CUMMINS KYD Series, 3.3KYD, 4KYD, 3.6KYD Installation Instructions Manual

Installation Manual

RV Generator Set

KYD (Spec A−C)

English − Original Instructions

2−2012 981−0636 (Issue 4)

!!

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

gasoline warnings

Table of Contents

SAFETY PRECAUTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Codes and Standards for Safety 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical Genset 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MECHANICAL INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enclosure 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST CONNECTIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Muffler 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tail Pipe 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL CONNECTIONS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gasoline 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LPG 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Connections 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Connections 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION REVIEW AND STARTUP 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Review 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOT AIR RECIRCULATION TEST 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OUTLINE DRAWING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM—60 HZ 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM—50 HZ 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OUTPUT CONNECTIONS—50 HZ 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

THIS PAGE IS INTENDED TO BE BLANK

2

Safety Precautions

Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can be obtained only when
equipment is operated and maintained properly.

The following symbols in this manual alert you to po­tential hazards to the operator, service person and
equipment.

alerts you to an immediate hazard
which will result in severe personal injury or
death.

WARNING

practice which can result in severe personal in­jury or death.

CAUTION

practice which can result in personal injury or
equipment damage.

When equipped with an integral or add−on Auto­matic Generator Starting System (AGS) control, ex­haust carbon monoxide (CO), electric shock, and
moving parts hazards are possible due to unex­pected starting. Turn off AGS whenever preforming
maintenance or service, when the vehicle is stored
between uses, is awaiting service, or is parked in a
garage or other confined area.

alerts you to a hazard or unsafe

alerts you to a hazard or unsafe

 Before working on the genset, disconnect the

negative (−) battery cable at the battery to pre­vent starting.

 Use caution when making adjustments while

the genset is running—hot, moving or electri­cally live parts can cause severe personal inju­ry or death.

 Used engine oil has been identified by some

state and federal agencies as causing cancer
or reproductive toxicity. Do not ingest, inhale, or
contact used oil or its vapors.

 Benzene and lead in some gasolines have

been identified by some state and federal
agencies as causing cancer or reproductive
toxicity. Do not to ingest, inhale or contact gaso­line or its vapors.

 Do not work on the genset when mentally or

physically fatigued or after consuming alcohol
or drugs.

 Carefully follow all applicable local, state and

federal codes.

GENERATOR VOLTAGE IS DEADLY!

 Disable the automatic genset feature (AGS) of

an inverter−charger or other automatic starting
device before servicing the genset to avoid
electric shock from an unexpected start.

GENERAL PRECAUTIONS

 Keep ABC fire extinguishers handy.

 Make sure all fasteners are secure and torqued

properly.

 To prevent accidental or remote startting while

working on the generator set, press the Stop
button and diconnect the battery cables at the
batteries to prevent starting durning mainte­nance and service. (Always disconnect nega­tive [−] first and reconnect last to prevent sparks
between tools and vehicle frame.)

 Keep the genset and its compartment clean.

Excess oil and oily rags can catch fire. Dirt and
gear stowed in the compartment can restrict
cooling air.

 Generator output connections must be made

by a qualified electrician in accordance with ap­plicable codes.

 The genset must not be connected to the public

utility or any other source of electrical power.
Connection could lead to electrocution of utility
workers and damage to equipment. An ap­proved switching device must be used to pre­vent interconnections.

 Use caution when working on live electrical

equipment. Remove jewelry, make sure cloth­ing and shoes are dry and stand on a dry wood­en platform.

ENGINE EXHAUST IS DEADLY!

 Learn the symptoms of carbon monoxide poi-

soning in this manual and never occupy the ve-

3

hicle while the genset is running unless the ve­hicle is equipped with a working carbon monox­ide detector.

 Prior to every startup and after every eight

hours of running, all carbon monoxide detec­tors must be tested and confirmed to be work­ing in accordance with the manufacturer’s in­structions or owners manual.

 Leaks can lead to explosive accumulations of

gas. Natural gas rises when released and can
accumulate under hoods and inside housings
and buildings. LPG sinks when released and
can accumulate inside housings and base­ments and other below-grade spaces. Prevent
leaks and the accumulation of gas.

BATTERY GAS IS EXPLOSIVE

 The exhaust system must be installed in accor-

dance with the genset Installation Manual. En­gine cooling air must not be used for heating the
working or living space or compartment.

 Inspect for exhaust leaks at every startup and

after every eight hours of running.

 Make sure there is ample fresh air when operat-

ing the genset in a confined area.

FUEL IS FLAMMABLE AND EXPLOSIVE

 Do not smoke or turn electrical switches ON or

OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equip­ment. Keep flame, sparks, pilot lights, arc-pro­ducing equipment and switches and all other
sources of ignition well away.

 Fuel lines must be secured, free of leaks and

separated or shielded from electrical wiring.

 Wear safety glasses and do not smoke while

servicing batteries.

 When disconnecting or reconnecting battery

cables, always disconnect the negative (−) bat­tery cable first and reconnect it last to reduce
arcing.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

 Disable the automatic genset starting feature

(AGS) of an inverter−charger or other automat-
ic starting device before servicing the genset to
avoid unexpected starting.

 Do not wear loose clothing or jewelry near mov-

ing parts such as PTO shafts, fans, belts and
pulleys.

 Keep hands away from moving parts.
 Keep guards in place over fans, belts, pulleys,

etc.

