Generac Power Systems 5500XL User manual

GEN RAC°I
Portable Products
Portable Generator Owner's Manual
Model No. 1314_0 (5500 Watt AC Generator) Manual No. B4360 Revision 4 (9/20/2000)
Visit our Generac website: www.generac-portables.com
_This isthe safety alert symbol. It isusedto alert you to potential personal injuryhazards.
Obey all safety messagesthat follow this symbol to avoidpossible injuryor death.

Generac Portable Products 5500XL Generator
EQUIPMENT
DESCRIPTION
This generator isan engine-driven, revolving field,
alternating current (AC) generator. It was designedto
supply electrical power for operating compatible electrical
lighting, appliance,tool and motor loads. This manual
contains informationfor a generator that operates 120
and/or 240 Volt AC, singlephase,60 Hz devicesthat
require up to 5,500 watts (5.5 kW) of power that pull up
to 45.8 Amps at 120Volts or 22.9Amps at 240 Volts.
_CAUTION! Do Not exceed the generator's
wattage/amperage capacity.Add up the rated watts
of all devicesyou 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 II.
The generator's revolving fieldisdriven at about 3,600rpm
by a single-cylinder engine and hasthe following features:
•120/240Volt AC, 30 Amp locking receptacle.
• 120Volt AC, 30 Amp locking receptacle.
• 120Volt AC, 20 Amp duplex receptacle.
• Low Oit Shutdown: Automatically shuts down the engine
if oit drops below safeoperation level.
• Sevengallon overhead fuel tank with fuel gauge.
_AUTION! Do Not tamper with engine
governed speed.High operating speedsare
dangerous and increaserisk of personal injuryor
damageto equipment The generator supplies
correct rated frequency and voltage only when
running at proper governed speed. Incorrect
frequency and/or voltage candamagesome
connected electrical loads.Operating at excessively
low speedsimposesa heavyload.When adequate
engine power isnot available,engine life may be
shortened.
SAFETY RULES
This generator set was designedand manufactured for
specific applications. Do Not attempt to modify the unit
or use it for anyapplication it was not designedfor. If you
haveany questions about your generator's application, ask
your dealer or consult the factory.
The manufacturer could not possibly anticipate every
circumstance that might involvea hazard. For that reason,
warnings in the manualand warnings on tagsor decals
affixed to the unit are not all-inclusive. Ifyou intend to
handle,operate or service the unit by a procedure or
method not specificallyrecommended by the manufacturer,
first make sure that such a procedure or method will not
render this equipment unsafeor 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 isolatethe generator from
the electric utility usingapproved transfer equipment
ifthis unit isusedfor 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
sumcient concentrations, carbon monoxide
can cause unconsciousness or death. Operate
this equipment outdoors where adequate ventilation
is available.
/2

Generac Portable Products 5500XL Generator
• The generator produces a very powerful voltage that can
causeserious injuryor death by electrocution. Never
touch bare wires or receptacles. Never permit a child
or anyunqualified person to operate the 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 injuryfrom electrocution may
result.
• Use a ground fault circuit interrupter (GFCI) in anydamp
or highly conductive area (such as metal decking or steel
work).
•Never useworn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury,
or property damagefrom 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 lawsregulatingstorage and
handling of gasoline.
•Do Not overfill the fuel tank. Always allow room for
fuel expansion. If tank is overfllled, fuel can overflow
onto a hot engine and cause a FIRE or an
EXPLOSION.
•Never store a generator with fuel in the tank where
gasolinevapors 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 adequateflow of cooling air for its
continued proper operation. Never operate the unit
insideany 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 sidesof
generator or you could damagethe unit. Read"Cold
Weather Operation" on page9.
•Never start or stop the unit with electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting anyelectrical loads. Disconnect all electrical
loadsbefore shutting down the generator.
•Do Not insertanyobject through cooling slots of the
engine.You could damagethe unit or injureyourself.
•Never operate the generator:
in rain; in any enclosed compartment; when connected
electrical devicesoverheat; if electrical output islost;if
engine or generator sparks; ifflame or smoke is
observed while unit isrunning; ifunit vibrates
excessively.
GROUNDING THE
G EN ERATO R
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 I).
_gNut
Generally, connecting a No. 12AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth-driven copper or brassgrounding rod
(electrode) provides adequate protection against electrical
shock. Be careful to keepthe 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 inyour area.
Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists inthe generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
/3

