981-0627 Onan KY Microlite 4000 series Installation manual
Contents
1. Du Supa sad 5 1 ACOUSTICS uu 5 2 EXHAUST SYSTEM SQ S 6 1 gt G sas nas ss 6 1 Muffler Recommendations 6 1 Exhaust Installation Guidelines 6 1 Tailpipe 6 1 FUEL SYSTEM u he ec de eh a no dene ba tee 7 1 Genera 7 1 Gasoline Fuel System 7 1 LPG Fuel 7 3 ELECTRICAL CONNECTIONS 8 1 ee a 8 1 __ _ 8 1 DG __________ 8 5 INITIAL START AND CHECKS 9 1 Pre SISrt Checks 6 9 1 Initial Starting and Checks 9 2 Installation Review te dado bees es 9 4 WIRING SCHEMATIC DIAGRAMS 10 1 Safety Precautions Before operating the generator set read the Operators Manual and become familiar with it and the equipment Safe and efficient operation can be achieved only if the unitis properly operated and mai2. _ Installation Manual KY MicroLite 4000 Series Printed U S A 2 93 981 0627 Redistribution publication of this document by any means is strictly prohibited Table of Contents SECTION 10 TITLE PAGE SAFETY PRECAUTIONS ii INTRODUCTION cece iin uo ahua q 1 1 gosto oho sie ee aoe ee we ewe eae 1 1 Installation Codes and Safety Recommendations 1 1 Component Locations 1 2 SPECIFICATIONS 2 1 STEP BY STEP INSTALLATION OUTLINE 3 1 ee od 3 1 25 _____________ 3 1 Compartment 0 3 2 Under Floor Mounting 3 3 Connecting to Vehicle Systems 3 5 Exhaust scene Meus ise 3 6 MOUNTING ein Oe oe 4 1 GONGA uu 4 1 Compartment Mount 4 1 Under Floor Mount nz Sas 4 4 VENTILATION AND ACOUSTICS 5 1
3. TAILPIPE NOT amp SUPPLIED WITH SET FIGURE 6 2 EXHAUST SYSTEM EXAMPLES FOR COMPARTMENT MOUNT INSTALLATIONS HANGER BRACKET IF REQUIRED DUE TO LENGTH OF TAILPIPE SHORT RADIUS 5 HANGER ELBOW SE 24 BRACKET hZ ON i 8 HANGER ___ BRACKET TAILPIPE NOT 81170 6 SUPPLIED WITH SET FIGURE 6 3 EXHAUST SYSTEM EXAMPLES FOR UNDER FLOOR MOUNT INSTALLATIONS 6 3 Redistribution publication of this document by any means is strictly prohibited 7 Fuel System GENERAL This section describes fuel system installations for recreational vehicles Fuel presents the hazard of fire or explosion that can result in severe personal injury or death Do not smoke or allow any flame spark pilot light are producing equip ment or other ignition sources around fuel or fuel components or in the installation area Keep a type ABC fire extinguisher nearby The ventilation system must provide a constant flow of air to expel any accumulation of fuel vapor while the vehicle is in transit Compart ments must vapor tight to the vehicle inte rior to prevent any fumes from entering these areas FUEL SYSTEM Fuel System Provisions Use a separate fuel pickup tube or a separate fuel tank Do not tie into the vehicle fuel supply line On some vehicles the generator set can share the vehicle fuel supply tank with the vehicle engine Connection to the vehicle
4. Housing kit installation instructions and provide an adequate support structure Use specified hardware and tighten all mounting hardware to the recommended torque settings FIGURE 3 7 UNDER FLOOR MOUNTING TEMPLATE 0 406 IN HOLES 4 FOR 3 8 BOLTS 2 Ifthe area above the compartmentis made 70 551 30 0 wood product you must install a 26 gauge 0 02 inch galvanized metal plate or equiva lent above the genset AREA ABOVE SET APPROX 20 INCH X 30 INCH MUST BE METAL FIGURE 3 8 UNDER FLOOR MOUNTING KIT WITH METAL CEILING NOT SUPPLIED WITH KIT 3 Assemble the Under Floor Housing kit accord ing to the instructions supplied with the kit Se curely mount hanger brackets and side panels to the under floor support structure Dropping the generator set can cause severe personal injury or death Make sure no one moves the vehicle during installation and keep feet and hands clear during installation FIGURE 3 9 UNDER FLOOR MOUNTING KIT 4 Assemble the front and back rails to the gen set Use a forklift to carefully raise the genset into position in the support frame Secure the rails to the support frame with the mounting hardware included in the Under Floor Housing 5 Proceed to the next section on connecting to the vehicle systems FIGURE 3 10 UNDER FLOOR INSTALLATION CONNECTING VEHICLE SYSTEMS 1 Route fuel line separate from electrical wires or BATTERY
5. Are air inlet and exhaust openings clear and large enough see Mounting section for proper airflow H the installation is for an under floor kit is there metal barrier between the genset and a combustible floor See Figure 3 8 Are fuel lines and electrical wires protected from chafing and damage and are they insulated from each other Refer to Figure 3 11 Are all fuel connections and hose clamps tight Refer to Figure 3 12 Is a flexible section of non conducting fuel line installed between the fuel inlet and the fuel line from the tank Refer to Figure 3 12 Are all electrical leads connected and protected and is the conduit adequately supported Refer to Figure 3 13 14 15 and 16 Does the exhaust system extend beyond the perimeter of the vehicle a minimum of 1 inch 25 mm See Figure 3 18 Are there operable windows doors or storage compartments within a triangle formed by a base one foot on either side of the exhaust pipe and 3 feet above the exhaust pipe Refer to Figure 3 21 Ifthe exhaust system is run into the angle of approach or departure see Figure 3 20 is it protected from bottoming out by use of skid bars rollers etc 15 the exhaust system secure and are all connections tight Are all required exhaust clamps hangers and support straps in place per the Exhaust System section of this manual and the kit instructions Is the generator set protected from direct road
6. CONDITIONERS GFCI BREAKERS POWER SUPPLY CORD C1463 7s FIGURE 8 1 SWITCHING DEVICE WIRING FOR UTILITY POWER 8 3 IMPORTANTI GROUND FAULT CIRCUIT INTERRUPTERS GFCls ARE REQUIRED BY THE NATIONAL ELECTRICAL CODE NFPA 70 551 9 IN ALL EXTERNAL AND SOME INTERNAL OUTLETS TO PROPERLY EQUIP YOUR RECREATIONAL VEHICLE WITH THESE PROTECTION DEVICES CONTACT YOUR RV MANUFACTURER OR DEALER FOR RECOMMENDATIONS JUNCTION BOX IF REQUIRED VEHICLE WIRING DISCONNECTING DEVICE 6 VEHICLE DISTRIBUTION PANEL MAIN BREAKER BREAKERS FOR AIR CONDITIONERS rm BREAKERS POWER SUPPLY CORD FIGURE 8 2 UTILITY POWER CORD FOR SWITCHING 8 4 DC WIRING Remote Control Option Onan offers optional remote control kits that can be connected to the generator set Figure 8 4 The Standard Remote Control includes a start stop switch and an indicator lamp The Deluxe Remote Control has these items plus a running time meter and a battery condition meter The remote control connector plug is located inside the housing Figure 8 3 Contact an Onan dealer for the proper remote connector plug and wiring harness lead assembly Use of remote control switch other than the optional Onan remote controls can result in generator set starting battery discharge in the stop condition The remote control Start Stop switch must be amomentary type switch In the St
7. a step by step overview of a typical installation This section includes Preparation Compartment Mounting Under Floor Mounting e Connecting to Vehicle Systems e Exhaust System Review this section then refer to the detailed instructions that are given in sections four through eight for specific procedures and important safety precautions before starting the installation The installer is responsible for complying with all appli cable installation codes and safety requirements PREPARATION 1 Remove the wooden shipping crate by prying the bottom of the crate s sides and ends out from the wooden skid base Carefully lift the crate off the genset and discard Remove the plastic bag covering the genset and collect loose shipped items like the Operators Manual and add them to the vehicle documentation package 2 Remove the mounting bolts that secure the wooden skid to the ends of the genset base GENSET SHIPPING BOLTS FIGURE 3 2 SKID BASE REMOVAL 3 1 COMPARTMENT MOUNTING Install the generator set in its own compartment If any part of the compartment is above the vehicle floor separate the compartment from the living quarters with vapor tight walls Refer to the Mount ing section for compartment construction details Vehicles that are unusually sensitive to vibration may require secondary Isolation and a larger compartment AWARNING Exhaust gases present the hazard of severe personal injur
