GENERAC

The Reliable Ones

5500 XL

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.

Problems?

Questions?

Before back call taking to the your store, unit

1–800–270–1408

M–F at

8–5

CT

Model No. 9778–7 (5500 Watt AC Generator) Manual No. B4372 Revision 2 (8/11/1999)

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.

Generac Portable Products 5500 XL Generator

EQUIPMENT DESCRIPTION

This generator is an engine–driven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, appliances, tools and motor loads.

This manual contains information for a generator that operates 120 and/or 240 Volt, single phase, 60 Hz devices that require up to 5500 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 wattage/amperage capacity. Add up the rated watts of all devices you are connecting to generator receptacles at one time. This total should not be greater than 5500 watts. In most cases rated watts of the electrical device can be found on the device nameplate. If the device nameplate gives only volts and amps, multiply volts times amps to obtain watts

(volts x amps = watts).

The 5500XL watt portable generator has the following features:

• 120/240 Volt, 30 Amp locking receptacle.

• 120 Volt 30 Amp locking receptacle.

• 120 Volt, 20 Amp duplex receptacle.

• Low Oil Shutdown: Automatically shuts down the engine if oil drops below safe operation level.

• Overhead fuel tank with fuel gauge.

• The generator’s revolving field is driven at about

3600 rpm by an 11 h.p. OHVI engine.

DANGER ! Do not tamper with engine governed speed. High operating speeds are dangerous and increase risk of personal injury or damage to equipment. The generator supplies correct rated frequency and voltage only when running at proper governed speed.

Incorrect frequency and/or voltage can damage some connected electrical loads.

Operating at excessively low speeds imposes a heavy load. When adequate engine power is not available engine life may be shortened.

SAFETY RULES

This generator set was designed and manufactured for specific applications. Do not attempt to modify the unit or use it for any application it was not designed for. If you have any questions about your generator’s application, ask your dealer or consult the factory.

The manufacturer could not possibly anticipate every circumstance that might involve a hazard. For that reason warnings in the Manual and warnings on tags or decals affixed to the unit are not all–inclusive. If you intend to handle, operate or service the unit by a procedure or method not specifically recommended by the manufacturer, first make sure that such a procedure or method will not render this equipment unsafe or pose a threat to you and others.

Read this manual carefully and become familiar with your generator set. Know its applications, its limitations and any hazards involved.

WARNING:

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 an 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. Dangerous electrical shock may result.

• The National Electric Code requires the frame and external electrically conductive parts of the generator 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 grounding requirements in your area.

• Use a ground fault circuit interrupter in any damp or highly conductive area (such as metal decking or steel work).

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Generac Portable Products 5500 XL Generator

• Do not use worn, bare, frayed or otherwise damaged electrical cord sets with the generator.

• Operate unit 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 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 FIRE or an

EXPLOSION.

• Never store a generator with fuel in the tank where gasoline vapors might reach an open flame, spark or pilot light (as on a furnace, water heater, clothes dryer). FIRE or an EXPLOSION may result.

• 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.

• Allow at least 2 feet of clearance on all sides of generator, even while operating unit outdoors, or you could damage the unit. Review Cold Weather

Operation on page 7.

• 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 any electrical loads.

Disconnect all electrical loads before shutting down the generator.

• Do not insert any object through cooling slots of the unit. You could damage the unit or injure yourself.

• Never operate the generator: in rain; in any enclosed compartment; when connected electrical devices overheat; if electrical output is lost; if engine or generator sparks; if flame or smoke is observed while unit is running; if unit vibrates excessively.

GROUNDING THE

GENERATOR

The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground. Local electrical codes may also require proper grounding of the unit. For that purpose, a

GROUNDING WING NUT is provided on the generator (Figure 1).

Figure 1 — 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. Be careful to keep the grounding wire attached after connecting the stranded copper wire. However, local codes may vary widely. Consult with a local electrician for grounding requirements in your area.

