McGraw-Edison Onan GenSet 3.ORDJA User manual

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SAFETY PRECAUTIONS
Thefollowingsymbolsinthismanualsignalpoten-
tiallydangerousconditionstotheoperatororequip-
ment.Readthismanualcarefully.Knowwhenthese
conditionscanexist.Then,takenecessarystepsto
protectpersonnelaswellasequipment.
WARNING I Onan'uses this symbol
* throughout this manual to
warn of possible serious personal injury.
This symbol refers to possible
equipment damage.
Donotworkonthisequipmentwhenmentallyor
physicallyfatigued.' .
Fuels, electricalequipment,batteries,exhaustgases
andmovingpartspresentpotentialhazardsthat
couldresultinserious,personalinjury.Takecare'in
followingtheserecommendedprocedures.
••Use ExtremeCautionNear Gasoline. A constant
potentialexplosiveor fire hazard exists.
Donotfillfueltankwithenginerunning.Donot
smokeoruseopenflameneartheunitorthefuel
.; tank.,
Besureallfuelsupplieshavea positiveshutoff
valve. • -
Thefuel supply and return lines must
be routed separately, and never tiedto-
gether with any'electrical wiring. Use
aflexible .section offuelline between
,' generator compartment and stationary re-
mote fuel tank in truck chassis. This
flexible section must-be 100%NON-MET-
ALLIC to prevent electrical current
^from using itasa conductor.
• Havea fire extinguishernearby.Be sure extin-
guisher isproperlymaintainedandbefamiliar
with itsproperuse. Extinguishers ratedABCby
the NFPA areappropriateforallapplications.
• GuardAgainst Electric Shock
Disconnectelectricpowerbeforeremovingpro-
tectiveshieldsortouchingelectricalequipment.
Userubberinsulativematsplacedondrywood
platformsoverfloorsthataremetalorconcrete
whenaroundelectricalequipment.Donotwear
dampclothing(particularlywetshoes)orallow
skinsurfacestpbedampwhenhandlingelectri-
calequipment.
r ,
Jewelryisa goodconductorofelectricityand
.shouldberemovedwhenworkingonelectrical
equipment.
DONOTPLUGMOBILE,PORTABLEOR'
STANDBYSETSDIRECTLYINTOA HOUSE
RECEPTACLETOPROVIDEEMERGENCY
POWER.Itispossibleforcurrentt'oflowfrom
generatorintotheutilityline.Thiscreatesex-
tremehazardstoanyoneworkingonlinestores-
torepower.
Useextremecautionwhenworkingonelectrical
components.Highvoltagescauseinjuryordeath.
Followallstateandlocalelectricalcodes.Have
allelectricalinstallationsperformedbya quali-
fiedlicensedelectrician. •''0'»,.
• DoNotSmokeWhile Servicing Batteries
Leadacidbatteriesemita'highlyexplosive
hydrogengasthatcanbeignitedbyelectrical
arcingorbysmoking.
• Exhaust Gases Are Toxic
Provide an adequate exhaus't'system to properly
expel discharged gases. Check exhaust system
regularly for leaks. Ensure that exhaust manifold's
are secure and not warped, -x-r.
Besuretheunitiswellventilated.Don'tusedis-
chargedcoolingairforcompartmentheating'
sinceitcouldcontainpoisonousexhaustgases.
• Keep The Unit AndSurroundingArea Clean
Removealloildeposits.Removeallunnecessary
greaseandoilfromtheunit.Accumulatedgrease
andoilcancauseoverheating-andsubsequent
.enginedamageandmaypresenta potentialfire
hazard.
DoNOTstoreanythinginthegeneratorcom-
partmentsuchasoiloVgascans,oilyrags,
chains,woodenblocks,etb.-Avfirecouldresultor
thegeneratorsetoperation(cooling,noiseand
vibration)maybeadverselyaffected.Keepthe
• compartmentfloorcleananddry.