8. can damage them Do not operate the set for more than a few minutes with the access cover removed or the generator set will overheat Fuel presents the hazard of explosion or fire that can result in severe personal injury or death If a fuel leak is found stop the generator set and have the leak repaired immediately A hot generator set can cause severe burns Always allow the generator set to cool down before performing service Examine the exhaust system for leaks If any leaks are found stop the set and have the exhaust system repaired immediately Exhaust gas presents the hazard of severe personal injury or death Inspect the exhaust system audibly and visually With the generator set running and the service access cover removed Inspect the muffler Do not operate the generator set if it 15 excessively noisy Have any leaks repaired immediately 9 3 4 Operate the set with a normal load monitoring fuel supply connections exhaust system set performance and amount of noise reduction If set performance is not acceptable see the Service Manual for adjustment procedures or contact an authorized Onan service center for assistance If the generator set requires adjust ment or repair disconnect the starting battery negative cable first to prevent accidental start up Accidental starting of the gen erator set during maintenance procedures can cause severe personal injury or death Disconnect the generat
9. extends more than 1 1 2 feet 0 46 m from the generator set attach an automotive tailpipe hanger for additional support Also use additional automotive type tailpipe hangers every 2 to 3 feet 0 6 to 0 9 of tailpipe run Always support the exhaust system at or near the perimeter of the vehicle to prevent the pipe from being damaged and pushed up under the vehicle THE TAILPIPE MUST NOT TERMINATE SO THAT ANY VENT WINDOW OR OPENING INTO THE LIVING AREA IS WITHIN THE TRIANGULAR AREA SEALED WINDOW TAILPIPE RV REAR VIEW a Y a g a 1 DEPARTURE ANGLE GROUND SKID BARS skirt Attach hangers to steel framework not wood or other floor materials Refer to Figures 6 2 and 6 3 for typical tailpipe installations Excessive exhaust back pressure can cause engine damage If a tailplpe deflector is used make sure It is large enough to prevent back pressure Water vapor can cause engine dam age Do not connect the generator set exhaust to the vehicle exhaust system because water vapor from one engine can damage the other EXHAUST TAILPIPE APPROACH ANGLE LOWER AXLE SHADED ZONE IS AREA CLEARANCE LINE OF RECOMMENDED TAILPIPE INSTALLATION 1715 36 FIGURE 6 1 TAILPIPE INSTALLATION SHORT RADIUS 7 HANGER BRACKET ELBOW DUE LENGTH OF TAILPIPE HANGER P al BRACKET Pa ee d
10. 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 tempera ture The exhaust system must extend a minimum 1 inch 25 mm beyond the perimeter of the vehicle Do not terminate the exhaust tailpipe under the vehicle Be aware that any vent window storage compartment or opening that can be opened that is not permanently sealed from the vehicle living space can be an avenue for carbon monoxide The tailpipe must not terminate so that any vent window or opening into the living area is within the triangular area shown in Figure 6 1 This area is defined as an isosceles triangle with a height of 3 feet measured from the tailpipe termination and 6 1 with a base of 2 feet measured one foot horizontally from the pipe in either direction AWARNING Exhaust gas presents the hazard severe personal injury or death Do not terminate an exhaust pipe under the vehicle The tailpipe must not terminate so that yent window or opening into the living area 15 within the triangular area shown in Figure 6 1 Keep all openings closed when the generator set is running To reduce the chance of damaging the tailpipe and emitting exhaust gases under the vehicle make ceriain that no part of the exhaust system intrudes into the departure angle or approach a
11. fuel tank must be made according to the chassis vehicle manufacturer s detailed instructions See Fuel Line Installation in this section The fuel pump has an integral fuel shutoff valve as a safety feature If the vehicle fuel tank becomes pressurized 3 psi maximum the positive fuel shut off prevents the engine from being flooded when the genset 5 not running The vehicle fuel tank gas cap should relieve pressure at 1 1 2 psi 7 1 Recommended Fuel Use clean fresh regular grade gasoline Fuel presents the hazard of fire or explosion that can cause severe personal injury or death Never fill the fuel tank when the engine is hot or is running Do not permit any flame spark pilot light cigarette or other ignition source near the fuel system Fuel Consumption Generator set fuel consumption varies proportion ately to differing electrical loads Refer to the Specifications section for approximate fuel consumption at no load half load and full load Fuel Line Installation Vehicle fuel systems operate at a specified fuel pressure For this reason do not change or remove the fuel fill tube fill limiter vent vapor canister vapor lines filler cap and all parts of the fuel system without the approval of the vehicle manufacturer Check the filler cap to make sure that the pressure vacuum relief valve functions properly at 1 1 2 psi replace it if necessary Do not the generator set fuel line into the ve hic
12. grille material from the material supplier Multiply the grille area by the free area percentage to get the free inlet area The minimum size of the free air inlet is 40 in 258 The compartment size air inlet opening size and grille design must meet the minimum air inlet opening requirements Air ducting must provide a direct free airflow path to the generator set with minimal bends The duct must 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 Otherwise hard starting could result from vapor locking hot combustion air etc Fuel and fuel leakage present the 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 The generator set compartment must be vapor tight to the vehicle interior to keep fumes from entering the vehicle Locating the free air inlet opening in the vehicle skirt side access door is recommended If the vehicle skirt does not extend to or below the bottom of the generator set provide an extension Inlet air taken from below the vehicle must come from the skirt side of the compartment ACOUSTICS The genset is designed to minimize noise levels If additional noise reduction is required line the top and sides of the gens
13. that the vehicle starting battery be used to operate the generator set Doing this can discharge the battery under some operating conditions For reliable cold weather starting the voltage drop from the battery terminals to the generator set starter should not exceed 0 12 volts per 100 amperes of current while the generator set is cranking Refer to Table 8 1 to determine cable size and Table 8 2 for battery rating TABLE 8 1 CABLES FOR COLD WEATHER STARTING 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 8 6 TABLE 8 2 COLD CRANKING AMPS FOR MINIMUM 12 VOLT BATTERY ABOVE 32 F BELOW 32 F 0 C 0 C 360 Cold Cranking 450 Cold Cranking Amps 95 amp hour Amps Approx 70 amp hour Approx Larger capacity batteries will be required if battery is also used to power other coach accessories Batiery Compartment Mount the battery in its own compariment away from the generator set and any spark producing device For ventilation provide the battery com partment with an opening of at least 1 7 in2 11 cm at the top and 1 7 2 11 at the bottom Mount the battery on a rigid support structure where leaks and accidental spills cannot damage the generator set fuel lines and wiring Batteries present the ha
14. the negative battery cable to chassis ground or the NEG battery post if the battery has a separate vehicle chassis ground cable Always connect the negative battery cable last to reduce the risk of arcing Batteries present the hazard of explosion which can result in severe personal Injury Because batteries produce explosive gas do not smoke or allow any arc producing devices in the battery area Do not disconnect cables from the battery while the generator set is cranking or running This causes arcing and can result in an explosion 4 Review the Operator s Manual and note the features of the genset Open the fuel supply valve to the generator set if equipped INITIAL STARTING AND CHECKS Exhaust gas presents the hazard of severe personal injury or death Do not operate the generator set inside any room or building Starting from the Set Mounted Control 1 Move the Start Stop switch to the START position Figure 9 2 The engine should crank and start The set may need more cranking during the initial start to prime the fuel system lf the genset fails to start see the Troubleshoot ing Guide in the Manual M1899 FIGURE 9 2 STANDARD CONTROL PANEL 9 2 2 After the set starts check for fuel leaks If any leaks are found stop the setimmediately close the fuel supply valve if equipped and have the leak s repaired Make sure that the fuel lines do not touch anything that
