Home

Installation

1. 10 VONUIQUON 10 11 EXHAUST SYSTEM 18 CGO E 13 Muffler Recommendations 13 Exhaust Installation Guidelines 13 Tailpipe Recommendations 13 FUEL SYSIEM uy uruy deen 16 General asua yaa 16 Gasoline Fuel System 16 Propane LPG Fuel System 17 ELECTRICAL CONNECTIONS 19 AG WIIN jag anette ree aR E O ONA 19 DO WING a 23 INSTALLATION CHECKS AND START UP 26 Pre Start Checks 26 Initial Start Up Inspection 26 Installation Review 28 Introduction Each RV generator set must be installed properly if it is to operate reliably quietiy and most importantly safely Therefore read the entire manual and housing exhaust kit instructions before starting the installation This manual details installation procedures for the Onan BGE and BGEL generator sets Fo
2. Ayn DK A Exhaust gas presents the hazard of WARNING severe personal injury or death Use only Onan specified exhaust equipment with generator set and support the system per kit instructions severe personal injury or death Do not terminate exhaust gas under vehicle Do not termi nate exhaust system directly under any vent window or opening which can be opened and which is not permanently sealed from the vehicle living space Keep all openings closed when the generator set is running AWARNING Exhaust gas presents the hazard of 13 ACAUTION Excessive exhaust back pressure can cause engine damage If tailpipe deflector is used make sure it is large enough to pre vent back pressure Water vapor can cause engine dam ACAUTION age Do noi connect the generator set exhaust to the vehicle exhaust system since water vapor from one engine can damage the other TAILPIPE RECOMMENDATIONS An exhaust tailpipe is NOT supplied because of varia tion in length requirements between motor home manu facturers After muffler is installed and prior to installing exhaust tailpipe refer to the following recommenda tions for additional tips and safety considerations Use 1 3 8 inch 18 gauge rigid steel tubing for tailpipe lA vara Dalai Exhaust gas presents the hazard of LAWARNING severe personal injury or death Do not use flexible exhaust tailpipe since it can leak or break due to road shock or vibration Do n
3. AIR FILTER u 4 222 I T x START STOP SWITCH 15 25 11 f It 5 09 N N 1625 i 1 FUEL INLET am P 25 HOSE 2 228 l soo QIL DRAIN 7 9 eal Suen 2 HOLES OIL FILTER 73 2 2 woes 2 15 16 06 200 546 407 9 sos 5 9 raj MOUNTING HOLES COOLING AIR DISCHARGE 9 ALT FUEL PUMP J LB 99 kg 50 Hz 228 g 25 SOSE 75 INCH CONDUIT WITH A C PIGTAILS 36 0 INCHES 0 92 m LONG ng k See 5 2 HINGE a 1 20 THO 6 KOLES 9 4 FOR MOUNTING TJ A VIEW B B POSITIVE BATTERY 4064 CONNECTION 500 2135 b 344 HOLES 7 R23 25 5910 MIN N CLEARANCE FOR UNIT SWG VIEW A A FIGURE 5 UNDER FLOOR MOUNT BGE BGEL BGE SHOWN Ventilation and Acoustics VENTILATION The most important factors of ventilation for an RV air cooled generator set are sufficient incoming air for combustion and cooling and adequate exhausting of heated air All generator sets for icles use Vacu Flo cooling A centrifugal tan in a scroll housing on the engine Fig ure 6 draws air from the generat
4. JUNCTION BOX 2 VEHICLE WIRING FLEXIBLE CONDUIT 4 b A T uki 30 AMP SET MOUNTED BREAKER DOUBLE POLE DOUBLE THROW a SWITCHING DEVICE 30 AMP VEHICLE MAIN BREAKER DISTRIBUTION PANEL HACR BREAKERS FOR AIR CONDITIONER BREAKERS IMPORTANTI GROUND FAULT CIRCUIT INTERRUPTERS GFCI s ARE REQUIRED BY THE NATIONAL ELECTRICAL CODE NFPA 70 551 7 ALL EXTERNAL AND SOME INTERNAL OUTLETS TO PROPERLY EQUIP YOUR E gt RECREATIONAL VEHICLE WITH THESE PROTECTION DEVICES CONTACT YOUR RV MANUFACTURER OR DEALER FOR RECOM MENDATIONS POWER SUPPLY CORD SC 1463 FIGURE 13 SWITCHING DEVICE WIRING FOR UTILITY POWER JUNCTION BOX FLEXIBLE CONDUIT 7 VEHICLE WIRING DISCONNECTING L r a DEVICE MAIN 30 AMP SET VEHICLE AC BREAKER MOUNTED BREAKER HACR DISTRIBUTION PANEL BREAKER FOR AIR CONDITIONER IMPORTANTI GROUND FAULT CIRCUIT INTERRUPTERS 5 ARE REQUIRED BY THE NATIONAL ELECTRICAL CODE NFPA 70 551 7 IN ALL EXTERNAL AND SOME INTERNAL OUTLETS TO PROPERLY EQUIP YOUR RECREATIONAL VEHICLE WITH THESE PROTECTION DEVICES CONTACT YOUR RV MANUFACTURER OR DEALER FOR RECOM MENDATIONS POWER SUPPLY CORD BREAKERS SC 1464 FIGURE 14 USING UTILITY POWER CORD FOR SWITCHING 20 BUS BAR 611 1174 Re
5. 2 3 8 IN 60 3 mm 1581 FIGURE 18 CUTOUT FOR DELUXE PANEL GENERATING LAMP GLOWS WHEN SET IS RUNNING DELUXE PANEL NOTE USE 18 GAUGE OR LARGER WIRE FOR INSTALLING THE REMOTE START SWITCH BACK SIDE OF M2 M1 REMOTE REMOTE CONTROL RUNNING TIME BATTERY CHARGE SWITCH METER RATE AMMETER STANDARD PANEL GENERATING LAMP GLOWS WHEN SET IS RUNNING ELECTRIC STANDARD REMOTE WIRING JUMPER ON DELUXE PANEL ONLY WIRE COLOR FUNCTION CODE GROUND BLACK LAMP AND RUNNING TIME METER BATTERY CHARGE RATE AMMETER 5 1530 FIGURE 19 WIRING CONNECTIONS FOR REMOTE CONTROLS Batteries and Connections The generator set should crank sufficiently under var ious operating conditions Before making any battery connections choose a battery and cables which are appropriate for the anticipated application and devise an adequate battery installation area Battery and Cable Selection 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 300 to 400 amperes 24 Consider application and weather conditions Forrelia ble cold weather starting voltage drop from the battery terminals to the generator set starter should not exceed 0 12 volts per 100 amperes of current while the genera tor set is cranking Refer to the following tables to aid in determining cable size and battery rating Cables for Reliabl
6. DRAIN VALVE FOR MOUNTING ge 62 1 0 HOSE 98 24 9 12 48 COOLING AIR 317 0 DISCHARGE FUEL INLET 9 25 HOSE 8488 ALT FUEL OPTIONAL EXHAUST OUTLET NOTES A C CIRCUIT BREAKER 1 DIMENSIONING INCLUDES 0 6 INCH 15 mm MINIMUM CLEARANCE REQUIRED BETWEEN SET AND INSULATION OR CONNECTOR PARTMENT WALLS 2 IF COMPARTMENT 15 LARGER THAN MIN IMUM SHOWN ALLOW EXTRA SPACE AT OIL FILL SIDE AND EQUALLY ON BOTH POSITIVE BATTERY ENDS CONNECTION 3 ALLOW MINIMUM OF 0 6 INCH 15 mm MOUNTING HOLE CLEARANCE BETWEEN TOP OF SET AND INSULATION OR COMPARTMENT CEILING MINIMUM HEIGHT 14 60 INCHES 4 WEIGHT 218 188 99 50 Hz 228 A C PIGTAILS 36 0 INCHES Lb 104 kg 0 92 m LONG 5 DIMENSIONSIN MILLIMETRES 500 2126 FIGURE 2 BGE BGEL COMPARTMENT MOUNT OUTLINE BGE SHOWN CONVENTIONAL COMPARTMENT MOUNT BGE BGEL WITH DOWN EXHAUST 19 75 501 6 CUT OUT FOR COOLING AIR DISCHARGE 8 29 gosi w 1 5 31 a T 028 CONVENTIONAL COMPARTMENT MOUNT BGE BGEL WITH END MOUNTED MUFFLER 201 513 1 6 62 i 168 1 lt 2200 13 0 330 0 2 08 52 8 OPENING COOLING AIR DISCHARGE FIGURE 3 COMPARTMENT FLOOR PLAN i 50 8 DRAIN HOLE 12 7 i 4 ans ok Cy i il s 7 ig
