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GEN RAC°IPortable 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 is usedto alert you to potential personal injury hazards.Obey all safety messagesthat follow this symbol to avoid possible injuryor death.

Generac Portable Products 5500XL Generator

EQUIPMENTDESCRIPTION

This generator is an engine-driven, revolving field,alternating current (AC) generator. It was designed tosupply electrical power for operating compatible electricallighting, appliance, tool and motor loads. This manualcontains informationfor a generator that operates 120and/or 240 Volt AC, single phase,60 Hz devices thatrequire up to 5,500 watts (5.5 kW) of power that pull upto 45.8 Amps at 120Volts or 22.9 Amps at 240 Volts.

_ CAUTION! Do Not exceed the generator'swattage/amperage capacity.Add up the rated wattsof all devices you are connecting to generatorreceptacles at one time. This total should not begreater than 5,500 watts. See"Don't Overload theGenerator" on page I I.

The generator's revolving field is driven at about 3,600 rpmby a single-cylinder engine and has the following features:

• 120/240 Volt AC, 30 Amp locking receptacle.

• 120Volt AC, 30 Amp locking receptacle.

• 120Volt AC, 20 Amp duplex receptacle.

• Low Oit Shutdown: Automatically shuts down the engineif oit drops below safeoperation level.

• Sevengallon overhead fuel tank with fuel gauge.

_ AUTION! Do Not tamper with enginegoverned speed.High operating speedsaredangerous and increaserisk of personal injuryordamageto equipment The generator suppliescorrect rated frequency and voltage only whenrunning at proper governed speed. Incorrectfrequency and/or voltage can damagesomeconnected electrical loads.Operating at excessivelylow speeds imposesa heavy load.When adequateengine power is not available,engine life may beshortened.

SAFETY RULES

This generator set was designed and manufactured forspecific applications. Do Not attempt to modify the unitor use it for any application it was not designed for. If youhaveany questions about your generator's application, askyour dealer or consult the factory.

The manufacturer could not possibly anticipate everycircumstance that might involvea hazard. For that reason,warnings in the manual and warnings on tagsor decalsaffixed to the unit are not all-inclusive. If you intend tohandle, operate or service the unit by a procedure ormethod not specifically recommended by the manufacturer,first make sure that such a procedure or method will notrender this equipment unsafeor pose a threat to you andothers.

Read this manual carefully and become familiarwith your generator set. Know its applications, its

limitations, and any hazards involved.

_ DANGER! You must isolatethe generator fromthe electric utility usingapproved transfer equipmentif this unit is used for backup power. Failure toisolate the generator from the power utilitymay result in injury or death to electric utilityworkers and damage to the generator due toa backfeed of electrical energy. Whenever unitis providing backup power, the electric utility mustbe notified.

_ DANGER! Generator exhaust gases containDEADLY carbon monoxide gas. If breathed insumcient concentrations, carbon monoxide

can cause unconsciousness or death. Operate

this equipment outdoors where adequate ventilationis available.

/

2


• The generator produces a very powerful voltage that cancauseserious injury or death by electrocution. Nevertouch bare wires or receptacles. Never permit a childor any unqualified person to operate the generator.

• Never handle any kind of electrical cord or device whilestanding in water, while barefoot, or while hands or feetare wet Death or serious injury from electrocution mayresult.

• Use a ground fault circuit interrupter (GFCI) in any dampor highly conductive area (such as metal decking or steelwork).

• Never use worn, bare, frayed or otherwise damagedelectrical cords with the generator. Death, serious injury,or property damagefrom electrical shock may result.

• Gasoline is highly FLAMMABLE and its vaporsare EXPLOSIVE. Never allow smoking, openflames, sparks or heat in the vicinity whilehandling gasoline. Avoid spilling gasoline on a hotengine. Comply with all laws regulating storage andhandling of gasoline.

• Do Not overfill the fuel tank. Always allow room forfuel expansion. If tank is overfllled, fuel can overflowonto a hot engine and cause a FIRE or anEXPLOSION.

• Never store a generator with fuel in the tank wheregasoline vapors might reach an open flame, spark or pilotlight (as on a furnace, water heater, clothes dryer). FIREor an EXPLOSION may result.

