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 BGE, NHE
Emerald Plus Series

965−0628
Printed U.S.A.
10−96
 ! !
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.

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by any means, is strictly prohibited.
Table of Contents
SECTION TITLE PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Installation Codes and Standards for Safety . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Genset Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Compartment Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Under-Floor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
4 VENTILATION AND ACOUSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
5 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Muffler Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Exhaust Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Tailpipe Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
6 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Gasoline Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Propane (LPG) Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Propane (LP-Vapor) Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
7 ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
DC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
8 INSTALLATION CHECKS AND START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Initial Starting and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Installation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9 OUTLINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

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i
Safety Precautions
Thoroughly read the INSTALLATION MANUAL • Do not work on the genset when mentally or
before installing the genset. Safe operation and physically fatigued or after consuming alcohol or
top performance can be obtained only with prop- drugs.
er genset installation. • Carefully follow all applicable local, state and
The following symbols in this Manual alert you to po- federal codes.
tential hazards to the operator, service person and
equipment. GENERATOR VOLTAGE IS DEADLY!
Alerts you to an immediate hazard • Generator output connections must be made by
which will result in severe personal injury or a qualified electrician in accordance with appli-
death. cable codes.
WARNING Alerts you to a hazard or unsafe prac- • The genset must not be connected to the public
tice which can result in severe personal injury or utility or any other source of electrical power.
death. Connection could lead to electrocution of utility
workers, damage to equipment and fire. An ap-
CAUTION Alerts you to a hazard or unsafe prac- proved switching device must be used to prevent
tice which can result in personal injury or equip- interconnections.
ment damage.
• Use caution when working on live electrical
Electricity, fuel, exhaust, moving parts and batteries equipment. Remove jewelry, make sure clothing
present hazards which can result in severe personal and shoes are dry and stand on a dry wooden
injury or death. platform on the ground or floor.
GENERAL PRECAUTIONS FUEL IS FLAMMABLE AND EXPLOSIVE
• Keep ABC fire extinguishers handy. • Keep flames, cigarettes, sparks, pilot lights,
• Make sure all fasteners are secure and torqued electrical arc-producing equipment and switches
properly. and all other sources of ignition well away from
areas where fuel fumes are present and areas
• Keep the genset and its compartment clean. Ex- sharing ventilation.
cess oil and oily rags can catch fire. Dirt and gear
stowed in the compartment can restrict cooling • Fuel lines must be secured, free of leaks and
air. separated or shielded from electrical wiring.
• Before working on the genset, disconnect the • Use approved non-conductive flexible fuel hose
negative (- ) battery cable at the battery to pre- for fuel connections at the genset.
vent starting. ENGINE EXHAUST IS DEADLY!
• Use caution when making adjustments while the
• Learn the symptoms of carbon monoxide poi-
genset is running—hot, moving or electrically
soning in this Manual.
live parts can cause severe personal injury or
death. • Never sleep in the vehicle while the genset is
running unless the vehicle has a working carbon
• Used engine oil has been identified by some monoxide detector.
state and federal agencies as causing cancer or
reproductive toxicity. Do not ingest, inhale, or • The exhaust system must be installed in accor-
contact used oil or its vapors. dance with the genset Installation Manual.
• Benzene and lead in some gasolines have been • Do not use engine cooling air to heat the vehicle
identified by some state and federal agencies as interior.
causing cancer or reproductive toxicity. Do not • Make sure there is ample fresh air when operat-
ingest, inhale or contact gasoline or its vapors. ing the genset in a confined area.

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ii
 MOVING PARTS CAN CAUSE SEVERE BATTERY GAS IS EXPLOSIVE
PERSONAL INJURY OR DEATH
• Do not wear loose clothing or jewelry near mov- • Wear safety glasses and do not smoke while ser-
ing parts such as PTO shafts, fans, belts and pul- vicing batteries.
leys.
• When disconnecting or reconnecting battery
• Keep hands away from moving parts. cables, always disconnect the negative (- ) bat-
• Keep guards in place over fans, belts, pulleys, tery cable first and reconnect it last to reduce arc-
etc. ing.

MBL-1

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iii
1. Introduction
ABOUT THIS MANUAL installation. These sets meet the basic require-
ments of the Standard for Safety for Engine Gener-
This manual is a guide for the installation of the gen- ator Sets for Recreational Vehicles, ANSI/RVIA
erator set (genset) models listed on the front cover. EGS-1. They are suitable for installation in accor-
Proper installation is essential for top performance. dance with:
Read through this manual before starting the instal-
lation. • The National Electrical Code, NFPA No. 70, Ar-
ticle 551
This manual addresses the following aspects of the
installation: • The Standard on Recreational Vehicles, NFPA
No. 501C
• Location and Mounting
Federal, State and local codes, such as the Califor-
• Exhaust Connections nia Administrative Code—Title 25 (RV installation),
might also be applicable. Installation codes and rec-
• Fuel Connections
ommendations can change from time-to-time and
• Electrical Connections (AC power output, con- are different in different countries, states and mu-
trol and battery) nicipalities. It is recommended that the standards in
• Startup Table 1-1 be obtained for reference.

WARNING Improper installation can result in

severe personal injury, death and equipment TABLE 1-1. REFERENCE CODES AND
damage. The installer must be qualified to per- STANDARDS
form the installation of electrical and mechani- NFPA Nos. National Fire Protection Association
70 & 501C 470 Atlantic Avenue, Boston, MA 02210
cal equipment.
Recreational Vehicle Industry Association
ANSI/RVIA-EGS-1
See the Operator’s Manual for operation and main- 14650 Lee Road, Chantily, VA 22021
tenance and the Service Manual for service. California Adminis-
State of California Documents Section
trative Code—Title
P.O. Box 1015, North Highlands, CA 95660
NOTE: Manuals are updated from time to time to re- 25, Chapter 3
flect changes in the equipment and its specifica-
tions. For this reason, only the copy of the installa-
tion manual supplied with the genset should be used GENSET OUTLINE DRAWINGS
as a guide for the installation.
See Outline Drawings for the dimensions of the
INSTALLATION CODES AND STANDARDS genset and the locations of the mounting bolt holes,
FOR SAFETY inlet and outlet air openings, oil drain plug, mainte-
nance access door and connection points (fuel, bat-
The builder of the RV bears sole responsibility for tery, remote control, AC, exhaust).
the selection of the appropriate genset, for its prop-
er installation and for obtaining approvals from the See your Onan dealer for large-scale drawings and
authorities (if any) having jurisdiction over the a floor template to locate the opening cutouts.

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1-1
 BGE/NHE
(Gasoline)

REMOTE START CABLE

CONNECTION

BGE/NHE
(LPG)

REMOTE START CABLE

CONNECTION

FIGURE 1-1. TYPICAL EMERALD PLUS GENERATOR SETS

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1-2
2. Specifications

GASOLINE MODELS
BGE NHE
GENERATOR: 4-Pole Revolving Field, Self-Excited, Electronically Regulated, 1-Phase
Power (watts) 4000 5000 4000 6500 5000
Frequency (Hertz) 60 50 60 50
110/220 110/220
Voltage 120 120 or 120 or
120/240 120/240
36.4/18.2 or 45.5/22.7 or
Current (amperes) 33.3 41.7 54.2
33.3/16.7 41.7/20.8
Speed (RPM) 1800 1800 1500 1800 1500
FUEL CONSUMPTION:
No load gph (l/h) 0.4 (1.5) 0.4 (1.5) 0.3 (1.1) 0.4 (1.5) 0.4 (1.5)
Half load gph (l/h) 0.6 (2.3) 0.7 (2.6) 0.5 (1.9) 0.7 (2.6) 0.7 (2.6)
Full load gph (l/h) 0.8 (3.0) 1.0 (3.8) 0.8 (3.0) 1.3 (4.9) 1.0 (3.8)
ENGINE: 2-Cylinder Opposed, 4-Cycle, Spark-Ignited, Side-Valve, Air Cooled
Bore 3.250 inches (83 mm) 3.563 inches (90 mm)
Stroke 2.875 inches (73 mm) 3.000 inches (76 mm)
Displacement 48 inches3 (782 cc) 60 inches3 (980 cc)
Compression Ratio 7.0 : 1 7.0 : 1
Oil Capacity (with filter)* 3.5 quarts (3.3 l) 3.5 quarts (3.3 l)
Intake Valve Clearance (Cold) 0.005 inches (0.13 mm) 0.005 inches (0.13 mm)
Exhaust Valve Clearance (Cold) 0.013 inches (0.33 mm) 0.013 inches (0.33 mm)
Spark Plug Gap 0.025 inches (0.64 mm) 0.025 inches (0.64 mm)
Spark Plug Tightening Torque 8 lbs-ft (10 N-m) 8 lbs-ft (10 N-m)
Ignition Timing 12° BTDC, 12° BTDC,
(electronic ignition) non-adjustable non-adjustable
CONTROL AND CRANKING SYSTEM: 12 VDC
Nominal Battery Voltage 12 volts 12 volts
Minimum Battery Cold Cranking
360/450 amperes 360/450 amperes
Capacity: Above/Below Freezing
Fuse F1 (control circuit) 5 amperes 5 amperes
Fuse F2 (autochoke/fuel pump) 10 amperes mini-bayonet 10 amperes mini-bayonet
WEIGHT: 216 lb (98 kg) 230 lb (105 kg)
* -See Periodic Maintenance for oil filling instructions.