Donotsteamcleanthegeneratorsetwhilethe
engineisrunning.Whehcleaning,donotspray
directlyintothegenerator,controlbox,orair
cleaner.,
•v
: r
• ProtectAgainst Moving Parts
Avoidmovingpartsofthe'unit.Loosejackets,-
shirtsorsleevesshouldnotbewornbecauseof
thedangerofbecomingcaughtinmovingparts.
Makesureallnutsandboltsare1secure.Keep
powershieldsandguardsinposition.
Ifadjustmentsmustbemade'whiietheunitis
running, us.eextremecautionaroundhotmani-
folds, movingparts,etc.
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TITLE PAGE
SafetyPrecautionsINSIDEFRONT COVER
.IntStfiWtelR^.^?* • •••
Pre-lnstallationInstructions -
Specifications 5
Compartment DISASSEMBLY • • • 6
Compartment and GenSetInstallation(Over-The-Rail Mount)?
'.COOLING SYSTEM. • 11
Exhaust System
Fuel System •'.15
Electrical Loads and Connections
18
RemoteStartingPanelInstallation 22
ConnectingGenSet To TruckBatteries 25

^ Introduction
This manual covers detailed installation
procedures andrecommended practices for
installing the Onan 3•ORDJA diesel powered
auxiliary generator setin sin "Over-The-
Rail" configuration ONLY, fysad through
theentire manualfor familiarity prior to
actually installing this generator set.
^.Thisnanual is arranged in a logical se-
quence of steps that should be followed
when performing the actual installation.
^Theremote control,muffler and exhaust
tubing, connectors and hardware required
for installation arepackagedin an acc-
essorykit suppliedwith eachset when
shipped. DoNOT proceed with the install-
ation if any items are missing.
Any items not supplied but required to
complete the installation are specified
and recommended where'appropriatethrough-,
out themanual. Some of theseitems will
be available in Optional kit formfrom
Onan. Allotheritems specified and re-
quired should be procured locally prior
to starting the actual installation.
Thisgenerator setis shippedfrom the
factory completely assembled within the
insulated compartment housing for pro-
tection duringshipping. Some housing
panels and internal compartment wiring
require disassembly prior to installing
the generator setin placeover the truck
frame rails.
WARNING
ONAN RECOMMENDS THAT GENERATORSET
INSTALLATIONANDALLSERVICEONLYBEDONE
BY PERSONSQUALIFIEDTOPERFORM ELECTRI-
CAL AND/OR MECHANICAL SERVICE. TOPREVENT
POSSIBLE INJURY AND/OR EQUIPMENTDAMAGE
ITISIMPERATIVE THAT THESERVICEPERSONBE
QUALIFIED.
IFITISNECESSARYTORELOCATEOR MODIFY ANY
MAJORTRUCKCHASSISCOMPONENTSSUCHAS
BATTERIES, TANKS,TOOLBOXESORANYOTHER
TRUCK ACCESSORIES, ALLWORK MUST BEPER-
FORMEDBYANEXPERIENCEDTRUCKDEALEROR
SERVICE PERSONONLY.THESE CONDITIONS
MUST BEIDENTIFIEDPRIORTOPERFORMINGANY
PARTOFTHEAUXILIARYGENERATORSETIN-
STALLATION.THECOMPLETEDINSTALLATION
MUST CONFORMTOFEDERAL MOTOR CARRIER
SAFETY REGULATIONS,TITLE49,PART393AND
FOLLOWTHERECOMMENDEDPRACTICESOFTHE
AMERICANTRUCKINGASSOCIATION MAIN-
TENANCECOUNCIL.

Pre^astollgtionInstructions
PRE-INSTALLATION EVALUATION
Eachtruckchassismustbeevaluatedandcertain_
measurementsmustbemadebytheinstallerpriorto
startinganyinstallation.Thesemeasurementsde--
terminewhetherthereissufficient,unobstructed
spacetopermitinstallationofthegeneratorsetcom-~
partmenta*wjM'h»"fuol tooU. intheirrecommended
locations..
fee-Tua/Sec"hv»u.^ . _, •,,•.„•
Thegeneratorsetsaredesignedprimarilyforinstall-
ationinClass7 or8 longhaultrucks.Exactcompart-
mentmountinglocationalonothetruckframerailwill
varybetweendifferent^^fwe?itiena4-truckmakesand
models.
