Generac Power Systems NP Series User manual

Manual No. 91355
INSTALLATION
Manual
NP Series and Q Series
AIR-COOLED
RECREATIONAL VEHICLE
GENERATORS
For Models Powered by Gasoline and LP GAS
CORPORATION
Revision 6 (10/6/97)
Printed in U.S.A.

GENERAL SAFETY RULES
THE MANUFACTURER SUGGESTS THAT THESE “RULES” FOR SAFE OPERATION BE
COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE RECREATIONAL VEHICLE.
SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS OF
THIS EQUIPMENT.
WARNING:
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or ot her reproductive harm. _
NOTICE TO INSTALLER
The Installation Instructions have been published by
Generac Corporation to aid in the installation of the
products described in this manual. Generac assumes
that installation personnel are familiar with the proce¬
dures for installing such products, or similar products
that Generac manufactures. Generac also assumes
that personnel have been trained in the recommended
installation procedures for these products and that
such training includes (a) use of common hand tools,
(b) use of special Generac tools, and (c) use of any
tools and/or equipment from other suppliers.
We could not possibly know of and advise the recre¬
ational vehicle trade of all conceivable methods, proce¬
dures or techniques by which to perform an installation.
We could not know of the possible hazards that might
result from each installation method, procedure or
technique. We have not undertaken any such wide
evaluation. Therefore, people who use a method, pro¬
cedure or technique that Generac does not specifically
recommend must first completely satisfy themselves
that their safety, the safety of the vehicle's occupants
and the products's safety is not endangered by the
method, procedure or technique selected.
information, illustrations, specifications, etc., contained
in this Installation Manual are based on the latest infor¬
mation available at the time of publication. Every effort
has been expended to be sure that such data is both
accurate and current. However, the manufacturer
reserves the right to change, alter or otherwise improve
his product at any time without prior notice.
SAFETY RULES
Gasoline is extremely FLAMMABLE and its vapors are
EXPLOSIVE. Do not permit smoking, open flame,
sparks or any source of heat in the vicinity while han¬
dling gasoline. Comply with all regulations governing
the storage and handling of gasoline.
• Fuel lines must be properly installed, properly fas¬
tened and free of leaks. There must be no possibility
of gasoline vapors entering vehicle interior.
• You are required to install an approved, flexible,
non-conductive fuel line between the generator fuel
connection point and rigid fuel lines.
A If the generator can be equipped with a liquid
propane (LP) gas fuel system, install the unit so it
complies with all codes, standards and regulations
pertaining to such systems. LP gas is highly explosive.
The gas tends to settle in low areas where even the
slightest spark can ignite it and cause an explosion.
Do not allow gas vapors to enter the vehicle.
• Engine exhaust gases contain DEADLY carbon
monoxide gas. This dangerous gas, if breathed in suf¬
ficient concentrations, can cause unconsciousness or
even death. Install the exhaust system in strict compli¬
ance with applicable codes, standards and regula¬
tions. There must be no possibility for exhaust gases
entering the vehicle interior and endangering people
or animals.
A The generator set produces dangerously high electri¬
cal voltage. Contact with bare wires, bare terminals,
etc., will result in extremely hazardous and possibly
lethal electrical shock.
• All applicable electrical codes, standards and regula¬
tions must be strictly complied with in the installation
and use of this equipment.
• The generator must be properly grounded (bonded)
to the vehicle chassis or frame.
A If the vehicle electrical circuits can be powered by any
other source of electricity (such as a "dockside"
power receptacle), there must be no possibility of
connecting the different power sources to the vehicle
circuits at the same time. The "dockside" (utility)
power source must be positively isolated from the
vehicle circuits whenever the generator is operating.
Failure to isolate the vehicle circuits from the dock-
side power supply when the generator is running
may result in damage to the generator or serious
injury or death to dockside (utility) power workers
due to backfeed of electrical energy.
• Never work on the equipment while standing in
water, while barefoot, or while hands or feet are
wet. Dangerous electrical shock will result.
• Jewelry conducts electricity, which can cause danger¬
ous electrical shock. Remove all jewelry (such as rings,
watches, or bracelets) before working on this equip¬
ment.
• The generator requires an adequate flow of air for
cooling and ventilation. Without sufficient cooling air
flow, the engine-generator quickly overheats, which
causes serious damage to the generator, a fire or an
explosion. Generator air inlet and outlet openings
must be provided in strict compliance with the manu¬
facturer's recommendations.
• Never work on this equipment while physically or
mentally fatigued. Stay alert at all times.
Storage batteries give off EXPLOSIVE hydrogen gas
while charging. The battery used for cranking and
starting this generator should be installed in its own
ventecT compartment. Provide adequate ventilation
for the battery, to prevent explosive hydrogen gas
from accumulating.
• Never insert any tool or other object through open¬
ings in the generator interior, even if the unit is not
running. You might seriously injure yourself or dam¬
age the equipment.
• Staying alert and using "common sense" are major
measures for preventing accidents.

TABLE OF CONTENTS
GENERAL SAFETY RULES.inside cover
GENERAL INFORMATION
Purpose and Scope of Manual. 2
Safety. 2
Standards Booklets.. 2
Equipment Description ;. 2
Engine Generator Operating Speed. 2
Reconnection for Dual Voltage. 3
SPECIFICATIONS
Generator Specifications. 4
Engine Specifications. 4
Recommended Fuel. 4
Fuel Consumption. 4
Recommended Engine Oil. 4
LOCATION AND SUPPORT
Generator Location. 5
Generator Support.. 5
Suspended Mounting. 5
Generator Restraint. 6
Swing Mount Generator Tray.. 6
GENERATOR COMPARTMENTS
Compartment Size. 7
Compartment Construction. 7
Sound Insulation Materials. 8
Compartment Roor Cutouts. 8
Acoustics’. 8-9
COOLING AND VENTILATION AIR
Generator Air Flow. 1 0
Cooling Air Inlet Openings.10
Compensating for Restrictions. 1 1
Testing the Installation.11
GASOLINE FUEL SYSTEM.. 12
Fuel Tank.12
Generator Fuel Supply Line...,.12
PROPANE GAS FUEL SYSTEM.13
Parts Not Included in Fuel System.13
Some Important Considerations.13
Vapor Withdrawal.14
Primary Regulator. 1 4
Gaseous Carburetion. 1 4
Fuel Supply Lines.15
Excess Flow Valve.15
Leakage Tests.15
EXHAUST SYSTEM. 1 6
Mufflers and Spark Arrestors.16
Type of Exhaust System.16
Exhaust System Safety. 1 6 - 17
ELECTRICAL CONNECTipNS
Electrical Junction Box..18
Wiring.18
Generator AC Connections.18
Conduit.19
Ground Fault Circuit Interrupters.19
Power Supply Cord.19
Isolating Different Power Sources. 1 9 - 2 0
DUAL VOLTAGE RECONNECTION
Reconnection Procedure.21
BATTERY INSTALLATION
Recommended Battery. 2 2
Battery Cables.22
Battery Cable Connections.22
Battery Compartment. 2 2
POST INSTALLATION TESTS
Before Initial Start Up.. 2 3
Initial Start.23
Checking No-Load Voltage and Frequency.23
Testing Under-load.23 - 24
Adjusting No-Load Frequency.......24 -25
Voltage Regulator Adjustment.25
INSTALLATION CHECK LIST..26
ELECTRICAL FORMULAS.27
MAJOR FEATURES AND DIMENSIONS.28 - 29

