5500XL
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 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.
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Model No. 9885-3 (5,500 Watt AC Generator) Part No. B2674 Revision 2 (6/28/2000) 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.
Generac Portable Products 5500XL Extended Life 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, 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 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 5,500 watts. See “Don’t 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 generator’s 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 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.
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.
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Generac Portable Products 5500XL Extended Life Generator
•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).
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 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.
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Generac Portable Products 5500XL 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 |
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Circuit Breakers (AC) |
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Recoil Starter |
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Choke Lever |
120 Volt AC, 30 Amp |
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Air Cleaner |
Receptacle |
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120/240 Volt AC, |
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Run/Stop Switch |
30 Amp Receptacle |
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12 Volt DC, 10 Amp |
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Receptacle |
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Spark Arrester Muffler |
120 Volt AC, 15 Amp |
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Idle Control Switch |
Receptacles |
Grounding Wing Nut |
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12 Volt DC, 10 Amp Receptacle — Recharge a |
Circuit Breakers (AC) — Each receptacle is provided |
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discharged 12 Volt automotive type battery through |
with a circuit breaker to protect the generator against |
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electrical overload. Breakers are "push to reset" type. |
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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.
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.
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Generac Portable Products 5500XL Extended Life Generator
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 owner’s manual for proper oil fill information.
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 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.
Figure 2 — Fuel Expansion Space
• 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 alcohol–blended 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.
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Generac Portable Products 5500XL Extended Life 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! Temperature of muffler and nearby areas may exceed 150°F (65°C). Avoid these areas.
•Unplug all electrical loads from unit’s receptacles before starting the engine.
•Make sure the unit is in a level position.
•Open the fuel shut–off valve (Figure 3).
Figure 3 — Fuel Valve In Open Position
Figure 4 — Choke Lever
“Full” Choke
Position
•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 owner’s manual for information regarding the low oil shutdown system.
•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).
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 “Don’t Overload the Generator” on page 10.
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