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Topic: generator electrical connection box (Read 1061 times) previous topic - next topic

generator electrical connection box

the wires that pass thru box at connection to generator apparently heated up,partially melting neutral to red hot wire.trying to figure out where these wires go into coach so i can get some slack towards generator and reinsulate them. looks like wire cap was not on tight at neutral wires...so far i am not able to see where the wires pass into coach...sure hope i don"t have go at it from bottom of coach...any knowledge would sure help!
Dale Gass
1993 U240 36                                                             

cat 3116 allison 3060

Re: generator electrical connection box

Reply #1 –
Sounds like your melted wire was from resistance caused by a loose wire nut.

But generator neutral wires have also been known to melt from carrying too many amps when generator is rated over 50 amps or 6,000 watts. This happens because most of our generators are internally wired to for 120-volt and not 240-volts.

Wiring generators for 120-volts eliminates possible issues from unbalanced 120-volt legs, but it can overload a neutral wire.

Re: generator electrical connection box

Reply #2 –
so any ideas on getting some slack in wires so i can insulate.no luck getting behind junc. box...hate to start cutting access holes
Dale Gass
1993 U240 36                                                             

cat 3116 allison 3060

Re: generator electrical connection box

Reply #3 –
Dale,

I have NO first hand information on this, as have never had the problem.  But, with your coach, I would start by assuming that the wiring from generator to ATS was run either in the central metal "trays" in the basement, or more likely in the channel on the left side of the coach.  That channel can be seen in areas under the sofa, behind the drawers in the galley, etc.

James Triana should be able to tell you which.  Then, just install another junction box in a convenient place and run new wiring from that box to the replacement one near the generator.

Brett
Brett Wolfe
EX: 1993 U240
Moderator, ForeForum 2001-
Moderator Diesel RV Club 2002-
Moderator, FMCA Forum 2009-2020
Chairman FMCA Technical Advisory Committee 2011-2020

Re: generator electrical connection box

Reply #4 –
Dale,
  I wondered the same when I took the genny out of our 93. I ended up using the original wires but there was juuuuuuuuust enough slack to get them connected. Might add that a contortionist would have had an easier time of it. Good luck and post photos if you can.
jor
93 225
95 300
97 270
99 320

Re: generator electrical connection box

Reply #5 –
yes its very tight...i wish outfit that did work to generator would have informed me of problem before re-installing generator...i have looked all under sofa,furnace,cabinets ect....cannot find where wires are run from ats to generator...i assume mr.triana works at FOT...fixing to give him a call...Barry is dead on in his theory...2 white wires from generator are discolored(slightly blackened)and insullation is burned where they connect....as he said.probably a loose wire nut....
Dale Gass
1993 U240 36                                                             

cat 3116 allison 3060

Re: generator electrical connection box

Reply #6 –
Quote from: dalegass –
yes its very tight...i wish outfit that did work to generator would have informed me of problem before re-installing generator...i have looked all under sofa,furnace,cabinets ect....cannot find where wires are run from ats to generator...i assume mr.triana works at FOT...fixing to give him a call...Barry is dead on in his theory...2 white wires from generator are discolored(slightly blackened)and insullation is burned where they connect....as he said.probably a loose wire nut....

If you should find wire nuts on these connections they need to hit the garbage can where they belong asap.  Use properly sized Kerneys, also called split bolt connectors for any splices. 

Chuck
"Not so  long ago we were a nation of risk takers, riding five million pounds of  thrust straight into space."  Joe Gresh
Chuck Pearson
1996 U295
2018 Can Am X3 TurboRS

Re: generator electrical connection box

Reply #7 –
thanks chuck.not familar with kerneys but i will find some..so far,no luck on finding back side of box.looks like i might have to remove sofa and cut hole in floor...yikes
Dale Gass
1993 U240 36                                                             

cat 3116 allison 3060

Re: generator electrical connection box

Reply #8 –
You can occasionally find these at home improvement stores but the best bet is to go by an electrical supplier.  What you want is one that is sized for the size and number of wires to be connected, don't buy oversized ones, get the right size.  Also pick you up some genuine Scotch electrical tape.  The proper way of installing them is to bolt them down tightly, apply a couple wraps of friction tape, and then vinyl electrical tape.  You will have a permanent, zero measurable resistance connection. 

Split Bolt Connector products, buy Split Bolt Connector products from

Chuck
"Not so  long ago we were a nation of risk takers, riding five million pounds of  thrust straight into space."  Joe Gresh
Chuck Pearson
1996 U295
2018 Can Am X3 TurboRS

Re: generator electrical connection box

Reply #9 –
I recently saw some split bolt connectors at my local true value store while looking for some other items.
Felix and Gail Mathieu
99 U320
Jeep Liberty CRD
Build number 5522