage to equipment. The generator supplies DANGER! Generator exhaust gases contain
correct rated frequency and voltage only when DEADLY carbon monoxide gas. Carbon
running at proper governed speed. Incorrect monoxide, if breathed in sufficient
frequency and/or voltage can damage some concentrations, can cause unconsciousness or
connected electrical loads. Operating at excessively death. Operate this equipment outdoors where
low speeds imposes a heavy load. When adequate adequate ventilation is available.
engine power is not available engine life may be
The Emission Control System for this generator is
shortened.
warranted for standards set by the Environmental
Protection Agency. For warranty information refer to the
engine owner’s manual.

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 Generac Portable Products 3,500 Watt Generator

• The generator produces a very powerful voltage that can • Never operate the generator:
cause serious injury or death by electrocution. Never in rain; in any enclosed compartment; when connected
touch bare wires or receptacles. Never permit a child electrical devices overheat; if electrical output is lost; if
or any unqualified person to operate the generator. engine or generator sparks; if flame or smoke is
• Never handle any kind of electrical cord or device while observed while unit is running; if unit vibrates
standing in water, while barefoot or while hands or feet excessively.
are wet. Death or serious injury from electrocution may
result. GROUNDING THE
• Use a ground fault circuit interrupter (GFCI) in any damp
or highly conductive area (such as metal decking or steel
GENERATOR
work). The National Electrical Code requires that the frame and
• Never use worn, bare, frayed or otherwise damaged external electrically conductive parts of this generator be
electrical cords with the generator. Death, serious injury properly connected to an approved earth ground. Local
and property damage from electrical shock may result. electrical codes may also require proper grounding of the
• Gasoline is highly FLAMMABLE and its vapors unit. For that purpose, a GROUNDING WING NUT is
are EXPLOSIVE. Never allow smoking, open provided on the generator end (Figure 1).
flames, sparks or heat in the vicinity while Figure 1 — Grounding Wing Nut
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 Grounding Wing Nut
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.
Generally, connecting a No. 12 AWG (American Wire
• The unit requires an adequate flow of cooling air for its Gauge) stranded copper wire to the grounding wing nut
continued proper operation. Never operate the unit and to an earth-driven copper or brass grounding rod
inside any room or enclosure where the free flow of (electrode) provides adequate protection against electrical
cooling air into and out of the unit might be obstructed. shock. Be careful to keep the grounding wire attached after
Allow at least 2 feet of clearance on all sides of generator, connecting the stranded copper wire. However, local codes
even while operating unit outdoors, or you could damage may vary widely. Consult with a local electrician for
the unit. grounding requirements in your area.
• Never start, or stop the unit with electrical loads Properly grounding the generator helps prevent electrical
connected to receptacles with the connected devices shock if a ground fault condition exists in the generator or
turned ON. Start the engine and let it stabilize before in connected electrical devices. Proper grounding also helps
connecting any electrical loads. Disconnect all electrical dissipate static electricity, which often builds up in
loads before shutting down the generator. ungrounded devices.
• Do Not insert any object through cooling slots of the
engine. You could damage the unit or injure yourself.

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 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.

120 Volt AC, 15 Amp

Receptacles
Circuit Breakers (AC) Fuel Tank

Fuel Shut–Off Valve

120/240 Volt AC, 20 Amp

Locking Receptacle
Run/Stop Switch

120 Volt AC, 30 Amp

Locking Receptacle

12 Volt DC, 10 Amp

Receptacle Grounding Wing Nut
Idle Control Switch

12 Volt DC, 10 Amp Receptacle — Use this receptacle Circuit Breakers (AC) — Each receptacle is provided
with battery charge cables to charge a 12 Volt battery. with a circuit breaker to protect the generator against
120 Volt AC, 15 Amp Receptacles — May be used to electrical overload. Breakers are "push to reset" type.
supply electrical power for the operation of 120 Volt AC, Fuel Shut Off Valve — Controls fuel supply to engine.
15 Amp, single phase, 60 Hz electrical lighting, appliance, Fuel Tank — Capacity of 4 U.S. gallons.
tool and motor loads.
Grounding Wing Nut — Provides a tie-point for
120 Volt AC, 30 Amp Locking Receptacle — May be connecting the generator frame to earth ground.
used to supply electrical power for the operation of
120 Volt AC, 30 Amp, single phase, 60 Hz electrical Idle Control Switch — The idle control runs the engine
lighting, appliance, tool and motor loads. at normal (high) speeds when there is a load present and
runs the engine at idle (low) speeds when a load is not
120/240 Volt AC, 20 Amp Locking Receptacle — present. This feature greatly improves fuel economy,
May be used to supply electrical power for the operation extends the life of the engine, and reduces engine noise.
of 120 and/or 240 Volt AC, 20 Amp, single phase, 60 Hz
AC electrical lighting, appliance, tool and motor loads. Run/Stop Switch — Must be in “Run” position to start
engine. Set to “Stop” to stop a running engine.

