Generac Portable Products 5500 XL 9778-7 User manual

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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, ill eliminate the danger. Al ays have at least t o feet of clearance on
all sides of the generator even hile 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 s itch if this unit is used for backup po er. 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 arranted for standards set by the
Environmental Protection Agency. For arranty information refer to the Engine O ners manual.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety
messages that follo this symbol to avoid possible injury or death.
Model No. 97787 (5500 Watt AC Generator) Manual No. B4372 Revision 2 (8/11/1999)
Visit our Generac ebsite: www.generacportables.com
5500XL
GENERAC
The Reliable Ones

Generac Portable Products 5500 XL Generator
2
EQUIPMENT DESCRIPTION
This generator is an enginedriven, revolving field,
alternating current (AC) generator. It as designed to
supply electrical po er 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 atts (5.5 kW) of
po er that pull up to 45.8 Amps at 120 Volts or
22.9 Amps at 240 Volts.
CAUTION! Do not exceed the generators
attage/amperage capacity. Add up the rated
atts of all devices you are connecting to
generator receptacles at one time. This total
should not be greater than 5500 atts. In
most cases rated atts 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 atts
(volts x amps = atts).
The 5500XL att portable generator has the
follo ing features:
 120/240 Volt, 30 Amp locking receptacle.
 120 Volt 30 Amp locking receptacle.
 120 Volt, 20 Amp duplex receptacle.
 Lo Oil Shutdo n: Automatically shuts do n the
engine if oil drops belo safe operation level.
 Overhead fuel tank ith fuel gauge.
 The generators revolving field is driven at about
3600 rpm by an 11 h.p. OHVI engine.
DANGER! Do not tamper ith 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 hen running at proper governed speed.
Incorrect frequency and/or voltage can
damage some connected electrical loads.
Operating at excessively lo speeds imposes
a heavy load. When adequate engine po er
is not available engine life may be shortened.
SAFETY RULES
This generator set as designed and manufactured
for specific applications. Do not attempt to modify the
unit or use it for any application it as 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 arnings in the Manual and arnings 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 ill 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 po erful voltage
that can cause extremely dangerous electrical
shock. Avoid contact ith bare ires, terminals,
etc. Never permit an unqualified person to operate
or service the generator.
 Never handle any kind of electrical cord or device
hile standing in ater, hile barefoot or hile
hands or feet are et. 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
ith 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 ork).
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 5500 XL Generator
3
 Do not use orn, bare, frayed or other ise
damaged electrical cord sets ith the generator.
 Operate unit only on level surfaces and here it
ill 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 hile handling
gasoline. Avoid spilling gasoline on a hot engine.
Comply ith all la s regulating storage and
handling of gasoline.
 Do not overfill the fuel tank. Al ays allo room for
fuel expansion. If tank is overfilled, fuel can
overflo onto a hot engine and cause FIRE or an
EXPLOSION.
 Never store a generator ith fuel in the tank here
gasoline vapors might reach an open flame, spark
or pilot light (as on a furnace, ater 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 here adequate
ventilation is available.
 The unit requires an adequate flo of cooling air
for its continued proper operation. Never operate
the unit inside any room or enclosure here the
free flo of cooling air into and out of the unit might
be obstructed. Without sufficient cooling air flo ,
the unit quickly overheats, damaging the generator
or nearby property.
 Allo at least 2 feet of clearance on all sides of
generator, even hile operating unit outdoors, or
you could damage the unit. Revie Cold Weather
Operation on page 7.
 Never start or stop the unit ith electrical loads
connected to receptacles AND ith the connected
devices turned ON. Start the engine and let it
stabilize before connecting any electrical loads.
Disconnect all electrical loads before shutting do n
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; hen
connected electrical devices overheat; if electrical
output is lost; if engine or generator sparks; if flame
or smoke is observed hile 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 ire to the grounding ing
nut and to an earthdriven copper or brass grounding
rod (electrode) provides adequate protection against
electrical shock. Be careful to keep the grounding
ire attached after connecting the stranded copper
ire. Ho ever, local codes may vary idely. Consult
ith 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, hich often builds up in ungrounded
devices.
Figure 1  Grounding Wing Nut
Grounding Wing Nut

