Generac 5500EXL Portable Generator User Manual
Contents
1. Q 120v EGER o 120V 444 20A HA 22 30A 44B 11A 44A WHITE 444 JA x G i ze WHITE G uB 204 204 304 304 L A Gi 114 CB CB CB CB B ap I z OZ DUTLET TAB X 448 MUST BE 11B BROKEN OFF GRN YEL 114 S 5 5 G 44 dia it 11 11 IDLE CONTROL BLU SWITCH 55 GRN BLU WHT 11 15 55 ee 44 IDLE CONTROL DC CB TRANSFORMER l A A 11 P 4 44 GRN 155 55 22 44 13 e eT o o SYSTEM f e CONTROL i z BOARD in 3 H ill BLK A5 uu o NA WHT BLK e e ai 44 55 fi d am RED BLU L ji 6 IDLE BLU WHT 1 i CONTROL YEL 22 2 CDIL Ti ea STATUR Jo HH WHT LOW OIL Hu Q Ss SNUBBER iH 3 PIN SWITCH 13 FEEDBACK CUNNECTUR L 2 S 66 CUSTOMER SHROUD LE GROUND n ANODE qn OIL 13 LUG XPUS BRUSH fi BLKL PRESSURE CL2. 19 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 ar
3. ARE LIMITED TO THE DURATION OF THIS WRITTEN WARRANT Y 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
4. Not light a cigarette or smoke when filling the fuel tank 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 Generac Portable Products 5500EXL Extended Life Generator To avoid engine problems the fuel system should be 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 Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur To add fuel Clean area around fuel fill cap remove cap 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 Figure 5 Fuel Tank Air Space E I 0 OI OO OO I I RI Mem A I IIR LO II I I I MR Install fuel cap and wipe up any spilled gasoline OPERATING THE GENERATOR CAUTION Never start or stop unit with electrical loads connected AND with the connected devices
5. air slots in the generator must not become clogged with snow leaves or any other foreign material Check the cleanliness of the generator frequently and clean when dust dirt oil moisture or other foreign substances are visible on its exterior surface 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 Clean the Generator Use a damp cloth or soft bristle brush to wipe exterior surfaces clean A vacuum cleaner may be used to pick up loose dirt and debris 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 SERVICE ADJUSTMENTS Refer to engine owner s manual for information 12 Generac Portable Products 5500EXL Extended Life Generator STORAGE The generator should be started at least once every seven days and allowed to run at least 30 minutes 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 Genera
6. is provided on the frame of your unit Figure 1 Location of Grounding Wing Nut Grounding Wing Nut 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 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 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 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 Fuel Tank Electric Start Button Recoil Starter Battery Tray Location TAR 120 Volt AC 30 Amp Receptacle 12 Volt DC 10 Amp Receptacle Used with battery charge cables to charge a 12 Volt battery 120 Volt AC 20 Amp Receptacles May be used to supply electrical power for the operation of 120 Volt AC single phase 60 Hz electric
7. turned ON Starting the Engine Disconnect all electrical loads from the generator Open the fuel shut off valve Figure 6 Figure 6 Fuel Shut Off Valve Fuel Tank Fuel Valve s Qpen Position Shown 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 Figure 7 Choke Positions L 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 Generac Portable Products 5500EXL Extended Life Generator When engine starts move choke lever to 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 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 NOTE If engine fires but does not continue to run move choke lever to Full choke position and repeat starting instructions Refer to the engine owner s manual fo
8. 4 battery tray screws from cradle Position the battery tray and install Figure 2 Figure 2 Install Battery Tray Generac Portable Products 5500EXL Extended Life Generator Retain battery to tray with 2 J bolts 2 lock washers and 2 hex nuts Figure 3 Connect the red battery cable from the engine start button to the positive terminal on battery Figure 4 Figure 4 Connect Battery Cables RED wire from Start Button BLACK wire from engine mount 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 connected to the engine mount not the frame You could damage the ground wire 1 CAUTION Be sure the black cable is BEFORE STARTING THE ENGINE Perform the following tasks before starting the unit Add Oil WARNING Any attempt to crank or start the A 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 DANGER NEVER fill fuel tank indoors A NEVER fill fuel tank when engine is running or hot Do
