Generac Power Systems 91355 User's Manual
Contents
1. 21 BATTERY INSTALLATION Recommended 22 Battery 22 Battery 22 Battery Compartment 22 POST INSTALLATION TESTS Before Initial Start Up 23 23 Checking No Load Voltage 23 Testing 23 24 Adjusting No Load 24 25 Voltage Regulator 25 INSTALLATION CHECK 26 ELECTRICAL 27 MAJOR FEATURES AND DIMENSIONG 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 installation requirements Give serious consid eration to information and instructions in the Manual both for safety and for continued reliable operation of the equipment Because of the different recreational vehicle models and the variations between the models it would be extremely difficult if not imprac2. 11 GASOLINE FUEL 12 12 Generator Fuel Supply 12 PROPANE GAS FUEL 13 Parts Not Included in Fuel System 13 Some Important Considerations 13 Vapor Withdrawal 2 2 22222221 14 Primary 14 Gaseous Carburetion EE 14 Fuel Supply 2 15 Excess 15 Leakage 15 EXHAUST 5 5 16 Mufflers and Spark 16 Type of Exhaust 16 Exhaust System Safety 16 17 ELECTRICAL CONNECTIONS Electrical Junction Box 18 18 Generator Connections 18 19 Ground Fault Circuit Interruptors 19 Power Supply Cord c csscsssssssessesesssesssevesevesssesecens 19 Isolating Different Power 19 20 DUAL VOLTAGE RECONNECTION Reconnection Procedure
3. DESCRIPTION Clamp Saddle Lock Washer 5 16 Nut Pipe Elbow Gasket Adaptor Bottom Out M6 1 0 x 20mm Screw Figure 21 Model 9742 Exhaust System 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 piug 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 series generators are available from Generac They include these Out the bottom exhaust system Model 9742 Figure 21 e 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 b
4. Negative Rated maximum continuous current 240 volts is 18 8 amps ENGINE SPECIFICATIONS Type of Engine 50 1 Cylinder 4 Cycle NP 66G LP Q 70G LP Q 40G Q 55G LP V Twin 4 Cycle Number of Cylinders Q 40G Q 55G LP NP 66G LP 70 2 NP 50G LP 1 Valve Configuration Overhead Valves Cooling Method Air Cooled Rated Horsepower NP 50G LP 13 at 3600 RPM 40 16 3600 5506 2 16 at 3600 RPM NP 66G LP 16 3600 Q 70G LP 19 at 3600 RPM Displacement 363 480 480 66 480 70 570 Compression 8 6 101 Cylinder Block Aluminum with cast iron sleeve Mechanical fixed speed Air Cleaner Paper element with foam pre cleaner Staite ris 12 volts DC electric Q 70G LP If ambien
5. 120V INSTALLER S HOT NEUTRAL HOT CONNECTIONS Ba di l 240v 1 DUAL VOLTAGE 41 AC OUTPUT 21 BATTERY INSTALLATION RECOMMENDED BATTERY Install a battery that meets the following require ments Battery must be a 12 volt automotive type storage bat tery For prevailing ambient temperatures above 32 F 0 C use a battery rated 70 amp hours and capable of deliver ing 360 cold cranking amperes For prevailing ambient temperatures below 32 F 0 C use a battery rated 95 amp hours and capable of deliver ing 450 cold cranking amperes IMPORTANT IF THE BATTERY IS TO BE USED TO POWER OTHER VEHICLE ACCESSORIES AS WELL AS START THE GENERATOR YOU MAY NEED A BATTERY WITH LARGER CAPACITY BATTERY CABLES Using battery cables that are too long or too small diameter may cause a drop in voltage which causes starting problems For best cold weather starting the voltage drop between battery terminals and the gen erator connection point should not exceed 0 12 volts per 100 amperes of cranking current generators are rated at about 100 amperes of cranking current Select battery cables based on a cable length and b prevailing ambient temperatures Generally the longer the cable and the colder the weather the larg er the cable size must be as in chart the next column 16 to 20 4 5 to 6 For wa
6. GENERATOR RESTRAINT Use four 3 8 16 hardened steel bolts parage 5 to fasten the generator to the supporting trame 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 Figure 5 Generator Restraint typical 1 2 inch thick Sb be 5 2 EE i Tubular Metal SupportFrame 22 87 inches 58 08cm Vehicle Chassis Metal Lined Bottom 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 i Figure 6 Generator Model 9164 Tray The tray on which the generator rests is hinged per mitting it to swing downward after two side support rails and center support rail are unbolted Instructions for tray installation are included with the tray mounting kit GENERATOR COMPARTMENTS The generator set may or may not be installed inside a compartment that is constructed sp
