Installation

Manual

GenSets

0 u LISTED

RV Electric Generating Set

This manual must be given to the customer,
along with the Operator’s Manual

965-0630
10-86
Printedin USA
Safety Precautions
This symbol warns of immediate Follow all state and local electrical codes. Have all electrical rr
hazards which will result in severe installations performed by a qualified licensed electrician.
personal injury or death.
Do Not Smoke While Servicing Batteries
6
This symbol refers to a hazard or
-AW*R"'G i unsafepractice which can result in
Batteries emit a highly-explosive gas that can be ignited by
electrical arcing or by smoking.
4 -

Severe personal injury or death.

Exhaust Gases Are Toxic
*-
This symbol refers to a hazard or Never sleep in the vehicle with the generator set running unless
*'AUT'' j unsafe practice which can result in the vehicle is equipped with an operating carbon monoxide
personal injury or product or property damage. detector.

Fuels,electrical equipment, batteries, exhaustgases and moving Provide an adequate exhaust system to properly expel dis-
parts present potential hazards that could result in serious, per- charged gases. Check exhaust system regularly for leaks.
sonal injury.Take carein followingthese recommendedprocedures. Ensure that exhaust manifolds are secure and not warped.

Do not work on this equipment when mentally or physically Be sure the unit is well ventilated.
fatigued.
Keep the Unit and Surrounding Area Clean
Use Extreme Caution Near Fuel. A constant potential explosive
or fire hazard exists. Remove all oil deposits. Remove all unnecessarygrease and oil
from the unit. Accumula:ed grease and oil can causs overheating
Do not fill fuel tank near unit with engine running. Do not smoke and subsequent engine damage and may present a potential fire
or use open flame near the unit or the fuel tank. hazard.

When cleaning generator set. provide cover or other protection

Be sure all fuel supplies have a positive shutoff valve.
so that cleaning and rinse water, and other contaminantsare not
Use a non-metallic, non-conductive, flexible section of fuel line allowed into the generator. air cleaner, control box, fuel solenoid,
or electrical connec:ors. Generator set operation and internal
between the generator set and stationary fuel line in vehicle.
components can be adversely affected.
LPG: The propane fuel supply lines MUST comply with all
requirementsofNFPA501CSection3-5.paragraphs1.1 and 1.2 Do NOT clean the generator set while unit is operating. This can
as well as Canadian Gas Association Bulletin 6149.2-78. The result in personal injury or product or property damage.
installer must review and comply with all applicable codes
regarding fuel tanks, supply lines.and pressure testing complete Do NOT use high pressure air. water, or steam for cleaning
system for leaksafter installationis completeand PRIORto initial generator set and compartment Dirt and other foreign matter can
be forced into generator, engine and control housings. Genera-
operation of the generator set
tor set operation and internal components can be adversely
Have a fire extinguisher nearby. Be sure extinguisher is properly aff9cted.
maintained and be familiar with its proper use. Extinguishers
rated ABC by the NFPA are appropriate for all applications. Do NOT use high strength solvents. They can damage electrical
connectors.
Consult the local fire department for the correct type of extin-
guisher for various applications.
Do NOTstoreanything in the generator compartmentsuch as oil
Guard Against Electric Shock or gas cans, oily rags, chains, wooden blocks portable propane
cylinders, etc. A fire could result or the generator set operation
[cooling, noise and vibration) may be adversely affected. Keep
Remove electric power before removing protective shields or
the compartment floor clean and dry.
touching electrical equipment Use rubber insulative mats
placed on dry wood platfqrms over floors that are metal or con-
crete when around electrical equipment Do not wear damp
Protect Against Moving Parts
clothing (particularly wet shoes) or allow skin surfaces to be
Avoid moving parts of the unit Loose jackets, shirts or sleeves ,
damp when handling electrical equipment
should not be permitted because of the danger of becoming
caught in moving parts.
Jewelry is agood conductorof electricity andshould be removed
when working on electrical equipment
Makesure all nuts and boltsaresecure. Keep power shieldsand
guards in position.
DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY
BUlLDlNG ELECTRICALSYSTEM.Hazardoe voltages can flow
from thegenerator set intotheutilityiine.Thiscreates a potential
If adjustments must be made while the unit is running, use
e
extreme caution around hot manifo!ds. moving parts, etc.
for electrocution or property damage. Connect onlythrough an
approved device and after building main switch is open. Consult
an electrician in regard to emergency power use. General

Use extreme caution when working on electrical components.

Do not work on this equipment when mentally or physically
fatigued, or after consuming any alcohol or drug that makes the
High voltages cause injury or death.
operation of equipment unsafe.
Redistribution or publication of this document,
RV-G.LP-4
by any means, is strictly prohibited.
 Table of Contents

SAFETY PRECAUTIONS ................................ Inside Front Cover

INTRODUCTION ....................................................... 2
' ... GENERAL SPECIFICATIONS ........................................... 4
MOUNTING ............................................................ 5
._ Conventional Compartment Mount ..................................... 5
Under-Floor Mount .................................................. 8
VENTILATION AND ACOUSTICS ....................................... 10
Ventilation......................................................... 10
Acoustics .......................................................... 11
EXHAUST SYSTEM ................................................... 13
General ............................................................13
Muffler Recommendations ........................................... 13
Exhaust Installation Guidelines ....................................... 13
Tailpipe Recommendations .......................................... 13
FUEL SYSTEM ....................................................... 16
General ............................................................. 16
Gasoline Fuel System ............................................... 16
.. Propane (LPG)Fuel System
.......................................... 17
ELECTRICAL CONNECTIONS .........................................19
AC Wiring .......................................................... 19
DC Wiring .......................................................... 23
INSTALLATION CHECKS AND START-UP .............................. 26
Pre-Start Checks ...................................................26
Initial Start-up Inspection ............................................ 26
Installation Review .................................................. 28

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1
 Introduction
Each RV generator set must be installed properly if it is The following list of installation codes and safe.,
to operate reliably,quietly,and most importantly - safely. recommendationspertains to the installation and opera-
Therefore, read the entire manual and housing/exhaust tion of this RV generator set. The address of each ‘
.kit instructions before starting the installation. This agency is listed so that you can obtain a copy for your
manual details installation procedures for the Onan own use.
BGE and BGELgeneratorsets. For operation and main- I
i
tenance procedures, refer to the Operator’s Manual INSTALLATION CODES AND
. * which accompanies each unit.
SAFETY RECOMMENDATIONS
Listed and certified,this generator set meets or exceeds
all requirements of the National Electrical Code, Article 1. ANSI-Al19.2 Recreational Veh.
551 (NFPA 70) as well as ANSI/RVIA Standard EGS-1. ANSI/RVIA-EGS-1 Industry Assoc.
UL Standard 1248, and CSA Bulletin 946. Recreational 14650 Lee Road
vehicle installationsMUST comply with these specifica- Chantilla VA 22021
tions as well as ANSI 119.2, Standard for Recreational
Vehicles. The recreational vehicle manufacturer and 2. NFPA 70 (N.E.C.) National Fire
generator set installer MUST also comply with any local NFPA-501C Protection Assoc.
codes such as California Administrative Code Title 25, 470 Atlantic Ave.
which pertains to the generator set installation. Boston MA 02210
UL listing and CSA certification applies to 60 Hz models only. 3. CSA Electrical Canadian Standards
Bulletin #946 Assoc. - Housing &
Requirements fo be considered prior to the installation Const. Materials Section
are listed below. Each is covered in the following text or 178 Rexdale Blvd.
associated kit instructions. Rexdale Ont. Canada
M9W 1R 3
0 Level and supportive mounting surface.
0 Adequate cooling air. 4. UL Standard 1248 Underwriters Lab Inc.
0 Discharge of circulated air. 333 Pfingsten Road
0 Discharge of exhaust gases. Northbrook IL 60062
0 Electrical connections. 5. California State of California
0 Fuel installation. Administrative Documents Section
0 Accessibility for maintenance and service. Code - Title 25 P.O.Box 1015
0 Noise levels. Chapter 3 North Highlands CA
95660

IAWARNINGI
Incorrect installation, service, or replacement of parts can result in severe
personal injury and/or equipment damage. Service personnel must be qualified
to perform electrical and mechanical component installation.