9. 7 93826 68 B96068 69 56893 70 B2153 71 22473 Parts Not Illustrated 37806 43438 72347 73111 84882 20820 65787 22129 45771 96925 96924 15453621 15553621 96923 22145 58443 RMA ND NN Lockwasher M8 Hex nut M8 Battery tiedown J bolt Battery cable positive Battery cable negative Battery tray Flat washer Screws battery tray Item Part Z A92070 23897 49226 91526 82538 82881 43181 43182 90418 75207A 75207 23365 68868 Qty 4 4 4 4 1 4 4 4 1 2 2 6 1 Description PANEL Control 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 18 Item Part 14 43437 15 68759 16 43180 17 22204 18 51715 19 64526 20 83970 21 64525 22 87962 23 84335 24 84134 25 B92069 26 84028 Qty 1 1 6 6 6 8 1 4 1 Generac Portable Products 5500EXL Extended Life Generator Description OUTLET 120V 240V 30A Locking Type 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 ASSEMBLY Wire Harness GROMMET Rubber Conn BOX Control Panel TRANSFORMER Idle Control Generac Portable Products 5500EXL Extended Life Generator NOTES
10. Choke is opened too soon 1 Move choke to halfway position Engine hunts or falters until engine runs smoothly 2 Carburetor is running too richor 2 Contact Generac service facility too lean 13 Generac Portable Products 5500EXL Extended Life Generator SCHEMATIC DIAGRAM POWER REGULATHR BHARD Mi i 1 2 4 s N U DPE B B E R S F H El E E D L B D A a K a IDLE E CONTROL TRANSFORMER i J se a po n N Y A L 155 156 op d IDLE CONTROL BLK SYSTEM CDIL BLK CONTROL FT BOARD T GRN YEL ay LEP AP LED e BLu RED 22 30A RED BLU WHT CB Q OFF e ON up 11 e N SW IDLE CONTROL SWITCH soo 18 11 T 120v RUN 304 A 30 STOP c B ENG SPARK iini b SWITCH PLUG aL 180V 204 so oo ENG kone h IGNITION 22 GB BATTERY CHARGE DO Me MA 5 44 7 GRN YEL sped 0 134 13A B nettet ae ene o ue START CL BATTERY se SWITCH IT 18 55 STARTER AUTO l TL RESET an E 35 Ms ER 104 C B n 120 240V OS SJi2v 10A DC 30 14 Generac Portable Products 5500EXL Extended Life Generator WIRING DIAGRAM
11. 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 Engine runs good at no load 2 Engine speed is too slow 2 Contact Generac service facility but bogs down when 3 Generator is overloaded 3 See Don t Overload the loads are connected Generator on page 11 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 fill with fresh fuel 5 Spark plug wire not connected to 5 Connect wire to spark plug spark plug 6 Bad spark plug 6 Replace spark plug Engine will not start or 7 Water in gasoline 7 Drain gas tank fill with fresh fuel starts and runs rough 8 Overchoking 8 Open choke fully and crank engine 9 Excessively rich fuel mixture 9 Contact Generac service facility 10 Intake valve stuck open or 10 Contact Generac service facility closed 11 Engine has lost compression 11 Contact Generac service facility 12 Failed battery 12 Replace battery Engine shuts down during 1 Outof gasoline 1 Fill fuel tank operation 2 Low oil level 2 Fill crankcase to proper level 1 Load is too high 1 See Don t Overload the Engine lacks power D Generator on page 11 2 Dirty air filter 2 Replace air filter 1
12. GENERAC The Reliable Ones 5S5500EXL Portable Generator Owner s Manual DANGER This generator is designed for outdoor use only Never use this generator inside any building A 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 A 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 EQUIPMENT DESCRIPTION This generator is an engin
13. OSEST TO it SHIELD 18 N LED 774 BEARING gt x LO GATE n CATHODE 134 TOP 4 Ht BLK WHT 1 i menn ELECTRIC o ENGINE START 77 1 RUN 18 SWITCH aji LI 9 BATTERY aoe 13 16 CHARGE 6 REGULATDR ii H Hu RECTIFIER B EA GRN e L_ 66a ii a SPARK 13A o PLUG ri ri 55 774 NUT ON ui To STARTER BOTTOM ENGINE BLOCK FRAME CUSTOMER GROUND SUPPLIED BATTERY lt 15 Generac Portable Products 5500EXL Extended Life Generator DETA 62 TO STARTER ELECTRIC START SWITCH EN A i e A Pu ay PARTS LIST Item Part Z 1 A92432 1 2 A92531 1 3 A92731 1 4 92247 1 5 92678G 1 6 94980A 1 7 65791 1 8 67451 1 9 22129 16 10 86307 4 11 28092 1 12 92609 2 13 82857 4 14 92532 1 15 90239 1 16 66476 2 17 A7433 1 18 40976 2 19 83083 1 20 81917 1 25 66825C 1 26 74908 4 27 86308A 4 28 65795 2 29 66849C 1 30 67022 1 31 84132 1 32 66386 1 33 66849 2 34 B67025 1 35 22769 1 36 86494 1 37 86292 1 38 77395 4 39 83465 4 40 57058 4 41 80270 1 42 78299 1 43 B4363 1 44 B1695 1 45 B92039 1 Generac Portable Products 5500EXL Extended Life Generator Qty Description CRADLE SUPPORT Engine SUPPORT Engine amp Muffler HOUSING Engine Adapter ASSEMBLY Rotor ASSEMBLY Stator BEARING WASHER Special Flat M8 WASHER Lock M8 HHMS 5 16 24 x 3 4 HHCS 5 16 24 x 9 1 4 MOUNT Vibration MOUNT Vibration BRACKET Muffler GA
14. SKET Muffler CAPSCREW M6 1 0 x 12mm 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 HHCS M6 1 0 x 55 VALVE Tank BUSHING Tank CAP with Gauge Fuel TANK Fuel 7 Gal SHIELD Heat 17 Qty OS N 6 A OO NN NN NN Description INSULATION 2 1 4 Thick CLIP Insulation WIRE Ground LW EXT Shakeproof M6 DECAL Danger DECAL Heat Shield NUT 5 16 18 Hex 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 CRIMPTITE 10 24 x 1 2 SCREW 12 Self Drill WASHER Flat M6 125V 30A Locking plug 240V 30A Locking plug Spark plug Air cleaner element Spark plug wrench Owners manual Battery charge cable Battery Tray Components Item Part 46 92665 47 85000 48 14353621 49 26850 51 92982 52 96057 55 25244 57 96058 58 92630 59 NSP 60 22531 61 22142 62 77282 63 22287 64 22097 65 22127 66 78289 6