7. VY3 8 16 une x WELDNUT 2 ae A a 4 C G 142 mm T 1572 13993 625 4 250 HOLE 63 5 50 g DRAIN HOLE 12 7 50 SQ HOLE 12 7 2 PLACES 1 DIMENSIONS INCLUDE 0 6 15 mm MINIMUM CLEARANCE REQUIRED BETWEEN SET AND INSULATION OR COM PARTMENT WALLS 2 IF COMPARTMENT IS LARGER THAN MIN IMUM SHOWN ALLOW EXTRA SPACE AT OIL FILL SIDES AND EQUALLY ON BOTH ENDS 3 ALLOW MINIMUM OF 0 6 INCH 15 mm CLEARANCE BETWEEN TOP OF SET AND INSULATION OR COMPARTMENT CEIL ING MINIMUM HEIGHT 14 60 INCHES 371 mm 4 DIMENSIONS ARE IN MILLIMETRES 5 SQUARE HOLES 6 50 12 7 ARE SUITABLE FOR USE OF 3 8 INCH CAGE NUT A 26 20 IN 665 51 16 50 11 00 4191 2 50 g 279 4 635 500 5 7 03 12 7 179 8 DRAIN HOLE CC C lt 6 3 8 16 UNC l I WELD 2 1825 375 9 l 157 T ss 3993 C G 142 mm i 16 25 312 8 250 HOLE 18 I 63 5 17 3 4 6 ZA 508 CRAIN HOLE 12 7 it CA Ret Aw 6 13 1 00 2 50 155 7 850 25 4 63 5 I 215 20 00 TRAY 508 0 50 SQ HOLE 12 7 2 PLACES UNDER FLOOR MOUNT For an under floor mount installation the generator is mounted in a housing below the floor and outside the coach of the recreational vehicle This hous
8. set removal Allow additional clear ance for easy access to the oil fill drain filter and oil dipstick as well as the air cleaner element circuit breaker governor adjustments carburetor adjustments Start Stop switch and DC fuse The locations of each are shown in Figure 1 Design the compartment large enough for the generator set with 0 6 inch 15 mm minimum clearance between the generator set and compartment walls and ceiling and acoustical material if used See Figures 2 and 3 Compartment Construction 1 Install the generator set in its own compartment Separate the compartment area from the living quar ters and any fuel supply gasoline or propane with a vapor tight wall See Figures 2 and for minimum clearances and compartment size 2 Line the compartment walls with 26 gauge galvan ized steel or a material of comparable strength dur ability and fire resistance see NFPA 70 NEC and California Title 25 for complete details 3 Construct the compartment floor a manner so as to prevent oil fuel or water accumulation Com partment drainage can be accomplished by 1 2 inch 13 mm diameter holes as shown on the com partment floor drawings Figure 3 Fire presents the hazard of AWARNING severe personal injury or death To prevent a fire hazard do not position the directly below a drain hole Do NOT use absorbent sound proofing material on compartment floor The floor should have min
9. weld mechanical joint For short distances one negative bat tery cable can be used between the generator set and baitery rather than separate cables to chassis ground Route the battery cables between the generator set and its starting battery Ensure the cables are sufficient length but do not connect to battery until instructed in 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 Postitive Battery Cable Connects to the start sole noid Assemble the B terminal boot cover supplied in the accessory kit onto the generator end of the cable Connect the B cable end to the starter solenoid termi nal tighten securely and place terminal boot over connection Failure to protect B terminal can ACAUTION result in personal injury and or equip ment damage if electrical short to control casting would occur Ensure that terminal connection is secure and boot protector is properly in place Negative Battery Cable Connects to the mounting plate Use the same size cable to connect battery nega tive to ground as used for battery positive Securely connect the negative cable to an accessible mounting plate fastener position Installation Checks and Start Up PRE START CHECKS Before starting the generator set perform these steps 1 2 3 Refer to Installation Review this section Add oil to the engine Se
10. with this method A temperature rise of 8 F 4 4 C between the outside ambient and air in the top openings of the generator housing ts acceptable MINIMUM FREE AIRFLOW TO GENERATOR SET COVPARTMENT MAY BE CUMULATIVE 85 2 548 Skirt RV Floor Skirt AIR INLET BETWEEN RV SKIRT AND GENERATOR SET Top View Duct Gen Set ACCESS DUCT FROM DOORAIR SIDEWALL INLET GENERATOR FIGURE 7 AIR INLET ALTERNATIVES FOR UNDER FLOOR MOUNT GENERATOR SET ACOUSTICS The Onan housing kit for the under floor mount genera tor set contains acoustical material to minimize noise Additional insulation is not necessary however you are constructing your own compartment or housing use the following guidelines For the conventional compartment mount if compart ment penetrates floor be sure all joints and corners of the compartment are vapor tight to the interior Lining the compartment is less effective if openings cracks doors and joints are not sealed Also seal compartment door edge to eliminate noise leaks around the door perimeter Cover the sound reflective surfaces back top and sides not compartment base with fiberglass or other self extinguishing acoustical material Acoustical material and adhesive should be rated for use at 200 F 90 C minimum 11 Rather than using one single material a combination of materials can reduce noise considerably For instance a sheet of lead or viscoel
11. 11 3 m3 min Fuel Inlet Connection huysa tas 1 4 in barb fitting eee cares 1 4 NPTF Voltage 12 volts Recommended Battery 360 cold cranking amperes Cranking CUEN desires 100 amperes r min at 60 Hertz 1800 1500 Under Floor mount generator set with compartment housing has slightly larger dimensions See Mounting section Mounting Read the entire manual and housing exhaust kit instructions before installing the generator set The generator set is designed for two very different types of installations conventional compartment mountinstalla tions and under floor mount installations Choose the appropriate section describing each carefully fol low the instructions given CONVENTIONAL COMPARTMENT MOUNT a conventional installation the generator set is actu ally installed on a framework that is part of the recrea tional vehicle RV This framework must be constructed in accordance with the safety approved specifications contained in the following Compartment Construction section Unless generator setis to be removed from underneath plan the location for an access opening to be large enough to permit
12. 4 15 16 Does the exhaust system extend to the perimeter of the vehicle and not below an open able window or door Are all required exhaust clamps hangers and support straps in place per kit instructions Do the hanger straps located at the perimeter and along the centerline of the generator set have double U shaped rubber isolators Is the compartment metal lined and sealed around edges ls a flexible section of non conducting fuel line installed between the fuel inlet and the fuel line from tank Does the installation allow 1 2 inch 13 mm free movement of generator set on its mounts Are ali fuel connections and hose clamps tight Is there 85 in 548 cm of free air inlet 15 generator set protected 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 e Change Oil and Filter Carburetor Adjustments Start Stop the Unit Change Air Filter Governor Adjustments e Operate AC Circuit Breakers e Change Spark Plugs Change Ignition Points Are tuel lines and electrical wires run separately Are wiring holes into the inside of coach including the inside of AC conduit sealed to prevent passage of exhaust gases Has rubber boot been installed on battery plus lead at the start solenoid connection in the contro