15. POSITIVE CABLE separate them with conduit or other sheathing 2 A Fuel presents the hazard of fire explosion that result severe C ENG personal injury or death Do not smoke or 3 allow any flame spark pilot light Z equipment or other ignition sources near fuel or in the installation area Read the important safety precautions in FIGURE 3 11 FUEL AND ELECTRIC LINES the Fuel Systems section FUEL LINE 2 Gasoline Fuel Connect 1 4 inch 1 0 fuel hose type SAE 30 R7 to the barb fitting on the generator set LPG Fuel Connect 3 8 inch 1 0 fuel hose see LPG Fuel System to the barb fitting on the generator set Secure fuel hose to barb fitting with a stainless steel clamp worm gear type Do not over tighten clamp or hose could be damaged FIGURE 3 12 FUEL LINE CONNECTION Install a listed 1 2 inch flexible conduit over the NFPA 70 NEC 551 30 e AC wiring Use water tight conduit for under floor mounting Secure the conduit to the fitting on the generator set Accidental starting can cause severe personal injury or death Do not connect the battery cables to the genset starting battery until instructed to in the CONDUIT Initial Start Checks section FIGURE 3 13 AC CONDUIT CONNECTION 4 Remove the service access cover Route the battery positive cable through the access hole in the left side of the
16. accidentally ignited by electrical sparks presenting the hazard of fire or explosion which can result in severe personal Injury or death For this reason when Installing the generator set e Do not tle electrical wiring to fuel lines e Do not run electrical lines and fuel lines through the same compartment openings e Keep electrical and fuel lines as far apartas possible e Place a physical barrier between fuel lines and electrical lines wherever possible e If electrical and fuel lines must pass through the same compartment opening make certain that they are physically separated by running them through individual channels or by passing each line through a separate plece of tubing LPG FUEL SYSTEM Fuel System Provisions The LPG models are designed to operate on LP Vapor at 6 to 8 ounces per square inch 10 to 14 inches of water column regulator must be stalled between the fuel cylinder and the genset that reduces the cylinder pressure to 6 to 8 ounces per square inch 10 to 14 inches of water column LPG fuel presents the hazard of explosion or fire that can result in severe personal injury or death Do not connect the genset fuel line directly to the LPG fuel cylinder or fuel leakage could result from excessive fuel inlet pressure A regulator must be used be tween the genset and the fuel cylinder that reduces cylinder pressure to 11 inches of water column LPG genset operation is highly sensitive
17. an la SAS avenue for carbon monoxide The tail pipe must not terminate so that any OPENINGS INTO vent window or opening into the living area is sa VEHICLE S INTERIOR within the triangular area shown in Figure 3 21 DOORS ARE ALLOWED IN THIS AREA 6 Refer to each of the sections in this manual for detailed installation instructions and for impor tant safety precautions Always follow the procedures in the Initial Start and Checks section when the installation is complete FIGURE 3 21 PIPE LOCATION 3 7 Redistribution publication of this document by any means is strictly prohibited 4 Mounting GENERAL MicroLite generator sets are designed for either compartment or underfloor mounting Choose the appropriate part of this section and carefully follow the instructions Read any applicable kit instruc tions before installing the generator set COMPARTMENT MOUNT in a compartment mount the gensetis installed frame that is part of the vehicle This frame must be constructed according to safety approved specifi cations see Compartment Construction in this section Vehicles that are unusually sensitive to vibration may require secondary isolation and larger compartment Unless the set will be removed from the vehicle make the access opening large enough to remove the set Allow enough clearance for removal of the access cover See Figure 1 1 Minimum co
18. and water or equivalent solution while the system is under gas or air pressure of at least 90 psi 620 kPa Other approved methods of detecting leaks may be used if appropriate This test shall NOT be made with a flame LPG fuel presents the hazard of ex plosion or fire which can result in severe per sonal injury or death Do not smoke or allow any flame spark pilot light arc producing equipment or other ignition sources around fuel or fuel components 8 Electrical Connections GENERAL This section covers installing the generator set electrical system for e Connecting the load e Connecting a remote control e Connecting the battery Connect the battery last to avoid accidentally start ing or short circuiting the set during installation Accidentally starting the generator set during Installation can cause severe per sonal injury or death Do not connect the starting battery until Instructed to do so In the Initial Start and Checks section The wiring must meet applicable electrical codes this reason a qualified electrician should install and inspect the wiring Mount switches and controls securely to prevent damage from vibration and road shocks All switches must be vibration proof to prevent acci dental opening or closing while the vehicle is in motion AC WIRING Wire Types The leads attached to the generator set output must have a current rating not less than 115 percent of the name
19. art and Stop positions Zx AN REMOTE gt CONTROL Ga gt gt REMOTE CONNECTOR 51994 FIGURE 8 3 REMOTE CONTROL CONNECTION Location of the remote control can vary by applica tion Refer to the instructions supplied with the remote control kit for more installation information and important safety precautions Be sure to seal all openings made for wiring so exhaust or fuel vapors cannot enter the living quarters If flexible metal conduit is used it must be sealed internally at the end where it terminates Flexible metal conduit is not vapor tight along its length due to its construction inhalation of exhaust gas or ignition of fuel vapor can cause severe personal Injury or death sure to vapor seal flexible metal conduit and all openings made during installa of the generator set with a silicone rubber based sealant GENERATING LAMP ILLUMINATES WHEN SET 15 OPERATING tl an DELUXE EIACTRIC FOWER STOP i RUNNING CONDITION TIME METER METER STANDARD PANEL GENERATING LAMP ILLUMINATES WHEN SET IS OPERATING 4538155 STOP ES16849 1 FIGURE 8 4 REMOTE CONTROL PANELS Starting Battery Cable Selections The generator set requires a 12 volt battery with a rating of 360 cold cranking amps A larger capacity battery will be required if it powers other coach accessories Onan does not recommend
20. cable remot ENTRANCE HOLES IN SHADED AREA control harness and AC conduit Design holes so they will not chafe or restrict the lines Ifthe remote control harness or AC conduit go directly into the interior of the vehicle seal around the wires and inside the conduit to prevent the passage of exhaust gases The fuel line must not be routed through the interior of the vehicle FIGURE 3 5 GENSET TO VEHICLE SYSTEMS CONNECTIONS 4 Mount the generator set in the compartment with four 5 16 16 screws Screw length must not protrude more than 1 2 inch 13 mm 1 2 INCH MAX through the genset base The exposed above PROTRUSION floor section of exhaust pipe must be shielded with the Onan supplied exhaust shield 5 Proceed to Connecting To Vehicle Systems page 3 5 J 5 16 16 SCREW SUPPORT UNDER FLOOR MOUNTING THICKNESS An optional kit is required for under floor mounting Support brackets are used to suspend the genset below the floor of the vehicle Refer to the instructions that are supplied with the kit for specific installation instructions and important safety precautions For additional under floor mounting information refer to the Mounting section 1 Use the template to locate the holes in the vehicle support structure Reference Onan template number 539 1382 Fallure to provide an adequate support structure can result In severe personal Injury death and or equipment damage Carefully follow the Under Floor