GENERAL INFORMATION
---- ^
PURPOSE AND SCOPE OF MANUAL
These Installation Instructions have been prepared
especially for the purpose of familiarizing installers
and owners of the applicable equipment with the pro¬
duct's instailation requirements. Give serious consid¬
eration to all information and instructions in the
Manual, both for safety and for coritinued reliable
operation of the equipment.
Because of the different recreational vehicle models
and the variations between the models, it wouid be
extremely difficult, if not impractical, to provide
detailed instructions on every installation possibility.
For that reason, instructions and illustrations in this
manual are general in nature. Illustrations are not
intended to sen/e as detailed installation blueprints. ,
The installation should comply strictly with all applica¬
ble codes, standards and regulations pertaining to the
installation and use of this product. If any portion of this
manual appears to be in conflict with such codes, stan¬
dards or regulations, the applicable codes, standards
or regulations must take precedence over the manual.
SAFETY
Before handling, installing, operating or servicing this
equipment, be sure to read carefully the “Notice to
Installer'’ and “Safety Rules” at front of this manual.
Comply with all SAFETY RULES to prevent death,
personal injury or damage to equipment and/or prop¬
erty. Stress safety to all installers, operators and ser¬
vice technicians who work on this equipment.
STANDARDS BOOKLETS
Installation, use and servicing of this equipment
should comply strictly with published standards, as
well as the manufacturer’s recommendations. The fol¬
lowing standards booklets (latest revision) are avail¬
able from the sources indicated:
1. N F P A Standard 501C, “Standard for Recreational
Vehicles", available from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
2. N F PA 70, “NFPA Handbook of the National Electric
Code", obtained from same address as Item 1.
3. ANSI C1-1975 and ANS1119.2-1975, available from the
American National Standards Institute, 1430 Broadway,
New York, NY 10018.
4. A NSI A119.2/NFPA 501C, available from the
Recreational Vehicle Association, 1896 Preston White
Drive, Reston, VA 22090.
5. California Administrative Code, Title 25, available from
the State of California, Documents Section, P.O. Box
1015, North Highlands, CA 95660.
6. C SA Electrical Bulletin 946, available from the Canadian
Standards Association, Housing and Constructions
Materials Section, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W1R3.
EQUIPMENT DESCRIPTION
Instructions and information in this section pertain to
Generac “NP and “Q” air-cooled generators, more
specifically as listed below. These generators are
designed specifically for installing in recreational vehi¬
cles. They operate 120 volts, 1-phase, 60 Hertz, AC
electrical loads.
NOTE: All units, except the Q40G, may be recon¬
nected for a dual voltage output of 120/240 volts AC.
Series
Power (wattage)
Max. Rated Current
at 120V
Q-40G
4200
35.0
Q-55G/LP
5500
45.8
Q-70G/LP
7000
58.3
NP-50G
5000
41.6
NP-50LP
4500
37.5
NP-66G/LP
6600
55
ENGINE GENERATOR
OPERATING SPEED
The generator’s revolving field (rotor) is driven by a 4-
cycle engine through a puiley and drive train arrange¬
ment (Figure 1). The generator supplies 120/240
volts AC at 60 Hertz when the rotor is operating at
3600 rpm. The drive train arrangement allows the
engine to operate at a lower speed than the rotor.
Engine speed is held nearly constant by a mechani¬
cal, fixed speed governor as follows:
Series Q-40G.2570 rpm
Series Q-55G/LP ..,. 2570 rpm
Series NP-50G/LP .2570 rpm
Series NP-66G/LP .2700 rpm
Series Q-70G/LP..2570 rpm
Figure 1 — Typical Pulley and Drive Train
— 2 —

RECONNEaiON FOR DUAL VOLTAGE
You can reconnect the generators to supply a dual
voltage AC output, if desired. That is, units may be
reconnected to operate 120 and/or 240 volts, 1-
phase, 60 Hertz, AC loads. This is done by connect¬
ing the hwo stator AC power windings in series as it is
shown in Figure 2.
IMPORTANT: UNITS RECONNECTED FOR
120/240 VOLTS DUAL VOLTAGE OUTPUT WILL
NOT BE LISTED PER RVIA.
NOTE: The Q-40G can NOT be reconnected for a
dual voltage output of 120/240 volts AC.
Figure 2 — Reconnection for Dual Voltage Output
When reconnecting for dual voltage output, the
installer should replace the main circiut breakers
(CB1 and CB2) with a single adequately rated circuit
breaker. Rated maximum continuous load currents
are listed below:
• NP-50LP —18.8 AC amperes
• NP-50G — 20.8 AC amperes
• Q-55G/LP — 22.9 AC amperes
• NP-66G/LP — 27.5 AC amperes
• Q-70G/LP — 29.1 AC amperes
NOTE: This option is unavailabe on the Q40 model.
— 3 —

