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Installation Manual
HDKCA, HDKCB
Printed in U.S.A. 981-0640
08-04
Page 3
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
diesel warnings
Page 4
Table of Contents
SECTION PAGE
SAFETY PRECAUTIONS ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. INTRODUCTION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Codes and Standards for Safety 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline Drawings 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. LOCATION, MOUNTING, AND VENTILATION 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. EXHAUST CONNECTIONS 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailpipe 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. FUEL CONNECTIONS 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. ELECTRICAL CONNECTIONS 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power Output 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batteries 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. INSTALLATION REVIEW AND STARTUP 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Review 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Air Recirculation Test 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. SPECIFICATIONS 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL SCHEMATIC A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety Precautions
Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can only be obtained 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.
DANGER
that will result in severe personal injury or
death.
WARNING
practice that can result in severe personal injury or death.
CAUTION
practice that can result in personal injury or
equipment damage.
Electricity, fuel, exhaust, moving parts and batteries present hazards which can result in severe personal injury or death.
alerts you to an immediate hazard
alerts you to a hazard or unsafe
alerts you to a hazard or unsafe
S Do not work on the genset when mentally or
physically fatigued or after consuming alcohol
or drugs.
S You must be trained and experienced to make
adjustments while the genset is running—hot,
moving or electrically live parts can cause severe personal injury or death.
S Used engine oil has been identified by some
U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
inhale, or contact used oil or its vapors.
S Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accordance with local environmental regulations.
S Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B
fires, combustible and flammable liquid fuels
and gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
S Genset installation and operation must comply
with all applicable local, state and federal
codes and regulations.
GENERAL PRECAUTIONS
S Keep children away from the genset.
S Do not use evaporative starting fluids. They
are highly explosive.
S To prevent accidental or remote starting while
working on the genset, disconnect the negative (−) battery cable at the battery.
S Let the engine cool down before removing the
coolant pressure cap or opening the coolant
drain. Hot coolant under pressure can spray
out and cause severe burns.
S 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.
S Make sure all fasteners are secure and
torqued properly.
GENERATOR VOLTAGE IS DEADLY
S Disable the automatic genset starting feature
of an inverter-charger or other automatic starting device before servicing the genset.
S Generator electrical output connections must
be made by a trained and experienced electrician in accordance with applicable codes.
S The genset must not be connected to the pub-
lic utility or any other source of electrical power.
Back-feed could lead to electrocution of utility
personnel and damage to equipment. An approved switching device must be used to prevent interconnections.
S Use caution when working on live electrical
equipment. Remove jewelry, make sure clothing and shoes are dry, stand on a dry wooden
platform or rubber insulating mat and use tools
with insulated handles.
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Page 6
ENGINE EXHAUST IS DEADLY
BATTERY GAS IS EXPLOSIVE
S Inspect for exhaust leaks at every startup and
after every eight hours of running.
S Learn the symptoms of carbon monoxide poi-
soning in the Operator’s Manual.
S Never sleep in the vehicle while the genset is
running unless the vehicle is equipped with a
working carbon monoxide detector.
S Do not operate the genset when the vehicle is
in a confined space, such as a garage.
S Disable the automatic genset starting feature
of an inverter-charger or other automatic starting device before storing the vehicle or parking
it in a garage or other confined space.
S The exhaust system must be installed in accor-
dance with the genset Installation Manual.
S Engine cooling air must not be used for heating
working or living spaces or compartments.
DIESEL FUEL IS COMBUSTIBLE
S 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 flames, sparks, pilot lights, arcproducing equipment and all other sources of
ignition well away.
S Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
S Wear safety glasses.
S Do not smoke.
S To reduce arcing when disconnecting or recon-
necting battery cables, always disconnect the
negative (−) battery cable first and reconnect
it last.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
S Disable the automatic genset starting feature
of an inverter-charger or other automatic starting device before servicing the genset.
S Do not wear loose clothing or jewelry near
moving parts such as PTO shafts, fans, belts
and pulleys.
S Keep hands away from moving parts.
S Keep guards in place over fans, belts, pulleys,
and other moving parts.
