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Installation Guideline

1. 6 4 4 3 2 I REL NO mm ho reyisioN Toke pk CKD Ayo DATE 132 PAN FRDI289 A 1 PRODUCTION RELEASE GAC RAR ROTH 04 30 99 28 81 FRD7062 B WAS 5X 6 4 25 4D DJA WH WH 10 02 00 FRDI4604 C UPDATE PICTORIALLY REM MIDDLE RIB ON COVERY 38 DJA WH Wn 11 11 02 FRD3I660 D ADDED SHEET 2 FOR 4KYFA 6747 EV P GENSET MAH KE ELAYED 04 12 07 T FRD32186 E REMOVE PICTORIAL LABELS sMB APP APP 08 30 07 ATT 5X 6X 5 16 18NC FOR 1 3 MOUNTING i 1199 0 291 13 1 50 MAX SCREW 9 D FOR DRAIN PROTRUDING INTO BASE 5 3 Let 63 2 481 COMPARTMENT FLOOR ED i 15 8 NOTES VIEWED LOOKING DOWN AT THE OIL DRAIN Ue A PRIMARY DIMENSIONS ARE MILLIMETERS e 16 611 OUTLET 2 COMPARTMENT ACCESS SHALL ALLOW J C G REMOVAL AND REPLACEMENT OF SERVICE 360 4 DOOR AND ACCESS TO THE FOLLOWING 353 8 114 ms SERVICEABLE COMPONENTS 13 93 l START STOP SWITCH FUSE 15 25 i CIRCUIT BREAKER OIL FILL AND CHECK 616 9 AIR CLEANER ELEMENT 24 29 IDLER STOP AND CHOKE ADJUSTMENTS 563 7 SPARK PLUG VALYE COVER 252 6 J 22 191 HE dd START SOLENOI 4 n A De 3 MIN UNIT CLEARAN
2. Is there access for draining engine oil Are all tail pipe connections tight and all hangers and support straps secure Does the tailpipe terminate at least 25 mm 1 in beyond the perimeter of the vehicle and at least 153 mm 6 in away from any opening into the vehicle Is the generator set located outside the vehicle interior or separated by approved vapor and fire resistive 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 been installed in a ventilated compartment isolated from the generator set 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 Has the fuel line s been secured at sufficiently close intervals to prevent chaffing and contact with sharp edges electrical wiring and hot exhaust parts Startup Batteries give off explosive gases that can cause severe personal injury Do not smoke near batteries Keep flames sparks pilot lights switches arc producing equipment and all other ignition sources away When all the items on the Installation Review check list have been checked connect the battery cables to
3. 0539_1546 SAGAS A 1 PRODUCTION RELEASE mop yi TEN D D RS ORG y 5 2 ri E i 640 21 i 21 68 15511 il Y I i I i te 14 17 i 316 11 y i i 3 i T9 1199 l i 1511 NOTES R0 5 i G3 1131 I i AA SERVICE SIDE CLEARANCE OF 25 INCH i i REQUIRES A DIRECT POE E d GENSET AIR INLET WITH OPENING IN COMPARTNENT i i ACCESS DOOR e i SERVICE SIDE CLEARANCE OF 1 5 INCH c REQUIRED WHEN OPENING IN CN l ACCESS DOOR AND GENSET AIR INLET i ARE NOT ALIGNED i i l VIEWED LOOKING DOWN i AT COMPARMENT FLOOR 12421 AIR OUTLET I l D2 16 AND EXHAUST OUTLET d 1701 OPENING i i OIL DRAIN E m OPENING EE jdn l 16 61 I 4221 20 i zl 5081 4 14 8 i 13761 nod 1 3 19 tot 153411 NOTES i 13 81 1961 i 3511 i 1 USE ORIGINAL DRAWING FOR ARTWORK 1 i 2 TEMPLATE SHALL BE PRINTED FULL SCALE i ESA 1 ON 20 70 LB BOND PAPER 1 I i i 3 REF OUTLINE DRAWING 500 2918 i i 4 TEMPLATE TO BE CUT OUT ON OUTERMOST LINE La 2 19 5 TEMPLATE MANUFACTURE NOT TO PUNCH HOLES 1563 11 OR CUT CUTOUTS i 8 i L T cs 6 DIMENSIONS SHOWN IN 1 ARE MILLIMETERS 8 i 1252 61 12091 i i l i don fisi I l i 1191 i TABULATION 4 p BRAIN HOLES T PART NUMBER DESCRIPTION i F 5 49 539 1546 01 TEMPLATE SEE NOTE 2 i 11391 E i I 539 1546 07 ARTWORK l m H i 2 01
4. 09 022 Lubricants used when connecting fuel hoses can leave residues that can clog fuel jets Only use soap free lubricants such as WD40 which runs through with the fuel without leaving residues that can clog fuel jets Fuel Lines Tubing Use 1 4 inch supply and 5 16 inch purge O D 0 003 inch welded and drawn Type 304L stainless or AISI 1008 1010 low carbon steel tubing of 0 028 inch minimum wall thickness Tubing must meet requirements for 150 psi operating pressure Ref ASTM A 539 99 and have corrosion resistance equal to or better than hot dipped zinc galvanized Hose Beads Use suitable tooling to form tubing ends into SAE J1231 Type 1 or Type 3 double flare hose beads Required for all tubing and fittings When connecting fuel hoses only use soap free lubricants such as WD 40 which runs through fuel without leaving residues that can clog fuel jets A041D129 Issue 4 33 5 Fuel Connections 2 2015 5 2 3 5 2 4 5 2 5 34 Flexible Hose Use 1 4 inch supply and 5 16 inch purge I D fuel hose that meets SAE J30R9 standards for working pressure and applicable standards for evaporative emissions Hose Clamps Use stainless steel ear clamps NOTICE Onan part number 0503 1951 11 and Oetiker part number 16700011 or equivalent worm screw type clamps are allowed Routing Fuel Lines Electric arcs can ignite gasoline leading to severe personal injury or death Do not run wiring and fuel
5. 4 0KY EVAP D q DOWN AT THE WOUNTING BASE 416 1 o 18 74 PAN d S D 9 307 81 232 3 350 7 5 E 12 121 19 15 13 8 O E O 214 34 o 6 9 ta 116 2 10 81 6 94 0 o 107 7 4 241 o 0 C9 MS Le O T 9 Lor pod INS gt Y L 23 2 0 911 r 9 941 La 616 9 24 29 640 2 25 2 i 381 4 115 25 x H o o E oren oven 7 7 LA REMOTE AND B mE CONNECTION ACCESS i IN WARNING See a E Ee Pa Es El l ae DES 9 3 O o e ee g dres Y Be FUEL INLET 1 4 TUBE GASOLINE 41 1 J L 40 52 1 61 11 61 pm rr PART NO DESCRIPTION OR MATERIAL NI i L PURGE LINE 5 16 l Ea NT Lon mas mar s G CoLLEEN e CUMMINS PONER GENERATION E ree Ein Qe er R A ROTH OUTLINE GENSET xx 0 38 17 50 24 99 0 30 0 13 s 04 08 99 SITE CODE Were nel ome 172 Padua ET TO KY POF 0500 3297 Pet 6 5 4 T 3 2 Pro ENGINEER FIGURE 29 0500 3297 SHEET 2 2 2015 A041D129 Issue 4 2 2015 B 2 A041D129 Issue 4 Outline Drawing Floor Cutout y ER ho Tura ho tvi iov zou oe ume APPROVED DATE
6. 6x T 9 i 0 25 16d I 54 1 62 1 36 i i i i re una 134 61 I i CI a MOUNTING HOLES iii 1 i 1 1 t I H 1 66 ZA 93 SERVICE SIDE OF VEHCLE si i 173 71 L aise AN 881 TYP COMPARTMENT WALL _ i i El i ee Ere FOLD ALONG THIS LINE FOR ai na T T ee Pease k 30 5 17751 539 1546 i ea de Metro nena deesses ee des id l m do m pesen Prick os More E ra DAVE OVERLAND 11 Jua 93 MINNEAPOLIS MINNESOTA 55432 BG JAY lcKOSKEr 44 20 93 J m mers PRE rs LEES TENPLATE MTG CARTWORK REN WT ara ORAA FF um 7 ER DY 0539 1546 iri FIGURE 30 0539 1546 Appendix B Outline Drawings 61 Appendix B Outline Drawings 2 2015 This page is intentionally blank 62 A041D129 Issue 4 Cummins Power Generation 1400 73rd Ave NE Minneapolis MN 55432 USA Phone 1 763 574 5000 Toll free 1 800 888 6626 Fax 1 763 574 5298 Copyright O 2015 Cummins Power Generation Inc All rights reserved Cummins Onan the C logo and Performance you rely on are trademarks of Cummins Inc
7. Battery Gas Is Explosive Battery gas is highly explosive and may cause personal injury or death if ignited Take the proper precautions to avoid personal injury e For personal safety wear appropriate PPE when working on or around the generator set e To make sure battery gas is not ignited do not smoke around the generator set To reduce arcing when disconnecting or reconnecting battery cables always disconnect the negative battery cable first and reconnect it last 1 10 Moving Parts Can Cause Severe Personal Injury or Death Moving parts can cause severe personal injury or death and hot exhaust parts can cause severe burns Make sure all protective guards are properly in place before starting the generator set Hot moving and electrically live parts can cause severe personal injury or death Keep children away from the generator set A041D129 Issue 4 5 1 Important Safety Instructions 2 2015 Hot moving and electrically live parts can cause severe personal injury or death Only trained and experienced personnel should make adjustments while the generator set is running Moving parts can catch on loose items such as clothing or jewelry Do not wear loose clothing or jewelry near moving parts such as PTO power take off shafts fans belts and pulleys Moving parts can entangle appendages such as fingers Keep the protective guards in place over fans belts pulleys and other moving parts and keep hands
8. cause cancer or reproductive toxicity Do not ingest breathe the fumes or contact used oil when checking or changing engine oil To prevent accidental or remote starting while working on the generator set disconnect the negative battery cable at the battery using an insulated wrench Unsecured or loose fasteners can cause equipment damage Make sure all fasteners are secure and properly torqued Oily rags and other material can cause fire and restrict cooling Keep the generator set drip pan and compartment clean Accumulated grease and oil can cause overheating and engine damage presenting a potential fire hazard Keep the generator set clean and repair any oil leaks promptly NOTICE Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combustible materials such as wood and cloth Class B fires involve combustible and flammable liquid fuels and gaseous fuels Class C fires involve live electrical equipment Refer to NFPA No 10 in applicable region 2 A041D129 Issue 4 2 2015 1 Important Safety Instructions 14 Automatic Generator Start Control Hazards Accidental starting can cause severe personal injury or death Turn off the AGS whenever performing maintenance or service when the vehicle is stored between uses is awaiting service or is parked in a garage or other confined area Unexpected starting may occur if the generator set is equipped with an inverter charger or other Autom