Properly grounding the generator helps prevent electrical shock if a ground fault condition exists in the generator or in connected electrical devices.

Proper grounding also helps dissipate static electricity, which often builds up in ungrounded devices.

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Generac Portable Products 5500 XL 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

Run/Stop Switch

Circuit Breakers (AC)

Air Cleaner

Recoil Starter

120 Volt AC,

30 Amp Receptacle

120/240 Volt AC,

30 Amp Receptacle

12 Volt DC, 10 Amp

Receptacle

Spark Arrestor Muffler

120 Volt AC, 20 Amp

Duplex Receptacle

12 Volt DC, 10 Amp Receptacle — Use this receptacle with battery charge cables to charge a

12 Volt battery.

Idle Control Switch

Grounding Wing Nut generator against electrical overload. Breakers are

"push to reset" type.

120 Volt AC, 20 Amp Duplex Receptacle — May be used to supply electrical power for the operation of

120 Volt AC, 20 Amp, single phase, 60 Hz electrical 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.

Fuel Tank — Capacity of 7 U.S. gallons (26 liters).

Grounding Wing Nut — Provides a tie–point for connecting the generator frame to earth ground.

Idle Control Switch — The idle control runs the engine at normal (high) speeds when there is a load present and runs the engine at idle (low) speeds when a load is not present. This feature greatly improves fuel economy, extends the life of the engine, and reduces engine noise.

Recoil Starter — Self-storing pull rope used to start the engine.

Run/Stop Switch — Must be in “Run” position to start engine. Set to “Stop” to stop a running engine.

Air Cleaner — Filters air supplied to the engine.

Circuit Breakers (AC) — Each receptacle is provided with a circuit breaker to protect the

Spark Arrestor Muffler — Limits sparks emitted from the muffler. Often mandated when used in forrested regions.

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Generac Portable Products 5500 XL Generator

CONTENTS

The following items are shipped with your generator:

• Main unit

• Engine and generator owner’s manuals

• 2 Bottles oil (28 oz.)

• Video

• Battery Charge Cable

• 120 Volt and 120/240 V 30 A Plugs

• Spark Plug Wrench

• Spare Air Filter and Spark Plug

BEFORE STARTING THE

ENGINE

Add Oil

WARNING ! Any attempt to crank or start the engine before it has been properly filled with the recommended oil may result in an engine failure.

Select the oil's viscosity grade according to your expected operating temperature. Do not use SAE

10W–40. Refer to the engine owner’s manual.

SAE 30, 10W–30

Synthetic 5W–20, 5W–30

Add Gasoline

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.

WARNING!

Do not overfill the fuel tank.

Always allow room for fuel expansion.

• Use regular UNLEADED gasoline with the generator engine. Do not use premium gasoline.

Do not mix oil with gasoline.

• Clean area around fuel fill cap, remove cap.

• Slowly add unleaded regular gasoline to fuel tank.

Be careful not to overfill. Allow about 1/2" of tank space for fuel expansion, as shown in Figure 2.

Figure 2 — Tank Expansion Space

• Above 40°F, use SAE 30 or 10W–30.

• Below 40°F, use synthetic 5W–20 or 5W–30.

To fill your engine with oil:

• Place generator on a level surface.

• Clean area around oil fill and remove oil fill cap.

• Pour oil into oil fill opening until oil reaches the point of overflowing. Do not overfill!

• Install oil fill cap.

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.

• Install fuel cap and wipe up any spilled gasoline.

IMPORTANT: It is important to prevent gum deposits from forming in essential fuel system parts such as the carburetor, fuel filter, fuel hose or tank during storage. Also, experience indicates that alcoholblended fuels (called gasohol, ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage an engine’s fuel system while in storage.

To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. See

“Storage” on page 11. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur.

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Generac Portable Products 5500 XL Generator

OPERATING THE

GENERATOR

CAUTION ! Never start or stop the unit with electrical loads connected to the receptacles

AND with the connected devices turned ON.