13. ABLE CONNECTION POSITIVE BATTERY TO PLATE CABLE CONNECTION LOCATION OPTIONAL REMOTE START CABLE CONNECTION M 1604 1 FIGURE 1 BGE AND BGEL GENERATOR SETS General Specifications ENGINE Onan opposed 2 cylinder 4 cycle air cooled gasoline fueled forthe BGE model and propane fueled for the BGEL model Remote start negative ground 12 volt automotive type siarter GENERATOR Onan built four pole revolving field permanently aligned to engine FICQUENCY yy s vex 60 Hz MV 3500 4000 ee 110 220 120 240 120 AIM DS ib tack hice rece tates 31 8 15 9 29 2 146 33 3 18 CONTROL Front mounted control features fixed battery charger and remote start capability GENERATOR SET Dimensions HOM 14 0 in 856 mm L zas 25 0 635 18 8 478 Weight 218 Ib 99 kg 1222 E 228 Ib 104 Air Requirements OO a alee awe te eases 480 3 13 6 m3 min 400 ft min
14. Chantilla VA 22021 2 NFPA 70 N E C National Fire 501 Protection Assoc 470 Atlantic Ave Boston MA 02210 3 CSA Electrical Bulletin 946 Canadian Standards Assoc Housing amp Const Materials Section 178 Bivd Rexdale Ont Canada M9W 1R3 4 UL Standard 1248 Underwriters Lab Inc 333 Pfingsten Road Northbrook iL 60062 5 California State of California Administrative Documents Section Code Title 25 P O Box 1015 Chapter 3 North Highlands CA 95660 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 GOVERNOR B G E SPARK ADJUSTMENTS PLUG IGNITION POINTS SPARK PLUG TRANSFORMER HOUSING 4 2205 lt Z 40 4 I AIR CLEANER BLOWER 77 9 SUMMER WINTER CARBURETOR ADJUSTMENT ADJUSTMENTS OIL FILTER FUEL PUMP INLET OIL FILL AC CIRCUIT BREAKERS DC FUSE START STOP DRAIN REMOTE START SWITCH CABLE CONNECTION NEGATIVE BATTERY TO PLATE CABLE CONNECTION LOCATION OPTIONAL G E L SPARK PLUG VAPORIZER TRANSFORMER SS HOUSING BLOWER i gt anne u HOUSING CARBURETOR ADJUSTMENTS OIL FILTER AC CIRCUIT BREAKER OIL FILL FUEL FILTER AND SOLENOID ASSEMBLY OIL DRAIN FUEL INLET NEGATIVE BATTERY C
15. MATIC 2 Al CRI RG i i GND REEN FIGURE 16 50 HZ RECONNECTABLE 4 WIRE GENERATOR SET WIRING DIAGRAM SCHEMATIC 22 BUS BAR 00000 12 Jl 2 I T 1 53 52 41 53 y 41 54 2 2 gt 85 86 Al K4 Al ALPES El 153 I 1 247 2 AK2 a o anp am s atw START STOP Al P3 1 NOMINAL NOLOADVAC 127544 5 V AG LEADS CR4 AC SI TODECREASE NOMINAL NO LOAD NORMAL NOMINALNO XI 4 CONNECTOR INSULATED JUMPER WIRE TRANSFORMER IGN COIL IGN POINTS SWITCH LOW OIL PRESSURE SWITCH START STOP RESISTOR BATTERY CHARGE i RELAY USED WITH LPG ONLY START SOLENOID CHOKE GENERATOR 5 FUEL PUMP OR FUEL SOLENOID SPARK PLUG CIRCUIT BREAKER AC OUTPUT BRIDGE RECTIFIER RECTIFIER USED WITH LPG ONLY CAPACITOR BATTERY STARTER STANDARD REMOTE CONTROL DELUXE REMOTE CONTROL CONTROL ASSY DC WIRING Remote Switch Wiring The standard remote control includes a start stop switch and indicator lamp The deluxe control contains these items plus a running time meter and a battery condition meter Install as f
16. RNISHED BY ONAN 5 1150 EXHAUST ACCESSORY KIT 542 0469 SHOWN gt 95 5 28 ay lt EXS 1149 FURNISHED BY ONAN TAILPIPE NOT FIGURE 10 EXHAUST SYSTEM KIT EXAMPLES FOR UNDER FLOOR MOUNT 19 Fuel System GENERAL This installation manual covers gasoline and LPG liquid propane gas fuel systems The Onan BGE model is gasoline fueled and the Onan BGEL model is liquid LPG fueled Separate procedures are given for each Fuel presents the hazard of fire or WARNING explosion which can result in severe personal injury or death Do not smoke or aliow any ignition sources in the installation area Keep a type tire extinguisher nearby The ventilation system of the installation area must provide a constant flow ofair to expel accumulation of fuel vapor while the vehi cle is in transit Compariments must be vapor tight to the vehicle interior to prevent any fumes from entering the vehicle interior GASOLINE FUEL SYSTEM Fuel System Provisions Generator set installations may be designed to share the vehicle fuel supply tank with the vehicle engine All connections to the vehicle fuel tank must be done in accordance with chassis vehicle manufacturer s detailed installation instructions See Fuel Line In stallation The generator set includes a fuel shut off valve as a safety feature and is an integral part of the fuel pum
17. RV Electric Generating Set This manual must be given to the customer along with the Operator s Manual 965 0630 10 86 Printed in USA Onon Installation Manual BGE BGEL GenSets Safety Precautions This symbol warns immediate A DANGER hazards which will result in severe personal injury or death This symbol refers to hazard AWARNING practice which can result in Severe personal injury or death This symbol refers to a hazard or ACAUTION unsafe practice which can result in personal injury or product or property damage Fuels electrical equipment batteries exhaust gases and moving parts present potential hazards that could result in serious per sonal injury Take carein following these recommended procedures Do not work on this equipment when mentally or physically fatigued Use Extreme Caution Near Fuel A constant potential explosive or fire hazard exists Do not fill fuel tank near unit with engine running Do not smoke or use open flame near the unit or the fuel tank Be sure all fuel supplies have a positive shutoff valve Use a non metallic non conductive flexible section of fuel line between the generator set and stationary fuel line in vehicle LPG The propane fuel supply lines MUST comply with all requirements of NFPA 501C Section 3 5 paragraphs 1 1 and 1 2 as well as Canadian Gas Association Bulletin 8149 2 78 The installer must review and comply w
18. al vehicle skirt for an air inlet if it is not sub jected to road splash See VENTILATION for more detailed information Air inlet openings to the generator set compartment must not allow dirt rock water or slush to directly hit the generator set Dust and salt entrance into the compartment must be minimized Pay special attention to protection of the generator control choke and governor areas Baffles might be required to protect certain areas I N REFER TO HOUSING KIT REFER TO INSTRUCTIONS EXHAUST KIT INSTRUCTIONS FIGURE 4 COMMON MOUNTING AREAS OF GENERATOR SET 8 Access Opening Provide an access opening on the side of the recreational vehicle for the generator set Make it large enough to allow for checking or adding for adjusting governor and carburetor and for access to the control panel and AC circuit breaker The opening should also provide access for oil and air filter replace ment so that the generator set does not have to be lowered for these procedures See Figure 1 for locations Mounting Clearance If the compartment door does open the full width of the generator set and to the bottom of the vehicle skirt provide 2 inches 51 mm minimum between the tray and the skirt of the recreational vehicle This distance allows lowering the generator set without hitting the vehicle skirt Figure 5 shows basic dimen sions of the under floor mount generator set Housing As