21. ch ring terminal Tighten the B connection securely Figure 8 5 Fallure to secure the B terminal can result in personal injury and or equipment damage from an electrical short See that the terminal connection 15 secure If necessary secure lead to prevent abraslon Negative Battery Cable Connectthis cable se curely to the genset base battery negative con nection with a 3 8 inch ring terminal Figure 8 5 Use the same size cable for both positive and nega tive battery connections Make sure that the bat tery negative circuit is tied to chassis ground at the starting battery negative terminal or at the battery negative connection on the genset base Check to confirm that good electrical ground con nection is made Figure 8 5 Batteries present the hazard of explosion which can result in severe personal injury Because batterles give off explosive gas always disconnect the negative cable first and connect it last to reduce the risk of arcing BATTERY NEGATIVE CONNECTION FIGURE 8 5 BATTERY CONNECTIONS 8 7 Redistribution publication of this document by any means is strictly prohibited 9 Initial Start and Checks AWARNING EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless and colorless gas Carbon monoxide is poisonous can cause unconsciousness and death Symptoms of carbon monoxide poisoning can include e Dizziness e Throbbing in Temple
22. e and service e Exhaust connections e Fuel supply e Electrical connections MicroLite is a trademark of the Onan Corporation INSTALLATION CODES AND SAFETY RECOMMENDATIONS The following list of Installation Codes and Safety Recommendations applies to the installation and operation of RV generator sets The address of each agency is listed so that copies of the codes may be obtained for reference Installation codes and recommendations are subject to change and may vary by location or over time The RV manufacturer and the genset installer bear sole responsibility for following all applicable codes and regulations 1 ANSI A119 2 Recreational Vehicle FMVSS 301 Industry Association 14650 Lee Road Chantilly VA 22021 2 NFPA 70 N E C National Fire Protection NFPA 501C Association NFPA 58 470 Atlantic Avenue Boston MA 02210 3 CSA Electrical Canadian Standards Bulletin 946 Association Housing and Construction Materials Section 178 Rexdale Bivd Rexdale Ontario Canada M9W 1R3 4 California State of California Administrative Documents Section Code Title 25 P O Box 1015 Chapter 3 North Highlands CA 95660 This manual contains information that is subject to change For this reason use only the installation manual supplied with the generator set for the installation Incorrect installation service or replacement of parts can result in severe personal injury death and or equipment damage Service personnel m
23. eld 2 Pole Frequency Hertz 60 Power Waits 4000 Voltage 120 Current Amperes 33 3 ENGINE Engine Model Engine Type Engine Speed Ignition Type Fuel Engine Oil Capacity Battery Requirements Battery Size Onan 95 4 Stroke Single Cylinder OHV 3600 rpm Electronic Magneto Breakerless Gasoline 1 7 gt 1 6 L 12 360 450 Below 32 F 0 C 0 025 in 0 64 mm Cold Cranking Amps Spark Plug Gap Average Fuel Consumption No Load Half Load Full Load 0 15 gph 0 57 L h 0 40 gph 1 51 L h 0 66 gph 2 5 L h GENERATOR SET DETAILS Dimensions Length Width Height Weight Air Requirements Combustion Engine Generator Cooling Fuel Pump Lift 30 in 762 mm 19 4 in 493 mm 13 8 in 850 2 mm 168 76 2 kg 19 ft8 min 0 54 m min 300 ft2 min 8 5 m min 3 ft 0 91m 2 1 Onan Revolving Field 2 Pole 60 3600 120 30 EO95H G 4 Stroke Single Cylinder OHV 3600 rpm Eiectronic Magneto Breakerless LPG Vapor 11 inches W C 1 7 qt 1 6 L 12 Volt 360 450 Below 32 F 0 0 025 in 0 64 mm 0 35 gph 0 54 L h 0 54 gph 2 L h 0 82 gph 3 1 L h 30 in 762 mm 19 4 in 493 mm 13 8 in 350 2 mm 168 76 2 kg 19 ft min 0 54 m min 300 fi min 8 5 m min Redistribution publication of this document by any means is strictly prohibited 3 Step By Step Installation Outline INTRODUCTION This section is
24. eratures in the com partment can present the hazard of fire which can result in severe personal Injury death To meet ANSI and CSA tempera ture rise requirements for vehicles the layer of insulation must not reduce the minimum compartment size specified in Figure 4 1 M1799 18 FIGURE 5 2 NCISE REDUCTION COMPARTMENT DESIGN 6 Exhaust System GENERAL Plan the exhaust system carefully proper installation is not only vapor tight it is also quieter and safer Use the Onan supplied exhaust shield for compartment installations whenever the ex haust elbow is turned down for through the floor in stallations The exhaust shield can be discarded for under floor installations The exhaust system in stallation must comply with all applicable stan dards local codes and regulations Study the fol lowing recommendations MUFFLER RECOMMENDATIONS The Onan installed spark arrester muffler is U S Forest Service approved and meets code require ments Failure to provide and maintain a spark ar rester can be a violation of the law Liability for damage or injury and warranty ex penses due to use of unapproved mufflers or instal lation modifications becomes the responsibility of the person installing the substitute muffler or per forming the modifications Contact an Onan dis tributor for approved exhaust system parts EXHAUST INSTALLATION GUIDELINES The exhaust system must be placed no closer than 3inches 76 mm
25. et compartment with a 1 inch 25 4 mm thickness of sound absorbing material The optional exhaust resonator can also be used to lower the noise level Locating the air inlet away from the genset air inlet opening will reduce the noise level however additional compartment space willbe required see Compartment Mounting in the Mounting section See the following guidelines to construct the housing e Make certain that all joints and comers of the compartment are vapor tight to the interior cab of the vehicle Lining the compartment is less effective if openings cracks doors and joints are not sealed Seal the compartment door edge to eliminate noise leaks around the door perimeter a s gt 2 5 gt 4 v SERVICE SIDE ACCESS PANEL SELF EXTINGUISHING ACOUSTICAL MATERIAL 1 2 TO 1 INCH 12 7 TO 25 4 MM THICK Cover the back top and sides of the compart ment not the compartment base with fiberglass or other self extinguishing sound absorbent material Sound insulation and adhesive should be rated at 200 F 90 C minimum See Figure 4 2 to design the set compartment for optimum noise reduction A combination of materials can reduce noise more than a single material can For instance a sheet of lead combined with a layer of acoustical material is more effective than either one alone High temp
26. housing Connect the battery positive cable to the B connection START on the start solenoid SOLENOID BATTERY POSITIVE CONNECTION FIGURE 3 14 BATTERY POSITIVE CONNECTION 3 5 5 Connect the battery negative cable with a 3 8 inch ring terminal to the ground connec tion on the left side of the base Refer to the Electrical Connections section for important genset grounding instructions Fallure to ground the genset properly can result in injury or death If the genset Is not grounded to the vehicle chas sis through the battery negative cable atiach an 8 AWG equipment ground wire between the vehicle chassis and the bat negative connection 6 Route the remote conirol connector through the access opening in the left side of the hous ing Connect the remote control connector to the mating connector inside the genset 7 Proceed to the next section on connecting the exhaust system EXHAUST SYSTEMS Exhaust gas presents the hazard of severe personal injury or death Do not terminate the exhaust pipe under the vehicle The exhaust pipe must not terminate so that any vent window or opening into the living area 15 within the triangular area shown in Figure 3 21 Read the Important safety precautions in the Exhaust Systems section 1 Connect the exhaust pipe 1 1 2 inch O D or 1 3 8 inch I D installer supplied to the genset with a U bolt clamp A short radius exhaust elbow i