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2-1
 LPG MODELS
BGE NHE
GENERATOR: 4-Pole Revolving Field, Self-Excited, Electronically Regulated, 1-Phase
Power (watts) 4000 4000 6300 5000
Frequency (Hertz) 60 50 60 50
110/220 110/220
Voltage 120 or 120 or
120/240 120/240
36.4/18.2 or 45.5/22.7 or
Current (amperes) 33.3 52.5
33.3/16.7 41.7/20.8
Speed (RPM) 1800 1500 1800 1500
FUEL CONSUMPTION:
No load lbs/h (kg/h) 1.8 (0.8) 1.5 (0.7) 2.2 (1.0) 2.0 (0.9)
Half load lbs/h (kg/h 2.6 (1.2) 2.6 (1.2) 3.8 (1.7) 3.5 (1.6)
Full load lbs/h (kg/h 4.0 (1.8) 4.0 (1.8) 6.6 (3.0) 5.1 (2.3)
ENGINE: 2-Cylinder Opposed, 4-Cycle, Spark-Ignited, Side-Valve, Air Cooled
Bore 3.250 inches (83 mm) 3.563 inches (90 mm)
Stroke 2.875 inches (73 mm) 3.000 inches (76 mm)
Displacement 48 inches3 (782 cc) 60 inches3 (980 cc)
Compression Ratio 7.0 : 1 7.0 : 1
Oil Capacity (with filter)* 3.5 quarts (3.3 l) 3.5 quarts (3.3 l)
Intake Valve Clearance (Cold) 0.005 inches (0.13 mm) 0.005 inches (0.13 mm)
Exhaust Valve Clearance (Cold) 0.013 inches (0.33 mm) 0.013 inches (0.33 mm)
Spark Plug Gap 0.025 inches (0.64 mm) 0.025 inches (0.64 mm)
Spark Plug Tightening Torque 8 lbs-ft (10 N-m) 8 lbs-ft (10 N-m)
Ignition Timing 12° BTDC, 12° BTDC,
(electronic ignition) non-adjustable non-adjustable
LPG Vapor Supply Pressure
9 to 13 inch (229 to 330 mm) 9 to 13 inch (229 to 330 mm)
(Range)—Vapor-Withdrawal
W.C. (water column) W.C. (water column)
Models Only
CONTROL AND CRANKING SYSTEM: 12 VDC
Nominal Battery Voltage 12 volts 12 volts
Minimum Battery Cold Cranking
360/450 amperes 360/450 amperes
Capacity: Above/Below Freezing
Fuse F1 (control circuit) 5 amperes 5 amperes
Fuse F2 (fuel solenoid) 10 amperes mini-bayonet 10 amperes mini-bayonet
WEIGHT: 216 lb (98 kg) 230 lb (105 kg)
* -See Periodic Maintenance for oil filling instructions.
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2-2
3. Location and Mounting
GENERAL WARNING EXHAUST GAS IS DEADLY.
Construct a suitable vapor barrier of ap-
Read the entire manual and housing/exhaust kit in- proved materials between the genset and
structions before installing the genset. The genset vehicle interior to keep out exhaust gas.
is designed for two very different types of installa- 2. Line the compartment with 26-gauge galva-
tion: conventional compartment mount installation nized steel or a material of comparable
and under-floor mount installation. Choose the ap- strength, durability, and fire resistance (see
propriate section and carefully follow the instruc- NFPA 70, NEC and California Title 25 for com-
tions given. plete details).
3. Construct the compartment floor in a manner
COMPARTMENT MOUNT so as to prevent oil, fuel, or water accumula-
tion. Compartment drainage to the outside of
In a conventional installation, the genset is installed the vehicle can be accomplished by 1/2-inch
on a framework that is part of the vehicle. This (13 mm) diameter holes as shown on the
framework must be constructed in accordance with compartment floor drawings in Section 9. Out-
the safety-approved specifications contained in the line Drawings.
Compartment Construction section following.
NOTE: Do not use absorbent sound proofing
material on compartment floor. The floor should
Unless the genset is to be removed from under- have minimal openings to reduce sound level.
neath the vehicle, plan the location for an access 4. Equip the base with an oil drain hole to the out-
opening to be large enough to permit genset remov- side on the compartment. Do not mount the
al. Typical locations are illustrated in Figure 3-1. Al- muffler below the oil drain hole.
low additional clearance for easy access to the oil
fill, drain, filter, and oil dipstick, as well as the air WARNING Fire presents the hazard of se-
cleaner element, circuit breaker, governor adjust- vere personal injury or death. To prevent a
ments, carburetor adjustments, spark plugs, Start/ fire hazard, do not position the muffler di-
Stop switch, and DC fuse. The locations of each are rectly below the drain hole.
shown in Figure 1-1 on Page 1-2.

Design the compartment large enough for the gen-

set to have a minimum clearance of 0.6 inch (15
mm) between the genset and compartment walls
and ceiling (and acoustical material, if used). See
Figures 9-4, 9-5, 9-7, and 9-9 on Pages 9-4, 9-5,
9-7, and 9-9 in Section 9. Outline Drawings for gen-
eral information when reviewing the following and
refer to the specific Outline Drawing when perform-
ing installation.

Compartment Construction

1. It is imperative that the genset compartment be

separated from the living quarters and any fuel
(gasoline or propane) supply with a vapor-tight, FIGURE 3-1. TYPICAL GENSET LOCATIONS
fire-resistant barrier. See the appropriate fig-
ures in Section 9. Outline Drawings (and spe- 5. Secure the genset mounting plate to the sup-
cific Outline Drawing) for minimum clearances port frame using 3/8-16 UNC, grade 5 screws.
and compartment size. The back two mounting holes are supplied with
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by any means, is strictly prohibited.

3-1
 weld nuts to facilitate installing screws. The haust kit instructions for further specifics regarding
front two holes can be secured with 3/8-16 under-floor mount instructions.
screws, lock-washers, and nuts. The front
holes are square to allow the use of 3/8-16 The vehicle construction must be able to support
cage nuts, if desired. See the appropriate fig- the weight of the genset (see General Specifica-
ure in Section 9. Outline Drawings. tions). It is the vehicle manufacturer’s and the in-
staller’s responsibility to provide a structurally
CAUTION Road vibrations can cause sound support frame, by using tubing, angle brack-
component damage to the genset if the unit ets, or steel reinforced plywood or other composi-
mounting plate is not fastened securely to tion board. Reinforcement of plywood or other com-
the vehicle compartment. Use screws of position board can be accomplished with 3-inch (76
sufficient length to allow a minimum of 11/2 mm) or larger washers or a full metal plate.
threads to extend through the nut for maxi-
mum holding power. WARNING Design the genset support struc-
ture carefully to prevent the genset from falling
UNDER-FLOOR MOUNT from the vehicle and possibly causing a serious
road accident.
In an under-floor mount installation, the genset is General
mounted in a housing below the floor and outside
the vehicle coach. This housing assembly should Genset Location. When choosing a location for
be as supplied or reviewed by Onan, and must be mounting the under-floor mount genset, consider
installed in accordance with the Installation Codes the following not only for mounting, but for protec-
and Safety Recommendations list in the Introduc- tion of the genset, as well. Figure 3-2 shows the
tion. Review the following text for general applica- most common mounting areas of an RV genset in a
tion information, and review the proper housing/ex- recreational vehicle.