19. astic material and a layer of acoustical materials is more effective than either alone To reduce line of sight noise a sound panel baffle should be added behind the air inlet The panel must be spaced to allow for minimum free air inlet of 85 in 548 Refer to Figure 8 to aid your generator set compartment design and noise reduction plans Size ducting to ensure that minimum free airflow of 85 548 is still attained after acoustical material is added High temperatures in the compart AWARNING ment can present the hazard of fire which can result in severe personal injury or death To meet UL ANSI and CSA temperature rise requirements for recreational vehicles insulation must not reduce the 0 6 inch 15 mm clearance specified SELF EXTINGUISHING _ INSULATION 222224 MATERIALS 3 4 INCH 19 mm THICK MINIMUM OF 85 IN 548 cm UNRESTRICTED AIR INLET ABOVE UNIT STORAGE COMPARTMENT OPTIONAL HEATED OUT SOUND SHIELD amp IN AIR DEFLECTOR 6 INCH 152mm MINIMUM FIGURE 8 NOISE REDUCTION COMPARTMENT DESIGN RECOMMENDATION 12 Exhaust System GENERAL Plan each individual exhaust system carefully proper installation is not only vapor tight but usually quieter and safer too sure to check all applicable standards local codes and regulations Refer to the following text for reco
20. cal installations performed by a qualified licensed electrician Do Not Smoke While Servicing Batteries Batteries emit a highly explosive gas that can be ignited by electrical arcing or by smoking Exhaust Gases Are Toxic Never sleep in the vehicle with the generator set running unless the vehicle is equipped with an operating carbon monoxide detecior Provide an adequate exhaust system to properly expel dis charged gases Check exhaust system regularly for leaks Ensure that exhaust manifolds are secure and not warped Be sure the unit is well ventilated Keep the Unit and Surrounding Area Clean Remove all oil deposits Remove all unnecessary grease and oil from the unit Accumulated grease and oi can cause overheating and subsequent engine damage and may presenta potential fire hazard When cleaning generator set provide cover or other protection so that cleaning and rinse water and other contaminants are not allowed into the generator air cleaner control box fuel solenoid or electrical connectors Generator set operation and internal components can be adversely affected Do NOT clean the generator set while unit is operating This can result in personal injury or product or property damage Do NOT use high pressure air water or steam for cleaning generator set compartment Dirtand other foreign matter be forced into generator engine and control housings Genera tor set operation and internal compone
21. cap 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 valve is functioning properly Replace if required if separate connection is not supplied for the generator adda second fuel pickup in the tank This pickup should not extend below the bottom 1 4 of tank so the vehicle can still be run after generator runs out of fuel Do NOT tee off the vehicle fuel line doing so may cause poor operation of the generator or the vehicle Consult _ with vehicle manufacturer for further specifics regard ing ashared fuel supply Unauthorized fuel system mod ifications could result in dangerous operating con ditions ACAUTION Connecting the generator set fuel fine with tee to the main fuel line can result the generator set starving for fuel when vehicle is operated at highway speeds The generator set fuel pump has neither the capacity nor the power to overcome the draw of the vehicle engine fuel pump Use a separate fuel line for the generator set Gasoline presents the hazard of explo AWARNING sion or fire which can result in severe personal injury or death Do not connect the generator set fuel line to the pressurized part of the vehicle fuel system Flooding of the generator set engine and com partment can occur resulting in a fire hazard install an approved flexible non metallic non conductive and no
22. e Cold Weather Starting to 20 F 29 C CABLE LENGTH IN FEET METRES 0 10 0 3 11 15 3 4 5 16 20 4 5 6 Distance from battery to set For warm weather operation 2 cable can be acceptable up to 20 feet 6 1 m Cold Cranking Amps for Minimum 12 Volt Battery BELOW 32 F 0 C 450 Cold Cranking Amps Approx 95 amp hour ABOVE 32 F 0 C 360 Cold Cranking Amps Approx 70 amp hour Larger capacity batteries may be required if battery is also used to power other coach accessories Battery Compartment Use a separate battery from the vehicle starting battery for the operation ofthe generator set House the battery in its own compartment away from the generator set and any spark producing device For ventilation purposes build the compartment with a minimum of 1 7 11 cm opening atthe top and 1 7 11 cm opening at the bottom Mount the battery on a rigid support structure and ina location where leaks and accidental won t dam age the set or battery 25 Catteries present the hazard of ex AWARNING plosion which can result in severe personal injury Because batteries give off explosive gas instailihe battery separate compartment from the generator set or any spark producing device Battery Connections Make sure the frame connector major frame member if possible is sufficient to minim ize resistance Try to avoid connection at a
23. e the Operator s Manual for the recommended oil and quantity Check that battery terminals and cable connectors are clean and dry Connect the positive battery cable to the POS battery post first then connect the negative battery cable to the NEG battery post last Batieries present the hazard of AWARNING explosion which can result in severe personal injury Because batteries give off explosive gas do not smoke or allow any arc producing devices in the battery area Do not dis connect batiery cables from the battery while the generator set is cranking or while it is running This causes arcing and can result an explosion Referto Operator s Manual and specifics of system Open fuel supply valves to generator set INITIAL START UP INSPECTION Start Generator Set at Unit Control 1 Place Start Stop switch to START position Engine should crank and start Unit may require more cranking at initial start than subsequent starts to prime fuel system If generator set fails to start refer to Troubleshooting in Operator s Manual After the generator set starts check for any fuel leaks lf you find any shut down the generator set immediately turn off the fuel supply and have leak s repaired Make sure the fuel lines do not rub against anything that can damage them Fuel presents the hazard of AWARNING explosion or fire which can result in severe personal injury or death If fuel leaks are