9. damage and secured to prevent kinking contact with sharp edges and chafing due to vibration 3 Route the LPG vent hose so that it vents to the outside or provide required openings 4 For a long fuel line run use seamless steel tubing with flared ends Make flexible hose connections at the fuel tank and at the generator set Use 3 8 inch D fuel line for runs up to 0 9 m 3 ft and 1 2 inch I D up to 4 6 m 15 ft Do not connect the generator set fuel supply line to any appliance fuel supply line The generator set 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 generator set and other appliances at the expected temperature conditions lt may be necessary to use a separate fuel tank for the generator set if sufficient fuel cannot be supplied with a single tank system N Description No Deseription 2 Reguator AA 4 eeneratorser L FIGURE 17 LPG FUEL LINE APPLIANCE CONNECTIONS 2 5 THROUGH 6 5 KW LPG SYSTEMS 38 Generators with LPG systems must have dedicated Regulator Piping Connections Upon completion of 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 Because variations in fuel altitude and ambient temperature affect perf
10. follow all guidelines for the installation Care must be taken to make sure that all installation requirements in this entire manual are met A representative installation of the generator set must be tested to determine that the generator set will not overheat due to recirculation of hot air back into the generator set Test Method EXHAUST GAS IS DEADL Y Do not operate the generator set when the vehicle is parked indoors or where exhaust can accumulate 1 Complete a representative installation 2 Set up a load bank to run the generator set at rated full load 3 Conduct the test at a location where the ambient air temperature will remain between 16 C and 38 C 60 F and 100 F 4 Measure temperatures with thermocouples not heavier than 0 21 mm 24 AWG a Measure generator set inlet air temperature with one thermocouple tied in the middle of the inlet air grille A041D129 Issue 4 2 2015 7 Installation Review and Startup b Measure ambient air temperature with a shielded thermocouple within 1 2 m 4 ft of the generator set and approximately the same height Make sure the thermocouple will not be affected by warm air discharged from the generator set or by sunlight Use 50 8 mm 2 in diameter white PVC piping at least 152 4 mm 6 in long as a thermocouple shield 5 Close all compartment doors and run the generator set at full load for at least an hour Record temperatures at 15 minute intervals until they
11. lines together 1 Route the fuel lines side by side along bulkheads and frame members such that they are protected The entire length of the fuel lines must be visible for inspection and accessible for replacement NOTICE The fuel lines should be at or above the top of the fuel tank to reduce siphoning if a line breaks or a hose comes off 2 Support and protect fuel lines to restrain movement and prevent chaffing or contact with sharp edges electrical wiring and hot exhaust parts Vapor and Fuel Return Line Requirements Evaporative EVAP requires an additional fuel vapor line from the carbon canister to the generator set Fuel Tank For compliance with evaporative emissions regulations the fuel tank must 1 Be metal 2 Have a 13 to 35 gallon capacity 3 Have a permanently tethered cap 4 Have cap that provides a vapor seal and that audibly signals that the vapor seal has been established click or snap 5 Have a roll over vent valve with connection for 5 16 inch I D hose The hose connects to the carbon canister 6 Have a fill neck and an anti spit back valve if it is a non top fill tank 7 Be constructed to meet the requirements of Section 393 67 joints fittings and threads of the Federal Motor Carrier Safety Administration Regulations A041D129 Issue 4 2 2015 5 Fuel Connections 5 2 6 Carbon Canister Gasoline vapors in the fuel tank accumulate in the carbon canister when the generator
12. not connect the generator set fuel supply line to any vehicle appliance supply line 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 NFPA 58 the Liquefied Petroleum Gas Code should be used as a guide for the installation of the LPG fuel system NFPA 1192 the Standard on Recreation Vehicles should be used as a guide for the installation of the LPG fuel system in regard to the following sections Propane Container Propane Supply Connection Connector Regulated High Pressure Piping Propane Systems Propane Piping Systems Propane Piping Design Propane Pipe Sizing NOTICE Generator is included in pipe sizing calculations and testing Special Requirement for High Pressure Testing e Testing Low Pressure Piping Systems for Propane Leakage After Appliances Are Connected NOTICE Generator is considered connected as an appliance for testing Testing Regulated High Pressure Piping System for Gas Leakage A041D129 Issue 4 37 5 Fuel Connections 2 2015 Connect LPG fuel system 1 Adjust the gas supply pressure at the gas inlet of the pressure regulator to at least 229 mm 9 in Water Column WC The pressure must not exceed 330 mm 13 in WC 2 Route LPG fuel lines away from electrical wiring and hot engine exhaust components Fuel lines should be accessible for inspection and replacement protected from
13. rig Fel Iesu Q A muyu e emu dead 29 5 2 Gasoline Nonmotorized EVAP iio it 30 5 21 Fuel H0S68 iS 33 5 2 2 Fuel Lines 28 I Es ER eee RRI asa 33 5 2 3 Route A OR EDD 34 5 2 4 Vapor and Fuel Return Line Requirements nono nonnnnncnnnnnnnnos 34 SS TENK TRUM ut _ epe A 34 DEACERO 35 52 mGeneratoneotlee nn n p o jc TS 36 A a act RC o ae a EES Es OL OSO 36 Cm ELECHRICAICONNEGCIIONS SERR A AAA 41 6 PAG Power OutpuviGonmections AA nonae oo neono re anoano 41 ONO COS EA E E 42 Os One single Shore Fewer e Mec WA ee a UT 42 o245emotexsontroleennesctions 99 Wa 43 SS Anna Battery Conn amp gtians 29 Imaman 44 6 3 EME A a 7 eese eene enne ern nein nnne innert einn 45 Co sp CAN 0X o 45 63 3 Battery Cables its S eut Mee e etel tenus 45 6 3 4 Battery Cable Connections at the Generator Set 47 6 3 5 Generator Set Equipment Grounding Screw 48 7 INSTALLATION REVIEW AND STARTUP neret nnn nnn nnn nin 49 7 1 InstallationllSeViG ci enhn nnne enne trennen rne ine renes daa daraus 49 FA SEE TUTO cocoocaaconacosgaoocosacoocasono AAEE EEE ANASA AA ANENA 49 La AANT RECUEI VES EN _ cece ccccsecccccdcceseedesesssserscesdevsssesdsessnsereusesgecacsusdssniess 50 SN A m RH ETA CCE CUA 50 7 3 2 Test Re
14. set is installed in a commercial or recreational vehicle The RV Generator Set Warranty applies only when the generator set is installed in a recreational vehicle The installer bears sole responsibility for the selection of the appropriate generator set for its proper installation and for obtaining approvals from the authorities if any having jurisdiction over the installation The generator sets meet the basic requirements of the Standard for Safety for Engine Generator Sets for Recreational Vehicles ANSI RVIA EGS 1 and are suitable for installation in accordance with ANSI A1192 NFPA No 501C Recreational Vehicles NFPA No 70 Article 551 Recreational Vehicles and RV Parks 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 listed in the table below for reference TABLE 1 REFERENCE CODES AND STANDARDS R a of ao Superintendent of Documents egulations Title 49 Chapter III and P O Box 371954 Chapter V Pittsburgh PA 15250 7954 National Fire Protection Association NFPA 58 70 1192 470 Atlantic Avenue Boston MA 02210 Recreational Vehicle I