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2
 GOVERNOR
BGE SPARK ADJUSTMENTS

' . .* SUMMER/WINTER
._ CARGURETOR
ADJUSTMENTS
ADJUSTMENT

FUEL PUMP INLET

AC CIRCUIT BREAKERS

REMOTESTART
CABLE CONNECTION

LOCATION O P ~ O N A L

SPARK
BGEL PLUG
VAPORIZER \\

ADJUSTMENTS

AC CIRCUIT BREAKER

FUEL FILTER AND

SOLENOIDASSEMBLY

NEGATIVE(-) BA'K
CABLECONNECTl POSITIVE(+) BATTERY
TO PLATE CABLECONNECTION
LOCATIONOPTIONAL
REMOTESTART
. CABLE CONNECTION
M-1604-1

FIGURE 1. BGE AND BGEL GENERATOR SETS

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3
 General Specifications
ENGINE
'
Onan opposed2-cylinder, 4-cycle,air-cooled,gasoline-fueled forthe BGE model c
and propane-fueled for the BGEL model. Remote start, negative ground, 12-volt,
automotive-type starter.

GENERATOR
.. .
.- Onan-built, four-pole,revolving field, permanently aligned to engine.
Frequency ....................... - 5 0 Hz.......................... 60 Hz
'Watts.. .......................... .3500 ............................ 4000
Volts.. .................... .11.0/220 or 1201240.. .................... 120
Amps.. .................. .31.8/15.9 or 29.2114.6.. .................. .33.3
Phase .............................. 10............................. .10

CONTROL
Front-mounted control features fixed battery charger and remote start capability.

. GENERATOR SET

.. Dimensions*
Height .............. :. ................................ 14.0 in. (356 mm)
Length.. .............................................. 25.0 in. (635 mm)
Width.. ............................................... 18.8 in. (478 mm)
Weight
60 Hz. ................................................... 218 Ib (99 kg)
SO Hz.. .................................................. 228 Ib (104 kg)
Air Requirements:
60 Hz ......................................... -480ft3/min (1 3.6 m3/min)
50 Hz ......................................... .400 ft3/min (11.3 m3/min)
Fuel Inlet Connection
BGE ...1 ............................................. 1/4 in. barb fitting
BGEL.. .................................................. - 1/4in. NPTF
Battery Voltage .................................................. .12 volts
Recommended Battery Capacity'. ................ .360 cold cranking amperes
Cranking Current ............................................. 100 amperes
rlmin at:
60 Hertz .......................................................... 7800
50 Hertz ......................................................... 1500

*Under-Floor mount generator set with compartmenthousing has slightly larger

dimensions. See Mounting section.

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Mounting
Read the entire manual and housing/exhaust kit 2. Line the compartment walls with 26-gauge galvan-
instructions before installing the generator set The ized steel or a materialof comparable strength, dur-
generator set is designed for two very different types of ability and fire resistance (see NFPA 70, NEC and
installations; conventional compartment mount installa: California Title 25 for complete details).
tions and under-floor mount installations. Choose the 3. Construct the compartmentfloor in a manner so as
appropriate section describing each and carefully fol- to prevent oil, fuel or water accumulation. Com-
low the instructions given. partment drainage can be accomplished by 1/2
inch (13 mm) diameter holes as shown on the com-
partmentfloor drawings, Figure 3.

CONVENTIONAL Fire presents the hazard of

COMPARTMENT MOUNT * jaWAR"G1 severe personal injury or death.
To prevent a fire hazard, do not position the
In a conventional installation the generator set is actu- muif/er directly below a drain hole.
ally installed on a framework that is part of the recrea-
tional vehicle (RV).This framework must be constructed Do NOT use absorbent sound proofing material on
in accordance with the safety-approved specifications compartment floor. The floor should have minimal
contained in the following Compartment Construction openings to reduce sound level.
section..
4. Equip base with an oil drain hole to the outside of
Unless generator set is to be removedfrom underneath, compartment. Do not mount the muffler below the
plan the location for an access opening to be large oil drain valve.
enough to permit set removal. Allow additional clear-
ance for easy access to the oil fill, drain, filter and oil Exhaust gases present the haz-
dipstick as well as the air cleaner element, circuit ard of severe personal injury or
breaker, governor adjustments,carburetor adjustments, death. Make the comparfment walls vapor-tight to
Start/Stop switch, and DC fuse. The locations of each the interior of the vehicle toprevent exhaust fumes
are shown in Figure 1. from entering ihe vehicle coach.
Designthe compartment large enoughfor the generator 5. Secure the generator set mounting plate to support
set, with 0.6 inch (15 mm) minimum clearance between frame using 318-1 E UNC, grade 5 screws. The back
the generator set and compartment walls and ceiling two mounting holes are supplied with weld nuts to
(and acoustical material, if used). See Figures 2 and 3. facilitate installing screws. The front two holes can
be secured with 318-16 screws, lockwashers and
nuts. The front holes are square to allow use of
3/8-16 cage nuts if desired. See Figure 3.
Compartment Construction

1. Install the generator set in its own compartment.

1-1 Road vibrations can cause com-
ponent damage to generator set
Separatethecompartmentareafrom the living quar- if unit mounting plate is not fastened securely to
ters and any fuelsupply (gasoline or propane)with a vehicle compartment, Use screws of sufficient
vapor-tight wall. See Figures 2 and 3 for minimum length to allow a minimum of 1-1f2 threads to
clearances and compartment size. extend through nut to ensure maximum holding
power.