FLAMMABLE VAPOR CAN CAUSE A
DIESEL ENGINE TO OVERSPEED
Flammable vapor can cause a diesel engine to
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and
death. Do not operate a diesel-powered genset
where a flammable vapor environment can be
created by fuel spill, leak, etc. The owners and
operators of the genset are solely responsible for
operating the genset safely.
Mobile-8
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1. Introduction
ABOUT THIS MANUAL
This manual is a guide for the installation of the generator sets (gensets) listed on the front cover. Proper installation is essential for top performance. Read
through this manual before starting the installation.
This manual addresses the following aspects of the
installation:
S Location and Mounting
S Exhaust Connections
S Fuel Connections
S Electrical Connections
S Startup
WARNING
tem. It can stop without warning. Children, persons with physical or mental limitations, and
pets could suffer personal injury or death. A personal attendant, redundant power or an alarm
system must be used if genset operation is critical.
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.
See the genset Operator’s Manual for operation
and maintenance.
This genset is not a life support sys-
Unauthorized modifications or re-
Recreational Vehicles, ANSI/RVIA EGS-1. They
are suitable for installation in accordance with:
S NFPA No. 1192—Recreational Vehicles
S NFPA No. 70, Article 551—Recreational Ve-
hicles and RV Parks
S 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),
could also apply. Installation codes and recommendations can change from time to time and are different in different countries, states and municipalities.
It is recommended that the standards in Table 1-1
be obtained for reference.
TABLE 1-1. REFERENCE CODES AND STANDARDS
Code of Federal
Regulations,
Title 49: Chapter III
and Chapter V
NFPA No 70, 1192
ANSI/RVIA-EGS-1
California Adminis-
trative Code—Title
25, Chapter 3
CAN/CSA-Z240
Recreational
Vehicles
Bulletin 946
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
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 genset installer 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
OUTLINE DRAWINGS
See the Outline Drawing (Page A-2) for installation
details: mounting bolt hole locations, connection
points (fuel, battery, exhaust, remote control, AC
output), sizes and types of fittings, cooling air openings, weight, service access points and overall dimensions. See your Onan dealer for a large-scale
Outline Drawing and full-size floor cutout template.
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.
1-1
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Page 10
2. Location, Mounting, and Ventilation
LOCATION
Typical genset locations on a vehicle are illustrated
in Figure 2-1.
1. Provide access to the operator’s console, front
and top service access doors, oil drain (bottom)
and coolant drain (lower left front) so that all periodic maintenance can be performed in accordance with the Operator’s Manual.
2. Provide access for connecting and disconnecting fuel lines, battery cables, remote control
wiring and AC wiring.
3. Make sure that frame cross members, exhaust
tail pipes and other equipment do not cross underneath the oil drain plug or air intake and discharge openings. These are the crosshatched
areas on the Outline Drawing (Page A-2).
4. Make sure the genset clears the ground by at
least 12 inches (305 mm) to provide adequate
ventilation and reduce the amount of dust
pulled in by the cooling fan.
WARNING
Construct a suitable vapor barrier of approved materials between the genset and
vehicle interior to keep out exhaust gas.
7. A genset compartment must be large enough
to provide at least 1/2 inch (12.5 mm) clearance at the top of the genset and 1/4 inch
(6.4 mm) clearance at the sides. These minimum clearances apply to the thermal or acoustic insulation with which the compartment may
be lined.
8. Acoustic/thermal insulation and adhesive must
be Classified as “Self-Extinguishing” at not less
than 200
compartment with insulation, which absorbs
spilled fuel and oil.
EXHAUST GAS IS DEADLY.
°F (90°C). Do not line the bottom of the
5. Protect the air inlets in the bottom of the genset
from road splash, especially when the genset
is located in line with the road wheels. It is preferable to mount the genset in front of, rather
than behind, the road wheels.
6. Provide a vapor-tight, fire-resistive barrier between the genset and the interior of the vehicle.
Use approved materials (26 gauge galvanized
steel or equivalent). See NFPA 1192 for details.