Incafl'-^v^rei^tfi-e*T9P^ttrucks<,for"Over-the-Rail"
installations,a locationas4^«6t-w¥pd^Sw.a«iback
walloftruckcabismostsuitableforpurposesof
betteraxleweightdistribution.SeeFigure2.
Distance"X"listedinTable1,whenmeasuringfor
installation.MUSTbemaintainedtoallowforany
truckmaneuverinordertoproceedwithanyOvar-
the-Rai! installation.Referencejiki&l&a-f+e^.when
measuringdistance"X".P.jjur-s.i_
KINGPIN
4INCHMINGENSET-TO-TRAILEB
CORNERCLEARANCE
TOPVIEWOFTRUCK
J-lijOrC-l^
t
4? O)( O
to
41& net tC"r*v*d
as AH
ffl1 zo
JO?-" W,^
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^COMPARTMENT SIZE ANDLOCATION
•Designvariablesintruckwheelbaseandcab
stylesmayrequirerelocationofbatteries,tool
~"boxes,etc.,tomakeroomforthegeneratorset
Somedegreeofmodificationandpossiblyrelo-
catingsomeofthesechassisComponentsmaybe.
necessarytoprovidethephysicalspace(length)
requiredtoproceedwiththeinstallationofthe
generatorcompartment.
~If It Is necessary to relocate or
modify any major truck chassis
WARNING
>A minimumverticalclearanceof1/2inchmustbe
maintainedbetweenthegeneratorsethousing
baseplate(whereinstalledovertruckframerails)
andanypermanenttruckchassiscomponent
underneathgeneratorsetcompartment.Spacers
shouldnotbeusedtoobtainthisclearance..
Housingbaseplatecanbemovedhorizontallyto
obtainthisclearanceaslongasminimumspace
(23-3/4inches)isNOTreduced.Housing
baseplatemustrestontruckframerails
wheninstalledasshowninFigure3>
components such as batteries, tanks or tool
boxes or any other truck accessories, all work
must be performed by an experienced truck
dealer or service person only. These conditions
must be identified prior to performing any part ol
the auxiliary generator set installation. The
completed installation must conform to Federal
Motor Carrier Safety Regulation, Title 49. Part
393 and follow the recommended practices ofthe
American Trucking Association Maintenance
Council.
Thephysicalsize(primarilydepth)ofthe
generatorcompartmentrequiresa MININUM,
UNOBSTRUCTEDOPENSPACEof23-3/4inches
parallelto(lengthwise)thetruckframerails
directlybehindthecab.Measurealongtheframe
railsinthedesiredmountinglocationtoverify
thisspaceisavailable.SeeFigure3forminimum
over-allinstallationdimensions.
I.SO—i
(REAR HOUSING PANEL)
23.75 — -
©3.38-
-— -v^v-
T-r.»
I-
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J.
is
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11
11
11
11
J—?
1\ 11
11
1.11
;1 1
1/ 1
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11
11
3.62
r-T75

he SI
metricequivalents are printed In parenthesisimmediatelyfollowing
theU.S.customaryunit of measure
\ 0/
COMPARTMENT SIZE
Height(Without Muffler) 31-38 in. (797inm)
Width 34.00 in. (8631™)
. Depth... 0 0 23.75 in. (603mjnj
Approximateweight including compartment 560 lbs. U.54kg)
Starting System Voltage //V * * \*\12~volts
130
Battery Ground C&V'f?^ .^ffVn^. P&b'firfJj Negative Ground Standard
.Starting System c ..«. .« Motorized Alternator Cranking
CrankingCurrent 300Amperes
Break-away Current (Maximum) • . 4-75Amperes
Fuel Diesel
demote Kael Tank G-jTpacity •rv.~y<T\ ^K^-G^llonsi^J-L)
rengt-fi .\ / /../.. .\/"'\/ 2VF1' (^9mm) )
"4Vjru
V 7 ' '
.\.........V / l<5.feo in. ^393nAi)
.^in^Ci^Qsim)
^e^th . . • • rv'. •..««...••«••«. V^-^-^. • • • • ... • r>^-. ...••o.. • >-.-^-^.. • 7
Fuel Pump Mechanical
Fuel Return and Supply line ConnectionSize SAE-4 370Flare
-NOTE: Refer to auxiliary generator set Operator's manualfor completeengine-
generator specifications.
