GENERAC
The Reliable Ones
5500EXL
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 system’s main
circuit breaker or main switch if this unit is used for backup power. Failure to isolate the generator from
the power utility may result in injury or death to electric utility workers and damage to the
generator due to a backfeed of electrical energy.
The Emission Control System for this generator is warranted for standards set by the
Environmental Protection Agency. For warranty information refer to the engine owner’s manual.
Model No. 9797-3 (5500 Watt AC Generator) Manual No. 20820 Revision 3 (2/17/2000)
Visit our Generac website: www.generac-portables.com
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
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Generac Portable Products 5500EXL Extended Life Generator
• Do Not use worn, bare, frayed or otherwise
• Never operate this generator:
damaged electrical cord sets with the generator.
in rain; in any enclosed compartment; when
connected electrical devices overheat; if electrical
output is lost; if engine or generator sparks; if flame
or smoke is observed while running; if unit vibrates
excessively.
• 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.
GROUNDING THE
GENERATOR
The National Electric Code requires the frame and
external electrically conductive parts of generator be
properly connected to approved earth ground.
• Do Not overfill the fuel tank. If overfilled, fuel can
contact the hot engine and cause FIRE or an
EXPLOSION.
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.
• 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.
Figure 1 — Location of Grounding Wing Nut
• 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.
Grounding Wing Nut
• 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.
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.
• 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.
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.
• Do Not insert any object through the unit’s cooling
slots. You could damage the unit or injure yourself.
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.
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Generac Portable Products 5500EXL Extended Life Generator
KNOW YOUR GENERATOR
Read this owner’s manual and safety rules before operating your generator.
Compare the illustrations with your generator to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.
Circuit Breakers (AC)
Fuel Tank
120/240 Volt AC
30 Amp Receptacle
120 Volt AC, 20 Amp
Receptacle
Electric Start Button
Recoil Starter
Idle Control Switch
12 Volt DC, 10 Amp
Receptacle
Battery Tray
Location
Grounding Wing Nut
120 Volt AC, 30 Amp
Receptacle
12 Volt DC, 10 Amp Receptacle — Used with battery
charge cables to charge a 12 Volt battery.
Circuit Breakers (AC) — Each receptacle is provided
with a "push to reset" circuit breaker to protect the
generator against electrical overload.
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.
Electric Start Button — Press to start unit.
Fuel Tank — Capacity of seven U.S. gallons of
unleaded fuel.
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.
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.
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.
Recoil Starter — Used as an alternate method of
starting the unit.
Battery Tray Location — Pre-tapped and installed
screws are found here for the battery tray
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Generac Portable Products 5500EXL Extended Life Generator
Your generator requires some assembly and is ready
for use after it has been properly serviced with the
recommended oil and fuel.
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.
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.
Install the battery as follows:
• Find battery tray and fasteners (loose) in carton.
Includes all parts needed to mount battery and tray.
REMOVE GENERATOR
FROM CARTON
• Set the carton on a rigid flat surface with “This Side
Up” arrows pointing upward.
• Remove the 4 battery tray screws from cradle.
• Position the battery tray and install (Figure 2).
Figure 2 — Install Battery Tray
• 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.
• Set battery onto tray (Figure 3).
• The generator
Figure 3 — Install Battery onto Battery Tray
• Electric start battery cables
• Generator and engine owner’s 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
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Generac Portable Products 5500EXL Extended Life Generator
• Retain battery to tray with 2 J-bolts, 2 lock washers
and 2 hex nuts (Figure 3).
BEFORE STARTING THE
ENGINE
Perform the following tasks before starting the unit:
• Connect the red battery cable from the engine start
button to the positive (+) terminal on battery
(Figure 4).
Figure 4 — Connect Battery Cables
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 owner’s manual.
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 Fuel
RED wire from
Start Button
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.
BLACK wire from
engine mount
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.
• 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.
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Generac Portable Products 5500EXL Extended Life Generator
To avoid engine problems, the fuel system should be
OPERATING THE
GENERATOR
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.
