Introduction

The Generac Portable Generator 5500 is a reliable and powerful source of electricity for your home or job site. With a running wattage of 5500 watts, this generator can handle a variety of tasks, from running power tools to keeping the lights on during an outage. The generator has a durable steel frame and a convenient fold-down handle, making it easy to transport. It is also equipped with a low-oil shutdown feature to protect the engine from damage. The estimated price of the Generac Portable Generator 5500 is around $700 to $800, and it is now available for purchase.

Detailed Specifications

The Generac Portable Generator 5500 has a 389cc OHV engine that produces 5500 running watts and 6875 starting watts. It has a 6.6-gallon fuel tank that provides up to 10.5 hours of run time at 50% load. The generator has a power dial that integrates start/run/stop functions into one easy-to-use dial. It also has a covered outlet design that provides protection from the elements. The generator has a noise level of 74 dBA and comes with a two-year residential warranty and a one-year commercial warranty.

General Information and Setup

Generator Components

12 Volt DC, 10 Amp Receptacle
120 Volt AC, 20 Amp Duplex Receptacle
120 Volt AC, 20 Amp, GFCI Duplex Receptacle (NEMA 5-20R)
120 Volt AC, 30 Amp Locking Receptacle (NEMA L14-30R)
120/240 Volt AC, 30 Amp Locking Receptacle (NEMA L14-30R)
120/240 Volt AC, 50 Amp Receptacle (NEMA 14-50R)
Circuit Breakers (AC)
Hour Meter
Idle Control Switch
Start/Run/Stop Switch
Choke Knob
Winter/Summer Valve
Fuel Tank
Grounding Lug
Air Cleaner
Oil Fill
10 Amp Fuse (behind control panel, not shown)

Know Your Generator

WARNING Consult the manual. Read and understand the manual completely before using the product. Failure to completely understand the manual and product could result in death or serious injury (000100a).

Replacement owner’s manuals are available at www.generac.com.

Emissions

The United States Environmental Protection Agency (US EPA) (and California Air Resources Board (CARB), for engines/equipment certified to California standards) requires this engine/equipment to comply with exhaust and evaporative emissions standards. Locate the emissions compliance decal on the engine to determine applicable standards. See the included emissions warranty for emissions warranty information. Follow the maintenance specifications in this manual to ensure the engine complies with applicable emissions standards for the duration of the product’s life.

Product Specifications

Generator Specifications

Rated Power: 15.1 / 17.5 kW**
Surge Power: 22.5 / 26.25 KVA
Rated AC Voltage: 120/240
Rated AC Load
- Current @ 240V: 62.9 / 72.9 Amps**
- Current @ 120V: 125.8 / 145.8 Amps**
Rated Frequency: 60 Hz @ 3600 RPM
Phase: Single Phase

Operating Temperature Range: -18°C (0°F) to 40°C (104°F). When operated above 25°C (77°F), there may be a decrease in power.

**Maximum wattage and current are subject to, and limited by, factors such as fuel Btu content, ambient temperature, altitude, engine condition, etc. Maximum power decreases about 3.5% for each 1,000 feet above sea level and will also decrease about 1% for each 6°C (10°F) above 16°C (60°F) ambient temperature.

Engine Specification

Displacement: 992 cc
Spark Plug Type: Champion RC14YC or Equivalent
Spark Plug Part No.: 0E7585A
Spark Plug Gap: 0.040 inch or (1.016 mm)
Gasoline Capacity: 60.5 L (16 U.S. gallons)
Oil Type: See Chart in the Add Engine Oil Section
Oil Capacity:
- With filter change: 1.6 L (1.7 qt.)
- Without filter change: 1.3 L (1.4 qt.)
Run Time at 50% Load: 10 Hours

Go to https://www.generac.com/ or contact an IASD for replacement parts.

Hour Meter

The Hour Meter tracks hours of operation for scheduled maintenance.

The SVC display will illuminate one hour before and one hour after each 200-hour interval providing a two-hour window to perform service.
When the hour meter is in flash alert mode, the maintenance message will alternate with elapsed time in hours and tenths. The hours will flash four times, then alternate with the maintenance message four times until the meter automatically resets.
200 hours - SVC: Change oil, oil filter, air filter, fuel filter, and spark plug. Clean spark arrestor screen (every 200 hrs).

NOTE: The hourglass icon will flash when the engine is running. This signifies the meter is recording hours of operation.

Connection Plugs

120 VAC, 20 Amp Duplex Receptacle

The 120 Volt outlet is overload protected by a 20 Amp push-to-reset circuit breaker. Each receptacle will power 120 Volt AC, single-phase, 60 Hz electrical loads requiring up to 2400 watts (2.4 kW) or 20 Amps of current. Use only high quality, well-insulated, 3-wire grounded cord sets rated for 125 Volts at 20 Amps (or greater).