GeneracPortableProducts5500XLGenerator
KNOW YOUR GENERATOR
Read this owner's manual and safety rules before operating your generator.
Compare the illustrationswith your generator, to familiarize yourself with the locationsof various controls and
adjustments. Savethis manualfor future reference.
Circuit Breakers (AC) 120Volt AC, 20 Amp
Duplex Receptacle
FuelTank
120Volt AC, 30 Amp
Receptacle
FuelShut-Off
Valve
120/240 Volt AC,
30 Amp Receptacle
12Volt DC, 10Amp
Receptacle Grounding Wing Nut
12 Volt DC, I0 Amp Receptacle -- Use this receptacle
with battery charge cablesto charge a 12Volt battery.
120 Volt AC, 20 Amp Duplex Receptacle -- May be
usedto supply electrical power for the operation of 120
Volt AC, 20 Amp, single phase,60 Hz electrical lighting,
appliance,toot and motor loads.
120 Volt AC, 30 Amp Receptacle -- May be usedto
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 120and/or
240 Volt AC, 30 Amp, single phase,60 Hz electrical
lighting, appliance, tool and motor loads.
Run/Stop Switch
Idle Control Switch
Circuit Breakers (AC) -- Eachreceptacle is provided
with a "push to reset" circuit breaker to protect the
generator against electrical overload.
Fuel Shut-Off Valve -- Controls fuel supply.
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 idlecontrol runs the engine
at normal (high) speedswhen there isaloadpresent and
runs the engine at idle(tow) speedswhen a toad isnot
present.
Run/Stop Switch -- Must be in "Run" position to start
engine.Set to "Stop" to stop a running engine.
/4

GeneracPortableProducts5500XLGenerator
INSTALL WHEEL KIT
To install your wheel kit you need the following:
•Socket wrench with 1/2" or 13mm socket.
Install Wheel Kit as follows: (SeeFigure 2)
• Placethe generator on a hard flat surface.
• Placetemporary blocks under unit to easeassembly.
• Slidethe axle through the holes in the brackets provided
on the generator cradle and then acidthe two spacerson
eachprotruding end of the axle.
• Slideon the wheels on eachend of the axle and secure
with washer and retaining pin.
NOTE: Make sure the wheel air inflation valves are facing
outward.
•Attach the vibration mounts to the support leg with M8
x 30mm capscrews,M8 washers and lock nuts.
• Attach the support leg with two M8 x 20ram capscrews
and two lock nuts. Removetemporary blocks.
• Attach the handle with four M8 x 45mm capscrewsand
four lock nuts in the location shown.
Handle
Capscrew,
M8 x 45mm
/
Lock Nut, M8
Support
Flat WasherJ
_Hex Head
J _/ _-Capscrew,
M8 x 20mm
_LockNut, M8
_ Hex Head
_Capscrew,
M8 x 30mm
Axle Wheel
jSpacer Wheel
/
/
Retaining Pin
/5

Generac Portable Products 5500XL Generator
BEFORE STARTING THE
ENGINE
Add Oil
_ARNING! Any attempt to crank or start the
engine before it hasbeen properly filledwith the
recommended oil mayresult in an enginefailure.
To fill your engine with oil:
•Place generator on a level surface.
• Clean area around oil fill and remove oil fill cap.
• Select the oil's viscosity grade and fill engine with oil
following the instructions given in the engine owner's
manual. Do Not overfil!!
•Install oil fill cap.
NOTE: The generator's revolving field rides on a pre-
lubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
Add Gasoline
_ANGER! Explosion Hazard! Never fillfuel tank
indoors.Never fillfuel tank when engine isrunning
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 the Generator
engine. Do Not use premium gasoline. Do Not mix oil
with gasoline.
• Clean area around fuel fill cap, remove cap.
• Add unleaded regular gasoline, slowly to fuel tank. Be
careful not to overfill. Allow about I/2" of tank space for
fuel expansion (Figure 3).
1/2" Air Space Tank
• 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 12. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
/6

