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 (90C). 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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