120 VAC, 20 Amp, GFCI Duplex Receptacle

120/240 VAC, 30 Amp Receptacle

Use a NEMA L14-30 plug with this receptacle (rotate to lock/unlock). Connect a suitable 4-wire grounded cord set to the plug and desired load. The cord set should be rated 250 Volts AC at 30 Amps (or greater). 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 or 240 Volt AC, 60 Hz, single-phase loads requiring up to 7200 watts (7.2 kW) of power at 30 Amps. The outlet is protected by two 30 Amp push-button-to-reset circuit breakers.

120 VAC, 30 Amp Receptacle

Use a NEMA L5-30 plug with this receptacle (rotate to lock/unlock). Connect a suitable 3-wire cord set to the plug and to the desired load. The cord set should be rated for 125 Volts AC at 30 Amps (or greater). Use this receptacle to operate 120 Volt AC, 60Hz, 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.

12 Volt DC, 10 Amp Receptacle

This receptacle can charge a 12-Volt automotive or utility style storage battery.

NOTE: This receptacle cannot charge 6-volt batteries and cannot be used to crank an engine having a discharged battery. See "Using the 12 VDC Battery Charger" before attempting to charge a battery.

120/240 VAC, 50 Amp Receptacle

Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire cord set rated for 250 Volts AC at 50 Amps to the plug. Use this receptacle to operate 120/240 Volt AC, 60 Hz electrical loads requiring up to 12,000 watts (12.0 kW) of power. This receptacle is protected by a 50 Amp 2-pole circuit breaker.

Idle Control Switch

This feature improves fuel economy. When the switch is ON, the engine operates at normal (high) RPM when an electrical load is present. The engine operates at a reduced RPM when the load is removed. When the switch is OFF, the engine operates at normal (high) RPM continuously. Always have this switch OFF when starting/stopping the engine and when using the generator as a backup power supply to a house/building connected via Power Inlet Box to a transfer switch.

Remove Contents from Carton

Open carton completely by cutting each corner from top to bottom.
Remove and verify carton contents prior to assembly. Carton contents should contain the following:

Accessories

Item	Qty.
Main Unit	1
Owner’s Manual	1
Liter Oil SAE 30	2
Handle (A)	1
Never-flat Wheel (B)	2
Frame Foot Assembly (C)	1
Axle (D)	1
Axle Bracket Assembly (E)	2
Spark Plug	2
Spark Plug Wrench	1
Air Filter	1
Oil Filter	1
Pre-cleaner	1
Battery Charge Cable	1
Product Registration Card	3
Service

Item	Qty.
Service Warranty	1
Emissions Warranty	1

Hardware Bag

Item	Qty.
Cotter Pin (F)	2
Spacer (G)	2
Locking Flange Nut (H)	10
Hex Head Bolt (J)	6
Lock Washer (K)	2
Flat Washer (L)	8
Capscrew (5/16 x 1) (M)	2
Capscrew (5/16 x 2-1/2) (N)	4

Call Generac Customer Service at 1-888-GENERAC (1-888-436-3722) with the unit model and serial number for any missing carton contents.
Record model, serial number, and date of purchase on the front cover of this manual.

Assembly

Call Generac Customer Service at 1-888-GENERAC (1-888-436-3722) for any assembly issues or concerns. Please have the model and serial number available.

The following tools are required to install the accessory kit:

Needle nose pliers
9/16” and 1/2” socket and ratchet
1/2” wrench

NOTE: The wheels are not intended for over-the-road use.

Install Wheels

Slide axle (D) through the flat washer (L), spacer (G), wheel (B), and axle bracket assembly (E) on the frame.
Insert cotter pin (F) through axle (D). Bend tabs of cotter pin outward to lock into place.
Install locking flange nut (H).

Install Frame Foot Assembly

Slide hex head bolts (J) through holes in frame rail.
Slide frame foot (C) onto hex head bolts (J). Install locking flange nut (H).
Slide capscrew (M) through frame foot assembly (C). Install lock washer (K), flat washer (L), and locking flange nut (H).

Install Handle

Slide capscrew (N) through flat washer (L), handle (A), and frame. Install flat washer (L) and locking flange nut (H).

Battery Cable Connection

CAUTION Equipment damage. Do not make battery connections in reverse. Doing so will result in equipment damage. (000167a)

The battery shipped with the generator has been provided fully charged. Caution must be taken when connecting the battery.

NOTE: A battery may lose some of its charge when not in use for prolonged periods of time.

Two 7/16” box wrenches are needed to connect battery cables.