FIGURE 2-1. TYPICAL GENSET LOCATIONS
2-1
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MOUNTING
Support the genset on a structure able to resist the
dynamic weight of the genset:
and
±1 g-force horizontal. See Section 7. Specifica-
±3 g-force vertical
tions for the weight of the genset. Use four Grade 5,
3/8-16 UNC screws to secure the genset vibration
isolating sub-frame to the floor or frame. Torque the
screws to 35 lb-ft (41 N-m).
A vibration isolator kit is available for models that do
not have the external vibration isolators and frame
illustrated in Figure 2-2. Follow the instructions in
the vibration isolator kit.
WARNING
The genset support structure must
be designed and installed to support and restrain the dynamic weight of the genset. Failure
to do so can result in the genset dropping onto
the roadway causing property damage, severe
personal injury and death.
VENTILATION
Unrestricted air flow for cooling, ventilation and
combustion is essential for proper genset perfor-
mance and service life (Figure 2-2). The air intake
and discharge openings are in the bottom of the
genset. These are the crosshatched areas on the
Outline Drawing (Page A-2). See also Hot Air Recir-
culation Test (Page 6-2).
If the genset is installed on a floor, cut out openings
in the floor that are at least as large as the openings
in the genset. The openings must line up so that the
air can flow straight through the space between the
genset opening and the floor cutout opening. If nec-
essary, duct the hot discharge air through the floor
to prevent recirculation inside the compartment.
Make sure frame cross members, exhaust tail pipes
and other equipment do not cross underneath the
air intake and discharge openings. Do not block the
air inlet and outlet openings with screens, expanded
metal or the like; they restrict air flow and could
cause the genset to overheat.
Note: The hot air discharges away from the end of the
genset at a slight angle to reduce recirculation (Figure 2-2). This space must also be free of frame cross
members, exhaust tail pipes and other equipment
that could deflect the discharged air back into the air
intake openings.
COOLING & VENTILATING
AIR UP THROUGH RADIATOR
FIGURE 2-2. COOLING, VENTILATION AND COMBUSTION AIR FLOWS
COMBUSTION
& GENERATOR
COOLING AIR
2-2
HOT DISCHARGE AIR
Page 12
3. Exhaust Connections
The exhaust system must be gas-tight and designed to limit entry of exhaust gases into the vehicle.
WARNING
EXHAUST GAS IS DEADLY! To keep
exhaust gases from entering the vehicle do not
terminate the exhaust tailpipe underneath the
vehicle or closer than specified to openings into
the vehicle (Figure 3-4) or route it such that it is
likely to be damaged (Figure 3-5). Use approved
materials and parts only.
CAUTION
Unauthorized modifications or replacement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in the State of
California.
MUFFLER
The muffler is mounted inside the genset housing. It
has a USDA (Forest Service) spark arrestor and
meets RVIA EGS-1 construction requirements.
Figure 3-1 illustrates the flanged exhaust outlet and
the clearance openings for rear and side tail pipe
connections. See the Outline Drawing (Page A-2)
for the dimensions of the exhaust outlet flange.
A genset without a properly installed and maintained spark arresting exhaust system can cause a
brush or forest fire, and is illegal on federal lands. Liability for damage, injury and warranty expense due
to the 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. Contact an Onan distributor for approved exhaust system parts.
Note: Block the side and rear exhaust exit openings
in the base if the genset is mounted in an enclosure
and the Hot Air Recirculation Test (Page 6-2) indi-
cates there is recirculation that could cause the genset to overheat.
EXHAUST OUTLET FLANGE
FIGURE 3-1. EXHAUST CONNECTIONS AT GENSET
SIDE EXIT—USE A
STRAIGHT ADAPTER
REAR EXIT—USE AN ELBOW ADAPT-
ER FOR BOTTOM OR REAR EXIT
3-1
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TAILPIPE
Tailpipe adapter kits are separately available. Use a
straight adapter for a tailpipe routed through the
side clearance hole. Use an elbow adapter for a tailpipe routed through the rear clearance hole or up
from below. When connecting and routing the tailpipe:
1. Use 1-3/8 inch ID, 18-gauge aluminized steel
tubing or equivalent for the tailpipe. (Do not use
flexible pipe. Flexible pipe is not gas tight or durable.)