Generac Portable Products 5500 XL Generator
4
12 Volt DC, 10 Amp Receptacle  Use this
receptacle ith battery charge cables to charge a
12 Volt battery.
120 Volt AC, 20 Amp Duplex Receptacle  May be
used to supply electrical po er 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 po er for the operation of 120 Volt
AC, 30 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120/2 0 Volt AC, 30 Amp Receptacle  May be
used to supply electrical po er 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  Filters air supplied to the engine.
Circuit Breakers (AC)  Each receptacle is
provided ith a circuit breaker to protect the
generator against electrical overload. Breakers are
"push to reset" type.
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 hen there is a load
present and runs the engine at idle (lo ) speeds
hen 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.
Spark Arrestor Muffler  Limits sparks emitted
from the muffler. Often mandated hen used in
forrested regions.
KNOW YOUR GENERATOR
Read this owners manual and safety rules before operating your generator.
Compare the illustrations ith your generator, to familiarize yourself ith the locations of various controls and
adjustments. Save this manual for future reference.
Circuit Breakers (AC)
Spark Arrestor Muffler
Idle Control S itch
Air Cleaner
Run/Stop S itch
Recoil Starter
120 Volt AC,
30 Amp Receptacle
120/240 Volt AC,
30 Amp Receptacle
12 Volt DC, 10 Amp
Receptacle
120 Volt AC, 20 Amp
Duplex Receptacle Grounding Wing Nut
Fuel Tank

Generac Portable Products 5500 XL Generator
5
CONTENTS
The follo ing items are shipped ith your generator:
 Main unit
 Engine and generator o ner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 ith
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 0. Refer to the engine o ners manual.
Above 0°F, use SAE 30 or 10W30.
Below 0°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 overflo ing. 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.
Add Gasoline
DANGER! NEVER fill fuel tank indoors.
NEVER fill fuel tank hen engine is running or
hot. DO NOT light a cigarette or smoke hen
filling the fuel tank.
WARNING! Do not overfill the fuel tank.
Al ays allo room for fuel expansion.
 Use regular UNLEADED gasoline ith the
generator engine. Do not use premium gasoline.
Do not mix oil ith gasoline.
 Clean area around fuel fill cap, remove cap.
 Slo ly add unleaded regular gasoline to fuel tank.
Be careful not to overfill. Allo about 1/2" of tank
space for fuel expansion, as sho n in Figure 2.
 Install fuel cap and ipe 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 hich leads to separation and
formation of acids during storage. Acidic gas can
damage an engines fuel system hile 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.
SAE 30, 10W30
Synthetic 5W20, 5W30
Figure 2  Tank Expansion Space

Generac Portable Products 5500 XL Generator
6
OPERATING THE
GENERATOR
CAUTION! Never start or stop the unit ith
electrical loads connected to the receptacles
AND ith 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 s itch is Off.
 Place Run/Stop s itch in the Run position
(Figure 3).
 Place the choke lever in the Full Choke position
by sliding it to the left to ard the valve cover in the
direction indicated by the arro (Figure 4).
 Grasp starter grip and pull slo ly until you feel
slight resistance, then pull quickly.
 When engine starts, move choke lever to Run
position by sliding it all the ay to the right (a ay
from the valve cover and under the arro ).
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 ith a
lo oil shutdo n system. See engine owners
manual for further information.
Connecting Electrical Loads
 Let engine stabilize and arm up for a fe 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 atts (or amps) of all loads to be
connected at one time. This total should not be
greater than the rated attage/amperage capacity
of the generator. See Dont Overload the
Generator on page 10.
Figure 3  Run/Stop S itch
Figure 4  Choke Lever
Full Choke
Position
Run/Stop S itch

Generac Portable Products 5500 XL Generator
7
Stopping the Engine
 Unplug all electrical loads from generator panel
receptacles. Never start or stop engine ith
electrical devices plugged in and turned on.
 Put the idle control s itch 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 s itch to Stop position.
 Close the fuel shutoff valve.
Operating Automatic Idle Control
This s itch is designed to greatly improve fuel
economy. When this switch is turned ON, the
engine ill only run at its normal high governed
engine speed hen an electrical load is connected.
When electrical loads are removed, the engine ill
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 eather conditions (temperatures
belo 40°F [4°C] and a high de 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 t o feet
clearance bet een 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 hen temperature is
above 40°F [4°C].
For a more permanent shelter, build a structure that
ill enclose three sides and the top of the generator:
 Make sure entire muffler-side of generator is
exposed, as sho n in Figure 5.
 Ensure a minimum of t o feet clearance bet een
open side of box and nearest object.
 Face exposed end a ay from ind 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 sho n.
Remove shelter hen temperatures are above
40°F [4°C].
Figure 5  Typical Temporary Shelter