27. in formation and study the under floor housing kitin _ structions for more information on under floor in stallations and important safety precautions The vehicle structure must be able to support the weight of the generator set see Specifications section The vehicle manufacturer and or the installer must provide a structurally sound support frame using tubing angle brackets or steel reinforced plywood or other composition board Plywood or particle board can be reinforced with 3 inch 76 mm or larger washers or a full metal plate ifthe generator set will be installed below a wooden floor a metal barrier must be installed between the wooden floor and the generator set Use 26 gauge 0 0217 inch painted or galvanized sheet metal or a material of comparable strength and fire resistance see NFPA 70 NEC and California Title 25 for complete details Under floor mounted sets do not require the exhaust pipe heat shield Fire presents the hazard of severe personal injury or death Install a metal barrier between the generator set and any wooden or flammable parts of the vehicle Generator Set Location Figure 4 3 shows the most common mounting areas for a generator set Protect the generator set from road splash and debris If possible drive the vehicle through mud and slush to test the installation Leave a minimum space of 1 1 2 inches 38 1 mm between the generator set and the vehicle skirt for an air inle
28. inte the base 8 5 4 IN 4 FUEL INLET 5 LPG 0 38 IN BARB 96 IN 4 5 IN 2 26 9 2 16 7 IN 06 45 1 8 IN 5 PRIMARY DIMENSIONS ARE MILLIMETERS COMPARTMENT ALLOW REMOVAL OF SERVICE DOOR AND ACCESS TO THE FOLLOWING SEVICEABLE COMPONENTS START STOP SWITCH FUSE CIRCUIT BREAKER MIN UNIT COMPARTMENT SURFACES TOP 6 4 25 IN ENGINE END 6 4 25 IN GEN END 6 4 25 IN SERVICE SIDE se 6 4 25 IN BACKSIDE 6 4 25 IN MIN FREE AIR AOIN 76 2KG 1681 5 AND ACCESS 40 IN FREE AIR INLET EXHAUST PIPE SHIELD MUST USED FOR COMPARTMENT INSTALL ATIONS FOR UNDERFLOOR INSTALLATIONS IT MAY BE REMOVED MINIMUM INSTALLATION SIZE IS VARIES WITH LARGER AND MOUNTING KIT USED FIGURE 4 1 COMPARTMENT OUTLINE DRAWING 4 2 72 28 0 IN 92 d 73 62 us _ 1 8 IN 137 7 5 4 IN 11 5 IN 5 15 18 FOR COMPARTMENT FLOOR 225 15 SCREW DOWN AT THE PROTRUDING INTO BASE MOUNING DRAWING NOTES ON PAGE 4 2 FIGURE 4 2 COMPARTMENT FLOOR PLAN 4 3 UNDER FLOOR In under floor installation the generator set is mounted below the floor and outside the passenger compartment of the vehicle This type of installa tion must comply with the Installation Codes and Safety Recommendations see Introduction sec tion Read this section for general application
29. le fuel supply line Unauthorized fuel system modifications can cause dangerous operating con ditions e Tying a generator set fuel line into a vacuum supply line vehicle fuel pump at the engine can cause the generator set to starve for fuel at highway speeds or during acceleration e Tying a generator set fuel line into a pressure supply line vehicle fuel pump in the fuel tank can cause poor generator set operation and create a hazard of fire or explosion caused by fuel leakage Some vehicle manufacturers permit tying into the fuel return line on high pressure fuel systems Contact the vehicle manufacturer for details and approval The fuel return line pressure at the point of connection must not exceed 1 1 2 psi or carburetor flooding could result Gasoline presents the hazard of explosion 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 compartment can occur resulting in a fire hazard The generator set could starve for fuel when the vehicle is operated at highway speeds if its fuel line is connected to the main fuel line with tee The generator set fuel pump has neither the capacity nor the power to overcome the draw of the vehicle engine fuel pump For this reason use a separate fuel line to the generator set or use a separate fuel tank separate connection is
30. ming any alcohol or drug that makes the operation of equipment unsafe RGA IN1 Redistribution publication of this document by any means is strictly prohibited 1 Introduction GENERAL This manual provides installation guidelines for the MicroLite generator set The generator set must be installed properly to operate reliably quietly and safely Read this entire manual before starting the installation For operation and maintenance procedures see the Operator s Manual 981 0132 that accompa nies each genset When properly installed this generator set meets or exceeds the following requirements e National Electrical Code NFPA 70 Article 551 e ANSI RVIA EGS 1 1986 Generator Set Standard e ANSI A119 2 NFPA 501C Standard for Recreational Vehicles e NFPA Liquefied Petroleum Gas e CSA Electrical bulletin 946 The RV manufacturer and or the set installer must comply with local codes such as California adminis trative Code title 25 which applies to generator set installation The RV installer bears sole responsi bility for the selection of the appropriate generator set installation design and installation Consider the following requirements before install ing the set Each topic is covered in the following text Level and supportive mounting surface e Adequate cooling air Adequate fresh induction air e Discharge of circulated air e Noise levels e Accessibility for maintenanc
31. mpartment dimensions are shown in Figure 4 1 Clearances between the genset and the compartment are included in these dimensions Allow for air intake at the front left side of the set and air discharge at the bottom of the set Air inlets to the set compartment must not allow dirt rocks water or slush to reach the set Minimize dust and salt entrance into the compartment See Ventila tion section Exposed above floor section of exhaust pipe must be shielded with the Onan supplied exhaust shield Compartment Construction 1 Install the gen set in its own compartment Allow a minimum of 1 4 inch 6 4 mm clearance at the front sides back and top of the set See Figures 4 1 and 4 2 Allow additional front service side clearance if the vehicle air inlet is not aligned with the genset air inlet to obtain the minimum free air inlet of 40in2 258 cm2 Example If the air inlet is along the entire bot tom front edge of the compartment increase the front clearance to 1 1 3 inches 34 mm 40 in 30 in air inlet length 1 1 3 in 4 1 lf insulation is used to line the compartment increase the compartment size to include the width of the insulation If any part of the compartment is above vehicle floor separate the compartment area from the living quarters and fuel supply with vapor tight walls Line the compartment walls with 26 gauge galvanized steel or a material of comparable strength and fire resi
32. mportant factors of ventilation for an air cooled generator set are sufficient incoming air for combustion and cooling and adequate exhausting of heated air A fan draws cooling air through the inlet on the generator end and pushes it across the generator and engine cooling fins The heated air is expelled through the air outlet on the bottom of the set See Figure 5 1 Make certain that nothing obstructs or restricts the air intake and air outlet Air recirculation must be minimized If a noise or dust deflector are added to the set it must be located a minimum of 6 inches 150 mm below the generator set and it must be open on three sides Exhaust gas presents the hazard of severe personal Injury or death Because dis charged cooling air can contain deadly exhaust gas never use discharged cooling air to heat the vehicle FIGURE 5 1 COOLING AIRFLOW 5 1 Operating the generator set with the cover removed can cause equipment damage Generator set cooling air does not circulate properly with the access cover removed Do not operate the generator set with the access cover removed When designing the air inlet and outlet for the set compartment see Figures 4 1 and 4 2 allow for the restriction of grilles and ductwork some expanded metal grilles provide only 60 percent free air inlet area per square foot The most efficient grille provides only 90 percent free inlet area per square foot Obtain the free inlet area of the