4

Introduction

ABOUT THIS MANUAL

This manual is a guide for the installation of the KYD
Series of generator sets (gensets). Proper installa­tion is essential for safe, reliable and quite opera­tion. Read through this manual before starting the
installation. Leave this manual with the Operator’s
Manual and other vehicle manuals.

This manual addresses the following aspects of the
installation:

 Location, Mounting and Enclosure
 Exhaust Connections
 Fuel Connections
 Electrical Connections
 Startup

See the Operator’s Manual for operation and main­tenance and the Service Manual for service.

Note: Manuals are updated from time-to-time to re­flect changes in the equipment and its specifica­tions. For this reason, only the copy of the installa­tion manual supplied with the genset should be used
as a guide for the installation.

INSTALLATION CODES AND STANDARDS

FOR SAFETY

The builder of the RV or work vehicle bears sole re­sponsibility for the selection of the appropriate gen­set, for its proper installation and for obtaining ap­provals from the authorities (if any) having jurisdic­tion over the installation. These sets meet the basic
requirements of the Standard for Safety for Engine
Generator Sets for Recreational Vehicles, ANSI/
RVIA EGS-1.

In the United States the installation must comply
with the following standards:

In Canada the installation must comply with:

 CSA Electrical Bulletin 946—Requirements for

Internal Combustion Engine-Driven Electric
Generators for Use in Recreational Vehicles

Federal, State and local codes, such as the Califor­nia Administrative Code—Title 25 (RV installation),
might also be applicable. Installation codes and rec­ommendations can change from time-to-time and
are different in different countries, states and munic­ipalities. Obtain the standards in Table 1 for refer­ence.

Code of Federal

Regulations,

Title 49: Chapter III

and Chapter V

NFPA Nos. 58, 70,

1192

ANSI A119.2

ANSI/RVIA-EGS-1

California Adminis-

trative Code—Title

25, Chapter 3

CAN/CSA-Z240

Recreational Ve-

hicles

Bulletin 946

TABLE 1. REFERENCE CODES AND STANDARDS

CAUTION

Unauthorized modifications or re-

Superintendent of Documents

P. O. Box 371954

Pittsburgh, PA 15250-7954

National Fire Protection Association

470 Atlantic Avenue

Boston, MA 02210

Recreational Vehicle Industry Association

14650 Lee Road

Chantily, VA 22021

State of California Documents Section

P.O. Box 1015

North Highlands, CA 95660

Canadian Standards Association

Housing and Construction Materials Section

178 Rexdale Blvd.

Rexdale, Ontario, Canada M9W 1R3

placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in the State of
California.

 ANSI A119.2 / NFPA No. 1192—Recreational

Vehicles

 NFPA No. 70, Article 551—Recreational Ve-

hicles and RV Parks

 NFPA No. 58—Liquefied Petroleum Gas Code

WARNING

Improper installation can result in
severe personal injury, death and equipment
damage. The installer must be qualified to per­form the installation of electrical and mechani­cal equipment.

5

TYPICAL GENSET

Figure 1 illustrates a typical genset. See OUTLINE
DRAWING (Page 27) for installation details: mount­ing bolt hole locations, connection points (fuel, bat­tery, remote control, AC output and exhaust), sizes
and types of fittings, inlet and outlet air openings,
weight and overall dimensions, etc. See your Onan

dealer for large-scale copies of the drawings and for
full-size floor template 539-4814 for floor opening
cutouts.

CAUTION

Do not tip the genset forward or oil
will spill into the breather. Tip the genset back­wards to loosen the shipping skid bolts.

AIR CLEANER

COVER

BATTERY CABLE

CONNECTIONS

MAINTENANCE

ACCESS COVER

ALTITUDE

ADJUST KNOB

(Gasoline Models)

CONTROL

SWITCH

CIRCUIT

BREAKER

MUFFLER

TAILPIECE &

SPARK ARRESTOR

OIL FILL CAP

& DIPSTICK

FIGURE 1. TYPICAL GENSET

6

SPARK

PLUG

OIL DRAIN
THROUGH

BOTTOM OF

BASE

Mechanical Installation

CAUTION

side) down while handling the genset. Other­wise, engine oil could drain into and soak the air
filter and cause hard starting and poor opera­tion until the filter is replaced.

The location, mounting and enclosure of a genset
must be such that mounting is secure; engine ex­haust, cooling air and fuel vapors are properly
vented and prevented from entering the vehicle;
rain and road debris are prevented from entering the
genset; and ready access is afforded for operating
the genset and performing periodic maintenance.

Avoid tipping the front (service

LOCATION

Review Exhaust Connections, Fuel Connections
and Electrical Connections before deciding where
to locate the genset. Figure 2 shows typical genset
locations.

MOUNTING

The genset support structure must be able to resist
the dynamic loads of the genset: cyclical forces of

3 g vertical and  1 g horizontal. A plywood or

particle board floor must be reinforced with steel to
resist the dynamic loads. See Specifications

(Page 23) for the weight of the specific model being
installed.

FIGURE 2. TYPICAL GENSET LOCATIONS

Mounting On Floor: The genset base pan has
four 5/16-18 UNC threaded holes in the bottom for
floor mounting. Use grade 5 screws to mount the
genset. To avoid interference with internal parts, the
screws must not protrude more 1/2 inch (12.7 mm)
from the sheet metal of the base pan.

Mounting Below Floor: Kit 541−0952 is available
from Onan for mounting the genset below the floor.
Carefully follow the instructions in the kit.