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 Generac Portable Products 3,500 Watt Generator

BEFORE STARTING THE • Use regular UNLEADED gasoline with the Generator
engine. Do Not use premium gasoline. Do Not mix oil
ENGINE 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
WARNING! Any attempt to crank or start the fuel expansion (Figure 2).
engine before it has been properly filled with the
Figure 2 — Fill Tank with Fuel
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
• Install fuel cap and wipe up any spilled gasoline.
additional lubrication for the life of the bearing.
IMPORTANT: It is important to prevent gum deposits
Add Gasoline from forming in essential fuel system parts such as the
carburetor, fuel filter, fuel hose or tank during storage.
DANGER! Explosion Hazard! Never fill fuel tank Also, experience indicates that alcohol-blended fuels (called
indoors. Never fill fuel tank when engine is running gasohol, ethanol or methanol) can attract moisture which
or hot. Do Not light a cigarette or smoke when leads to separation and formation of acids during storage.
filling the fuel tank. Acidic gas can damage the fuel system of an engine while in
storage.
WARNING! Do Not overfill the fuel tank. To avoid engine problems, the fuel system should be
Always allow room for fuel expansion. 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.

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 Generac Portable Products 3,500 Watt Generator

OPERATING THE 6. Move the choke lever to “Half” choke position, and
pull recoil handle twice.
GENERATOR • If engine fails to start, repeat steps 4 thru 6.

CAUTION! Never start or stop, the engine with 7. Move choke lever to “Run” position. If engine falters,
electrical loads connected to the unit and with the move choke lever to “Half ” choke position until the
connected devices turned ON. engine runs smoothly and then to “Run” position.
NOTE: If engine still fails to start after 3 pulls, check for
Starting the Engine proper oil level in crankcase. This unit is equipped with a
Low Oil Shutdown System. See engine manual.
Disconnect all electrical loads from the generator. Use the
following start instruction steps by numerical order: Refer to the engine owner’s manual for complete
1. Make sure the Idle Control switch is in “Off” position. starting instructions.
2. Turn the fuel valve to the “On” position. • Grasp starter grip and pull slowly until you feel slight
resistance, then pull quickly. Ease the starter rope back
3. Set the Run/Stop switch to “Run” position (Figure 3).
into the engine.
Figure 3 — Run/Stop Switch
• 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.
4. Place the choke lever in the “Full” choke position
(Figure 4). Connecting Electrical Loads
Figure 4 — Choke Lever • Let engine stabilize and warm up for a few minutes after
starting.
Full Choke
• Plug in and turn on the desired 120 and/or 240 Volt AC,
Position
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
5. Grasp the recoil handle and pull slowly until slight Overload the Generator” on page 10.
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.

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 Generac Portable Products 3,500 Watt Generator

Stopping the Engine To recharge 12 Volt batteries, proceed as follows:

• Unplug all electrical loads from generator panel • Check fluid level in all battery cells. If necessary, add
receptacles. Never start or stop engine with electrical ONLY distilled water to cover separators in battery cells.
devices plugged in and turned on. Do Not use tap water.
• Put the idle control switch in the “Off” position. • If the battery is equipped with vent caps, make sure they
are installed and are tight.
• Let engine run at no-load for 30 seconds to stabilize the
internal temperatures of engine and generator. • If necessary, clean battery terminals.
• Move run/stop switch to “Stop.” • Connect battery charge cable connector plug to panel
receptacle identified by the words “12-VOLT D.C.”
• Close the fuel shut–off valve.
• Connect battery charge cable clamp with red handle to
the positive (+) battery terminal (Figure 5).
Operating Automatic Idle Control
Figure 5 — Battery Connections
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 • Connect battery charge cable clamp with black handle
blindness or other serious injury. to the negative (–) battery terminal (Figure 5).
• Start engine. Let the engine run while battery recharges.
DANGER! Do Not permit smoking, open flame, • When battery has charged, shut down engine
sparks or any other source of heat around a battery.
Wear protective goggles, rubber apron and rubber NOTE: Use an automotive hydrometer to test battery
gloves when working around a battery. Battery state of charge and condition. Follow the hydrometer
electrolyte fluid is an extremely caustic sulfuric acid manufacturer’s instructions carefully. Generally, a battery is
solution that can cause severe burns. If spill occurs, considered to be at 100% state of charge when specific
flush area with clear water immediately. gravity of its fluid (as measured by hydrometer) is 1.260 or
higher.
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.