24. enerator set with minimal bends and materials used should be smooth and non restrictive to airflow Air inlet openings should be located as high as possible to allow for convection cooling of heated air from the generator set compartment after unit shutdown Other wise hard starting might result due to vapor locking gasoline fuel hot combustion air etc Fuel or fuel leakage presents the AWARNING hazard of fire or explosion which can cause severe personal injury or death The ventilation system should provide a constant flow of air to expel any accumulation of fuel vapor Compartments must be vapor tight to the vehicle interior to keep fumes from entering the vehicle To obtain the 85 548 free air inlet area Onan recommends bringing in cooling air through the recrea tional vehicle skirt This can be accomplished by using the access door ducting into the 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 MOUNTING section See Figure 7 for reference to these areas If the skirt of the vehicle does not extend to or below the 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 recreational vehicle is both parked and while the vehicle is moving at highway speeds to ensure proper cooling
25. found shut down the generator set immediately and have the leak repaired as soon as possible 26 Examine the exhaust system for leaks If any leak are found shut down the generator set immediately and have the leak s repaired as soon as possible AWARNING Exhaust gas presents the c hazardof severe personal injury or death Do not operate the generator set if it is excessively noisy Have it inspected and repaired immediately by an authorized Onan service center Refer to Operators Manual and perform Break In Procedure Stop generator set by placing the unit Start Stop switch to STOP position Start Generator Set at Remote Control 1 Place the Remote Start Stop switch to START posi tion Engine should crank and start If generator set fails to crank and start refer to Troubleshooting i Operator s Manual Perform checks of all remot control wiring and connections Correct as requirea and perform restart After the generator set starts check battery condi tion meter if equipped to confirm its proper operation Refer to Operator s Manual for operating checks Allow generator set to operate at a normal load condition and continue to monitor fuel supply con nections exhaust system unit performance and quality of noise reduction if so designed If genera tor set performance is not correct refer to Service Manual for adjustment or contact an Onan distribu tor for assistance If fuel s
26. imal openings to reduce sound level 4 Equip base with an oil drain hole to the outside of compartment Do not mount the muffler below the oil drain valve AWARNING Exhaust gases present the haz A WARNING ard of severe personal injury or death Make the compartment walls vapor tight to the interior of the vehicle to prevent exhaust fumes from entering the vehicle coach 5 Secure the generator set mounting plate to support frame using 3 8 16 UNC grade 5 screws The back two mounting holes are supplied with weld nuts to facilitate installing screws The front two holes be secured with 3 8 16 screws lockwashers and nuts The front holes are square to allow use of 3 8 16 cage nuts if desired See Figure 3 Road vibrations can cause com ACAUTION ponent damage to generator set if unit mounting plate is not fastened securely to vehicie compartment Use screws of sufficient length to allow minimum of 1 1 2 threads to extend through nut to ensure maximum holding power 477 5 AIR FILTER 3 44 54 74 OIL FILTER REMOVAL U 2500 1775 6350 P 49 I I x A j 0 1 OIL FILL 8 CHECK START STOP SWITCH 14 00 te 355 6 vo eof 220 UNC 2 HOLES i Sas cau re 414 44 HOSE GARE OIL FILTER 9 MOUNTING HOLE 685 381 7 9 402 6 OIL
27. ing assem bly should be as supplied or approved by Onan and must be instailed in accordance with safety approved specifications Review the following text for general application information and review the proper housing exhaust kit instructions for further specifics regarding under floor mount installations The vehicle construction must be able to support the weight of the generator set see General Specifications is the vehicle manufacturer s and the installer s responsibility to provide and assure a structurally sound support frame by using tubing angle brackets or with stee reinforced plywood or other composition board Reinforcement of plywood or particle board can be with 3 inch 76 mm or larger washers or a full metal plate General Generator Set Location When choosing a location for mounting the under floor mount generator set consider the following not only for mounting but for protection of the generator set as well Figure 4 shows the most common mounting areas of a RV generator set in a recreational vehicle If the genera tor set is mounted on the curb side location 1 or 2 protect the generator end of the generator setfrom road splash and debris lf mounted on the side loca tion 3 or 4 protect the engine end of the generator Installation should be verified by road test mud and slush Refer to shaded areas of Figure 4 Leave an area between the generator set and the recreation
28. ith all applicable codes regarding fuel tanks supply lines and pressure testing complete system for leaks after installation is complete and PRIOR to initial operation of the generator set Have a fire extinguisher nearby Be sure extinguisher is properly maintained and be familiar with its proper use Extinguishers rated ABC by the NFPA are appropriate for all applications Consult the local fire department for the correct type of extin guisher for various applications Guard Against Electric Shock Remove electric power before removing protective shields or touching electrical equipment Use rubber insulative mats placed on dry wood platforms over floors that are metal or con crete when around electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surfaces to be damp when handling electrical equipment Jewelry is a good conductor of electricity and should be removed when working on electrical equipment DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM Hazardous voltages can flow from the generator setinto the utility line This creates a potential for electrocution or property damage Connect only through an approved device and after building main switch is open Consult an electrician in regard to emergency power use Use extreme caution when working on electrical components High voltages cause injury or death Follow state and local electrical codes Have all electri
29. l On a liquid propane generator set has system been tested for leaks if installation uses under floor hinge kit is there 2 inches 51 mm clearance between front of tray and vehicle skirt is skirt part of door to allow set to swing down for service Are all electrical leads connected and protected and conduit is adequately supported 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 Redistribution or publication of this document by any means is strictly prohibited Onan Corporation Telephone 612 574 5000 1400 73 Avenue N E Telex 275477 Minneapolis Minnesota 55432 Cable ONAN