2. Secure the tailpipe or adapter flange to the muffler flange with a gasket and two stainless steel
M8 x 1.25 bolts, which are supplied.
3. Use U-bolt muffler clamps to connect sections
of tailpipe. It is recommended that the overlapping pipe be slotted as shown in Figure 3-2.
4. Use automotive-type tailpipe hangers every
2 to 3 feet (0.6 to 0.9 m). Attach the hangers to
steel framework, not to wood or other combustible material.
3/4 INCH (19 MM)
MAXIMUM SLOT
(BOTH SIDES)
FIGURE 3-2. EXHAUST TAILPIPE CONNECTIONS
5. Do not terminate the tailpipe underneath the
vehicle. Extend it a minimum of 1 inch (25 mm)
beyond the perimeter of the vehicle (Figure 3-3). Support the end of the tailpipe such
that it cannot be pushed inward and up under
the skirt of the vehicle by backing up into a curb
or other obstacle.
Note: Do not terminate the tailpipe underneath a
slide-out room
of the slide-out, including skirts and moldings,
is at least 3 feet above the end of the tailpipe.
(Figure 3-5), unless the bottom
6. Do not route the tailpipe such that it will interfere
with draining engine oil or coolant or restrict the
air inlet.
7. Do not route the tailpipe 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
°F (65°C).
8. Do not route the tail pipe near fuel lines or fuel
tanks or terminate it below or near a fuel fill
opening.
1 INCH
(25 mm)
LAST TAILPIPE HANGER AS
CLOSE TO END AS
PRACTICAL
FIGURE 3-3. TERMINATING THE EXHAUST TAIL-
PIPE
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
MINIMUM
9. Do not terminate the tailpipe such that it is closer than 6 inches (153 mm) to any opening into
the vehicle interior (door, window, vent). See
Figure 3-4.
TAILPIPE
FIGURE 3-4. MINIMUM DISTANCES TO OPENINGS
3-2
Page 14
10. Route the tailpipe such that it will not likely be
struck when the vehicle is moving. At least keep
it out of the approach and departure angles of
the vehicle and above the axle clearance line
(Figure 3-5).
CAUTION
Interconnecting the engine exhaust systems will allow exhaust condensates and soot to migrate into the engine
that is idle, causing engine damage.
UNDERNEATH A
SLIDE-OUT ROOM
11. Do not connect the genset to the vehicle engine
12. Exhaust back pressure under full load must not
DO NOT
TERMINATE
TAILPIPE
exhaust system.
CAUTION
Excessive back pressure can
cause loss of performance and engine damage.
exceed 2 inches (51 mm) water column (WC)
as measured within 6 inches (154 mm) of the
muffler outlet flange.
DEPARTURE
ANGLE
AXLE CLEARANCE LINE
APPROACH
ANGLE
FIGURE 3-5. APPROACH AND DEPARTURE ANGLES AND AXLE CLEARANCE LINE
3-3
Page 15
Page 16
4. Fuel Connections
WARNING
Diesel fuel is a combustible and can
cause severe personal injury or death. Do not
smoke or allow any flame, spark, pilot light, arcproducing equipment, electrical switch or other
ignition source around fuel or fuel components,
or in areas sharing ventilation. Keep a type ABC
fire extinguisher handy.
Do not interconnect genset and vehicle engine fuel
lines. Follow the vehicle chassis manufacturer’s instructions when making connections to the vehicle
engine fuel tank.
CAUTION
Either or both engines could starve
for fuel if the genset and vehicle engine fuel
lines are interconnected. Always use separate
fuel lines or a separate fuel tank for the genset.
To prevent the genset from running the vehicle out
of fuel, do not extend the genset fuel pickup tube
down into the fuel tank as far as the pickup tube for
the vehicle engine.
Fuel lines (supply and return) must have at least a
1/4 inch (6.4 mm) ID See Figure 4-1 for connections at the genset.
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 (1 meter).
Route 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.
