Generac Portable Generator 5500EXL User Manual

GENERAC  
The Reliable Ones  
5500EXL  
Portable Generator Owner’s Manual  
DANGER! This generator is designed for outdoor use only. Never use this generator inside any building  
or enclosure including the generator compartment of a recreational vehicle (RV). Carbon monoxide  
poisoning, fire and/or an explosion may result. No user performed modifications, including venting of  
exhaust and/or cooling ventilation, will eliminate the danger. Always have at least two feet of clearance on  
all sides of the generator even while operating the unit outdoors.  
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.  
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.  
Model No. 9797-3 (5500 Watt AC Generator) Manual No. 20820 Revision 3 (2/17/2000)  
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 5500EXL Extended Life Generator  
Do Not use worn, bare, frayed or otherwise  
• Never operate this generator:  
damaged electrical cord sets with 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 running; if unit vibrates  
excessively.  
• Operate the generator only on level surfaces and  
where it will not be exposed to excessive moisture,  
dirt, dust or corrosive vapors.  
• Gasoline is highly FLAMMABLE and its vapors are  
EXPLOSIVE. Do Not permit smoking, open flames,  
sparks or heat in the vicinity while handling gasoline.  
Avoid spilling gasoline on a hot engine. Comply with  
all regulations requiring storage and handling of  
gasoline.  
GROUNDING THE  
GENERATOR  
The National Electric Code requires the frame and  
external electrically conductive parts of generator be  
properly connected to approved earth ground.  
Do Not overfill the fuel tank. If overfilled, fuel can  
contact the hot engine and cause FIRE or an  
EXPLOSION.  
Local electrical codes may also require proper  
grounding of this unit. For that purpose, a  
GROUNDING WING NUT (Figure 1) is provided on the  
frame of your unit.  
• Never store the generator with fuel in its tank where  
gasoline vapors might reach an open flame, spark or  
pilot light (as on a furnace, water heater or clothes  
dryer). FIRE or EXPLOSION might result.  
Figure 1 — Location of Grounding Wing Nut  
• Generator exhaust gases contain DEADLY carbon  
monoxide gas. This dangerous gas, if breathed in  
sufficient concentrations, can cause  
unconsciousness or even death. Operate this  
equipment only in the open air where adequate  
ventilation is available.  
• 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. Without sufficient cooling air flow, the unit  
quickly overheats, damaging the generator or nearby  
property.  
Grounding Wing Nut  
• Allow at least 2 feet of clearance on all sides of the  
generator or you could damage the unit. Review  
“Cold Weather Operation” on page 8.  
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.  
• Never start or stop the unit with electrical loads  
connected to receptacles AND with the connected  
devices turned ON. Start the engine and let it  
stabilize before connecting electrical loads.  
Disconnect all electrical loads before shutting the  
unit down.  
However, local codes may vary widely. Consult with a  
local electrician for grounding requirements in your  
area. Be sure to keep the ground wire attached while  
you connect the electrode.  
Do Not insert any object through the unit’s cooling  
slots. You could damage the unit or injure yourself.  
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 to dissipate the static electricity  
which may build up in ungrounded devices.  
3
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Generac Portable Products 5500EXL Extended Life 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.  
Circuit Breakers (AC)  
Fuel Tank  
120/240 Volt AC  
30 Amp Receptacle  
120 Volt AC, 20 Amp  
Receptacle  
Electric Start Button  
Recoil Starter  
Idle Control Switch  
12 Volt DC, 10 Amp  
Receptacle  
Battery Tray  
Location  
Grounding Wing Nut  
120 Volt AC, 30 Amp  
Receptacle  
12 Volt DC, 10 Amp Receptacle — Used with battery  
charge cables to charge a 12 Volt battery.  
Circuit Breakers (AC) — Each receptacle is provided  
with a "push to reset" circuit breaker to protect the  
generator against electrical overload.  
120 Volt AC, 20 Amp Receptacles — May be used to  
supply electrical power for the operation of 120 Volt  
AC, single phase, 60 Hz electrical lighting, appliance,  
tool and motor loads.  
Electric Start Button — Press to start unit.  