0Q. U)tV<. >• XJO orcvi^*
7#-

ment wiring, require disassembly, prior to
insialling. thegenerator seVin place over
thetruck frame rails to .simplify the
mounting plate and wiring connections to
thetruckchassi:
Proceed as follows!
1. Eemove the/cpmpartment front.cover
. •' by releasing the rubber straps on/
•top apd then-lift cover up and^out
froprietents on bottom of front
a-hel. .
Remove thetop compartment panel by
removing eight5/l6-l8/x 3/4 inch hex
head capscrews aroundrthetophousing
perimeter as shown in Figure 4.
Remove the four 5/16-18 x 3/4 inch hex
head capscrews which secure the left
side housing pdriel to the rear(back)
panel of the/compartment as shown in
Figure 4."
resu/f \l the baseplate shouiti tail oil fra.'mj ran*,
during the installation procedure.
Remove the ..four 5/16-I 8 x 3/4 inch hex
.head capscrews which secure the right
' side housingpanel tothe rear(back)
panel ofthe compartment as shown in
Figure 4.•'
NOTE: • Left/and right sides are- determined
While facing the hinged front covery.of the
generator/set. / •
/' /
4. 'Remove the two 1/4-20 x 5/8 inch hex
head capscrews on the ex'terior of the
rear(back)housing panel which secure
the compartment fan/assembly to the
rear(back)panel as/shown in Figure 4.
These, two bo Its .-are 5-7/8 inches in
(to center)from left rear corner o£
.the compartment. . yy
5. Unplug the/fan assembly AC"cord andthe
water solenoid AC cord from-theduplex
receptacle ontopof the, generator end
ofthe^setinside the^ho'using.
6. Remove the three 3/8-16 x 3/4 inch hex
head capscrews thathold the left side
panel tothe mounting tray as shown^irT
• yFigure4./. Set'this panel aside^for now.
Use an appropriately sized chain or
. portable hoist with chain ihserted
... through/the lifting eye^on top of
engine/to position the/generator set
"in^iace" over the truck frame rails
in/the desired mounting location and
. check for adequa^/clearance(over-all
/compartment dimensions, are shown in/ .
Figure 3j, / . - / '
"WARNING certain that housing base-
'plate Is adequately/supported
9. Remove thetwo 3/8-16 x 3/4 inch hex
head capscrews and ..the single (front) v..'.
3/8-16 x l-3/4^i-rich hex head capscrew', -
• that hold ^e^right side panel to .the V
mounting-"tray as shown in Figure . 4. •
carefully . lift and place this panel
;«vV,
'
on top of the generator set for now. '
NOTE: This panel will be reassembled-
after mounting':clamps and truck battery,'/'.''
cables have been installed. •. .•, :t
r
7.
6

Compartment DISASSEMBLY and Installation
._CAUTION: DoNOTdisconnectorremovethe
A-bvL
AC duPlex«ceptacle
internal wiring or
r ^ theexternalcoverand gasket installedm
^£^toc>oe.j^ji*p^^^ topcenterof right sidehousingpanel.