• The unit requires an adequate flow of cooling air for itscontinued proper operation. Never operate the unitinsideany room or enclosure where the free flow ofcooling air into and out of the unit might be obstructed.Allow at least 2 feet of clearance on all sidesof

generator or you could damage the unit. Read "ColdWeather Operation" on page9.

• Never start or stop the unit with electrical loadsconnected to receptacles with the connected devicesturned ON. Start the engine and let it stabilize beforeconnecting any electrical loads. Disconnect all electricalloadsbefore shutting down the generator.

• Do Not insert any object through cooling slots of theengine. You could damagethe unit or injure yourself.

• Never operate the generator:in rain; in any enclosed compartment; when connected

electrical devices overheat; if electrical output is lost; ifengine or generator sparks; if flame or smoke isobserved while unit is running; if unit vibratesexcessively.

GROUNDING THEG EN ERATO R

The National Electrical Code requires that the frame andexternal electrically conductive parts of this generator beproperly connected to an approved earth ground. Localelectrical codes may also require proper grounding of theunit For that purpose, a GROUNDING WING NUT isprovided on the generator (Figure I).

_gNut

Generally, connecting a No. 12AWG (American WireGauge) stranded copper wire to the grounding wing nutand to an earth-driven copper or brassgrounding rod(electrode) provides adequate protection against electricalshock. Be careful to keep the grounding wire attached tothe generator when connecting the stranded copper wireto the grounding rod. However, local codes may varywidely. Consult with a local electrician for groundingrequirements inyour area.

Properly grounding the generator helps prevent electricalshock if a ground fault condition exists in the generator orin connected electrical devices. Proper grounding also helpsdissipate static electricity, which often builds up inungrounded 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 andadjustments. Savethis manual for future reference.

Circuit Breakers (AC)

120Volt AC, 20 AmpDuplex Receptacle

FuelTank

120Volt AC, 30 AmpReceptacle

Fuel Shut-OffValve

120/240 Volt AC,30 Amp Receptacle

12Volt DC, 10AmpReceptacle Grounding Wing Nut

12 Volt DC, I 0 Amp Receptacle -- Use this receptaclewith battery charge cablesto charge a 12Volt battery.

120 Volt AC, 20 Amp Duplex Receptacle -- May beusedto supply electrical power for the operation of 120Volt AC, 20 Amp, single phase,60 Hz electrical lighting,appliance, toot and motor loads.

120 Volt AC, 30 Amp Receptacle -- May be used tosupply 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 usedto supply electrical power for the operation of 120and/or240 Volt AC, 30 Amp, single phase,60 Hz electricallighting, appliance, tool and motor loads.

Run/Stop Switch

Idle Control Switch

Circuit Breakers (AC) -- Eachreceptacle is providedwith a "push to reset" circuit breaker to protect thegenerator 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 forconnecting the generator frame to earth ground.

Idle Control Switch -- The idle control runs the engineat normal (high) speedswhen there is a load present andruns the engine at idle (tow) speedswhen a toad is notpresent.

Run/Stop Switch -- Must be in "Run" position to startengine.Set to "Stop" to stop a running engine.

/

4


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 providedon the generator cradle and then acidthe two spacers oneach protruding end of the axle.

• Slide on the wheels on each end of the axle and secure

with washer and retaining pin.

NOTE: Make sure the wheel air inflation valves are facingoutward.

• Attach the vibration mounts to the support leg with M8x 30mm capscrews,M8 washers and lock nuts.

• Attach the support leg with two M8 x 20ram capscrewsand two lock nuts. Remove temporary blocks.

• Attach the handle with four M8 x 45mm capscrews andfour lock nuts in the location shown.

Handle

Capscrew,M8 x 45mm

/Lock Nut, M8

Support

Flat WasherJ

_Hex HeadJ _/ _-Capscrew,

M8 x 20mm

_LockNut, M8

_ Hex Head_Capscrew,

M8 x 30mm

Axle Wheel

jSpacer Wheel/

/Retaining Pin

/

5


BEFORE STARTING THEENGINE

Add Oil

_ ARNING! Any attempt to crank or start theengine before it has been properly filledwith therecommended 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'smanual. 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 fill fuel tankindoors.Never fillfuel tank when engine is runningor hot Do Not light a cigarette or smoke whenfilling 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 forfuel expansion (Figure 3).