SPECIFICATIONS
GENERATOR SPECIFICATIONS
SERIES
Q-40G
NP-50G
NP-50LP
Q-55G/LP
NP-66G/LP
Q-70GA.P
Rotor RPM
3600
3600
3600
3600
3600
3600
Rotor Poles
2
2
2
2
2 2
Engine RPM
2570
2570
2570
2570
2700
2570
Wattage*
4200
5000
4500
5500
6600
7000
Voltage*
120
120
120
120
120
120
Rated Amps*
35
41.6V 37.5*
45.8*
.55*
58.3A
Phase
1
1
1
1
1 1
Frequency
60
60
60
60 Hertz
60 Hertz
60 Hertz
Weight
215 lbs.
207 lbs.
207lbs.
215 lbs.
213 lbs.
222 lbs.
Length
25 inches
Width
18.5 inches
Height
16.68 inches ■
All units, except Q-40G, are reconnectable to
120/240 volts, dual voltage output. When reconnect¬
ed for dual voltage, units are not listed per RVIA.
V Rated maximum continuous current at 240 volts is
20.8 amps.
t Rated maximum continuous current at 240 volts is
22.9 amps.
t Rated maximum continuous current at 240 volts is
27.5 amps.
A Rated maximum continuous current at 240 volts is
29.1 amps.
* Rated maximum continuous current at 240 volts is
18.8 amps.
ENGINE SPECIFICATIONS
Type of Engine
NP-50G/LP.1 Cylinder, 4 Cycle OHVI
NP-66G/LP, Q-70G/LP
Q-40G, Q-55G/LP.V-Twin, 4 Cycle OHVI
Number of Cylinders
Q-40G, Q-55G/LP, NP-66G/LP, Q-70G/LP.2
NP-50G/LP .1
Valve Configuration.Overhead Valves
Cooling Method .Air-Cooled
Rated Horsepower
NP-50G/LP . 1 3 at 3600 RPM
Q-40G.16 at 3600 RPM
Q-55G/LP .16 at 3600 RPM
NP-66G/LP .16 at 3600 RPM
Q-70G/LP .19 at 3600 RPM
Displacement
NP-50G/LP .363cc
Q-40G .480cc
Q-55G/LP.480CC
NP-66G/LP .480CC
Q-70G/LP.570CC
Compression Ratio.8.6 tol
Cylinder Block.Aluminum with cast iron sleeve
Type of Governor.Mechanical, fixed speed
Air Cleaner.Paper element with foam pre-cleaner
Starter.12 volts DC electric
Recommended Spark Plugs.Champion RC12YC
Spark Plug Gap.0.030 inch (0.8mm)
Oil Filter ..Generac Part No. 70185
Crankcase Oil Capacity .1.5 U.S. quarts
Battery Voltage.12 volts DC
Recommended Battery§
Amp-Hour Rating .70 amp-hour
Cold Cranking Amperes .360.
Cranking Current...100 DC amperes
Battery Ground..Negative (-)
§ If ambient temperature is usually below 32“F (O^C),
use a battery rated at 95 amp-hours and 450 cold¬
cranking amperes.
RECOMMENDED FUEL
For the gasoline-powered units: Use clean, fresh
UNLEADED gasoline with a minimum octane rating of
87. Leaded REGULAR grade gasoline is an accept¬
able substitute.
■ FOR GASEOUS FUEL-POWERED UNITS
Use clean, fresh commercial propane gas. The
optional LP gas system was designed for a VAPOR
WITHDRAWAL type system.
FUEL CONSUMPTION
Gasoline fuel system In U.S. gallons per hour:
% '
OF WATTS
1 SERIES 1
NP-50G Q-40G Q-55G
NP-66G Q-70G
25% 0.16
0.16 0.21
0.25
0.27
50^S^
0.32
0.32 0.42 0.50
0.54
75%
0.46
0.47 0.62
0.74 0.81
100% 0.63
0.63
0.83 0.99 1.08
RECOMMENDED ENGINE OIL
Use oil classified “For Service SP and having an SAE
viscosity rating of 10W-30. Engine crankcase oil
capacity is 1.5 U.S. quarts (1.6 liters).
— 4 —

LOCATION AND SUPPORT
GENERATOR LOCATION
The most desirable location for the generator set is
between the vehicle's main frame members However,
this is seldom possible. Most units must be installed
on the side of the vehicle and are difficult to reinforce.
Many recreational vehicles have been factory
equipped with an area for the generator set. Some
vehicles may even have a generator compartment,
provided by the vehicle manufacturer.
Plan the generator location based on the following;
• The generator set must be installed on a framework that
is part of the recreational vehicle, as outlined in the para¬
graph entitled “Generator Support.”
• The location must provide an access opening that is large
enough to permit generator removal (unless the genera¬
tor is to be removed from underneath the supporting
framework.
• The location must provide easy access to frequently ser¬
viced components, such as filters, oil drains, spark plugs
and other common maintenance parts.
• The location must provide sufficient room to allow mini¬
mum clearance of at least 1 inch between all sides and 1 •
1/2 inches on top of the generator. If sound insulation is
to be used on compartment walls and ceiling, the mini¬
mum recommended applies to the space between the
generator and such insulation.
• The location must provide adequate cooling and ventilat¬
ing air flow for the generator without a great deal of work
and expense.
GENERATOR SUPPORT
The generator must be securely attached to a metal
framework that has been made part of the vehicle
frame structure by bolting or welding. The metal
framework on which the generator will rest and which
will restrain the generator set should consist of at
least two horizontal beams. These beams should con¬
sist of (a) 1-1/2 inch square, 11 gauge steel tubing
OR (b) 1-1/2 inch, 11 gauge angle iron. A typical sup¬
porting frame with horizontal support tubing, is shown
in Figure 3.
The generator can be installed so that it sits on top of
the horizontal support tubing, if the vehicle design
permits. Another method is to suspend the generator
below the horizontal support tubing by means of suit¬
able, structurally sound metal framework. The follow¬
ing general rules apply:
• Vehicle construction MUST be capable of supporting the
weight of the generator.
• Whether the generator is mounted above the horizontal
support tubing or suspended below the tubing, the sup¬
porting frame used must be structurally sound.
• If the generator cannot be bolted directly to the support¬
ing frame or support tubing, consider using additional
tubing, angle brackets or other supports to give the sup¬
porting frame sufficient strength.
Figure 3 — Typical Horizontal Support Frame
SUSPENDED MOUNTING
If you are going to suspend the generator below the
horizontal support tubing, the suspension method you
use with the vehicle frame members must have the
following; (a) be able to support the weight of the gen¬
erator; and (b) provide sufficient restraint for the gen¬
erator. One typical suspended mounting system is
shown in Figure 4. The location of a suspended
mounting system must be carefully planned, keeping
the following general rules in mind:
• Protect the generator against road splash and debris.
Baffles or splash guards may be required to protect cer¬
tain areas of the generator. To make sure the generator is
adequately protected, road test the installation through
mud, water and slush.
Figure 4 — Typical Suspended Mounting System
• The installer must make certain the selected location will
permit adequate cooling and ventilating air flow to be
supplied.
— 5 —

GENERATOR RESTRAINT
Use four 3/8''-16 hardened steel bolts (Grade 5) to
fasten the generator to the supporting frame or the
support tubing. These bolts must pass through (a) the
generator mounting base, (b) the compartment floor,
if a compartment is used, and (c) the supporting
framework (Figure 5). All bolts must be long enough
so that when tight, at least 3 threads are visible past
the retaining lock nuts. Refer to “COMPARTMENT’
section for location of generator mounting holes.
SWING MOUNT GENERATOR TRAY
If you use a suspended mounting system, the installer
may wish to consider using the Generac Model 9164
Swing Mount Generator Tray, The Model 9164 tray
allows you to swing the generator downward and
away from the vehicle frame. This makes it simple to
remove the unit and have easy access to parts
(Figure 6).'
The tray on which the generator rests is hinged, per¬
mitting it to swing downward after two side support
rails and a center support rail are unbolted.
Instructions for tray installation are included with the
tray mounting kit.
— 6 —