7. and mechanically secured Such seams may be manufactured welded bolt ed riveted or screwed Manufactured lock seams are shown in Figure 7 Figure 7 Types of Lock Seams Fold Locked Off Set Standing Double Seam Double Lock a a SL Acme Lock Gordon 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 the ceiling AFTER you have lined the compartment with metal and you have installed sound insulation Figure NOTE Refer to the Dimensions and Features draw ing in the back of this manual Figure 8 Provide Clearance Around Generator 1 INCH 2 54 MINIMUM CLEARANCE ON ALL SIDES PLYWOOD gt TOP VIEW GENERATOR Rene METAL LINING 00087 COMPARTMENT CONSTRUCTION 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 7 Line the exterior underside of the compartment floor with 26 gauge galvanized steel Vapor seal all c
8. Figure 12 Typical Compartment Door Construction STRENGTHENING INSULATION A TIMES MUST EQUAL AT LEAST 100 FREE AIR OPENING 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 Without 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 FLAMMABLE OR EXPLOSIVE ASES 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 muffle
9. 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 4 GAS POSITIVE PRESSURE ZERO PRESSURE LOW PRESSURE AREA 14 The following facts about 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 FUEL SUPPLY LINES 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 EXCESS FLOW VALVE Propane gas tanks should have an excess flow valve according to NFPA 501C Paragraph 3
10. 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 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 utilit
11. Figure 15 Figure 15 Suspended Mount Inlet Door od MINIMUM FREE INLET AREA 100 INCHES ductwork Figure 16 on 11 The installer must be sure air is available to the top of generator since air inlets are located at the op 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 Figure 16 Air Inlet Using Ductwork Figure 17 Air Inlet in Vehicle Skirt RECOMMENDED CLEARANCE 1 1 2 38 1MM MINIMUM CLEARANCE 1 IN 25 4MM VEHICLE VEHICLE FLOOR ENGINE SIDE VIEW COMPENSATING FOR RESTRICTIONS 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
12. SPECIFICATIONS GENERATOR SPECIFICATIONS 50 3600 3600 3600 3600 3600 eae ES a 2 2570 4200 50 40 50 60 700 wo 40 240 120 Ps ne 75 48 5 a o gt 0 60 222 Ibs 25 5 18 5 inches Height 16 68 inches f All units except Q 40G are reconnectable to eaei Solid state with flywheel magneto 120 240 volts dual voltage output When reconnect Recommended Spark Plugs Champion RC12YC ed for dual voltage units are not listed per RVIA Spark Plug 0 030 inch 0 8mm Rated maximum continuous current at 240 volts is ain Generac No 70185 20 8 amps Crankcase Oil 1 5 U S quarts Rated maximum continuous current at 240 volts is Battery Voltage 12 volts DC 22 9 amps Recommended Battery Rated maximum continuous current at 240 volts is Rating 70 amp hour 27 5 Cranking 20 0 4 4 4 0 360 Rated maximum continuous current at 240 volts is Cranking Current 100 DC amperes 29 1 amps Battery Ground
13. connect ed at the same time POWER SUPPLY CORD The power supply cord must comply with all applica ble codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected GROUND FAULT CIRCUIT INTERRUPTERS The National Electric Code NFPA 70 551 7 requires that you install ground fault circuit interrupters GFCls on all external and some internal electrical receptacles Contact your manufacturer or dealer for recommendations Figure 24 Transfer Switch Isolation Method FROM HACR BREAKER JUNCTION FLEXIBLE CONDUIT 2ND AIR CONDITIONER VEHICLE WIRING VEHICLE A C DISTRIBUTION PANEL MAIN BREAKER HACR BREAKERS FOR AIR CONDITIONERS p gt BREAKERS POWER SUPPLY CORD 19 Figure 25 Installation with Isolation Receptacle DOCKSIDE POWER RECEPTACLE JUNCTION BOX FLEXIBLE CONDUIT VEHICLE A C DISTRIBUTION PANEL DUAL VOLTAGE NOTE sure to read Reconnection for Dual Voltage on page 3 Installers must be aware that if they reconnect the generator for dual voltage AC out put the generator is not listed per RVIA When reconnecting these units for dual voltage replace the existing circuit breakers with a single suit ably rated circuit breaker RECONNECTION PROCEDURE NOTE Not applicable to Q 40G model 1 Gain access to t