30. mitations between 240 and 375 psi depending XFS 1622 tank selected 18 FIGURE 12 FLOW DIAGRAM LIQUID LPG FUEL SYSTEM Electrical Connections All wiring must meet applicable local electrical codes Accordingly have a qualified electrician install and inspect the wiring Mount switches and controls securely to prevent dam age from vibration and road shocks All switches must vibration proof to prevent accidental opening or closing while the vehicle is in motion AC WIRING Wire Types The conductors of the generator set must have an ampere rating not less than 115 percent of the name plate current rating of the generator The Onan supplied AC feeder conductor insulation is rated at 125 C Wires connected to the Onan feeder conductors must meet this insulation rating or must be of a larger wire size see National Electrical Code NFPA 70 Exhaust gas presents the hazard of AWARNING severe personal injury or death To prevent exhaust gas from entering vehicle interior seal all openings made for conduit wiring etc wiring within conduit itself Conduit Install generator load conductors supplied with the generator set in a flexible metallic conduit Cut conduit to desired length leaving extra wire as required for the junction box connecting wires must be appropriately sized and insulated for the specified current rating Prepare ends of conduit to prevent sharp edges from cutting wi
31. mmendations to fol low when installing the exhaust system Then refer to the installation instructions supplied with the exhaust system kit for specific mounting procedures See Fig ures 9 and 10 for exhaust kit options MUFFLER RECOMMENDATIONS Onan supplied muffler spark arresters are forest ser vice approved and meet code requirements Failure to provide and maintain a spark arrester can be in violation of the law Use only ONAN UL CSA tested mufflers Liability for damage or injury and warranty expenses due to use of unapproved mufflers or installation modifi cations becomes the responsibility of the person instal ling substitute muffler or performing the modifications Contact an Onan distributor for approved exhaust sys tem parts and installation instructions EXHAUST INSTALLATION GUIDELINES The exhaust system must be no closer than 3 inches 76 mm from combustible material wood felt cotton organic fibers etc or be so located insulated or shielded that it does not raise the temperature of any combustible material more than 117 F 65 C above the ambient air inlet temperature The exhaust system must extend a minimum 1 inch 25 mm beyond the perimeter of the vehicle generator set tailpipe is on the same side of the coach as the compartment try to terminate the tailpipe of the generator set air intake to reduce the possibility of exhaust recirculation by directing the exhaust down and to the rear
32. n organic fuel line between the veh icle fuel system and the generator set to absorb vibra tion Onan recommends using a seamless steel tubing and flared connections for long runs between the fuel tank and the flexible connector to the generator set Run fuel lines at the same height as the top level of tank to a point as close to the engine as possible This redu ces the danger of fuel siphoning out of the tank if the line should break Keep lines away from hot engine or exhaust areas This reduces chance of vaporlock Install lines so that they are accessible and protected from damage Use metal straps without sharp edges to secure them 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 generator sets contain a filter cartridge 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 components used on the genera tor set Generator set operation using liquid LPG is very sensi tive to altitude temperature and BTU content of the gas Variation in any one of these factors directly affects the performance of the generator set Because of this minor adjustments might be required after the installation
33. nts can be adversely affected Do NOT use high strength solvents They can damage electrical connectors Do NOT store anything in the generator compartment such as 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 the compartment floor clean and dry Protect Against Moving Parts Avoid moving parts of the unit Loose jackets shirts or sleeves should not be permitted because of the danger of becoming caught in moving parts Make sure all nuts and bolts are secure Keep power shields and guards in position adjustments must be made while the unit is running use extreme caution around hot manifolds moving parts etc General Do not work on this equipment when mentally or physically fatigued or after consuming any alcohol or drug that makes the operation of equipment unsafe 4 Table of Contents SAFETY PRECAUTIONS Inside Front Cover INTRODUCTION 2 GENERAL SPECIFICATIONS 4 MOUNTING as ance ate eae ee be 5 Conventional Compartment 5 WNGCrFIOOF MOUNT 8 VENTILATION AND
34. ollows 1 Select control location Use Figures 17 and 18 as guides Drill screw holes and cuthole to accommodate remote switch in dash panel 2 Following national and local electrical codes and using 18 or larger insulated wires of predetermined length connect remote control to generator set Refer to Figure 19 for wiring connections 3 Connect jumper between terminal 5 and 6 on deluxe panel Electrical induction can occur ACAUTION when DC wires are run with AC wires and can cause operational problems 4 Insert remote control in hole cutoutand secure with woodscrews supplied with switch Exhaust gases present the AWARNING hazard of severe personal injury or death Seal all holes to prevent entrance of exhaust gases into recreational vehicle interior Incorrect connections can dam ACAUTION age control remote switch and interconnecting wiring Ensure that leads 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 Battery charge rate ammeter running time meter and generating lamp should be operating only while the generator set is running 6 If the set starts by itself or cannot stop check for short circuited remote control wiring 23 1 5 16 33 3 mm 1 5 8 IN 41 4 mm M 1580 FIGURE 17 CUTOUT FOR STANDARD CONTROL
35. or end of the compart ment through the generator generator also has a cool ing fan and over the cooling surfaces of the engine then discharges the heated air out through the Vacu Flo discharge opening Make sure nothing obstructs or restricts discharged airflow and that recirculation of air is minimal A dust or noise deflector if added must be a minimum of 6 inches 150 mm below the generator set and open on three sides Exhaust gas presents the hazard of AWARNING severe personal injury or death Since discharged cooling air can contain some exhaust gas never use discharged cooling air for heating The free air inlet area is critical for proper generator set operation and cooling A minimum free air inlet area of 85 in 548 with no restrictions is required Refer ence the generator set air discharge rate is 480 ft8 min 13 6 3 FIGURE 6 VACU FLO COOLING SYSTEM When planning the air inlet to the generator set allow for airflow restrictions caused by grilles and duct work Some expanded metal grilles provide only 60 percent free air inlet area per square foot Even the most efficient grille only provides about 90 percent free inlet area per square foot The free inlet area of the material can be obtained from the material supplier Multiply the grille area times the percent of free area of the grill to obtain the free inlet area inlet air ducting should provide a direct free airflow path to g