Cut tie wrap cable holding the RED and BLACK battery cables to the stator.
Connect RED battery cable (A) to battery Positive terminal (+). Make sure the connection is tight and slip the rubber boot over the terminal.
Connect BLACK battery cable (B) to battery Negative terminal (–). Make sure the connection is tight.
Install battery post cover (included).

Add Engine Oil

CAUTION Engine damage. Verify the proper type and quantity of engine oil prior to starting the engine. Failure to do so could result in engine damage. (000135)

Place generator on a level surface.
Remove dipstick and wipe clean.
Insert dipstick and remove again to check oil level. Oil level is checked with dipstick fully installed.
Clean area around oil fill. Remove oil fill cap.
Add recommended engine oil. Climate determines proper engine oil viscosity. See the chart to select the correct viscosity.

NOTE: Use petroleum-based oil (supplied) for engine break-in before using synthetic oil.

NOTE: Verify oil level often during the filling process to ensure overfilling does not occur.

NOTE: Some units have more than one oil fill location. It is only necessary to use one oil fill point.

Remove dipstick and verify oil level is within safe operating range.
Install dipstick and oil fill cap and hand-tighten.

Fuel

DANGER Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well-ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury. (000105)

DANGER Explosion and Fire. Do not overfill the fuel tank. Fill to 1/2 inch from the top of the tank to allow for fuel expansion. Overfilling may cause fuel to spill onto the engine causing fire or explosion, which will result in death or serious injury. (000166b)

Fuel requirements are as follows:

Clean, fresh, unleaded gasoline.
Minimum rating of 87 octane/87 AKI (91 RON).
Up to 10% ethanol (gasohol) is acceptable (where available; non-ethanol-premium fuel is recommended).
DO NOT use E85.
DO NOT use a gas-oil mix.
DO NOT modify the engine to run on alternate fuels. Stabilize fuel prior to storage.

Verify the unit is OFF and cooled for a minimum of two minutes prior to fueling.
Place the unit on level ground in a well-ventilated area.
Clean area around fuel cap and remove cap slowly.
Slowly add recommended fuel (A). Do not overfill (B).
Install fuel cap.

NOTE: Allow spilled fuel to evaporate before starting the unit.

IMPORTANT NOTE: It is important to prevent gum deposits from forming in fuel system parts such as the carburetor, fuel hose, or tank during storage. Alcohol-blended fuels (called gasohol, 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 the Storage section. Never use engine or carburetor cleaner products in the fuel tank as permanent damage may occur.

Description

The Generac Portable Generator 5500 is a versatile and powerful generator that is ideal for a variety of applications. It has a sturdy steel frame and a durable 1 1/4" steel tubing that provides a stable platform for the generator. The fold-down handle and never-flat wheels make it easy to transport. The generator has a low-oil shutdown feature that protects the engine from damage. It also has a hour meter that tracks usage, making it easy to keep up with maintenance. The generator is easy to start, with a single touch electric start and a recoil start backup.

Operation

Operation and Use Questions

Call Generac customer service at 1-888-GENERAC (1-888-436-3722) with questions or concerns about equipment operation and maintenance.

Before Starting Engine

Verify engine oil level is correct.
Verify fuel level is correct.
Verify the unit is secure on level ground, with proper clearance and is in a well-ventilated area.

Prepare Generator for Use

DANGER

Asphyxiation: Running engines produce carbon monoxide, a colorless, odorless poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. (000103)
- If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air IMMEDIATELY. See a doctor, as you could have carbon monoxide poisoning.

DANGER

Asphyxiation: The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury. (0001790)

WARNING

Asphyxiation: Always use a battery-operated carbon monoxide alarm indoors and install it according to the manufacturer's instructions. Failure to do so could result in death or serious injury. (0001788)

WARNING

Risk of Fire: Do not use the generator without a spark arrestor installed. Failure to do so could result in death or serious injury. (000118a)

WARNING

Risk of Fire: Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury. (000110)

WARNING

Hot Surfaces: When operating the machine, do not touch hot surfaces. Keep the machine away from combustibles during use. Hot surfaces could result in severe burns or fire. (000108)

CAUTION

Equipment and Property Damage: Disconnect electrical loads prior to starting or stopping the unit. Failure to do so could result in equipment and property damage. (000136)

Grounding the Generator When Used as a Portable

The generator is equipped with a terminal for grounding the electrical system. Connect the frame of the generator to a grounding electrode system when the generator supplies power to connected equipment through the receptacles on the generator. When the generator supplies power to a 3-pole manual transfer switch or distribution panel, a grounding electrode system may be installed and connected to the grounding electrode terminal on the generator. See NEC 250.30, 250.34, and 250.52 for clarification.

Neutral Bonded to Frame

Special Requirements

Review all Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Consult a qualified electrician, electrical inspector, or the local agency having jurisdiction:

In some areas, generators are required to be registered with local utility companies.
If the generator is used at a construction site, there may be additional regulations that must be observed.