WARNING

lead to severe personal injury or death if the
genset falls from the vehicle. Design the struc­ture carefully, follow applicable mounting kit in­structions and torque mounting bolts properly.

A weak supporting structure can

7

ENCLOSURE

Compartment Dimensions

General

The genset must not share a compartment or ven­tilation with sources of flammable vapors, such as
batteries and fuel tanks. A genset can ignite flam­mable vapors.

The genset must be shielded from rain and from de­bris and water thrown up by the vehicle tires.

Do not duct genset cooling air into the vehicle: the
cooling air may include deadly exhaust gases.

WARNING

DEADLY! — Install a vapor-tight and fire-resis­tive barrier of approved materials between the
genset and the vehicle interior — Do not duct
genset cooling air into the vehicle for heating.

EXHAUST GAS AND FIRE ARE

Fire and Vapor Barriers

Floor-Mounted Installations: When the genset is
mounted on the floor of the vehicle, construct a va­por-tight, fire-resistive compartment equivalent to
26 gauge galvanized steel to isolate the genset
from the vehicle interior. Seal all openings through
the barrier, such as for bolts and wiring.

Note: If the floor is of wood or other combustible ma­terial, it must be lined with 26 gauge galvanized steel
or equivalent material where the distance is less than
3 inch (76 mm) from the muffler, mounting bracket or
tail pipe.

See Specifications (Page 23) and the outline draw­ing (Page 23) to determine the minimum inside di­mensions of a genset compartment. If the compart­ment has thermal or acoustic insulation, increase
the minimum compartment dimensions by the thick­nesses of the insulation. The minimum clearance
required between the genset and the compartment
or its insulation is 1/4 inch (6.4 mm) on the sides
and back, 1/2 inch (12.8 mm) on top and 1-1/4 inch
(31.8 mm) in front. The space on the left side must
be sufficient for making fuel and electrical connec­tions.

Acoustic Insulation

Acoustic and thermal insulation and adhesive
should be Classified as “Self-Extinguishing” for use
at not less than 200
of the compartment with insulation, which absorbs
spilled fuel and oil.

F (90C). Do not line the bottom

Access for Operation and Maintenance

Provide ready access for starting and stopping the
genset and performing all periodic maintenance
procedures.

The compartment floor must not block off the oil
drain plug or air outlets. See your Onan dealer for a
full-size floor cutout template (539-4814).

Below-Floor Installations: When the genset is
mounted below the floor of the vehicle and outside
the interior envelope of the vehicle, install a vapor­tight, fire-resistive barrier above the genset equiva­lent to 26 gauge galvanized steel. Seal all openings
through the barrier, such as for bolts and wiring.

Compartment Drain

The floor of the genset compartment must have
holes which allow water and fuel to drain. Refer to
floor template 539-4814 for recommend drain hole
locations.

8

VENTILATION

Air for combustion, cooling and ventilation enters
through the column of rectangular openings on the
left front of the genset and exits through the two
openings in the base pan (Figure 3). To prevent
overheating, the installation must minimize the re­circulation of warm air back into the genset.

It is recommended that the genset compartment
door have an air opening in line with the genset air
openings and that the opening have a seal around it
that takes up the space between the door and gen­set, forming an air duct. The opening must have the
equivalent of 40 square inches

(258 cm

“free air” and should be baffled or louvered to keep
out rain. Check with the manufacturer of the louver,

AIR INLETS

2

) or more of

grille or expanded metal to determine how to size
the air opening to obtain the required area on a “free
air” basis.

If the compartment door air inlet is not in line with the
genset air inlets, block any gap between the genset
base pan and the front of the compartment to pre­vent the hot air discharge below the genset from be­ing recirculated into the air inlets.

The compartment floor must not block off the two
ventilating air outlet openings in the base pan. Also,
the space below the outlets must be unobstructed
and open on at least three sides to let the warm air
disperse. See your Onan dealer for large-scale cop­ies of the drawings and for full-size floor template
539-4814 for floor opening cutouts.

AIR OUTLETS

FIGURE 3. AIR FLOW THROUGH GENSET

9

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10

Exhaust Connections

MUFFLER

WARNING

exhaust gases from entering the vehicle — Do
not terminate the exhaust tail pipe underneath
the vehicle or closer than 6 inches (153 mm) to
openings into the vehicle — Route the exhaust
system such that it is protected from damage —
Use approved materials only.

The genset exhaust system must be gas-tight and
prevent entry of exhaust gases into the vehicle.

Figure 4 illustrates installation of the muffler kit
available from Onan. Carefully follow the instruc­tions in the kit. The muffler has a USDA (Forest Ser­vice) spark arrestor, meets RVIA EGS-1 require­ments for construction and complies with emissions
certification of the genset.

Note: A muffler must have a USDA (Forest Service)
spark arrestor and meet RVIA EGS-1 requirements
for construction (aluminized steel or equivalent and
welded or crimped joints). A genset without a proper­ly installed and maintained spark arresting exhaust
system can cause a brush fire or forest fire and is ille­gal on federal lands.

EXHAUST GAS IS DEADLY! Keep

FIGURE 4. MUFFLER KIT 541−0916

Liability for damage, injury and warranty expense
due to modification of the exhaust system or to use
of unapproved parts is the responsibility of the per­son performing the modification or installing the un­approved parts.

CAUTION

placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in the State of
California.