FIGURE 3-2. COMMON UNDER-FLOOR MOUNTING AREAS OF GENSET

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3-2
 • If the genset is mounted on the curb side (loca- minimum between the tray and the skirt of the recre-
tion 1 or 2), protect the generator end of the ational vehicle. This distance allows lowering the
genset from road splash and debris. genset without hitting the vehicle skirt. Figure 9-4 on
• If the genset is mounted on the driver’s side Page 9-4 shows basic dimensions of the under-
(location 3 or 4), protect the engine end of the floor mount genset. Refer to specific Outline Draw-
genset from road splash and debris. ing when performing installation.

• Leave an area between the genset and the rec- Housing Assembly
reational vehicle skirt for an air inlet if it is not
subjected to road splash. See Section 4. Ven- The recreational vehicle must be adapted for the
tilation and Acoustics for more detailed infor- under-floor housing. The vehicle frame must sup-
mation. port the weight of the genset. It is the vehicle
manufacturer’s responsibility to provide a structur-
NOTE: Air inlet openings to the genset compartment
must not allow dirt, rock, water, or slush to directly
ally sound frame and carriage bolts or equivalent to
hit the genset. Dust and salt entrance into the attach the housing kit.
compartment must be minimized. Pay special atten-
tion to protection of the generator, control, choke, CAUTION Failure to meet Onan review for
and governor areas. Baffles might be required to pro- modifications of housing kits or for non-Onan
tect certain areas. kit housing installations may void intent of
NCTI/CSA approval. Liability for damage or inju-
Access Opening. Provide an access opening on ry and warranty expenses becomes the respon-
the side of the recreational vehicle for the genset. sibility of the person making the modifications.
Make it large enough to allow for checking or adding
oil, for adjusting the governor and carburetor, and Use the template supplied with the housing kit so
for access to the control panel and AC circuit break- that panels are installed square to each other. Fail-
er. The opening should also provide access for oil ure to mount panels square may result in spark plug
and air filter replacement so that the genset does breakage.
not have to be lowered for these procedures. See
Figure for location of genset components. Review Exhaust System section and exhaust sys-
tem kit installation instructions and component
Mounting Clearances. If the compartment door parts. Plan clearance for movement or removal of
does not open the full width of the genset and to the exhaust components when the genset is lowered
bottom of the vehicle skirt, provide 2 inches (51 mm) for inspection or maintenance purposes.

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3-3
4. Ventilation and Acoustics
WARNING EXHAUST GASES ARE DEADLY!
Never sleep in the vehicle with the genset run-
ning unless the vehicle is equipped with an op-
erating carbon monoxide detector with an audi-
ble alarm.

WARNING Provide an adequate exhaust sys-

tem to properly expel discharged gases. In-
spect exhaust system daily for leaks per the
maintenance schedule. Check that exhaust
manifolds are secure and not warped. Do not
use exhaust gases to heat a compartment.

WARNING Be sure the unit is well ventilated.

FIGURE 4-1. VACU-FLO COOLING SYSTEM
VENTILATION
The air inlet area is critical for proper genset opera-
The most important factors of ventilation for an RV tion and cooling. A minimum air inlet area of 85 in 2
air-cooled genset are sufficient incoming air (for (548 cm2) with no restrictions is required. Refer-
combustion and cooling) and adequate exhausting ence: the genset air discharge rate is 480 ft3/min
of heated air. The BGE/NHE genset uses Vacu- (13.6 m3/min).
Flo cooling.
When planning the air inlet to the genset, allow for
airflow restrictions caused by grilles and duct work.
A centrifugal fan in a scroll housing on the engine Some expanded metal grilles provide only 60 per-
(Figure 4-1) draws air from the generator end of the cent free air inlet area per square foot. Even the
compartment, through the generator (the generator most efficient grille only provides about 90 percent
also has a cooling fan), and over the cooling sur- free inlet area per square foot. The free air inlet area
faces of the engine. Then, it discharges the heated of the material can be obtained from the material
air out through the Vacu-Flo discharge opening. supplier. Multiply the grille area times the percent of
free area of the grill to obtain the free inlet area.
Make sure nothing obstructs or restricts discharged
airflow and that recirculation of air is minimal. A dust Inlet air ducting should provide a direct, free, air-
or noise deflector, if added, must be a minimum of 3 flow path to the genset, with minimal bends. Materi-
inches (76 mm) below the genset and open on three als used should be smooth and non-restrictive to
sides. airflow.

Air inlet openings should be located as high as pos-

WARNING Exhaust gas presents the hazard of sible to allow for convection cooling of heated air
severe personal injury or death. Because dis- from the genset compartment after unit shutdown.
charged cool air can contain some exhaust gas, Otherwise, hard starting might result due to vapor
never use discharged cooling air for heating. locking (gasoline fuel), hot combustion air, etc.

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4-1
 WARNING Fuel and fuel leakage present the zontal area between RV skirt and the genset along
hazard of fire or explosion, which can cause se- with the vertical area (if road splash is not a problem
vere personal injury or death. The ventilation —see the Location and Mounting section). See Fig-
system should provide a constant flow of air to ure 4-2 for reference to these areas. If the skirt of the
expel any accumulation of fuel vapor. The gen- RV does not extend to or below the top of the genset
set compartment must be vapor-tight to the ve- drip tray, provide an extension.
hicle interior to keep fumes from entering the
vehicle. Air can be brought from under the RV for cooling.
However, run tests while the RV is both parked and
To obtain the 85 in2 (548 cm2) free air inlet area, while moving at highway speeds to make sure of
Onan recommends bringing in cooling air through proper cooling with this method. A temperature rise
the recreational vehicle skirt. This can be accom- between the outside ambient and air in the top
plished by using the access door, ducting into the openings of the genset housing should not exceed
generator end from the side wall, or using the hori- 8F (4.4C).

FIGURE 4-2. AIR INLET ALTERNATIVES FOR UNDER-FLOOR MOUNT GENSET

Redistribution or publication of this document,

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4-2
 ACOUSTICS instance, a sheet of lead or viscoelastic material
and a layer of acoustical material is more effective
The Onan housing kit for the under-floor mount gen- than either alone.
set contains acoustical material to minimize noise.
Additional insulation is not necessary. If, however,
you are constructing your own compartment or To reduce line-of-sight noise, a sound panel (baffle)
housing, use the following guidelines. should be added behind the air inlet. The panel
must be spaced to allow for minimum free air inlet of
For the conventional compartment mount, if 85 in2 (548 cm2).
compartment penetrates floor, be sure all joints and
corners of the compartment are vapor-tight to the Refer to Figure 4-3 on Page 4-4 to aid your genset
interior. Lining the compartment is less effective if compartment design and noise reduction plans.
openings, cracks, doors, and joints are not sealed. Size ducting to make sure that minimum free airflow
Seal the compartment door edge to eliminate noise of 85 in2 (548 cm2) is still attained after acoustical
leaks around the door perimeter. material is added.
Cover the sound reflective surfaces, back, top, and
sides (not the compartment base) with fiberglass or WARNING High temperatures in the compart-
other self-extinguishing acoustical material. Acous- ment can present the hazard of fire which can
tical material and adhesive should be rated for use result in severe personal injury or death. To
at 200F (90C) minimum. meet ANSI and CSA temperature rise require-
ments for recreational vehicles, insulation must
Rather than using one single material, a combina- not reduce the 0.6-inch (15-mm) clearance spe-
tion of materials can reduce noise considerably. For cified.

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4-3
FIGURE 4-3. NOISE REDUCTION - COMPARTMENT DESIGN RECOMMENDATION

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4-4
5. Exhaust System
WARNING EXHAUST GASES ARE DEADLY! lation modifications becomes the responsibility of
Never sleep in the vehicle with the genset run- the person installing substitute muffler or perform-
ning unless the vehicle is equipped with an op- ing the modifications. Contact an Onan distributor
erating carbon monoxide detector with an audi- for approved exhaust system parts and installation
ble alarm. instructions.