33. ngle of the vehicle unless it is protected by a skid bar or other protection device The shaded areas in Figure 6 1 illustrate typical mounting locations Exhaust gas presents the hazard of severe personal injury or death Do not mount any portion of the exhaust sysiem into the approach or departure angle unless It Is adequaiely protected Use only Onan specified exhaust equipment with the generator set Use sufficient number of hangers to prevent dislocation of the system TAILPIPE RECOMMENDATIONS An exhaust tailpipe is not supplied with the generator set because length requirements vary between vehicle manufacturers A short radius exhaust elbow is supplied with the generator set for installations that require a tight turn of the exhaust pipe at the outlet Referto the following recommen dations for information and safety considerations Use 1 1 2 inch O D 1 3 8 inch 1 0 18 gauge alu minized steel or stainless steel tubing for tailpipe Exhaust gas presents the hazard of severe personal injury or death Doe net use fiexible exhaust iallpipe because it can leak or break from road shock or vibration Do not terminate ine exhaust system under the vehicie Direct exhaust gases away from window door cr compartment openings Do not operate the generator set without an exhaust talipipe Use 1 3 8 inch U bolt type automotive muffler clamp to connect the exhaust tailpipe to the ex haust elbow If the tailpipe
34. not supplied for the gen set add a second fuel pickup in the tank This pickup should not extend below the bottom 1 4 of the tank so the vehicle will run after the generator runs out of fuel BARB FITTING CLAMP FUEL HOSE 81857 FIGURE 7 1 FUEL LINE CONNECTION Connect 1 4 inch I D fuel hose type SAE 30 R7 to the barb fitting on the generator set Figure 7 1 Secure fuel hose to barb fitting with a stainless steel clamp worm gear type Do not over tighten clamp or hose could be damaged Fuel hose must be long enough to allow generator set movement and prevent binding stretching or breaking Onan recommends copper or hot dip coated seamless steel tubing conforming to ASTM A 254 and double fiared connections for long runs between the fuel tank and the flexible connector to the generator set Run fuel line at the same height as the top of the fuel tank or above the tank to a point as close to the genset as possible This reduces the danger of fuel siphoning out of the tank if the line should break The maximum fuel pump lift of the genset is 3 feet 0 91m Keep fuel lines away from hot engine or exhaust areas to reduce the chance of vapor lock Fuel lines should be accessible and protected from damage Use metal straps without sharp edges to secure fuel lines Do not run fuel lines where they may contact sharp or rough surfaces or where they may be kinked pinched chaffed or struck Gasoline fuel may be
35. ntained Many accidents are caused by failure to follow fundamental rules and precautions The following symbols found throughout this man ual alert you to potentially dangerous conditions to the operator service personnel or the equipment This symbol warns of immediate hazards which will result in severe personal injury or death This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death This symbol refers to a hazard or unsafe practice which can result in personal Injury or product or property damage FUEL AND FUMES ARE FLAMMABLE Fire explosion and personal injury can result from improper practices Do not smoke or allow an open flame or spark producing equipment near the generator set or fuel tank e Fuel lines must be adequately secured and free of leaks Fuel connection at the engine should be made with an approved flexible non conductive line GASOLINE AND LPG FUEL MAY BE ACCI DENTALLY IGNITED BY ELECTRICAL SPARKS presenting the hazard of fire or ex plosion that result in severe personal Injury or death When Installing the generator set Keep electrical and fuel lines as far apart as possible Do not allow contact unless both lines are sheathed EXHAUST GASES ARE DEADLY Never sleep in the vehicle with the generator set running unless the vehicle is equipped with an operating carbon monoxide detector Provide an adequate exhaust system to pro
36. or set starting battery negative cable first before performing maintenance Move the Start Stop switch to the STOP posi tion to stop the generator set Starting from the Remote Control 1 Move the Remote Start Stop switch to the START position The engine should crank and start as indicated by indicator light on the switch If it does not see the Troubleshooting Guide in the Operators Manual Check all remote control connections repair if neces sary and restart the set After the genset starts check the battery condition meter if equipped to confirm its proper operation Move the Start Stop switch to the STOP posi tion to stop the generator set INSTALLATION REVIEW Prior to initial start up of the generator set check each of the following items For a proper installation each answer must be yes if not that aspect of the installation should be reworked or provision made to satisfy the requirement If installed in a compartment Is the compartment metal lined and sealed around all edges Are wiring holes into the inside of coach including the inside of AC conduit sealed to prevent passage of exhaust gases Can the following routine maintenance items be performed through the vehicle access panel Refer to Figure 3 3 e Change oil e Adjust carburetor e Start Stop the unit e Change air filter e Adjust governor e Access AC circuit breaker and control fuse e Change spark plug
37. perly expel discharged gases Do not use engine ing air to heat a compartment sure the unit is well ventilated MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Before starting work on the generator set disconnect batteries This will prevent accidental starting and electrical arcs Disconnect the Negative battery cable first to reduce the risk of arcing Keep your hands away from moving parts Make sure that fasteners on the generator set are secure Tighten supports and clamps keep guards in position over fans drive belts etc Do not wear loose clothing or jewelry while working on generator sets Loose clothing and jewelry can become caught in moving parts Jewelry can short out electrical contacts and cause shock or burning if adjustment must be made while the unit is running use extreme caution around hot manifolds moving parts etc ELECTRICAL CAUSE SEVERE PERSONAL INJURY OR DEATH e Disconnect the negative cable at the starting battery before removing protective shields or touching electrical equipment Use rubber insulative mats placed on dry wood platforms on the ground or over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surfaces to be damp when handling electrical equipment Use extreme caution when working on electrical components High voltages can cau
38. plate current rating of the generator set The Onan supplied AC feeder conductor insulation is rated at 125 C Wires connected to the Onan feeder conductors must 8 1 either meet this insulation rating be larger size see National Electrical Code NFPA 70 Use stranded wire for all load connections Load wiring must be appropriately sized and insulated for the specified current rating Grounding must comply with all codes Conduit Install the generator load conductors in a flexible conduit Cut the conduit to length leaving extra wire for the junction box connections Connecting wires must be correctly sized and insulated for the current rating Round off or cover the ends of the conduit to prevent its sharp edges from cutting the insulation Use waterproof conduit if the conduit is run outside of a compartment To reposition the 90 conduit fitting loosen the locking nut toothed ring turn fitting counterclock wise to desired location and retighten locking nut Seal all openings made for conduit into the vehicle interior so exhaust or fuel vapor cannot enter the living quarters Flexible metal conduit must be sealed internally at the end where it terminates inside the junction box or panel board flexible conduit is not vapor tight along its length Exhaust gas and fuel fumes present the hazard of severe personal Injury or death To prevent exhaust gas and fuel fumes from entering the vehicle interior