36. ot terminate exhaust system under the vehicle Direct exhaust gases away from any window door or compariment openings Do not operate the generator 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 If tailpipe extends beyond 1 1 2 feet 0 46 from muffler attach an automotive tailpipe hanger for additiona support The exhaust system should be supported at or near the perimeter of the vehicle to prevent the pipe from being damaged and pushed up under the skirt Angular mounting of muffler and tail ACAUTION pipe hanger brackets can resuit in exhaust system damage Properly mounted hanger brackets will absorb much road shock vibration and prolong the usefulness of exhaust sysiem components Mount muffler and tailpipe hanger brackets directly above the component supported not atan angle not twist the rubber sections of any hangers EXHAUST ACCESSORY KIT 542 0472 SHOWN HANGER BRACKET 8 FOOT 1 METRE FROM DOWNPIPE OR AT PERIMETER OF VEHICLE TAILPIPE FURNISHED BY ONAN 5 1147 EXHAUST ACCESSORY KIT 542 0471 SHOWN TAILPIPE NOT FURNISHED BY ONAN 6 1146 FIGURE 9 EXHAUST SYSTEM KIT EXAMPLES FOR CONVENTIONAL COMPARTMENT MOUNT GENERATOR SET 14 gt O 4 95 l x TAILPIPE NOT FU
37. p Should the vehicle fuel tank become pressurized the positive fuel shut off prevents flooding of the generator set when the set is not operating For the possibility of contaminated fuel Onanrecommendsan in line tue filter Recommended Fuel Use clean fresh unleaded or regular grade gasoline Using unleaded gasoline results in extended periods 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 Unleaded gasoline may be safely used after lead depos its have been removed Do not alternate between leaded ACAUTION regular and unleaded gasoline Lead deposits can cause engine damage if not removed before using unleaded gasoline Fuel Consumption It should be noted that under varying electrical loads fuel consumption of engines for recreational vehicle generator sets varies accordingly GASOLINE FUEL CONSUMPTION Ful 1 5 1 hr 2 3 i hr 3 0 0 35 gal hr 0 53 gal hr 0 73 gal hr eee Fuel Line Installation Recreational vehicle fuel systems are designed to oper ate in a Critical pressure range it is very important dur ing the installation of the generator set that the vehicle fuel supply design NOT be altered The fuel fill tube fill 16 limiter vent vapor canister vapor lines and gas fill
38. r operation and main tenance procedures refer to the Operator s Manual _ which accompanies each unit Listed and certified this generator set meets or exceeds all requirements of the National Electrica Code Article 551 NFPA 70 as well as ANSI RVIA Standard EGS 1 UL Standard 1248 and CSA Bulletin 946 Recreational vehicle installations MUST comply with these specifica tions as well as ANSI 119 2 Standard for Recreational Vehicles The recreational vehicle manufacturer and generator set installer MUST also comply with any local codes such as California Administrative Code Title 25 which pertains to the generator set installation UL listing and CSA certification applies to 60 Hz models only Requirements to be considered prior to the installation are listed below Each is covered in the following text or associated kit instructions Level and supportive mounting surface e Adequate cooling air e Discharge of circulated air e Discharge of exhaust gases e Electrical connections e Fuel installation Accessibility for maintenance and service e Noise levels The following list of installation codes and safe recommendations pertains to the installation and opera tion of this RV generator set The address of each agency is listed so that you can obtain a copy for your own use INSTALLATION CODES AND SAFETY RECOMMENDATIONS 1 ANSI A119 2 Recreational Veh ANSI RVIA EGS 1 Industry Assoc 14650 Lee Road
39. re insulation 19 To reposition 90 conduit fitting loosen locking nut toothed ring turn fitting counterclockwise to desired location and retighten locking nut Run conduit in such a way as not to interfere with the movement of the set This ts especially pertinent to the under floor installation in which the set must be free to move Wiring Disconnect Method The feeder conductors from the set compartment must terminate in a properly sized double pole double throw positive off switching device before the vehicle distribution panel or connect to a generator set receptacle box This assures the outside power source cannot be connected simultaneously with the generator set Figures 13 and 14 illustrate two possible wiring connections Figures 15 and 16 show generaior set wiring diagrams and schematics K Electrical shock can cause severe A WARNING personal injury or death Use only approved power supply assemblies Never remove grounding pin from assemblies Incorrect orno ground can cause the recreational vehicle to become electri hot Equip the recreational vehicle with ade quate Ground Fauit Circuit Protection devices to meet the National Electrical Code 70 551 7 personal safety n Gasoline and liquid LPG fuel present AWARNING the hazard of fire or explosion which can result in severe personal injury or death Do not tie electrical wiring to fuel lines
40. refer to Generator Set Service Manual if adjustments are required Recommended Fuel Use clean fresh commercial propane or HD 5 grade liquid propane gas in a mixture of at least 90 percent propane Propane fuels other than HD 5 grade can con tain more than 2 5 percent butane and can resultin poor fuel vaporization and poor engine starting in low ambient temperatures below 32 F 0 C Fuel Consumption it should be noted that under varying electrical loads fuel consumption of engines for recreational vehicle generator set varies accordingly Average fuel con sumption at various loads is shown in the table below LPG FUEL CONSUMPTION 0 5 gal hr 0 8 gal hr 1 3 gal hr 1 9 1 4 0 1 3 0 1 hr Propane Fuel Lines and Supply Tank The installer must review all codes that apply to the particular installation Paragraph 3 5 1 Gas Piping Sys tems of NFPA Pamphlet 501C deals specifically with propane fuel linesbutdoesnotnecessarily cover allapplicable codes and regulations You obtain this pamphlet from the address listed in the beginning of this manual 17 When installing the fuel lines keep the following in mind 1 Install all propane fuel lines so they are accessible yet protected from damage FUEL SOLENOID FUEL FILTER BODY FIGURE 11 FUEL SOLENOID VALVE AND FILTER 2 Use metal straps without sharp edges to secure fuel lines 3 Keep fuel lines away from hot engine or exhau