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5
 ;E,y m: :& OIL FILTER REMOVAL

*-AIR FILTER

-
FUEL INLET 114 INCH

1317.0 1 DISCHARGE
OIL DRAIN VALVE FOL
.62 1.0. HOSE
I

\
“L FUEL INLET
0 25 nos€ ¶4RB
ALT FUEL PUMP

(
OPTIONAL EXHAUST OUTLET

NOTES:

1. DIMENSIONING INCLUDES 0.6 INCH (15

mm) MINIMUM CLEARANCE REQUIRED
BEMlEENSETANDlNSUIATlONORCOM-
PARTMENTWALLS.
2. IF COMPARTMENTIS LARGERTHANMIN-
IMUM SHOWN. ALLOW EXTRA SPACE AT
OIL FILL SIDE AND EQUALLY ON BOTH
ENDS.
3. ALLOW MINIMUM OF 0.6 INCH (15 mm)
CLEARANCEBETWEENTOP OF SET AND
INSULATlON OR COMPARTMENT
CEILING. MINIMUM HEIGHT14.60 INCHES.
.75 INCHCONDUITWITH
4. WEIGHT - 218 LBS. (99 kg). 50 Hz-228 AC. PIGTAILS36.0 INCHES
Lb1104 kg. VIEW A-A (0.92 m) LONG
5. DIMENSIONSIN ( ) IN MILLIMETRES.
500-2126

FIGURE 2. BGElBGEL COMPARTMENT MOUNT OUTLINE (BGE SHOWN)

6 Redistribution or publication of this document,

by any means, is strictly prohibited.
 X I
19.75 s o sa. HOLE NOTES.
(501.6) (127)2 PLACES
CUT-OUT FOR COOLING 1. DIMENSIONS INCLUDE 0.6 INCH (15 mm)
AIR DISCHARGE MINIMUM CLEARANCE REQUIRED
BETWEENSETANDiNSUWTlONOR COM-
PARTMENTWALLS.
. 2. IF COMPARTMENTISLARGERMAN MIN-
IMUM SHOWN. ALLOW EXTM SPACE AT
OIL FILL SIDES AND EQUALLY ON BOTH
ENDS.
3. ALLOW MINIMUM OF 0.6 INCH (15 mm)
CLEARANCEBETWEENTOP OF SETAND
CONVENTIONALCOMPARTMENTMOUNT BGE-BGEL INSULATION OR COMPASTMENT CEIL-
WlTH END-MOUNTEDMUFFLER
ING. MlNiMUMHEIGHT- 14.60 INCHES(371
mm).
4. DIMEF.!SIDNS ( ] A R E IN MILUMETRES.

5. SWARE HOLES (5.5il/127)

ARE SUITABLE
FOR USE OF 3 8 IWCHCASE MU.

.JOBDRAIN HOLE

(127)2 PLACES

FIGURE 3. COMPARTMENT FLOOR PLAN . Redistribution or publication of this document,

by any means, is strictly prohibited.
7
 UNDER-FLOOR MOUNT Access Opening: Provide an access opening og the
For an under-floor mount installation,the generator set side of the recreational vehicle for the generator set.
is mounted in a housing belowthe floor and outsidethe Make it largeenoughto allow for checking or adding oil,
coach of the recreational vehicle. This housing assem- for adjusting governor and carburetor, and for accessto
bly should be as supplied or approved by Onan, and the control panel and AC circuit breaker. The opening
must be installed in accordance with safety approved should also provide accessfor oil and air filter replace- 8

specifications. Review the following text for general ment so that the generator set does not have to be
applicationinformation,and reviewthe proper housing/ lowered for these procedures. See Figure 1 for
exhaust kit instructions for further specifics regarding locations.
Y
under-floor mount installations.
Mounting Clearance: If the compartment door does not .
.- openthe full width of the generatorset andto the bottom
The vehicle construction must be able to support the
weight of the generator set (see General Specifications). of the vehicle skirt, provide 2 inches (51 mm) minimum
It is the vehicle manufacturer’s and the installer’s betweenthe tray andthe skirt of the recreationalvehicle.
responsibilityto provideand assure a structurallysound This distance allows loweringthe generator set without
support frame, by using tubing, angle brackets, or with hitting the vehicle skirt. Figure 5 shows basic dimen-
steel reinforced plywood or other composition board. sions of the under-floor mount generator set.
Reinforcementof plywoodor particle boardcan be with
3 inch (76 mm) or larger washers or a full metal plate. Housing Assembly
The recreationalvehicle must be adapted forthe under-
General floor housing.The constructionof the vehicle mustsup-
Generator Set Location: When choosing a location for port the weight of the generator set. It is the vehicle
mountingthe under-floormount generatorset, consider manufacturer‘s responsibility to provide a structurally
the following not only for mounting, but for protectionof sound frame and carriage bolts or equal to attach the
the generator set as well. housing kit.

Figure 4 shows the most common mounting areas of a failure to meet Onan approval for
RV generator set in a recreationalvehicle. If the genera- modifications of housing kits or for
tor set is mounted on the curb side, location l or 2, non-Onan kit housing installations may void intent of
protect the generator end of the generator setfrom road U L K S A approval. Liability for damage or injury and
splash and debris. If mounted on the driver’s side, loca- warranty expenses becomes the responsibility of the
tion 3 or 4, protect the engine end of the generator. person making the modifications.
(Installationshould be verified bya road test in mud and
slush). Refer to shaded areas of Figure 4. Use template supplied with housing kit to insure that
panels are installed square to each other. Failure to
Leave an area between the generator set and the mount panelssquare may result in spark plug breakage.
recreational vehicle skirt for an air inlet if it is not sub-
jected to road splash. See V€NTlLATlON for more Review the exhaust system kit installation instructions
detailed information. and componentparts. Plan clearancesfor movement or
removal of exhaust components when generator set is
Air inlet openings to the generator set compartment must not allow lowered for inspection/maintenancepurposes.
dirt, rock, water, or slush to directly hit the generator set. Oust and
salt entrance into the compartment must be minimized. Pay special
attention to protection of the generator, control, choke, and governor
~

areas. Baffi&might be required to protect certain areas.

REFER TO INSTRUCTIONS
EXHAUST KIT
INSTRUCTIONS
FIGURE 4. COMMON MOUNTING
AREAS OF GENERATOR s
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by any means, is strictly prohibited.
 r OIL FILL AM0 CHECK

NOTES
ALT NELPUMP
1. DIMENSIONS INCLUDE 0.E INCH (15 mm)
MIN REQUIRED CLEAWNSE BETWEEN
SET AND INSULATION OR COMPART-
MENT WALLS.
2. IF COMPARTMENT IS LARGER THAN MIN
SHOWN. ALLOW !EXTRA SPACE AT OIL
FILL SIDE AND EQUALLY ON BOTH ENDS.
3. WEIGHT 213 LB (93kg) 50 Hz-228
Lb1104 kg.
4. DIMENSIONS IN ( ) ARE IN mm. NEL $NET
m 2:WE 8410

.75 INCH CONDUIT WITH

AC. PIGTAILS 36.0 INCHES

A.C. CIRCUIT BREAKERS

RU.a 159LOlYIN
\'
CLCkUNCC rOR UIT 5WW .
'w VIEW A-A

500-2135
FIGURE 5. UNDER-FLOOR MOUNT BGEIBGEL (BGE SHOWN)
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9
 Ventilation and Acoustics
VENTILATION When planningthe air inlettothegeneratorset,allowfor
I

The most important factors of ventilation for an RV air- airflow restrictions caused by grilles and duct work.
cooled generator set are sufficient incoming air (for Some expanded metal grilles provide only 60 percent
combustion and cooling) and adequate exhausting of free air inletarea per squarefoot. Eventhe most efficient
heated air. All Onan generatorsets for recreational veh- grille only provides about 90 percentfree inlet area per
icles use Vacu-Flo@cooling. square foot The free inlet area of the material can be ..
obtained from the material supplier. Multiply the grille
Acentrifugal fan in a scroll housing on the engine (Fig- area times the percent of free area of the grill to obtain
the free inlet area. ..
ure 6 ) draws air from the generator end of the compart-
ment,through the generator (generator also has a cool-
ing fan), and over the cooling surfaces of the engine, Inlet air ducting should provide a directfree-airflow path
then discharges the heated air out through the Vacu- to generator set, with minimal bends;and materials used
Floe discharge opening. should be smooth and non-restrictiveto airflow.