39. s e Nausea e Muscular Twliching e Headache e Vomiting e Weakness and Sleepiness e 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 attention 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 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 PRE START CHECKS Before starting the generator set perform these steps 1 Perform the Installation Review described in this section 2 Check the engine oil level Remove and clean the oil level indicator Insert the oil level indica tor into the oil filler neck It is not necessary to screw the oil level indicator in to obtain an oil level reading If low add oil very slowly until the Full markis reached Screw the oil level indica tor into the filler neck securely to prevent oil leakage INDICATOR FULL MARK k 5 9 SS FIGURE 9 1 Oil LEVEL INDICATOR 151171 2 9 1 3 Checkthat battery terminals and cable tors are clean and dry Connect the positive battery cable to the POS battery post first then connect
40. s supplied with the generator set for installations that require a tight turn of the exhaust pipe at the outlet Use the Onan supplied exhaust shield for compart ment mount installations whenever the exhaust elbow is tumed down for through the floor installations BATTERY NEGATIVE CONNECTION FIGURE 3 15 BATTERY NEGATIVE CONNECTION FIGURE 3 16 REMOTE CONTROL CONNECTION FIGURE 3 17 EXHAUST PIPE CONNECTION 3 6 2 Do not terminate the exhaust tail pipe under the vehicle The exhaust tail pipe must terminate 1 inch 25 4 mm beyond the side or EXTEND TAIL PIPE end of the vehicle 1 PAST OUTSIDE EDGE OF VEHICLE ANSI 119 2 3 4 3 OUTSIDE EDGE OF VEHICLE lL FIGURE 3 18 TAIL PIPE EXTENSION BEYOND VEHICLE 3 Support the tail pipe as close to the outside of the vehicle as possible LOCATE TAIL PIPE HANGER CLOSE TO OUTSIDE EDGE OF VEHICLE OUTSIDE TAIL PIPE HANGER FIGURE 3 19 EXHAUST PIPE SUPPORT 4 Termination of the exhaust tail pipe below the ANSI 119 2 PAR 3 4 3 angle of departure lowest point on rear of vehicle to the tire ground contact point must LOCATE TAIL be protected by a skid bar trailer hitch or PIPE IN SHADED some frame member AREA OR ABOVE DASH LINE FIGURE 3 20 TAIL PIPE PROTECTION 5 Be aware that any vent window or opening that can be opened and that is not permanently INCLUDING ENTRY sealed from the vehicle living space can be
41. se injury or death Follow all state and local electrical codes Have all electrical installations performed by a qualified electrician Tag open switches to avoid acciden tal closure DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM Hazardous voltages can flow from the generator set into 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 GENERAL SAFETY PRECAUTIONS e Wear safety glasses and protective clothing when servicing batteries DO NOT SMOKE while servicing batteries Lead acid batteries emit a highly explosive hydrogen gas that can be ignited by electrical arcing or by smoking Have a fire extinguisher rated ABC nearby Maintain extinguisher properly and become familiar with its use Benzene and lead found in some gasoline have been identified by some state and federal agencies as causing cancer or reproductive toxicity When checking draining or adding gasoline take care not to ingest breathe the fumes or contact gasoline Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity When checking changing engine oil take care not to ingest breathe the fumes or contact used oil Do not work on this equipment when mentally or physically fatigued or after consu
42. seal all openings made for conduit wiring etc Also seal the wiring within the conduit itself Use a silicone rubber based sealant Wiring Disconnect Method There mustbe no chance that an outside power Source be connected to the generator set Feeder conductors from the set compartment must terminate in a 120 volt double pole double throw positive off switching device mounted ahead of the vehicle distribution panel orthey must connectto a generator set receptacle box Figures 8 1 and 8 2 show examples of the wire connection Line Circuit Breaker The generator set has a line circuit breaker mounted on the front of the set mounted control panel The breaker provides short circuit and over load protection for the generator Load Connections The generator output voltage and maximum current rating are specified on the generator name plate Load wiring must be appropriately sized and insulated for the specified current rating Ground ing procedure must comply with codes A lead to be connected to an output feeder conduc tor shall not be more than two AWG sizes smaller than the output lead conductor and the insulation shall be Rubber with braid neoprene or thermoplas tic with a wall thickness of at least 0 030 inch 0 76 mm 8 2 e Other material having the same better electrical and mechanical properties Electrical shock can cause severe personal injury or death Use only approved power suppl
43. splash from vehicle wheels 9 4 10 Wiring Schematic Diagram 2 E 2 LOCAL START INPUT LOCAL RETURN LOCAL STOP INPUT REMOTE RUN OUTPUT REMOTE RUN OUTPUT REHOTE STOP INPUT REMOTE RETURN Hem _____ REGULATOR VOLTAGE COIL IGNITION SWITCH LOW OIL LEVEL SWITCH START STOP RESISTOR BATTERY CHARGE SOL REGULATOR LP RELAY STARTER MAGNETO IGNITION GENERATOR FUSE FUEL PUMP FUEL SHUTOFF SOLENOID LP SPARK PLUG RECTIFIER BRIDGE CIRCUIT BREAKER AC OUTPUT BATTERY 12V MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY REMOTE START INPUT gt AVR FIELO FLASH STARTER SOL OUTPUT OUTPUT BATTERY INPUT INPUT OIL LEVEL INPHT 1 12 FUEL PUMP DUTPUT 41 11 62 INPUT Jt 10 BATTERY INPUT 41 7 IGN ENABLE OUTPUT P5 486 _ f LI LOAD 120 2 NEUT F GND FIGURE 10 1 WIRING SCHEMATIC 611 1194 10 1 2 lt 5 i j J jo C I LOAD E2 2 81 12 52 2 ae 2 7 O x 81 1 2 6 6 LOA LINE Lt P2 BROWN 1 2 BLALK 3 YELLOW Piet PCB J6 48 FIGURE 10 2 WIRING DIAGRAM 611 1194 10 2 Redistribution publication of this document by any means is strictl
44. stance see NFPA 70 NEC and California Title 25 for complete details Exhaust gases present the hazard of severe personal injury or death Make the compartment walls vapor tight to the interior of the vehicle to prevent exhaust fumes from entering Construct a compartment floor that will prevent oil fuel or water accumulation Provide openings in the compartment floor according to the Compartment Floor Plan Figure 4 2 Do not use absorbent soundproofing material on the compartment floor or oil and gas could cause a fire hazard The floor should have as few openings as possible to reduce the noise level Equip the base with oil drain hole to the outside of the compartment Do not mount the exhaust pipe below the oil drain hole Fire presents the hazard of se vere personal Injury or death Do not posi tion the exhaust pipe directly below a drain hole Hot exhaust can Ignite fuel or oll Secure the genset mounting base to the sup port frame with four 5 16 18 UNC grade 5 screws The mounting bolts must not extend more than 1 2 inch 13 mm into the base See Figures 4 1 and 4 2 Torque 5 16 inch mount ing screws to 15 ft Ibs 20 Nem If the mounting base Is not fas tened securely to the vehicle compartment road vibration will damage the genset com ponents Use long enough screws for at least 1 1 2 threads to exiend through the weld nut The mounting bolts must not ex tend more than 1 2 In 13mm
45. t side air inlet is not aligned with the genset air inlet Provide a minimum back top and side clearance of 0 25 inches 6 4 mm The air inlet opening to the generator set compart ment must not admit dirt rocks water or slush The entrance of dust and salt into the compartment must be minimized Baffles may be needed to protect certain areas See the Ventilation section of this manual for more detailed information M1742 FIGURE 4 3 COMMON GENERATOR SET MOUNTING AREAS 4 4 Mounting Brackets vehicle must be adapted for use with the under floor mounting bracket kit The construction of the vehicle must support the weight of the generator set see Specifications section Itis the vehicle manufacturer and or the installers responsibility to provide hardware to attach the mounting brackets Review the Exhaust System section Plan clear ances for moving or removing exhaust components when the set is removed for service 4 5 Access Opening Provide an access opening to the generator set on the side of the vehicle Make the access large enough to allow for removal of the generator set access cover Also allow access to the oil drain located at the bottom of the set so the generator set does not have to be removed for servicing see Figure 1 1 for service locations Redistribution publication of this document by any means is strictly prohibited 5 Ventilation and Acoustics VENTILATION The most i