Fuel Tank — Capacity of seven U.S. gallons of  
unleaded fuel.  
120 Volt AC, 30 Amp 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.  
Grounding Wing Nut— Use this connection to  
properly ground the generator.  
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.  
120/240 Volt AC, 30 Amp Receptacle — May be used  
to supply electrical power for the operation of 120  
and/or 240 Volt AC, 30 Amp, single phase, 60 Hz  
electrical lighting, appliance, tool and motor loads.  
Recoil Starter — Used as an alternate method of  
starting the unit.  
Battery Tray Location — Pre-tapped and installed  
screws are found here for the battery tray  
4
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Generac Portable Products 5500EXL Extended Life Generator  
Your generator requires some assembly and is ready  
for use after it has been properly serviced with the  
recommended oil and fuel.  
INSTALLING TRAY AND  
BATTERY  
You must purchase and install a 12 Volt DC battery  
(Series U1-109). The battery should be serviced with  
electrolyte fluid and fully charged prior to installation.  
If you have any problems with the assembly of  
your generator, please call the generator helpline  
at 1-800-270-1408.  
IMPORTANT: Any attempt to run the unit before it has  
been serviced with the recommended oil will result in  
an engine failure.  
Install the battery as follows:  
• Find battery tray and fasteners (loose) in carton.  
Includes all parts needed to mount battery and tray.  
REMOVE GENERATOR  
FROM CARTON  
• Set the carton on a rigid flat surface with “This Side  
Up” arrows pointing upward.  
• Remove the 4 battery tray screws from cradle.  
• Position the battery tray and install (Figure 2).  
Figure 2 — Install Battery Tray  
• Carefully open the top flaps of the shipping carton  
(review “Cold Weather Operation” on page 8).  
• Cut down corners at one end of carton from top to  
bottom and lay that side of carton down flat.  
• Remove all packing material, carton fillers, etc.  
• Remove the generator from the shipping carton.  
CARTON CONTENTS  
Check all contents. If any parts are missing or  
damaged, call the generator helpline at  
1-800-270-1408.  
• Set battery onto tray (Figure 3).  
• The generator  
Figure 3 — Install Battery onto Battery Tray  
• Electric start battery cables  
• Generator and engine owner’s manuals  
• Locking 20 Amp and 30 Amp plugs  
• Battery charge cables  
• Battery tray mounting bracket/hardware  
• Spare spark plug and air filter element  
• Spark plug wrench  
5
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Generac Portable Products 5500EXL Extended Life Generator  
• Retain battery to tray with 2 J-bolts, 2 lock washers  
and 2 hex nuts (Figure 3).  
BEFORE STARTING THE  
ENGINE  
Perform the following tasks before starting the unit:  
• Connect the red battery cable from the engine start  
button to the positive (+) terminal on battery  
(Figure 4).  
Figure 4 — Connect Battery Cables  
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.  
• Follow the oil grade recommendations and oil fill  
instructions given in the engine owner’s manual.  
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 Fuel  
RED wire from  
Start Button  
DANGER: 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.  
BLACK wire from  
engine mount  
CAUTION: Do Not overfill the fuel tank.  
Always allow room for fuel expansion.  
Use only regular UNLEADED 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  
(gasohol, ethanol or methanol) attract moisture,  
leading to separation and formation of acids during  
storage. Acidic gas can damage the fuel system of an  
engine.  
• Connect the black battery cable to the negative (–)  
terminal on battery (Figure 4).  
• Connect the other end of the black cable to the  
engine mount, not the frame.  
CAUTION: Be sure the black cable is  
connected to the engine mount, not the frame.  
You could damage the ground wire.  
6
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Generac Portable Products 5500EXL Extended Life Generator  
To avoid engine problems, the fuel system should be  
OPERATING THE  
GENERATOR  
emptied before storage of 30 days or longer. Drain the  
gas tank, start engine and let it run until the fuel lines  
and carburetor are empty. Use fresh fuel next season.  
See “Storage” on page 12.  
CAUTION! Never start or stop unit with  
electrical loads connected AND with the  
connected devices turned ON.  
Never use engine or carburetor cleaner products in the  
fuel tank or permanent damage may occur.  