Make sure nothing obstructs or restricts discharged

Air inlet openingsshould be locatedas high as possible
airflow and that recirculationof air is minimal. A dust or
to allow for convection cooling of heated air from the
noise deflector if added must be a minimum of 6 inches
generator set compartmentafter unit shutdown. Other-
(150 mm) below the generator set and open on three
wise, hard starting might result due to vapor locking
sides. (gasolinefuel), hot combustion air, etc.
Exhaust gas presenfs the hazard of
(BWARNINGI severe personal injury or death.
Since discharged cooling air can contain some Fuel or fuel leakage presents the
exhaust gas, never use discharged cooling air for
heating.
IBWAR”G1 hazardoffireor explosion which can
cause severe personal injury or death. The ventilation
system should provide a constant flow o f air to expel
The free air inlet area is critical for proper generator set any accumulation of fuel vapor. Compartments must
operation and cooling. A minimum free air inlet area of be vapor-tight to the vehicle interior to keep fumes
- 85 in2 (548 cm2)with no restrictions is required. Refer- fromentering the vehicle.
ence: the generator set air discharge rate is 480 ft3/min
(1 3.6 m3/min).
To obtain the 85 in2(548 cm2) free air inlet area, Onan
recommendsbringing in coolingairthtough the recrea-
tional vehicle skirt. This can be accomplished by using
the access door, ducting intothe generator end from the
side wall, or using the horizontal area between the
recreational vehicle skirt and the generator set along
with the vertical area (if road splash is not a problem -
see the MOUNTINGsection).SeeFigure7for reference
to these areas. If the skirt of the vehicle does not extend
to or belowthe top of the generator set drip tray, provide
an extension. ,

You can bring air from under the coach for cooling.
However, run tests while the recreationalvehicle is both
parked and while the vehicle is moving at highway
speeds to ensure proper cooling with this method. A b
temperature rise of 8°F (4.4OC) between the outside
ambient and air in the top openings of the generator
housing is acceptable.
FIGURE 6. VACU-FLO@COOLING SYSTEM

. .

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10
 I I
MINIMUMFREE AIRFLOW TO
Duct
GENERATORSET COMPARTMENT
(MAY BE CUMULATIVE):
85 IN2 (548cmt)
Skirt

R V Floor7 1 Air In

,Skirt

AIR INLET ACCESS DUCT FROM

BETWEEN RV SKIRT Air Out DOORAIR SIDEWALL
AND GENERATOR SET INLET TO GENERATOR

FIGURE 7. AIR INLET ALTERNATIVES FOR UNDER-FLOOR

, MOUNT GENERATOR SET.

ACOUSTICS Rather than using one single material, a combination of

The Onan housing kit for the under-floor mountgenera- materials can reduce noise considerably. For instance,
tor set contains acoustical material to minimize noise. a sheet of lead or viscoelastic material and a layer of
Additional insulation is not necessary. If, however, you acoustical materials is more effectivethan either alone.
are constructing your own compartment or housing,
use the following guidelines. To reduce line of sight noise, a sound panel (baffle)
should be added behindtheair inlet. The panel must be
For the conventional compartment mount, if compart- spaced to allow for minimumfree air inlet of 85 in2 (548
ment penetrates floor, be sure all joints and comers of cm2).
the compartment are vapor-tight to the interior. Lining
the compartment is less effective if openings, cracks, Referto Figure8 to aid your generator set compartment
doors, and joints are not sealed. Also, seal compartment design and noise reduction plans. Size ducting to
door edge to eliminate noise leaks around the door ensure that minimum free airflow of 85 in2(548 em*) is
perimeter. still attained after acoustical material is added.

High temperatures in the compart-

Cover the sound reflectivesurfaces, back, top and sides
(not compartment base) with fiberglass or other self- l3iE@@I ment can present the hazard fire
which can resulf in severe personal injury or death. To
of
extinguishing acoustical material. Acoustical material
and adhesive should be rated for use at 2OOOF (90°C) meet UL,ANSl and CSA femperafurerise requirements
minimum. for recreational vehicles, insulafionmust not reduce
fhe 0.6 inch (15 mm) clearance specified.

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11
 Redistribution or publication of this document,
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12
 Exhaust System
GENERAL Excessive exhaust back pressure
Plan each individual exhaust system carefully.A proper can cause engine damage. If tai/pipe
installation is not only vapor-tight, but usually quieter deflector is used, make sure it is large enougb to pre-
and safer too. Be sure to check all applicable standards, vent back pressure.
local codes and regulations.
Water vapor can cause engine dam-
.. Refer to the following text for recommendations to fol- / exhaust
- to the vehicle
age. Do not connectthe generator set
exhaust .system since water
.- low when installing the exhaust system. Then refer to
the installation instructions supplied with the exhaust vapor from one engine can damage the other.
system kit for specific mounting procedures.%ee Fig-
ures 9 and 10 for exhaust kit options.

MUFFLER RECOMMENDATIONS
Onan supplied mufflerisparkarresters are forest ser-
vice approved and meet code requirements. (Failureto TAILPIPE RECOMMENDATIONS
provide and maintain a sparkarrestercan be in violation An exhaust tailpipe is NOT supplied because of varia-
of the law.) Use only ONAN UL/CSA tested mufflers. tion in length requirements between motor home manu-
facturers.After muffler is installed and prior to installing
Liability for damage or injury and warranty expenses exhaust tailpipe, refer to the following recommenda-
dueto use of unapproved mufflers or installation modifi- tions for additional tips and safety considerations.
cations becomes the responsibilityof the person instal-
ling substitute muffler or performing the modifications. Use 1-318 inch I.D. 18 gauge rigid steel tubing for
Contact an Onan distributor for approved exhaust sys- tailpipe.
tem parts and installation instructions.
I Exhaust gas presents the hazard oi
EXHAUST INSTALLATION GUlDELlNES ~AWARNING severe personal injury or death. Do
not use flexible exhaust tailpipe since it can leak or
The exhaustsystem must be no closerthan 3 inches (76 break due to road shock or vibration. Do not terminate
mm) from combustible material (wood, felt, cotton, exhaust sysiem under the vehicle. Direct exhaust
organic fibers, etc.), or be so located, insulated or gases away from any window, door, or compartment
shielded, that it does not raise the temperature of any openings. Do not operate the generator set without an
combustiblematerial more than 1 1 7 O F (65OC)abovethe exhaust tailpipe.
ambient air inlet temperature.
Use U-bolt type automotive muffler clamps marked 1-
The exhaust system must extend a minimum 1 inch (25 318 and double rubber, U-shaped shock mounted
mm) beyond the perimeter ofthe vehicle. If the generator hangers for supporting the exhaust system. If tailpipe
set tailpipe is on the same side of the coach as the extends beyond 1-1/2feet (0.46 m) from muffler. attach
compartment. try to terminate the tailpipe aft of the an automotive tailpipe hanger for additional support
generator set air intake to reduce the possibility of The exhaust system should be supported at or near the
exhaust recirculation, by directing the exhaust down perimeter of the vehicle to prevent the pipe from being
and to the rear. damaged and pushed up under the skirt.
Exhaust gas presents the hazard of Angular mounting of muifier and tail-
severe personal injury or death. Use :igCAUT'oN pipe hanger brackets can result in
only Onan specified exhaust equipment with generator exhaust system damage. Properly mounted hanger
set and support the system per kit instructions. brackets wili absorb much road shock vibration and
prolong the usefulness of exhaust system components.
Exhaust gas presents the hazard of
iAWARNiNG 1 severe personal inibry or death. Do
not terminate exhaust gas under vehicle. Do not termi-
Mount muffler and iailpipe hanger brackets directly
above the componentsupported,not at an angle. Do not
twist the rubber sections of any hangers.
nate exhaust system directly under any vent, window,
or opening which can be opened and which is not
pennanenilysealed from the vehicle living space. Keep
all openings closed when the generator set is running.