1/2" Air Space Tank

• Install fuel cap and wipe up any spilled gasoline.

IMPORTANT: It is important to prevent gum depositsfrom 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 (calledgasohol, 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.

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6


OPERATING THEG EN ERATO R

_ AUTION! Never start or stop the engine withelectrical loadsconnected to the unit and with theconnected devices turned ON.

Starting the Engine

Disconnect all electrical loadsfrom the generator. Use thefollowing 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(Figure 6).

5. Grasp the recoil handle and pull slowly until slightresistance is felt Then pull rapidly one time only tostart engine.

• If engine starts, proceed to step 7.

• If engine fails to start, proceed to step 6.

6. Move the choke lever to "Half" choke position, andpull 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 theengine runs smoothly, and then to "Run" position.

NOTE: If engine still fails to start after 3 pulls, check forproper oil level in crankcase. This unit is equipped with aLow Oil Shutdown System. See engine manual.

Connecting Electrical Loads• Let engine stabilize and warm up for a few minutes after

starting.

• Plug in and turn on the desired 120 and/or 240 Volt AC,single phase,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 upthe rated watts (or amps) of all loadsto be connected atone time. This total should not be greater than the ratedwattage/amperage capacity of the generator. See "Don'tOverload the Generator" on page I I.

Stopping the Engine

• Unplug all electrical loads from generator panelreceptacles. Never start or stop engine with electricaldevices plugged in and turned on.

• Put the Idle Control switch in the "Off' position.

• Let engine run at no-load for 30 seconds to stabilize theinternaltemperatures of engine and generator.

• Move Run/Stop switch to "Stop".

• Close the fuel shut-off valve.

/7


Operating Automatic Idle ControlThis switch is designed to greatly improvefuel economy.When this switch is turned ON, the engine will onlyrun at its normal high governed engine speed when anelectrical load is connected. When the electrical load is

removed, the engine will run at a reduced speed. Withthe switch off, the enginewill run at a constant highengine speed. Always have the switch "Off" when

starting and stopping the engine.

Charging a Battery

A ANGER! Storage batteries give off explosivehydrogen gaswhile recharging.An explosive mixturewill remain around the battery for a long time afterit has been charged. The slightest spark can ignitethe hydrogen and causean explosion. Such anexplosion can shatter the battery and causeblindnessor other serious injury.

A DANGER! Do Not permit smoking, open flame,sparks,or any other source of heat around abattery. Wear protective goggles, rubber apron andrubber gloves when working around a battery.Battery electrolyte fluid is an extremely causticsulfuric acid solution that can causesevere burns. Ifspill occurs, flusharea with clear water immediately.

Your generator hasthe capability of recharging a discharged12Volt automotive or utility style storage battery. Do Notuse the unit to charge any 6 Volt batteries. Do Not usethe 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,addONLY distilled water to cover separators in batterycells. Do Not use tap water.

• If the battery is equipped with vent caps, make sure theyare installedand are tight.

• If necessary,clean battery terminals.

• Connect battery charge cable connector plug to panelreceptacle identifiedby the words "12-VOLTS D.C"

• Connect battery charge cable clamp with red handle tothe positive (+) battery terminal (Figure 7).

12 VOLT D.C.RECEPTACLE

+POS NEG

12 VOLT BA'I-rERY

• Connect battery charge cable clamp with black handleto the negative (-) battery terminal (Figure 7).

• Start engine. Let the engine run while battery recharges.

• When battery has charged, shut down engine

NOTE: Use an automotive hydrometer to test batterystate of charge and condition. Follow the hydrometermanufacturer's instructionscarefully. Generally, a battery isconsidered to be at 100%state of charge when specificgravity of its fluid (as measured by hydrometer) is 1.260 orhigher.

/

8


COLD WEATH EROPERATION

Under certain weather conditions (temperatures below40°F [4°C] and a high dew point), your generator mayexperience icingof the carburetor and/or the crankcasebreather system.

In an emergency, use the original shipping box as atemporary shelter:

• Cut off all flaps.

• Cut out one of the long sides of the box to exposeexhaust side of unit. Ensure a minimum of two feet

clearance between open side of box and nearest object.

• Cut appropriate slots to accessreceptacles of unit. Youmay also need to cut a clearance slot for the handle.

• Start unit, then place box over it.