Starting the Engine

DANGER ! Never run engine indoors or in enclosed poorly ventilated areas. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

WARNING ! Burn Hazard! Temperature of muffler and nearby areas may exceed 150°F

(65°C). Avoid these areas.

• Unplug all electrical loads from generator receptacles before starting the engine.

• Make sure the unit is in a level position.

• Open the fuel shut–off valve.

• Make sure the Idle Control switch is “Off”.

• Place Run/Stop switch in the “Run” position

(Figure 3).

Figure 3 — Run/Stop Switch

Run/Stop Switch

• Place the choke lever in the “Full Choke” position by sliding it to the left toward the valve cover in the direction indicated by the arrow (Figure 4).

Figure 4 — Choke Lever

Full Choke

Position

• Grasp starter grip and pull slowly until you feel slight resistance, then pull quickly.

• 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 “1/2 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 further information.

Connecting Electrical Loads

• Let engine stabilize and warm up for a few minutes after starting.

• Plug in and turn on the desired 120 and/or 240 Volt

AC, single phase, 60 Hz electrical loads.

• Do not connect 240 Volt loads to the 120 Volt duplex receptacles.

• Do not connect 3–phase loads to the generator.

• Do not connect 50 Hz loads to the generator.

• DO NOT OVERLOAD THE GENERATOR. Add up the rated watts (or amps) of all loads to be connected at one time. This total should not be greater than the rated wattage/amperage capacity of the generator. See “Don’t Overload the

Generator” on page 10.

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Generac Portable Products 5500 XL Generator

Stopping the Engine

• Unplug all electrical loads from generator panel receptacles. Never start or stop engine with electrical devices plugged in and turned on.

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

• Let engine run at no–load for 30 seconds to stabilize the internal temperatures of engine and generator.

• Move Run/Stop switch to “Stop” position.

• Close the fuel shut–off valve.

Operating Automatic Idle Control

This switch is designed to greatly improve fuel economy. When this switch is turned ON, the engine will only run at its normal high governed engine speed when an electrical load is connected.

When electrical loads are removed, the engine will run at a reduced speed. With the switch off, the engine runs at its normal constant 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.

• Cut out one of the long sides of the box to expose exhaust side of unit. Ensure a minimum of two feet clearance between open side of box and nearest object.

• Cut appropriate slots to access receptacles of unit.

• 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, as shown in Figure 5.

Figure 5 — Typical Temporary Shelter

• Ensure a minimum of two feet clearance between open side of box and nearest object.

• Face exposed end away from wind and elements.

• Enclosure should hold enough heat created by the generator to prevent icing problem.

CAUTION : NEVER run unit indoors. Do Not enclose generator any more than shown.

Remove shelter when temperatures are above

40°F [4°C].

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Generac Portable Products 5500 XL Generator

Charging a Battery

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 serious injury.

DANGER ! Do not permit smoking, open flame, sparks or any other source of heat around a battery. Wear protective goggles, rubber apron and rubber gloves when working around a battery. Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. If spill occurs, flush area with clear water immediately.

Your generator has the capability of recharging a discharged 12 Volt automotive or utility style storage battery. Do not use the unit to charge any 6 Volt batteries. Do not use the unit to crank an engine having a discharged battery.

To recharge 12 Volt batteries, proceed as follows:

• Check fluid level in all battery cells. If necessary, add ONLY distilled water to cover separators in battery cells. Do not use tap water.

• If the battery is equipped with vent caps, make sure they are installed and are tight.

• If necessary, clean battery terminals.

• Connect battery charge cable connector plug to panel receptacle identified by the words

“12-VOLT DC”.

• Connect battery charge cable clamp with red handle to the positive (+) battery terminal

(Figure 6).

Figure 6 — Battery Connections

12 VOLT D.C.

RECEPTACLE

• Connect battery charge cable clamp with black handle to the negative (–) battery terminal

(Figure 6).

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

• When battery has charged, shut down engine.