Do not mount the muffler closer than 3 inches
(76 mm) to combustible material (wood, felt, cotton,
organic fibers, etc.) unless it is insulated or shielded.
The temperature rise (above ambient) on adjacent
combustible material must not exceed 117

C).

(65

Unauthorized modifications or re-

F

11

TAIL PIPE

1. For the tail pipe, use 18-gauge, 1-1/8 inch I. D.
aluminized steel tubing or material of equiva­lent heat and corrosion resistance. Do not use
flexible tubing, which is neither gas tight nor du­rable.

2. Use U-bolt muffler clamps (available from
Onan) for tail pipe connections. Overlapping
pipe should be slotted (Figure 5).

3. Support the tail pipe near its end and at inter­vals of 3 feet (0.9 m) or less. Use automotive­type tail pipe hangers (available from Onan).
Tail pipe hangers must hang straight down.
Otherwise, the hanger will pull the tail pipe to
side, front or back causing noise and/or dam­age to the muffler and tail pipe.

4. Do not route the tail pipe near fuel lines and fuel
tanks or closer than 3 inches (76 mm) to com­bustible material (wood, felt, cotton, organic fi­bers, etc.) unless it is insulated or shielded. The
temperature rise (above ambient) on adjacent
combustible material must not exceed 117

C).

(65

F

5. To prevent damage to the tail pipe and muffler
while the vehicle is moving, keep it out of the
approach and departure angles and above the
axle clearance line (Figure 6).

3/4 INCH (19 MM) SLOT

(BOTH SIDES)

FIGURE 5. EXHAUST TAIL PIPE CONNECTIONS

DEPARTURE ANGLE AXLE CLEARANCE LINE

FIGURE 6. DEPARTURE ANGLE &

AXLE CLEARANCE LINE

6. Do not terminate the tailpipe underneath the
vehicle. Extend it a minimum of 1 inch (25 mm)
beyond the perimeter of the vehicle (Figure 7).

Support the end of the tail pipe such that it can­not be pushed in and up under the skirt of the
vehicle.

7. Do not terminate the tail pipe such that it is clos­er than 6 inches (153 mm) to any opening, such
as a door, window, vent or unsealed compart­ment, into the vehicle interior (Figure 8)

8. Make sure a tail pipe deflector will not cause ex­cessive back pressure (Specifications,
Page 23).

CAUTION

Excessive back pressure may
void emissions certifications and cause en­gine damage.

12

1 INCH (25 mm)
MINIMUM

LAST TAILPIPE HANGER AS

CLOSE TO END AS PRACTICAL

FIGURE 7. TERMINATING THE TAILPIPE

NO OPENING INTO THE VEHICLE INTERIOR MAY

BE CLOSER THAN 6 INCHES (153 mm) TO THE

END OF THE TAIL PIPE (WITHIN SHADED AREA)

6 in

153 mm

TAILPIPE

FIGURE 8. MINIMUM DISTANCES TO OPENINGS

Fuel Connections

See the Operator’s Manual for recommended fuels
and Specifications for fuel consumption rates.

WARNING

Gasoline and LPG are flammable
and explosive and can cause severe personal
injury or death. Do not smoke or allow any
flame, spark, pilot light, arc-producing equip­ment, switches or other ignition sources around
fuel or fuel components, or in areas sharing ven­tilation. Keep an ABC fire extinguisher handy.

GASOLINE

Onan recommends a dedicated fuel pickup tube or
a separate fuel tank for the genset. The genset must
never be connected to the fuel supply line of the
vehicle engine—either to a high-pressure system
(pump in tank), which can overpressurize the gen­set fuel system, or to a vacuum system (pump on
engine), which can cause the genset to starve for
fuel. Some vehicle chassis manufacturers allow
connections to the fuel return line on high pressure
fuel systems. Contact the vehicle chassis manufac­turer for approval. Fuel line pressure at the point
where the genset is connected must not exceed
1-1/2 psi under any condition.

WARNING

the genset causing a fire. Genset fuel supply
line pressure must not exceed 1-1/2 psi under
any condition.

SAE J1508 Type D screw & nut hose clamps (Fig­ure 9) are recommended for all fuel hose connec­tions.

For separate fuel pickup tube installations:

1. Contact the vehicle chassis manufacturer re­garding installation of the second fuel pickup.
Do not change or remove the fuel fill tube, fill
limiter vent, vapor canister, vapor lines, filler
cap or any other part of the fuel system without
the approval of the vehicle chassis manufactur­er. Doing so could affect vehicle engine opera­tion or vehicle emissions regulation com­pliance.

2. Terminate the genset pickup above the vehicle
pickup to prevent the genset from running the
vehicle out of fuel.

Excessive fuel pressure can flood

BARB

FITTING

HOSE

FUEL

HOSE

FIGURE 9. GASOLINE FUEL CONNECTION

CLAMP

13

Note: Federal standards for vehicle fuel tanks may
require the installation of an automatic shutoff valve
at the genset fuel tank pickup to prevent leakage in
the event of a roll-over. Federal standards for vehicle
impact, roll-over and emissions may also apply to a
separate genset fuel tank. Check with the vehicle
chassis manufacture regarding these standards.

For long runs use copper or hot dip coated seam­less steel tubing (ASTM A-254) with double-flared
fittings. See Figure 9 for the connection at the gen­set. Use 1/4 inch I. D. fuel hose (SAE 30-R7 or bet­ter) and stainless steel hose clamps.

