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
2
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
3
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
4
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
5
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
6
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
Generac Portable Products 5500EXL Extended Life Generator
7
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.
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 turned ON.
Starting the Engine
Disconnect all electrical loads from the generator.
Open the fuel shut-off valve (Figure 6).
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).
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.
Figure 7 Choke Positions
Figure 5 Fuel Tank Air Space
Figure 6 Fuel Shut Off Valve
Generac Portable Products 5500EXL Extended Life Generator
8
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 owners manual for 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
Dont Overload the Generator on page 11.
Stopping the Engine
Disconnect all electrical loads.
Set the 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 shutoff 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 units receptacles.
Start unit, then place box over it. Ensure a minimum
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
Wind
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 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 D.C..
Connect battery charge cable clamp with red handle
to the positive (+) battery terminal (Figure 9).
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
manufacturers 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.
Generac Portable Products 5500EXL Extended Life Generator
9
Figure 9 Battery Charge Cable Connection
Red
Black
Generac Portable Products 5500EXL Extended Life Generator
10
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
receptacle to operate 120 Volt AC, single phase, 60 Hz
electrical loads requiring up to 2400 watts (2.4 kW) at
20 Amps of current.
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).
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.
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 outlet states it has 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.
Figure 12 120/240 Volt AC, 30 Amp Receptacle
Figure 11 120 Volt, 30 Amp Receptacle
Figure 10 120 Volt AC, 20 Amp Receptacles
Generac Portable Products 5500EXL Extended Life Generator
11
DONT 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 generators wattage capacity.
If the appliance, tool or motor does not give wattage,
multiply 120 Volts times ampere rating to determine
watts (volts x amps = watts).
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 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.
Device . . . . . . . . . . . . . . . . . . . . . . . . . . Load (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
Device . . . . . . . . . . . . . . . . . . . . . . . . . . Load (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.
Figure 13 Wattage Reference Guide
Generac Portable Products 5500EXL Extended Life Generator
12
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.
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 owners manual for information.
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
Generator.
Check that cooling air slots and openings on
generator are open and unobstructed.
Disconnect the negative battery cable from the
battery.
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 owners manual for instructions on how to
properly store the engine.
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 Volts. . . . . . . . . . . . . . . 22.9 Amperes
at 120 Volts. . . . . . . . . . . . . . . 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
13
TROUBLESHOOTING
Problem Cause Correction
Engine is running, but no
AC output is available.
1. One of the circuit breakers is
open.
2. Fault in generator.
3. Poor connection or defective
cord set.
4. Connected device is bad.
1. Reset circuit breaker.
2. Contact Generac service facility.
3. Check and repair.
4. Connect another device that is in
good condition.
Engine runs good at no-load
but bogs down" when
loads are connected.
1. Short circuit in a connected load.
2. Engine speed is too slow.
3. Generator is overloaded.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. Contact Generac service facility.
3. See Don't Overload the
Generator on page 11.
4. Contact Generac service facility.
Engine will not start; or
starts and runs rough.
1. Run/Stop Switch set to Stop.
2. Dirty air cleaner.
3. Out of gasoline.
4. Stale gasoline.
5. Spark plug wire not connected to
spark plug.
6. Bad spark plug.
7. Water in gasoline.
8. Overchoking.
9. Excessively rich fuel mixture.
10. Intake valve stuck open or
closed.
11. Engine has lost compression.
12. Failed battery.
1. Set switch to Run.
2. Clean or replace air cleaner.
3. Fill fuel tank.
4. Drain gas tank; fill with fresh fuel.
5. Connect wire to spark plug.
6. Replace spark plug.
7. Drain gas tank; fill with fresh fuel.
8. Open choke fully and crank
engine.
9. Contact Generac service facility.
10. Contact Generac service facility.
11. Contact Generac service facility.
12. Replace battery.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
1. Fill fuel tank.
2. Fill crankcase to proper level.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
1. See Don't Overload the
Generator on page 11.
2. Replace air filter.
Engine hunts or falters.
1. Choke is opened too soon.
2. Carburetor is running too rich or
too lean.
1. Move choke to halfway position
until engine runs smoothly.