GENERATOR COMPARTMENTS
The generator set may or may not be installed inside
a compartment that is constructed specifically for
housing a generator. This section applies to generator
compartments when they are installed. The following
general rules apply to compartments:
• The generator compartment should be either
constructed of, or lined with, 26 gauge galvanized
steel.
IMPORTANT: ALUMINUM IS NOT AN ACCEPT¬
ABLE ALTERNATIVE TO GALVANIZED STEEL.
DUE TO ALUMINUM'S LOW MELTING POINT.
• If the compartment is lined with galvanized steel,
it may be constructed of any material. Generac
recommends that the compartment be construct¬
ed of 1/2-inch thick plywood, with the floor made
of a double thickness of plywood for added
strength.
• All seams, splices and joints of the compartment
walls (unless vapor tight by design) should be
caulked.
IMPORTANT: CAULKING MUST BE DONE SO
THAT THE CAULKING MATERIAL WILL STAY IN
PLACE PERMANENTLY. PRESSING SUCH MATE¬
RIALS AS PUTTY TAPE ONTO JOINTS AND
SEAMS WILL NOT MEET THAT REQUIREMENT. A
HIGH QUALITY SILICONE RUBBER SEALANT IS
RECOMMENDED.
• Holes and openings through the compartment
walls for passage of electrical conduit, conduc¬
tors, etc, into vehicle living area must be sealed
vapor-tight with silicone rubber base sealant.
• If you use flexible metal conduit, seal the conduit
at the end where it terminates inside the junction
box. Flexible metal conduit is NOT vapor tight
along its entire length.
• Seams and joints of the galvanized steel
(whether used as a liner or the compartment
itself) must be lapped and mechanically secured.
Such seams may be manufactured, welded, bolt¬
ed, riveted, or screwed. Manufactured lock
seams are shown in Figure 7.
Fold Locked Off Set
Standing Double Lock Double Seam
Acme Lock Gordon Seam Lock Seam
COMPARTMENT SIZE
Plan the compartment size carefully. Provide a mini¬
mum of at least 1 inch of clearance between the gen¬
erator and compartment walls and 1-1/2 inch of clear¬
ance between the generator and the ceiling AFTER
you have lined the compartment with metal, and
AFTER you have installed sound insulation (Figure
8 ).
NOTE: Refer to the “Dimensions and Features” draw¬
ing in the back of this manual.
Figure 8 — Provide Clearance Around Generato
1 INCH (2.S4CM)
PLYWOOD MINIMUM CLEARANCE
L— INSULATION METAL LINING—^
COMPARTMENT CONSTRUaiON
• The generator compartment should be constructed of 1/2
inch thick plywood. Make the compartment floor a double
thickness of 1/2 inch plywood with the grain of the wood
at cross section for added strength (Figure 9).
Figure 9 — Typical Compartment Construction
• Line the entire compartment interior with 26 gauge galva¬
nized steel as described above.

• Line the exterior (underside) of the compartment floor
with 26 gauge galvanized steel.
• Vapor seal all compartment seams and joints, to prevent
poisonous, flammable or explosive vapors from entering
the vehiclef interior.
NOTE: Silicone rubber base sealant is an acceptable
caulking material. Pressing putty tape onto compart¬
ment joints and seams is NOT acceptable.
• After the compartment has been metal lined and vapor
sealed, line the compartment interior walls and ceiling
with an approved, non-flammable sound insulating mater¬
ial. See “Sound Insulating Materials.”
DANGER: DO NOT INSTALL SOUND INSULATION
OR ANY ABSORBENT MATERIAL ON THE COM¬
PARTMENT FLOOR INTERIOR. SUCH MATERIALS
WILL BECOME SOAKED WITH COMBUSTIBLE OR
EXPLOSIVE VAPORS AND LIQUIDS AND WILL
BECOME A FIRE HAZARD.
• Openings in compartment walls for passage of electrical
conduit, conductors, hoses, cables, etc., must be made
vapor tight with suitable caulking material.
• Flexible conduit must be sealed internally at the end
where it terminates inside a compartment's electrical
junction box.
NOTE: The preceding is required because flexible
conduit, due to its unique construction, is not vapor-
tight along its entire length.
DANGER: DO NOT INSTALL ANY FLAMMABLE
MATERIAL DIRECTLY ABOVE OR AROUND THE
COMPARTMENT. HEAT, TRANSFERRED THROUGH
THE COMPARTMENT STRUCTURE, MAY BE SUF¬
FICIENT TO IGNITE, CHAR OR DISCOLOR SEAT
CUSHIONS, FIBERBOARD AND OTHER FLAMMA¬
BLE MATERIALS. YOU MAY NEED TO USE
APPROVED NON-FLAMMABLE INSULATING
MATERIALS IN HIGH TEMPERATURE AREAS.
SOUND INSULATING MATERIALS
Once installers have determined that compartments
are properly constructed and metal lined, they can
add acoustical material. This may include additional
sealant or insulating material, to reflect noise away
from the vehicle interior.
Sound insulating materials should be of a non-flam¬
mable type. One excellent insulating material is a 1
inch thick fiberglass having a 2-pound density. When
fiberglass is used, its coated side should face toward
the compartment interior.
Using a combination of sound insulating materials can
often reduce noise more effectively than a single
material. For example, a sheet of lead or visco-elastic
material, along with a layer of other acoustical materi¬
al, is more effective than when a single material is
used.
COMPARTMENT FLOOR CUTOUTS
You rriust provide openings in the generator compart¬
ment for the following items (Figure 10):
• Engine exhaust and cooling air outlets
• Generator cooling air inlet
• Four holes for passage of generator mounting bolts. See
“Generator Restrainf on Page 6.
DANGER: FUEL UNES AND EXHAUST PIPING
MUST NOT PENETRATE INTO VEHICLE LIVING
AREA.
Figure 10 — Compartment Floor Cutout
If excessive noise levels should become a problem,
the installer may wish to consider the following:
• Using special sound insulating materials.
• Construction of a special noise abatement compartment.
IMPORTANT: ANY METHOD USED TO REDUCE
NOISE MUST NOT ADVERSELY AFFECT THE
FLOW OF COOLING AND VENTILATING AIR INTO
OR OUT OF THE COMPARTMENT.
o
— 8 —