Connecting the Generator to a Building Electrical System

When connecting directly to a building electrical system, it is recommended that a manual transfer switch be used. Connections for a portable generator to a building electrical system must be made by a qualified electrician and in strict compliance with all national and local electrical codes and laws.

Know Generator Limits

Overloading a generator can result in damage to the generator and connected electrical devices. Observe the following to prevent overload:

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.
- The rated wattage of lights, appliances, and motors can be found on a data label or decal affixed to the device.
If the appliance, tool, or motor does not give wattage, multiply volts times the ampere rating to determine watts (volts x amps = watts).
Some electric motors, such as induction motors, require more power for starting than for running. This surge of power lasts only a few seconds when starting such motors. Make sure to allow for high starting wattage when selecting electrical devices to connect to the generator:
1. Figure the watts needed to start the largest motor.
2. Add to that figure the running watts of all other connected loads.

Wattage Reference Guide

Device	Running 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
Chain Saw	1200
Circular Saw (7-1/4)	1250 to 1400
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
Dehumidifier	650
Disc Sander (9)	1200
Edge Trimmer	500
Electric Blanket	400
Electric Nail Gun	1200
Electric Range (per element)	1500
Electric Skillet	1250
Freezer	700
Furnace Fan (1/2 HP)	800
Garage Door Opener	875
Hair Dryer	1250
Hand Drill	250 to 1100
Hedge Trimmer	450
Impact Wrench	500
Iron	1200
Jet Pump	800
Lawn Mower	1200
Light Bulb	100
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 (hand-held)	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.

Transporting/Tipping of the Unit

Do not operate, store, or transport the unit at an angle greater than 15 degrees.

Starting Electric Start Engines

CAUTION

Equipment and Property Damage: Disconnect electrical loads prior to starting or stopping the unit. Failure to do so could result in equipment and property damage. (000136)

Unplug all electrical loads from the unit's receptacles before starting the engine.
Place generator on a level surface.
Open the fuel shut-off valve. See Figure 3-4.
On the control panel, turn the idle control switch Off. See Figure 2-2.
Move the choke knob outward to Full choke position.
Press and hold Start/Run/Stop switch in the Start position. When the engine starts, release the switch to the RUN position.
When the engine starts, move the choke knob to the half-choke position until the engine runs smoothly, then move to the RUN position.

IMPORTANT NOTE: Do not overload the generator. Also, do not overload individual panel receptacles. These outlets are protected against overload with push-to-reset type circuit breakers. If the operating load on any circuit breaker is exceeded, the breaker opens and electrical output to that receptacle is lost. Read Know Generator Limits carefully.

Using the 12 VDC Battery Charger

WARNING

Explosion: Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury. (000137a)
Risk of Burn: Do not open or mutilate batteries. Released electrolyte can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention. (000163a)
Risk of Burns: Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury. (000138a)

CAUTION

Equipment Damage: Do not make battery connections in reverse. Doing so will result in equipment damage. (000167a)

The 12 VDC receptacle may be used to recharge 12 VDC automotive batteries only. The DC charging output is not regulated. The circuit protector does not prevent overcharging a battery.

Connect the charging cable to the generator first, then the battery. ALWAYS connect the red lead to positive (+), and the black lead to negative (-).
Start the generator and use it as normal. Charging time will vary with battery size and condition.
Check voltage at battery terminals once the charging cable has been unplugged, or the generator has been shut down.

NOTE: This receptacle cannot recharge 6 Volt batteries and cannot be used to crank an engine having a discharged battery.

Maintenance

Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing. To obtain emissions control warranty service free of charge, the work must be performed by an IASD. See the emissions warranty.

NOTE: Call 1-888-GENERAC (1-888-436-3722) with questions about component replacement.

Maintenance Schedule

Follow maintenance schedule intervals, whichever occurs first according to use.

NOTE: Adverse conditions will require more frequent service.

NOTE: All required service and adjustments should be performed each season as detailed in the following chart.

At Each Use

Check engine oil level

Every 100 Hours or Every Year

Inspect/clean spark arrestor

Every 200 Hours or Every Year

Replace spark plug
Replace fuel filter
Change oil ǂ
Inspect/clean air filter**
Check valve clearance***

ǂ Change oil after first 25 hours of operation, then every season.

Change oil and oil filter every month when operating under heavy load or in high temperatures. ** Clean more often under dirty or dusty operating conditions. Replace air filter parts if they cannot be adequately cleaned. *** Check valve clearance and adjust if necessary after first 50 hours of operation and every 200 hours thereafter.

Preventive Maintenance

Dirt or debris can cause improper operation and equipment damage. Clean generator daily or before each use. Keep area around and behind the muffler free from combustible debris. Inspect all cooling air openings on the generator.

