Pramac ES5500X 5.5 KW, Supplemental Instructions, Page: 3 / 17

Pramac Industries SERVICE BULLETIN TSB1001
Page 1 of 3
Date: 23-Jun-03
PRODUCTS INVOLVED
ES5500X(ES5500MYHDI-AB00W) generators with serial numbers between 2002US21034 and
2003US25890.
ISSUE
Some generators may have been produced with the wiring between the alternator and the electrical
panel connected improperly. There may also be a ground to neutral jumper wire in the control panel.
This bulletin has been produced to define parts and procedures in correcting the wiring.
SYMPTOMS
On generators with this problem, one of the circuit breakers will trip upon cranking. This can go un-
noticed because the generator may continue to perform, however, maximum capacity cannot be
obtained. The circuit breakers also have weather boots, which can disguise the fact that the circuit
breaker has tripped. There may also be problems with the GFCI tripping when using certain tools,
specifically a Milwaukee brand 6460 circular saw. Note: This does not present a safety problem.
ACTIONS
For generators within the defined serial number range and model number experiencing the
previously described problems a new wiring harness, part number PIT0005, will be provided under
warranty. Contact the Service/Warranty Manager at (770) 479-2922 and reference this TSB number.
Note that the existing wiring diagram in the generator manual is correct and may be used when
connecting the new wire harness. An electrical diagram is also shown on page 2. Where the ground
to neutral jumper exists on the panel, use the following procedures to remove it.
There are 2 sets of procedures below. If your generator exhibits both problems the corrective actions
can easily be combined. Read both sets of procedures thoroughly.
Upon receipt of the wiring harness from the Service/Warranty Department follow the steps below to
correct the generator wiring.
Tools required: Phillips head screwdriver, small standard screwdriver, 10mm Socket or wrench.
Make certain that the generator is not running before beginning.
Read the instructions completely
before beginning work. Refer to page 2 for photos showing the harness correctly installed.
1. Remove the back cover from the alternator using a Phillips head screwdriver and removing
the 4 screws in the corners.
2. Disconnect the green wire from the alternator body inside the panel with the same
screwdriver.
3. Disconnect the existing harness from the alternator by pulling the white connector apart.
4. Remove the bolts around the perimeter of the control panel using the 10mm socket or wrench
and rotate the panel down.
5. Using the standard screwdriver, disconnect the existing harness(5 wires
–
1 green, 2 white, 2
black) from the bottom of the terminal block which is mounted on the control panel.
6. Remove the existing harness from the generator and discard. Route the new harness into
roughly the same position as the old one.