2. Contact Generac service facility.
Generac Portable Products 5500EXL Extended Life Generator
14
SCHEMATIC DIAGRAM
Generac Portable Products 5500EXL Extended Life Generator
15
WIRING DIAGRAM
Generac Portable Products 5500EXL Extended Life Generator
16
EXPLODED VIEW
Generac Portable Products 5500EXL Extended Life Generator
17
PARTS LIST
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 94980A 1 ASSEMBLY, Stator
7 65791 1 BEARING
8 67451 1 WASHER, Special Flat - M8
9 22129 16 WASHER, Lock - M8
10 86307 4 HHMS, 5/16-24 x 3/4
11 28092 1 HHCS, 5/16-24 x 9-1/4
12 92609 2 MOUNT, Vibration
13 82857 4 MOUNT, Vibration
14 92532 1 BRACKET, Muffler
15 90239 1 GASKET, Muffler
16 66476 2 CAPSCREW, M6 - 1.0 x
12mm
17 A7433 1 MUFFLER
18 40976 2 SCREW, M8 - 1.25 x 20
19 83083 1 SCREEN, Spark Arrester
20 81917 1 PIN, Roll 4mm x 10
25 66825C 1 CARRIER, Rear Bearing
26 74908 4 TAPTITE, M5-0.8 x 10
27 86308A 4 BOLT, Stator M6-1 x 145mm
28 65795 2 RECTIFIER, Battery Charge
29 66849C 1 TAPTITE, M5-0.8 x 30
30 67022 1 GROMMET, Rubber
31 84132 1 ASSEMBLY, Power Regulator
32 66386 1 ASSEMBLY, Brush Holder
33 66849 2 TAPTITE, M5-0.8 x 16
34 B67025 1 COVER, Bearing Carrier
35 22769 1 WASHER, Shakeproof Int. #10
36 86494 1 SCREW, M6-1.0 x 16 Wing
37 86292 1 HHCS, - #10 Self Driller
38 77395 4 NUT, Flange Lock - M6
39 83465 4 GROMMET, Tank
40 57058 4 HHCS, M6-1.0 x 55
41 80270 1 VALVE, Tank
42 78299 1 BUSHING, Tank
43 B4363 1 CAP, with Gauge, Fuel
44 B1695 1 TANK, Fuel 7 Gal.
45 B92039 1 SHIELD, Heat
Item Part # Qty. Description
46 92665 1 INSULATION, #2-1/4" Thick
47 85000 1 CLIP, Insulation
48 14353621 1 WIRE, Ground
49 26850 2 LW, EXT, Shakeproof M6
51 92982 1 DECAL, Danger
52 96057 2 DECAL, Heat Shield
55 25244 12 NUT, 5/16-18 Hex
57 96058 1 DECAL, Control Panel
58 92630 1 ASSEMBLY, Control Box
59 NSP 1 ENGINE
60 22531 2 HHCS, 5/16-18 x 1-3/4"
61 22142 2 SCREW, 5/16-18 x 3/4"
62 77282 1 SWITCH, Starter
63 22287 2 SCREW, 1/4 - 20 x 3/4
64 22097 2 LOCKWASHER, M6
65 22127 2 NUT, 1/4 - 20 Hex
66 78289 1 BRACKET, Starter Switch
67 93826 1 DECAL, Start Instructions
68 B96068 1 SHIELD, Heat
69 56893 5 CRIMPTITE, 10-24 x 1/2
70 B2153 8 SCREW, #12 Self Drill
71 22473 4 WASHER, Flat M6
Parts Not Illustrated:
37806 1 125V 30A Locking plug
43438 1 240V 30A Locking plug
72347 1 Spark plug
73111 1 Air cleaner element
84882 1 Spark plug wrench
20820 1 Owners manual
65787 1 Battery charge cable
Battery Tray Components:
22129 2 Lockwasher, M8
45771 2 Hex nut M8
96925 1 Battery tiedown
96924 2 J-bolt
15453621 1 Battery cable, positive
15553621 1 Battery cable, negative
96923 1 Battery tray
22145 2 Flat washer
58443 4 Screws, battery tray
Generac Portable Products 5500EXL Extended Life Generator
18
Item Part # Qty. Description
1 A92070 1 PANEL, Control
2 23897 4 FLAT WASHER, #10 M5
3 49226 4 LOCK WASHER, M5
4 91526 4 SCREW, M5-0.8 x 12mm
5 82538 1 SWITCH, Idle Control
6 82881 4 LOCK WASHER, 7/16"
7 43181 4 SCREW, M3 - 0.5 x 10mm
8 43182 4 LOCK WASHER, M3
9 90418 1 OUTLET, 12V
10 75207A 2 CIRCUIT BREAKER, 30A
11 75207 2 CIRCUIT BREAKER, 20A
12 23365 6 WASHER, #8 Shakeproof
13 68868 1 OUTLET, 120 Volt, 30 Amp
Locking Type
Item Part # Qty. Description
14 43437 1 OUTLET, 120V/240V, 30A
Locking Type
15 68759 1 OUTLET, 120V, 20A Duplex
16 43180 6 FLAT WASHER, M4
17 22264 6 LOCK WASHER, #8 M4
18 51715 6 NUT, M4-0.7 Hex
19 64526 8 SCREW, #6-32 x 3/8"
20 83970 1 BOARD, System Control
21 64525 4 STAND-OFF, 3/4" Hex
22 87962 1 CIRCUIT BREAKER. 12V,
10A (auto)
23 84335 1 ASSEMBLY, Wire Harness
24 84134 1 GROMMET, Rubber Conn
25 B92069 1 BOX, Control Panel
26 84028 1 TRANSFORMER, Idle Control
CONTROL PANEL EXPLODED VIEW & PARTS LIST
Generac Portable Products 5500EXL Extended Life Generator
19
NOTES
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 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 COMPANYs 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
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