Generac Portable Products 5500XL Generator
OPERATING THE
GEN ERATO R
_ AUTION! Never start or stop the engine withelectrical loadsconnected to the unit and with the
connected devicesturned ON.
Starting the Engine
Disconnect all electrical loadsfrom the generator. Use the
following start instructionsteps by numerical order:
I. Make sure the Idle Control switch is in "Off' position.
2. Turn the fuel valve to the "On" position (Figure 4).
3. Set the Run/Stop switch to "Run" position (Figure 5).
@
Run/Stop Switch
4. Placethe choke leverin the "Full" choke position
(Figure6).
5. Grasp the recoil handle and pull slowly until slight
resistance isfelt Then pull rapidly one time only to
start engine.
• If engine starts, proceed to step 7.
• Ifengine failsto start, proceed to step 6.
6. Move the choke lever to "Half" choke position, and
pull recoil handle twice.
• If engine fails to start, repeat steps 4 thru 6.
7. Move choke lever to "Run" position. If enginefalters,
move choke lever to "Half" chokeposition until the
engine runs smoothly, and then to "Run" position.
NOTE: If engine still fails to start after 3 pulls, check for
proper oil levelin crankcase.This unit isequipped with a
Low Oil Shutdown System.See engine manual.
Connecting Electrical Loads
•Let engine stabilize and warm up for a few minutes after
starting.
• Plugin and turn on the desired 120 and/or 240 Volt AC,
singlephase,60 Hertz electrical loads.
•Do Not connect 240 Volt loads to 120Volt receptacles.
•Do Not connect 3-phase loadsto the generator.
•Do Not connect 50Hz loads to the generator.
•DO NOT OVERLOAD THE GENERATOR. Add up
the rated watts (or amps) of all loadsto be connected at
one time. This total should not be greater than the rated
wattage/amperagecapacity of the generator. See "Don't
Overload the Generator" on page I I.
Stopping the Engine
• Unplug all electrical loadsfrom generator panel
receptacles. Never start or stop engine with electrical
devicesplugged in and turned on.
• Put the Idle Control switch in the "Off' position.
• Let engine run at no-load for 30 secondsto stabilizethe
internaltemperatures of engine and generator.
• Move Run/Stop switch to "Stop".
• Close the fuel shut-off valve.
/7

Generac Portable Products 5500XL Generator
Operating Automatic Idle Control
This switch isdesignedto greatly improvefuel economy.
When this switch is turned ON, the engine will only
run at itsnormal high governed engine speed when an
electrical load isconnected. When the electrical load is
removed, the engine will run at a reduced speed. With
the switch off, the enginewill run at a constant high
engine speed. Always have the switch "Off" when
starting and stopping the engine.
Charging a Battery
AANGER! Storage batteries give off explosive
hydrogen gaswhile recharging.An explosive mixture
will remain around the battery for a long time after
it hasbeen charged. The slightest spark canignite
the hydrogen and causean explosion. Suchan
explosion can shatter the battery and cause
blindnessor other serious injury.
ADANGER! 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 isan extremely caustic
sulfuric acid solution that can causesevere burns. If
spill occurs, flusharea with clear water immediately.
Your generator hasthe capability of recharging a discharged
12Volt 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 havinga discharged battery.
To recharge 12 Volt batteries, proceed as follows:
•Check fluid levelin all battery cells. If necessary,add
ONLY distilled water to cover separators in battery
cells. Do Not use tap water.
• If the battery isequipped with vent caps,make sure they
are installedand are tight.
•If necessary,clean battery terminals.
• Connect battery charge cableconnector plug to panel
receptacle identifiedbythe words "12-VOLTS D.C"
• Connect battery charge cableclamp with red handle to
the positive (+) battery terminal (Figure7).
12 VOLT D.C.
RECEPTACLE
+
POS NEG
12 VOLT BA'I-rERY
• Connect battery charge cableclamp with black handle
to the negative (-) battery terminal (Figure7).
• Start engine. Let the engine run while battery recharges.
• When battery hascharged, shut down engine
NOTE: Use an automotive hydrometer to test battery
state of charge and condition. Follow the hydrometer
manufacturer's instructionscarefully. Generally, a battery is
considered to be at 100%state of chargewhen specific
gravity of its fluid (as measured by hydrometer) is 1.260or
higher.
/8