14. 2 After taking frequency and voltage readings determine if any adjustment is required as follows If frequency and voltage are both good adjust ment is needed if frequency is high low adjust the engine gov ernor to obtain 62 Hertz at no load Then recheck voltage reading If frequency is good but voltage is high or low adjust the voltage regulator to obtain 124 volts at 62 Hz no load NOTE the generator has been reconnected to vide a dual voltage AC output Page 18 line to line frequency and voltage readings may be used Frequency at no load should be about 62 Hz line to line voltage should be about 244 252 volts TESTING UNDER LOAD After it has been determined that no load frequency and voltage are correct apply electrical loads equal to about 75 100 of the unit s rated wattage amperage capacity Check with electrical load applied The frequency should not drop below about 58 Hz under load Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling air flow is available You must not allow the unit to over heat during prolonged operation 23 NOTE The generator engine is equipped with a high oil temperature switch The switch has normally open contacts which will close at about 284 140 C When the switch contacts close engine shuts d
15. 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 Propane gas lines must be accessible but protected 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 vaive The leak test must comply fully with NFPA Paragraph 318 All 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 leaks may be used if appropriate DO NOT USE ANY FLAME TO TEST FOR LEAKS 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 FITTING AND CAUSE AN EXPLOSION 15 EXHAUST SYSTEM The generator exhaust system must be safely and
16. INSTALLATION Manual AIR COOLED RECREATIONAL VEHICLE GENERATORS GENERAG GENERAL SAFETY RULES COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE RECREATIONAL VEHICLE THE MANUFACTURER SUGGESTS THAT THESE RULES FOR SAFE OPERATION BE 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 other 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
17. OR Factory installed generator fuel s components include a fuel filter 12 volt DC electric pump 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 generat
18. OT 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 6 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 diaphragm 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
19. OVERSPEEDING THE ENGINE BEFORE INITIAL START UP Before starting complete the following 1 Check engine crankcase oil level and if necessary fill to dipstick FULL mark with the recommended oil Do not fill above FULL mark 2 Check the fuel supply Gaseous fue lines must have been properly purged and leak tested in accordance with applicable fuel gas codes All fuel shutoff valves in the fuel supply lines must be open DANGER IF AN LP PROPANE GAS FUEL SYS TEM HAS BEEN INSTALLED IT MUST HAVE BEEN PROPERLY TESTED FOR LEAKS BEFORE OPER ATING THE SYSTEM IN COMPLIANCE WITH ANSI A119 2 NFPA 501C NO LEAKAGE IS PERMITTED YOU MUST BE SURE NO GASEOUS FUEL VAPORS ENTER THE VEHICLE INTERIOR INITIAL START When absolutely certain that the unit has been prop ae installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator main circuit breakers to their OFF or OPEN position 2 Refer to the Owner s Manual shipped with unit for crank ing and starting instructions The engine may require more cranking for initial starting since the fuel lines have to be primed 3 Let the engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When engine has stabilized and warmed u