To add fuel:  
Starting the Engine  
• Clean area around fuel fill cap, remove cap.  
• Disconnect all electrical loads from the generator.  
• Slowly add “UNLEADED” regular gasoline to fuel  
tank. Leave about a 1/2" space in the fuel tank for  
fuel expansion (Figure 5). Do Not overfill fuel tank.  
• Open the fuel shut-off valve (Figure 6).  
Figure 6 — Fuel Shut Off Valve  
Figure 5 — Fuel Tank Air Space  
• Set the Run/Stop switch to “Run” position.  
• Make sure the Idle Control switch is in “Off” position.  
• Move engine choke to “Full” choke position  
(Figure 7).  
• Install fuel cap and wipe up any spilled gasoline.  
Figure 7 — Choke Positions  
For electric start:  
• Press electric start button until engine cranks and  
starts.  
For manual start:  
• Pull slowly on recoil handle until you feel some  
resistance. Then pull rapidly to start engine. Return  
recoil slowly, Do Not let it “snap back”.  
7
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Generac Portable Products 5500EXL Extended Life Generator  
• When engine starts, move choke lever to  
COLD WEATHER  
OPERATION  
Under certain weather conditions (temperatures below  
40°F [4°C] and a high dew point), your generator may  
experience icing of the carburetor and/or the  
“Half” choke position until the engine runs smoothly  
and then 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 fails to start after 3 pulls, move the  
choke lever to “Run” position and pull starter rope  
again.  
crankcase breather system. In an emergency, use the  
original shipping box as a temporary shelter:  
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.  
• Cut off all flaps and one of the long sides of the box  
to expose exhaust side of unit. Cut appropriate slots  
to access unit’s receptacles.  
NOTE: If engine fires, but does not continue to run,  
move choke lever to “Full” choke position and repeat  
starting instructions.  
• Start unit, then place box over it. Ensure a minimum  
of two feet clearance between open side of box and  
nearest object.  
Refer to the engine owner’s manual for complete  
starting instructions.  
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,  
with two feet clearance between open side of box and  
nearest object. Face exposed end away from wind and  
elements (Figure 8).  
Applying Electrical Loads  
• Let engine stabilize and warm up for about five  
minutes after starting.  
• Plug in and turn on the desired 120 or 240 Volt AC,  
single phase, 60 Hz electrical loads.  
DO NOT OVERLOAD THE GENERATOR. Review  
“Don’t Overload the Generator” on page 11.  
Figure 8 — Temporary Cold Weather Shelter  
Wind  
Stopping the Engine  
• Disconnect all electrical loads.  
• Set the idle control to “Off” position.  
• Run engine at no-load for about two minutes.  
• Place the the 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 engine speed when an  
electrical load is connected. When the electrical load is  
removed, the engine will run at a reduced speed. With  
the switch OFF, the engine will run constantly at the  
normal high engine speed. Always have the switch  
OFF when starting and stopping the engine.  
8
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Generac Portable Products 5500EXL Extended Life Generator  
Charging a Battery  
Figure 9 — Battery Charge Cable Connection  
DANGER: Storage batteries give off explosive  
hydrogen gas while recharging. An 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 injury.  
Red  
Black  
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.  
• Connect battery charge cable clamp with black  
handle to the negative (–) battery terminal  
(Figure 9).  
• Start engine. Let the engine run while battery  
recharges.  
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.  
• 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.  
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 9).  
9
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Generac Portable Products 5500EXL Extended Life Generator  
Use this receptacle to operate 120 Volt AC, 60 Hz,  
CORD SETS/RECEPTACLES  
This generator is equipped with the following  
receptacles:  
single phase loads requiring up to 3600 watts (3.6 kW)  
of power at 30 Amps. The outlet is protected by a  
30 Amp push-to-reset circuit breaker.  
120/240 Volt AC, 30 Amp Locking  
Receptacle  
Use a NEMA L14-30 plug with this receptacle. Connect  
a 4-wire cord set rated for 250 Volt AC loads at  
30 Amps (or greater) (Figure 12). You can use the  
same 4-wire cord if you plan to run a 120 Volt load.  