Generac Portable Products 5500 XL Generator
8
Charging a Battery
DANGER! Storage batteries give off
explosive hydrogen gas hile recharging. An
explosive mixture ill 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 hen orking
around a battery. Battery electrolyte fluid is an
extremely caustic sulfuric acid solution that
can cause severe burns. If spill occurs, flush
area ith clear ater 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 ater to cover separators in
battery cells. Do not use tap water.
 If the battery is equipped ith 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 ords
12-VOLT DC.
 Connect battery charge cable clamp ith red
handle to the positive (+) battery terminal
(Figure 6).
 Connect battery charge cable clamp ith black
handle to the negative () battery terminal
(Figure 6).
 Start engine. Let the engine run hile battery
recharges.
 When battery has charged, shut do n engine.
NOTE: Use an automotive hydrometer to test battery
state of charge and condition. Follo the hydrometer
manufacturers instructions carefully. Generally, a
battery is considered to be at 100% state of charge
hen specific gravity of its fluid (as measured by
hydrometer) is 1.260 or higher.
Figure 6  Battery Connections
12 VOLT D.C.
RECEPTACLE

Generac Portable Products 5500 XL Generator
9
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) atts at
20 Amps of current (Figure 7).
120/2 0 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L1430 plug ith this receptacle.
Connect a 4 ire 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 po ers 120/240 Volt AC, 60 Hz,
single phase loads requiring up to 3600 atts
(3.6 kW) of po er at 30 Amps for 120 Volts, or
5500 atts of po er (5.5 kW) at 22.9 Amps for
240 Volts. The outlet is protected by a 30 Amp
pushtoreset circuit breaker.
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L530 plug ith this receptacle.
Connect a 3 ire cord set rated for 125 Volts AC at
30 Amps to the plug (Figure 9).
Use this receptacle to operate 120 Volt AC, 60 Hz,
single phase loads requiring up to 3600 atts
(3.6 kW) of po er at 30 Amps. The outlet is protected
by a 30 Amp pushtoreset circuit breaker.
Figure 8  120/240 Volt, 30 Amp Locking Receptacle
Figure 9  120 Volt, 30 Amp Locking Receptacle
Figure 7  120 Volt, 20 Amp Duplex Receptacle

Generac Portable Products 5500 XL Generator
10
DONT OVERLOAD THE
GENERATOR
Overloading a generator in excess of its rated
attage capacity can result in damage to the
generator and/or connected electrical devices.
Observe the follo ing, to prevent overloading the
unit:
 Add up the total attage of all electrical devices to
be connected at one time. This total should NOT
be greater than the generators attage capacity.
 The rated attage of lights can be taken from light
bulbs. The rated attage of tools, appliances and
motors can usually be found on a data plate or
decal affixed to the device.
 If the appliance, tool or motor does not give
attage, multiply 120 Volts times ampere rating to
determine atts (volts x amps = atts).
 Some electric motors, such as induction types,
require about three times more atts of po er for
starting than for running. This surge of po er lasts
for only a fe seconds hen starting such motors.
Be sure you allo for this high starting attage
hen selecting electrical devices to connect to your
generator. First figure the atts needed to start the
largest motor. Add to that figure the running atts
of all other connected loads.
 A attage reference guide (Figure 10) is provided
to help you to determine ho many items the
generator can operate at one time.
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 Sa ......................................................1200
Circular Sa (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 .............................................Running Watts
Hedge Trimmer.................................................450
Impact Wrench..................................................500
Iron .................................................................1200
*Jet Pump .........................................................800
La n Mo er ...................................................1200
Light Bulb..........................................................100
Micro ave 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
Slo 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 Sa (10")................................1750 to 2000
Television...............................................200 to 500
Toaster...............................................1000 to 1650
Weed Trimmer ..................................................500
* Allo 3 times the listed atts for starting these devices.
Figure 10  Wattage Reference Guide