15. stabilize Temperature is considered stable when there is no change in 3 consecutive readings The following table illustrates how the data can be arranged for recording and analysis TABLE 8 TEMPERATURE DATA TEMPERATURE C F THERMOCOUPLE Time of Reading LOCATION AMBIENT AIR INLET AIR No Description Description Ambient Air Inlet Air 1 2 m 4 ft FIGURE 26 THERMOCOUPLE LOCATIONS FOR HOT AIR RECIRCULATION TEST 7 3 2 Test Requirement High ambient operating temperatures could reduce maximum generator set power output if the air temperature rise measured in this test is on the high end of the acceptable range A041D129 Issue 4 51 7 Installation Review and Startup 2 2015 The rise in inlet air temperature over ambient air temperature must not exceed 8 C 15 F in all modes of operation 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 52 A041D129 Issue 4 Appendix A Wiring Diagrams Table of Contents Figure 27 0611 1267 A y A ss A041D129 Issue 4 53 Appendix A Wiring Diagrams 2 2015 This page is intentionally blank 54 A041D129 Issue 4 2 2015 A 0 Wiring Diagram Appendix A Wiring Diagrams LOCAL START STOP SAI ICH S start si 3 GND SI 2 3 LOCAL START 1 LOCAL STOP 2 LOCAL GROUND g LOCAL STATUS 7 Al CONTROL BOARD 11 1 STA
16. the battery positive cable first A041D129 Issue 4 49 7 Installation Review and Startup 2 2015 7 3 7 3 1 50 Read the Operator Manual and perform the maintenance and pre start checks as instructed The generator set is shipped from the factory with the proper level of engine oil but the oil level should be checked before starting the generator set This product incorporates a catalyst exhaust system which leads to subsequent higher exhaust gas temperatures and higher cooling air outlet temperatures Due to these higher exhaust gas temperatures and higher cooling air outlet temperatures the installer must review and follow all guidelines for the installation Care must be taken to ensure that all installation requirements in this entire manual are met EXHAUST GAS IS DEADLY Do not operate the generator set when the vehicle is indoors or where exhaust can accumulate Start and operate the generator set following all the instructions and safety precautions in the Operator Manual Check for fuel and exhaust leaks and unusual noises while the generator set is running under full and intermediate loads Do not place the generator set in service until all fuel and exhaust leaks have been fixed and operation is satisfactory Hot Air Recirculation Test This product incorporates a catalyst exhaust system which leads to higher exhaust gas temperatures and higher cooling air outlet temperatures The installer must review and
17. to provide and maintain a spark arrester can be a violation of the law Liability for damage injury and warranty expense due to the modification of the exhaust system or the use of unapproved parts is the responsibility of the person performing the modification or installing the unapproved exhaust system parts EXHAUST GAS IS DEADLY To keep exhaust gases from entering the vehicle do not terminate the exhaust tailpipe underneath the vehicle or closer than 153 mm 6 in to openings into the vehicle or route it such that it is not protected Use approved materials only The tailpipe of the generator set will be hot during operation and can cause severe burns To reduce the risk of contact concentration must be used where the tailpipe will be located and routed The generator set exhaust system must be gas tight and designed to prevent entry of exhaust gasses into the vehicle interior Tailpipe Installation The muffler is mounted inside the generator set and has a flange to which the tailpipe adapter available from Cummins Onan is bolted or a collar to which the tailpipe is clamped or a short adapter bolted to its oulet flange Flexible pipe is not gas tight or durable and can cause exhaust gas leaks Do not use flexible pipe for tailpipe 1 Use 18 gauge 1 3 8 inch I D aluminized steel tubing or material of equivalent heat and corrosion resistance for the tailpipe 2 Support a tailpipe longer than 457 mm 1 1 2 ft near its end a
18. CE FROM COMPARTMENT 5 Eum 1 4 241 SURFACES 6 3 i 4 53 1 0 251 que 2 111 34 6 ENGINE EN dd usn s 9 1 1 LU GEN END 6 4 125 IN i Od L SERVICE SIDE 82 6 4 25 IN mw d E 6 4 25 IN 6 35 lt L 5 16 18NC MOUNTING IN FREE 0 25 0 31 ETT HANGER 13 501 n S INLE 258CM 40 INS YA PROTRUDING INTO BASE ki 99 9 5X xa SERVICE SIDE CLEARANCE OF 25 IN S 19 68 AIR INLETS REQUIRES DIRECT ALIGNNENT OF SE H H L T AIR INLET AND OPENING IN ACCESS DOOR IF COMPARTMENT AIR INLET IS LOCATED Sa ELSEWHERE 1 50 IN MIN IS REQUIRED T BETWEEN SET AND ACCESS DOOR TO MAINTAIN 40 IN FREE AIR INLET YY bs FOR DETAILED INSTALLATION SIZE B 285 2 REO MENTS SEE B Y 111231 539 1546 TEMPLATE COMPARTMENT Wv 6 I 539 1535 TEMPLATE UNDERFLOOR SERVICE REMOTE AND B DOOR CONNECTION 4 UNIT WEIGHT WITH OI ACCESS 353 3 i 13 9 60 HZ 19 KG 114 LBS Ac OUT 2773 44 LONG 164 6 14 4 X 20 X 30 5 INCHES AND VARIES a U L 6 481 36 WITH MOUNTING KIT USED AND SERVICE 28 6 eta 350 4 z 14 DOOR ACCESS ps 15 06 13 8 L 493 SERVICE DOOR v a i a 762 8 SEE NOTE 5 Pa 301 L hal E 114 1 aT 1 9 FUEL INLET 30 51 10 071 A 25 IN HOSE BARB A 625 18 Wen Ti zs 18U I ITH SAE 45 FLARE LPG a o ror d TO NAINTAL LIA LTH REQUIREMENT IIT y SEE NOTE 5 a ee Ree ao 9m ow PART Wo DESCRIPTION OR MATERIAL CHASSIS AND silo 0500 2918 ww G_COLLEEN CUMMNS POWER GENERATION BATTERY GROUND MAL ON Desta CONTROL FACILITIES
19. CT DO NOT SCALE PRAT oro RACROTH e 1400 T3RD AYENUE KE MINNEAPOLIS MN 56432 VICES is EH REG dea RART OUTLINE GENSET Celta i 17 80 24 389 20 300 13 Tome 04 08 98 SITE CODE 3 ron i FIRST USED ON Fy SWEET Y GES Ey PGF 310500 3297 m 6 4 3 2 1 Pro ENGINEER FIGURE 28 0500 3297 SHEET 1 59 Appendix B Outline Drawings B 1 60 Outline Drawing EVAP 6 5 4 LV 3 2 l 1 REL No trt wo revisio 10kc ok exo TT DATE FRDI289 A GAC RAR ROTH 04 30 99 fos 132 PAN FRDT052 B SEES 28 8 FRD14604 C jeje se E Z S FRD3I660 1 D MAH KE ELAYED 04 12 07 FRD32186 E SEE SHEET 1 sMa APP APP 08 30 07 4 Y o 0 o 51 9 Me Q 2 041 o O 9 qd 1 o 429 5 Q 16 9 l CONF ARTHENT Gon E VIEWED LOOKING
20. Cummins Onan Installation Manual RV Generator Set KY Spec P English Original Instructions 2 2015 A041D129 Issue 4 California Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Table of Contents 1 IMPORTANT SAFETY INS TRUCLIQNS perennes a 1 1 Overview 9m TEN NIS RET 1 2 Warning Caution and Note Styles Used in This Manual 1 3 General aie ty A A EE oc aaa 1 4 Automatic Generator Start Control Hazards e eee 1 5 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death 1 ovGeneratorsvoltage s Mealy cere a Mile Wa m 1 7 Engine Exhaust Carbon Monoxide Is Deadly 25 attente tinere 1 8 Fuel Is Flammable and Explosive sh mOn nennen enne enne EDGAR S RR UU E 1 10 Moving Parts Can Cause Severe Personal Injury or Death Tau ARB nn nn C lo cc O ss s 2 INTRODUCTION cea me MD A a ZA AOUR TAS vlanual Eme III o OQ oe 224 related IteratultiGy MERE ai ANAHISI nein ener erinnern nente rinde n karen enira 2 3 Installation Codes and Standards for Safety a 2 4 Electromagnetic Compatibility Compli
21. MP REMOTE RUN START p STOP START STOP SWITCH CONNECTOR END VIEW A A WIRE END VIEW B B Pin Description Pin Description Ls Stop Prime jFjSestght p Notused atu FIGURE 22 REMOTE CONTROL CONNECTOR PLUG AND TYPICAL CONNECTIONS METER t 6 3 Starting Battery Connections Accidental starting of the generator set can cause severe personal injury or death Do not connect the starting battery until instructed in Chapter 7 on page 49 44 A041D129 Issue 4 2 2015 6 Electrical Connections The generator set has a 12 VDC negative ground engine control and cranking system See Section 2 5 on page 9 for the requirements for cranking batteries 6 3 1 Battery Compartment 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 Batteries must be mounted in a separate compartment from that of the generator set and away from spark producing equipment A compartment must have openings of at least 11 cm 1 7 in at the top and bottom for ventilation of battery gasses It should be mounted such that spills and leaks will not
22. NITIONS Alternating Current Automatic Generator Start American Iron and Steel Institute A C GS ISI i i Direct Current A041D129 Issue 4 11 2 Introduction 2 2015 Acronym EEPROM Electronically Erasable Programmable Read Only Memory Electromagnetic Compatibility Environmental Protection Agency Grounded Fault Circuit Interrupters High Pressure Inside Diameter SO International Organization for Standardization LED Light emitting Diode 318 Q LPG Liquid Petroleum Gas NFPA National Fire Protection Agency NPTF National Pipe Taper Fuel Outside Diameter Original Equipment Manufacturer Personal Protective Equipment Power Take Off Random Access Memory Read Only Memory z E ES lt Recreational Vehicle RVIA RV Industry Association Society of Automotive Engineers gt m NC Unified National Coarse US U S United States C Water Column TABLE 5 ACRONYMS FOR UNITS OF MEASUREMENT Ampere Ampere SO Feet foot Foot pounds Gallons per hour Height 12 A041D129 Issue 4 2 2015 2 Introduction o iI TZ SZ De w RPM Revolutions per AA i Volts Direct Current w watts Width A041D129 Issue 4 13 2 Introduction 2 2015 This page is intentionally blank 14 A041D129 Issue 4 3 Location Mounting and Ventilation The location mounting and ventilation of a generator set must be such that mounting is secure engine exhaust and f