Redistribution or publication of this document,

13 by any means, is strictly prohibited.
 .
HANGER BRACKET ..
(3 FOOTll METRE
FROM DOWNPIPE. OR AT
PERIMETER OF VEHICLB

EXS1147

..

EXHAUST ACCESSORY
KIT 542-0471 SHOWN

us-1146

fIGURE 9. EXHAUST SYSTEM K K EXAMPLES FOR CONVENTIONAL

COMPARTMENT MOUNT GENERATOR SET

Redistribution or publication of this document,

14 by any means, is strictly prohibited.
EXHAUST ACCESSORY
KIT 542-0482 SHOWN

TAILPIPE NOT
FURNISHED BY ONAN

EXHAUST ACCESSORY
KIT 542-0469 SHOWN

EXHAUST ACCESSORY
KIT 542-0470 SHOWN

Exs-1149

%-- TAILPIPE NOT

FURNISHED BY ONAN

FIGURE 10. EXHAUST SYSTEM KIT EXAMPLES FOR UNDER-FLOOR MOUNT

Redistribution or publication of this document,
15 by any means, is strictly prohibited.
 Fuel System
GENERAL
This installation manual covers gasoline and LPG *
(liquid-propane gas) fuel systems. The Onan BGE Model No Load Half Load Full Load
model is gasoline-fueled, and the Onan BGEL model is 60 Hz 0-4 gallhr 0.6 gal/hr 0.8 gallhr
liquid LPG fueled. Separate procedures are given for (1.5 Ilhr) (2.3 I/hr) (3.0 Ilhr)
each. b .

50 Hz 0.35 gal/hr 0.53 gallhr 0.73 gal/hr

Fuel presents the hazard of fire or (1.3Ilhr) (2.0Ilhr) (2.8Ilhr)
explosion which can result in severe
personal injury or death. Do not smoke or allow any Fuel Line Installation
ignition sources in the installation area. Keep a type
ABC fire extinguisher nearby. The ventilation system of Recreational vehicle fuel systems are designed to oper- .
the installation area mustprovidea constant flow of air ate in a critical pressure range. It is very important dur-
to expelany accumulation of fuel vapor while the vehi- ing the installation of the generator set that the vehicle
cle is in transit. Compartments must be vapor tight to fuel supply design NOT be altered. The fuel fill tube, fill
fhe vehicle interior to prevent any fumes from entering
limiter vent, vapor canister, vapor lines and gas fill cap
the vehicle interior. should never be changed, removed or replaced without
PRIOR approval from the vehicle manufacturer. Check
the filler cap to ensure that the pressure vacuum relief
GASOLINE FUEL SYSTEM . valve is functioning properly. Replace if required.
Fuel System Provisions
Generator set installationsmay be designed to sharethe If separate connection is not supplied for the generator,
vehicle fuel supply tank with the vehicle engine. AI1 addasecondfuel pickup inthetank.This pickupshould
connections to the vehicle fuel tank must be done in not extend below the bottom 1/4 of tank so the vehicle
accordance with chassis (vehicle) manufacturer's can still be run, after generator runs out of fuel.
detailed installation instructions. See Fuel Line In-
stallation. Do NOTtee off the vehiclefuel line, doing so may cause
poor operation of the generator or the vehicle. Consult
The generator set includes a fuel shut-off valve as a with vehicle manufacturer forfurther specifics regard-
. safety feature and is an integral part of the fuel pump. ing ashared fuelsupply. Unauthorized fuel system mod-
Should the vehicle fuel tank become pressurized, the ifications could result in dangerous operating con-
positive fuel shut-off prevents flooding of the generator ditions.
set when the set is not operating.
Forlhe possibility of contaminatedfuel, Onanrecommendsan in-line
luel filter.
aA C A ~ O N Connecfingfhe generator set fuelline
with a fee to the main fuel.line can
resun in fhe generafor set starving for fuel when ihe
vehicle is operated at highway speeds. The generafor
Recommended Fuel set fuelpump has neither the capacity nor the power to
Use clean, fresh, unleaded or regular grade gasoline. overcomefhe draw of the vehicleenginefuelpump. Use
Using unleaded gasoline results in extended periods a separafe fuel line forthe generafor set.
between service, longer spark plug life, and reduced
carbon.clean-out maintenance. If regular gasoline is
used, lead deposits must be removed from the cylinder
heads as required to 'alleviate engine power loss.
I-[ Gasolinepresentsthe hazardof explo-
sion orfire which can resulf in severe
personal injury or death. Do not connect the generator
Unleaded gasolinemay be safely used after lead depos- set fuel line to the pressurized part of the vehicle fuel
its have been removed. . . system. Flooding of the generator set engineand com-
partmenf can occur, resulfing in a fire hazard.
Do not alternate between leaded
k&%! @ l (regular) and unleaded gasoline.
Lead deposits can cause engine damage if not
tnstall an approved, flexible non-metallic (non-
conductive)and non-organic fuel line between the veh-
removed before using unleaded gasoline. ickfuel system and the generator set to absorb vibra-
tion. Onan recommends using a seamless steel tubing
Fuel Consumption
and flared connections for long runs between the fuel .
tank and the flexible connector to the generator set.
It should be noted that under varying electrical loads,
fuel consumption of engines for recreational vehicle Run fuel lines at the same height as the top level of tank
generator sets varies accordingly. to a point as close to the engine as possible. This redu-
cesthedangeroffuelsiphoningoutofthetankiftheline
should break. Redistribution or publication of this document,
by any means, is strictly prohibited.
16
 Keep fuel lines awayfrom hot engine or exhaust areas. When installing the fuel lines, keep the following in
This reduces chance of vaporlock. Install lines so that mind:
they are accessible and protected from damage. Use
metal straps without sharp edges to secure them. 1. Install all propane fuel lines so they are accessible,
yet protected from damage.
Flexible line must be long enough to allow for set
movement in order to prevent binding, stretching or
breaking.
PROPANE (LPG) FUEL SYSTEM
(60 Hz Only)
+ - Fuel System Provisions
' ..- Onan liquid LPG generatorsets contain afiltercartridge
and magnet in the fuel solenoid valve to protect the
solenoid valve and regulator valves from dirt and con-
taminants. The solenoid valve and filter is shown in
Figure 11. Figure 12 shows the flow diagram for the
liquid LPG fuel system componentsused on thegenera-
tor set
Generator set operation using liquid LPG is very sensi-
tive to altitude,temperature,and BTU contentof the gas.
Variation in any one of these factors directly affectsthe
performance of the generatorset. Because of this, minor
adjustments might be required after the installation,
refer to Generator Set ServiceManual if adjustmentsare
required. . ,