^-k^Z,d^jflMsg^A.p*Yop*iM~NOTE: Removalofrear(back)panel-isNOT
- J ) • i / jT, • ,1cv/11> requiredforinstallationofthegenerator
S^ed hon-f (^set taet^lvf<x^r)x 560/bp^

^fc.)Rc--fgcj. DON*Vale, c-k^cjc-^ov-yproye^
Jdtkfc5:assemble_
requirednumberofspacerstoallfourmounting
clampsusing5/16-18x 1-1/2inchalienheadcap-
screwsand5.'16locknutsprovidedTorquenuts
tci15footpounds(20N«m).SeeFiguref.Top"
spacerhasrecessedmountingholetoaccept_
specialalienheadcapscrews.
.... Temporarilyholdonemountingclampinpositior
(insidefromunderneath)againsttopframerail
— flangeoftruckasshowninFigured.Determine
thenumberof1/4inchand/or1/16inchthick
spacers(inanycombinationNOTtoexceed3/4
_ inchpermountingclamp)requiredtofillanygap
betweenbaseplateandmountingclampunder
" baseplate.Thesespacersarenecessaryto bal-
anceouttheleverageofeachmountingclamp«
" Totalthickness"
Choose anytwoof"ten possible pairs
of pre-drilledmounting holes(per side)
that doNOT interfere with any exist-
ing chassis hardware, frame cross mem-
bers orany other chassis components
(underneath baseplatgV '•—
"of spacers used must match truck frame
rail flange thickness under each of.
thefourmounting clamps. Usethe same
combination and number of spacers with
each ofthefourmounting brackets.
_r* "fkisrlt-.hjtXj
lnstallAfourmountingclampswithspacers
neepnTFercfytwooneachsideundertopflangeof
truckframerails(•fafflmrrrtsid'e£IrSEi3Q322S£tSiusing•
1/2-13 x 2 inchhexheadcapscrewsandtwo
special1'2inchconicalwashersoneachcap-
screwpositionedasshowninFigureS^bfitaSE^'
Tightenalleightcapscrewsuntilconicalwashers
areflat(approximately10-20footpounds-13.5
-27N»m).DoNOTover-torque.
.COHI
* PLACES
(ZEACMSlOe)

Compartment and GenSet Installation
OVER-THE-RAIL MOUNT ONLY
After generatorsetis positioned properly A Mrmn+i,fr ^ v,
on truck frame -rails andmininumclearances ' * flanPS have weldnutsto simplify
have heen checked,mounting tray must be installation. These special washers deter-
securely clampedto truck frame rails using ^"LI
cofrect
^ountofclamping force
blamps,spacersandhardware supplied in ? bearir? surfaces ofj^e^jnounting
the unit accessorypackage.Proceed as %^M^1: '
follows:
1.
COMPARTMENT ASSEMBLY
-^oneach side of
truck.(4 mountingclamps total).
2./
3. The humber ofspacersused will vary
depending upon the thickness ofthe
truck frame rails. ^—
1..."
Do NOT exceedthe 3/4 inch maximum sp-
acer thickness foreachclamp. See
Figure 4 and detail A.NOTE:The longer right front housing bolt
(3/8-46 x 1-3/4 inches)andhardwareis left
4. Remove housingmountingclampand/ . out until the battery cablesare installed.
See Page , Step , shown in Figure
2. t
Capscrews
_ _ .— are inserted from exterior side of rear
panel (near corner)through flange of
side panelwhich contains self-cinching
nuts on inside of rear panel as required.
See Figure 4^^" ~'" ~
3.

e
T0L
1/
After tne generator setis installed onthe
truck chassis, the'compartment housing can
be partially assembled and wired.as follows:
X-BFT-LIW>
2.Position the coiopartment interior exha
shield in the upper right rearcorner
around the generator set exhaustpipe.
Line up mountingholes and secureusing
1/4-20x 5/8 inch hex headcapscrews
supplied in accessory package. Capscrews
are inserted from exterior side ofthe
compartment into self-cinching nuts that
arealready positioned onthe shield.