23. Onan Part Number 0148 1343 vent filter to the hose barb A041D129 Issue 4 35 5 Fuel Connections 2 2015 No Description so Description 2 Horizontal _ L FIGURE 16 ACCEPTABLE CANISTER MOUNTING ORIENTATIONS 5 2 7 Generator Set 1 Connect the 5 16 inch generator set hose barb to the vapor purge hose from the carbon canister 2 Connect the 1 4 inch hose barb to the fuel supply hose from the fuel tank 5 3 LPG 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 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 trained and experienced personnel 36 A041D129 Issue 4 2 2015 5 Fuel Connections 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 LPG leaks from the vent hose can lead to explosive accumulations inside the generator set compartment Route the LPG vent hose so that it vents to the outside or provide required openings 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
24. RT STOP J1 1 J1 14 GROUND 4 5 11 9 pec STATUS INDICATOR 31 23 0 A041D129 Issue 4 P8 F REMOTE STATUS ja AC SENSE L1 P8 C REMOTE START ps DS Tac SENSE L2 P8 B REMOTE STOP Hs P8 A REMOTE GROUND P8 E REMOTE RUN P8 G XMT SERIAL DATA P8 H Prev SERIAL DATA i RCV SERIAL DATA 4 FUEL CUTOFF 4 J1 18 FUEL CUT OFF 11 15 2 E3 1 TRA O NEUTRAL J1 8 FUEL PUMP B 2 E2 1 J1 6 eb STARTER SOLONO D 48 T1 IGN E1 SPARK B En GROUND SoH K1 cal eal a an A diis T4 i ES v T2 L21 3 iL LP ONLY GROUND CHASSIS CHASSIS GROUND GROUND BIl GROUND FIGURE 27 0611 1267 55 Appendix A Wiring Diagrams 2 2015 This page is intentionally blank 56 A041D129 Issue 4 Appendix B Outline Drawings Table of Contents Figure 28 0500 3295 ho A AS Figure 29 05003270100 G2 rro yo EEES A A gt Figure 30 0539 1346 a a E A A s A041D129 Issue 4 57 Appendix B Outline Drawings 2 2015 This page is intentionally blank 58 A041D129 Issue 4 2 2015 B 0 A041D129 Issue 4 Outline Drawing Appendix B Outline Drawings
25. ance seem 2 5 Specifications no nee Ea dena ine Rinder ree NANE ANASA WAMAMA 2 5 1 Gasoline Model SpecificatiONS ooooonccccicnncccncnnnnnncnnnnnnnnnnnonnn non nono nennen 2 5 2 LPG Model Specifications BC CP C CU ooo REBEDOORQNQOO TQUE 3 LOCATION MOUNTING AND VENTILATION cooocccconocccccononccnnononcncnononcnnonanccnnnannnnnncnnnncnnannnnncnanns Sl LOSE MAN li s PNE 3 1 1 Typical Generator Set Locations Class A RV n 3 1 2 Typical Generator Set Locations Class C RV eene 3 1 3 Typical Generator Set Locations Class B Van esee 3 1 4 Typical Generator Set Locations Pickup Truck Camper 32 oun nqge sce n n ee et ME MI E EE IE 3 Belo ww Floor A OUI UIA sese erc ec Ri E Me I a ar doc suiatindg a di EE 3 2 3 Fire and Exhaust Barriere is 3 8 RU IEEE ISTIS 4 EXHAUSTECONNEGTIORNS rers oe nn n e 4 1 Tailpipe Installationzz oe eR UT DRM RT 4 2 Vehicle ClearaneeselassAMS VETERE UU UA 4 3 Vehicle Clearances Class B Nani AAA AAA 4 4 Vehicle Clearances Pickup Truck Camper ssssssssssee emen 5 FUEL CONNECTIONS ui diia 521 Gasoline Motorized ac A041D129 Issue 4 wow SR a aa O O CC AC OO O ON NN a ok A e ea RE LA 2 CO CO CO CO CO CO Y Y OOO N N A NNN an NN o Table of Contents 2 2015 StI Fuel AO T ERR E 28 GRIP Fuel LIMOS ET 29 9 1 5 Ixol
26. atic Generator Start AGS control This may cause exposure to Unexpected generator starting Moving parts hazards Electric shock Exhaust carbon monoxide CO 1 5 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death Electrical shocks and arc flashes can cause severe personal injury or death Adhere to the following guidelines Only qualified service personnel certified and authorized to work on power circuits should work on exposed energized power circuits All relevant service material must be available for any electrical work performed by certified service personnel Exposure to energized power circuits with potentials of 50 VAC or 75 VDC or higher poses a significant risk of electrical shock and electrical arc flash Refer to standard NFPA 70E or equivalent safety standards in corresponding regions for details of the dangers involved and for safety requirements 1 6 Generator Voltage Is Deadly Improperly connected generator electrical output connections can cause equipment damage severe personal injury or death Electrical connections must be made by a trained and experienced electrician in accordance with applicable codes Improper installations can cause equipment damage severe personal injury or death All installations must be conducted by trained and experienced personnel in accordance with the installation instructions and all applicable codes Back feed to shore power can cause elec
27. away from all moving parts 1 11 CARB 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 The California Air Resources Board CARB has requirements regarding modification amp repair of fuel system amp exhaust components 6 A041D129 Issue 4 2 Introduction 2 1 About This Manual This manual is a guide for the installation of the generator sets listed on the front cover Proper installation is essential for top performance Read through this manual before starting the installation Leave this manual in the vehicle The installer must be qualified to perform installation of electrical and mechanical equipment This manual addresses the following aspects of the installation e Location Mounting and Ventilation Exhaust Connections Fuel Connections Electrical Connections Startup See the Operator Manual for operation and maintenance and the Service Manual for service The information contained within the manual is based on information available at the time of printing In line with Cummins Power Generation policy of continuous development and improvement information may change at any time without notice The users should therefore make sure that before commencing any work they have the latest information available The latest version of this manual is available on QuickServe Onl
28. ay from going into the generator set The generator set housing is not rain proof If the generator set is installed where snow and rain will hit the top of the generator set a sheet metal or plastic cover should be used to prevent large amounts of water from running in the seams of the generator set housing Space to mount the generator set with at least 25 4 mm 1 in clearance on the left side 25 4 mm 1 in clearance at the top 38 1 mm 1 5 in clearance in front and 6 35 mm 1 4 in clearance on the remaining sides of the generator set Minimum clearances apply to any thermal or acoustic insulation with which a compartment may be lined A041D129 Issue 4 15 3 Location Mounting and Ventilation 2 2015 NOTICE For rooftop or other high acceleration locations Certain locations for generator set installations can result in 30 g forces affecting the generator set These high road input forces can cause generator set performance issues from rough running or stalling to many different types of broken generator set components It is highly recommended that the generator set not be located more than 1 524 m 5 ft above the floor and aft of the rear axle s on a trailer or motorized application Damage due to high road input forces as follows will not be covered under warranty Broken generator mounts Broken exhaust components Damaged housings or shrouds from excessive internal generator set component movement Torn
29. d space such as a garage basement or building of any kind Make sure the exhaust system is installed in accordance with the generator set installation manual Never use engine cooling air for heating a working or living space compartment Carbon Monoxide CO is odorless colorless tasteless and non irritating It cannot be seen or smelled Exposure even to low levels of CO for a prolonged period can lead to asphyxiation lack of oxygen Mild effects of CO poisoning include headache dizziness drowsiness fatigue chest pain confusion More extreme symptoms include vomiting Seizure loss of consciousness A041D129 Issue 4 2 2015 1 Important Safety Instructions 1 8 Fuel ls Flammable and Explosive Fuel and fuel vapor is highly explosive Adhere to the following bullets to avoid igniting fuel and fuel vapors 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 all other sources of ignition well away from fuel lines and sources Fuel lines must be secured free of leaks and separated or shielded from electrical wiring Leaks can lead to explosive accumulations of gas LPG sinks when released and can accumulate inside housings and basements and other below grade spaces NOTICE Natural gas is identifiable by a rotten egg smell 1 9