20. Purpose and Scope of 2 Say 2 Standards Booklets 2 Equipment Description 2 Engine Generator Operating 2 Reconnection for Dual 3 SPECIFICATIONS Generator Specifications 4 Engine Specifications 4 Recommended 4 Fuel Consumption 224024 0 4 Recommended Engine 4 LOCATION AND SUPPORT Generator daisies Generator Support Suspended Mounting Generator iii Swing Mount Generator Tray 6 GENERATOR COMPARTMENTS Compartment 7 Compartment 7 Sound Insulation Materials 8 Compartment Floor Cutouts 8 ACOUSTICS 9 COOLING AND VENTILATION AIR Generator 10 Cooling Air Inlet 5 10 Compensating for Restrictions 11 Testing the
21. S 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 more effective than when a single material is used COMPARTMENT FLOOR CUTOUTS You must 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 Restraint on Page 6 DANGER FUEL LINES AND EXHAUST PIPING MUST NOT PENETRATE INTO VEHICLE LIVING AREA Figure 10 Compartment Floor Cutout FRONT AIR FILTER SIDE ACOUSTICS 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 compartm
22. UALIFIED 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 PARTS NOT INCLUDED IN FUEL SYSTEM The propane fuel system does NOT include such 2 items as a gas tank gas piping fittings d valves and e primary regulator used to store the gaseous fuel and deliver it to the gaseous fuel sole noid Figure 19 PROPANE GAS FUEL SYSTEM 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 MITTED 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 leaka
23. al voltage AC output See Dual Voltage Reconnection on page 3 CAUTION Do NOT connect electrical loads in 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 tess than the unit s rated wattage amperage capacity 18 CONDUIT Route the conductors between the generator and the junction box through approved flexible conduit The following general rules apply Cut wiring to the required length and allow extra wire for junction box connections Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation Route conduit so it does not interfere with generator movement If you use metallic conduit vapor seal the end of the con duit where it enters the junction box Do this because flexible metallic conduit is not vapor proof along its entire length ISOLATING DIFFERENT POWER SOURCES Conductors from the junction box must terminate in a double pole double throw transfer switch Figure 24 An alternate method for isolating different power sources is by using an isolating receptacle Figure 25 on Page 20 Whichever method you use you must be certain that both power sources are NOT
24. ase has openings for either bottom out or side out exhaust systems Use the cover plate provided with the gen erator to cover the opening you do NOT use 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 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 enough exhaust system hangers to prevent any part of the system from being dislocated 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 i
25. 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 1 GASOLINE FUEL SYSTEM Installing a gasoline fuel system Figure 18 for recre ational vehicle 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 ENGINE CARB FUEL FILTER INLET AIR FILTER FUEL PUMP 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 GASOLINE VAPORS MUST NOT ENTER THE VEHICLE INTERI
26. 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 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 A 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 ling 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