CAUTION! Never start or stop unit with
electrical loads connected AND with the
connected devices turned ON.
Never use engine or carburetor cleaner products in the
fuel tank or permanent damage may occur.
To add fuel:
Starting the Engine
• Clean area around fuel fill cap, remove cap.
• Disconnect all electrical loads from the generator.
• 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.
• Open the fuel shut-off valve (Figure 6).
Figure 6 — Fuel Shut Off Valve
Figure 5 — Fuel Tank Air Space
• 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).
• Install fuel cap and wipe up any spilled gasoline.
Figure 7 — Choke Positions
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”.
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Generac Portable Products 5500EXL Extended Life Generator
• When engine starts, move choke lever to
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
“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.
crankcase breather system. In an emergency, use the
original shipping box as a temporary shelter:
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.
• Cut off all flaps and one of the long sides of the box
to expose exhaust side of unit. Cut appropriate slots
to access unit’s receptacles.
NOTE: If engine fires, but does not continue to run,
move choke lever to “Full” choke position and repeat
starting instructions.
• Start unit, then place box over it. Ensure a minimum
of two feet clearance between open side of box and
nearest object.
Refer to the engine owner’s manual for complete
starting instructions.
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).
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
“Don’t Overload the Generator” on page 11.
Figure 8 — Temporary Cold Weather Shelter
Wind
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 shut–off 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.
8
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Generac Portable Products 5500EXL Extended Life Generator
Charging a Battery
Figure 9 — Battery Charge Cable Connection
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.
Red
Black
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.
• Connect battery charge cable clamp with black
handle to the negative (–) battery terminal
(Figure 9).
• Start engine. Let the engine run while battery
recharges.
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.
• When battery has charged, shut down engine.
NOTE: Use an automotive hydrometer to test battery
state of charge and condition. Follow the hydrometer
manufacturer’s 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.
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).
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Generac Portable Products 5500EXL Extended Life Generator
Use this receptacle to operate 120 Volt AC, 60 Hz,
CORD SETS/RECEPTACLES
This generator is equipped with the following
receptacles:
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.
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.
Figure 10 — 120 Volt AC, 20 Amp Receptacles
Figure 12 — 120/240 Volt AC, 30 Amp Receptacle
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).
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.
Figure 11 — 120 Volt, 30 Amp Receptacle
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.
10
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Generac Portable Products 5500EXL Extended Life Generator
• The rated wattage of lights can be taken from
DON’T 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:
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.
• 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.
• If the appliance, tool or motor does not give wattage,
multiply 120 Volts times ampere rating to determine
watts (volts x amps = watts).
Figure 13 — Wattage Reference Guide
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
Device . . . . . . . . . . . . . . . . . . . . . . . . . . Load (watts)
Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Impact Wrench. . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800
Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Chain Saw. . . . . . . . . . . . . . . . . . . . . . . . . . . . L.ig.h1t 2B0u0lb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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
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.
11
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Generac Portable Products 5500EXL Extended Life Generator
GENERAL MAINTENANCE
RECOMMENDATIONS
STORAGE
The generator should be started at least once every
seven days and allowed to run at least 30 minutes.
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.
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.”
Engine Maintenance
See engine manual for instructions.
• Check that cooling air slots and openings on
generator are open and unobstructed.
Generator Maintenance
• Disconnect the negative battery cable from the
battery.
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.
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.
Check the cleanliness of the generator frequently and
clean when dust, dirt, oil, moisture or other foreign
substances are visible on its exterior surface.
Engine Storage
See engine owner’s manual for instructions on how to
properly store the engine.
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.
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.
Clean the Generator
• Use a damp cloth or soft bristle brush to wipe
exterior surfaces clean.
SPECIFICATIONS
Rated Maximum Continuous
• A vacuum cleaner may be used to pick up loose dirt
and debris.
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
• 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.
Rated AC Frequency. . . . . . . . . 60 Hertz
Number of Rotor Poles . . . . . . . 2
Driven Speed of Rotor . . . . . . . . 3600 RPM
SERVICE/ADJUSTMENTS
Refer to engine owner’s manual for information.
