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