GeneracPortableProducts5500XLGenerator
COLD WEATH ER
OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icingof the carburetor and/or the crankcase
breather system.
In an emergency, usethe original shipping box asa
temporary shelter:
•Cut off all flaps.
• Cut out one of the long sides of the box to expose
exhaust side of unit. Ensurea minimum of two feet
clearance between open sideof box and nearest object.
• Cut appropriate slots to accessreceptacles of unit. You
may also need to cut a clearance slot for the handle.
• Start unit, then place box over it.
IMPORTANT: Remove shelter when temperature is
above 40°F [4°C].
For a more permanent shelter, build a structure that will
enclose three sidesand the top of the generator:
• Make sure entire muffler-side of generator is exposed, as
shown in Figure 8. Note that your generator's
appearancemay differ from that shown here.
•Ensure a minimum of two feet clearance between open
side of box and nearest object.
• Face exposed end away from wind and elements.
•Enclosure should hold enough heat created by the
generator to prevent icing problem.
ACAUTION! Never run unit indoors.Do Not
enclosegeneratoranymore than shown.Remove
shelterwhentemperatures are above40°F [4°C].
RECEPTACLES
This generator isequipped with the following receptacles:
120 Volt AC, 20 Amp Receptacle
This outlet is protected against overload by a 20 Amp
)ush-to-resetcircuit breaker (Figure 9).
Use eachoutlet to operate 120 Volt AC, singlephase,
60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)
at 20 Amps. Use cord sets that are rated for 125 Volt loads
at 20 Amps (or greater).
/9

Generac Portable Products 5500XL Generator
120/240 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA LI4-30 plug with this receptacle. Connect a
4-wire cord set rated for 250 Volt AC loads at 30 Amps
(or greater) (Figure 10).You can usethe same4-wire cord
if you plan to run a 120Volt load.
120 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L5-30 plug with this receptacle. Connect a
3-wire cord set rated for 125Volts AC at 30 Amps to the
plug (Figure I I).
I- - I|_otv/lJte€[;]r,__ _m
Ij_l_m Ilo_ IPIOTP,1E[O__ _l'_
4-Wire CordSet
This receptacle powers 120/240Volt AC, 60 Hz, single
phaseloadsrequiring up to 3,600 watts of power at
30 Amps for 120 Volts; 5,500 watts of power (5.5 kW) at
22.9 Amps for 240 Volts. The outlet isprotected by
30 Amp push-to-reset circuit breakers.
3-Wire Cord Set
NEMA L5-30
I_-- Neutral
-----_ Hot
F_7 GrOund
(Green)
Use this receptacle to operate 120Volt AC, 60 Hz, single
phaseloadsrequiring up to 3,600 watts (3.6 kW) of power
at 30 Amps. The outlet isprotected by a 30 Amp push-to-
reset circuit breaker.
/10