-Torque at? foot pounds(9N'M)• See
Figure
Install threaded endof9-1/4 inch
flexible exhausttube(supplied in
accessorypackage)intogenerator set
exhaustpipe elbowinupper right rear-
corner of compartment as shown inFig-
ure_JSZ Tightensecurely.
NOTE:
The left hand side ofthe compartment
housing canbe installedafterall AC
and DC wiring is completed inside the
generator set control panel and through
the rearpanel of compartment housing
as outlined inthe Electrical Loads
and ConnectionsSection.
Replacethe right hand sidepanel of
- the compartment housing by installing
_ tsre5?-3/8-l6 x 3/4 inch hex headcapscrews
i n-*^e-^*40.ro^(^te33=^^
-securepanel tothe mounting tray. See
_Figure"7. Torque all 3/8 inch capscrews
at 25 foot jounds(34N'M).
Install the-four 5/16-I8 x 3/4 inch hex
. headcapscrews whichsecure the right
hand sidepanel tothe rear(back)panel
"ofthe compartment housing. /
'^ Torque~cnese bolts at
15 foot pounds(20N•M).
^-f-e^M Water-tight 3/4 inch metal strain
relief connectors(supplied by customer)
should be installed in thetwo l^i^inch
diameterholes in the lower right hand
corner of the rear(back)panel at this
time.- See FigureBatterycables
are installed throughtheseconnectors
later but for ease of installation, the
connectorsshould be installedprior to
reassembling the compartment housing.
Determine wbrylni knockouts^.n the rear
(back)panel of the housing will be »»e^ f>jhb/<
for the ex ternal'^lo amp AC load circuits^ *»Ji ~r*d
/>V1<ULwe.-IWt. CA.\O
J=...... 9 (RE.*"H"

iLt^iarf^iS^. : _
Install
a3A inch water-tightstrain relief .
connectorm -^nass hole^outdonot
tighten yet.
Removeselectedknockoutsinrear("back)
paneland install -^^o-rl/2 inch water-
tight strain.reliefconnectorsasre-
quired^to^'eaT wiring and cables butdc
not tightenyet.
"7
_/

^U-'V-C== = —=
GENERAL WIRING RECOMMENDATIONS
Wfpifigharnessesforkitereonnection-oftheauxiliary
g^ptep^tors^to^e^.ch/1'individualAC
lQ£djj>rpuit/ariargnpotest.ar-t-ipanelmustberabTP)
cai^a^p'dhandwireddaringthe-instalJ^tidrhortbe
generatorset.
WARNING Installation of all wiring must con-
form to all applicable codes and fol-
low National Electrical Code standards and recom-
mended practices. A qualified electrician should
Inspect all wiring.
•Usemultistrandwirethroughoutthetruckduring
installation.Specificsizesformainfeeder con-
ductorsandindividualACloadcircuitwiringare
specified(whererequired)inthissectionofthe
installationguide.Allwiringmustbeofadequate
size, properlyinsulated,andsupportedinan
approvedmanner.Observeallwiringsizere-
commendationsandamperagespecifications
wherelisted.DoNOTspliceanyMinng^^Lki&xaaia^
A€=feedefccondcictoirs,r
Do WOT use so//d metal con-
ductors anywhere In this Instal-
lation. They may develop metal fatigue from
vibration and eventually break.
Mount all switches and controls securely to pre-
vent damage from vibration and road shock. All
switches must be vibration-proof to prevent
accidental opening or closing while the truck is in
motion. A/© /viarcu^ij or Yiie*f*t-JittUa
RouteallACandDCwiringalongtheinsideofthe
truckframerailswherepossible.Keepawayfrom
rotatingormovingshaftsandlinkagesofthe
truck.Useinsulatedhold-downclampsspaced
approximatelyevery18inchesandcloserto-
getherinbendsornearhighheatsources.Plastic
tiewrapscanbeusedinbetweenheavierinsu
latedclamps.Useadditionalprotectivesleevinc
(suchasheaterhose)overwiringwherever
crossesoverframerailsorinsharpbends.Any
existingholesintruckcrosssuportfram >
membersusedforroutingofwiringshouldbp
grommetedtoprotectwiring.