Run the fuel line at or above the top of the fuel tank to
reduce the risk of siphoning fuel out of the tank if the
line should break. The maximum fuel pump lift is
36 inches (914 mm).

Route gasoline fuel lines away from electrical wiring
and hot engine exhaust components. (Heat can
cause fuel vapor lock.) Fuel lines should be accessi­ble for inspection and replacement, protected from
damage and secured to prevent kinking, contact
with sharp edges and chafing due to vibration.

WARNING

Sparks can ignite gasoline, leading
to severe personal injury or death. Do not run
electrical wiring and fuel lines together. Sepa­rate them with conduit or tubing if run through
the same opening. Do not tie them together.

LPG

WARNING

LPG is flammable and explosive

and can cause asphyxiation. NFPA 58, Section

1.6 requires all persons handling LPG to be
trained in proper handling and operating proce­dures.

Adjust the gas supply pressure (at the gas inlet of
the pressure regulator) to at least 9 inches (229 mm)
Water Column (WC). The pressure must not exceed
13 inches (330 mm) WC.

WARNING

High LPG supply pressure can
cause gas leaks which can lead to fire and se­vere personal injury or death. LPG supply pres­sure must be adjusted to Specifications by qual­ified personnel.

Route LPG fuel lines away from electrical wiring and
hot engine exhaust components. Fuel lines should
be accessible for inspection and replacement, pro­tected from damage and secured to prevent kinking,
contact with sharp edges and chafing due to vibra­tion.

WARNING

Sparks can ignite LPG, leading to
severe personal injury or death. Do not run elec­trical wiring and fuel lines together. Separate
them with conduit or tubing if run through the
same opening. Do not tie them together.

Route the LPG vent hose (Figure 10) so that it vents
outside the genset compartment.

WARNING

LPG leaks from the vent hose can
lead to explosive accumulations inside the gen­set compartment. Route the LPG vent hose so
that it vents to the outside.

Follow the Standard for the Storage and Handling of
Liquified Petroleum Gases (NFPA No. 58) when
installing the LPG fuel system. Figure 10 illustrates
a typical LPG fuel system.

For a long fuel line run, use seamless steel tubing
with flared ends. Make flexible hose connections at
the fuel tank and at the genset. Use 3/8-inch I.D. fuel
line for runs up to 3 feet (0.9 m) and 1/2-inch I.D. up
to 15 feet (4.6 m).

14

Do not connect the genset fuel supply line to any 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 sufficient fuel
for normal operation of the genset and other ap­pliances at the expected temperature conditions. It
may be necessary to use a separate fuel tank for the
genset if sufficient fuel cannot be supplied with a
single tank system.

Upon completing the installation, fill the LPG tank
and test every joint and fitting in the LPG supply sys­tem using an approved method, such as soap
bubbles.

WARNING

Testing for gas leaks with a flame
can cause a fire or explosion that could lead to
severe personal injury or death. Use approved
methods only.

WARNING

The flameout of an unvented LPG
appliance can lead to explosive accumulations
of gas inside the vehicle and the danger of se­vere personal injury or death. Do not connect
the genset fuel supply line to any vehicle ap­pliance supply line.

VAPOR SHUTOFF VALVE

FUEL LINE SIZE:

3/8-INCH I.D. UP TO

3 FEET (0.9 m)

1/2-INCH I.D. UP TO

15 FEET (4.6 m)

TWO STAGE REGULATOR

Because variations in fuel, altitude and ambient
temperature affect performance, it might be neces­sary to make governor and fuel mixture adjustments
once the genset has been installed. See the Service
Manual.

11 INCHES W.C.

OUTLET PRESSURE

DEMAND

REGULATOR

5/8 - 18 45

FLARE FITTING

LPG VENT HOSE

(VENT OUTSIDE

COMPARTMENT)



FUEL SHUTOFF

SOLENOID

FIGURE 10. TYPICAL LPG VAPOR WITHDRAWAL FUEL SYSTEM

15

LPG CARBURETOR

THIS PAGE IS INTENDED TO BE BLANK

16

Electrical Connections

Do not connect the battery cables to the battery until
Installation Review and Startup (Page 25) has been
completed to prevent accidental starting of the gen­set during installation.

WARNING

can cause severe personal injury or death. Do
not connect the starting battery until Installa­tion Review and Startup has been completed.

Accidental starting of the genset

GENERATOR CONNECTIONS

The genset is equipped with 104 inch (2.6 m) long
AC power output leads which exit through a 1/2 inch
trade size conduit connector (Figure 11). See Figure
12 for typical connections.

Wiring Methods

Follow the National Electrical Code, especially not­ing the following:

1. Have a qualified electrician supervise and in­spect the installation of all AC wiring.

5. Seal all conduit openings into the vehicle interi­or to keep out exhaust gas. Apply silicone rub­ber or an equivalent type of sealant inside and
outside each conduit connector. (Flexible con­duit is not vapor-tight and will allow exhaust gas
to enter along the wires if not sealed.)

WARNING

Seal all wiring openings into the vehicle in­terior to keep out exhaust gas.

6. Bond the genset and all connected AC and DC
equipment and controls to a common ground­ing point in accordance with applicable codes.

WARNING

fire and electrocution, resulting in severe
personal injury or death. Grounding must
be in accordance with applicable codes.

EXHAUST GAS IS DEADLY!