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 Generac Portable Products 3,500 Watt Generator

COLD WEATHER • Ensure a minimum of two feet clearance between open

side of box and nearest object.
OPERATION • Face exposed end away from wind and elements.
Under certain weather conditions (temperatures below • Enclosure should hold enough heat created by the
40°F [4°C] and a high dew point), your Generac generator generator to prevent icing problems.
may experience icing of the carburetor and/or the
CAUTION! Never run unit indoors; Do Not
crankcase breather system.
enclose generator any more than shown. Remove
In an emergency, use the original shipping box as a shelter when temperatures are above 40°F [4°C].
temporary shelter:
• Cut off all flaps. RECEPTACLES
• Cut out one of the long sides of the box to expose
exhaust side of unit. Ensure a minimum of two feet 120 Volt AC, 15 Amp Receptacles
clearance between open side of box and nearest object.
Each of these outlets is protected against overload by
• Cut appropriate slots to access receptacles of unit. You 15 Amp push-to-reset circuit breakers (Figure 7).
may also need to cut a clearance slot for the handle.
Figure 7 — 120 Volt, 15 Amp Receptacles
• 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.
Figure 6 — Temporary Cold Weather Shelter

Wind

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.

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 Generac Portable Products 3,500 Watt Generator

120/240 Volt AC, 20 Amp Locking 120 Volt AC, 30 Amp Locking
Receptacle Receptacle
Use a NEMA L14-20 plug with this receptacle. Connect a Use a NEMA L5-30 plug with this receptacle. Connect a 3-
4-wire cord set rated for 250 Volts AC at 30 Amps (or wire cord set rated for 125 Volts AC at 30 Amps to the
greater) (Figure 8). You can use the same 4-wire cord if plug (Figure 9).
you plan to run a 120 Volt load. Figure 9 — 120 Volt, 30 Amp Locking Receptacle
Figure 8 — 120/240 Volt, 20 Amp Locking Receptacle

This receptacle powers 120/240 Volt AC, 60 Hz, single Use this receptacle to operate 120 Volt AC, 60 Hz, single
phase loads requiring up to 2,400 watts of power at phase loads requiring up to 3,500 watts (3.5 kW) of power
20 Amps for 120 Volts OR 3,500 watts of power (3.5 kW) at 29.2 Amps. The outlet is protected by a push-to-reset
at 14.6 Amps for 240 Volts. The outlet is protected by a circuit breaker.
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.

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 Generac Portable Products 3,500 Watt Generator

DON’T OVERLOAD THE • If the appliance, tool or motor does not give wattage,
multiply 120 Volts times ampere rating to determine
GENERATOR watts (volts x amps = watts).
• Some electric motors, such as induction types, require
Overloading a generator in excess of its rated wattage about three times more watts of power for starting than
capacity can result in damage to the generator and/or for running. This surge of power lasts for only a few
connected electrical devices. Observe the following, to seconds when starting such motors. Be sure you allow
prevent overloading the unit: for this high starting wattage when selecting electrical
• Add up the total wattage of all electrical devices to be devices to connect to your generator. First figure the
connected at one time. This total should NOT be watts needed to start the largest motor. Add to that
greater than the generator’s wattage capacity. figure the running watts of all other connected loads.
• The rated wattage of lights can be taken from light bulbs. • Items in the wattage reference guide (Figure 10) are
The rated wattage of tools, appliances and motors can provided to help you to determine how many items the
usually be found on a data plate or decal affixed to the generator can operate at one time.
device.

