Generac Power Systems 5500EXL Manuel utilisateur
Problems?
Questions?
Before taking your unit
back to the store,
call the generator
helpline at
1-800-270-1 08
M-F 8-5 CT
Portable Generator Owner’s Manual
DANGER! This generator is designed for outdoor use only. Never use this generator inside any building
or enclosure including the generator compartment of a recreational vehicle (RV). Carbon monoxide
poisoning, fire and/or an explosion may result. No user performed modifications, including venting of
exhaust and/or cooling ventilation, ill eliminate the danger. Al ays have at least t o feet of clearance on
all sides of the generator even hile operating the unit outdoors.
DANGER! You must isolate the generator from the electric utility by opening the electrical systems main
circuit breaker or main s itch if this unit is used for backup po er. Failure to isolate the generator from
the power utility may result in injury or death to electric utility workers and damage to the
generator due to a backfeed of electrical energy.
The Emission Control System for this generator is arranted for standards set by the
Environmental Protection Agency. For arranty information refer to the engine o ners manual.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follo this symbol to avoid possible injury or death.
5500EXL
GENERAC
The Reliable Ones
Model No. 9797-3 (5500 Watt AC Generator) Manual No. 20820 Revision 3 (2/17/2000)
Visit our Generac ebsite: www.generac-portables.com
Generac Portable Products 5500EXL Extended Life Generator
2
EQUIPMENT DESCRIPTION
This generator is an engine-driven, revolving field,
alternating current (AC) generator. It as designed to
supply electrical po er for operating compatible
electrical lighting, appliance, tool and motor loads.
This manual contains information for a generator that
operates 120 and/or 240 Volt AC, single phase, 60Hz
devices that require up to 5,500 atts (5.5 kW) of
po er that pull up to 45.8 Amps at 120 Volts or
22.9 Amps at 240 Volts.
CAUTION: Do Not exceed the generators
attage/amperage capacity. Add up the rated
atts of all devices you ill connect to
generator receptacles at one time. This total
should not be greater than 5,500 atts for this
generator. Revie Dont Overload the
Generator on page 11.
The generators revolving field is driven at about
3600 rpm by a single-cylinder engine.
Every effort has been made to ensure that information
in this manual is accurate and current. Ho ever,
Generac reserves the right to change, alter or
other ise improve the product and this document at
any time ithout prior notice.
DANGER: Do Not tamper ith engine
governed speed. High operating speeds are
dangerous and increase the risk of personal
injury or damage to equipment. The unit
supplies correctly rated frequency and voltage
only hen running at proper governed speed.
Incorrect frequency and/or voltage can damage
some connected electrical loads. Operating at
excessively lo speeds imposes a heavy load
on the engine, and may shorten engine life.
SAFETY RULES
This generator set as designed and manufactured for
specific applications. Do Not attempt to modify the unit
or use it for any application it as not designed for. If
you have any questions about your generators
application, ask your dealer or consult the factory.
The manufacturer could not possibly anticipate every
circumstance that might involve a hazard. For that
reason, arnings in the manual and arnings on tags
or decals affixed to the unit are not all-inclusive. If you
intend to handle, operate or service this unit by a
procedure or method not specifically recommended by
the manufacturer, first make sure the procedure or
method ill not render this equipment unsafe or pose a
threat to you and others.
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
The generator produces a very po erful voltage that
can cause extremely dangerous electrical shock.
Avoid contact ith bare ires, terminals, etc. Never
permit any unqualified person to operate or service
the generator.
Never handle any kind of electrical cord or device
hile standing in ater, hile barefoot or hile
hands or feet are et.
The National Electric Code requires the frame and
external electrically conductive parts of the unit to be
properly connected to an approved earth ground.
Local electrical codes may also require proper
grounding of the generator. Consult ith a local
electrician for requirements in your area.
Use a ground fault circuit interrupter in any damp or
highly conductive area (such as metal decking or
steel ork).
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other
reproductive harm.
WARNING:
Generac Portable Products 5500EXL Extended Life Generator
3
Do Not use orn, bare, frayed or other ise
damaged electrical cord sets ith the generator.
Operate the generator only on level surfaces and
here it ill not be exposed to excessive moisture,
dirt, dust or corrosive vapors.
Gasoline is highly FLAMMABLE and its vapors are
EXPLOSIVE. Do Not permit smoking, open flames,
sparks or heat in the vicinity hile handling gasoline.