FUEL SUPPLY
(1/8 INCH NPT)
FIGURE 4-1. FUEL CONNECTIONS
FUEL RETURN
(1/8 INCH NPT)
4-1
Page 17
Page 18
5. Electrical Connections
To prevent accidental starting of the genset during
installation, do not connect the battery cables at the
battery until so instructed in Section 6. Installation
Review and Startup and make sure an automatic
genset starting system is disabled.
AC TERMINAL
COVER
WARNING
Accidental starting of the genset
can cause severe personal injury or death. Do
not connect the starting battery until so
instructed in Installation Review and Startup.
Make sure an automatic genset starting system
is disabled.
AC POWER OUTPUT
The genset is equipped with a terminal block and
conduit connector knockouts for AC power output
connections (Figure 5-1).
Wiring Methods
Follow the National Electrical Code, especially noting the following:
1. Have a trained and experienced electrician supervise and inspect the installation of all AC wiring.
2. Secure only one lead at each AC output terminal. The terminals are suitable for wire sizes up
to No. 6 AWG.
3. Use vibration-proof switches and controls to
prevent the opening and closing of circuits
while the vehicle is in motion.
4. Use rain-tight conduit, conduit connectors and
junction boxes for all exterior wiring.
5. Provide ground fault circuit interrupters
(GFCIs) for all convenience power receptacles.
3 SETS OF 3/4 &
1 INCH CONDUIT
KNOCKOUTS
FIGURE 5-1. ACCESS FOR AC OUTPUT AND
REMOTE CONTROL CONNECTIONS
2 CONTROL WIRING
KNOCKOUTS
5-1
Page 19
6. Seal all conduit openings into the vehicle interior to keep out exhaust gas. Apply silicone rubber or equivalent 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
EXHAUST GAS IS DEADLY!
Seal all wiring openings into the vehicle interior to keep out exhaust gas.
8. Connect the grounding terminal (Terminal
TB2-4, Figure 5-2) in accordance with applicable codes.
WARNING
Faulty grounding can lead to
fire or electrocution and severe personal injury or death. Grounding must be in accordance with applicable codes.
Connecting the Vehicle to Utility Power
7. Route or protect AC wiring so that it will not be
cut or abraded, exposed to hot surfaces or
damaged by road debris. Keep AC wiring away
from fuel lines and control wiring (see Remote
Control).
WARNING
Routing AC wiring with fuel
lines can lead to fire and severe personal injury or death. Keep AC wiring away from
fuel lines.
NOTE: THIS IS NOT A RECONNECTABLE GENSET
GENSET
TB2
GENERATOR
T1
T4
CB1
T2
T3
CB2
1
2
3
4
1
2
3
4
A vehicle with provisions for connecting utility
(shore) power must have an approved device to
keep the genset and utility from being interconnected. See Figure 5-2 for typical connections.
WARNING
Interconnecting the genset and the
public utility (or any other power source) can
lead to electrocution of utility line workers,
equipment damage and fire. Use an approved
switching device to prevent interconnections.
50 AMP 3-POLE TRANSFER SWITCH
120V240V
120V
L1
N
L2
GND
L1
N
L2
GND
120V
120V
240V
50 AMP SHORE POWER
L1 N* L2
TO VEHICLE AC DISTRIBUTION PANEL
FIGURE 5-2. TYPICAL AC CONNECTIONS
5-2
GND
Page 20
REMOTE CONTROL
Leads for connection to a remote control panel are
terminated in a 10-pin sealed connector and are
stowed inside the AC terminal enclosure when the
genset leaves the factory. See the Outline Drawing
(Page A-2) for details of the connector and its mate.
Refer to Figure 5-3 for pin connections. For further
reference also see the Wiring Schematic
(Page A-1).
TYPICAL REMOTE CONTROL PANEL
+
VOLTMETER
−
+
HOURMETER
−
SWITCH & LIGHT
+
−
FIGURE 5-3. REMOTE CONTROL CONNECTOR PLUG AND TYPICAL CONNECTIONS
SWITCHED B+
STOP
UNUSED
START
STATUS LIGHT
GND
GENSET CONNECTOR PLUG (P8)
UNUSED
UNUSED
5-3
Page 21
Remote Control Panels
Onan offers harnesses of various lengths with mating receptacles and three remote control kits as follows:
• Remote switch / status lamp (Figure 5-4).