IMPORTANT: Remove shelter when temperature isabove 40°F [4°C].

For a more permanent shelter, build a structure that willenclose three sidesand the top of the generator:

• Make sure entire muffler-side of generator is exposed, asshown in Figure 8. Note that your generator'sappearance may 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.

A CAUTION! Never run unit indoors.Do Notenclosegenerator any more than shown.Removeshelter when temperatures are above40°F [4°C].

RECEPTACLES

This generator is equipped with the following receptacles:

120 Volt AC, 20 Amp ReceptacleThis outlet is protected against overload by a 20 Amp)ush-to-resetcircuit breaker (Figure 9).

Use each outlet 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 loadsat 20 Amps (or greater).

/9


120/240 Volt AC, 30 Amp LockingReceptacle

Use a N EMA LI4-30 plug with this receptacle. Connect a4-wire cord set rated for 250 Volt AC loads at 30 Amps(or greater) (Figure 10). You can use the same4-wire cordif you plan to run a 120Volt load.

120 Volt AC, 30 Amp LockingReceptacle

Use a NEMA L5-30 plug with this receptacle. Connect a3-wire cord set rated for 125Volts AC at 30 Amps to theplug (Figure I I).

I - - I|_otv/lJte€[;]r,__ _mIj_l_m Ilo_ IPIOTP,1E[O__ _l'_

4-Wire Cord Set

This receptacle powers 120/240 Volt AC, 60 Hz, singlephase loadsrequiring up to 3,600 watts of power at30 Amps for 120 Volts; 5,500 watts of power (5.5 kW) at22.9 Amps for 240 Volts. The outlet is protected by30 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, singlephase loadsrequiring up to 3,600 watts (3.6 kW) of powerat 30 Amps. The outlet is protected by a 30 Amp push-to-reset circuit breaker.

/10


DON'T OVERLOAD THEGENERATOR

Overloading agenerator in excess of its rated wattagecapacity can result in damageto the generator and/orconnected electrical devices.Observe the following toprevent overloading the unit:

• Add up the total wattage of all electrical devices to beconnected at one time. This total should NOT be

greater than the generator's wattage capacity.

• The rated wattage of lightscan be taken from lightbulbs.The rated wattage of tools, appliancesand motors canusually be found on a data plate or decal affixed to thedevice.

• If the appliance, tool or motor does not give wattage,multiply 120Volts times ampere rating to determinewatts (volts x amps = watts).

• Some electric motors, such as induction types, requireabout three times more watts of power for starting thanfor running. This surge of power lastsfor only a fewseconds when starting such motors. Be sure you allowfor this high starting wattage when selecting electricaldevices to connect to your generator. First figure thewatts needed to start the largest motor. Add to thatfigure the running watts of all other connected loads.

• Items in the wattage reference guide (Figure 12)areprovided to help you to determine how many items thegenerator can operate at one time.

Recreational/Home Uses

Tool/Appliance .................................................... WattsAM/FM clock radio .....................................................................50

Light bulb ....................................................................................100Fan................................................................................................200

20" color TV ..............................................................................400

*Deep freezer ............................................................................500

Personal computer and 15" monitor ...................................800

*1/3 hp furnace fan blower .....................................................800Microwave oven ........................................................................800

*18 cuft refrigerator ...............................................................800

Sump pump ..............................................................................1000Electric skillet ..........................................................................1250

*Y2 hp water well pump ........................................................1400

* 12,000 Btu window air conditioner .................................1400

Space heater ............................................................................1800Electric water heater .............................................................4000

Professional/C ontractor Uses

Tool/Appliance .................................................... Watts

"1/3 hp airless sprayer .............................................................6003/8" hammer drill .....................................................................600

Variable speed Sawzalt® ..........................................................960

Y2" power drill .........................................................................1000

Quartz-halogen work light...................................................1000Belt sander ...............................................................................1200

7 ¼" circular saw ...................................................................1500

7 ¼" worm drive saw............................................................1600

*1 Y2 hp air compressor ........................................................1800

* I0" power miter saw ...........................................................IB00

6" bench grinder .....................................................................IB00

"6" table planer .......................................................................1800*10" table/radial arm saw .....................................................2000

Wire feed welder ...................................................................2400

* allow 3 times listed watts for starting this device

/II


GENERAL MAINTENANCERECOMMENDATIONS

The owner/operator is responsible for making sure that allperiodic maintenance tasks are completed on a timelybasis; that all discrepanciesare corrected; and that the unitis kept clean and properly stored. Never operate adamaged or defective generator.