In addition to the effective use of sound insulatingma-
terials, construction of a special noise abatement
compartment might be considered to reduce noise
levels. Such a compartment might be constructed as
follows (Figure 11):
Figure 11 — Typical Noise Abatement
Compartment
PLYWOOD
5/8” THICK
EXTERIOR
SOUND
INSULATION
METAL LINER
FIBERGLASS
INSULATION
PLYWOOD
5/8" THICK
• Use 5/8-inch thick or 3/4-inch thick plywood in the com¬
partment.
• Construct the compartment floor of a double thickness of
5/8-inch or 3/4-inch plywood.
• Line the compartment interior walls and floor, as well as
the underside of the floor, with 26-gauge galvanized
steel.
-DANGER: DO NOT INSTALL ANY INSULATION OR
OTHER ABSORBENT MATERIALS ON THE INTERI-
_OR OR UNDERSIDE OF THE COMPARTMENT
FLOOR.
• Seal all compartment door edges to prevent noise leak¬
age around the door perimeter.
• Line the compartment door interior (except for air open¬
ings) with suitable, fire proof sound insulation (such as 1 -
inch thick fiberglass with a 2-pound density) See Figue
12 .
INSULATION ooow
A TIMES B MUST EQUAL^AT LEAST
100 IN.'OF FREE AIR OPENING
• Vapor seal all compartment seams and joints.
• Over the galvanized steel lining, install a selected combi¬
nation of acoustical materials as mentioned in ‘Sound
Insulating Materials."
— 9 —

COOLING AND VENTILATING AIR
---
It is absolutely essential that an adequate flow of air
for cooling, ventilating and engine combustion be sup¬
plied to the generator set. V\/ithout sufficient air flow,
the engine-generator quickly overheats. Such over¬
heating can cause serious operating difficulties and
may also cause fire and personal injury. The installer
must make sure that sufficient air is available to the
generator for cooling, ventilating and combustion. The
installer must also provide for a path for exhausting
the cooling air to the exterior of a compartment, if so
equipped.
-^DANGER: NEVER USE DISCHARGED
▲ COOLING AIR FOR HEATING OR PERMIT
SUCH AIR TO ENTER THE VEHICLE INTE-
- RIOR. THIS AIR CONTAINS DEADLY CAR¬
BON MONOXIDE GAS AND OTHER POISO¬
NOUS, FLAMMABLE OR EXPLOSIVE
GASES.
GENERATOR AIR FLOW
Engine operation drives cooling fans for the 2-stage
cooling air system. A pressure fan draws cooling air
into the top of generator and into the side of the con¬
trol panel (Figure 13). This air flow cools the engine-
generator and electronic .components. The second
part of cooling system, a suction fan, draws air that is
heated from a hot engine into a collector pan at the
base of the unit. This heated air (although cooler than
exhaust muffler) is directed across the muffler to cool
it. The heated air flow is then deflected out the bottom
toward the ground.
Figure 13 — Air Flow Through Engine-Generator
COOLING AIR INLET OPENING
Minumum size of the air inlet opening, whether the
generator is housed in a conventional compartment or
not, is at least 100 square inches. This rule applies
whether inlet air is brought in through an opening in
the compartment door (Figure 14) or other means.
NOTE: Screening, louvers, or expanded metal that
cover air openings restrict air flow that you must com¬
pensate for by making the actual air opening propor¬
tionately larger. See “Compensating for Restnctions."
For conventional compartment mounted units, the air
inlet is generally provided in the compartment door.
IMPORTANT: IF YOU PLAN TO INSTALL THE GEN¬
ERATOR IN A COMPARTMENT, BE SURE TO
LEAVE AT LEAST ONE AND A HALF (1-1/2") INCH¬
ES OF CLEARANCE BETWEEN THE GENERATOR
AND COMPARTMENT CEILING. INCLUDE 26
GAUGE GALVANIZED STEEL LINING AND SOUND
INSULATION WHEN YOU MEASURE FOR THIS 1-
1/2 INCH CLEARANCE. ALLOW 1” ON ALL SIDE
WALLS.
Figure 14 — Air Inlet in Compartment Door
When the unit is installed on a suspended mounting
system, one of several different methods of supplying
air flow may be used as follows:
• Provide a door in the vehicle skirt having an air
inlet opening (Figure 15).
Figure 15 — Suspended Mount: Inlet Door
• Using ductwork (Figure 16 on Page 11). The
instafler must be sure air is available to the top of
the generator since air inlets are located at the
top.
• By providing an opening in the vehicle skirt and
space above the generator for cooling air flow
(Figure 17 on Page 11). Recommended clear¬
ance above the top of the generator is at least 1 -
1/2 inches.
— 10 —

COMPENSATING FOR
RESTRiaiONS
Such materials as screening, louvers, or expanded
metal can restrict the free flow of air. Compensate for
this restriction by making the actual air opening pro¬
portionately larger.
Some materials may offer only a 60 percent “free air
inlet area.” Other more efficient materials may provide
up to a 90 percent free air inlet area. The percentage
of free air inlet opening is usually available from the
material supplier or manufacturer.
TO DETERMINE THE ACTUAL AIR INLET OPEN¬
ING SIZE REQUIRED, DIVIDE 100 SQUARE INCH¬
ES BY THE PERCENTAGE OF FREE AIR INLET
AREA FOR THE MATERIAL YOU WILL USE.
For example: If you plan to use screening with an
80% free air inlet area, divide 100 by 0.8, which
results in 125 square inches. Minimum actual size of
air inlet opening in this case is 125 square inches. An
opening that measures 8 inches wide by 16 inches
long provides the required air flow (8 x 16 = 128
square inches).
TESTING THE INSTALLATION
Generac recommends testing the installation to be
sure adequate cooling air flow is available to the unit
before placing the unit into service. If the unit shows
signs of overheating, you will need to enlarge the air
openings. Never place a unit into service until
absolutely certain that cooling and ventilation is ade¬
quate.
IMPORTANT: YOU MUST TEST THE INSTALLA¬
TION ESPECIALLY IF YOU BRING IN AIR FROM
BELOW THE GENERATOR SET.
—11 —