Use a damp cloth to wipe exterior surfaces clean.
Use a soft bristle brush to loosen caked-on dirt, oil, etc.
Use a vacuum to pick up loose dirt and debris.
Low-pressure air (not to exceed 25 psi) may be used to blow away dirt. Inspect cooling air slots and openings on the generator. These openings must be kept clean and unobstructed.

NOTE: DO NOT use a garden hose to clean the generator. Water can enter the engine fuel system and cause problems. If water enters the generator through cooling air slots, some water will be retained in voids and crevices of rotor and stator winding insulation. Water and dirt buildup on generator internal windings will decrease the insulation resistance of windings.

Engine Maintenance

WARNING

Accidental start-up: Disconnect spark plug wires when working on the unit. Failure to do so could result in death or serious injury. (000141)

Engine Oil Recommendations

To maintain the product warranty, the engine oil should be serviced in accordance with the recommendations of this manual. For your convenience, maintenance kits designed and intended for use on this product are available from the manufacturer that includes engine oil, oil filter, air filter, spark plug(s), a shop towel, and funnel. These kits can be obtained from an Independent Authorized Service Dealer (IASD).

Inspect Engine Oil Level

WARNING

Risk of burns: Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (000139)

Inspect engine oil level prior to each use, and after every 8 hours of operation.

Place generator on a level surface.
Remove dipstick and wipe clean. See Figure 4-1.
Insert dipstick and remove again to check oil level. Oil level is checked with dipstick fully installed. See Figure 4-2.
Clean area around oil fill. Remove oil fill cap.
Add recommended engine oil as necessary.
Remove dipstick and verify oil level is within the safe operating range.
Install dipstick and oil fill cap and hand-tighten.

NOTE: Some units have more than one oil fill location. It is only necessary to use one oil fill point.

Change Engine Oil

WARNING

Accidental start-up: Disconnect spark plug wires when working on the unit. Failure to do so could result in death or serious injury. (000141)

When using the generator under extreme, dirty, dusty conditions, or in extremely hot weather, change oil more frequently.

NOTE: Don’t pollute. Conserve resources. Return used oil to collection centers.

Change oil while the engine is still warm from running, as follows:

Place generator on a level surface.
Disconnect the spark plug wire from the spark plug and place the wire where it cannot contact the spark plug.
Clean the area around the oil fill and oil drain plug.
Remove oil fill cap.
Remove oil drain plug and drain oil completely into a suitable container.
Install oil drain plug and tighten securely.
Coat the gasket of the new filter with clean engine oil and install.
Slowly pour oil into the oil fill opening until the oil level is between L and H marks on the dipstick. DO NOT overfill.
Install dipstick and oil fill cap, and hand-tighten.
Wipe up any spilled oil.
Properly dispose of oil in accordance with all applicable regulations.

Air Filter

The engine will not run properly and may be damaged if run with a dirty air filter. Service air filter more frequently in dirty or dusty conditions.

To service air filter:

Turn knobs (A) and remove air filter cover (B). See Figure 4-3.
Remove wing nut (C) and filter (D). Gently tap filter on a solid surface. Replace if necessary.
Clean air filter cover before installation.

NOTE: To order a new air filter, contact the nearest authorized service center at 1-888-436-3722.

Service Spark Plug

To service spark plug:

Clean area around spark plug.
Remove and inspect spark plug.
Inspect electrode gap with wire feeler gauge and reset spark plug gap to 0.04 in (1.01 mm). See Figure 4-4.

NOTE: Replace spark plug if electrodes are pitted, burned, or porcelain is cracked. Use ONLY recommended replacement plug. See Specifications.

Install spark plug finger tight, and tighten an additional 3/8 to 1/2 turn using spark plug wrench.

Battery Replacement (if applicable)

NOTE: The battery shipped with the generator has been fully charged. A battery may lose some charge when not in use for prolonged periods of time.

WARNING

Accidental Start-up: Disconnect the negative battery cable, then the positive battery cable when working on the unit. Failure to do so could result in death or serious injury. (000130)

Disconnect negative (-) battery terminal FIRST (B).
Disconnect positive (+) battery terminal SECOND (A).
Install new battery. Install hold-down bracket and tighten.
Connect positive (+) battery terminal (A) FIRST. Slide rubber boot over connection hardware.
Connect negative (-) battery terminal (B) SECOND.
Slide rubber boot over connection hardware.

Inspect Muffler and Spark Arrester

NOTE: It is a violation of California Public Resource Code, Section 4442, to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order. Other states or federal jurisdictions may have similar laws. Contact the original equipment manufacturer, retailer, or dealer to obtain a spark arrester designed for the exhaust system installed on this engine.

NOTE: Use ONLY original equipment replacement parts.