Avoid spilling gasoline on a hot engine. Comply ith
all regulations requiring storage and handling of
gasoline.
Do Not overfill the fuel tank. If overfilled, fuel can
contact the hot engine and cause FIRE or an
EXPLOSION.
Never store the generator ith fuel in its tank here
gasoline vapors might reach an open flame, spark or
pilot light (as on a furnace, ater heater or clothes
dryer). FIRE or EXPLOSION might result.
Generator exhaust gases contain DEADLY carbon
monoxide gas. This dangerous gas, if breathed in
sufficient concentrations, can cause
unconsciousness or even death. Operate this
equipment only in the open air here adequate
ventilation is available.
The unit requires an adequate flo of cooling air for
its continued proper operation. Never operate the
unit inside any room or enclosure here the free flo
of cooling air into and out of the unit might be
obstructed. Without sufficient cooling air flo , the unit
quickly overheats, damaging the generator or nearby
property.
Allo at least 2 feet of clearance on all sides of the
generator or you could damage the unit. Revie
Cold Weather Operation on page 8.
Never start or stop the unit ith electrical loads
connected to receptacles AND ith the connected
devices turned ON. Start the engine and let it
stabilize before connecting electrical loads.
Disconnect all electrical loads before shutting the
unit do n.
Do Not insert any object through the units cooling
slots. You could damage the unit or injure yourself.
Never operate this generator:
in rain; in any enclosed compartment; hen
connected electrical devices overheat; if electrical
output is lost; if engine or generator sparks; if flame
or smoke is observed hile running; if unit vibrates
excessively.
GROUNDING THE
GENERATOR
The National Electric Code requires the frame and
external electrically conductive parts of generator be
properly connected to approved earth ground.
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.
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper ire to the grounding ing
nut and to an earth-driven copper or brass grounding
rod (electrode) provides adequate protection against
electrical shock.
Ho ever, local codes may vary idely. Consult ith a
local electrician for grounding requirements in your
area. Be sure to keep the ground ire attached hile
you connect the electrode.
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
hich may build up in ungrounded devices.
Figure 1 Location of Grounding Wing Nut
Grounding Wing Nut
120/240 Volt AC
30 Amp Receptacle
Generac Portable Products 5500EXL Extended Life Generator
4
KNOW YOUR GENERATOR
Read this owners manual and safety rules before operating your generator.
Compare the illustrations ith your generator to familiarize yourself ith the locations of various controls and
adjustments. Save this manual for future reference.
12 Volt DC, 10 Amp Receptacle Used ith battery
charge cables to charge a 12 Volt battery.
120 Volt AC, 20 Amp Receptacles May be used to
supply electrical po er for the operation of 120 Volt
AC, single phase, 60 Hz electrical lighting, appliance,
tool and motor loads.
120 Volt AC, 30 Amp Receptacle May be used to
supply electrical po er for the operation of 120 Volt
AC, 30 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120/2 0 Volt AC, 30 Amp Receptacle May be used
to supply electrical po er for the operation of 120
and/or 240 Volt AC, 30 Amp, single phase, 60 Hz
electrical lighting, appliance, tool and motor loads.
Battery Tray Location Pre-tapped and installed
scre s are found here for the battery tray
Circuit Breakers (AC) Each receptacle is provided
ith a "push to reset" circuit breaker to protect the
generator against electrical overload.
Electric Start Button Press to start unit.
Fuel Tank Capacity of seven U.S. gallons of
unleaded fuel.
Grounding Wing Nut Use this connection to
properly ground the generator.
Idle Control Switch The idle control runs the
engine at normal (high) speeds hen there is a load
present and runs the engine at idle (lo ) speeds hen
a load is not present.
Recoil Starter Used as an alternate method of
starting the unit.
120 Volt AC, 20 Amp
Receptacle
Idle Control S itch
Recoil Starter
Electric Start Button
Battery Tray
Location
120 Volt AC, 30 Amp
Receptacle
Circuit Breakers (AC)
12 Volt DC, 10 Amp
Receptacle
Grounding Wing Nut
Fuel Tank
Generac Portable Products 5500EXL Extended Life Generator
5
Your generator requires some assembly and is ready
for use after it has been properly serviced ith the
recommended oil and fuel.
If you have any problems with the assembly of
your generator, please call the generator helpline
at 1-800-270-1 08.
IMPORTANT: Any attempt to run the unit before it has
been serviced ith the recommended oil ill result in
an engine failure.