Generac Portable Products 5500XL Generator
DON'T OVERLOAD THE
GENERATOR
Overloading agenerator in excess of its rated wattage
capacity can result in damageto 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 generator's wattage capacity.
• The rated wattage of lightscan be taken from lightbulbs.
The rated wattage of tools, appliancesand motors can
usually be found on a data plate or decal affixed to the
device.
•Ifthe appliance, tool or motor does not give wattage,
multiply 120Volts times ampere rating to determine
watts (volts x amps = watts).
• Some electric motors, such as induction types, require
about three times more watts of power for starting than
for running. This surge of power lastsfor only a few
seconds when starting such motors. Be sure you allow
for this high starting wattage when selecting electrical
devicesto 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.
• Items in the wattage reference guide (Figure 12)are
provided to help you to determine how many items the
generator can operate at one time.
Recreational/Home Uses
Tool/Appliance .................................................... Watts
AM/FM clock radio .....................................................................50
Light bulb....................................................................................100
Fan................................................................................................200
20" color TV ..............................................................................400
*Deep freezer ............................................................................500
Personal computer and 15" monitor ...................................800
*1/3 hp furnace fan blower .....................................................800
Microwave oven ........................................................................800
*18 cuft refrigerator ...............................................................800
Sump pump ..............................................................................1000
Electric skillet ..........................................................................1250
*Y2 hp water well pump ........................................................1400
* 12,000 Btu window air conditioner .................................1400
Space heater ............................................................................1800
Electric water heater .............................................................4000
Professional/C ontractor Uses
Tool/Appliance .................................................... Watts
"1/3 hp airless sprayer .............................................................600
3/8" hammer drill .....................................................................600
Variable speed Sawzalt® ..........................................................960
Y2"power drill .........................................................................1000
Quartz-halogen work light...................................................1000
Belt sander ...............................................................................1200
7¼" circular saw ...................................................................1500
7¼" worm drive saw............................................................1600
*1 Y2hp air compressor ........................................................1800
*I0" power miter saw ...........................................................IB00
6" bench grinder .....................................................................IB00
"6" table planer .......................................................................1800
*10" table/radial arm saw .....................................................2000
Wire feed welder ...................................................................2400
* allow 3times listed watts for starting this device
/II

Generac Portable Products 5500XL Generator
GENERAL MAINTENANCE
RECOMMENDATIONS
The owner/operator isresponsible for making sure that all
periodic maintenancetasks are completed on a timely
basis;that all discrepanciesare corrected; and that the unit
is kept clean and properly stored. Never operate a
damaged or defective generator.
Engine Maintenance
Seeengine manualfor instructions.
Generator Maintenance
Generator maintenanceconsists 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,
leavesor anyother foreign material.
NOTE: Do Not usea garden hose to cleangenerator.
Water canenter 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 windings wilt eventually
decrease the insulationresistance of these windings.
To Clean the Generator
•Use a damp cloth to wipe exterior surfacesclean.
• A soft bristle brush may be usedto loosen caked on dirt
or oil.
• A vacuum cleaner may be used to pick up loosedirt and
debris.
• Low pressure air (not to exceed 25 psi) may be used to
blow awaydirt. Inspect cooling air slots and opening on
generator. These openings must be kept clean and
unobstructed.
STORAGE
The generator should be started at least once every seven
daysand allowed to run at least30 minutes. If this cannot
be done and you must store the unit for more than 30
days,usethe following guidelinesto prepare it for storage.
Generator Storage
• Clean the generator asoutlined in "To Clean the
Generator."
• Check that cooling air slots and openings on generator
are open and unobstructed.
_DANGER! Storagecovers canbe flammable. Do
Not placea storage cover over a hot generator. Let
the unit coot for a sufficient time before placingthe
cover on the unit
Engine Storage
See engine owner's manual for instructions.
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 that
fuel with this unit.
• Store in clean and dry area.
SPECIFICATIONS
Maximum SurgeWatts ................. 6,875 watts
Continuous Wattage Capacity ........... 5,500 watts
Power Factor .............................. 1.0
Rated Maximum Continuous Load Current
At 120Volts ....................... 45.8 Amps
At 240 Volts ....................... 22.9 Amps
Phase ................................. I-phase
Rated Frequency ....................... 60 Hertz
FuelTank Capacity .................. 7 U.S.gallons
/12