WARNING Provide an adequate exhaust sys- EXHAUST INSTALLATION GUIDELINES

tem to properly expel discharged gases. In-
spect exhaust system daily for leaks per the The exhaust system must be placed no closer than
maintenance schedule. Check that exhaust 3 inches (76 mm) from combustible material (wood,
manifolds are secure and not warped. Do not felt, cotton, organic fibers, etc.), or be so located, in-
use exhaust gases to heat a compartment. Be sulated, or shielded, that it does not raise the tem-
sure the unit is well ventilated. perature of any combustible material more than
117F (65C) above the ambient air inlet tempera-
GENERAL ture.

Plan each individual exhaust system carefully. A The exhaust system must extend a minimum of 1
proper installation is not only vapor tight, but is also inch (25 mm) beyond the perimeter or bumper of the
quieter and safer. Be sure to check all applicable vehicle. If the genset tailpipe is on the same side of
standards, local codes, and regulations. the vehicle as the compartment, try to terminate the
tailpipe aft of the genset air intake to reduce the pos-
Refer to the following text and figures for recom- sibility of exhaust recirculation. Direct the exhaust
mendations to follow when installing the exhaust down and to the rear. See Figure 5-1.
system. Refer to the installation instructions sup-
plied with the exhaust system kit for specific mount-
ing procedures. See Figures 5-4 and 5-5 on Pages
5-4 and 5-5 for exhaust kit options.

MUFFLER
If the genset was supplied without a muffler we rec-
ommend that you purchase an Onan RV spark ar-
resting muffler approved by RVIA and USDA. The 1 INCH (25 mm)
RVIA/ANSI EGS-1 standard requires that the muf- MINIMUM
fler be constructed of aluminized steel or equivalent LAST TAILPIPE HANGER AS
CLOSE TO END AS PRACTICAL
corrosion resistant material and be of welded or
crimped construction. The spark arrestor must be
FIGURE 5-1. EXHAUST TAILPIPE TERMINATION
USDA approved. It may be integral to the muffler or
of the add-on type. The muffler back pressure rating To reduce the possibility of damaging the tailpipe
must not exceed 35 inch water (2.57 inch mercury) and emitting exhaust gases under the vehicle, be
for Model BGE or 65 inch water (4.78 inch mercury) sure no part of the exhaust system intrudes into the
for Model NHE. departure angle or approach angle unless it is ade-
quately protected by a skid bar or other protection
CAUTION Failure to use and maintain a spark device. See shaded areas in Figure 5-2 on Page
arresting exhaust system is illegal on federally 5-2 for typical mounting locations.
owned lands and could lead to a brush or forest
fire. WARNING Exhaust gas presents the hazard of
severe personal injury or death. Use only Onan
Liability for damage or injury, and warranty ex- specified exhaust equipment with generator set
penses due to use of unapproved mufflers or instal- and support the system per kit instructions.
Redistribution or publication of this document,
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5-1
 WARNING Exhaust gas presents the hazard of CAUTION Excessive exhaust back pressure
severe personal injury or death. Do not termi- can cause engine damage. If tailpipe deflector is
nate exhaust gas under vehicle. Do not termi- used, make sure it is large enough to prevent
nate exhaust system directly under any vent, back pressure.
window, or opening that can be opened and that CAUTION Water vapor can cause engine dam-
is not permanently sealed from the vehicle liv- age. Do not connect the generator set exhaust
ing space. Keep all openings closed when the to the vehicle exhaust system, because water
generator set is running. vapor from one engine can damage the other.

SEALED WINDOW
TAILPIPE
(RV REAR VIEW)

DEPARTURE APPROACH
ANGLE ANGLE
GROUND
AXLE LOWER
SKID BARS SHADED ZONE IS AREA CLEARANCE
OF RECOMMENDED LINE
TAILPIPE INSTALLATION

TAILPIPE MUST EXTEND A MINIMUM

6 IN.
OF 1 INCH (25.4 mm) BEYOND THE TAILPIPE
(152.4 mm)
PERIMETER OF THE VEHICLE

NO OPENINGS INTO THE VEHICLE’S INTERIOR, INCLUDING

ENTRY DOORS, ARE ALLOWED IN THE SHADED AREA

FIGURE 5-2. APPROACH AND DEPARTURE ANGLES AND AXLE CLEARANCE LINE

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5-2
 TAILPIPE RECOMMENDATIONS CAUTION Excessive exhaust back pressure
can cause engine damage. If a tailpipe deflector
An exhaust tailpipe is not supplied because of varia- is used, make sure it is large enough to prevent
tion in length requirements between RV manufac- back pressure.
turers. Prior to installing an exhaust tailpipe, refer to
the following recommendations for additional tips CAUTION Water vapor can cause engine dam-
and safety considerations. age. Do not connect the genset exhaust to the
vehicle exhaust system, because water vapor
Use 1-1/2-inch O.D. (1-3/8-inch I.D.) 18 gauge alu- from one engine can damage the other.
minized steel or stainless steel tubing for the tail-
CAUTION Angular mounting of muffler and
pipe.
tailpipe hanger brackets can result in exhaust
system damage. Properly mounted hanger
WARNING Exhaust gas presents the hazard of brackets will absorb much road shock vibration
severe personal injury or death. Do not use flex- and prolong the usefulness of exhaust system
ible exhaust tailpipe since it can leak or break components. Mount muffler and tailpipe hanger
due to road shock or vibration. Do not terminate brackets directly above the component sup-
exhaust system under the vehicle. Direct ex- port, not at an angle. Do not twist the rubber
haust gases away from any window, door, or sections of any hangers.
compartment openings. Do not operate the gen-
erator set without an exhaust tailpipe.

Use U-bolt type automotive muffler clamps marked

1-3/8 and double rubber, U-shaped shock mounted
hangers for supporting the exhaust system. (See
Figure 5-3.) If the tailpipe extends beyond 1-1/2 feet
(0.46 m) from the muffler, attach one or more auto-
motive tailpipe hangers every 2 to 3 feet (0.6 to 0.9
m) of tailpipe run. Support the exhaust system at or
near the perimeter of the vehicle to prevent the pipe 3/4 INCH (19 MM)
from being damaged and pushed up under the ve- MAXIMUM SLOT
hicle skirt. Attach hangers to steel framework, not (BOTH SIDES)
wood or other floor materials Refer to Figures 5-4
and 5-5 on Pages 5-4 and 5-5 for a typical tailpipe
installation. FIGURE 5-3. EXHAUST TAILPIPE CONNECTIONS

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5-3
FIGURE 5-4. EXHAUST SYSTEM KIT EXAMPLES FOR CONVENTIONAL COMPARTMENT MOUNT GENSETS
Redistribution or publication of this document,
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5-4
FIGURE 5-5. EXHAUST SYSTEM KIT EXAMPLES FOR UNDER-FLOOR MOUNT GENSETS
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5-5
6. Fuel System
GENERAL gine power loss, Unleaded gasoline may be safely
used after lead deposits have been removed.
This installation manual covers gasoline and LPG
(liquid propane gas) fuel systems. Separate proce- CAUTION Lead deposits can cause engine
dures are given for each. damage if they are not removed before using
unleaded gasoline. Do not alternate between
leaded (regular) and unleaded gasoline.
WARNING Fuel presents the hazard of fire or
explosion which can result in severe personal WARNING Fuel presents the hazard of fire or
injury or death. Do not smoke or allow any explosion that can cause severe personal injury
spark, pilot light, arcing switch or equipment, or or death. Never fill the fuel tank when the engine
other ignition sources in the installation area or is hot or is running. Do not permit any flame,
areas sharing ventilation. Keep a type ABC fire spark, pilot light, cigarette or other ignition
extinguisher nearby. The ventilation system of source near the fuel system.
the installation area must provide a constant
flow of air to expel any accumulation of fuel va-
por while the vehicle is in transit. Compart- Fuel Consumption
ments must be vapor tight to the vehicle interior
to prevent any fumes from entering the vehicle See Section 2. Specifications in this manual.
interior.
Fuel Line Installation