Recommended Fuel
Use clean, fresh commercial propane or HD-5 grade
FUEL FILTER
liquid propane gas in a mixture of at least 90 percent BODY
propane. Propane fuelsotherthan HD-5 gradecan con-
tain more than 2.5 percent butane and can result in poor
fuel vaporization and poor engine starting in low
ambient temperatures (below 32°F or OOC). FIGURE 11. FUEL SOLENOlO VALVE AND FILTER

Fuel Consumption 2. Use metal strapswithoutsharpedgesto securefuel

lines.
It should be noted that under varying electrical loads,
fuel consumption of engines for recreational vehicle 3. Keep fuel lines away from hot engine or exhaust
generator set varies accordingly. Average fuel con- areas.
sumption at various loads is shown in the table below. 4. Do NOT run fuel lines in conjunction with electrical
wiring.
LPG FUEL CONSUMPTION Most propane (LPG) liquid withdrawal generator set
installations are designed to sharethe vehicle propane
No &ad Half Load Full Load fuel supplytank(s). The vehicle propanefuel supply tank
0.5 gal/hr 0.8 gal/hr 1.3 gal/hr MUST have a dip tube to ensure liquid withdrawal.
(1.9 I/hr) (3.0 Vhr) (4.0 I/hr)
An excess flow valve MUST be mounted internal to the
propane fuel supplytank(s)per NFPA 501C, Paragraph
Propane Fuel Lines and Supply Tank . 3-4.4. This excess flow valve and propane fuel lines
MUST be sized so the excessflowvalve will close with a
The installer must review all codes that apply to the completely severed (broken) propane fuel line. For
particular installation. Paragraph 3-5.1 (GasPiping Sys- operation at the lowest ambient temperature, a valve
tems) of NFPA Pamphlet 501C deals specifically with rated at 2.6 gallons per hour (9.9 Vhr) flow rate and 6.5
propanefuel linesbutdoesnotnecessadycoverallapplicable pounds per square inch (45 kPa) differentialpressure is
codes and regulations. You can obtain this pamphlet recommended. Consultthe Natural LP Gas Association
from the address listed in the beginning of this manual. for the limitations of excess flow valves.

Redistribution or publication of this document,

17 by any means, is strictly prohibited.
 Install an approved flexible non-metallic (non- Testing Fuel System for Leaks
conductive)and non-organic fuel line betweentheveh- The completed propane fuel system installation MUST
icle fuel system and the generator set to absorb vibra- be checked and tested for leaks before the generator set
tion. Onan recommends using a seamless steel tubing is operated. The fuel solenoid MUST be energized from
and flared connection for long runs between the fuel a separate 12 volt DC source before testing the fue
tank and the flexible connector to the generator set. system for leaks. The test MUST conformto procedure:
listed in NFPA-58, Paragraph318,or UL recommended
A manual shut-0%valve MUST be mounted on the pro- test procedure as follows:
pane fuel supply tank. This supply tank valve MUST be
fully open when operating the generator set to ensure After assembly and prior lo initial operation, all iuel system connec-
the excess flow valve will close with a severed (broken) tions, hose, valves, regulators,andfittings must be testedand proven
propane fuel line. free of any leaks using a soap and water or equivalent solution while .
the system is under a gas or air pressure of not less than 90 pounds ..
per square inch (620 kPa).
.-A hydrostatic pressure relief valve MUST be installed
between the propane fuel supply tank manual shut-off Other approved methods of detecting leaks may be
valve and the propane fuel solenoid valve and filter used if appropriate. Test shall NOT be made with a
assembly. flame.

Liquid LPG fuel presents fhe hazard

This relief valve protects the propane fuel line from
pressurebuildup if boththe supply tank manual shut-off Ei S Si E I of explosion or fire which can result
'

in severe personal injury or deafh. Do not smoke or

valve and the fuel solenoid valve are closed at the same
time. allow any ignition sources in the installation area.

C.

CARBURETOR
*l/enluri lype with bolh a "Main"andI 'Idle-
!et adjustments.

when carburetor provides suclion Io fuel outlet.

"

w
.

Must Close with Completeline

a l d o t I u r V ~ ~ ) Breakage. Consult National LP Gas
Mu3 confonnto ASME or dol and
CTC slandards. (Working pressure Associalion Publication 113-78
For Limitations.
VblQZ

FIGURE 12 FLOW DIAGRAM OF UQUIDLPG FUEL SYSTEM

Redistribution or publication of this document,
by any means, is strictly prohibited.
18
 Electrical Connections
All wiring must meet applicable local electrical codes. To reposition 90” conduit fitting, loosen locking nut
Accordingly, have a qualified electrician install and (toothed ring), turn fitting counterclockwiseto desired
inspect the wiring. location, and retighten locking nut
Mount switches and controls securely to prevent dam- Run conduit in such a way as not to interfere with the
age from vibration and road shocks. All switches must movement of the set. This is especially pertinent to the
& be vibration-proof to prevent accidental opening or under-floor installationin which the set must be free to
* _
closing while the vehicle is in motion. move.
I _

AC WIRING
Wiring Disconnect Method
Wire Types The feeder conductors from the set compartment must
terminate in a properly sized double-pole, double-throw
The conductors of the generator set must have an positive offswitching device before the vehicle distn‘bution
ampere rating not less than 115 percent of the name- panel, or connect to a generator set receptacle box This
plate current rating of the generator. The Onan- assures the outside power source cannot be connected
supplied AC feeder conductor insulation is rated at simultaneously with the generator set Figures 13 and 14
125°C. Wires connectedto the Onan feeder conductors illustrate two possible wiring connections. Figures 15 and
must meet this insulation rating, or must be of a larger 16 show generator set wiring diagrams and schematics.
wire size (see National Electrical Code, NFPA 70).
Electrical shock can cause severe
Exhaust gas presents the hazard of
1-1 severe personal injury or death. To
prevent exhaust gas from entering vehicle interior,
i*wARNlNGi personal injury or death. Use only
approved power supply assemblies. Never remove
grounding pin from assemblies. Incorrect or no ground
seal all openings made for conduit, wiring, etc. Seal can cause the recreational vehicle to become electri-
wiring within conduit itself. cally “hot”. Equip fhe recreational vehicle with ade-
quate Ground-fault Circuit Protecfion devices fo meet
Conduit the ffafional Electrical Code (fffPA 70,557-7 (C) and
Install generator load conductors supplied with the personal safety.
generator set in a flexible metallic conduit. Cut conduit
to desired length, leaving extra wire as requiredfor the I Gasolineand liquid LP G fuel present
junction box (connecting wires must be appropriately
sized and insulated for the specified current rating).
1 aWARNING ! fhe hazard of fire or explosion which
can result in severe personalinjury or death. Do not fie
Prepare ends of conduit to prevent sharp edges from electrical wiring to fuel lines.
cutting wire insulation.