Figure 10 — Wattage Reference Guide

Recreational/Home Uses Professional/Contractor Uses
Tool/Appliance....................................................Watts Tool/Appliance....................................................Watts
AM/FM clock radio.....................................................................50 *1/3 hp airless sprayer.............................................................600
Light bulb....................................................................................100 3/8" hammer drill .....................................................................600
Fan................................................................................................200 Variable speed Sawzall®..........................................................960
20" color TV..............................................................................400 ½" power drill.........................................................................1000
*Deep freezer............................................................................500 Quartz-halogen work light...................................................1000
Personal computer and 15" monitor ...................................800 Belt sander...............................................................................1200
*1/3 hp furnace fan blower.....................................................800 7 ¼" circular saw ...................................................................1500
Microwave oven........................................................................800 7 ¼" worm drive saw............................................................1600
*18 cu ft refrigerator ...............................................................800 *1½ hp air compressor ........................................................1800
Sump pump..............................................................................1000 *10" power miter saw...........................................................1800
Electric skillet..........................................................................1250 6" bench grinder.....................................................................1800
*½ hp water well pump........................................................1400 *6" table planer.......................................................................1800
*12,000 Btu window air conditioner .................................1400 *10" table/radial arm saw .....................................................2000
Space heater............................................................................1800 Wire feed welder...................................................................2400
Electric water heater.............................................................4000 * allow 3 times listed watts for starting this device

10

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 Generac Portable Products 3,500 Watt Generator

SPECIFICATIONS To Clean the Generator

Maximum Surge Watts . . . . . . . . . . . . . .4,375 watts • Use a damp cloth to wipe exterior surfaces clean.
Continuous Wattage Capacity . . . . . . . .3,500 watts • Soft, bristle brush may be used to loosen caked on dirt
Power Factor . . . . . . . . . . . . . . . . . . . . .1.0 or oil.
Rated Maximum Continuous Load • A vacuum cleaner may be used to pick up loose dirt and
At 120 Volts . . . . . . . . . . . . . . . . . . .29.2 Amps debris.
At 240 Volts . . . . . . . . . . . . . . . . . . .14.6 Amps • Low pressure air (not to exceed 25 psi) may be used to
blow away dirt. Inspect cooling air slots and opening on
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . .1 phase
generator. These openings must be kept clean and
Rated Frequency . . . . . . . . . . . . . . . . . .60 Hertz unobstructed.
Fuel Tank Capacity . . . . . . . . . . . . . . . . .4 U.S. gallons
STORAGE INSTRUCTIONS
GENERAL MAINTENANCE The generator should be started at least once every seven
RECOMMENDATIONS days and allowed to run at least 30 minutes. If this cannot
be done and you must store the unit for more than 30
The Owner/Operator is responsible for making sure that days, use the following guidelines to prepare it for storage.
all periodic maintenance tasks are completed on a timely
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. Never operate a
Generator Storage
damaged or defective generator. • Clean the generator as outlined in “To Clean the
Generator.”
Engine Maintenance • Check that cooling air slots and openings on generator
See engine manual for instructions. are open and unobstructed.

DANGER! Storage covers can be flammable. Do

Generator Maintenance Not place a storage cover over a hot generator. Let
Generator maintenance consists of keeping the unit clean the unit cool for a sufficient time before placing the
and dry. Operate and store the unit in a clean dry cover on the unit.
environment where it will not be exposed to excessive
dust, dirt, moisture or any corrosive vapors. Cooling air Engine Storage
slots in the generator must not become clogged with snow, See engine owner’s manual for instructions.
leaves or any other foreign material.
NOTE: Do Not use a garden hose to clean generator. Other Storage Tips
Water can enter engine fuel system and cause problems. In
• Do Not store gasoline from one season to another.
addition, if water enters generator through cooling air
slots, some of the water will be retained in voids and • Replace your gasoline can if it starts to rust. Rust and/or
cracks of the rotor and stator winding insulation. Water dirt in a gasoline can cause problems when you use
and dirt buildup on the generator internal windings will contaminated fuel with this unit.
eventually decrease the insulation resistance of these • Store in clean and dry area.
windings.

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 Generac Portable Products 3,500 Watt Generator