GASOLINE FUEL SYSTEM Vehicle fuel systems are designed to operate within
a particular range of fuel pressure. It is very impor-
tant that the vehicle fuel supply system not be al-
Fuel System Provisions
tered when the genset is being installed. The fuel fill
tube, fill limiter vent, vapor canister, vapor lines, and
On some vehicles, genset installations may be de- gas fill cap should not be changed, removed, or re-
signed to share the vehicle fuel supply tank with the placed without the approval of the vehicle manufac-
vehicle engine. Use a separate fuel pickup tube in turer. Check the filler cap and see that the pressure
the vehicle tank, or use a separate tank. Do not tie vacuum relief valve is functioning properly— re-
into the vehicle engine fuel supply line. See Fuel place if it is necessary.
Line Installation in this section.
If a separate connection is not supplied for the gen-
The genset includes a fuel shut-off valve as a safety set, add a second fuel pickup in the tank. Onan rec-
feature and is an integral part of the fuel pump. ommends a separate fuel pickup tube in the vehicle
Should the vehicle fuel tank become pressurized, fuel tank to provide a proper and safe fuel pressure
the positive fuel shut-off valve prevents flooding of at the genset carburetor. The opening of this pickup
the genset when the set is not operating. tube should not extended into the bottom 1/4 of the
tank so that the last 1/4 tank of gasoline is reserved
for vehicle operation only.
Recommended Fuel
Do not tie the genset fuel line into the vehicle
Use clean, fresh, unleaded or regular grade gaso- fuel supply line.
line. Using unleaded gasoline results in extended
periods between service, longer spark plug life, and • Tying a genset fuel line into a vacuum supply
reduced carbon clean-out maintenance If regular line (vehicle fuel pump at the tank side of the
gasoline is used, lead deposits must be removed pump) may cause the genset to starve for fuel
from the cylinder heads as required to alleviate en- at highway speeds or during acceleration.
Redistribution or publication of this document,
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6-1
 CAUTION If the genset fuel line is con- sharp or rough surfaces, or where they may be-
nected to the main fuel line with a tee, the come kinked, pinched, chaffed, or struck.
genset may starve for fuel when the vehicle
is operated at highway speeds. The genset PROPANE (LPG) FUEL SYSTEM
fuel pump has neither the capacity nor the
power to overcome the draw of the vehicle Fuel System Provisions
engine fuel pump. For this reason, use a
separate fuel line to the genset, or a sepa- Onan LPG gensets contain a filter cartridge and
rate fuel tank. magnet connected to the fuel solenoid valve to pro-
tect the solenoid valve and regulator valves from
• Tying a genset fuel line into a pressure supply dirt and contaminants. The solenoid valve and filter
line (vehicle fuel pump at the engine side of the are shown in Figure 6-1. Figure 6-2 on Page 6-3
fuel pump) may cause poor genset operation shows the flow diagram for the LPG fuel system
and create a hazard of fire or explosion caused components used on the genset.
by fuel leakage.
Genset operation using LPG is very sensitive to alti-
WARNING Gasoline presents the hazard
tude, temperature, and BTU content of the gas.
of explosion or fire, which can result in se-
Variation in any one of these factors directly affects
vere personal injury or death. Do not con-
the performance on the genset. Because of this, mi-
nect the genset fuel line to the pressurized
nor adjustments might be required after the installa-
part of the vehicle fuel system. Flooding of
tion. Refer to the Generator Set Service Manual if
the genset engine and compartment with
adjustments are required.
gasoline can occur, resulting in a fire haz-
ard. Recommended Fuel
Some vehicle manufacturers permit tying into the
fuel return line on high pressure fuel systems. Con- Use clean, fresh commercial propane or HD-5
tact the vehicle manufacturer for details and ap- grade liquid propane gas in a mixture of at least 90
proval. percent propane. Propane fuels other than HD-5
grade can contain more than 2.5 percent butane
and can result in poor fuel vaporization and poor en-
Install an approved, flexible, non-metallic, non-con-
gine starting in low ambient temperatures (below
ductive, and non-organic fuel line between the ve-
32F or 0C).
hicle fuel system and the genset, to absorb vibra-
tion. The flexible fuel line must be long enough to al-
low genset movement, to prevent binding, stretch-
ing, or breaking. Onan recommends seamless steel
tubing and flared connections for long runs between
the fuel tank and the flexible connector to the gen-
set.

Run fuel lines at the same height as the top level of

the tank to a point as close to the engine as pos-
sible. This reduces the danger of fuel siphoning out
of the tank if the line should break.

Keep fuel lines away from hot engine or exhaust

areas to reduce the chance of vapor lock. Fuel lines
should be accessible and protected from damage.
Use metal straps without sharp edges to secure fuel
lines. Do not run fuel lines where they may contact FIGURE 6-1. FUEL SOLENOID VALVE AND FILTER
Redistribution or publication of this document,
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6-2
TWO-STAGE, DEMAND-TYPE VENTURI-TYPE CARBURETOR
PRESSURE REGULATOR WITH MAIN AND IDLE
MIXTURE ADJUSTMENTS

THE LPG IS VAPORIZED BY

EXHAUST MANIFOLD HEAT.

USE AN APPROVED,
THE FUEL SOLENOID
NON-CONDUCTING FLEXIBLE
SHUTOFF VALVE ALLOWS
FUEL HOSE MARKED 350 PSI
BACKFLOW TO RELIEVE
WORKING PRESSURE AND
PRESSURE WHILE THE
LP-GAS OR PROPANE TO
VAPORIZER COOLS
CONNECT THE GENSET TO THE
FOLLOWING SHUTDOWN.
GAS SUPPLY LINE.

AN APPROVED
FUEL SUPPLY HYDROSTATIC RELIEF
CONNECTION VALVE OF APPROPRIATE
AT THE RATING TO PROTECT THE
GENSET GAS LINE. WHEN VALVES
(1/4 INCH NPTF) ON BOTH ENDS ARE
CLOSED

THE FUEL FILTER HAS A

STRAINER ELEMENT
ACCESSIBLE FOR
CLEANING AND A MAGNET
FOR TRAPPING IRON
PARTICLES.

APPROVED GAS
LINES AND FITTINGS
SUITABLE FOR A
AN APPROVED DOT OR WORKING
ASME LPG SUPPLY TANK PRESSURE OF AT
LEAST 250 PSI (1.7
MPa)

AN APPROVED PRESSURE RELIEF VALVE APPROVED MANUAL SHUTOFF AND

OF APPROPRIATE RATING DIP EXCESS FLOW VALVES RATED FOR A
COMMUNICATING WITH THE VAPOR SPACE TUBE WORKING PRESSURE OF AT LEAST 250 PSI
INSIDE THE TANK (1.7MPa)