Redistribution or publication of this document,

by any means, is strictly prohibited.
19
 DOUBLEPOLE '.
DOUBLETHROW
..
SWITCHINGDEVICE

*IMPORTANTI
GROUND-FAULT CIRCUK INTERRUPTERS
(GFCl's) ARE REQUIRED BY THE NATIONAL
ELECTRICAL CODE (NFPA 70. 551-7(C) IN
ALL EXTERNAL AND SOME INTERNAL
OUTLETS. TO PROPERLY EQUIP YOUR
RECREATIONAL VEHICLE WITH THESE
PROTECTIONDEVICES.CONTACTYOURRV
MANUFACTURERORDEALERFORRECOM-
MENDATIONS POWER SUPPLY CORD

..
SC-1463

FIGURE 13. SWITCHING DEVICE WIRING FOR UTILITY POWER

30 AMP
U VWlCLE AC
MAIN
DISTFIlBUTIONPANEL
\
30 AMP SET
MOUNTEDBREAKER HACR
*IMPORTANTI BREAKER
GROUND-FAULT ClRCUrr INTERRUPTERS FOR AIR
(GFCl's) ARE REQUIRED BY THE NATIONAL CONDITIONER
ELECTRICAL CODE (NFPA 70. 551-7(C) IN
ALL EXTERNAL AND SOME INTERNAL
OUTLRS. TO PROPERLY EQUIP YOUR
RECREATIONAL VEHICLE WITH THESE t
I
PROTECTION DMCESCONIACTYOURRV
MANUFACTUREROR DEALW FOR UECOM-
MENDATIONS. POWER SUPPLYCORD I
FIGURE 14. USING UTILITY POWER CORD FOR SWITCHING
Redistribution or publication of this document,
20 by any means, is strictly prohibited.
 REMOTE PANELS
DELUXE STANnAun

ADD JUMPER

WIRING DIAGRAM
I, +v
I I

i
I A3
I REMOTE
I
I
I
I
I
I
I
I
I
I
I
I
- 1 I I

I I1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
-1
I
I
I
I

K5 1RELAY-USEOWiTHLffiONLY
KI ISTART SOLENOID

I
E3 FUEL PUMPlOR FUELSOLENOIO
E12 ISPARK PLUG
CIRCUIT BREAKER (AC OUTPUT1

611-1174 (Rd) CI lCAPAClToR

BTI I WdlERY 12V

flGURE 15.60 Hi! GENERATOR SET WRING DIAGRAM/SCHEMATIC

Redistribution or publication of this document,
by any means, is strictly prohibited.
21
 REMOTE PANELS
DELUXE STANDARD

..

W1.2 JUMPER-WIRE
T2 TRANSFORMER
TI IGN COIL
U IGN POINTS
SZ SWITCH- LOW OIL PRESSURE
SI SWITCH-STMISTOP
R6 RESISTOR-BATTERY CHARGE
KS RELAY-USE0WITH Lffi WLY
KI STARTSOLEWD
‘CROUHKD
Ac LEAD HI CHOKE
GI GENERATOR
FI FUSE
E3 FUEL PUMP/OR FUEL SOLENOID
E12 SPARKPWG
fB.2
CR4
WRWlT BREAKER (AC OUTPUT)
BRIDGE RECTIFIER
,
CRS RECTIFIER -USED WITH LPG ONLY
CI CAPACITOR
_I

BTI E A T E R Y 12V
e1 STARTER
A3 STANDARD REMOTE CONTROL
A2 D U X € REYOTE CONTROL
611-1177 AI CONTROL ASSY

Redistribution or publication of this document,

by any means, is strictly prohibited.
 DC WIRING
1-5/16IN.
Remote Switch Wiring
The standard remote control includes a start-stop
-Y(33.3;1n)
switch and indicator lamp. The deluxe control contains
these items plus a running time meter and a battery
condition meter. Install as follows:
1. Select control location. Use Figures 17 and 18 as
guides. Drillscrew holesand cut holeto accommodate
+ *
remote switch in dash panel.
2. Following nationaland localelectricalcodesandusing
.. #18 or larger insulated wires of predetermined length,
connect remotecontrolto generatorset Referto Figure
19 for wiring connections.
3. Connect jumper betwezn terminal 5 and 6 on
deluxe panel.

'v! flectrical induction can occur

when DC wires are run with AC
wires and can cause operational problems.
M-1580

4. insert remote control in hole cutoutand secure with FiGURE 17. CUTOUT FOR STANDARD CONTROL
woodscrews supplied with switch. .

Exhaust gases present the

1 - or1 death. Seal allhazard of severe personalinjury
holes to prevent entrance of
4-1.'81N
exhaust gases in20 recreational vehicle interior.
1- Incorrect connections can darn-
age control, remote switch, and
interconnecting wiring. Ensure that leads from
remote switch connect with the corresponding
terminals on generator set.
5. When wiring is complete, check for proper opera-
tion by starting and stopping set at the set control
and from the remote control panel.
M-1581
Battery charge rate ammeter, running time meter
and generatinglamp should be operatingonly while
the generator set is running.
6. If the set starts by itself or cannot stop, check for
short-circuited remote control wiring. FIGURE 18. CUTOUT FOR DELUXE PANEL

Redistribution or publication of this document,

by any means, is strictly prohibited.
23
 GENERATING LAMP
(GLOWSWHEN SET
IS RUNNING) - I
- DELUXE PANEL

NOTE: USE i a GAUGE OR

LARGER WIRE FOR INSTALLING THE
REMOTE START SWITCH.

BACK SIDE OF
REMOTE REMOTECONTROL
R BATI'ERY CHARGE CONNECTOR SWITCH
METER RATEAMMETER

c- STANDARD PANEL

GENERATING LAMP
[GLOWS WHEN SET
IS RUNNING1

SETTERMINAL REMOTE SWITCH WIRE COLOR

TERMINAL FUNCTION CODE
1 1 GROUND BLACK
2 2 STOP BROWN
3 3 START YELLOW
LAMP AND RUNNING
6 6 TIME M n E R RED
BATlERY CHARGE
RATE AMMETER

ES-1530

FIGURE 19. WIRING CONNECTIONSFOR REMOTE CONTROLS

Batteries and Connections Consider applicationand weather conditions. For relia-

The generator set should crank sufficiently under var- ble cold weather starting, voltage drop from the battery
ious operating conditions. Before making any battery terminalsto the generator set starter should not exceed
connections, choose a battery and cables which are 0.12 volts per 100 amperes of current while the genera-
appropriate for the anticipated application and devise tor set is cranking. Refer to the following tables to aid in
an adequate battery installation area. determining cable size and battery rating. ,
Batteryand CableSe1ection:Choose a battery that suits
the generator set current rating. The starter has a cur-
rent draw of 60 to 100 amperes. The inrush current is b

300 to 400 amperes.