NOTE: Use an automotive hydrometer to test battery state of charge and condition. Follow the hydrometer manufacturer’s instructions carefully. Generally, a battery is considered to be at 100% state of charge when specific gravity of its fluid (as measured by hydrometer) is 1.260 or higher.

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Generac Portable Products 5500 XL Generator

RECEPTACLES

120 Volt AC, 20 Amp, Duplex

Receptacle

Each of these receptacles is protected against overload by 20 Amp push–to–reset circuit breaker.

Use each receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring 2400 (2.4kW) watts at

20 Amps of current (Figure 7).

Figure 7 — 120 Volt, 20 Amp Duplex Receptacle

Figure 8 — 120/240 Volt, 30 Amp Locking Receptacle

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5–30 plug with this receptacle.

Connect a 3–wire cord set rated for 125 Volts AC at

30 Amps to the plug (Figure 9).

Figure 9 — 120 Volt, 30 Amp Locking Receptacle

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 Volts at

30 Amps (or greater) (Figure 8). You can use the same cord if you plan only to run a 120 Volt load.

This receptacle powers 120/240 Volt AC, 60 Hz, single phase loads requiring up to 3600 watts

(3.6 kW) of power at 30 Amps for 120 Volts, or

5500 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.

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.

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Generac Portable Products 5500 XL Generator

DON’T OVERLOAD THE

GENERATOR

Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and/or connected electrical devices.

Observe the following, to prevent overloading the unit:

• Add up the total wattage of all electrical devices to be connected at one time. This total should NOT be greater than the generator’s wattage capacity.

• The rated wattage of lights can be taken from light bulbs. The rated wattage of tools, appliances and motors can usually be found on a data plate or decal affixed to the device.

Figure 10 — Wattage Reference Guide

Device .............................................Running 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

Chain Saw......................................................1200

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

• If the appliance, tool or motor does not give wattage, multiply 120 Volts times ampere rating to determine watts (volts x amps = watts).

• Some electric motors, such as induction types, require about three times more watts of power for starting than for running. This surge of power lasts for only a few seconds when starting such motors.

Be sure you allow for this high starting wattage when selecting electrical devices to connect to your generator. First figure the watts needed to start the largest motor. Add to that figure the running watts of all other connected loads.

• A wattage reference guide (Figure 10) is provided to help you to determine how many items the generator can operate at one time.

Device .............................................Running Watts

Hedge Trimmer.................................................450

Impact Wrench..................................................500

Iron .................................................................1200

*Jet Pump .........................................................800

Lawn Mower ...................................................1200

Light Bulb..........................................................100

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.

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Generac Portable Products 5500 XL Generator

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 air slots in the generator must not become clogged with snow, leaves or any other foreign material.

NOTE: We do not recommend using 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.

To Clean the Generator

• Use a damp cloth to wipe exterior surfaces clean.

• Soft, bristle brush may be used to loosen caked on dirt or oil.

• 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.

STORAGE INSTRUCTIONS

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

Generator.”

• Check that cooling air slots and openings on generator are open and unobstructed.

• Check that the fuel shut-off valve is closed.

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.

Engine Storage

See Engine Owner’s Manual for instructions.

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 that fuel with this unit.

• Store in clean and dry area.

SPECIFICATIONS

Maximum Surge Watts . . . . . . . . . . . . .6875 watts

Continuous Wattage Capacity . . . . . . . .5500 watts

Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . .1.0

Rated Maximum Continuous Load

At 120 Volts . . . . . . . . . . . . . . . . . . .45.8 Amps

At 240 Volts . . . . . . . . . . . . . . . . . . .22.9 Amps

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase

Rated Frequency . . . . . . . . . . . . . . . . . . .60 Hertz

Fuel Tank Capacity . . . . . . . . . . . . . 7 U.S. gallons

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Generac Portable Products 5500 XL Generator

TROUBLESHOOTING

Problem

Engine is running, but no AC output is available.