Engine MaintenanceSeeengine manual for instructions.

Generator Maintenance

Generator maintenance consists of keeping the unit cleanand dry. Operate and store the unit in a clean dryenvironment where it will not be exposed to excessivedust, dirt, moisture or any corrosive vapors. Cooling airslots in the generator must not become clogged with snow,leavesor any other foreign material.

NOTE: Do Not use a garden hose to clean generator.Water can enter engine fuel system and cause problems. Inaddition, if water enters generator through cooling airslots, some of the water will be retained in voids and

cracks of the rotor and stator winding insulation.Waterand dirt buildup on the generator windings wilt eventuallydecrease the insulationresistance of these windings.

To Clean the Generator

• Use a damp cloth to wipe exterior surfacesclean.

• A soft bristle brush may be used to loosen caked on dirtor oil.

• A vacuum cleaner may be used to pick up loose dirt anddebris.

• Low pressure air (not to exceed 25 psi) may be used toblow awaydirt. Inspect cooling air slots and opening ongenerator. These openings must be kept clean andunobstructed.

STORAGE

The generator should be started at least once every sevendaysand allowed to run at least30 minutes. If this cannotbe done and you must store the unit for more than 30days, use the following guidelines to prepare it for storage.

Generator Storage• Clean the generator as outlined in "To Clean the

Generator."

• Check that cooling air slots and openings on generatorare open and unobstructed.

_ DANGER! Storage covers can be flammable. DoNot place a storage cover over a hot generator. Letthe unit coot for a sufficient time before placing thecover on the unit

Engine StorageSee engine owner's manual for instructions.

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 thatfuel with this unit.

• Store in clean and dry area.

SPECIFICATIONSMaximum SurgeWatts ................. 6,875 watts

Continuous Wattage Capacity ........... 5,500 wattsPower Factor .............................. 1.0Rated Maximum Continuous Load Current

At 120Volts ....................... 45.8 AmpsAt 240 Volts ....................... 22.9 Amps

Phase ................................. I -phase

Rated Frequency ....................... 60 HertzFuel Tank Capacity .................. 7 U.S.gallons

/12


TROUBLESHOOTING

Problem

Engine is running, but no ACoutput is available.

Engine runs good but bogsdown when loads are

connected.

Engine will not start; orstarts and runs rough.

Cause

1. Circuit breaker is open.2. Poor connection or defective

cord set.

3. Connected device is bad.

4. Fault in generator.

I. Short circuit in a connected load.2. Generator is overloaded.

3. Engine speed is too slow.

4. Shorted generator circuit.

I. Run/Stop switch set to "Stop".2. Dirty air cleaner.3. Out of gasoline.4. Stalegasoline.5. Spark plug wire not connected to

spark plug.6. Badspark plug.7. Water in gasoline.8. Overchoking.9. Low oil level.

10. Excessivelyrich fuet mixture.I I. Intake valve stuck open or

closed.Enginehas lostcompression.

SolutionI. Reset circuitbreaker.2. Check and repair.

3. Connect another device that is in goodcondition.

4. Contact Generac service facility.

I. Disconnect shorted electrical load.

2. See "Don't Overload the Generator" on

page I 1.3. Contact Generacservice facility.

4. Contact Generac service facility.

I. Set switch to "Run".

2. Clean or replace air cleaner.3. Fill fuel tank.

4. Drain gas tank and fitt with fresh fuel.

5. Connect wire to spark plug.

6. Replacespark plug.7. Drain gas tank; fitl with fresh fuel.8. Put choke lever to "no choke" position.9. Fill crankcaseto proper level.10. Contact Generac service facility.I I. Contact Generac service facility.

12. 12.

I. Out of gasoline. I.Engine shuts down during 2. Low oit level. 2.

operation. 3. Fault in engine. 3.

I. Load is too high. I.

Engine lacks power. 2. Dirtyair filter. 2.

3. Engine needs to be serviced. 3.

I. Choke is opened too soon. I.

Engine "hunts" or falters.2. Carburetor is running too rich or

too lean.

2.

Contact Generac service facility.