Redistribution or publication of this document,

by any means, is strictly prohibited.
24
 Cables for Reliable Cold Weather Batteries presenf the hazard of ex-
Starting to -2OOF(-29'C)
;aWARN"G ! plosion which can result in severe
personal injury. Because batteries uive off exalosive
*CABLE LENGTH CABLE the generator set or any spark-producing device.
IN FEET (METRES) SIZE
0-10 (0-3) 2**
4 11-15 (3-4.5) 0
16-20 (4.5-6) 000 Battery Connections: Make sure the frame connector

Cold Cranking Amps for Minimum Route the battery cables between the generator set and
12-Volt Battery*** its starting battery. Ensure the cables are sufficient
length, but do not connect to battery until instructed in
ABOVE 32°F BELOW 32OF Installation Checks and Start-up section. Provide ade-
quate support of battery cables to avoid abrasion wear
due to vibrations when vehicle is in transit
360 Cold Cranking 450 Cold Cranking
Amps
(Approx. 70 amplhour) (Approx 95 amplhour)
Postifive (+) Battery Cable: Connects to the start sole-
*** - Larger capacity batteries may be required if noid. Assemble the B+ terminal boot cover supplied in
battery is also used to power other coach the accessory kit onto the generator end of the cable.
accessories. Connect the B+ cable end to the starter solenoid termi-
nal, tighten securely, and place terminal boot over
connection.

failure protect B+ terminal can

to
1 -ment damage ifresult in personal injury and/orequip-
electrical short fo control casting
Battery Compartment:Use a separate battery from the
vehicle starting battery forthe operation of the generator would occur. Ensure that terminal connection is
set. House the battery in its own compartment, away secure and booi protector is properly in place.
from the generator set and any spark-producing device.
. For ventilation purposes, build the compartment with a
minimumof1.7in2(ll cm*)openingatthetopand1.7in2
(11 cm2) opening at the bottom. Negative (-) Battery Cable: Connects to the mounting
plate. Use the same size cableto connect battery nega-
Mount the battery on a rigid support structure and in a tive to ground as used for battery positive. Securely
location where leaks and accidental spills won't dam- connect the negative cable to an accessible mounting
age the set or battery. plate fastener position.

Redistribution or publication of this document,

by any means, is strictly prohibited.
25
 Bnstallation Checks and Start-Up
PRE-START CHECKS Examine the exhaust system for leaks. If any leal.
are found, shut down the generator set immediately
Before starting the generator set, perform these steps: and have the leak($ repaired as soon as possible. ,
1. Refer to li%tall$ion Review, this section.
2. Add oil to theengine. See the Operator's Manual for AWARN~NG Exhaust gas presents the
the recommended oil and quantity. hazard of severe personalinjury ,
3. Check that battery terminals and cable connectors or death. Do not operate the generator set if it is
excessively noisy. Have it inspected and repaired
. - are clean and dry. Connect the positive (+) battery immediately by an authorized Onan service
cable to the POS (+) battery postfirst, then connect
t h e negative (-) battery cable to the NEG (-) battery center.
post last.
Refer to Operator's Manual and perform Break-in
Batteries present the hazard of Procedure.
IBWARNING] explosion which can result in Stop generator set by placing the unit Start/Stop
severe personal injury. Because batteries give off switch to STOP position.
explosive gas, do not smoke or allow any arc-
producing devices in the battery area. Do not dis-
connect baftery cables from the battery while the
generator set is cranking or while it is running.
This causes arcing and can result in an explosion.

4. Referto Operator's Manual and specifics of system.

Open fuel supply valves to generator set
Start Generator Set at Remote Control
INITIAL START-UP/INSPECTION 1. Placethe Remote Start/Stopswitch to START posi-
Start Generator Set at Unit Control
tion. Engine should crank and start. If generator set
fails to crank and start, refer to Troubleshooting i
Place Start/Stop switch to START position. Engine Operator's Manual. Perform checks of all remot
should crank and start Unit may require more control wiring and connections. Correct as requirea
cranking at initial start than subsequent starts to and perform restart
prime fuel system. If generator set fails to start, refer 2. After the generator set starts, check battery condi-
to Troubleshooting in Operator's Manual. tion meter (if equipped)to confirm its proper operation.
After the generator set starts, check for any fuel 3. Refer to Operator's Manual for operating checks.
leaks. If you find any, shut down the generator set
immediately, turn off the fuel supply and have leak@) 4. Allow generator set to operate at a normal load
repaired. Make sure the fuel lines do not rub against condition and continue to monitor fuel supply con-
anything that can damage them. nections, exhaust system, unit performance, and
quality of noisereduction (id so designed), If genera-
(BWARNINGI Fuel presents the hazard of tor set performance is not correct, refer to Service
Manual foradjustment, or contact an Onan distribu-
explosion or fire which can
result in severe personalinjuryordeath. liany fuel tor for assistance. if fuel supply, exhaust system, or
leaks are found, shut down the generator set other aspect of installation requires corrective
immediately and have the leak repairedassoon as action disconnect starting battery to prevent acci-
possible. dental start-up while performing rework.

Redistribution or publication of this document,

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26
 EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide,an odorless and colorless gas. Carbon
monoxide is poisonous and can cause unconsciousness and death. Symptomsof
carbon monoxide poisoning can include:
e Dizziness Throbbing in Temples
t Nausea Muscular Twitching
0 Headache 0 Vomiting
.- 0 Weakness and Sleepiness Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT
INTO THE FRESH AIR IMMEDIATELY. I f symptoms persist, seek medical atten-
tion. Shut down the unit and do not operate until it has been inspected and
repaired.
Never sleep in vehicle with the generator set running unless the vehicle interioris
equipped wifhan operating carbon monoxide detector. Protectionagainst carbon
monoxide inhalationalso includes proper exhaust system installationand visual
and audible inspection of the complete exhaust system at the start of each
generator set operation,
1-RV

Redistribution or publication of this document,

by any means, is strictly prohibited.
27
 INSTALLATION REVIEW
Prior to initial start-up of generator set, address each of the following installation review items. For a safe and effective
installation, each answer must be affirmative; if not,that aspect ofthe installation should be reworkedor provision madl
to satisfy the requirement.

1. Does the exhaust system extend to the perimeter of the vehicle, and not below an open-
able window or door?
.
2. Are all required exhaust clamps, hangers and support straps in place per kit
instructions?
3. Do the hanger straps located at the perimeter and along the centerline of the generator
set have double “U” shaped rubber isolators?
4. is the compartmentmetal-lined and sealed around all edges?
5. Is a flexible section of non-conductingfuel line installed between the fuel inlet and the
fuel line from tank?
6. Does the installation allow 112 inch (13 mm) free movement of generator set on its
mounts?
7. Are all fuel connections and hose clamps tight?
8. Is there 85 in* (548 cm2) of free air inlet?
9. Is generator set protecfed from direct road splash from vehicle wheels?
10. Can the following routine maintenance items be performed (through vehicle access door
or removal or cover panel, or swing down/drop out of generator set):
0 Change Oil and Filter
0 Carburetor Adjustments
Startistop the Unit
0 Change Air Filter

Governor Adjustments
0 Operate AC Circuit Breakers
0 Change Spark Plugs
0 Change Ignition Points

11. Are fuel lines and electrical wires run separately?

12. Are wiring holes into the inside of coach (including the inside of AC conduit) sealed to
prevent passage of exhaust gases?
13. Has rubber boot been installed on battery plus (+) lead at the start solenoid connection in
the control?
14. On a liquid propane generator set, has system been tested for leaks?
15. If 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 set to swing down for
service?
16. Are all electrical leads connected and protected, and conduit is adequately supported?

Redistribution or publication of this document,

by any means, is strictly prohibited.
28
Redistribution or publication of this document,
by any means, is strictly prohibited.
Redistribution or publication of this document,
by any means, is strictly prohibited.
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