FIGURE 6-2. FLOW DIAGRAM OF LPG FUEL SYSTEM

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6-3
Fuel Consumption and flared connections for long runs between the
fuel tank and the genset location. A short length of
See Section 2. General Specifications in this manu- the flexible fuel line should be used to complete the
al. connection between the end of the steel tubing and
the genset itself.
Propane Fuel Lines and Supply Tank
A manual shut-off valve MUST be mounted on the
Review each of the codes that apply to LPG genset propane fuel supply tank. This supply valve MUST
installation. Refer to paragraph 2-11 (LP-Gas En- be fully open when operating the genset to ensure
gine Fuel Installations) of NFPA Pamphlet 501C the excess flow valve will close with a severed (bro-
and paragraph 3-6.2.5 of NFPA 58 (Piping, Hose, ken) propane fuel line.
and Fittings). These sections deal with fuel tanks
and lines, but do not cover all applicable codes and A hydrostatic pressure relief valve MUST be
regulations. Obtain this literature by writing to the installed between the propane fuel supply tank
address listed in the beginning of this manual. manual shut-off valve and the propane fuel solenoid
valve and filter assembly. This relief valve protects
When installing the fuel lines, keep the following in the propane fuel line from pressure buildup if both
mind: the supply tank manual shut-off valve and the fuel
solenoid valve are closed at the same time.
1. Install all propane fuel lines so they are acces-
sible, yet protected from damage.
Testing Fuel System for Leaks
2. Use metal straps without sharp edges to se-
cure fuel lines. The completed propane fuel system installation
MUST be checked and tested for leaks before the
3. Keep fuel lines away from hot engine or ex-
genset is operated. The fuel solenoid valve MUST
haust areas.
be energized from a separate 12-volt DC source be-
4. Do NOT run fuel lines in conjunction with elec- fore testing the fuel system for leaks. The test
trical wiring. MUST conform to procedures listed in NFPA-58,
Most LPG liquid withdrawal gensets are designed Paragraph 318, or NCTI (US Testing) recom-
to share the vehicle propane fuel supply tank(s). mended test procedure as follows:
The vehicle propane fuel supply tank MUST have a
dip tube for liquid withdrawal. After assembly and prior to initial operations, all
fuel system connections, hose, valves, regula-
An excess flow valve MUST be mounted internal to tors, and fittings must be tested and proven free
the propane fuel supply tank(s) per NFPA 501C, of any leaks using a soap and water or equiva-
Paragraph 2-2.7.7. This excess flow valve and pro- lent solution while the system is under a gas or
pane fuel lines MUST be sized so the excess flow air pressure of not less than 90 pounds per
valve will close with a completely severed (broken) square inch (620 kPa).
propane fuel line. For operation at the lowest ambi-
ent temperature, a valve rated at 2.6 gallons per Other approved methods of detecting leaks may be
hour (9.9 l/hr) flow rate and 6.5 pounds per square used if appropriate. Test shall NOT be made with a
inch (45 kPa) differential pressure is recom- flame.
mended. Consult the Natural LP Gas Association
for the limitations of excess flow valves. WARNING Liquid LPG fuel presents the hazard
of explosion or fire which can result in severe
Install an approved flexible non-metallic, non-con- personal injury or death. Do not smoke or allow
ductive, and non-organic fuel line between the ve- any spark, pilot light, arcing switch or equip-
hicle fuel system and the genset to absorb vibration. ment, or other ignition sources in the installa-
Onan recommends using a seamless steel tubing tion area or areas sharing ventilation.
Redistribution or publication of this document,
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6-4
 PROPANE (LP-VAPOR) FUEL SYSTEM
Before installing a genset converted to an LPG fuel
system, refer to the Conversion Kit Instruction
Sheet included with the kit components for further
information regarding compartment design and
component location requirements. Follow the pro-
cedures outlined in the kit instruction sheet to install
the genset.

Redistribution or publication of this document,

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6-5
7. Electrical Connections
GENERAL Genset Rating

Installing the genset electrical system includes con- The generator output voltage and maximum current
necting the load, remote control (if used), and con- rating are specified on the generator nameplate.
necting the battery. The battery should always be
connected last to avoid accidental starting or short Conduit
circuiting the unit during installation. Connect the
negative (-) battery cable last to reduce the risk of Install the generator load conductors supplied with
arcing. the genset in a flexible metallic conduit. Cut the con-
duit to the desired length, leaving extra wire as re-
WARNING Accidental starting of the generator quired for the junction box (connecting wires must
set while working on it can cause severe per- be appropriately sized and insulated for the speci-
sonal injury or death. Do not connect the start- fied current rating). Prepare the ends of the conduit,
ing battery until instructed to in the Installation to prevent its sharp edges from cutting the wire in-
Checks and Start-Up section. sulation.

All wiring must meet applicable local electrical Run the conduit in such a way as not to interfere with
codes. For this reason, a qualified electrician the movement of the set.
should install and inspect the wiring.
Use waterproof conduit whenever conduit is ex-
Mount switches and controls securely to prevent posed to the elements.
damage from vibration and road shock. All switches
must be vibration-proof to prevent accidental open- Be sure to seal all openings made for wiring so ex-
ing or closing while the vehicle is in motion. haust or fuel vapor cannot enter the living quarters.
If flexible metal conduit is used, it must be sealed in-
Do not run wiring where it may contact sharp, rough, ternally at the end where it terminates within the
or hot surfaces or where it may become kinked, junction box or panel board. Flexible conduit is not
pinched, or chaffed. vapor tight along its length due to it unique construc-
tion.

AC WIRING WARNING Exhaust gas and fuel fumes present

the hazard of severe personal injury or death. To
Wiring Methods prevent exhaust gas and fuel fumes from enter-
ing the vehicle interior, seal all opening made
Wiring methods must be in accordance with appli- for conduit, wiring, etc. Also seal the wiring
cable codes, such as the National Electrical Code within the conduit itself. Use a silicone/rubber-
(NFPA No. 70). based sealant.

Use stranded wire for all load connections. Load Wiring Disconnect Method
wiring must be appropriately sized and insulated for
the specified current rating. Grounding procedure There must be no possibility of the outside power
must comply with codes. source being connected to the genset. The feeder
conductors from the genset compartment must ter-
Line Circuit Breaker minate in a 120-volt, 2- or 3-pole, double-throw,
positive-off switching device mounted ahead of the
The genset has line circuit breakers mounted on the vehicle distribution panel; or must connect to a gen-
side of the control panel. The breakers provide erator set receptacle box. Refer to Figures 7-1
short circuit and overload protection for the genera- through 7-3 on Pages 7-3 and 7-4 for examples
tor. of the wire connections.
Redistribution or publication of this document,
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7-1
 WARNING Electrical shock can cause severe WARNING Fuel presents the hazard of fire or
personal injury or death. Use only approved explosion, which can result in personal injury or
power supply assemblies. Never remove the death. Do not tie electrical wiring to fuel lines.
grounding pin from assemblies. Incorrect
ground or no ground can cause the vehicle to
become electrically “hot.” Equip the vehicle
with adequate Ground-Fault Circuit Protection
devices to meet the National Electrical Code
(NFPA 70, 551-9[C]) and for personal safety.

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7-2
 DOUBLE-POLE, DOUBLE-POLE SWITCH USED FOR SWITCHING

SCHEMATIC—UP TO JUNCTION BOX

GENSET JUNCTION BOX

L1
30A BLK
120V
L0
WHT

GND
GRN

UTILITY POWER CORD USED FOR SWITCHING

FIGURE 7-1. CONNECTIONS—4.0 KW GENSET AND 30 AMP SHORE POWER

Redistribution or publication of this document,
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7-3
 SCHEMATIC—UP TO JUNCTION BOX

2ND A/C

GENSET
BLK/GRN
20A
L1
30A BLK
120V 120V
L0
WHT
WHT
GND
GRN
JUNCTION BOX

FIGURE 7-2. CONNECTIONS—5.0-6.5 KW GENSET, 30 AMP SHORE POWER, 2ND AIR CONDITIONER

50 AMP 3-POLE TRANSFER SWITCH

WITH NEUTRAL RATED AT LEAST 60 AMP

JUNCTION BOX
GENSET
BLK/GRN 120V 240V

50 AMP SHORE POWER

L1 L1
30A**
BLK
N N
30A
120V
WHT
L2 L2
120V
WHT 120V

GRN

* This neutral conductor must have

an ampacity of at least 60 amps.
** Replace with a 30 amp circuit
breaker if rated 20 amps.
L1 N* L2 GND
TO VEHICLE AC DISTRIBUTION PANEL***

***

FIGURE 7-3. SCHEMATIC—5.0-6.5 KW GENSET AND 50-AMP SHORE POWER

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7-4
 DC WIRING

Remote Control (Option)

INDICATOR
LAMP
Onan offers optional remote control kits that can be
connected to the genset. There are three models
available:

• Remote panel with start/stop switch and indica- START/STOP

tor lamp only (see Figure 7-4). SWITCH

• Remote panel with start/stop switch, indicator

lamp, and hour (elapsed time) meter (see Fig-
ure 7-5). FIGURE 7-4. REMOTE PANEL WITH START/STOP
SWITCH ONLY
• Remote panel with start/stop switch, indicator
lamp, and battery DC voltmeter (see Figure
7-6).
The location of the remote control panel can vary by START/STOP
application. Refer to the instructions supplied with SWITCH
the remote control kit for more installation informa- INDICATOR
LAMP
tion and important safety precautions.