15. al lighting appliance tool and motor loads 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 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 Battery Tray Location Pre tapped and installed screws are found here for the battery tray Circuit Breakers AC 120 240 Volt AC 30 Amp Receptacle 120 Volt AC 20 Amp 1 p Receptacle l m Idle Control Switch 12 Volt DC 10 Amp Receptacle Grounding Wing Nut Circuit Breakers AC Each receptacle is provided with a push to reset circuit breaker to protect the generator against electrical overload Electric Start Button Press to start unit Fuel Tank Capacity of seven U S gallons of unleaded fuel 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 Recoil Starter Used as an alternate method of starting the unit Generac Portable Products 5500EXL Extended Life Generator Your generator requires some assembly and is ready for use after it has been properly s
16. ceptacle 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 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 Figure 11 120 Volt 30 Amp Receptacle 3 Wire Cord Set Neutral 120V Hot Ground 7 Green NEMA L5 30 Use this receptacle to operate 120 Volt AC 60 Hz 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 Figure 12 120 240 Volt AC 30 Amp Receptacle 4 Wire Cord Set Q Neutral NEMA L14 30 Green 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 CAUTION Although this o
17. 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 e e 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 e Figure 9 Battery Charge Cable Connection 12 VOLT D C RECEPTACLE Connect battery charge cable clamp with black handle to the negative battery terminal Figure 9 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 10096 state of charge when specific gravity of its fluid as measured by hydrometer is 1 260 or higher Generac Portable Products 5500EXL Extended Life Generator CORD SETS RECEPTACLES This generator is equipped with the following receptacles 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 re
18. e driven revolving field alternating current AC generator It was designed to supply electrical power for operating compatible electrical lighting appliance tool and motor loads This manual contains information for a generator that operates 120 and or 240 Volt AC single phase 60Hz devices that require up to 5 500 watts 5 5 kW of power that pull up to 45 8 Amps at 120 Volts or 22 9 Amps at 240 Volts CAUTION Do Not exceed the generator s A wattage amperage capacity Add up the rated watts of all devices you will connect to generator receptacles at one time This total should not be greater than 5 500 watts for this generator Review Don t Overload the Generator on page 11 The generator s revolving field is driven at about 3600 rpm by a single cylinder engine Every effort has been made to ensure that information in this manual is accurate and current However Generac reserves the right to change alter or otherwise improve the product and this document at any time without prior notice DANGER Do Not tamper with engine A governed speed High operating speeds are dangerous and increase the risk of personal injury or damage to equipment The unit supplies correctly 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 on the engine and may shorten engine life gl G
19. e 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
20. e 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 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 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 Do Not insert any object through the unit s cooling slots You could damage the unit or injure yourself Never operate this 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 GROUNDING THE GENERATOR The National Electric Code requires the frame and external electrically conductive parts of generator be properly connected to approved earth ground Local electrical codes may also require proper grounding of this unit For that purpose a GROUNDING WING NUT Figure 1
21. enerac Portable Products 5500EXL Extended Life Generator 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 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 this unit by a procedure or method not specifically recommended by the manufacturer first make sure the 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 A WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The generator produces a very powerful voltage that can cause extremely dangerous electrical shock Avoid contact with bare wires terminals etc Never permit any unqualified person to operate or service the generator Never handle any kind of electrical cord or device while standing in water while barefoot or while hands or feet are wet The National E