120 Volt AC, 20 Amp Receptacles  
Each socket (Figure 10) is protected against overload  
by a 20 Amp push-to-reset circuit breaker. Use each  
receptacle to operate 120 Volt AC, single phase, 60 Hz  
electrical loads requiring up to 2400 watts (2.4 kW) at  
20 Amps of current.  
Figure 10 — 120 Volt AC, 20 Amp Receptacles  
Figure 12 — 120/240 Volt AC, 30 Amp Receptacle  
Use cord sets that are rated for 125 Volt AC loads at  
20 Amps (or greater).  
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 11).  
This receptacle powers 120/240 Volt AC, 60 Hz, single  
phase loads requiring up to 3,600 watts of power  
(3.6 kW) at 30 Amps for 120 Volts OR 5,500 watts of  
power (5.5 kW) at 22.9 Amps for 240 Volts. The outlet  
is protected by a 30 Amp push-to-reset circuit breaker.  
Figure 11 — 120 Volt, 30 Amp Receptacle  
CAUTION! Although this outlet states it has a  
240 Volt 30 Amp rating (up to 7,200 watts), the  
generator is only rated for 5,500 watts.  
Powering loads that exceed the wattage/  
amperage capacity of the generator can  
damage it or cause serious injuries.  
240 Volt loads powered through this outlet  
should not exceed 22.9 Amps of current draw.  
10  
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Generac Portable Products 5500EXL Extended Life Generator  
• The rated wattage of lights can be taken from  
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:  
wattage listed on the light bulbs. The rated wattage  
of tools, appliances and motors can usually be found  
on a data plate or decal affixed to the device. Use  
Figure 13 below as a general reference.  
• 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.  
• 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.  
• If the appliance, tool or motor does not give wattage,  
multiply 120 Volts times ampere rating to determine  
watts (volts x amps = watts).  
Figure 13 — Wattage Reference Guide  
Device . . . . . . . . . . . . . . . . . . . . . . . . . . Load (watts)  
*Air Conditioner (12,000 Btu). . . . . . . . . . . . . . . . 1700  
*Air Conditioner (24,000 Btu). . . . . . . . . . . . . . . . 3800  
*Air Conditioner (40,000 Btu). . . . . . . . . . . . . . . . 6000  
Battery Charger (20 Amp) . . . . . . . . . . . . . . . . . . . 500  
Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . 1000  
Device . . . . . . . . . . . . . . . . . . . . . . . . . . Load (watts)  
Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . 450  
Impact Wrench. . . . . . . . . . . . . . . . . . . . . . . . . . . . 500  
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200  
*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800  
Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200  
Chain Saw. . . . . . . . . . . . . . . . . . . . . . . . . . . . L.ig.h1t 2B0u0lb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100  
Circular Saw (6-1/2") . . . . . . . . . . . . . . . . 800 to 1000  
*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . 5750  
*Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . 700  
*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . 1150  
Coffee Maker. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750  
*Compressor (1 HP) . . . . . . . . . . . . . . . . . . . . . . 2000  
*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . 1800  
*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . 1400  
Curling Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700  
*Freezer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700  
*Dehumidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650  
Disc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . . 1200  
Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500  
Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . 400  
Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . 1200  
Electric Range (per element). . . . . . . . . . . . . . . . 1500  
Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250  
*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . 875  
*Garage Door Opener . . . . . . . . . . . . . . . . 500 to 750  
Hair Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200  
Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . 250 to 1100  
Microwave Oven. . . . . . . . . . . . . . . . . . . . 700 to 1000  
*Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100  
Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . 300  
Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . 400  
Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . 225  
Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . 150  
*Paint Sprayer, Airless (1/3 HP). . . . . . . . . . . . . . . 600  
Paint Sprayer, Airless (handheld) . . . . . . . . . . . . . 150  
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 200  
*Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700  
Slow Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200  
*Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . 2800  
*Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . 2000  
*Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . 1500  
*Sump Pump . . . . . . . . . . . . . . . . . . . . . . 800 to 1050  
*Table Saw (10"). . . . . . . . . . . . . . . . . . . 1750 to 2000  
Television . . . . . . . . . . . . . . . . . . . . . . . . . . 200 to 500  
Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 to 1650  
Weed Trimmer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 500  
* Allow 3 times the listed watts for starting these devices.  