TROUBLESHOOTING
Problem Cause Solution
1. Circuit breaker is open. 1. Reset circuit breaker.
2. Poor connection or defective 2. Check and repair.
Engine is running, but no AC cord set.
output is available. 3. Connected device is bad. 3. Connect another device that is in good
condition.
4. Fault in generator. 4. Contact Generac service facility.
1. Short circuit in a connected load. 1. Disconnect shorted electrical load.
Engine runs good but bogs 2. Generator is overloaded. 2. See "Don't Overload the Generator" on
down when loads are page 10.
connected. 3. Engine speed is too slow. 3. Contact Generac service facility.
4. Shorted generator circuit. 4. Contact Generac service facility.
1. Run/Stop switch set to "Stop". 1. Set switch to "Run".
2. Dirty air cleaner. 2. Clean or replace air cleaner.
3. Out of gasoline. 3. Fill fuel tank.
4. Stale gasoline. 4. Drain gas tank and fill with fresh fuel.
5. Spark plug wire not connected to 5. Connect wire to spark plug.
spark plug.
Engine will not start; or starts
6. Bad spark plug. 6. Replace spark plug.
and runs rough.
7. Water in gasoline. 7. Drain gas tank; fill with fresh fuel.
8. Overchoking. 8. Put choke lever to "no choke" position.
9. Low oil level. 9. Fill crankcase to proper level.
10. Excessively rich fuel mixture. 10. Contact Generac service facility.
11. Intake valve stuck open or closed. 11. Contact Generac service facility.
12. Engine has lost compression. 12. Contact Generac service facility.
1. Out of gasoline. 1. Fill fuel tank.
Engine shuts down during
2. Low oil level. 2. Fill crankcase to proper level.
operation.
3. Fault in engine. 3. Contact Generac service facility.
1. Load is too high. 1. See "Don't Overload the Generator" on
page 10.
Engine lacks power.
2. Dirty air filter. 2. Replace air filter.
3. Engine needs to be serviced. 3. Contact Generac service facility.
1. Choke is opened too soon. 1. Move choke to halfway position till
engine runs smoothly.
Engine "hunts" or falters.
2. Carburetor is running too rich or 2. Contact Generac service facility.
too lean.

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 Generac Portable Products 3,500 Watt Generator

NOTES

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 Generac Portable Products 3,500 Watt Generator

SCHEMATIC DIAGRAM

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 Generac Portable Products 3,500 Watt Generator

WIRING DIAGRAM

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 Generac Portable Products 3,500 Watt Generator

EXPLODED VIEW – MAIN UNIT

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 Generac Portable Products 3,500 Watt Generator

PARTS LIST – MAIN UNIT

Item Part # Qty. Description Item Part # Qty. Description
1 93199 1 CRADLE, XL 38 66849 2 TAPTITE, M5-0.8 x 16
2 84021 1 SUPPORT, Engine 39 B4871 1 COVER, Bearing Carrier
3 NSP 1 ENGINE, 6.5 HP XL 41 86494 1 SCREW, M6-1.0 x 16mm Wing
4 66365 1 HOUSING, Engine Adapter 42 86292 1 SCREW, 10-16 x 3/4" Self Drill
5 84141 1 ASSEMBLY, Rotor 43 77395 4 NUT, M6 Flange Lock
6 83540 1 ASSEMBLY, Stator 44 83465 4 GROMMET, Tank
7 65791 1 BEARING 46 78831B 4 SCREW, M6-1.0 x 60 (black)
8 67451 1 WASHER, M8 Flat 47 80270 1 VALVE, Tank
10 86307 4 SCREW, 5/16-24 x 3/4 48 78299 1 BUSHING, Plastic Tank
11 47480 1 SCREW, 5/16-24 x 7" Cap 49 85134 1 GUAGE, Fuel Cap
12 84508 2 MOUNT, 45º Vibration 50 88325 1 TANK, Fuel
13 52858 8 NUT, M8 Locking 51 84042 1 SHIELD, Heat
14 83208 1 BRACKET, Muffler 52 84687 1 INSULATION, #2 1/4"
15 B4986 1 DECAL, Ground 53 85000 1 CLIP, Insulation
16 66476 2 SCREW, M6 - 1.0 x 12 54 14353621 1 WIRE, Ground
17 89476 1 GASKET, Exhaust 55 23762 1 WASHER, #10 Shakeproof
18 70644 1 SCREW, M8-1.25 x 20 PPHM 56 26850 2 WASHER, M6 Shakeproof
19 84346 3 SCREW, M8 x 35 PPHM 60 84679 1 DECAL, Control Panel
20 40976 2 SCREW, M8 - 1.25 x 20 61 92982 1 DECAL, Danger
21 83083 1 SCREEN, Spark Arrest 62 84678 2 DECAL, Heat Shield
22 83071 1 MUFFLER 64 87116 1 ASSY., Control Panel
23 81917 1 PIN, M4 x 10 Roll 66 93826 1 DECAL, Start Instruction
25 66825B 1 CARRIER, Rear Bearing 67 73054 1 DECAL, Fuel Shut-Off
26 85652 2 MOUNT, Vibration 68 B2153 4 HHCS, 12 - 14 x 7/8" Self Drill
27 67989 2 NUT, M8 Flanged Serrated 69 84409 1 SLEEVING, Flexo HW 1/2" x .83
30 74908 4 TAPTITE, M5-8.0 x 10 ft.
32 86308 4 BOLT, M6-1.0 x 115 Stator
33 65795 1 RECTIFIER, Battery Charge
34 66849A 1 M5-0.8 x 20 Taptite Accessories Not Illustrated:
35 67022 1 GROMMET, Rubber 65787 1 Battery Charge Cables
36 84132 1 MODULE, Drive 43483 1 120/240 Volt 20 Amp Plug
37 66386 1 ASSEMBLY, Brush Holder 37806 1 120 Volt 30 Amp Plug