22. erviced with the recommended oil and fuel Ifyou 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 REMOVE GENERATOR FROM CARTON Set the carton on a rigid flat surface with This Side Up arrows pointing upward e 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 e 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 The generator e Electric start battery cables Generator and engine owner s manuals e Locking 20 Amp and 30 Amp plugs Battery charge cables e Battery tray mounting bracket hardware Spare spark plug and air filter element e Spark plug wrench 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 Install the battery as follows Find battery tray and fasteners loose in carton Includes all parts needed to mount battery and tray Remove the
23. lectric Code requires the frame and external electrically conductive parts of the unit to be properly connected to an approved earth ground Local electrical codes may also require proper grounding of the generator Consult with a local electrician for requirements in your area Use a ground fault circuit interrupter in any damp or highly conductive area such as metal decking or steel work e e e e e Generac Portable Products 5500EXL Extended Life Generator pitt Do Not use worn bare frayed or otherwise damaged electrical cord sets with the generator 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 Do Not overfill the fuel tank If overfilled fuel can contact the hot engine and cause FIRE or an EXPLOSION 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 Generator exhaust gases contain DEADLY carbon monoxide gas This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Operat
24. nimum of two feet clearance between open side of box and nearest object 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 Figure 8 Temporary Cold Weather Shelter Generac Portable Products 5500EXL Extended Life Generator Charging a Battery 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 DANGER Storage batteries give off explosive DANGER Do Not permit smoking open A 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
25. r complete starting instructions 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 Stopping the Engine Disconnect all electrical loads Setthe 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 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 crankcase breather system In an emergency use the original shipping box as a temporary shelter 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 Start unit then place box over it Ensure a mi
26. tor Check that cooling air slots and openings on generator are open and unobstructed Disconnect the negative battery cable from the battery A Engine Storage See engine owner s manual for instructions on how to properly store the engine 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 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 SPECIFICATIONS Rated Maximum Continuous AC Power Output 5500 watts 5 5 kW Rated AC Voltage 120 240 Volts Rated Maximum AC Current at 240 Voltis 22 9 Amperes at 120 Voltis 45 8 Amperes Phase 1 Rated AC Frequency 60 Hertz Number of Rotor Poles 2 Driven Speed of Rotor 3600 RPM Generac Portable Products 5500EXL Extended Life Generator TROUBLESHOOTING Problem Cause Correction 1 One of the circuit breakers is open 1 Reset circuit breaker MM 2 Fault in generator 2 Contact Generac service facility Engine is running but no 3 Poor connection or defective 3 Check and repair AC output is available cord set 4
27. urge 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 Hedge Trimmer Impact Wrench Jet Pump Lawn Mower Light Bulb Microwave Oven Milk Cooler Oil Burner on Furnace Oil Fired Space Heater 140 000 Btu Oil Fired Space Heater 85 000 Btu Oil Fired Space Heater 30 000 Btu Paint Sprayer Airless 1 3 HP Paint Sprayer Airless handheld Refrigerator Slow Cooker Submersible Pump 1 1 2 HP Submersible Pump 1 HP Submersible Pump 1 2 HP Sump Pump Table Saw 10 Television Toaster Weed Trimmer Allow 3 times the listed watts for starting these devices MAINTENANCE GENERAL MAINTENANCE RECOMMENDATIONS 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 Engine Maintenance See engine manual for instructions Generator Maintenance 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
28. utlet states it has a 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 Generac Portable Products 5500EXL Extended Life 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 e 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 Circular Saw 6 1 2 Clothes Dryer Electric Clothes Dryer Gas Clothes Washer Furnace Fan 3 5 HP Garage Door Opener 11 The rated wattage of lights can be taken from 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 s
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