Inspect the muffler for cracks, corrosion, or other damage. Remove spark arrester, if equipped, and inspect for damage or carbon blockage. Replace parts or clear carbon from the screen as required.

Inspect Spark Arrester Screen

WARNING

Hot Surfaces: When operating the machine, do not touch hot surfaces. Keep the machine away from combustibles during use. Hot surfaces could result in severe burns or fire. (000108)

Remove screw (A) and retaining bracket (B). See Figure 4-6.
Remove screen (C) and replace if torn, perforated, or otherwise damaged. If the screen is not damaged, clean with commercial solvent.
Replace screen and secure with bracket and screw.

Valve Clearance

Important: Please contact an Independent Authorized Service Dealer for service assistance. Proper valve clearance is essential for prolonging the life of the engine.

Check valve clearance after the first fifty hours of operation. Adjust as necessary.

Intake — 0.15 +/- 0.02mm (cold), (0.006 +/- 0.0008 inches)
Exhaust — 0.20 +/- 0.02mm (cold) (0.008 +/- 0.0008 inches)

Storage

General

DANGER

Explosion and Fire: Fuel and vapors are extremely flammable and explosive. Store fuel in a well-ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury. (000143)

WARNING

Risk of Fire: Verify the machine has properly cooled before installing the cover and storing the machine. Hot surfaces could result in fire. (000109)

It is recommended to start and run the generator for 30 minutes, every 30 days. If this is not possible, refer to the following list to prepare the unit for storage.

DO NOT place a storage cover on a hot generator. Allow the unit to cool to room temperature before storage.
DO NOT store fuel from one season to another unless properly treated.
Replace the fuel container if rust is present. Rust in fuel will cause fuel system problems.
Cover the unit with a suitable protective, moisture-resistant cover.
Store the unit in a clean and dry area.
Always store the generator and fuel away from heat and ignition sources.

Prepare Fuel System for Storage

Fuel stored over 30 days can go bad and damage fuel system components. Keep fuel fresh, and use a fuel stabilizer.

If the fuel stabilizer is added to the fuel system, prepare and run the engine for long-term storage. Run the engine for 10-15 minutes to circulate the stabilizer throughout the fuel system. Adequately prepared fuel can be stored for up to 24 months.

NOTE: If fuel has not been treated with fuel stabilizer, it must be drained into an approved container. Run the engine until it stops from a lack of fuel. Use of fuel stabilizer in the fuel storage container is recommended to keep fuel fresh.

Change engine oil.
Remove spark plug.
Pour a tablespoon (5-10cc) of clean engine oil or spray a suitable fogging agent into the cylinder.

WARNING

Vision Loss: Eye protection is required to avoid spray from the spark plug hole when cranking the engine. Failure to do so could result in vision loss. (000181)

Push the start button several times to distribute oil in the cylinder.
Install the spark plug.

Change Oil

Change engine oil before storage. See Change Engine Oil.

Setup Guide

To set up the Generac Portable Generator 5500, first make sure that you have a level surface to place the generator on. Next, add fuel to the tank and make sure that the oil level is correct. Then, turn the fuel valve to the "On" position. To start the generator, turn the power dial to the "Start" position and press the electric start button. If the generator does not start, use the recoil start. Once the generator is running, plug in your appliances and tools and adjust the load as needed.

Safety Rules

The manufacturer cannot anticipate every circumstance that might involve a hazard. The alerts in this manual, and on tags and decals affixed to the unit, alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Alert definitions are as follows:

DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Notes contain additional information important to a procedure and will be found within the regular text of this manual. These safety alerts cannot eliminate the hazards. Strict compliance with the special instructions while performing the action or service is essential to preventing accidents.

Safety Symbols and Meanings

DANGER

Asphyxiation: Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury (000103).
- If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air IMMEDIATELY. See a doctor, as you could have carbon monoxide poisoning.

DANGER

Electrocution: Water contact with a power source, if not avoided, will result in death or serious injury (000104).

DANGER

Electrocution: Turn utility and emergency power supplies to OFF before connecting power source and load lines. Failure to do so will result in death or serious injury (000116).

WARNING

Equipment and Property Damage: Do not alter the construction of, installation, or block ventilation for the generator. Failure to do so could result in unsafe operation or damage to the generator (000146).

WARNING

Asphyxiation: Always use a battery-operated carbon monoxide alarm indoors and installed according to the manufacturer's instructions. Failure to do so could result in death or serious injury (000178a).

WARNING

Equipment and Property Damage: Do not operate the unit on uneven surfaces or in areas of excessive moisture, dirt, dust, or corrosive vapors. Doing so could result in death, serious injury, property, and equipment damage (000250).

WARNING

Moving Parts: Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury (000111).