27. e GOVERONOR SPRING down one slot on LEVER For greater stability move the GOVERNOR SPRING up one slot on LEVER 6 After repositioning the SPRING LEVER slot recheck frequency reading and if necessary ADJUSTER NUT to obtain 62 Hertz at no load 7 When frequency is correct at no load check the AC volt age reading If voltage is incorrect the regulator may require adjustment VOLTAGE REGULATOR ADJUSTMENT The voltage regulator is housed inside the generator contro panel Remove the cover and front panel as shown in Figure 32 Figure 32 Removing Cover and Panel VOLTAGE REGULATOR With frequency at 62 Hertz AC voltage should read 124 volts If voltage is incorrect slowly tum the VOLT AGE ADJUST POT on voltage regulator Figure 33 until AC voltage is correct Figure 33 Voltage Regulator VOLTAGE ADJUST POTENTIOMETER 25 INSTALLATION CHECK LIST LOCATION AND SUPPORT ___1 The generator is properly located ___2 The generator is properly supported 3 The generator is properly restrained COMPARTMENT 1 Compartment construction is proper ____2 Holes openings are vapor sealed ___3 Compartment size is correct ___4 Compartment is vapor sealed 5 Sound insulation is ___6 Floor cutouts properly completed COOLING and VENTILATING AIR 22 1 Air flow is adequate ___2 Air inlet opening is correct 3 Compensate for r
28. ecifically for housing a generator This section applies to generator compartments when they are installed The foliowing general rules apply to compartments The generator compartment should be either of or lined with 26 gauge galvanized steel IMPORTANT ALUMINUM 18 NOT AN ACCEPT ABLE ALTERNATIVE TO GALVANIZED STEEL DUE TO ALUMINUM S LOW MELTING POINT 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 wale vapor tight by design should be caulked IMPORTANT CAULKING MUST BE DONE SO THAT THE CAULKING MATERIAL WILL STAY PLACE PERMANENTLY PRESSING SUCH MATE RIALS AS PUTTY TAPE ONTO JOINTS AND SEAMS WILL NOT MEET THAT REQUIREMENT A HIGH QUALITY SILICONE RUBBER SEALANT 15 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
29. ent IMPORTANT ANY METHOD USED TO REDUCE NOISE MUST NOT ADVERSELY AFFECT THE FLOW OF COOLING AND VENTILATING AIR INTO OR OUT OF THE COMPARTMENT 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 EXTERIOR SOUND INSULATION METAL LINER PLYWOOD 5 8 THICK FIBERGLASS INSULATION PLYWOOD 5 8 THICK Use 5 8 inch thick or 3 4 inch thick plywood in the com partment e 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 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 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 density See 12 A DANGER DO NOT INSTALL ANY INSULATION OR
30. estrictions 4 Installation has been tested GASOLINE FUEL SYSTEM ___1 Fuel tank complies with code ___2 Fuel system properly installed EXHAUST SYSTEM ___1 Complies with code requirements 2 2 Properly and safely installed OPTIONAL PROPANE GAS SYSTEM ___1 System is properly installed 2 Correct pressure at regulator inlet 3 Rated flow of primary regulator is ___4 All parts are properly installed ___5 System was properly tested for leaks 6 System properly tested adjusted ELECTRICAL CONNECTIONS 1 Comply with code requirements Junction box properly installed 3 Wiring meets all standards 4 All connections are correct ___5 Conduit properly installed and sealed 6 Generator properly bonded to vehicle BATTERY INSTALLATION 1 Recommended battery is installed 2 Recommended cables are installed i 3 Cables are clean and tight 4 Cables are properly connected 5 Proper ventilation is provided POST INSTALLATION TESTS _ 1 All tests properly completed 26 KNOWN VALUES 3 PHASE Volts Current Power Factor 1 73 1000 1000 AMPERES kW Volts Power Factor WATTS Volts Amps Power Factor NO OF ROTOR Frequency RPM POLES FREQUENCY RPM No of Rotor Poles KILOWATTS kW Frequency No of Rotor Poles HP x 0 746 Eff
31. ge Test the entire fuel system for leaks using approved test methods Figure 19 Typical Propane Gas Fuel System CARBURETOR REGULATOR LOCKOFF SOLENOID VAPOR 0 WIDTHDRAWAL TANK Optimum gas pressure at the inlet to the gaseous fuel solenoid valve and secondary regulator is 11 inches water column The installer 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 N
32. he engine to operat at a lower speed than the rotor Engine speed is held nearly constant a mechani cal fixed speed govemor as follows NP 50LP NP 66G LP Series 40 2570 rpm Series Q 55G LP 2570 rpm Series NP SOG LP 2570 rpm Series 66 2700 rpm Series Q 70G LP 2570 rpm 2 RECONNECTION 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 two 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