12
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Generac Portable Products 5500EXL Extended Life Generator
TROUBLESHOOTING
Problem
Cause
Correction
1. Reset circuit breaker.
1. One of the circuit breakers is
open.
2. Fault in generator.
3. Poor connection or defective
cord set.
2. Contact Generac service facility.
3. Check and repair.
Engine is running, but no
AC output is available.
4. Connected device is bad.
4. Connect another device that is in
good condition.
1. Short circuit in a connected load. 1. Disconnect shorted electrical load.
2. Engine speed is too slow.
3. Generator is overloaded.
2. Contact Generac service facility.
3. See “Don't Overload the
Generator” on page 11.
4. Contact Generac service facility.
Engine runs good at no-load
but “bogs” down" when
loads are connected.
4. Shorted generator circuit.
1. Run/Stop Switch set to “Stop”.
2. Dirty air cleaner.
3. Out of gasoline.
1. Set switch to “Run”.
2. Clean or replace air cleaner.
3. Fill fuel tank.
4. Stale gasoline.
4. Drain gas tank; fill with fresh fuel.
5. Spark plug wire not connected to 5. Connect wire to spark plug.
spark plug.
6. Bad spark plug.
7. Water in gasoline.
8. Overchoking.
6. Replace spark plug.
Engine will not start; or
starts and runs rough.
7. Drain gas tank; fill with fresh fuel.
8. Open choke fully and crank
engine.
9. Excessively rich fuel mixture.
10. Intake valve stuck open or
closed.
9. Contact Generac service facility.
10. Contact Generac service facility.
11. Engine has lost compression.
12. Failed battery.
11. Contact Generac service facility.
12. Replace battery.
1. Out of gasoline.
2. Low oil level.
1. Fill fuel tank.
2. Fill crankcase to proper level.
Engine shuts down during
operation.
1. Load is too high.
1. See “Don't Overload the
Generator” on page 11.
2. Replace air filter.
Engine lacks power.
2. Dirty air filter.
1. Choke is opened too soon.
1. Move choke to halfway position
until engine runs smoothly.
Engine “hunts” or falters.
2. Carburetor is running too rich or
too lean.
2. Contact Generac service facility.
13
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Generac Portable Products 5500EXL Extended Life Generator
SCHEMATIC DIAGRAM
14
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Generac Portable Products 5500EXL Extended Life Generator
WIRING DIAGRAM
15
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Generac Portable Products 5500EXL Extended Life Generator
EXPLODED VIEW
16
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Generac Portable Products 5500EXL Extended Life Generator
PARTS LIST
Item Part #
Qty. Description
Item Part #
Qty. Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
A92432
A92531
A92731
92247
92678G
94980A
65791
67451
22129
86307
28092
92609
82857
92532
90239
66476
1
1
1
1
1
1
1
1
CRADLE
46
47
48
49
51
52
55
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
92665
85000
14353621 1
1
1
INSULATION, #2-1/4" Thick
CLIP, Insulation
WIRE, Ground
SUPPORT, Engine
SUPPORT, Engine & Muffler
HOUSING, Engine Adapter
ASSEMBLY, Rotor
ASSEMBLY, Stator
BEARING
26850
92982
96057
25244
96058
92630
NSP
22531
22142
77282
22287
22097
22127
78289
93826
B96068
56893
B2153
22473
2
1
2
LW, EXT, Shakeproof M6
DECAL, Danger