GASOLINE FUEL SYSTEM
Installing a gasoline fuel system (Figure 18) for recre¬
ational vetiicle generator sets must comply with
applicable codes, standards and regulations. The
entire fuel system must be completely free of leaks.
There must be no possibility of gasoline vapors enter¬
ing the vehicle interior.
Figure 18 — Generator Fuel System
DANGER; GASOLINE IS HIGHLY FLAMMABLE
AND ITS VAPORS ARE EXPLOSIVE. COMPLY
WITH ALL CODES, STANDARDS AND REGULA¬
TIONS PERTAINING TO GASOLINE FUEL SYS¬
TEMS USED IN INDUSTRIAL MOBILE GENERA¬
TORS. PROPERLY INSTALL AND MAINTAIN THE
FUEL SYSTEM AND KEEP IT ENTIRELY FREE OF
LEAKS. GASOUNE VAPORS MUST NOT ENTER
THE VEHICLE INTERIOR.
Factory installed generator fuel system components
include (a) fuel filter, (b) 12-volt DC electric pump, (c)
engine carburetor, and (d) interconnecting lines and
fittings. Connect a fuel supply line to the fuel filter inlet.
Use a flexible length of approved fuel hose between
the fuel filter inlet connection and rigid fuel lines.
FUEL TANK
Either the generator must share the vehicle engine's
fuel tank, or you must install a separate fuel tank for
the generator set. All fuel tanks installed on the vehi¬
cle must be constructed, installed, restrained so it
complies with applicable codes, standards and regu¬
lations.
If the generator is to share the vehicle engine's tank,
separate fuel pickup tubes are required for the engine
and the generator. Generac recommends that you
make the fuel pickup tube about 2 to 3 inches shorter
than the vehicle engine's pickup tube. This prevents
the generator from depleting the entire fuel supply
during prolonged generator operating periods.
CAUTION: Do NOT tee the generator fuel supply
line into the vehicle engine fuel supply line. If this
is done, the generator will be starved of fuel when
both engines are operating at the same time. Also,
while the vehicle engine is not running, generator
operation may drain the vehicle engine supply line,
making it difficult to start the vehicle engine.
GENERATOR FUEL SUPPLY LINE
■ RIGID FUEL LINES _
Those lines used to supply fuel from a tank to the
generator must comply with applicable codes, stan¬
dards and regulations. The following generator rules
apply to rigid fuel lines:
• Rigid lines should be of annealed, seamless, drawn alu¬
minum or steel.
• Lines and fittings must comply with SAE J512F,
“Standard Automotive Fittings”, or with ANSI B126.26
(latest edition).
• Route the fuel line so that at least 2 inches of clearance
is maintained between the line and any exhaust system
parts.
• Do not attach electrical wiring to fuel lines. Route the
wiring so it cannot come into contact with any fuel line.
• Route fuei lines so if they ieak, fuel does not drip onto
any electrical or exhaust system parts.
• Use non-ferrous metal straps without sharp edges to
secure fuel lines.
■ FLEXIBLE FUEL LINE _
Use an approved flexible length of fuel hose between
the generator fuel inlet connection and rigid fuel lines.
This prevents breaking of the line caused by vibration,
shifting, settling or movement. The following rules
apply:
• The flexible hose must comply with SAE J30B, “Standard
for Fuel and Oil Hose”. It must be approved for use with
gasoline.
• The hose should be at least 6 inches ionger than is need¬
ed to prevent the hose from rupturing if the generator
shifts or settles.
— 12 —

PROPANE GAS FUEL SYSTEM
DANGER: LP (PROPANE) GAS IS HIGHLY EXPLO¬
SIVE. THE GAS IS HEAVIER THAN AIR AND
TENDS TO SEHLE IN LOW AREAS, WHERE EVEN
THE SLIGHTEST SPARK CAN IGNITE IT AND
CAUSE AND EXPLOSION. ONLY COMPETENT,
QUALIFIED PERSONS SHOULD BE ALLOWED TO
INSTALL, TEST, ADJUST OR SERVICE AN LP GAS
FUEL SYSTEM. INSTALL THE OPTIONAL FUEL
SYSTEM IN COMPLIANCE WITH APPLICABLE
CODES, STANDARDS AND REGULATIONS. AFTER
THE INSTALLATION, DO NOTHING THAT MIGHT
RENDER THE SYSTEM IN NON-COMPLIANCE
WITH APPLICABLE CODES AND STANDARDS.
The LP powered range of Gensets are fitted with non-
adjustable factory set system. These systems are
tamper-proof to meet 1997 California Air Resources
Board for Engine Emmissions.
DANGER: USE ONLY APPROVED COMPONENTS
IN THE GAS SUPPLY SYSTEM. ALL COMPONENTS
MUST BE PROPERLY INSTALLED IN ACCOR¬
DANCE WITH APPLICABLE CODES. IMPROPER
INSTALLATION OR USE OF UNAUTHORIZED COM¬
PONENTS MAY RESULT IN FIRE OR AN EXPLO¬
SION. FOLLOW APPROVED METHODS TO TEST
THE SYSTEM FOR LEAKS. NO LEAKAGE IS PER-
MIHED. DO NOT ALLOW FUEL VAPORS TO
ENTER THE VEHICLE INTERIOR.
SOME IMPORTANT CONSIDERATIONS
When installing an LP gas system, consider seriously
the following items;
• All fittings, lines, hoses and clamps must be tight and free
of leaks. Apply a pipe sealant to threads when assem¬
bling threaded connections. This reduces the possibility
of leakage.
PARTS NOT INCLUDED IN FUEL SYSTEM
The propane fuel system does NOT include such
items as (a) gas tank, (b) gas piping, (c) fittings, (d)
valves, and (e) primary regulator, used to store the
gaseous fuel and deliver it to the gaseous fuel sole¬
noid (Figure 19).
• Test the entire fuel system for leaks, using approved test
methods.
Figure 19 — Typical Propane Gas Fuel System
— 13 —

• Optimum gas pressure at the inlet to the gaseous fuel
solenoid valve and secondary regulator is 11 inches
water column.
• The instaljer’s fuel supply connection point is at the
gaseous fuel solenoid valve. This is a 3/4 inch (female)
connection. Provide a suitable 3/4 inch NPT (male) con¬
nector to attach to the fuel supply line.
• Use a length of approved flexible fuel hose between
gaseous fuel solenoid valve and rigid gas piping. The
flexible line should be at least six (6) inches longer than
necessary.
VAPOR WITHDRAWAL
Liquid propane (LP) gas is stored in pressure tanks
as a liquid. The gas systems used with these genera¬
tors were designed only for “vapor withdrawal” type
systems. Vapor withdrawal systems use the gas
vapors that form above the liquid fuel in the tank. Do
NOT attempt to use the generator with any “liquid
withdrawal" type system.
PRIMARY REGULATOR
Gas pressure delivered to the solenoid valve must be
properly regulated by means of a primary gas regula¬
tor. Mount the primary regulator at the gas tank outlet
or in the supply line from the gas tank. The following
rules apply;
• For best results, the primary regulator supplies gaseous
fuel to the secondary regulator at 11 inches water col¬
umn. Do NOT exceed 14 inches water column.
• The installer must be sure the primary regulator is rated
at sufficient gas flow to operate the generator plus all
other gas appliances in the circiut.
NOTE: Recommended MINIMUM gas flow rate for all
air-cooled NP or Q series generators is 67 cubic feet
per hour.
IMPORTANT: IF AN EXISTING PRIMARY GAS
REGULATOR DOES NOT HAVE A SUFFICIENT
FLOW CAPACITY FOR THE GENERATOR AND
OTHER GAS APPLIANCES IN THE CIRCUIT, (a)
INSTALL A PRIMARY REGULATOR WITH ADE¬
QUATE FLOW RATE, OR (b) INSTALL A SEPA¬
RATE REGULATOR ONLY AND RATED AT LEAST
67 CUBIC FEET PER HOUR. THE INLET SIDE OF
ANY PRIMARY REGULATOR THAT SUPPLIES THE
GENERATOR MUST CONNECT DIRECTLY TO
GAS TANK PRESSURE. DO NOT TEE THE GEN¬
ERATOR LINE INTO A GAS CIRCUIT FEEDING
OTHER AREAS.
GASEOUS CARBURETION
LP gas vapors should be supplied to the secondary
regulator inlet at about 11 inches water column (posi¬
tive pressure). The engine pistons draw air in during
the intake stroke (Figure 20). This air passes through
a carburetor venturi which creates a low pressure that
is proportional to the quantity of air being pumped.
The low pressure from the carburetor venturi acts on
the regulator diaphragm, to pull the diaphragm toward
the source of low pressure. A lever attached to the
diaphraghn opens a valve to permit gas glow through
the carburetor.
The greater the air flow through the carburetor ven¬
turi, the lower the presure at the venturi throat. The
lower the pressure at the venturi throat, the greater
the diaphragm movement and the greater the move¬
ment of the regulator valve. The more the regulator
valve opens, the greater the gas flow that Is propor¬
tional to air flow through the generator.
Figure 20 — Propane Gas Carburetion Diagram
AIR gas at
AREA
— 14 —