Generac Portable Products 5500XL Generator
TROUBLESHOOTING
Problem
Engine isrunning, but no AC
output is available.
Engine runs good but bogs
down when loads are
connected.
Engine will not start; or
starts and runs rough.
Cause
1. Circuit breaker isopen.
2. Poor connection or defective
cord set.
3. Connected device isbad.
4. Fault in generator.
I. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed istoo slow.
4. Shorted generator circuit.
I. Run/Stopswitch set to "Stop".
2. Dirty air cleaner.
3. Out of gasoline.
4. Stalegasoline.
5. Sparkplug wire not connected to
spark plug.
6. Badspark plug.
7. Water in gasoline.
8. Overchoking.
9. Low oil level.
10. Excessivelyrich fuet mixture.
I I. Intake valve stuck open or
closed.
Enginehaslostcompression.
Solution
I. Reset circuitbreaker.
2. Check and repair.
3. Connect another device that is in good
condition.
4. Contact Generac service facility.
I. Disconnect shorted electrical load.
2. See "Don't Overload the Generator" on
page I 1.
3. Contact Generacservice facility.
4. Contact Generac service facility.
I. Set switch to "Run".
2. Clean or replace air cleaner.
3. Fill fuel tank.
4. Drain gas tank and fitt with fresh fuel.
5. Connect wire to spark plug.
6. Replacespark plug.
7. Drain gastank; fitl with fresh fuel.
8. Put choke leverto "no choke" position.
9. Fill crankcaseto proper level.
10. Contact Generac service facility.
I I. Contact Generac service facility.
12. 12.
I. Out of gasoline. I.
Engine shuts down during 2. Low oit level. 2.
operation. 3. Fault in engine. 3.
I. Load istoo high. I.
Engine lacks power. 2. Dirtyair filter. 2.
3. Engine needs to be serviced. 3.
I. Choke is opened too soon. I.
Engine "hunts" or falters. 2. Carburetor is running too rich or
too lean.
2.
Contact Generac service facility.
Fillfuel tank.
Fillcrankcase to proper level.
Contact Generac service facility.
See "Don't Overload the Generator" on
page I I.
Replace air filter.
Contact Generac service facility.
Move choke to halfway position till
engine runs smoothly.
Contact Generac service facility.
I13

Generac Portable Products 5500XL Generator
ID_ELF_i_I_
ELECTRICAL SCHEMATIC
11
T
E
BATTERY CHARGE
66 55 77
IlA
30_
I
14

Generac Portable Products 5500XL Generator ID_'! _
WIRING DIAGRAM
NUT DN
EN6INE _LDCK
i15

I
? j/_ ]
Generac Portable Products 5500XL Generator
EXPLODED VIEW - HAIN UNIT
46
45_
/
51
,_/47 62
38
10 \
<
5
27
so\\ I
55 I
2O
21
61
\ 55
65
65
_9
55
/16

