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 systems 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 ners 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

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 generators

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 Dont Overload the

Generator on page 11.

The generators 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 generators

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

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 units 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

KNOW YOUR GENERATOR

Read this owners 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

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 ners 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

 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 ner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

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

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

 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 owners 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

Dont 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 shutoff 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 units 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

manufacturers 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

Figure 9  Battery Charge Cable Connection

Red

Black

Generac Portable Products 5500EXL Extended Life Generator

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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