30. d standards for additional information e All seams and openings in the barriers for wiring mounting screws etc must be sealed 33 Ventilation Generator set cooling air must not be obstructed A free air inlet size of at least 258 cm 40 in is required Grilles louvers and other kinds of decorative treatments for air openings are restrictive Contact the manufacturer of the decorative assembly or material to find out how large of an opening is required to obtain the minimum free air inlet size e Unless the compartment air inlet lines up directly with the generator set air inlet a clearance of at least 50 8 mm 2 in is required at the front of the generator set for air to get to the generator set inlet Staggering a compartment side opening or pulling the air up under the skirt of the vehicle will reduce line of sight noise but requires the extra clearance in front A041D129 Issue 4 19 3 Location Mounting and Ventilation FIGURE 5 GENERATOR SET COOLING AIR INLET AND OUTLET 2 2015 20 A041D129 Issue 4 4 1 Exhaust Connections This product incorporates a catalyst exhaust system which leads to higher exhaust gas temperatures The installer must review and follow all guidelines for the installation Care must be taken to make sure that all installation requirements in this entire manual are met The generator set is equipped with a U S Forest Service approved spark arrest muffler Failure
31. drip acid on fuel lines wiring and other equipment that could be damaged e Stand alone applications will require a starting battery and a battery charger e RVs often connect house batteries to the generator set All RVs should be equipped with a battery charger to charge the batteries 6 3 2 Battery Cable Sizes TABLE 7 BATTERY CABLE SIZES FOR TEMPERATURES DOWN TO 29 C 20 F 1 Battery cable lengths are total lengths from battery to the generator back to the battery and when using a total of 1000 CCA Cold Cranking Amps 2 A total length of up to 6 m 20 ft may be used in warmer climates or when battery capacity totals at least 1000 CCA 6 3 3 Battery Cables Size battery cables according to the Battery Cable Sizes table The current path between the generator set 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 generator set to the negative battery terminal Note also that codes may require bonding conductors from the generator set and the battery to the vehicle frame If a vehicle frame is used as the path between the negative battery terminal and the generator set all frame members in the path of battery cranking currents must have substantial crossections The electrical resistance of riveted or bolted frame joints must also be carefully considered espec
32. ed inside the generator set are low permeation fuel hoses which meet Federal 50 state standards for gasoline evaporative emissions Low permeation fuel hose is required to meet the requirements for gasoline generator sets sold in or used for commerce in all 50 states The following hose materials are acceptable Avon Automotive Greenbar EO G 05 018 SAE J30R7 Avon Automotive Greenbar 1200 EO C U 05 009 SAE J30R12 Gates 4219D EO C U 06 002 SAE J30R9 Gates Barricade EO Q 09 019 28 A041D129 Issue 4 2 2015 5 1 2 5 1 3 5 Fuel Connections Kubota EO C U 05 003 SAE J30R7 Mark IV Automotive Gen2 EO C U 05 002 SAE J30R7 Mark IV Automotive Fluoroperm EO C U 07 017 SAE J30R9 Mark IV Automotive Dayperm EO C U 06 030 SAE J30R7 Mark IV Automotive Dayperm EO G 05 016 e Mold Ex Division of SETI Inc SETiFLEX II EO G 05 17A SAE J30R7 Parker Hannifin Corp Super Flex FL 7 series 389XX EO Q 08 013 Veyance Technologies Inc Goodyear Flexshield EO Q 09 022 Lubricants used when connecting fuel hoses can leave residues that can clog fuel jets Only use soap free lubricants such as WD40 which runs through with the fuel without leaving residues that can clog fuel jets Fuel Lines Tubing Use 1 4 inch I D 0 003 inch welded and drawn Type 304L stainless or AISI 1008 1010 low carbon steel tubing of 0 028 inch minimum wall thickness Tubing must meet requ
33. essure can cause loss of performance and engine damage 12 Make sure a tailpipe deflector will not cause excessive back pressure FIGURE 6 TYPICAL TAILPIPE INSTALLATION FIGURE 7 EXHAUST TAILPIPE CONNECTIONS 22 A041D129 Issue 4 2 2015 4 Exhaust Connections No Description so Description Tailpipe 153 mm 6 in No opening into the vehicle interior may be closer than 153 mm 6 in to the end of the tail pipe within area 2 identified in this image FIGURE 8 MINIMUM DISTANCES TO OPENINGS A041D129 Issue 4 23 4 Exhaust Connections 2 2015 No Description so Description 25 mm 1 inch Straight on view 2 The last tailpipe hanger must be as close to the end as possible FIGURE 9 TERMINATING THE EXHAUST TAILPIPE 42 Vehicle Clearances Class A RV No Description No Description Approach Angle Departure Angle 2 Axle Clearance Line MR FIGURE 10 VEHICLE CLEARANCES CLASS A RV 24 A041D129 Issue 4 2 2015 4 Exhaust Connections 43 Vehicle Clearances Class B Van No Description No Description Approach Angle Departure Angle Axle Clearance Line FIGURE 11 VEHICLE CLEARANCES CLASS B VAN 4 4 Vehicle Clearances Pickup Truck Camper No Description No Description Approach Angle Departure A
34. ially 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 generator set NOTICE The generator set mounting bolts are not considered an adequate means of bonding the generator set to the vehicle frame either for the purpose of carrying cranking currents or for complying with requirements for generator set system grounding A041D129 Issue 4 45 6 Electrical Connections 2 2015 Coat all battery cable connections with a battery terminal oxidation inhibitor Routing battery cables with fuel lines can lead to fire and severe personal injury or death Keep battery cables away from fuel lines 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 No Description No Description ES ES FIGURE 23 FULL LENGTH CABLE FROM BATTERY NEGATIVE TERMINAL 46 A041D129 Issue 4 2 2015 6 Electrical Connections No Description No Description Generator Set Cable size per table Battery i FIGURE 24 VEHICLE FRAME AS PATH FROM BATTERY NEGATIVE TERMINAL 6 3 4 Battery Cable Connections at the Generator Set Terminate the battery cables with ring terminals sized for 5 16 inch screws and connect them to the generator set Secure the insulating boot o
35. ine https qsol cummins com info index html 2 2 Related Literature Before any attempt is made to operate the generator set the operator should take time to read all of the manuals supplied with the generator set and to familiarize themselves with the warnings and operating procedures A generator set must be operated and maintained properly if you are to expect safe and reliable operation The Operator manual includes a maintenance schedule and a troubleshooting guide The Health and Safety manual must be read in conjunction with this manual for the safe operation of the generator set e Health and Safety Manual 0908 0110 The relevant manuals appropriate to your generator set are also available the documents below are in English Operator Manual for RV Generator Set KY Spec P A041D131 Installation Manual for RV Generator Set KY Spec P A041D129 Generator Set Service Manual for RV Generator Set KY Spec P A041D133 Recommended Spares List RSL for RV Generator Set KY Spec P A043Y023 A041D129 Issue 4 7 2 Introduction 2 2015 Parts Manual for RV Generator Set KY Spec P 0981 0246 Standard Repair Times AF Family 0900 0606 Service Tool Manual A043D529 Failure Code Manual F1115C e Warranty Manual A040W374 Global Commercial Warranty Statement A028U870 2 3 Installation Codes and Standards for Safety The Commercial Generator Set Warranty applies only when the generator
36. ing 450 CCA 18 C 0 F Minimum Free Air Inlet Area 1 60 Hz models are listed by CSA and the US Testing Company 2 See the Installation Manual for additional considerations when sizing the generator set compartment 2 5 2 LPG Model Specifications TABLE 3 LPG MODEL SPECIFICATIONS GENERATOR 2 Pole Revolving Field Self Excited 1 Phase Microprocessor Regulated 230 Volts FUEL CONSUMPTION ENGINE 1 Cylinder 4 Cycle Spark Ignited OHV Air Cooled Mechanically Governed Stroke 62 mm 2 44 in 304 om 18 5 in 85 1 1 5 liters 1 6 at 0 05 mm 0 002 in 0 05 mm 0 002 in 0 51 mm 0 020 in 17 Nm 13 ft lbs 10 A041D129 Issue 4 2 2015 2 Introduction 3 6 KY 3 3 KY Ignition Timing 25 BTDC non adjustable Magneto Air Gap 0 23 0 38 mm 0 009 0 015 in Compression 3 9 kgf cm 55 47 Ibf in 500 RPM DC SYSTEM Battery Voltage Minimum Battery Rating 450 CCA 18 C 0 F INSTALLATION Exhaust O D Fuel Connection Minimum Free Air Inlet Area Muffler Outlet Collar O D LPG Vapor Supply Pressure LPG Liquid Connection Pressure 1 4 18 NPTF Tank Pressure Weight 81 kg 178 lbs 84 kg 184 lbs Minimum Compartment Size H x D x VV 366 x 508 x 775 mm 14 4 x 20 x 30 5 in 1 60 Hz models are listed by CSA and the US Testing Company 2 See the Installation Manual for additional considerations when sizing the generator set compartment 2 6 List of Acronyms TABLE 4 ACRONYM DEFI