33. he 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 a
34. he generator panel interior by removing the generator cover and the front panel Figure 26 Figure 26 Removing Cover and Panel 2 Disconnect stator leads 11 33 1 red and black from the main circuit breakers CB1 and CB2 Figure 27 Set aside leads T1 red and T3 black for later use Figure 27 Existing Wiring Connections 120 Volts 3 Disconnect stator leads 11 and 33 from the 4 tab terminal connector TC 4 Disconnect stator leads 22 and 44 from the grounding terminal GT 5 Disconnect one of the two 2 white leads from the grounding terminal 6 Remove existing circuit breakers 1 and install new appropriately rated circuit breaker 7 Connect stator leads 11 and 44 to the new circuit breaker as shown in Figure 28 Also attach leads T1 red and T3 black to the circuit breaker as shown 8 Connect stator leads 22 and 33 to the grounding terminal GT as shown Figure 28 9 Be sure a neutral lead is installed and routed from the grounding terminal for connection loads 10 Routs leads T1 red and T3 black and the grounded neutral lead through the conduit clamp and out of the panel 11 Reassemble the panel and generator cover Loads may now be connected as follows Figure 28 T3 black to Neutral 120 volts T1 red to Neutral 120 volts e 1 to 240 volts Figure 28 Reconnected for Dual Voltage APPROVED CIRCUIT BREAKER
35. iciency Efficiency kW required for Motor Horsepower Efficiency Motor AMPERES Ohms Volts R E VOLTS AMPERES R RESISTANCE OHMS PF POWER FACTOR 27 MAJOR FEATURES AND DIMENSIONS Q 40G NP 66G LP Q 55G LP Q 70G LP CONTROL PANEL SPARK PLUG both sides OIL FILL AND LEVEL FUEL FILTER OIL ORAIN PLUG FUEL PUMP OIL FILTER AIR FILTER 8 GROUND LUG 15 75 STARTER CONTACTOR MAJOR FEATURES AND DIMENSIONS NP 50G LP CUSTOMER CONNECTION REMOTE START my CUSTOMER CONNECTION a 5 1 ea ery POVER SUPER VINTER LEVER AIR CLEANER 4 S 1 22 H i i 5 FILTER 190 17 09 FOR STORING UNIT 10 COACH 4 REQUIRED SIDE Exmaust CONNECTION OPTIONAL gt 3 6 16 TAPPED FILTER SIDE DIMENSIONS IN ARE INCHES BOTTOM OUT EXrAUST CONE CTION OPTIONAL VIEW FROM 389 15 311 FRONT AIR 194 7 64 183 7 20 11 16 19 9 1 571 97 12 6 gt gt 29 GENERAG Se has ee PO Box 8 Waukesha WI 53187 Telephone 414 544 4811 FAX 414 544 4851
36. nteri 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 Figure 22 Model 9743 Exhaust Kit DESCRIPTION Gasket Adaptor M6 1 0 x 20mm Muffler Adaptor Outlet Adaptor Gasket 10 24 x 1 2 Crimptite PART NO 77643 90863 79246 92676 95277 56893 DESCRIPTION 5 16 Lockwasher 8 1 25 x 16 Screw 9 8 1 25 Hex Nut 10 Exhaust Pipe Extension 11 Exhaust Muffler 12 1 120 Exhaust Clamp 13 Muffler Bracket 7 TEM NO QTY 1 22129 2 42907 3 45771 4 81107 5 92675A 6 7 ITEM 8 94670 76508 47 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
37. obtained from same address as Item 1 3 ANSI 1 1975 and ANSI 119 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANS 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 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to Generac NP and 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 ca NOTE All units except the Q40G be recon nected for a dual voltage output of 120 240 volts AC Power wattage Max Rated Current 5500 7000 P5000 4500 6600 ENGINE GENERATOR OPERATING SPEED The revolving field rotor is driven by 4 cycle engine through a pulley 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 t
38. ompartment seams and joints to prevent poisonous flammable or explosive vapors from entering the vehicle 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 AREA
39. or 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 fuel lines so if they leak 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 It must be approved for use with gasoline The hose should be at least 6 inches longer than is need ed to prevent the hose from rupturing if the generator shifts or settles E DANGER LP PROPANE GAS IS HIGHLY EXPLO SIVE THE GAS 15 HEAVIER THAN AIR AND TENDS TO SETTLE IN LOW AREAS WHERE EVEN THE SLIGHTEST SPARK CAN IGNITE IT AND CAUSE AND EXPLOSION ONLY COMPETENT Q