REMOVE GENERATOR
FROM CARTON
Set the carton on a rigid flat surface ith This Side
Up arro s pointing up ard.
Carefully open the top flaps of the shipping carton
(revie Cold Weather Operation on page 8).
Cut do n corners at one end of carton from top to
bottom and lay that side of carton do n 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
1-800-270-1 08.
The generator
Electric start battery cables
Generator and engine o ners manuals
Locking 20 Amp and 30 Amp plugs
Battery charge cables
Battery tray mounting bracket/hard are
Spare spark plug and air filter element
Spark plug rench
INSTALLING TRAY AND
BATTERY
You must purchase and install a 12 Volt DC battery
(Series U1-109). The battery should be serviced ith
electrolyte fluid and fully charged prior to installation.
Install the battery as follows:
Find battery tray and fasteners (loose) in carton.
Includes all parts needed to mount battery and tray.
Remove the 4 battery tray scre s from cradle.
Position the battery tray and install (Figure 2).
Set battery onto tray (Figure 3).
Figure 3 Install Battery onto Battery Tray
Figure 2 Install Battery Tray
Generac Portable Products 5500EXL Extended Life Generator
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Retain battery to tray ith 2 J-bolts, 2 lock ashers
and 2 hex nuts (Figure 3).
Connect the red battery cable from the engine start
button to the positive (+) terminal on battery
(Figure 4).
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 ire.
BEFORE STARTING THE
ENGINE
Perform the follo ing tasks before starting the unit:
Add Oil
WARNING! Any attempt to crank or start the
engine before it has been properly filled ith the
recommended oil may result in an engine
failure.
To fill your engine with oil:
Place generator on a level surface.
Follo the oil grade recommendations and oil fill
instructions given in the engine o ners manual.
NOTE: The generators revolving field rides on a
prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.
Add Fuel
DANGER: NEVER fill fuel tank indoors.
NEVER fill fuel tank hen engine is running or
hot. Do Not light a cigarette or smoke hen
filling the fuel tank.
CAUTION: Do Not overfill the fuel tank.
Al ays allo 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.
Figure 4 Connect Battery Cables
RED ire from
Start Button
BLACK ire from
engine mount
Generac Portable Products 5500EXL Extended Life Generator
7
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.
Never use engine or carburetor cleaner products in the
fuel tank or permanent damage may occur.
To add fuel:
Clean area around fuel fill cap, remove cap.
Slo ly 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.
Install fuel cap and ipe up any spilled gasoline.
OPERATING THE
GENERATOR
CAUTION! Never start or stop unit ith
electrical loads connected AND ith the
connected devices turned ON.
Starting the Engine
Disconnect all electrical loads from the generator.
Open the fuel shut-off valve (Figure 6).
Set the Run/Stop s itch to Run position.
Make sure the Idle Control s itch is in Off position.
Move engine choke to Full choke position
(Figure 7).
For electric start:
Press electric start button until engine cranks and
starts.
For manual start:
Pull slo ly on recoil handle until you feel some
resistance. Then pull rapidly to start engine. Return
recoil slo ly, Do Not let it snap back.
Figure 7 Choke Positions
Figure 5 Fuel Tank Air Space
Figure 6 Fuel Shut Off Valve
Generac Portable Products 5500EXL Extended Life Generator
8
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.
NOTE: If engine fails to start after 3 pulls, move the
choke lever to Run position and pull starter rope
again.
NOTE: If engine still fails to start after 3 pulls, check for
proper oil level in crankcase. This unit is equipped ith
a Lo Oil Shutdo n System. See engine manual.
NOTE: If engine fires, but does not continue to run,
move choke lever to Full choke position and repeat
starting instructions.
Refer to the engine owners manual for complete
starting instructions.
Applying Electrical Loads
Let engine stabilize and arm 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. Revie
Dont Overload the Generator on page 11.
Stopping the Engine
Disconnect all electrical loads.
Set the idle control to Off position.
Run engine at no-load for about t o minutes.
Place the the Run/Stop s itch to Stop.
Close the fuel shutoff valve.
Operating Automatic Idle Control
This s itch is designed to greatly improve fuel
economy. When this s itch is turned ON, the engine
ill only run at its normal high engine speed hen an
electrical load is connected. When the electrical load is
removed, the engine ill run at a reduced speed. With
the s itch OFF, the engine ill run constantly at the
normal high engine speed. Always have the switch
OFF when starting and stopping the engine.