Faulty grounding can lead to

2. Install vibration-proof switches and controls
that won’t open and close circuits when the ve­hicle is in motion.

3. Provide ground fault circuit interrupters
(GFCIs)for all convenience power receptacles.

4. Route AC wiring, remote control wiring and fuel
lines separately.

AC OUTPUT

LEADS

FIGURE 11. AC OUTPUT LEADS AND CONDUIT

1/2 INCH CONDUIT

CONNECTOR

17

Connecting the Vehicle to Utility Power

When the vehicle has provision for connecting utility
power it must have an approved device to keep the
genset and utility from being interconnected. See
Figure 12 for typical connections.

WARNING

Interconnecting the genset and the
public utility (or any other power source) can
lead to the electrocution of personnel working
on the utility lines, damage to equipment and
fire. An approved switching device must be
used to prevent interconnections.

TO VEHICLE AC

DISTRIBUTION PANEL

GND

L1 N

GNDGND

N

L1L1

120V120V

GENSET

GREEN

WHITE

BLACK

N

TRANSFER SWITCH

FIGURE 12. TYPICAL CONNECTIONS WITH TRANSFER SWITCH AND UTILITY

UTILITY POWER

18

REMOTE CONTROL CONNECTIONS

Onan offers three varieties of remote control panel:

 Remote start/stop switch with status indicator

light only (Figure 13).

 Remote start/stop switch with status indicator

light and hour meter (Figure14).

 Remote start/stop switch with status indicator

light and DC voltmeter (Figure15).

The genset has an 8-pin connector for remote con­trol connections (Figure 16). Remote control wiring
harnesses in several lengths are available sepa­rately. To make connections to a remote control
panel:

1. Push the remote control wire harness connec­tor through the entrance hole in the side of the
genset housing and snap it together with the
genset connector. If the wiring harness is made
up by others, insulated 18 AWG copper con­ductors should be used for distances up to 30
feet (9 meters) and heavier gauge conductors
for distances that are greater. Use flexible
sheathing to protect remote control wiring. Fig­ure 17 is a schematic of typical remote control
connections. It identifies the function of each
connector pin number. The remote panel end of
each lead should be marked to identify the con­nector pin number.

FIGURE 13. REMOTE CONTROL

FIGURE 14. REMOTE CONTROL / HOUR METER

FIGURE 15. REMOTE CONTROL / DC VOLTMETER

2. Route control leads separately from AC power
leads to reduce the possibility of erratic opera­tion due to false induced signals.

3. Seal the opening where the leads enter the ve­hicle interior with silicone rubber or an equiva­lent type of sealant to keep out exhaust gas.

WARNING

EXHAUST GAS IS DEADLY!
Seal all wiring openings into the vehicle in­terior to keep out exhaust gas.

FIGURE 16. REMOTE CONTROL CONNECTOR

19

REMOTE CONTROL

PANEL

+

DC

VOLTMETER

OPTIONAL

−

DC VOLTMETER

+

HOUR METER

OPTIONAL

−

HOUR METER

START/STOP SWITCH

+

LED

−

FIGURE 17. SCHEMATIC OF TYPICAL REMOTE CONTROL CONNECTIONS

STATUS

INDICATOR LIGHT

REMOTE RUN

START

GND

STOP

REMOTE CONTROL

CONNECTOR

B

E

F

GH

WIRE END

B

F

C

A

B

WIRE END

(VIEW B−B)

CONNECTOR END

GENSET

CONNECTOR

A

CONNECTOR END

A

D

C

B

A

CONNECTOR END

(VIEW A−A)

WIRE END

E

F

G

H

BATTERY CONNECTIONS

Do not connect the battery cables to the battery until
Installation Review and Startup (Page 25) to pre­vent accidental starting of the genset during installa­tion.

WARNING

can cause severe personal injury or death. Do
not connect the starting battery until Installa­tion Review and Startup (Page 25).

The genset has a 12 VDC, negative-ground engine
control and cranking system. See Specifications for
the requirements for cranking batteries.

Accidental starting of the genset

Battery Compartment

Batteries must be mounted in a separate compart­ment from that of the genset and away from spark­producing equipment. A compartment must have
openings of at least 1.7 square inches (11 square
centimeters) at the top and bottom for ventilation of
battery gasses. It should be mounted such that
spills and leaks will not drip acid on fuel lines, wiring
and other equipment that could be damaged.

WARNING

Arcing can ignite the explosive hy­drogen gas given off by the battery, causing se­vere personal injury. The battery compartment
must be ventilated and must isolate the battery
from spark-producing equipment.

20

Battery Cables

Size battery cables according to Table 2. The cur­rent path between the genset and the negative (−)
battery terminal must also be able to carry full crank­ing current without causing excessive voltage drop.
It is highly recommended that a full-length cable be
used to connect the genset to the negative (−) bat-
tery terminal (Figure 18). Note also that codes may
require bonding conductors from the genset and the
battery to the vehicle frame.

If a full-length negative (−) cable is not run from the
battery (Figure 19), all vehicle frame members in
the path of battery cranking currents must have sub­stantial cross sections. The electrical resistance of
riveted or bolted frame joints must also be carefully
considered, especially if the joints will be exposed to
corrosive conditions. A cable must be used to con­nect the frame to the designated negative (−) termi­nal on the genset (Figure 19). The cable must be
sized according to Table 2. The genset mounting

bolts are not considered adequate means for
bonding the genset to the vehicle frame, either
for the purpose of carrying cranking currents or
for complying with requirements for genset/
system grounding.