The following facts about the secondary regulator
must be emphasized;
• The regulator must be sensitive to venturi throat pressure
changes throughout the operating range.
• The regulator must be properly adjusted so it will stop the
flow of gas when the engine is not running (no air flow
through the carburetor).
• The slightest air flow (and vacuum in the venturi throat
should move the regulator valve off its seat and permit
gas to flow.
LEAKAGE TESTS
Do not place the generator into service until you have
properly tested the gas system for leaks. To test the
system, you need a separate source of 12 volts DC to
open the gaseous fuel solenoid valve.
The leak test must comply fully with NFPA, Paragraph
318. AN connections, hoses, valves regulators, fit¬
tings, and other fuel system parts must be tested
under gas or air pressure of not less than 90 psi
(620kPa), while using soap and water or equivalent
solution to check for leaks. Other approved methods
of testing for leaks may be used, if appropriate. DO
NOT USE ANY FLAME TO TEST FOR LEAKS.
FUEL SUPPLY LINES
• Propane gas lines must be accessible, but protected
against possible damage.
• Do NOT connect electrical wiring to any propane gas fuel
line or run wiring alonside the lines.
• Route gas lines away from hot engine exhausts.
• Retain gas lines with metal clamps that do not have
sharp edges.
• Install an approved length of flexible hose between the
gaseous fuel solenoid valve and rigid fuel supply lines.
The flexible line must be non-metallic, non-organic and
non-conductive. It must be approved for use with LP gas.
DANGER; GASEOUS FUEL LINES BETWEEN THE
TANK AND THE SECONDARY REGULATOR ARE
UNDER A POSITIVE PRESSURE (ABOUT 11 INCH¬
ES WATER COLUMN). GAS PRESSURE AT THE
OUTLET SIDE OF THE SECONDARY REGULATOR,
HOWEVER, IS A NEGATIVE PRESSURE AND CAN
DRAW FLAME INSIDE A LINE OR FIHING AND
CAUSE AN EXPLOSION.
EXCESS FLOW VALVE
Propane gas tanks should have an excess flovy valve,
according to NFPA 501C, Paragraph 3-4.4. This valve
and the gas lines must be carefully sized so the valve
will close when a fuel line is severed or broken.
Consult the Natural-LP Gas Association for informa¬
tion and limitations of excess flow valves.
Manual shutoff valves on the supply tank and else¬
where in the system must be fully open when operat¬
ing the generator. The excess flow valve functions
properly only if all valves are fully open.
— 15 —

EXHAUST SYSTEM
The generator exhaust system must be safely and
properly installed. Only approved mufflers and other
exhaust system parts must be used. A properly
installed exhaust system must be vapor tight, quiet
and completely safe.
CAUTION: Never tee the generator engine exhaust
pipe into the vehicle engine exhaust piping. This
causes excessive back pressure on the generator
engine. Also, water from one engine can damage
the other engine.
DANGER: THE GENERATOR ENGINE GIVES OFF
DEADLY CARBON MONOXIDE GAS THROUGH ITS
EXHAUST SYSTEM. THIS DANGEROUS GAS, IF
BREATHED IN SUFRCIENT CONCENTRATIONS, CAN
CAUSE UNCONSCIOUSNESS OR EVEN DEATH. SYMP¬
TOMS OF CARBON MONOXIDE POISONING ARE (a)
INABILITY TO THINK COHERENTLY, (b) VOMITING, (c)
TVVITCHING MUSCLES, (d) THROBBING IN TEMPLES,
(e) DIZZINESS, (f) HEADACHE, (g) WEAKNESS AND
SLEEPINESS. IF ANY OF THESE SYMPTOMS ARE
EXPERIENCED, MOVE INTO FRESH AIR IMMEDIATELY.
IF SYMPTOMS PERSIST, GET MEDICAL ATTENRON.
DO NOT OPERATE THE GENERATOR UNTIL ITS
EXHAUST SYSTEM HAS BEEN INSPECTED AND
REPAIRED.
MUFFLERS AND SPARK ARRESTORS
If the generator is not equipped with a spark arrestor
exhaust muffler and is to be used on any forest cov¬
ered, brush covered or grass covered unimproved
land, you may have to install a spark arrestor. The
spark arrestor must be maintained in effective work¬
ing order by the vehicle owner/operator.
For assistance in ordering, installing and maintaining
spark arrestor exhaust mufflers, contact your neared
authorized service facility.
A
A
Exhaust mufflers supplied by Generac are spark
arrestor types. Generac exhaust mufflers for NP and
Q series generators do not have a spark arrestor
screen, but are of the more efficient “toroid” or “swirl”
type. To remove carbon and combustion deposits
from such mufflers, remove the PLUG from muffler
and run engine for about 15 minutes. Shut down, let
the muffler cool and install the plug.
WARNING: BE SURE TO RE-INSTALL THE PLUG
FROM THE MUFFLER TIGHTLY. ENGINE VIBRA¬
TION COULD CAUSE A LOOSE PLUG TO FALL OUT.
WITHOUT THE PLUG IN PLACE, HOT ENGINE
EXHAUST IS DIRECTED OUT THE OPENING. THIS
HOT EXHAUST, DEPENDING ON THE INSTALLA¬
TION, COULD BE DIRECTED TO AREAS NOT ABLE
TO WITHSTAND THE EXTREME HEAT SUCH AS
WOODEN FLOOR BOARDS OR OTHER FLAMMA¬
BLE MATERIALS. THIS COULD RESULT IN A FIRE.
TYPE OF EXHAUST SYSTEM
Two types of exhaust systems for “NP” and “Q” series
generators are available from Generac. They include
these;
• “Out-the-bottom” exhaust system, Model 9742 (Figure
21 ) . ■
• “Out-the-side” exhaust system, Model 9743 (Figure 22 on
Page 17).
NOTE: No matter what type of exhaust kit best fits
your recreational vehicle, the mounting base has
openings for either “bottom-ouf or “side-out exhaust
systems. Use the cover plate provided with the gen¬
erator to cover the opening you do NOT use.
ITEM PART NO. DESCRIPTION QTY.
1 52108 Muffler 1
2 46591 Hanger 1
3
28238
U-Bolt 3
4
28237 Clamp, Saddle
3
5 22129
Lock VVasher
6
6
22259 5/16”Hex Nut
6
7
75238 Pipe
1
8
75411 Elbow 1
9 77643 Gasket 2
10
77642 Adaptor, Bottom Out 1
11 68527
M6-1.0 X 20mm Screw 2 ,
— 16 —