• Remote switch / status lamp and hour meter
(Figure 5-5).
• Remote switch / status lamp and DC voltmeter
(Figure 5-6).
If another source is used for the remote panel:
1. The control switch should be a two-pole, momentary-contact, center-return/center-off type
of switch with an indicator light.
2. The total load connected to P2-E (Switched B+)
should not exceed 2 amp.
3. The total load connected to P2-F (Status Light)
should not exceed 2 amp.
Wiring Methods
1. Remove the AC terminal access cover and remove one of the control wiring knockouts.
2. Pull out the remote control connector plug, fit
the bushing around the connector leads into
the knockout slot and secure the access cover.
3. Snap the connector plug and harness receptacle together.
4. If the harness does not have a plug for connections at the control panel, use solder-type butt
connectors and heat-shrink insulation tubing to
connect to the wiring from the remote panel.
Use insulated 18 AWG copper conductors for
the wiring from the remote panel.
5. Keep control leads away from AC power leads
to reduce the possibility of erratic operation due
to induced signals.
6. Seal the hole where the leads enter the interior
of the vehicle to keep out exhaust gas. Use silicone rubber or an equivalent type of sealant.
FIGURE 5-4. REMOTE SWITCH
FIGURE 5-5. REMOTE SWITCH / HOUR METER
FIGURE 5-6. REMOTE SWITCH / DC VOLTMETER
WARNING
EXHAUST GAS IS DEADLY!
Seal all wiring openings into the vehicle interior to keep out exhaust gas.
5-4
Page 22
BATTERIES
Battery Recharging
To prevent accidental starting of the genset during
installation, do not connect the battery cables at the
battery until so instructed in Section 6. Installation
Review and Startup and make sure an automatic
genset starting system is disabled.
WARNING
Accidental starting of the genset
can cause severe personal injury or death. Do
not connect the starting battery until so
instructed in Installation Review and Startup.
Make sure an automatic genset starting system
is disabled.
Battery Capacity
The genset has a 12 VDC, negative-ground control
and starting system. See Specifications for the re-
quirements for cranking batteries.
An external battery charger will need to be provided
to recharge the genset cranking battery.
Battery Compartment
Batteries must be mounted in a separate compartment from that of the genset and away from sparkproducing equipment. An enclosed compartment
must have openings of at least 1.7 square inches
(11 square centimeters) at the top and bottom for
ventilation of battery gasses. Batteries should be
mounted such that spills and leaks will not drip acid
on fuel lines, wiring and other equipment that could
be damaged.
WARNING
drogen 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.
Arcing can ignite the explosive hy-
5-5
Page 23
Battery Cables
Size battery cables according to Table 5-1. 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 5-7). Note also that codes may
require a bonding conductor between the genset
and vehicle frame and between the battery and vehicle frame.
If the vehicle frame is used as the path between the
negative (−) battery terminal and the genset (Figure 5-8), all 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 sized according to Table 5-1 must
be used to connect the frame to the designated negative (−) terminal on the genset (Figure 5-8). 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 5-1. BATTERY CABLE SIZES FOR AMBIENT
TEMPERATURES TO −20° F (−29° C)
TOTAL CABLE LENGTH,
FEET (METERS)
0 to 15 (0 to 4.5) 0*
16 to 20 (4.5 to 6) 000
* − A total length of up to 25 feet (7.6 meters) may be
used in warmer climates or when battery capacity totals
at least 1200 CCA (Cold Cranking Amps).
SIZE PER
GENSET
+
−
VEHICLE FRAME
FIGURE 5-7. FULL-LENGTH CABLE FROM
BATTERY NEGATIVE (−) TERMINAL
GENSET
+
−
TABLE 5-1
#8 AWG
MINIMUM
SIZE PER
TABLE 5-1
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.