11  
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Generac Portable Products 5500EXL Extended Life Generator  
GENERAL MAINTENANCE  
RECOMMENDATIONS  
STORAGE  
The generator should be started at least once every  
seven days and allowed to run at least 30 minutes.  
The owner/operator is responsible for making sure that  
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 damaged or defective generator.  
If this cannot be done and you must store the unit for  
more than 30 days, use the following guidelines to  
prepare it for storage.  
Generator Storage  
• Clean the generator as outlined in “To Clean the  
Generator.”  
Engine Maintenance  
See engine manual for instructions.  
• Check that cooling air slots and openings on  
generator are open and unobstructed.  
Generator Maintenance  
• Disconnect the negative battery cable from the  
battery.  
Generator maintenance consists of keeping the unit  
clean and dry. Operate and store the unit in a clean dry  
environment where it will not be exposed to excessive  
dust, dirt, moisture or any corrosive vapors. Cooling air  
slots in the generator must not become clogged with  
snow, leaves or any other foreign material.  
DANGER: Storage covers can be flammable.  
Do Not place a storage cover over a hot  
generator. Let the unit cool for a sufficient time  
before placing the cover on the unit.  
Check the cleanliness of the generator frequently and  
clean when dust, dirt, oil, moisture or other foreign  
substances are visible on its exterior surface.  
Engine Storage  
See engine owner’s manual for instructions on how to  
properly store the engine.  
NOTE: Do Not use a garden hose to clean generator.  
Water can enter engine fuel system and cause  
problems. In addition, if water enters generator through  
cooling air slots, some of the water will be retained in  
voids and cracks of the rotor and stator winding  
insulation. Water and dirt buildup on the generator  
internal windings will eventually decrease the  
insulation resistance of these windings.  
Other Storage Tips  
Do Not store gasoline from one season to another.  
• Replace your gasoline can if it starts to rust. Rust  
and/or dirt in a gasoline can cause problems when  
you use contaminated fuel with this unit.  
• Store in clean and dry area.  
Clean the Generator  
• Use a damp cloth or soft bristle brush to wipe  
exterior surfaces clean.  
SPECIFICATIONS  
Rated Maximum Continuous  
• A vacuum cleaner may be used to pick up loose dirt  
and debris.  
AC Power Output. . . . . . . . . . . . 5500 watts (5.5 kW)  
Rated AC Voltage . . . . . . . . . . . 120/240 Volts  
Rated Maximum AC Current:  
at 240 Volts. . . . . . . . . . . . . . . 22.9 Amperes  
at 120 Volts. . . . . . . . . . . . . . . 45.8 Amperes  
Phase . . . . . . . . . . . . . . . . . . . . 1  
• Low pressure air (not to exceed 25 psi) may be used  
to blow away dirt. Inspect cooling air slots and  
opening on generator. These openings must be kept  
clean and unobstructed.  
Rated AC Frequency. . . . . . . . . 60 Hertz  
Number of Rotor Poles . . . . . . . 2  
Driven Speed of Rotor . . . . . . . . 3600 RPM  
SERVICE/ADJUSTMENTS  
Refer to engine owner’s manual for information.  
12  
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Generac Portable Products 5500EXL Extended Life Generator  
TROUBLESHOOTING  
Problem  
Cause  
Correction  
1. Reset circuit breaker.  
1. One of the circuit breakers is  
open.  
2. Fault in generator.  
3. Poor connection or defective  
cord set.  
2. Contact Generac service facility.  
3. Check and repair.  
Engine is running, but no  
AC output is available.  
4. Connected device is bad.  
4. Connect another device that is in  
good condition.  
1. Short circuit in a connected load. 1. Disconnect shorted electrical load.  
2. Engine speed is too slow.  
3. Generator is overloaded.  
2. Contact Generac service facility.  
3. See “Don't Overload the  
Generator” on page 11.  
4. Contact Generac service facility.  
Engine runs good at no-load  
but “bogs” down" when  
loads are connected.  