EXHAUST SYSTEM SAFETY
Maintain a clearance of at least 3 inches (76mm)
between exhaust system parts and any combustible
material (such as wood, felt, cotton, organic fibers or
other like material). If you cannot maintain the 3-inch
clearance, locate, insulate or shield the exhaust part(s)
so that the temperature of any combustible material is not
raised more than 117°F (65°C) above the ambient air
temperature.
Terminate the exhaust tailpipe such that exhaust gases
will not be drawn back into the generator compartment
and recirculated.
If there is any possibility of the tailpipe or muffler being
damaged, protect these damage prone areas by means
of a protective device (such as a “skid bar").
Install the generator exhaust system according to safe
automotive practices.
• Use exhaust system parts recommended by
Generac. Using unapproved exhaust mufflers
and exhaust system parts is the responsibility of
the person(s) installing such unauthorized parts.
• Do not terminate the exhaust system under the
vehicle.
• , Do not terminate the exhaust system under any
opening, window or vent which can be opened or
is not permanently sealed from the vehicle interi¬
or.
• Exhaust piping must be large enough to prevent
excessive back pressure on the generator
engine.
• Never tee the generator engine exhaust pipe into
the vehicle engine exhaust piping. This causes
excessive back pressure on the generator
engine. Also, water from one engine can damage
the other engine.
• Plan exhaust system installation carefully.
Comply with all applicable codes, standards and
regulations.
Use enough exhaust system hangers to prevent
any part or the system from being dislocated.
Figure 22 — Model 9743 Exhaust Kit
ITEM
PART NO.
DESCRIPTION
QTY. ITEM
PART NO.
DESCRIPTION
QTY.
1
.22129
5/16”-M8 Lockwasher
4 8
77643
Gasket
2
2
42907
M8-1.25X 16 Screw
4 9
90863
Adaptor
1
3
45771
M8-1.25 Hex Nut
2
10
79246
M6-1.0 X 20mm Capscrew 2
4
81107
Exhaust Pipe Extension
1
11 92676
Muffler Adaptor
1
5
92675A
Exhaust Muffler
1
12
95277
Outlet Adaptor Gasket
1
6
94670
1.120 Exhaust Clamp
2 13
56893
#10-24 X 1/2 Crimptite 3
7
76508
. Muffler Bracket
1
-17 —

ELECTRICAL CONNECTIONS
The following general rules apply to electrical connec¬
tions in a recreational vehicle:
• Qualified electricians who are familiar with applicable
codes, standards and regulations should install electrical
wiring.
• The wiring should comply with codes, standards and reg¬
ulations. The National Electric Code (NFPA 70), as well
as state and local codes, apply.
• Switches and circuit breakers should be of a type
approved for use in recreational vehicles and must be
mounted and installed to prevent damage from road
shock.
• Wiring must be of adequate size, with approved insulative
qualities, and properly supported.
Conduit and wire openings into generator compartment
(if used) must be vapor-sealed, to prevent entry of flam¬
mable, explosive or poisonous gases into the vehicle.
ELEamCAL JUNQION BOX
Install an approved, square electrical junction box that
has a blank cover on the interior or exterior wall of the
area you plan to install the generator (NOT on the
generator). Route the generator's AC output leads
into this junction box through approved flexible con¬
duit, and into this junction box. This is the point of first
termination for generator AC output leads.
WIRING
• Wiring should be of stranded copper to reduce chance
that vibration may cause breakage.
• Wire gauge size of wires should be large enough to han¬
dle at least 115% of the installed generator's rated maxi¬
mum current.
• If neutral conductors are used, they must be the same
size as other leg wires.
• Route power supply conductors from generator AC output
leads T1 (red) and T2 (white), T3 (black) and the green
ground wire through approved flexible conduit to the elec¬
trical junction box on the compartment wall.
If flexible metal conduit is used between the generator
and the compartment junction box, the conduit end that
terminates the compartment junction box, must be vapor-
sealed. Flexible metal conduit is NOT vapor tight along its
entire length.
• From the junction box route power supply wires through
approved conduit to either (a) double-pole, double-throw
transfer switch, or (b) approved isolation receptacle.
Connecting to a transfer switch or isolation receptacle
must prevent vehicle electrical circuits from being con¬
nected to two different power supplies at the same time
(such as generator and dockside power).
• Conductors must be rated 22rF (105“C) or must be of a
larger conductor size.
GENERATOR AC CONNEaiONS
Generator AC output leads T1 (red) and T2 (white)
and T3 (black) come out of the generator as shown in
Figure 23. Leads T1 (red) and T3 (black) are “hot,”
while T2 (white) is the grounded “neutral”. There is
also a green lead that connects to ground in the junc¬
tion box of the recreational vehicle.
Figure 23 — Generator AC Output Leads
Line T1 (red) to T2 (white) is protected against over¬
load by the circuit breaker (CB1). Use this line-to-neu-
tral connection separately to operate 120 volts, 1-
phase, 60 Hz, AC loads requiring up to 3600 watts
(3.6 kW) of power. Line T3 (black) to T2 (white) is
also protected against overload by a circuit breaker
(CB2). Use this line-to neutral connection separately
to operate similar loads. However, be sure the total
unit load does NOT exceed the maximum rating of
the generator. The neutral line (T2, white) on all units
is a grounded neutral.
NOTE: The generator may be reconnected for dual
voltage AC output. (See “Dual Voltage Reconnection
on page 3).”
CAUTION: Do NOT connect electrical loads in
excess of any circuit breaker rating or you will
develop problems with circuit breaker tripping,
which causes a loss of AC output Also, do NOT
exceed the generator's rated wattage capacity. Add
the watts or amperes of all lighting, appliance, tool
and motor loads the generator will operate at one
time. This total should be less than the unit's rated
wattage/amperage capacity.
— 18 —