WARNING

Hot Surfaces: When operating the machine, do not touch hot surfaces. Keep the machine away from combustibles during use. Hot surfaces could result in severe burns or fire (000108).

WARNING

Personal Injury: Do not insert any object through the air cooling slots. The generator can start at any time and could result in death, serious injury, and unit damage (000142a).

WARNING

Risk of Injury: Do not operate or service this machine if not fully alert. Fatigue can impair the ability to service this equipment and could result in death or serious injury (000215).

WARNING

Equipment Damage: Do not attempt to start or operate a unit in need of repair or scheduled maintenance. Doing so could result in serious injury, death, or equipment failure or damage (000291).

For safety reasons, it is recommended that the maintenance of this equipment be performed by an IASD. Inspect the generator regularly, and contact the nearest IASD for parts needing repair or replacement.

Exhaust and Location Hazards

DANGER

Asphyxiation: Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury (000103).
- If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air IMMEDIATELY. See a doctor, as you could have carbon monoxide poisoning.

DANGER

Asphyxiation: The exhaust system must be properly maintained. Do not alter or modify the exhaust system to render it unsafe or noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury (000179b).

WARNING

Equipment and Property Damage: Do not alter the construction of, installation, or block ventilation for the generator. Failure to do so could result in unsafe operation or damage to the generator (000146).

WARNING

Asphyxiation: Always use a battery-operated carbon monoxide alarm indoors and installed according to the manufacturer's instructions. Failure to do so could result in death or serious injury (000178a).

WARNING

Fire Risk: Hot engine exhaust can ignite certain materials. Maintain at least five feet clearance on all sides of the generator, including overhead, to reduce the risk of fire, property damage, or personal injury (000590).
- If you start to feel sick, dizzy, or weak after using the generator, move to fresh air IMMEDIATELY. See a doctor, as you could have carbon monoxide poisoning.
- NEVER run a generator indoors or in a partly enclosed area such as garages.
- ONLY use outdoors and far away from windows, doors, vents, crawlspaces, and in an area where adequate ventilation is available and will not accumulate deadly exhaust gas.
- Point the muffler exhaust away from people and occupied buildings.
- Using a fan or opening a door will not provide sufficient ventilation.

Electrical Hazards

DANGER

Electrocution: Contact with bare wires, terminals, and connections while the generator is running will result in death or serious injury (000144).

DANGER

Electrocution: Water contact with a power source, if not avoided, will result in death or serious injury (000104).

DANGER

Electrocution: In the event of an electrical accident, immediately shut power OFF. Use non-conductive implements to free the victim from the live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury (000145).

WARNING

Accidental Start-up: Disconnect the negative battery cable, then the positive battery cable when working on the unit. Failure to do so could result in death or serious injury (000130).

The National Electric Code (NEC) requires the frame and external electrically conductive parts of the generator be properly connected to an approved earth ground. Local electrical codes may also require proper grounding of the generator. Consult with a local electrician for grounding requirements in the area. Use a ground fault circuit interrupter in any damp or highly conductive area (such as metal decking or steel work).

Fire Hazards

DANGER

Explosion and Fire: Fuel and vapors are extremely flammable and explosive. Add fuel in a well-ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury (000105).

DANGER

Explosion and Fire: Do not overfill the fuel tank. Fill to 1/2 inch from the top of the tank to allow for fuel expansion. Overfilling may cause fuel to spill onto the engine causing fire or explosion, which will result in death or serious injury (000166b).

DANGER

Risk of Fire: Allow fuel spills to completely dry before starting the engine. Failure to do so will result in death or serious injury (000174).

WARNING

Fire Risk: Fuel and vapors are extremely flammable. Do not operate indoors. Doing so could result in death, serious injury, or property or equipment damage (000281).

WARNING

Explosion and Fire Risk: Do not smoke near the unit. Keep fire and spark away. Failure to do so could result in death, serious injury, or property or equipment damage (000282).

WARNING

Explosion and Fire: Do not smoke while refueling the unit. Failure to do so could result in death, serious injury, or property or equipment damage (000284a).

WARNING

Fire Risk: Hot engine exhaust can ignite certain materials. Maintain at least five feet clearance on all sides of the generator, including overhead, to reduce the risk of fire, property damage, or personal injury (000590).
- Wipe up any fuel or oil spills immediately. Verify that no combustible materials are left on or near the generator. Keep the area surrounding the generator clean and free from debris and keep a clearance of five (5) feet on all sides to allow for proper ventilation of the generator and to reduce the risk of fire. Do not use in an enclosed or partially enclosed structure.
- Do not operate the generator if connected electrical devices overheat, if electrical output is lost, if engine or generator sparks, or if flames or smoke are observed while the unit is running.
- Keep a fire extinguisher near the generator at all times.