Fillfuel tank.

Fillcrankcase to proper level.


See "Don't Overload the Generator" on

page I I.

Replace air filter.


Move choke to halfway position till

engine runs smoothly.


I

13

Generac Portable Products 5500XL GeneratorID_ELF_i_I_

ELECTRICAL SCHEMATIC

11

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BATTERY CHARGE

66 55 77

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Generac Portable Products 5500XL Generator ID_'! _

WIRING DIAGRAM

NUT DNEN6INE _LDCK

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EXPLODED VIEW - HAIN UNIT

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PARTS LIST

Item Part # Qty.1 G924322 G925313 G927314 922475 92678G6 92680G7 657918 967969 22129 14l0 86307 411 28092 I12 92609 213 82857 414 92532 I15 90239 I16 66476 2

17 A7433 I18 40976 219 83083 I20 81917 I21 B4986 I25 66825C I26 74908 427 86308A 428 65795 I29 66849A I30 67022 I31 84132 I32 66386 I33 66849 234 B4871 I35 22769 I36 86494 I37 86292 I38 77395 439 83465 4

- MAIN UNIT

Description Item Part #CRADLE 40 57058SUPPORT,Engine 41 80270SUPPORT,Engine& Muffler 42 78299HOUSING, EngineAdapter 43 B4363ASSEMBLY,Rotor 44 B1998ASSEMBLY,Stator 45 B92039BEARING 46 92665WASHER, M8 Flat 47 85000WASHER, M8 Lock 48 14353621SCREW,5/16-24 x 3/4 Mach. 49 26850SCREW,5/16-24 x 9-1/4" 51 92982MOUNT, Vibration 52 B4361MOUNT, Vibration 55 25244BRACKET,Muffler 57 B4362GASKET,Exhaust 58 92630ASCREW, M6 - I x 12 Cap with 59 NSPLock Washer 60 22531MUFFLER 61 22142SCREW, M8 - 1.25 x 20 Cap 62 93826SCREEN,Spark Arrest 63 56893PIN, 4mm x 10 Roll 64 B96068DECAL, Ground 65 B2153CARRIER, Rear Bearing 66 22473TAPTITE, M5-0.8 x 10BOLT, M6-1 x 145mm StatorRECTIFIER,Battery ChargeTAPTITE, M5-0.8 x 20GROMMET, RubberASSEMBLY,Power RegulatorASSEMBLY,Brush HolderTAPTITE, M5-0.8 x 16COVER, Bearing CarrierWASHER, #10 Int. ShakeproofSCREW, M6-1.0 x 16WingSCREW,#10 Self DrillingNUT, M6 FlangeLockGROMMET, Tank

Qty.4

2I212III22I5I64

DescriptionHHMS, M6-1.0 x 55VALVE,TankBUSHING, Plastic TankGAUGE, FuelTANK, 7 Gal.SHIELD, HeatINSULATION, #2- I/4"CLIP, InsulationWIRE, GroundWASHER, M6 ShakeproofDECAL, DangerDECAL, Heat ShieldNUT, 5/16-18 HexDECAL, Control PanelASSEMBLY,Control BoxENGINEHHCS, 5/16-18 x 1-3/4SCREW,5/16 - 18x 3/4 CapDECAL, Start InstructionsSCREW, 10-24 x I/2 CrimptiteSHIELD, HeatSCREW,#12-14 x 7/8" Self DrillWASHER, M6 Flat

Item Not Illustrated65787 IB4360 INSP IBB3061 23780643438

Battery Charge CableGenerator Owner's ManualEngineOwner's ManualOil, 28 oz.120Volt AC 30 Amp Plug120/240 Volt AC 30 Amp Plug

Optional Accessories Not Included84883 Cord Wrap

/17

I7 j/_ I


EXPLODED VIEW AND PARTS LIST - WHEEL KIT

lO

11

94

ItemI23456789l0li12t3

Part #B93393A8974293693A87005B89635B9369627007429095285822247392532214539287

8

Qty. DescriptionI HANDLE2 WHEELI AXLE2 PIN, Retaining2 SPACER,WheelI LEG, Support2 MOUNT, Vibration2 CAPSCREW, Hex Hd. M8 - 1.25 x 308 NUT, Lock M82 WASHER, Wheel2 CAPSCREW, Hex Hd. - M8 - 1.25x 202 WASHER, Vibration Mtg.4 HHCS, M8 - 1.25x 45 GR 10.9