37. irements for 150 psi operating pressure Ref ASTM A 539 99 and have corrosion resistance equal to or better than hot dipped zinc galvanized Hose Beads Use suitable tooling to form tubing ends into SAE J1231 Type 1 or Type 3 double flare hose beads Recommended for all tubing and fittings Flexible Hose Use 1 4 inch I D fuel hose that meets applicable standards for evaporative emissions Routing Fuel Lines Electric arcs can ignite gasoline leading to severe personal injury or death Do not run wiring and fuel lines together 1 Route the fuel line along bulkheads and frame members such that it is protected The entire length of the fuel line must be visible for inspection and accessible for replacement It is preferred that fuel line routing be parallel to the motorized chassis fuel line A041D129 Issue 4 29 5 Fuel Connections 2 2015 5 2 30 FIGURE 14 FUEL LINE PREFERRED ROUTING NOTICE The fuel line should be at or above the top of the fuel tank to reduce siphoning if a line breaks or a hose comes off 2 Support and protect fuel lines to restrain movement and prevent chaffing or contact with sharp edges electrical wiring and hot exhaust parts Gasoline Nonmotorized EVAP Evaporative generator sets are used in trailers fifth wheel trailers and other non motorized vehicles where on board gasoline fuel storage is self contained in the trailer equipment Completing the installatio
38. n of the generator set fuel evaporative system provides compliance with the California code of regulations for small off road equipment effective January 1 2008 and Federal Small SI regulation effective January 1 2011 t is the responsibility of the towable equipment manufacturer OEM to complete the installation of the evaporative fuel system exactly as specified in the CARB EO amp EPA certification for the Cummins Onan product being installed Any deviation from the installation specifications causes forfeiture of the emissions certification on the fuel system and transfers engine evaporative emission certification responsibility to the trailer equipment manufacturer OEM per CFR 40 Part 1060 f purchasing a complete or partial fuel system kit or components from a third party fuel system manufacturer the requirements of the Installation Manual shall be met and the system must be verified by the OEM and fuel system supplier as meeting these requirements before completing the installation e Any construction deviations from these assembly requirements would invalidate the evaporative certification per CFR 40 Part 1060 and Article 1 Chapter 9 Division 3 Title 13 sections 2400 through 2773 and the towable equipment OEM would then be responsible for recertification of the fuel system with California Air Resources Board and US EPA Any questions regarding the installation or evaporative emission certification should be directed to Cummins Powe
39. n that if not avoided will result in death or serious injury Indicates a hazardous situation that if not avoided could result in death or serious injury Indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE Indicates information considered important but not hazard related e g messages relating to property damage 13 General Safety Precautions Operation of equipment is unsafe when mentally or physically fatigued Do not operate equipment in this condition or after consuming any alcohol or drug A041D129 Issue 4 1 1 Important Safety Instructions 2 2015 Maintaining or installing a generator set can cause severe personal injury Wear personal protective equipment such as safety glasses protective gloves hard hats steel toed boots and protective clothing when working on equipment Running the generator set without the cover or service door can cause severe personal injury or equipment damage Do not operate the generator set with the cover or service doors removed Starting fluids such as ether can cause explosion and generator set engine damage Do not use Benzene found in some fuels has been identified by some state and federal agencies to cause cancer or reproductive toxicity Do not ingest breathe the fumes or contact gasoline when checking draining or adding gasoline Used engine oils have been identified by some state and federal agencies to
40. n the positive terminal and tie it to the battery cable with the tie wrap in the bag with the manuals Torque the positive cable terminal to 8 Nm 6 ft lbs Torque the negative cable terminal to 8 Nm 6 ft lbs No Description No Description Negative Battery Terminal Ground Terminal Postive Battery Terminal py FIGURE 25 BATTERY CABLE CONNECTIONS A041D129 Issue 4 47 6 Electrical Connections 2 2015 6 3 5 Generator Set Equipment Grounding Screw When required connect the generator set grounding screw to the vehicle frame with a No 8 AWG or larger stranded cable having a ring terminal sized for a 3 8 inch screw Torque the grounding screw to 26 Nm 20 ft lbs 48 A041D129 Issue 4 7 1 7 2 Installation Review and Startup Installation Review Before starting the generator set inspect the installation and check Y each of the following questions if it can be answered YES If an item cannot be checked provision must be made to satisfy the requirement Is the control panel on the generator set easily accessible for starting and stopping the generator set and resetting the circuit breaker Is there easy access for checking and adding engine oil replacing the spark plugs and changing the air filter Is the generator set securely bolted in place Are all specified clearances provided Are the air inlet and outlet openings free of obstructions
41. nd at intervals of 900 mm 3 ft or less Use automotive type tailpipe hangers Do not attach the hangers to combustible material such as wood 3 Use U bolt muffler clamps to connect sections of tailpipe Overlapping pipe should be slotted 4 Do not route the tailpipe within 25 4 mm 1 inch of fuel lines or fuel tanks 5 Do not route the tailpipe closer than 76 mm 3 in 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 65 C 117 F 6 Do not route the exhaust tailpipe underneath the oil drain A041D129 Issue 4 21 4 Exhaust Connections 2 2015 7 Do not route the exhaust tailpaipe such that it will restrict the air inlet outlet 8 To keep the tailpipe from being damaged do not route it such that it protrudes into the approach or departure angles of the vehicle or below the axle clearance line 9 Do not interconnect generator set and vehicle engine exhaust systems 10 Do not terminate the tailpipe underneath the vehicle Extend it a minimum of 25 mm 1 in beyond the perimeter of the vehicle Support the end of the tailpipe such that it cannot be pushed in and up under the skirt of the vehicle 11 Do not terminate the tailpipe such that it is closer than 153 mm 6 in to any opening such as a door window vent or unsealed compartment into the vehicle interior Excessive back pr
42. ndustry Association ANSI RVIA EGS 1 14650 Lee Road Chantily VA 22021 JA ee State of California Documents Section ministrative Code Title 25 P O Box 1015 Chapter 3 North Highlands CA 95660 CAN CSA Z240 Canadian Standards Association Housing and Construction Materials Section Recreational Vehicles 178 Rexdale Blvd Bulletin 946 Rexdale Ontario Canada M9W 1R3 8 A041D129 Issue 4 2 2015 2 Introduction SAE World Headquarters BA o 400 Commonwealth Drive Warrendale PA 15096 2 4 Electromagnetic Compatibility Compliance Generator sets emit and receive electromagnetic radio frequency energy If the generator set affects operation of nearby devices or nearby devices affect generator set operation increase the distance between them When used in countries where compliance to the EMC directive is required This generator set has been evaluated for use in the residential commercial and light industrial environments 2 5 Specifications 2 5 1 Gasoline Model Specifications TABLE 2 GASOLINE MODEL SPECIFICATIONS GENERATOR 2 Pole Revolving Field Self Excited 1 Phase Microprocessor Regulated 230 Volts FUEL CONSUMPTION ENGINE 1 Cylinder 4 Cyle Spark Ignited OHV Air Cooled Mechanically Governed 17 Nm 13 felbs 25 BTDC non adjustable 0 23 0 38 mm 0 009 0 015 in A041D129 Issue 4 9 2 Introduction 2 2015 poy ey 3 9 kgf cm 55 47 Ibf in 500 RPM Battery Voltage Minimum Battery Rat