VEHICLE FRAME
FIGURE 5-8. VEHICLE FRAME AS PATH FROM
BATTERY NEGATIVE (−) TERMINAL
5-6
Page 24
Genset Bonding Terminal
The negative (−) battery cable terminal shown in
Figure 5-9 is also the bonding terminal for grounding the genset to the vehicle chassis. If the grounding cable is also going to carry starter motor current,
it must be sized the same as the battery cables.
Connecting Battery and Bonding Cables
Terminate the battery cables with ring terminals
sized for the 5/16 inch genset terminal screws (Figure 5-9). Permanently mark each end of each cable
as to its polarity, positive (+) or negative (−). After
making sure the battery cables are not connected at
the battery and that an automatic genset starting
system is disabled, connect the battery and grounding cables to the genset.
FIGURE 5-9. BATTERY CABLE TERMINALS
5-7
Page 25
Page 26
6. Installation Review and Startup
INSTALLATION REVIEW
Before starting the genset inspect the installation
and check off (
can be answered “YES”. If a question cannot be
checked off, review the appropriate section in the
manual.
[ ] Is the operator’s console easily accessible for
starting and stopping the genset, resetting circuit breakers and checking and adding engine
coolant?
[ ] Is the genset securely bolted in place?
[ ] Is there clearance all around the genset?
[ ] Are the cooling and combustion air inlet and
outlet openings free of obstructions?
[ ] Is there easy access for draining the engine oil?
[ ] Is there easy access for draining the engine
coolant?
[ ] Is there easy access for changing the air filter,
checking oil level and adding oil?
[ ] Is there easy access (through the top service
access cover) for cleaning out the spark-arrest
muffler?
[ ] 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 and not under a slideout room or near a fuel fill opening?
[ ] Is the tailpipe routed such that it is not likely to
be struck while the vehicle is moving?
[ ] Is the genset located outside the interior space
of the vehicle and separated by approved vapor-tight and fire-resistive materials?
√) each of the following questions if it
with sharp edges, fuel lines and hot exhaust
parts?
[ ] Is the genset bonding terminal (negative [−]
battery cable terminal) properly grounded to
the vehicle chassis?
[ ] Are all fuel connections tight?
[ ] Have the fuel lines been secured at sufficient
intervals to prevent chaffing and contact with
sharp edges, electrical wiring and hot exhaust
parts?
[ ] Is the genset protected from road splash?
[ ] Does the genset clear the ground by at least
12 inches (305 mm)?
STARTUP
When all installation requirements have been met,
connect the battery cables to the battery, positive (+)
cable first.
WARNING
light switches or other equipment, and flames or
sparks, can ignite battery gas causing severe
personal injury—Ventilate battery area before
working on or near battery—Wear safety
glasses—Do not smoke—Switch work light ON
or OFF away from battery—Stop genset and disconnect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.
Read through the Operator’s Manual and perform
the maintenance and pre-start checks instructed.
The genset is shipped from the factory with proper
levels of engine oil and coolant, which should nevertheless be checked before the genset is started.
Start and operate the genset, following all the instructions and precautions in the Operator’s Manual.
Arcing at battery terminals or in
[ ] Are all wiring holes into the vehicle interior (in-
side and outside conduit connectors) sealed to
keep out exhaust gas?
[ ] Have the AC output connections been made
properly.
[ ] Have properly sized batteries and battery
cables been installed?
[ ] Have the battery cables been secured at suffi-
cient intervals to prevent chaffing and contact
WARNING
operate the genset when the vehicle is indoors
unless there is ample fresh air ventilation.
Check for fuel, coolant and exhaust leaks and unusual noises while the genset is running under full
and intermediate loads. To calculate electrical loads
see POWERING EQUIPMENT in the Operator’s
Manual. Do not place the genset in service until all
leaks have been fixed and operation is satisfactory.
EXHAUST GAS IS DEADLY! Do not
6-1
Page 27
HOT AIR RECIRCULATION TEST
LOCATION
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. Conduct the test in a well ventilated space in
which carbon monoxide cannot accumulate,
but that is protected from cross drafts that could
affect temperature measurements.