Generac Portable Products 5500XL Generator
I
l/!
m
PARTS LIST
Item Part # Qty.
1 G92432
2 G92531
3 G92731
4 92247
5 92678G
6 92680G
7 65791
8 96796
9 22129 14
l0 86307 4
11 28092 I
12 92609 2
13 82857 4
14 92532 I
15 90239 I
16 66476 2
17 A7433 I
18 40976 2
19 83083 I
20 81917 I
21 B4986 I
25 66825C I
26 74908 4
27 86308A 4
28 65795 I
29 66849A I
30 67022 I
31 84132 I
32 66386 I
33 66849 2
34 B4871 I
35 22769 I
36 86494 I
37 86292 I
38 77395 4
39 83465 4
- MAIN UNIT
Description Item Part #
CRADLE 40 57058
SUPPORT,Engine 41 80270
SUPPORT,Engine& Muffler 42 78299
HOUSING, EngineAdapter 43 B4363
ASSEMBLY,Rotor 44 B1998
ASSEMBLY,Stator 45 B92039
BEARING 46 92665
WASHER, M8 Flat 47 85000
WASHER, M8 Lock 48 14353621
SCREW,5/16-24 x 3/4 Mach. 49 26850
SCREW,5/16-24 x 9-1/4" 51 92982
MOUNT, Vibration 52 B4361
MOUNT, Vibration 55 25244
BRACKET,Muffler 57 B4362
GASKET,Exhaust 58 92630A
SCREW, M6 - I x 12 Cap with 59 NSP
Lock Washer 60 22531
MUFFLER 61 22142
SCREW, M8 - 1.25x 20 Cap 62 93826
SCREEN,SparkArrest 63 56893
PIN, 4mm x 10 Roll 64 B96068
DECAL, Ground 65 B2153
CARRIER, RearBearing 66 22473
TAPTITE, M5-0.8 x 10
BOLT, M6-1 x 145mm Stator
RECTIFIER,Battery Charge
TAPTITE, M5-0.8 x 20
GROMMET,Rubber
ASSEMBLY,Power Regulator
ASSEMBLY,Brush Holder
TAPTITE, M5-0.8 x 16
COVER, Bearing Carrier
WASHER, #10 Int. Shakeproof
SCREW, M6-1.0 x 16Wing
SCREW,#10 Self Drilling
NUT, M6 FlangeLock
GROMMET,Tank
Qty.
4
2
I
2
12
I
I
I
2
2
I
5
I
6
4
Description
HHMS, M6-1.0 x 55
VALVE,Tank
BUSHING, PlasticTank
GAUGE, Fuel
TANK, 7 Gal.
SHIELD, Heat
INSULATION, #2- I/4"
CLIP,Insulation
WIRE, Ground
WASHER, M6 Shakeproof
DECAL, Danger
DECAL, Heat Shield
NUT, 5/16-18 Hex
DECAL, Control Panel
ASSEMBLY,Control Box
ENGINE
HHCS, 5/16-18 x 1-3/4
SCREW,5/16 - 18x 3/4 Cap
DECAL, Start Instructions
SCREW, 10-24 x I/2 Crimptite
SHIELD, Heat
SCREW,#12-14 x 7/8" SelfDrill
WASHER, M6 Flat
Item Not Illustrated
65787 I
B4360 I
NSP I
BB3061 2
37806
43438
Battery Charge Cable
Generator Owner's Manual
EngineOwner's Manual
Oil, 28 oz.
120Volt AC 30 Amp Plug
120/240Volt AC 30 Amp Plug
Optional Accessories Not Included
84883 Cord Wrap
/17

I
7j/_ I
Generac Portable Products 5500XL Generator
EXPLODED VIEW AND PARTS LIST - WHEEL KIT
lO
11
94
Item
I
2
3
4
5
6
7
8
9
l0
li
12
t3
Part #
B93393A
89742
93693A
87005
B89635
B93696
27007
42909
52858
22247
39253
22145
39287
8
Qty. Description
I HANDLE
2 WHEEL
I AXLE
2PIN, Retaining
2 SPACER,Wheel
I LEG,Support
2 MOUNT, Vibration
2 CAPSCREW,Hex Hd. M8 - 1.25x 30
8 NUT, Lock M8
2 WASHER, Wheel
2 CAPSCREW,Hex Hd. - M8 - 1.25x 20
2 WASHER, Vibration Mtg.
4 HHCS, M8 - 1.25x 45 GR 10.9
/18