40. oward GOVERNOR SHAFT For greater stability move the GOVERNOR SPRING to the right on notched teeth of BRACKET 6 After repositioning the SPRING on the BRACKET notched teeth recheck frequency reading and if necessary read just ADJUSTER NUT to obtain 62 Hertz at no load 7 When frequency is correct at no load check the AC volt age reading If voltage is incorrect the voltage regulator may require adjustment For Series NP 50G LP generators proceed as follows Figure 31 NOTE The governor system is located behind the engine wrapper on the left hand side of the unit 1 Loosen the GOVERNOR CLAMP BOLT 2 Push spring end of GOVERNOR LEVER clockwise to wide open throttle position of lever Hold the GOVERNOR LEVER at wide open throttle and with a pair of pliers rotate the GOVERNOR SHAFT fully counter clockwise Figure 31 Governor Adjustment for NP 50G GOVERNOR SPRING GOVERNOR GOVERNOR CLAMP BOLT ADJUSTOR NUT GOVERNOR SHAFT 24 While holding the GOVERNOR SHAFT fully clock wise and the GOVERNOR LEVER at wide open throttle tighten the GOVERNOR CLAMP BOLT to 70 inch pounds 8N m 3 Start engine let it stabilize and warm up at no oad 4 Turn the ADJUSTER NUT to obtain frequency reading of 62 Hertz 5 Determine if the GOVERNOR SPRING is properly locat ed in the slot of the GOVERNOR LEVER as follows e If droop is excessive move th
41. own automatically IMPORTANT GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOLING ADJUSTING NO LOAD FREQUENCY With engine stopped visually inspect the ANTI LASH SPRING Replace spring if broken or damaged attach if disconnected For Series Q 40G NP 66G LP Q 55G LP and Q 70G LP generators proceed as follows Figure 30 1 Loosen the GOVERNOR CLAMP NUT 2 Push spring end of GOVERNOR LEVER all the way up to its wide open throttle position Hold the GOVERNOR LEVER at wide open throttle and insert screwdriver into slotted end of GOVER NOR SHAFT Rotate the GOVERNOR SHAFT fully counterclockwise CCW While holding the GOVERNOR SHAFT fully coun terclockwise and the GOVERNOR LEVER at wide open throttle tighten the GOVERNOR CLAMP NUT to 70 inch pounds 8 N m Figure 30 Governor Adjustment for NP 66G et al IDLE STOP SCREW gt CARBURETOR 7 THROTTLE LEVER ADJUSTER NUT AS ANTI LASH SPRING OTC CECE GOVERNOR SPRING ADJUSTMENT CLAMP NUT GOVERNOR LEVER 3 Start engine let it stabilize and warm up at no load 4 Turn the ADJUSTER NUT to obtain a frequency reading of 62 Hertz 5 Determine if the GOVERNOR SPRINGis properly located in the notched teeth of the GOVERNOR ADJUSTMENT BRACKET as follows If droop is excessive move the GOVERNOR SPRING to the left on the notched teeth of BRACKET t
42. p check the no load voltage and frequency See Checking No Load Voltage and Frequency Initial tests and adjustments done at no load condition 6 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load See Testing Under Load Run the unit at least 30 minutes with loads applied 7 Turn off all electrical loads by setting the generator main circuit breakers to OFF or OPEN 8 Let the unit run at no load for a few minutes to stabilize internal engine generator temperatures Then shut down the engine IMPORTANT THE GENERATOR SET WAS THOR OUGHLY TESTED AND ADJUSTED AT THE FAC TORY BEFORE SHIPPING NO ADDITIONAL ADJUSTMENT SHOULD BE NECESSARY ONLY QUALIFIED SERVICE TECHNICIANS WHO HAVE BEEN TRAINED SHOULD PERFORM ADJUST MENTS OUTLINED IN THIS MANUAL CHECKING NO LOAD VOLTAGE AND FREQUENCY Connect an accurate AC voltmeter and an AC fre guancy meter across the generator s AC output leads his can be done at a convenient point in the circuit such as the transfer switch terminals isolatin receptacle Connect the meters across lines T1 2 white across line black white Line to neutral readings will be taken with unit at no load condition 1 With generator running stabilized and warm check the AC frequency and voltage Frequency shoud be about 62 Hz voltage about 122 126 volts AC