46. to variations in altitude temperature and fuel BTU content For this reason the fuel system may need to be adjusted after installation Referto the Service Manual if adjustments are required Recommended Fuel Use commercial propane or HD 5 grade LPG ina mixture of at least 90 percent propane Propane fuels other than HD 5 may contain more than 2 5 percent butane and may cause poor engine starting in low temperatures below 32 F or 0 C Fuel Consumption Generator set fuel consumption varies proportion ately to differing electrical loads Refer to Speci fications section for approximate fuel consumption at no load half load and full load Propane Fuel Lines and Supply Tank LP gas Propane presents the haz ard of fire or explosion that can cause severe personal injury or death Do not permit any flame spark pilot light cigarette or other Ignition source near the fuel system Keep an ABC type fire extinguisher nearby Review each of the codes that apply to LPG gen erator set installation Paragraph 2 11 LP Gas Engine Fuel installations of NFPA Pamphlet 501C and paragraph 3 6 2 5 of NFPA 58 piping hose and fittings These sections deal with fuel tanks and lines but does not cover all applicable codes and regulations Obtain this pamphlet by writing to ihe address listed in the beginning of this manual Mount a manual shutoff valve on the fuel supply tank When installing the fuel lines keep these fac
47. tors in mind e Install LPG fuel lines to be accessible but protected from damage Use metal straps without sharp edges to secure fuel lines Keep fuel lines away from hot engine or exhaust Do not run fuel lines next to electrical wiring Do not connect the genset fuel supply line to appliance fuel supply line The genset can draw fuel away from other appliances and cause a flame out To prevent the possibility of flameout the fuel supply system must be designed to deliver suffi cient fuel for normal operation of the genset and other appliances at the expected temperature con ditions It may be necessary to use a separate fuel tank for the genset if sufficient fuel cannot be sup plied with a single tank system LPG fuel presents the hazard of ex plosion or fire which can result in severe per sonal injury or death If flameout occurs with an unvented appliance LP gas can accumulate in side the vehicle and create a safety hazard Do not connect the generator set fuel supply line to an LP gas supply line that is supplying another appliance 7 4 Testing Fuel System for Leaks Before operating the set test the LPG fuel system for leaks Testing must conform to procedures listed in NFPA 58 or to the UL recommended test procedure as follows After assembly and before initial operation all fuel sysiem connections hose valves regulators and fittings must be tested and proven free of leaks us ing a soap
48. ust be qualified to perform electrical and or mechanical component installation COMPONENT LOCATIONS The standard control panel and routine mainte nance items are located behind the access cover Figure 1 1 To remove the access cover Rotate the fasten ers on the access cover one quarter turn clockwise so the arrows point to the right Pull the top of the cover away from the housing To secure the access cover Position the bottom of the cover over the base Push the top of the cover in and turn fasteners one quarter turn coun terclockwise so the arrows point up Operation of the generator set with the access cover removed result in severe sonal Injury or equipment damage Hot components are exposed when the access cover is removed and generator set cooling air does not circulate properly Do not operate the generator set with the access cover removed AIR FILTER BATTERY POSITIVE HOUSING lt REMOTE CONTROL HARNESS OPENING MUFFLER INSIDE COVER SPARK PLUG ACCESS OIL DRAIN ON BOTTOM FUEL LINE OIL GHE NOT SHOWN CONNECTION AND FILL CARBURETOR QUARTER TURN ALTITUDE FASTENERS AC CONDUIT CONTROL CIRCUIT ADJUST CONNECTION SREAKER START STOP FUSE BATTERY SWITCH NEGATIVE CONNECTION 1896 1 FIGURE 1 1 MICROLITE KY GENERATOR SET COMPONENT LOCATIONS 1 2 2 Specifications MODEL 4000 KY 3600 KY LP GENERATOR Generator Type Onan Revolving Fi
49. y assemblies Never remove the grounding pin from assemblies Incorrect ground or no ground can cause the vehicle to become electrically hot Equip the vehicle with adequate Ground Fault Circuit Protection devices to meet the National Electrical Code 70 551 9 and for personal safety AWARNING Gasoline fuel can be accidentally ignited by electrical sparks presenting the hazard of fire or explosion which can result in severe personal injury or death For this reason when Installing the generator set Do not tie electrical wiring to fuel lines Do not run electrical lines and fuel lines through the same compartment openings unless they are physically separated by running them through Individual channels or by passing each line through a separate piece of tubing Keep electrical and fuel lines as far apart as possible Place a physical barrier between fuel lines and electrical lines wherever possible MPORTANTI GROUND FAULT CIRCUIT INTERRUPTERS GFCIs ARE REQUIRED BY THE NATIONAL ELECTRICAL CODE NFPA 70 551 9 IN ALL EXTERNAL AND SOME INTERNAL OUTLETS TO PROPERLY EQUIP YOUR RECREATIONAL VEHICLE WITH THESE PROTECTION DEVICES CONTACT YOUR AV MANUFACTURER OR DEALER FOR RECOMMENDATIONS JUNCTION BOX CONDUIT FLEXIBLE CONDUIT DOUBLE POLE DOUBLE THROW SWITCHING DEVICE VEHICLE AC DISTRIBUTION PANEL MAIN BREAKER HACR BREAKERS IT im FOR AIR m 01
50. y or death Make the compartment walls vapor tight to the Interior of the vehicle to prevent exhaust fumes from entering the living quarters The generator set requires an unobstructed airinlet of at least 40 square inches 258 cm Referto the Mounting and Ventilation section for details Pro vide an adequate genset access for maintenance 11 25 X 19 5 inch minimum opening and service removal either through the door or out the bottom 1 Carefully measure the compartment size to make sure there will be proper clearance for the generator set Figure 3 3 shows the compartment dimensions Add 1 2 inch to compartment depth if 1 2 inch insulation is used inside the door Allowing one to two inches of added space on the left side of the compartment will make electrical and fuel connections easier 2 Put holes in the bottom of the compartment for genset mounting air outlet and oil drain Figure 3 4 ifthe bottom of the compartment is wooden remove the wooden section under compartment and replace it with a sheet metal floor and an adequate steel support frame Refer to Onan template number 539 1383 3 2 NFPA 70 551 30 d MINIMUM COMPARTMENT DIMENSIONS GENSET MOUNTING HOLES AIR USE TEMPLATE OR SEE FIGURE 4 2 FIGURE 3 4 COMPARTMENT FLOOR TEMPLATE 3 Put holes the compartment to run mee Ga bate cable LOCATE FUEL AND ELECTRICAL LINE tions for the fuel line ry
51. y prohibited Onon Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 763 574 5000 Fax 763 574 8087 Cummins and Onan are registered trademarks of Cummins Inc
52. zard of explosion which can result in severe personal injury Because batteries give off explosive gas install the battery in a separate compart ment from the generator set and away from all flames pilot light arcing or spark producing devices Battery Connections Make sure that the frame ground connection major frame member if possible is secure enough to minimize electrical resistance Avoid making this connection at a weld or mechanical joint On short cable runs the negative battery cable can be connected between the generator set and the bat tery as long as the battery negative has a sepa rate 8 AWG chassis ground connection Fallure to ground the genset prop erly can result In injury or death If the genset Is not grounded to the vehicle chassis through the battery negative cable atiach 8 AWG equipment ground wire between the vehicle chassis and the battery negative connec Route the battery cables between the genset its starting battery Make sure that the cables are long enough but do not connect them to the battery until instructed to do so in the Initial Start and Checks section of this manual Provide adequate support for the battery cables to avoid abrasion wear due to vibrations when the vehicle is in transit START RELAY BATTERY POSITIVE CONNECTION 1993 2 Positive Battery Cable Connect this cable to the start relay B post with a 3 8 in
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