4. Shorted generator circuit.  
1. Run/Stop Switch set to “Stop”.  
2. Dirty air cleaner.  
3. Out of gasoline.  
1. Set switch to “Run”.  
2. Clean or replace air cleaner.  
3. Fill fuel tank.  
4. Stale gasoline.  
4. Drain gas tank; fill with fresh fuel.  
5. Spark plug wire not connected to 5. Connect wire to spark plug.  
spark plug.  
6. Bad spark plug.  
7. Water in gasoline.  
8. Overchoking.  
6. Replace spark plug.  
Engine will not start; or  
starts and runs rough.  
7. Drain gas tank; fill with fresh fuel.  
8. Open choke fully and crank  
engine.  
9. Excessively rich fuel mixture.  
10. Intake valve stuck open or  
closed.  
9. Contact Generac service facility.  
10. Contact Generac service facility.  
11. Engine has lost compression.  
12. Failed battery.  
11. Contact Generac service facility.  
12. Replace battery.  
1. Out of gasoline.  
2. Low oil level.  
1. Fill fuel tank.  
2. Fill crankcase to proper level.  
Engine shuts down during  
operation.  
1. Load is too high.  
1. See “Don't Overload the  
Generator” on page 11.  
2. Replace air filter.  
Engine lacks power.  
2. Dirty air filter.  
1. Choke is opened too soon.  
1. Move choke to halfway position  
until engine runs smoothly.  
Engine “hunts” or falters.  
2. Carburetor is running too rich or  
too lean.  
2. Contact Generac service facility.  
13  
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Generac Portable Products 5500EXL Extended Life Generator  
SCHEMATIC DIAGRAM  
14  
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Generac Portable Products 5500EXL Extended Life Generator  
WIRING DIAGRAM  
15  
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Generac Portable Products 5500EXL Extended Life Generator  
EXPLODED VIEW  
16  
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Generac Portable Products 5500EXL Extended Life Generator  
PARTS LIST  
Item Part #  
Qty. Description  
Item Part #  
Qty. Description  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
A92432  
A92531  
A92731  
92247  
92678G  
94980A  
65791  
67451  
22129  
86307  
28092  
92609  
82857  
92532  
90239  
66476  
1
1
1
1
1
1
1
1
CRADLE  
46  
47  
48  
49  
51  
52  
55  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
92665  
85000  
14353621 1  
1
1
INSULATION, #2-1/4" Thick  
CLIP, Insulation  
WIRE, Ground  
SUPPORT, Engine  
SUPPORT, Engine & Muffler  
HOUSING, Engine Adapter  
ASSEMBLY, Rotor  
ASSEMBLY, Stator  
BEARING  
26850  
92982  
96057  
25244  
96058  
92630  
NSP  
22531  
22142  
77282  
22287  
22097  
22127  
78289  
93826  
B96068  
56893  
B2153  
22473  
2
1
2
LW, EXT, Shakeproof M6  
DECAL, Danger  
DECAL, Heat Shield  
12 NUT, 5/16-18 Hex  
WASHER, Special Flat - M8  
1
1
1
2
2
1
2
2
2
1
1
1
5
8
4
DECAL, Control Panel  
ASSEMBLY, Control Box  
ENGINE  
HHCS, 5/16-18 x 1-3/4"  
SCREW, 5/16-18 x 3/4"  
SWITCH, Starter  
SCREW, 1/4 - 20 x 3/4  
LOCKWASHER, M6  
NUT, 1/4 - 20 Hex  
BRACKET, Starter Switch  
DECAL, Start Instructions  
SHIELD, Heat  
16 WASHER, Lock - M8  
4
1
2
4
1
1
2
HHMS, 5/16-24 x 3/4  
HHCS, 5/16-24 x 9-1/4  
MOUNT, Vibration  
MOUNT, Vibration  
BRACKET, Muffler  
GASKET, Muffler  