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 Generac Portable Products 3,500 Watt Generator

EXPLODED VIEW/PARTS LIST – CONTROL PANEL

Item Part # Qty. Description Item Part # Qty. Description

1 83976 1 PANEL, Control 13 84028 1 TRANSFORMER, Idle Control
2 83975 1 BOX, Control 14 67022 1 GROMMET, Rubber
3 66818 2 OUTLET, 120 Volts AC 15 85584 1 BAR, Bus
4 66821 1 OUTLET, 12 Volts DC 16 84543A 2 SCREW, 3.0 x 12mm
5 68867C 1 OUTLET, 120/240 Volts, 20 Amp 17 84543C 9 SCREW, 3.5 x 18mm
Locking 18 84198 3 SHIELD, Circuit Breaker
6 68868C 1 OUTLET, 120 Volts, 30 Amp 19 84197 1 BAR, Circuit Breaker Retaining
Locking 21 75476 2 SCREW, 4.15 x 16mm
7 75207A 1 CIRCUIT BREAKER, 30 Amp 22 22264 4 WASHER, M4 Lock
8 75207G 2 CIRCUIT BREAKER, 18 Amp 23 51715 4 NUT, M3 Hex
9 82538 1 SWITCH, On/Off Rocker 24 84543B 10 SCREW, 3.5 x 12mm
10 84134 1 GROMMET, Rubber 25 84335 1 WIRE HARNESS
11 83514 1 CIRCUIT BREAKER, 10 Amp 26 82542 1 BAR, DC Outlet Retaining
12 83970 1 CONTROL BOARD, System

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 Generac Portable Products 3,500 Watt Generator

NOTES

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 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.
Consumer* Commercial*
Alternator 2 years (2nd year parts only) 1 year
Engine Warranted solely by the engine manufacturer
With the exception of European Community Countries, all units bound for export shall be warranted for One (1)
Year in Consumer applications, and 90 days in Commercial applications as defined below.
*NOTE: For the purpose of this warranty "consumer use" means personal residential household use by
original purchaser. This warranty does not apply to units used for Prime Power in place of utility.
"Commercial Use" means all other uses, including rental, construction, commercial and income producing
purposes. Once a generator has experienced commercial use, it shall thereafter be considered a
commercial use generator for the purposes of this warranty.
During said warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination by the
COMPANY, is found to be defective under normal use and service**. Starting batteries are not warranted by the
COMPANY. All transportation costs under warranty, including return to the factory if necessary, are to be borne by the
purchaser and prepaid by the purchaser. This warranty does not cover normal maintenance and service and does not apply
to a generator set, alternator, or parts which have been subjected to improper or unauthorized installation or alteration,
misuse, negligence, accident, overloading, overspeeding, improper maintenance, repair or storage so as, in the
COMPANY’s judgement, to adversely affect its performance and reliability.
**NORMAL WEAR: As with all mechanical devices, the generator need periodic parts service and
replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of
a part or generator.
THERE IS NO OTHER EXPRESS WARRANTY. THE COMPANY HEREBY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE DURATION OF
ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO THE TIME PERIOD AS
SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL
DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS
ANY RESPONSIBILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, SUCH AS THE LOSS OF
TIME OR THE USE OF THE POWER EQUIPMENT, OR ANY COMMERCIAL LOSS DUE TO THE FAILURE
OF THE EQUIPMENT: AND ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS
WRITTEN WARRANTY.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or
consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal
rights and you may also have other rights, which vary from state to state.
For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Warranty service
can be performed only by a COMPANY authorized service facility. This warranty will not apply to service at any other
facility. At the time of requesting warranty service, evidence of original purchase date must be presented.

GENERAC PORTABLE PRODUCTS

Jefferson, Wisconsin U.S.A.

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