Generac 5500EXL User Manual
Problems?
Questions?
Before taking your unit
back to the store,
call the generator
helpline at
1-800-270-1408
M-F 8-5 CT
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 systems 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 owners manual.
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.
5500EXL
GENERAC
The Reliable Ones
Model No. 9797-3 (5500 Watt AC Generator) Manual No. 20820 Revision 3 (2/17/2000)
Visit our Generac website: www.generac-portables.com
Generac Portable Products 5500EXL Extended Life Generator
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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, 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 generators
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 Dont Overload the
Generator on page 11.
The generators 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
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.
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 generators
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.
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 Electric 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).
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other
reproductive harm.
WARNING:
Generac Portable Products 5500EXL Extended Life Generator
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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. 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 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 units 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) is provided on the
frame of your unit.
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.
Figure 1 Location of Grounding Wing Nut
Grounding Wing Nut
120/240 Volt AC
30 Amp Receptacle
Generac Portable Products 5500EXL Extended Life Generator
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KNOW YOUR GENERATOR
Read this owners 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.
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 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.
Battery Tray Location Pre-tapped and installed
screws are found here for the battery tray
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.
120 Volt AC, 20 Amp
Receptacle
Idle Control Switch
Recoil Starter
Electric Start Button
Battery Tray
Location
120 Volt AC, 30 Amp
Receptacle
Circuit Breakers (AC)
12 Volt DC, 10 Amp
Receptacle
Grounding Wing Nut
Fuel Tank
Generac Portable Products 5500EXL Extended Life Generator
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Your generator requires some assembly and is ready
for use after it has been properly serviced with the
recommended oil and fuel.
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.
REMOVE GENERATOR
FROM CARTON
Set the carton on a rigid flat surface with This Side
Up arrows pointing upward.
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.
The generator
Electric start battery cables
Generator and engine owners 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
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 4 battery tray screws from cradle.
Position the battery tray and install (Figure 2).
Set battery onto tray (Figure 3).
Figure 3 Install Battery onto Battery Tray
Figure 2 Install Battery Tray
Generac Portable Products 5500EXL Extended Life Generator
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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).
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.
BEFORE STARTING THE
ENGINE
Perform the following tasks before starting the unit:
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 owners manual.
NOTE: The generators 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.
NEVER fill fuel tank when engine is running or
hot. Do 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.
Figure 4 Connect Battery Cables
RED wire from
Start Button
BLACK wire from
engine mount
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