DECAL, Heat Shield
12 NUT, 5/16-18 Hex
WASHER, Special Flat - M8
1
1
1
2
2
1
2
2
2
1
1
1
5
8
4
DECAL, Control Panel
ASSEMBLY, Control Box
ENGINE
HHCS, 5/16-18 x 1-3/4"
SCREW, 5/16-18 x 3/4"
SWITCH, Starter
SCREW, 1/4 - 20 x 3/4
LOCKWASHER, M6
NUT, 1/4 - 20 Hex
BRACKET, Starter Switch
DECAL, Start Instructions
SHIELD, Heat
16 WASHER, Lock - M8
4
1
2
4
1
1
2
HHMS, 5/16-24 x 3/4
HHCS, 5/16-24 x 9-1/4
MOUNT, Vibration
MOUNT, Vibration
BRACKET, Muffler
GASKET, Muffler
CAPSCREW, M6 - 1.0 x
12mm
17
18
19
20
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
A7433
40976
83083
81917
66825C
74908
86308A
65795
66849C
67022
84132
66386
66849
B67025
22769
86494
86292
77395
83465
57058
80270
78299
B4363
B1695
B92039
1
2
1
1
1
4
4
2
1
1
1
1
2
1
1
1
1
4
4
4
1
1
1
1
1
MUFFLER
SCREW, M8 - 1.25 x 20
SCREEN, Spark Arrester
PIN, Roll 4mm x 10
CARRIER, Rear Bearing
TAPTITE, M5-0.8 x 10
BOLT, Stator M6-1 x 145mm
RECTIFIER, Battery Charge
TAPTITE, M5-0.8 x 30
GROMMET, Rubber
ASSEMBLY, Power Regulator
ASSEMBLY, Brush Holder
TAPTITE, M5-0.8 x 16
COVER, Bearing Carrier
WASHER, Shakeproof Int. #10
SCREW, M6-1.0 x 16 Wing
HHCS, - #10 Self Driller
NUT, Flange Lock - M6
GROMMET, Tank
CRIMPTITE, 10-24 x 1/2
SCREW, #12 Self Drill
WASHER, Flat M6
Parts Not Illustrated:
37806
43438
72347
73111
84882
20820
65787
1
1
1
1
1
1
1
125V 30A Locking plug
240V 30A Locking plug
Spark plug
Air cleaner element
Spark plug wrench
Owners manual
Battery charge cable
Battery Tray Components:
22129
45771
96925
96924
15453621 1
15553621 1
96923
22145
58443
2
2
1
2
Lockwasher, M8
Hex nut M8
Battery tiedown
J-bolt
Battery cable, positive
Battery cable, negative
Battery tray
HHCS, M6-1.0 x 55
VALVE, Tank
BUSHING, Tank
CAP, with Gauge, Fuel
TANK, Fuel 7 Gal.
SHIELD, Heat
1
2
4
Flat washer
Screws, battery tray
17
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Generac Portable Products 5500EXL Extended Life Generator
CONTROL PANEL EXPLODED VIEW & PARTS LIST
Item Part #
Qty. Description
Item Part #
Qty. Description
1
2
A92070
23897
49226
91526
82538
82881
43181
43182
90418
75207A
75207
23365
68868
1
4
4
4
1
4
4
4
1
2
2
6
1
PANEL, Control
14
43437
1
OUTLET, 120V/240V, 30A
Locking Type
FLAT WASHER, #10 M5
LOCK WASHER, M5
SCREW, M5-0.8 x 12mm
SWITCH, Idle Control
LOCK WASHER, 7/16"
SCREW, M3 - 0.5 x 10mm
LOCK WASHER, M3
OUTLET, 12V
CIRCUIT BREAKER, 30A
CIRCUIT BREAKER, 20A
WASHER, #8 Shakeproof
OUTLET, 120 Volt, 30 Amp
Locking Type
3
4
5
6
7
8
9
15
16
17
18
19
20
21
22
68759
43180
22264
51715
64526
83970
64525
87962
1
6
6
6
8
1
4
1
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)
10
11
12
13
23
24
25
26
84335
84134
B92069
84028
1
1
1
1
ASSEMBLY, Wire Harness
GROMMET, Rubber Conn
BOX, Control Panel
TRANSFORMER, Idle Control
18
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Generac Portable Products 5500EXL Extended Life Generator
NOTES
19
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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
Engine
2 years (2nd year parts only)
Warranted solely by the engine manufacturer
1 year
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 COMPANY’s 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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