Be sure to seal all openings made for wiring so

exhaust or fuel vapors cannot enter the living
HOUR
quarters. If flexible metal conduit is used, it must be METER
sealed internally at the end where it terminates.
Flexible metal conduit is not vapor-tight along its
length due to its construction.
FIGURE 7-5. REMOTE PANEL WITH START/STOP
WARNING Inhalation of exhaust gas or ignition SWITCH AND HOUR METER
of fuel vapor can cause severe personal injury
or death. Be sure to vapor-seal flexible metal
conduit and all openings made during installa-
tion of the genset with a silicone/rubber based START/STOP
sealant. SWITCH
INDICATOR
A remote control connector is located inside the LAMP
housing (see Figure 1-1 on Page 1-2). Keep the
connector inside the genset housing to keep it
clean. Contact an Onan dealer for the proper re-
mote connector plug and wiring harness assembly. BATTERY DC
VOLTMETER

For non-Onan remote control panels, refer to Figure

7-7 on Page 7-6 for a typical remote control wiring
diagram. The connector which mates with the gen-
set connector can be ordered from Onan. Refer to FIGURE 7-6. REMOTE PANEL WITH START/STOP
the Onan Accessory Catalog. SWITCH AND DC VOLTMETER
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by any means, is strictly prohibited.

7-5
 CONTROL PANEL CONNECTOR GENSET
CONTROL PANEL (USER SUPPLIED) CONNECTOR
+ B A

CONNECTOR END
CONNECTOR END
OPTIONAL

WIRE END

E F G H

WIRE END
DC
VOLTMETER

-
DC VOLTMETER B A

+
OPTIONAL

HOUR METER

D E
-
C F
HOUR METER
F A G
B
SWITCHED B+ C B
START/STOP SWITCH A H
+ START
LED
GND
-
STOP CONNECTOR END
(VIEW A-A)
WIRE END
(VIEW B-B)

FIGURE 7-7. TYPICAL REMOTE CONTROL WIRING DIAGRAM

BATTERIES TABLE 7-1. COLD CRANKING AMPS FOR MINIMUM

12-VOLT BATTERY
To prevent accidental starting of the genset during ABOVE 32° F BELOW 32° F
installation, do not connect the battery cables at the (0° C) (0° C)
battery until so instructed in the Installation Checks 360 Cold Cranking 450 Cold Cranking
and Start-Up section. Amps Amps
(Approx. 70 amp/hour) (Approx. 95 amp/hour)
WARNING Accidental starting of the genset
can can cause severe personal injury or death. Battery Recharging
Do not connect the starting battery until so
instructed in the Installation Checks and Start- The majority of gensets are not equipped with a bat-
Up section. tery charger. Other means will have to be provided
for maintaining the battery charge level.
Onan does not recommend that the vehicle starting
battery be used to operate the genset. Doing this A kit is available for field installation of the battery
can discharge the battery under some operating charger. See your Onan distributor for information.
conditions. Battery Compartment
Battery Capacity Mount the battery in its own compartment, away
from the genset and any spark-producing device.
The genset has a 12 VDC, negative-ground control For ventilation, provide the battery compartment
and starting system. See Table 7-1 for minimum with an opening of at least 1.7 in2 (11 cm2) at the top
battery capacity requirements. and 1.7 in2 (11 cm2) at the bottom.
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7-6
Mount the battery on a rigid support structure, (see Figure 7-8). (Do not connect the other end to
where leaks and accidental spills cannot damage the battery at this time.)
the genset, fuel lines, and wiring.
Alternate Negative (-) Battery Connection. In
WARNING Batteries present the hazard of cases where the distance from the battery to the
explosion, which can result in severe personal genset is quite long, the vehicle frame (ground) can
injury. Because batteries give off explosive gas, be used for the return cranking current:
install the battery in a separate compartment
1. Connect one end of a short, negative (-) bat-
from the genset and away from all flames, pilot
tery cable (of the same size as the positive (+)
light, arcing, or spark-producing devices.
battery cable) to the vehicle frame near the bat-
Battery Cables tery. (Do not connect the other end to the bat-
tery at this time.)
Because of the high cranking currents involved, it is 2. Connect one end of a short, negative (-) bat-
highly recommended that a negative (-) battery tery cable (of the same size as the positive (+)
cable be run with the positive (+) battery cable be- battery cable) to the vehicle frame near the
tween the battery and the genset. Size the cables genset. Connect the other end to the genset
according to Table 7-2. Total cable length is the sum ground. See Figure 7-8.
of the lengths of the positive (+) and negative (-)
cables. In other words, total cable length will be NOTE: Make sure that the frame (ground) con-
approximately twice the distance between the bat- nections (to major frame members, if possible)
tery and the genset. are secure enough to minimize electrical
resistance. Avoid making these connections at
Alternatively, use rated cranking current as the ba- welds or mechanical joints.
sis for calculating battery cable size. Rated crank-
ing current for these gensets is 180 amperes at 0F
(-18 C). The cables should be sized so that voltage
NEGATIVE (-) BATTERY
across the cranking motor terminals will be within 1 CONNECTION
volt of the voltage across the battery terminals. (GENSET GROUND)

TABLE 7-2. CABLES FOR COLD WEATHER

STARTING TO -20°F (-29°C)
*CABLE LENGTH CABLE
IN FEET (METERS) SIZE

0-10 (0-3) 2
11-15 (3-4.5) 0
16-20 (4.5-6) 000**

* Total battery cable length including both posi-

tive (+) and negative (-) cables.
** #2 cable is acceptable up to 20 feet (6.1 m) if
the battery capacity exceeds 1000 CCA.

POSITIVE (+) BATTERY

Negative (-) Battery Connection. Connect one CONNECTION
end of the negative (-) battery cable to the genset
ground. Tighten the ground connection securely FIGURE 7-8. BATTERY CABLE CONNECTIONS

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by any means, is strictly prohibited.

7-7
Positive (+) Battery Connection. Connect one Method 1. If the genset negative battery connection
end of the positive (+) battery cable to the genset B+ is made with a single cable connected between the
post. Tighten the B+ connection securely (see Fig- genset ground and the negative (-) battery terminal
ure 7-8 on Page 7-7). (see Negative (-) Battery Connection on Page
7-7), an additional bonding connection must be
Route battery cables away from fuel lines and hot made. Connect an 8-AWG (minimum) cable be-
engine exhaust components. Battery cable should tween either:
be accessible for inspection and replacement, pro-
tected from damage and secured to prevent chafing • the genset ground (see Figure 7-8) and the ve-
due to vibration. hicle frame (ground).
WARNING Routing battery cables with fuel • the negative (-) battery terminal and the ve-
lines can lead to fire and severe personal injury hicle frame (ground).
or death. Keep battery cables away from fuel Method 2. If the vehicle frame (ground) is used as a
lines. path for the negative (-) genset-battery circuit (see
CAUTION Failure to secure the battery cable Alternate Negative (-) Battery Connection on Page
terminals can result in personal injury and/or 7-7), the negative cable between the genset and
equipment damage from an electrical short. See the vehicle frame (ground) serves as the bonding
that terminal connections are secure. If connection. However, this cable must be of the
necessary, secure cables to prevent abrasion. same size as the positive (+) battery cable.

Genset Bonding Terminal NOTE: Make sure that the frame (ground) con-
nections (to major frame members, if possible)
The genset ground, as shown in Figure 7-8 on Page are secure enough to minimize electrical
7-7, is also the bonding terminal for grounding the resistance. Avoid making these connections at
genset to the vehicle frame (ground). This connec- welds or mechanical joints.
tion must be made for proper and safe operation of
the genset. Onan recommends that this connection WARNING Failure to ground the genset prop-
be made in one of two ways based on which nega- erly can result in injury or death. The genset
tive battery connection method was used. must be grounded to the vehicle frame.

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7-8
8. Installation Checks and Start-Up

WARNING
EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless and colorless gas.

Carbon monoxide is poisonous and can cause unconsciousness and death.
Symptoms of carbon monoxide poisoning can include:

• Dizziness • Throbbing in Temples

• Nausea • Muscular Twitching
• Headache • Vomiting
• Weakness and Sleepiness • Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET

OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medi-
cal attention. Shut down the unit and do not operate until it has been in-
spected and repaired.

