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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

—