Standards Index

National Fire Protection Association (NFPA) 70: The NATIONAL ELECTRIC CODE (NEC) available from www.nfpa.org
National Fire Protection Association (NFPA) 5000: BUILDING CONSTRUCTION AND SAFETY CODE available from www.nfpa.org
International Building Code available from www.iccsafe.org
Agricultural Wiring Handbook available from the Electricity Resource Council, P.O. Box 309, Wilmington, OH 45177-0309
ASAE EP-364.2 Installation and Maintenance of Farm Standby Electric Power available from www.asabe.org, American Society of Agricultural & Biological Engineers, 2950 Niles Road, St. Joseph, MI 49085

This list is not all-inclusive. Check with the Authority Having Jurisdiction (AHJ) for any local codes or standards which may be applicable to your jurisdiction.

Troubleshooting

PROBLEM	CAUSE	CORRECTION
Engine is running, but AC output is not available.	1. Circuit breaker OPEN.	1. Reset circuit breaker.
	2. Poor connection or defective cord set.	2. Check and repair.
	3. Connected device is bad.	3. Connect another device that is in good condition.
	4. Fault in generator.	4. Contact IASD.
	5. GFCI receptacle is OPEN (if equipped).	5. Correct ground fault and press reset button on GFCI receptacle (if equipped).
Engine runs well at no-load, but bogs when load is applied.	1. Short circuit in a connected load.	1. Disconnect shorted electrical load.
	2. Generator is overloaded.	2. See Know Generator Limits.
	3. Engine speed is too slow.	3. Contact IASD.
	4. Shorted generator circuit.	4. Contact IASD.
Engine will not crank.	1. 10 Amp fuse has melted open.	1. Replace fuse.
	2. Battery weak or dead.	2. Charge or replace battery.
Engine will not start; or starts and runs rough.	1. Fuel shut-off is OFF.	1. Turn fuel shut-off ON.
	2. Dirty air filter.	2. Clean or replace air filter.
	3. Out of fuel.	3. Fill fuel tank.
	4. Stale fuel.	4. Drain fuel tank and fill with fresh fuel.
	5. Spark plug wire not connected to spark plug.	5. Connect wire to spark plug.
	6. Bad spark plug.	6. Replace spark plug.
	7. Water in fuel.	7. Drain fuel tank; fill with fresh fuel.
	8. Overchoking.	8. Set choke to no choke position.
	9. Low oil level.	9. Fill crankcase to correct level.
	10. Excessive rich fuel mixture.	10. Contact IASD.
	11. Intake valve stuck open or closed.	11. Contact IASD.
	12. Engine lost compression.	12. Contact IASD.
Engine shuts down during operation.	1. Out of fuel.	1. Fill fuel tank.
	2. Low oil level.	2. Fill crankcase to correct level.
	3. Fault in engine.	3. Contact IASD.
Engine lacks power.	1. Load is too high.	1. Reduce load (see Know Generator Limits).
	2. Dirty air filter.	2. Clean or replace air filter.
	3. Engine needs to be serviced.	3. Contact IASD.
Engine surges or stumbles.	1. Choke is opened too soon.	1. Set choke to halfway position until engine runs smoothly.
	2. Carburetor is running too rich or too lean.	2. Contact IASD.
No battery charge DC output.	1. Battery posts corroded.	1. Clean battery posts.
	2. Bad battery cable.	2. Replace cable.
	3. Defective battery.	3. Check battery condition. Replace if defective.
	4. Bad receptacle.	4. Contact IASD.

Introduction

Detailed Specifications

General Information and Setup

Generator Components

Know Your Generator

Emissions

Product Specifications

Generator Specifications

Engine Specification

Hour Meter

Connection Plugs

Idle Control Switch

Remove Contents from Carton

Accessories

Hardware Bag

Assembly

Install Wheels

Install Frame Foot Assembly

Install Handle

Battery Cable Connection

Add Engine Oil

Fuel

Description

Operation

Prepare Generator for Use

Grounding the Generator When Used as a Portable

Special Requirements

Connecting the Generator to a Building Electrical System

Know Generator Limits

Wattage Reference Guide

Starting Electric Start Engines

Using the 12 VDC Battery Charger

Maintenance

Maintenance Schedule

Preventive Maintenance

Engine Maintenance

Inspect Engine Oil Level

Change Engine Oil

Air Filter

Service Spark Plug

Battery Replacement (if applicable)

Inspect Muffler and Spark Arrester

Inspect Spark Arrester Screen

Storage

General

Prepare Fuel System for Storage

Setup Guide

Safety Rules

Safety Symbols and Meanings

Exhaust and Location Hazards

Electrical Hazards

Fire Hazards

Standards Index

Troubleshooting

Pros & Cons

Pros

Cons

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