Cause

1. Circuit breaker is open.

2. Poor connection or defective cord set.

3. Connected device is bad.

Engine runs good but bogs down when loads are connected.

Engine will not start; or starts and runs rough.

Engine shuts down during operation.

Engine lacks power.

Engine “hunts” or falters.

Solution

1. Reset circuit breaker.

2. Check and repair.

4. Fault in generator.

1. Short circuit in a connected load.

2. Generator is overloaded.

3. Engine speed is too slow.

4. Shorted generator circuit.

1. Run/Stop switch set to Stop.

2. Dirty air cleaner.

3. Out of gasoline.

4. Stale gasoline.

1. Set switch to Run.

2. Clean or replace air cleaner.

3. Fill fuel tank.

4. Drain gas tank and fill with fresh fuel.

5. Connect wire to spark plug.

5. Spark plug wire not connected to spark plug.

6. Bad spark plug.

7. Water in gasoline.

8. Overchoking.

9. Low oil level.

10. Excessively rich fuel mixture.

11. Intake valve stuck open or closed.

12. Engine has lost compression.

6. Replace spark plug.

7. Drain gas tank; fill with fresh fuel.

8. Put choke lever to “No Choke” position.

9. Fill crankcase to proper level.

10. Contact Generac service facility.

11. Contact Generac service facility.

12. Contact Generac service facility.

1. Out of gasoline.

2. Low oil level.

3. Fault in engine.

1. Load is too high.

2. Dirty air filter.

3. Engine needs to be serviced.

1. Choke is opened too soon.

2. Carburetor is running too rich or too lean.

3. Connect another device that is in good condition.

4. Contact Generac service facility.

1. Disconnect shorted electrical load.

2. See “Don’t Overload the

Generator” on page 10.

3. Contact Generac service facility.

4. Contact Generac service facility.

1. Fill fuel tank.

2. Fill crankcase to proper level.

3. Contact Generac service facility.

1. See “Don’t Overload the

Generator” on page 10.

2. Replace air filter.

3. Contact Generac service facility.

1. Move choke to halfway position till engine runs smoothly.

2. Contact Generac service facility.

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NOTES

Generac Portable Products 5500 XL Generator

13

SCHEMATIC

Generac Portable Products 5500 XL Generator

14

WIRING DIAGRAM

Generac Portable Products 5500 XL Generator

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Generac Portable Products 5500 XL Generator

EXPLODED VIEW – MAIN UNIT

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Generac Portable Products 5500 XL Generator

PARTS LIST – MAIN UNIT

Item Part # Qty Description

1 A92432 1 CRADLE

2 A92531 1 SUPPORT, Engine

3 A92731 1 SUPPORT, Engine & Muffler

4 92247 1 HOUSING, Engine Adapter

5 92678G 1 ASSEMBLY, Rotor

6 92680G 1 ASSEMBLY, Stator

7 65791

8 67451

9 22129

10 86307

11 28092

12

13

14

15

16

92609

82857

92532

90239

66476

1 BEARING

1 WASHER, M8 Flat

16 WASHER, M8 Lock

4 SCREW, 5/16-24 x 3/4 Mach.

1 ROTOR BOLT, 5/16-24 x 9-

1/4"