41. s of detecting leaks may be used if appropriate Test shall NOT be made with a flame Liquid LPG fuel presents the hazard AWARNING of explosion or fire which can result in severe personal injury or death Do not smoke or allow any ignition sources in the installation area EAN es 7 CARBURETOR Venturi type with both Main and idle jet adjustments SOLENOID VALVE A Normally Closed valve which allows fuel tiow ONLY when engine is cranking or running This valve also back flows to prevent hydrostatic pressure build up in vaporizer and regulator FUEL FILTER Protects engine and fuel system components from contaminates An internal magnet stops all magnetic particles that may collect on fuet lock solenoid plunger and foul its action or plug HYDROSTATIC RELIEF VALVE Must be located after manual shutoff y valve Relief pressure between 400 and 500 PSIG MUST be properly vented MANUAL SHUTOFF VALVE Customer Supplied and tnstalted Must Be Mounted on Tank Hardware Customer Must Satisfy UL 1248 NFPA 58 CSA946 CAN1 B149 2 78 and Any Local Codes That Apply gt lt 4 Pipings Hoses and Fittings ee 2 ve Must be Approved For LPG Fuel INTERNAL EXCESS FLOW VAL System Use pists Set Must Close with Complete Line Must to ASME or dot and Breakage Consult National LP Gas Association Publication 113 78 CTC standards Working pressure For Li
42. sembly The recreational vehicle must be adapted for the under floor housing The construction of the vehicle must sup port the weight of the generator set It is the vehicle manufacturer s responsibility to provide a structurally sound frame and carriage bolts or equal to attach the housing Kit ACAUTION Failure to meet Onan approval for modifications of housing kits or for non Onan kit housing installations may void intent of UL CSA approval Liability for damage or injury and warranty expenses becomes the responsibility of the person making the modifications Use template supplied with housing kit to insure that panels are installed square to each other Failure to mount panels square may result in spark plug breakage Review the exhaust system kit installation instructions and component parts Plan clearances for movementor removal of exhaust components when generator set is lowered for inspection maintenance purposes 14 00 355 81 NOTES 1 DIMENSIONS INCLUDE 0 6 INCH 15 mm MIN REQUIRED CLEARANCE 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 218 15 104 4 DIMENSIONSIN ARE IN mm gt CIRCUIT BREAKERS REMOTE CABLE CONNECTION 402 1021 FUL CHECK 28 27 20 34 344 28 21 516 6 REMOVAL A 2500 1634
43. st areas 4 Do NOT run fuel lines in conjunction with electrical wiring Most propane LPG liquid withdrawal generator set installations are designed to share the vehicle propane fuel supply tank s The vehicle propane fuel supply tank MUST have a dip tube to ensure liquid withdrawal An excess flow valve MUST be mounted internal to the propane fuel supply tank s per NFPA 501C Paragraph 3 4 4 This excess flow valve and propane fuel lines MUST be sized so the excess flow valve will close witha completely severed broken propane fuel line For operation at the lowest ambient temperature a valve tated at 2 6 gallons per hour 9 9 Ihr flow rate and 6 5 pounds per square inch 45 kPa differential pressure is recommended Consult the Natural LP Gas Association for the limitations of excess flow valves Install an approved flexible non metallic non conductive and non organic fuel line between the veh icle fuel system and the generator set to absorb vibra tion Onan recommends using a seamless steel tubing and flared connection for long runs between the fuel tank and the flexible connector to the generator set A manual shut off valve MUST be mounted on the pro pane fuel supply tank This supply tank valve MUST be fully open when operating the generator set to ensure the excess flow valve will close with a severed broken propane fuel line hydrostatic pressure relief valve MUST be installed between the propane fuel s
44. t REMOTE 5 DELUXE STANDARD ADD JUMPER WIRING DIAGRAM H T2 BTI REMOTE R6 AI CRIAI FI 7 4 2 2 2 a oe Al K3 Al K4 I x Ar PI 3 CRS oe Al PI 5 Al K3 Al K3 jt i AFCR2 AFP3 6 i l 2 K5 7 0 3 3 START STOP Al P3 I NOMINALNOLOAD VAC i275 4 5vac CR4 AC 1 i TODECREASE NOMINAL x3 X6 LOAD VAC L gt 2 5 I l i NOMINAL LOAD 832 LOAD WHITE I o BLACK NEUTRAL t TRANSFORMER IGN COIL IGN POINTS SWITCH LOW OIL PRESSURE SWITCH START STOP RESISTOR BATTERY CHARGE RELAY USEO WITH LPG ONLY START SOLENOID CHOKE GENERATOR FUSE FUEL PUMP OR FUEL SOLENOID SPARK PLUG CIRCUIT BREAKER AC OUTPUT BRIDGE RECTIFIER 5 CRS RECTIFIER USED WITH LPG ONLY CAPACITOR BATTERY BI STARTER ISTANDARD REMOTE CONTROL Al OELUXE REMOTE CONTROL CONTROL ASSY FIGURE 15 60 HZ GENERATOR SET WIRING DIAGRAM SCHEMATIC 21 RECONNECTION CHART IPH SWIRE 611 1177 REMOTE PANELS DELUXE STANDARD SCHE
45. upply exhaust system or other aspect of installation requires corrective action disconnect starting battery to prevent acci denial start up while performing rework AWARNING 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 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 interior is equipped with an operating carbon monoxide detector Protection against carbon monoxide inhalation also includes proper exhaust system installation and visual and audible inspection of the complete exhaust system at the start of each generator set operation 2 INSTALLATION REVIEW Prior to initial start up of generator set address each ofthe following installation review items For a safe effective installation each answer must be affirmative if not that aspect of the installation should be reworked or provision mad to satisfy the requirement 11 12 13 1
46. upply tank manual shut off valve and the propane fuel solenoid valve and filter assembly This relief valve protects the propane fuel line from pressure buildup if both the supply tank manual shut off valve and the fuel solenoid valve are closed atthe same time Fists Z 4 S 7 SF 5 REGULATOR Two stage design that will ONLY flow fuel when catburetor provides suction to luel outlet VAPORIZER Changes propane tuel from a liquid state 7 to a gas using exhaust manifold heat on generator set fuel fitter ambient PRESSURE RELIEF VALVE Locate in vapor space internal to tank Relief pressure between 274 and 375 PSI depending on tank specified and expected Testing Fuel System for Leaks The completed propane fuel system installation MUST be checked and tested for leaks before the generator set is operated The fuel solenoid MUST be energized from a separate 12 volt DC source before testing the fue system for leaks The test MUST conform to procedures listed in NFPA 58 Paragraph 318 or UL recommended test procedure as follows After assembly and prior to initial operation all tue system connec tions hose valves regulators and fittings must be tested and proven free of any leaks using a soap and waiter or equivalent solution while the system is under a gas or air pressure of not less than 90 pounds per square inch 620 kPa Other approved method

Installation

Contents

Download Pdf Manuals

Related Search

Related Contents