3. Connect a large, constant load to the genset. If
a load bank is available, connect at least 3/4 full
load. If not, connect and run the largest combination of constant loads that can be kept on
during the test without tripping the genset circuit breaker. For example, run a combination of
air conditioners, hair dryers and lights. Make
sure the air conditioners stay on and do not
cycle during the test.
ters) 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.
7. Close all genset compartment doors and run
the genset for at least 90 minutes. Record temperatures at 15 minute intervals. See Table 6-1
for an example of how the data can be arranged
for recording and analysis.
TABLE 6-1. TEMPERATURE DATA TABLE
TEMPERATURE (° F)
THERMOCOUPLE
Intake Air Temperature
Ambient Air Temperature
Temperature Difference
(Intake − Ambient )
Time of Reading (Minutes)
0 15 30 45 60 75 90
4. Measure temperatures with thermocouples not
2
heavier than No. 24 AWG (0.21 mm
).
5. Measure genset intake air temperature with
one or two thermocouples tied about 1 inch
away from the face of the radiator in the intake
air opening (Figure 6-1). Make sure the thermocouples don’t touch the radiator.
6. Measure ambient air temperature with a
shielded thermocouple within 4 feet (1.2 me-
AMBIENT AIR TEMPERATURE
INTAKE AIR TEMPERATURE
Test Requirement
The difference in temperature between genset intake air and ambient air must be no more than
5° F − 10° F after 90 minutes. A higher temperature
difference indicates that hot discharged air is recirculating back into the cooling air intakes. Steps
must be taken to reduce recirculation to an acceptable degree. Review VENTILATION (Page 2-2).
FIGURE 6-1. THERMOCOUPLE LOCATIONS FOR HOT AIR RECIRCULATION TEST
6-2
Page 28
7. Specifications
MODEL:
GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller
GENERATOR: Single-Bearing, 4-Pole Rotating Field, 1800 RPM
Power (@1.0 power factor) 10,000 W 12,500 W
Voltage 120 / 240 120 / 240
Frequency 60 Hz 60 Hz
Number of Phases 1 1
Current 41.7 amps per leg 52.1 amps per leg
Line Circuit Breaker 2-pole, 45 amp 2-pole, 50 amp
FUEL CONSUMPTION:
No-load
Half-load
Full-load
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection (IDI), 4-Stroke Cycle Diesel
Bore 3.43 in (87 mm)
Stroke 3.64 in (92.4 mm)
Displacement 100.5 in3 (1,647 cc)
Compression Ratio 22.6 : 1
Fuel Injection Timing (BTDC) 14.5°
Firing Order 1−3−2
Fuel Nozzle Injection Pressure 1991 psi (13.731 mPa)
Cylinder Compression Test 370 psi (2.55 mPa) minimum
Valve Lash: Intake & Exhaust (cold)
Oil Capacity (with filter)
Cooling System Capacity
DC SYSTEM:
Nominal Battery Voltage
Minimum Battery Capacity
CCA (Cold Cranking Amps)
Battery Recharging
WEIGHT: 792 lbs (359 kg) 816 lbs (370 kg)
SIZE (L x W x H): 41.4 x 24.5 x 27 in (105 x 62 x 68.6 cm)
SOUND LEVEL: 68 dB(A) @ 10 ft (3m) & 54 dB(A) @ 50 ft (15m)—in “free field site” @ half load
HDKCA HDKCB
0.11 gph (0.41 lph)
0.48 gph (1.82 lph)
1.01 gph (3.8 lph)
0.11 gph (0.41 lph)
0.48 gph (1.82 lph)
1.2 gph (4.54 lph)
0.0071 to 0.0087 in (0.18 to 0.22 mm)
5.9 quart (5.6 liter)
6.6 quart (6.2 liter)
12 volts
475 amps down to 0° F (−17° C)
650 amps down to −20° F (−29° C)
Installer must provide for battery charging
7-1
Page 29
Page 30
A-1
630-2676
CONTROL SCHEMATIC
Page 31
A-2
500-4040
OUTLINE DRAWING
Page 32
Page 33
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-528-7229
Cummins and Onan are registered trademarks of Cummins Inc.
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