2 MOUNT, Vibration

4 MOUNT, Vibration

1 BRACKET, Muffler

1 GASKET, Exhaust

2 SCREW, M6 - 1 x 12 Cap w/Lock Washer

1 MUFFLER

2 SCREW, M8 - 1.25 x 20 Cap

1 SCREEN, Spark Arrest

1 PIN, 4mm x 10 Roll

17 91153

18 40976

19 83083

20 81917

21 B4986 1 DECAL, Ground

25 66825C 1 CARRIER, Rear Bearing

26 74908 4 TAPTITE, M5-0.8 x 10

27 86308A 4 BOLT, M6-1 x 145mm Stator

28 65795 1 RECTIFIER, Battery Charge

29 66849A 1 TAPTITE, M5-0.8 x 20

30 67022

31 84132

1 GROMMET, Rubber

1 ASSEMBLY, Power Regulator

1 ASSEMBLY, Brush Holder

2 TAPTITE, M5-0.8 x 16

32 66386

33 66849

34 B67025 1 COVER, Bearing Carrier

35 22769

36

37

38

86494

86292

77395

1 WASHER, #10 Int.

Shakeproof

1 SCREW, M6-1.0 x 16 Wing

1 SCREW, #10 Self Drilling

4 NUT, M6 Flange Lock

Item Part # Qty Description

39 83465 4 GROMMET, Tank

40 78831B 4 HHMS, M6-1.0 x 60

41

42

43

44

80270

78299

B4363

B1998

1 VALVE, Tank

1 BUSHING, Tank

1 CAP, Fuel

1 TANK, Fuel

45 B92039 1 SHIELD, Heat

46 92665 1 INSULATION, #2-1/4"

1 CLIP, Insulation 47 85000

48 143-53621 1 WIRE, Ground

49 26850

50 57593

51 92982

52 B4373

55 25244

57 B4374

58 92630

59 NSP

60 22531

61 22142

62 93826

63 56893

2 WASHER, M6 Shakeproof

1 MOUNT, Cable Tie

1 DECAL, Danger

2 DECAL, Heat Shield

12 NUT, 5/16-18 Hex

1

1

1

2

2

1

5

DECAL, Control Panel

ASSEMBLY, Control Box

ENGINE, 11 H.P.

HHCS, 5/16-18 x 1-3/4

SCREW, 5/16 - 18 x 3/4 Cap

DECAL, Start Instructions

SCREW, 10-24 x 1/2 Crimptite

64 B96068 1 SHIELD, Heat

65 B2153 6 SCREW, Self Drill 12-14 x 7/8

Parts Not Illustrated:

65787

B4372

37806

43438

72347

84882

73111

B4572

Battery Charge Cable

Generator Owner’s Manual

120 Volt AC 30 Amp Plug

120/240 Volt 30 Amp Plug

Spark Plug

Spark Plug Wrench

Air Filter

Video

Optional Accessory Not Included:

84883 Cord Wrap

17

Generac Portable Products 5500 XL Generator

EXPLODED VIEW AND PARTS LIST – CONTROL PANEL

Item Part # Qty. Description

1

8

9

6

7

4

5

2

3

92070

23897

49226

91526

82538

82881

43181

43182

90418

10 75207A 2 CIRCUIT BREAKER, 30A

11 75207

12 23365

13 68868

14 43437

1 PANEL, Control

4 FLAT WASHER, #10 M5

4

4

4

4

LOCK WASHER, M5

SCREW, M5-0.8 x 12mm

1 SWITCH, Idle Control

4 LOCK WASHER, 7/16"

SCREW, M3 - 0.5 x 10mm

LOCK WASHER, M3

1 OUTLET, 12V

2 CIRCUIT BREAKER, 20A

6 WASHER, #8 Shakeproof

1 OUTLET, 120 V, 30A Locking

1 OUTLET, 120V/240V, 30A

Locking

Item Part # Qty. Description

15 68759

16 43180

17 22264

18 51715

19 64526

20 83970

21 64525

22 87962

23

24

25

26

84335

84134

92069

84028

1 OUTLET, 120V, 20A Duplex

6 FLAT WASHER, M4

6 LOCK WASHER, #8 M4

6 NUT, M4-0.7 Hex

8 SCREW, #6-32 x 3/8"

1 BOARD, System Control

4 STAND-OFF, 3/4" Hex

1 CIRCUIT BREAKER. 12V,

10A (auto)

1 ASSEMBLY, Wire Harness

1 GROMMET, Rubber Conn.

1 PANEL, Control Box

1 TRANSFORMER, Idle Control

18

NOTES

Generac Portable Products 5500 XL Generator

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.

Alternator

Engine

Consumer*

2 years (2nd year parts only)

Commercial*

1 year

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 53549