Generac Portable Products 5500XL Generator
I
Ill
m
EXPLODED VIEW AND PARTS LIST - CONTROL PANEL
2O
19\\
21
19
25
8
7
6
10
10 16
6 11 15
11 \
/
95
€
7
26 22
18 7
14
Item
I
2
3
4
5
6
7
8
9
I0
II
12
13
Part#
A92070
23897
49226
91526
82538
82881
43181
43182
90418
75207A
75207
23365
68868
Qty. Description
I PANEL,Control
4 FLATWASHER, #10 M5
4 LOCK WASHER, M5
4 SCREW, M5_0.8x 12mm
I SWITCH, Idle Control
4 LOCK WASHER, 7/16"
4 SCREW, M3 - 0.5 x 10mm
4 LOCK WASHER, M3
I OUTLET, 12V
2 CIRCUIT BREAKER,30A
2 CIRCUIT BREAKER,20A
6 WASHER, #8 Shakeproof
I OUTLET, 120Volt, 30 Amp
Locking
Item Part#
14 43437
15 68759
16 43180
17 22264
18 51715
19 64526
20 83970
21 64525
22 87962
23 84335
24 84134
25 B92069
26 84028
Qty.
IDescription
OUTLET, 120V/240V,30A
Locking
OUTLET, 120V,20A Duplex
FLAT WASHER, M4
LOCK WASHER, #8 M4
NUT, M4-0.7 Hex
SCREW,#6-32 x 3/8"
BOARD, System Control
STAND-OFF, 3/4" Hex
CIRCUIT BREAKER.12V,10A
(auto)
ASSEMBLY, Wire Harness
GROMMET, Rubber Conn.
BOX, Control Panel
TRANSFORMER, Idle Control
/19

LIMITED WARRANTY
FOR "GN" ENGINE DRIVEN PORTABLE GENERATORS
GENERAC PORTABLEPRODUCTS (hereafter referred to asthe COMPANY) warrants to the original purchaser that the
alternator and control panel for itsportable generator wilt be free from defects in materials or workmanship for the items
and period set forth below from the date of original purchase.This warranty isnot transferable and appliesonly to portable
generators driven by a GN-Series engine.
Consumer* Commercial*
Alternator 2 years (2ridyear parts only) I year
Engine Warranted solely by the engine manufacturer
With the exception of European Community Countries, all unitsbound for export shall be warranted for One (I)
Yearin Consumer applications, end 90 daysin 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 saidwarranty period, the COMPANY wilt, at isoption, repair or replace anypart which, upon examination bythe
COMPANY, isfound to be defective under normal useand service**. Starting batteries are not warranted by the
COMPANY. All transportation costs under warranty, includingreturn to the factory ifnecessary,are to be borne bythe
purchaser and prepaid by the purchaser.This warranty does not cover normal maintenanceand service anddoes not apply
to a generator set,alternator, or parts which havebeen subjected to improper or unauthorized installation or alteration,
misuse, negligence,accident, overloading, overspeeding,improper maintenance, repair or storage so as,in the COMPANY's
judgement, to adverselyaffect 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.
THEREIS NO OTHER EXPRESSWARRANTY. THE COMPANY HEREBYDISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND
FITNESSFOR A PARTICULAR PURPOSETO THE EXTENT PERMITTED BY LAW. THE DURATION OF
ANY IMPLIEDWARRANTIES WHICH CANNOT BEDISCLAIMED ISLIMITED TO THE TIME PERIODAS
SPECIFIEDIN THE EXPRESSWARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL
DAMAGES UNDER ANY AND ALL WARRANTIES ISEXCLUDED. THE COMPANY ALSO DISCLAIMS
ANY RESPONSIBILITYFOR INCIDENTAL OR CONSEQUENTIAL DAMAGES,SUCH AS THE LOSSOF
TIME OR THE USEOF 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 impliedwarranty lasts,or the exclusion or limitation of incidentalor
consequential damages,sothe abovelimitationsor exclusions may not applyto you. This warranty givesyou specific legal
rights andyou may also haveother rights, which vary from state to state.
For service, seeyour 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 purchasedate must be presented.
GENERAC PORTABLE PRODUCTS
Jefferson, Wisconsin 53549