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EXPLODED VIEW AND PARTS LIST - CONTROL PANEL

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21

19

25

87

6

1010 166 11 15

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7

26 22

187

14

ItemI23456789I0II1213

Part#A92070238974922691526825388288143181431829041875207A752072336568868

Qty. DescriptionI PANEL,Control4 FLATWASHER, #10 M54 LOCK WASHER, M54 SCREW, M5_0.8x 12mmI SWITCH, Idle Control4 LOCK WASHER, 7/16"4 SCREW, M3 - 0.5 x 10mm4 LOCK WASHER, M3I OUTLET, 12V2 CIRCUIT BREAKER,30A2 CIRCUIT BREAKER,20A6 WASHER, #8 ShakeproofI OUTLET, 120Volt, 30 Amp

Locking

Item Part#14 43437

15 6875916 4318017 2226418 5171519 6452620 8397021 6452522 87962

23 8433524 8413425 B9206926 84028

Qty.I

DescriptionOUTLET, 120V/240V,30ALockingOUTLET, 120V,20A DuplexFLAT WASHER, M4LOCK WASHER, #8 M4NUT, M4-0.7 HexSCREW,#6-32 x 3/8"BOARD, System ControlSTAND-OFF, 3/4" HexCIRCUIT BREAKER. 12V, 10A(auto)ASSEMBLY, Wire Harness

GROMMET, Rubber Conn.BOX, Control PanelTRANSFORMER, Idle Control

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LIMITED WARRANTYFOR "GN" ENGINE DRIVEN PORTABLE GENERATORS

GENERAC PORTABLEPRODUCTS (hereafter referred to as the COMPANY) warrants to the original purchaser that thealternator and control panel for its portable generator wilt be free from defects in materials or workmanship for the itemsand period set forth below from the date of original purchase. This warranty is not transferable and applies only to portablegenerators driven by a GN-Series engine.

Consumer* Commercial*

Alternator 2 years (2rid year parts only) I yearEngine Warranted solely by the engine manufacturer

With the exception of European Community Countries, all units bound for export shall be warranted for One (I)Year in Consumer applications, end 90 days in Commercial applications as defined below.

*NOTE: For the purpose of this warranty "consumer use" means personal residential household use byoriginal 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 producingpurposes. Once a generator has experienced commercial use, it shall thereafter be considered acommercial use generator for the purposes of this warranty.

During said warranty period, the COMPANY wilt, at isoption, repair or replace any part which, upon examination by theCOMPANY, isfound to be defective under normal use and service**. Starting batteries are not warranted by theCOMPANY. All transportation costs under warranty, includingreturn to the factory if necessary,are to be borne by thepurchaser and prepaid by the purchaser. This warranty does not cover normal maintenance and service anddoes not applyto 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'sjudgement, to adversely affect its performance and reliability.

**NORMAL WEAR: As with all mechanical devices, the generator need periodic parts service andreplacement to perform well. This warranty will not cover repair when normal use has exhausted the life ofa part or generator.

THERE IS NO OTHER EXPRESSWARRANTY. THE COMPANY HEREBYDISCLAIMS ANY AND ALLIMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY ANDFITNESSFOR A PARTICULAR PURPOSETO THE EXTENT PERMITTED BY LAW. THE DURATION OFANY IMPLIEDWARRANTIES WHICH CANNOT BEDISCLAIMED IS LIMITED TO THE TIME PERIOD ASSPECIFIEDIN THE EXPRESSWARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIALDAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMSANY RESPONSIBILITYFOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, SUCH AS THE LOSSOFTIME OR THE USE OF THE POWER EQUIPMENT, OR ANY COMMERCIAL LOSS DUE TO THE FAILUREOF THE EQUIPMENT: AND ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THISWRITTEN WARRANTY.

Some states do not allow limitations on how long an impliedwarranty lasts,or the exclusion or limitation of incidentalorconsequential damages,so the above limitationsor exclusions may not apply to you. This warranty givesyou specific legalrights andyou may also haveother 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 canbe 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 purchasedate must be presented.

GENERAC PORTABLE PRODUCTS

Jefferson, Wisconsin 53549

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