CAPSCREW, M6 - 1.0 x  
12mm  
17  
18  
19  
20  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
A7433  
40976  
83083  
81917  
66825C  
74908  
86308A  
65795  
66849C  
67022  
84132  
66386  
66849  
B67025  
22769  
86494  
86292  
77395  
83465  
57058  
80270  
78299  
B4363  
B1695  
B92039  
1
2
1
1
1
4
4
2
1
1
1
1
2
1
1
1
1
4
4
4
1
1
1
1
1
MUFFLER  
SCREW, M8 - 1.25 x 20  
SCREEN, Spark Arrester  
PIN, Roll 4mm x 10  
CARRIER, Rear Bearing  
TAPTITE, M5-0.8 x 10  
BOLT, Stator M6-1 x 145mm  
RECTIFIER, Battery Charge  
TAPTITE, M5-0.8 x 30  
GROMMET, Rubber  
ASSEMBLY, Power Regulator  
ASSEMBLY, Brush Holder  
TAPTITE, M5-0.8 x 16  
COVER, Bearing Carrier  
WASHER, Shakeproof Int. #10  
SCREW, M6-1.0 x 16 Wing  
HHCS, - #10 Self Driller  
NUT, Flange Lock - M6  
GROMMET, Tank  
CRIMPTITE, 10-24 x 1/2  
SCREW, #12 Self Drill  
WASHER, Flat M6  
Parts Not Illustrated:  
37806  
43438  
72347  
73111  
84882  
20820  
65787  
1
1
1
1
1
1
1
125V 30A Locking plug  
240V 30A Locking plug  
Spark plug  
Air cleaner element  
Spark plug wrench  
Owners manual  
Battery charge cable  
Battery Tray Components:  
22129  
45771  
96925  
96924  
15453621 1  
15553621 1  
96923  
22145  
58443  
2
2
1
2
Lockwasher, M8  
Hex nut M8  
Battery tiedown  
J-bolt  
Battery cable, positive  
Battery cable, negative  
Battery tray  
HHCS, M6-1.0 x 55  
VALVE, Tank  
BUSHING, Tank  
CAP, with Gauge, Fuel  
TANK, Fuel 7 Gal.  
SHIELD, Heat  
1
2
4
Flat washer  
Screws, battery tray  
17  
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Generac Portable Products 5500EXL Extended Life Generator  
CONTROL PANEL EXPLODED VIEW & PARTS LIST  
Item Part #  
Qty. Description  
Item Part #  
Qty. Description  
1
2
A92070  
23897  
49226  
91526  
82538  
82881  
43181  
43182  
90418  
75207A  
75207  
23365  
68868  
1
4
4
4
1
4
4
4
1
2
2
6
1
PANEL, Control  
14  
43437  
1
OUTLET, 120V/240V, 30A  
Locking Type  
FLAT WASHER, #10 M5  
LOCK WASHER, M5  
SCREW, M5-0.8 x 12mm  
SWITCH, Idle Control  
LOCK WASHER, 7/16"  
SCREW, M3 - 0.5 x 10mm  
LOCK WASHER, M3  
OUTLET, 12V  
CIRCUIT BREAKER, 30A  
CIRCUIT BREAKER, 20A  
WASHER, #8 Shakeproof  
OUTLET, 120 Volt, 30 Amp  
Locking Type  
3
4
5
6
7
8
9
15  
16  
17  
18  
19  
20  
21  
22  
68759  
43180  
22264  
51715  
64526  
83970  
64525  
87962  
1
6
6
6
8
1
4
1
OUTLET, 120V, 20A Duplex  
FLAT WASHER, M4  
LOCK WASHER, #8 M4  
NUT, M4-0.7 Hex  
SCREW, #6-32 x 3/8"  
BOARD, System Control  
STAND-OFF, 3/4" Hex  
CIRCUIT BREAKER. 12V,  
10A (auto)  
10  
11  
12  
13  
23  
24  
25  
26  
84335  
84134  
B92069  
84028  
1
1
1
1
ASSEMBLY, Wire Harness  
GROMMET, Rubber Conn  
BOX, Control Panel  
TRANSFORMER, Idle Control  
18  
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Generac Portable Products 5500EXL Extended Life Generator  
NOTES  
19  
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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  
Engine  
2 years (2nd year parts only)  
Warranted solely by the engine manufacturer  
1 year  
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 53549  
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