43. pply 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 LOCATION AND SUPPORT 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
44. 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 SUFFICIENT CONCENTRATIONS CAN CAUSE UNCONSCIOUSNESS OR EVEN DEATH SYMP TOMS OF CARBON MONOXIDE POISONING ARE a INABILITY TO THINK COHERENTLY 0 VOMITING TWITCHING MUSCLES d THROBBING IN TEMPLES DIZZINESS f HEADACHE 9 WEAKNESS AND SLEEPINESS IF ANY OF THESE SYMPTOMS ARE EXPERIENCED MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL ATTENTION 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 maintainin spark arrestor exhaust mufflers contact your neares authorized service facility
45. r to cool it The heated air flow is then deflected out the bottom toward the ground Figure 13 Air Flow Through Engine Generator AIR OUT AIR OUT J 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 Restrictions 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 CLEARANCE ALLOW 1 ON ALL SIDE WALLS Figure 14 Air Inlet in Compartment Door TOO INS MINIMUM FREE INLET 224559222 AREA 100 INCHES When the unit is installed on a suspended mounting system one of several different methods of supplying air flow may be used as follows e Provide door in the vehicle skirt having an air inlet opening
46. re 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 221 F 105 C or must be of a larger conductor size GENERATOR AC CONNECTIONS 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 du
47. rm weather use No 2 cable up to 20 feet BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or termi nal indicated by a POSITIVE POS or to the large lug on the starter contactor Figure 29 2 Connect the battery cable from the battery post indicated by a NEGATIVE NEG or to the frame ground connec tion Figure 27 3 Connect cables so the connectors are clean and tight NOTE Check to be sure the battery cable boot for the starter cable has been installed BATTERY COMPARTMENT Install the generator battery in its own vented com partment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compart ment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage Figure 29 Connecting Battery Cables STARTER CONTACTOR GROUND LUG ATTACH NEGATIVE BATTERY CABLE TO ONE OF THESE LUGS POST INSTALLATION TESTS The air cooled generator set was factory tested and adjusted to provide maximum power You should not be required to adjust the unit any further except under special circumstances WARNING DO NOT MAKE ANY UNNECESSARY ADJUSTMENTS FACTORY SETTINGS ARE COR RECT FOR MOST APPLICATIONS WHEN MAKING ADJUSTMENTS HOWEVER BE CAREFUL TO AVOID
48. t temperature is usually below 32 F 0 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 RECOMMENDED ENGINE OIL Use oil classified For Service SF and having an SAE viscosity rating of 10W 30 Engine crankcase oil capacity is 1 5 U S quarts 1 6 liters pee ee 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 t
49. tical 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 serve 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 10 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 0 1 NFPA Standard 501C Standard for Recreational Vehicles available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 70 NFPA Handbook of the National Electric Code
50. 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 ELECTRICAL JUNCTION BOX Install an approved square electrical junction box that has a blank cover on the interior or exterior wall of the area you 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 e Wiring should be of stranded copper to reduce chance that vibration may cause breakage e 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 wail 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 enti
51. y 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 A Storage batteries give off EXPLOSIVE hydrogen gas while charging The battery used for cranking and starting this generator shold be installed in its own vented 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 RULEG inside cover GENERAL INFORMATION
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