43. ngle Axle Clearance Line FIGURE 12 VEHICLE CLEARANCES PICKUP TRUCK CAMPER A041D129 Issue 4 25 4 Exhaust Connections 2 2015 This page is intentionally blank 26 A041D129 Issue 4 5 Fuel Connections See the Operator Manual for recommended fuels and Section 2 5 on page 9 for fuel consumption Unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited by law in California 5 1 Gasoline Motorized The maximum fuel pump lift is 914 mm 36 in The generator set and propulsion engine fuel supply and return lines must not be interconnected Connections meet the requirements of the following SAE standards when applicable e J1231 Formed Tube Ends for Hose Connections and Hose Fittings e J1508 Hose Clamp Specifications J2260 Nonmetallic Fuel System Tubing with One or More Layers J2044 Quick Connector Specification for Liquid Fuel and Vapor Emissions Systems Terminate the generator set fuel pickup above the vehicle engine pickup in the supply tank to keep the generator set from running the vehicle out of fuel Connect 1 4 inch fuel line from the vehicle fuel tank to the generator set A041D129 Issue 4 27 5 Fuel Connections 2 2015 No gt Description No Description pu T ssOc m FIGURE 13 GASOLINE MOTORIZED FUEL CONNECTION 5 1 1 Fuel Hoses The fuel hoses us
44. ns The generator set has an 8 pin connector for remote control connections Wiring harnesses in several lengths are available separately for connections between the generator set and remove control panel To make connections to a remote control panel 1 Push the generator set remote control connector through the entrance hole in the side of the generator set housing and snap it together with the remote wiring harness connector male 2 Refer to the following table to fabricate the remote control panel and or wiring harness when not using the accessories available from Cummins Onan Mark the remote control end of each lead to identify the connector pin number at the generator set Use insulated 18 AWG copper conductors for distances up to 9 m 30 ft and heavier gauge conductors for greater distances Protect the wiring with full length flexible sheathing 3 Route control leads separately from AC power leads to reduce the possibility of erratic operation due to false induced signals 4 Seal the opening where the leads enter the vehicle interior with silicone rubber or equivalent sealant to keep out exhaust gas A041D129 Issue 4 43 6 Electrical Connections 2 2015 FIGURE 21 REMOTE CONTROL CONNECTOR TYPICAL REMOTE CONTROL PANEL REMOTE CONTROL CONNECTOR GENERATOR SET CONNECTOR A WIRE END WIRE END CONNECTOR END T CONNECTOR END j STATUS LA
45. nt Hose to Clean Outside Air Space or PN Generator Set 0148 1343 Vent Filter 5 16 in Purge Hose Vapor 1 4 in Fuel Line Liquid Fuel Tank i FIGURE 15 GASOLINE NONMOTORIZED EVAP CONNECTIONS 32 A041D129 Issue 4 2 2015 5 2 1 5 2 2 5 Fuel Connections Fuel Hoses The fuel hoses used inside the generator set are low permeation fuel hoses which meet Federal 50 state standards for gasoline evaporative emissions The vapor and liquid hoses connecting the fuel tank to the generator set the fuel tank to the carbon canister and the carbon canister to the generator set must also be low permeation fuel hoses Low permeation fuel hose is required to meet the requirements for gasoline generator sets sold in or used for commerce in all 50 states The following hose materials are acceptable Avon Automotive Greenbar EO G 05 018 SAE J30R7 Avon Automotive Greenbar 1200 EO C U 05 009 SAE J30R12 e Gates 4219D EO C U 06 002 SAE J30R9 Gates Barricade EO Q 09 019 Kubota EO C U 05 003 SAE J30R7 Mark IV Automotive Gen2 EO C U 05 002 SAE J30R7 Mark IV Automotive Fluoroperm EO C U 07 017 SAE J30R9 Mark IV Automotive Dayperm EO C U 06 030 SAE J30R7 Mark IV Automotive Dayperm EO G 05 016 e Mold Ex Division of SETI Inc SETiFLEX II EO G 05 17A SAE J30R7 Parker Hannifin Corp Super Flex FL 7 series 389XX EO Q 08 013 Veyance Technologies Inc Goodyear Flexshield EO Q
46. ormance it might be necessary to make governor and fuel mixture adjustments once the generator set has been installed See the Service Manual A041D129 Issue 4 2 2015 5 Fuel Connections No Description NI Description Vapor Shutoff Valve 6 Fuel Shutoff Solenoid meo ie es dt L7 LPG Vent Hose vent outside compartment 3111 inches W C Outlet Pressure g 5 8 18 45 Flare Fitting Demand Regulator Fuel Line Size 3 8 inch 1 D up to 0 9 m 3 ft or 1 2 inch I D up to 4 6 m 15 ft 5 LPG Carburetor ws FIGURE 18 TYPICAL LPG VAPOR WITHDRAWAL FUEL SYSTEM A041D129 Issue 4 39 5 Fuel Connections 40 This page is intentionally blank 2 2015 A041D129 Issue 4 6 1 Electrical Connections HAZARDOUS VOLTAGE Touching uninsulated live parts inside the generator set and connected equipment can result in severe personal injury or death For your protection stand on a dry wooden platform or rubber insulating mat make sure your clothing and shoes are dry remove jewelry from your hands and use tools with insulated handles Secure protective covers when completing installation IMPROPER WIRING can cause fire or electric shock resulting in severe personal injury or death Accidental starting of the generator set can cause severe personal injury or death Do not connect the starting battery until instructed in Chapter 7 on page 49 AC Power Output Connections The generator set is equi
47. out wiring harnesses Stalling or rough running while the vehicle is in motion Locating the generator set in these limited access areas also affects proper maintenance Major engine damage due to lack of maintenance will not be covered under warranty 3 1 1 Typical Generator Set Locations Class A RV FIGURE 1 TYPICAL GENERATOR SET LOCATIONS CLASS A RV 16 A041D129 Issue 4 2 2015 3 Location Mounting and Ventilation 3 1 2 Typical Generator Set Locations Class C RV FIGURE 2 TYPICAL GENERATOR SET LOCATIONS CLASS C RV 3 1 3 Typical Generator Set Locations Class B Van FIGURE 3 TYPICAL GENERATOR SET LOCATIONS CLASS B VAN A041D129 Issue 4 17 3 Location Mounting and Ventilation 2 2015 3 1 4 3 2 3 2 1 3 2 2 18 Typical Generator Set Locations Pickup Truck Camper FIGURE 4 TYPICAL GENERATOR SET LOCATIONS PICKUP TRUCK CAMPER Mounting The generator set support structure must be designed and installed to support and restrain the dynamic weight of the generator set Failure to do so can result in the generator set dropping onto the roadway causing property damage severe personal injury or death Support the generator set on a structure able to resist the dynamic weight of the generator set 3 g force vertical and 1 g force horizontal See Section 2 5 on page 9 for the weight of the generator set See
48. pped with a circuit breaker and 3 2 m 126 in long 12 AWG leads for AC power output which exit through a rain tight 1 2 inch trade size conduit connector The leads can be terminated at the main AC distribution panel where individual breakers can be provided for vehicle trailer AC loads If longer AC cable is required or code stipulates a 4 x 4 inch junction box should be mounted near the generator set Use a weather type junction box if it is exposed to the elements When extending this cable use the proper size wire for amperage and insulation temperature rated wire typically 12 AWG to the main AC distribution panel The generator set is equipped with 126 inch 3 2 m long AC power output leads which exit through a 1 2 inch trade size conduit connector Figure 19 See Figure 20 for typical connections f these leads must be replaced by longer leads make sure their ampacity as determined by the appropriate chart in the National Electrical Code NEC is at least 115 percent of the amps marked on the genset circuit breaker Unless 125 C rated wiring is available heavier gauge wiring may be required to obtain the required ampacity FIGURE 19 AC OUTPUT CONDUIT A041D129 Issue 4 41 6 Electrical Connections 2 2015 6 1 1 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 2 Install vibration proof swi