COLD WEATHER
OPERATION
Under certain eather conditions (temperatures belo
40°F [4°C] and a high de point), your generator may
experience icing of the carburetor and/or the
crankcase breather system. In an emergency, use the
original shipping box as a temporary shelter:
Cut off all flaps and one of the long sides of the box
to expose exhaust side of unit. Cut appropriate slots
to access units receptacles.
Start unit, then place box over it. Ensure a minimum
of t o feet clearance bet een open side of box and
nearest object.
IMPORTANT!: Remove shelter hen temperature is
above 40°F [4°C].
For a more permanent shelter, build a structure that
ill enclose three sides and the top of the generator.
Make sure entire muffler-side of generator is exposed,
ith t o feet clearance bet een open side of box and
nearest object. Face exposed end a ay from ind and
elements (Figure 8).
Figure 8 Temporary Cold Weather Shelter
Wind
Charging a Battery
DANGER: Storage batteries give off explosive
hydrogen gas hile recharging. An explosive
mixture ill remain around the battery for a long
time after it has been charged. The slightest
spark can ignite the hydrogen and cause an
explosion. Such an explosion can shatter the
battery and cause blindness or other injury.
DANGER: Do Not permit smoking, open
flame, sparks or any other source of heat
around a battery. Wear protective goggles,
rubber apron and rubber gloves hen orking
around a battery. Battery electrolyte fluid is an
extremely caustic sulfuric acid solution that can
cause severe burns. If spill occurs, flush area
ith clear ater immediately.
Your generator has the capability of recharging a
discharged 12 Volt automotive or utility style storage
battery. Do Not use the unit to charge any 6 Volt
batteries. Do Not use the unit to crank an engine
having a discharged battery.
To recharge 12 Volt batteries, proceed as follows:
Check fluid level in all battery cells. If necessary, add
ONLY distilled ater to cover separators in battery
cells. Do Not use tap water.
If the battery is equipped ith vent caps, make sure
they are installed and are tight.
If necessary, clean battery terminals.
Connect battery charge cable connector plug to
panel receptacle identified by the ords
12-VOLT D.C..
Connect battery charge cable clamp ith red handle
to the positive (+) battery terminal (Figure 9).
Connect battery charge cable clamp ith black
handle to the negative () battery terminal
(Figure 9).
Start engine. Let the engine run hile battery
recharges.
When battery has charged, shut do n engine.
NOTE: Use an automotive hydrometer to test battery
state of charge and condition. Follo the hydrometer
manufacturers instructions carefully. Generally, a
battery is considered to be at 100% state of charge
hen specific gravity of its fluid (as measured by
hydrometer) is 1.260 or higher.
Generac Portable Products 5500EXL Extended Life Generator
9
Figure 9 Battery Charge Cable Connection
Red
Black
Generac Portable Products 5500EXL Extended Life Generator
10
CORD SETS/RECEPTACLES
This generator is equipped ith the follo ing
receptacles:
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 atts (2.4 kW) at
20 Amps of current.
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 ith this receptacle. Connect
a 3- ire cord set rated for 125 Volts AC at 30 Amps to
the plug (Figure 11).
Use this receptacle to operate 120 Volt AC, 60 Hz,
single phase loads requiring up to 3600 atts (3.6 kW)
of po er at 30 Amps. The outlet is protected by a
30 Amp push-to-reset circuit breaker.
120/2 0 Volt AC, 30 Amp Locking
Receptacle
Use a NEMA L14-30 plug ith this receptacle. Connect
a 4- ire cord set rated for 250 Volt AC loads at
30 Amps (or greater) (Figure 12). You can use the
same 4- ire cord if you plan to run a 120 Volt load.
This receptacle po ers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 atts of po er
(3.6 kW) at 30 Amps for 120 Volts OR 5,500 atts of
po er (5.5 kW) at 22.9 Amps for 240 Volts. The outlet
is protected by a 30 Amp push-to-reset circuit breaker.
CAUTION! Although this outlet states it has a
240 Volt 30 Amp rating (up to 7,200 atts), the
generator is only rated for 5,500 atts.
Po ering loads that exceed the attage/
amperage capacity of the generator can
damage it or cause serious injuries.
240 Volt loads po ered through this outlet
should not exceed 22.9 Amps of current dra .
Figure 12 120/240 Volt AC, 30 Amp Receptacle
Figure 11 120 Volt, 30 Amp Receptacle
Figure 10 120 Volt AC, 20 Amp Receptacles
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