Route battery cables away from fuel lines and hot
engine exhaust components. Battery cables should
be accessible for inspection and replacement, pro­tected from damage and secured to prevent chafing
due to vibration.

TABLE 2. BATTERY CABLE SIZES FOR

TEMPERATURES DOWN TO −20 F (−29C)

TOTAL CABLE LENGTH*

FEET (METERS)

0 to 10 (0 to 3) 2**

11 to 15 (3 to 4.5) 0

16 to 20 (4.5 to 6) 000

* − Add the negative battery cable lengths with the positive
battery cable lengths for the total.

** − A total length of up to 20 feet (6 meters) may be used
in warmer climates or when battery capacity totals at least
1000 CCA (Cold Cranking Amps).

SIZE PER TABLE 2

GENSET

+

−

FIGURE 18. FULL-LENGTH CABLE FROM

BATTERY NEGATIVE (−) TERMINAL

GENSET

+

−

#8 AWG

MINIMUM

VEHICLE FRAME

SIZE PER TABLE 2

CABLE SIZE

AWG

− +

BAT

− +

BAT

WARNING

Routing battery cables with fuel
lines can lead to fire and severe personal injury
or death. Keep battery cables away from fuel
lines.

Terminate the battery cables with appropriately
sized eyelet connectors and connect them to the
genset as shown in Figure 20.

VEHICLE FRAME

FIGURE 19. VEHICLE FRAME AS PATH FROM

BATTERY NEGATIVE (−) TERMINAL

NEG (−) BATTERY

CABLE CONNECTION

& GROUND TERMINAL

POS (+) BATTERY

CABLE CONNECTION

FIGURE 20. BATTERY CABLE CONNECTIONS

21

THIS PAGE IS INTENDED TO BE BLANK

22

Specifications

GASOLINE MODELS LPG MODELS

4KYD 3.6KYD 3.6KYD 3.3KYD

GENERATOR: 2-Pole Revolving Field, Self-Excited, 1-Phase, Microprocessor Regulated

Power 4000 watts 3600 watts 3600 watts 3300 watts

Frequency 60 Hertz 50 Hertz 60 Hertz 50 Hertz

Voltage 120 volts 230 volts 120 volts 230 volts

Current 33.3 amperes 15.7 amperes 30 amperes 14.3 amperes

Speed 3600 rpm 3000 rpm 3600 rpm 3000 rpm

FUEL CONSUMPTION:

No load
Half load
Full load

ENGINE: 1-Cylinder, 4-Stroke Cycle, Spark-Ignited, OHV, Air Cooled, Mechanically Governed

Bore 3.11 inch (79 mm) 3.11 inch (79 mm)

Stroke 2.44 inch (62 mm) 2.44 inch (62 mm)

Displacement 18.5 inch3 (304 cc) 18.5 inch3 (304 cc)

Compression Ratio 8.5 : 1 8.5 : 1

Oil Capacity 1.6 quart (1.5 l) 1.6 quart (1.5 l)

Intake Valve Lash (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm)

Exhaust Valve Lash (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm)

Spark Plug Tightening Torque 13 lbs-ft (17 N-m) 13 lbs-ft (17 N-m)
Ignition Timing (magneto) 25 BTDC, non-adjustable 25 BTDC, non-adjustable

Magneto Air Gap 0.009-0.015 inch (0.23-0.38 mm) 0.009-0.015 inch (0.23-0.38 mm)

Spark Plug Gap 0.025 inch (0.64 mm) 0.020 inch (0.51 mm)

DC SYSTEM:

Nominal Battery Voltage 12 volts 12 volts

Min. Battery Rating: Cold
Cranking Amps (CCA)
@ 0 F (−18 C)

Battery Charging Current − 10 amp (regulated) − 10 amp (regulated)

INSTALLATION:

Weight with Muffler 172.6 lb (78.3 Kg) 172.6 lb (78.3 Kg)

Minimum Compartment Size
(H x D x W)

Minimum Free Air Inlet Area 40 inch2 (258 cm2) 40 inch2 (258 cm2)

Muffler Outlet Collar O. D. 1.13 inch 1.13 inch

Max. Exhaust Back Pressure 32 inch WC 32 inch WC
Fuel Connection 1/4 inch barb fitting for gasoline hose 5/8-18UNC, SAE 45 Flare Fitting

LPG Vapor Supply Pressure −

1. See the Installation Manual for additional considerations when sizing the genset compartment.

1

0.29 gph (1.1 l/h)

0.48 gph (1.8 l/h)

0.71 gph (2.7 l/h)

14.55 inch x 20.13 inch x 26.31 inch

(369.25 mm x 511.3 mm x 668.3 mm)

0.21 gph (0.79l/h)

0.37 gph (1.4 l/h)

0.58 gph (2.2 l/h)

450 450

1.5 lbs/h (0.7 kg/h)

2.2 lbs/h (1.0 kg/h)

3.3 lbs/h (1.5 kg/h)

14.55 inch x 20.13 inch x 26.31 inch

(369.25 mm x 511.3 mm x 668.3 mm)

9-13 inch (228-330 mm)

Water Column (WC)

1.1 lbs/h (0.5 kg/h)

2.0 lbs/h (0.9 kg/h)

2.9 lbs/h (1.3 kg/h)

23

THIS PAGE IS INTENDED TO BE BLANK

24

Installation Review and Startup

INSTALLATION REVIEW

Before starting the genset inspect the installation
and check (
be answered “YES”. If an item cannot be checked,
provision must be made to satisfy the requirement.