49. quirement n MEER 51 APBPENDIXAACWIRING BIAGRAMS3A 02 E UR n S LER ERE TRE ra cen MA DASS aura la 53 FO OD IA MA s cec E RUM 55 APPENDIX Be QURINEDRAWINS Sosa a E 57 A Hr t ET D een css 59 E GEM APS matar ere e A EM UE Ee ede 60 B 2 Quiline Drawings Bloom Cut UL tee elucet IL EET 61 ii A041D129 Issue 4 1 Important Safety Instructions 1 1 Overview Thoroughly read the Operator Manual before operating the generator set It contains important instructions that should be followed during operation and maintenance Safe operation and top performance can only be achieved when equipment is properly operated and maintained The owners and operators of the generator set are solely responsible for its safe operation Generator set operation maintenance and installation must comply with all applicable local state and federal codes and regulations Electricity fuel exhaust moving parts and batteries present hazards which can result in severe personal injury or death Only trained and experienced personnel with knowledge of fuels electricity and machinery hazards should perform generator set installation or adjustment procedures or remove dismantle or dispose of the generator set 1 2 Warning Caution and Note Styles Used in This Manual The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator service personnel or equipment DANGER Indicates a hazardous situatio
50. r Generation for clarification Third party companies provide the fuel tank carbon canister and all related components with Executive Order EO certificates These products are allowed and the OEM is responsible to meet third party EO requirements The maximum fuel pump lift is 914 mm 36 in A041D129 Issue 4 2 2015 5 Fuel Connections e The generator set and propulsion engine fuel supply and return lines must not be interconnected Connections meet the requirements of the following SAE standards when applicable J1231 Formed Tube Ends for Hose Connections and Hose Fittings J1508 Hose Clamp Specifications J2260 Nonmetallic Fuel System Tubing with One or More Layers J2044 Quick Connector Specification for Liquid Fuel and Vapor Emissions Systems J2599 Fuel Filler Pipe Assembly Design Practice to Meet Low Evaporative Emission Requirements Terminate the generator set fuel pickup above the vehicle engine pickup in the supply tank to keep the generator set from running the vehicle out of fuel Connect 1 4 inch fuel line from the vehicle fuel tank to the generator set NOTICE Evaporative EVAP requires an additional fuel vapor line from the carbon canister to the generator set A041D129 Issue 4 31 5 Fuel Connections 2 2015 No Description No Description Carbon Canister 5 16 in Purge Hose Vapor 2 5 8 in Ve
51. set is not running Vapors are drawn into the engine combustion chamber and burned while the generator set is operating Use a Delphi carbon canister shown below No other carbon canisters are acceptable Part Number Description Onan Part Number 17208238 3 1 liters 196 g working capacity 0159 1755 17208262 3 3 liters 233 8 g working capacity 0159 1754 Mount the canister in one of three orientations shown in the figure below in accordance with its instructions NOTICE Use 1 inch hose for vapor lines Use an SAE J2044 quick connect fuel fitting on the canister hose barb or use a soap free lubricant such as WD40 to slip the hoses on the canister hose barbs Secure the hoses with Oetiker ear type clamps or equivalent Connect the 1 4 inch hose from the vent of the fuel tank identified as 1 4 inch Purge Hose Vapor to the 1 4 barb Canister Connection Connect the adjacent 5 16 inch hose barb on the canister to the generator set Do not vent the canister 5 8 inch line into the vehicle or other confined space where the vapors could accumulate to a flammable level Blockage of the canister vent or vent hose could lead to collapse of system components due to vacuum To prevent dirt from entering the canister vent when it is mounted in a dirty location connect the 5 8 inch hose barb to a hose terminated outside the living space of the vehicle at a location that is not exposed to road splash or dust Alternatively secure
52. tches 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 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 Faulty grounding can lead to fire and electrocution resulting in severe personal injury or death Grounding must be in accordance with applicable codes 6 Bond the generator set and all connected AC and DC equipment and controls to a common grounding point in accordance with applicable codes 6 1 2 Connecting to Shore Power Interconnecting the generator set and shore power can lead to electrocution of utility line workers equipment damage and fire Use an approved switching device to prevent interconnections A vehicle with provisions for connecting to utility power must have an approved device to keep the generator set and utility from being interconnected 42 A041D129 Issue 4 2 2015 6 Electrical Connections No Description No Description EE CA CIT TS PERA A mr ES FIGURE 20 TYPICAL CONNECTIONS WITH TRANSFER SWITCH AND UTILITY 6 2 Remote Control Connectio
53. the outline drawings in Appendix B on page 57 for mounting bolt hole locations TABLE 6 MOUNTING SCREWS Quantity UE NEN 5 16 18 NC bolts 26 Nm 20 ft lbs Below Floor Mounting Mounting kits are available for below floor mounting Follow the instructions in the kit Do not mount the generator set within the approach or departure angles of the vehicle or below the axle line Refer to Exhaust Connections Vehicle Clearances Class A RV Insulating Materials Acoustic thermal insulation and adhesive must be classified as Self Extinguishing at not less than 90 C 200 F Do not line the bottom of a compartment with insulation since it absorbs fuel and oil A041D129 Issue 4 2 2015 3 Location Mounting and Ventilation 3 2 3 Fire and Exhaust Barriers Exhaust gas and fire are deadly Install a vapor tight and fire resistant barrier of approved materials between the generator set and the vehicle interior Do not duct generator set cooling air into the vehicle for heating Barriers to provide vapor and fire resistance must be installed between the generator set and the interior of the vehicle if the generator set is mounted below the floor f the generator set is mounted in a compartment on the floor of the vehicle the entire compartment must be lined with vapor and fire resistive materials e Use approved materials 26 gauge galvanized steel or equivalent See NFPA 1192 for details Refer to local codes an
54. trocution and damage to equipment The generator set must not be connected to shore power or to any other source of electrical power An approved switching device must be used to prevent interconnections A041D129 Issue 4 3 1 Important Safety Instructions 2 2015 1 7 Live electrical equipment can cause electrocution 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 Engine Exhaust Carbon Monoxide Is Deadly Substances in exhaust gases have been identified by some state and federal agencies to cause cancer or reproductive toxicity Do not breathe in or come into contact with exhaust gases Carbon monoxide is a poisonous gas Inhalation of this gas can cause severe personal injury or death Adhere to the following bullet points to make sure carbon monoxide is not being inhaled by occupants of the vehicle as well as others working on or around the generator set Inspect for exhaust leaks and test and confirm that all carbon monoxide detectors are working in accordance with the manufacturer s instructions or owner s manual prior to every startup and after every 8 hours of running Never occupy the vehicle while the generator set is running unless the vehicle is equipped with a working carbon monoxide detector Never operate the generator set when the vehicle is in a confine
55. uel vapors are prevented from entering the vehicle rain and road debris are prevented from entering the generator set and ready access is afforded for operating the generator set and performing periodic maintenance 3 1 Location Typical locations for generator set installation are shown below The location must provide Ready access for starting and stopping the generator set and performing all periodic maintenance Separation from sources of flammable vapors such as batteries and fuel tanks which the generator set could ignite Access for connecting and disconnecting fuel lines battery cables remote control wiring and AC wiring Access to single fuel pump screw after removal of control board through service door Access from below for draining engine oil Unobstructed space below the generator set for proper cooling air flow The generator set must not share a compartment or ventilation with batteries or fuel tanks An operating generator set can ignite flammable vapors Make sure that in the first 305 mm 12 in of ground clearance there is at least 152 4 mm 6 in of unobstructed space below the generator set and open on at least three sides which is required for proper cooling air flow Locate or shield the generator set cooling air openings from direct rain road splash and debris thrown up by the road wheels NOTICE Mudflaps air ducts and deflectors must be used to prevent road debris and tire spr

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