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.
Generac Portable Products 5500EXL Extended Life Generator EQUIPMENT DESCRIPTION SAFETY RULES This generator is an engine-driven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, appliance, tool and motor loads. This generator set was designed and manufactured for specific applications. Do Not attempt to modify the unit or use it for any application it was not designed for.
Generac Portable Products 5500EXL Extended Life Generator Do Not use worn, bare, frayed or otherwise damaged electrical cord sets with the generator. Never operate this generator: in rain; in any enclosed compartment; when connected electrical devices overheat; if electrical output is lost; if engine or generator sparks; if flame or smoke is observed while running; if unit vibrates excessively.
Generac Portable Products 5500EXL Extended Life Generator KNOW YOUR GENERATOR Read this owners manual and safety rules before operating your generator. Compare the illustrations with your generator to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference.
Generac Portable Products 5500EXL Extended Life Generator INSTALLING TRAY AND BATTERY Your generator requires some assembly and is ready for use after it has been properly serviced with the recommended oil and fuel. If you have any problems with the assembly of your generator, please call the generator helpline at 1-800-270-1408. 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.
Generac Portable Products 5500EXL Extended Life Generator BEFORE STARTING THE ENGINE Retain battery to tray with 2 J-bolts, 2 lock washers and 2 hex nuts (Figure 3). Connect the red battery cable from the engine start button to the positive (+) terminal on battery (Figure 4).
Generac Portable Products 5500EXL Extended Life Generator OPERATING THE GENERATOR To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. Drain the gas tank, start engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel next season. See Storage on page 12. CAUTION! Never start or stop unit with electrical loads connected AND with the connected devices turned ON.
Generac Portable Products 5500EXL Extended Life Generator COLD WEATHER OPERATION When engine starts, move choke lever to Half choke position until the engine runs smoothly and then to Run position. If engine falters, move choke lever to Half choke position until the engine runs smoothly and then to Run position. Under certain weather conditions (temperatures below 40°F [4°C] and a high dew point), your generator may experience icing of the carburetor and/or the crankcase breather system.
Generac Portable Products 5500EXL Extended Life Generator Charging a Battery Figure 9 Battery Charge Cable Connection DANGER: Storage batteries give off explosive Red 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.
Generac Portable Products 5500EXL Extended Life Generator CORD SETS/RECEPTACLES Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps. The outlet is protected by a 30 Amp push-to-reset circuit breaker. This generator is equipped with the following receptacles: 120/240 Volt AC, 30 Amp Locking Receptacle 120 Volt AC, 20 Amp Receptacles Each socket (Figure 10) is protected against overload by a 20 Amp push-to-reset circuit breaker.
Generac Portable Products 5500EXL Extended Life Generator DONT OVERLOAD THE GENERATOR The rated wattage of lights can be taken from wattage listed on the light bulbs. The rated wattage of tools, appliances and motors can usually be found on a data plate or decal affixed to the device. Use Figure 13 below as a general reference. Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and/or connected electrical devices.
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.
Generac Portable Products 5500EXL Extended Life Generator TROUBLESHOOTING Problem Engine is running, but no AC output is available. Engine runs good at no-load but bogs down" when loads are connected. Engine will not start; or starts and runs rough. Cause 1. One of the circuit breakers is open. 2. Fault in generator. 3. Poor connection or defective cord set. 4. Connected device is bad. 1. Short circuit in a connected load. 2. Engine speed is too slow. 3. Generator is overloaded. Engine lacks power.
Generac Portable Products 5500EXL Extended Life Generator SCHEMATIC DIAGRAM 14
Generac Portable Products 5500EXL Extended Life Generator WIRING DIAGRAM 15
Generac Portable Products 5500EXL Extended Life Generator EXPLODED VIEW 16
Generac Portable Products 5500EXL Extended Life Generator PARTS LIST Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 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 Part # Qty.
Generac Portable Products 5500EXL Extended Life Generator CONTROL PANEL EXPLODED VIEW & PARTS LIST Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part # A92070 23897 49226 91526 82538 82881 43181 43182 90418 75207A 75207 23365 68868 Qty. 1 4 4 4 1 4 4 4 1 2 2 6 1 Description PANEL, Control FLAT WASHER, #10 M5 LOCK WASHER, M5 SCREW, M5-0.8 x 12mm SWITCH, Idle Control LOCK WASHER, 7/16" SCREW, M3 - 0.
Generac Portable Products 5500EXL Extended Life Generator NOTES 19
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.
