Generac 5500XL User 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.
Problems?
Questions?
Before taking your unit
back to the store,
call the generator
helpline at
1-800-270-1408
M-F 8-5 CT
Model No. 9885-3 (5,500 Watt AC Generator) Part No. B2674 Revision 2 (6/28/2000)
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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 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.
5500XL
Generac Portable Products 5500XL 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 Volts AC, single phase,
60 Hz 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 are connecting to
generator receptacles at one time. This total
should not be greater than 5,500 watts. See
Dont Overload The Generator on page 10.
The 5500XL generator has the following features:
120/240 Volt AC, 30 Amp locking receptacle, a
120 Volt AC, 30 Amp locking receptacle, a
120 Volt AC, 15 Amp duplex receptacle, and a
12 Volt DC, 10 Amp receptacle.
Low Oil Shutdown: Automatically shuts down the
engine if oil drops below safe operation level.
Seven gallon overhead fuel tank with fuel gauge.
The generators revolving field is driven at
approximately 3,600 rpm by a Generac Power
Systems 11 HP 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 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 allinclusive. 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.
DANGER! You must isolate the generator from
the electric utility using approved transfer
equipment 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. Whenever unit is providing backup
power, the electric utility must be notified.
DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. If breathed
in sufficient concentrations, carbon
monoxide can cause unconsciousness or
death. Operate this equipment outdoors where
adequate ventilation is available.
The generator produces a very powerful voltage that
can cause serious injury or death by electrocution.
Never touch bare wires or receptacles. Never
permit a child or unqualified person to operate the
generator.
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 5500XL Extended Life Generator
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Never handle any kind of electrical cord or device
while standing in water, while barefoot, or while
hands or feet are wet. Death or serious injury from
electrocution may result.
Use a ground fault circuit interrupter (GFCI) in any
damp or highly conductive area (such as metal
decking or steel work).
Never use worn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious
injury, or property damage from electrical shock may
result.
Gasoline is highly FLAMMABLE and its vapors
are EXPLOSIVE. Never allow 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 a 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.
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. Allow at least 2 feet of clearance on all
sides of generator, or you could damage the unit.
Read 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 any electrical loads.
Disconnect all electrical loads before shutting down
the generator.
Do Not insert any object through cooling slots of the
engine. 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).
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing
nut and to an earthdriven copper or brass grounding
rod (electrode) provides adequate protection against
electrical shock. Be careful to keep the grounding wire
attached to the generator when connecting the
stranded copper wire to the grounding rod. 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.
Figure 1 - Grounding Wing Nut
Grounding Wing Nut
Generac Portable Products 5500XL Extended Life Generator
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12 Volt DC, 10 Amp Receptacle Recharge a
discharged 12 Volt automotive type battery through
this receptacle.
120 Volt AC, 15 Amp Receptacles May be used to
supply electrical power for the operation of 120 Volt
AC, 15 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120 Volt AC, 30 Amp Locking 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 Locking 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.
Air Cleaner Uses a dry type filter element and
foam pre-cleaner to limit the amount of dirt and dust
sucked into the engine.
Choke Lever Used when starting a cold engine.
Circuit Breakers (AC) Each receptacle is provided
with a circuit breaker to protect the generator against
electrical overload. Breakers are "push to reset" type.
Fuel Tank Capacity of seven (7) U.S. gallons.
Grounding Wing Nut Used for proper grounding of
unit.
Idle Control Switch With this switch set to ON,
printed circuit board in control panel automatically
reduces engine speed when no load is connected and
increases engine to proper speed when load is
applied. However, be sure switch is OFF when starting
engine.
Recoil Starter Used for starting the engine.
Run/Stop Switch Set this switch to "RUN" before
using recoil starter. Set switch to "STOP" to switch
OFF engine.
Spark Arrester Muffler Exhaust muffler lowers
engine noise and is equipped with a spark arrester
screen.
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.
Circuit Breakers (AC)
Spark Arrester Muffler
Idle Control Switch
Air Cleaner
Fuel Tank
Recoil Starter
120 Volt AC, 30 Amp
Receptacle
120/240 Volt AC,
30 Amp Receptacle
12 Volt DC, 10 Amp
Receptacle
Choke Lever
Run/Stop Switch
120 Volt AC, 15 Amp
Receptacles
Grounding Wing Nut
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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.
Place generator on a level surface.
Refer to your engine owners manual for proper oil
fill information.
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 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 unit. 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" tank space
for fuel expansion, as shown in Figure 2.
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 the fuel system of an engine
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.
Figure 2 Fuel Expansion Space
Generac Portable Products 5500XL Extended Life Generator
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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! Temperature of muffler and nearby
areas may exceed 150°F (65°C). Avoid these
areas.
Unplug all electrical loads from units receptacles
before starting the engine.
Make sure the unit is in a level position.
Open the fuel shutoff valve (Figure 3).
Make sure the Idle Control switch is Off.
Place the Run/Stop switch in the Run position.
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).
Grasp starter grip and pull slowly until you feel slight
resistance, then pull quickly. Do Not let handle
snap back into engine.
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 Half 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 owners manual for
information regarding the low oil shutdown system.
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 Hertz electrical loads.
Do Not connect 240 Volt loads to the 120 Volt
receptacles.
Do Not connect 3-phase or 50 Hz loads to the
generator.
DO NOT OVERLOAD THE GENERATOR. See
Dont Overload the Generator on page 10.
Figure 3 Fuel Valve In Open Position
Full Choke
Position
Figure 4 Choke Lever
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