[ ] Is the control panel on the genset easily acces-

sible for starting and stopping the genset and
resetting the circuit breaker?

[ ] Is there easy access for checking and adding

engine oil, replacing the spark plug and chang­ing the air filter?

[ ] Is the genset securely bolted in place?

[ ] Are all specified clearances provided?

[ ] Are the air inlet and outlet openings free of ob-

structions?

[ ] Is there access for draining engine oil?

[ ] Are all tailpipe connections tight and all hang-

ers and support straps secure?

[ ] Does the tailpipe terminate at least 1 inch

(25 mm) beyond the perimeter of the vehicle
and at least 6 inches (153 mm) away from any
opening into the vehicle?

) each of the following questions if it can

[ ] Has the fuel line been secured at sufficient in-

tervals to prevent chaffing and contact with
sharp edges, electrical wiring and hot exhaust
parts?

STARTUP

When all the items on the Installation Review check
list have been checked, connect the battery cables
to the battery, positive (+) cable first.

WARNING

that can cause severe personal injury. Do not
smoke near batteries. Keep flames, sparks, pilot
lights, electrical arcs and arc-producing equip­ment and all other ignition sources well away.

Read the Operator’s Manual and perform the main­tenance and pre-start checks instructed. The gen­set is shipped from the factory with the proper level
of engine oil, which should nevertheless be checked
before the genset is started. Start and operate the
genset, following all the instructions and safety pre­cautions in the Operator’s Manual.

WARNING

operate the genset when the vehicle is indoors
or where exhaust can accumulate.

Batteries give off explosive gases

EXHAUST GAS IS DEADLY! Do not

[ ] Is the genset located outside the vehicle interior

or separated by approved vapor-tight and fire­resistive materials?

[ ] Are all openings into the vehicle, such as for AC

wiring, sealed to keep out engine exhaust? Are
AC conduit connectors sealed inside and out­side?

[ ] Have all AC connections been inspected and

approved?

[ ] Has a properly sized battery for genset starting

and control been installed in a ventilated
compartment isolated from the genset?

[ ] Have properly sized battery cables been

installed and secured at sufficient intervals to
prevent chaffing and contact with sharp edges,
fuel lines and hot exhaust parts?

[ ] Are all fuel connections tight?

Check for fuel and exhaust leaks and unusual
noises while the genset is running under full and in­termediate loads. Do not place the genset in service
until all fuel and exhaust leaks have been fixed and
operation is satisfactory.

HOT AIR RECIRCULATION TEST

A representative installation of the genset must be
tested to determine that the genset will not overheat
due to recirculation of hot air back into the genset.

Test Method

1. Complete a representative installation.

2. Set up a load bank to run the genset at rated
full-load.

3. Conduct the test at a location where the ambi­ent air temperature will remain between 60F
and 100F (16C and 38C).

25

WARNING

LOCATION

EXHAUST GAS IS DEADLY! Do
not operate the genset when the vehicle is
parked indoors or where exhaust can accu­mulate.

4. Measure temperatures with thermocouples not
heavier than No. 24 AWG (0.21 mm

2

).

ings. Table 2 illustrates how the data can be ar­ranged for recording and analysis.

TABLE 2. TEMPERATURE DATA

TEMPERATURE C (F)

THERMOCOUPLE

Time Of Reading

A. Measure genset inlet air temperature with

one thermocouple tied in the middle of the
inlet air grille (Figure 18).

B. Measure ambient air temperature with a

shielded thermocouple within 4 feet
(1.2 meters) of the genset and at approxi­mately the same height. Make sure the
thermocouple will not be affected by warm
air discharged from the genset or by sun­light. Use 2 inch diameter white PVC pip­ing at least 6 inches long as a thermocou­ple shield.

5. Close all compartment doors and run the gen­set at full-load for at least an hour. Record tem­peratures at 15 minute intervals until they sta­bilize. Temperature is considered stable when
there is no change in three consecutive read-

AMBIENT AIR

AMBIENT AIR

INLET AIR

Test Requirement

The rise in inlet air temperature over ambient air
temperature must not exceed 15F (8C). A rise in
inlet air temperature indicates hot air recirculation. If
the rise exceeds the requirement, steps must be
taken to reduce recirculation to an acceptable level.
Review VENTILATION (Page 8).

CAUTION

tures could reduce maximum genset power out­put if the air temperature rise measured in this
test is on the high end of the acceptable range.
This guide is for air flow testing only and does
not completely verifiy Cooling for generators
that use both air and liquid cooling systems.

High ambient operating tempera-

INLET AIR

FIGURE 21. THERMOCOUPLE LOCATIONS FOR HOT AIR RECIRCULATION TEST

26

500-3717

OUTLINE DRAWING

27

0611-1267

WIRING DIAGRAM—60 HZ

28

0611-1268-1

WIRING DIAGRAM—50 HZ

29

KYD

0611-1268-2

30

OUTPUT CONNECTIONS—50 HZ

Cummins Power Generation

1400 73rd Ave. NE
Minneapolis, MN 55432 USA

Phone [phone]
Toll-free 1 800 888 6626
Fax [phone]
Email www.cumminsonan.com/contact
www.cumminsonan.com

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are trademarks of Cummins Inc.

E2012 Cummins Power Generation, Inc. All rights reserved.