Never sleep in vehicle with the generator set running unless the vehicle inte-
rior is equipped with an operating carbon monoxide detector with an audible
alarm. Protection against carbon monoxide inhalation also includes proper
exhaust system installation and visual and audible inspection of the com-
plete exhaust system at the start of each generator set operation.
2-RV

PRE-START CHECKS WARNING Batteries present the hazard of

explosion, which can result in severe per-
sonal injury. Because batteries produce ex-
Before starting the genset, perform these steps:
plosive gas, do not smoke or allow any arc-
producing devices in the battery area. Do
1. Perform the Installation Review described in not disconnect cables from the battery
this section. while the genset is cranking or running.
This causes arcing and can result in an ex-
2. With the vehicle parked on a level surface, plosion.
check the engine oil level. See the Operator’s 4. Review the Operator’s Manual, and note the
Manual for the oil type and quantity. When fin- features of the genset. Open the fuel supply
ished, screw the oil level indicator into the filler valve to the genset (if equipped).
neck securely to prevent oil leakage.
INITIAL STARTING AND CHECKS
3. Check that battery terminals and cable connec- WARNING Exhaust gas presents the hazard of
tors are clean and dry. Connect the positive (+) severe personal injury or death. Do not operate
battery cable to the POS. (+) battery post first, the genset inside any room or building.
then connect the negative (-) battery cable to
the NEG. (-) battery post. Always connect the Starting from the Genset Control
negative (-) battery cable last to reduce the risk 1. Move the Start/Stop switch to the START (I)
of arcing. position. The engine should crank and start.
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8-1
 The genset may need more cranking during the 4. Perform the Break-In Procedure described in
initial start to prime the fuel system. If the gen- the Operator’s Manual.
set fails to start, see the Troubleshooting Guide
in the Operator’s Manual. WARNING Accidental starting of the gen-

2. After the genset starts, check for fuel leaks. If set during maintenance procedures can
any leaks are found, stop the genset immedi- cause severe personal injury or death. Dis-
ately, close the fuel supply valve (if equipped) connect the genset starting battery, nega-
and have the leak(s) repaired. Make sure that tive (-) cable first, before performing main-
the fuel lines do not touch anything that can tenance.
damage them.
WARNING Fuel presents the hazard of ex-
5. Move the Start/Stop switch to the STOP (O)
plosion or fire that can result in severe per-
sonal injury or death. If a fuel leak is found, position to stop the genset.
stop the genset and have the leak repaired
immediately. Starting from the Remote Control
WARNING A hot genset can cause severe
burns. Always allow the genset to cool 1. Move the Remote Start/Stop switch to the
down before performing service. START (I) position. The engine should crank
and start as indicated by indicator light on the
3. Examine the exhaust system for leaks. If any
leaks are found, stop the genset and have the switch. If it does not, see the Troubleshooting
exhaust system repaired immediately. Make Guide in the Operator’s Manual. Check all re-
sure the exhaust pipe terminates outside the mote control connections, correct if necessary,
perimeter of the vehicle. and restart the genset.
WARNING Exhaust gas presents the haz-
ard of severe personal injury or death. In- 2. After the genset starts, check the battery DC
spect the exhaust system audibly and visu- voltmeter or hour meter (if equipped) to confirm
ally. With the genset running, inspect the proper operation.
muffler. Do not operate the genset if it is ex-
cessively noisy. Have any leaks repaired 3. Move the Start/Stop switch to the STOP (O)
immediately. position to stop the genset.

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8-2
 INSTALLATION REVIEW
Prior to initial start-up of the genset, check (√) each of the following items. For a proper installation, each an-
swer must be yes: if not, that aspect of the installation should be reworked or provision made to satisfy the
requirement.

If installed in a compartment, Is the compartment metal-lined and sealed around all edges?

Are wiring holes into the inside of coach (including the inside of AC conduit) sealed to prevent passage
of exhaust gases?

Can the following routine maintenance items be performed through the vehicle access panel?

Change oil

Adjust carburetor

Start/Stop the unit

Change air filter

Adjust governor

Access AC circuit breaker and control fuse

Change spark plugs

Are air inlet and exhaust openings clear and large enough (see Mounting section) for proper airflow?

If the installation is for an under-floor kit, is there a metal barrier between the genset and a combustible
floor?

Are fuel lines and electrical wires protected from chafing and damage and are they insulated from each
other?

Are all fuel connections and hose clamps tight?

Is a flexible section of non-conducting fuel line installed between the fuel inlet and the fuel line from the
tank?

Are all electrical leads connected and protected, and is the conduit adequately supported?

Does the exhaust system extend beyond the perimeter of the vehicle a minimum of 1 inch (25 mm)?

If there are any windows, doors or storage compartments within a portions of an arc with a radius of 6
inches from the exhaust pipe and covering the vehicle between boundries formed by the vehicle skirt (see
Figure 5-2 on Page 5-2), are they permanently closed?

If the exhaust system is run into the angle of approach or departure, is it protected from bottoming out by
use of skid bars, rollers, etc.?

Is the exhaust system secure and are all connections tight? Are all required exhaust clamps, hangers, and
support straps in place per the Exhaust System section of this manual and the kit instructions?

Is the genset protected from direct road splash from vehicle wheels?

Do the hanger straps located at the perimeter and along the centerline of the genset have double U-
shaped rubber isolators?

Does the installation allow 1/2 inch (13 mm) of free movement of genset on its mounts?

Has rubber boot been installed on the positive (+) battery connection at the start solenoid connection in the
control?

On an LPG fueled genset, has the system been tested for leaks?

If the installation uses under-floor hinge kit, is there 2 inches (51 mm) clearance between front of tray and
vehicle skirt (or is skirt part of door) to allow genset to swing down for service?
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8-3
9. Outline Drawings
The genset outline drawings in this manual are sub-
ject to change and are included for reference only.
See Table 9-1 for a list of the drawings in this sec-
tion. If necessary, contact your Onan distributor for
a detailed outline drawing.
NOTE: Fuel pump appearance may differ from those
shown in these outline drawings.

The negative (-) battery connection on all BGE/

NHE gensets is now the location shown in Figure
9-1.

FIGURE 9-1. BATTERY NEGATIVE (-)

CONNECTION ON ALL BGE/NHE GENSETS

TABLE 9-1. OUTLINE DRAWINGS

Figure No. Drawing No. Description Page No.

9-2 500-2179 BGE (Gasoline) - Below Floor 9-2
9-3 500-2180 BGE (Gasoline) - Below Floor (with NHE Pan) 9-3
9-4 500-2181 BGE (Gasoline) - Above Floor/Compartment 9-4
9-5 500-2184 BGE (LPG) - Above Floor/Compartment 9-5
9-6 500-2185 BGE (LPG) - Below Floor 9-6
9-7 500-2177 NHE (Gasoline) - Above Floor/Compartment 9-7
9-8 500-2178 NHE (Gasoline) - Below Floor 9-8
9-9 500-2186 NHE (LPG) - Above Floor/Compartment 9-9
9-10 500-2187 NHE (LPG) - Below Floor 9-10

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9-1
 FIGURE 9-2. BGE (GASOLINE) - BELOW FLOOR
Redistribution or publication of this document,
by any means, is strictly prohibited.
9-2
 FIGURE 9-3. BGE (GASOLINE) - BELOW FLOOR (WITH NHE PAN)
Redistribution or publication of this document,
by any means, is strictly prohibited.
9-3
 FIGURE 9-4. BGE (GASOLINE) - ABOVE FLOOR/COMPARTMENT
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by any means, is strictly prohibited.
9-4
 FIGURE 9-5. BGE (LPG) - ABOVE FLOOR/COMPARTMENT
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9-5
 FIGURE 9-6. BGE (LPG) - BELOW FLOOR
Redistribution or publication of this document,
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9-6
 FIGURE 9-7. NHE (GASOLINE) - ABOVE FLOOR/COMPARTMENT
Redistribution or publication of this document,
by any means, is strictly prohibited.
9-7
 FIGURE 9-8. NHE (GASOLINE) - BELOW FLOOR
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9-8
 FIGURE 9-9. NHE (LPG) - ABOVE FLOOR/COMPARTMENT
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9-9
 FIGURE 9-10. NHE (LPG) - BELOW FLOOR
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9-10
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-528-7229
Redistribution or publication of this document,
Cummins and Onan are registered trademarks of Cummins Inc. by any means, is strictly prohibited.