CAUTION \ DoNOTdrillBiyzddWonalnew
L^^^^^J,holes In the truck frame rails or
cross-support frame members for routing wiring
through. Any existing holes used for routing of
wiring should be protected with grommets.
Use water-tight strain relief connectors (1/2 inch
or3/4 inch) whenever wiring passes through any
exterior panel, cabwallor truck-cab
compartment. Use Romex, connectors asfowL
interior wiring/^s^thro^h cabwall*
partitions, panels or shelves.
LOAD CIRC I
RECOMMEN "*
Onanrecommendsusing
conductor(typeSO)neoprene-jacke"te"dmuTtr-"
strandwireratedat600volts,AC90oCooeration
forall20-ampcircuitssuchas
sleeper cab air conditioners. Most other
truck chassis starting aids such as lube oil heat-
ers, battery heaters, electric cab heaters, etc
should use 14-gauge, 3-conductor (type SO)
neoprene-jacketed multistrand wire rated at 600
volts AC, 90oCoperation for these IS-amo cir-
cuits. Romex connectors must be used in set
control panel knock-outs to secure wiring. Some
•slack should be allowed in wiring for movemerr.
caused by vibration to prevent breakage. -E^africsa'
Gennec-tors-must-be-used-on-load-wiTing'co'nnec='
tion s-at-15-amp-ei rcuiWbr-eak-erSTto-safe-lysecare
w+img«Gonnection s-beca tFse-of^size. "
WARNING
WARNING 1 Do NOT tie any electrical wiring
to the fuel or hydraulic tines of
the truck because of fire hazard. Keep all wirin
away from the exhaust pipe.
WARNING All holes to the Inside of the truck
cab must be sealed to prevent poi-
sonous qxhaust gases from entering the interior or a
storage compartment. Use water tight strain reliefs
(1/2 inch or 3/4 inch) or silicone rubber sealant to seal
around all openings made for electrical wiring.
Do NOT use Poly-vinyl-chloride
type wire on any AC or DC load or
control circuit wiring In this application. Overloading
this type of wire causes a chlorine gas emission
which creates a poisonous hydrochloric acid con-
dition.
•O-n-an-recommerrds-asing-l^gauge—3-corrdtrctor"
(type—SO-)—aeoprene-jacketed—aw ft istrand—wir e <
rated-at-eoO-vol-ts-AerSO^e-operatiomfof^a^ 15-
amp-circuits-such-as-AG-duplex-receptacles-€<
otbe£-accessor.yJoads-no,t-to-excee d -XS-arops^"
Rome^-aDnTTe&tofs^.usUDe_used4n-se.t-Gon-tr.oi
-panehknock^outs-ta-secare~wrrirfg—Some-sfack—
SiiQuLcLhe-a11owed-irvwk \ n§4of-movementcatrs'ed
by-vi-brati-o-n-taprevent-break-age^SarxeLccLanfi.c^-
o ts_mus-t-be-usechorrfoa-d~wrring-conrredrcms-at
ys^amp-eirctiit-break-ers-1o-sa fe Iy-secure-wiriptg
cofl-rvectiorrs-because-of-s i ze^-Grou rvd-f a u11•c-ketH-t
bfee-ker-does-rrot-require-barfel-GonnectoF*.
ubricateTKewireouterjacketwithliquidsoap,motoroilor
othersuitablematerialtoaidinassemblyofstrainrelief
connectors. "•9

G 3-
MOUNTINGREMOTEPANEL
Aremotecontrolpanelisprovidedwhichallowsthe
drivertostartthegeneratorsetfromwithinthecab"
areaofthe.truck.Thepanelcontainsstart-stopand
;<preheat" rockerswitches,runningtimemeter,
buzzeralarmandoneACduplexreceptacle.
-.Cffl^^C dA-ki.I _ \\ _ II1 . I.....J
4U
.0*1.
be. Ofctd U^VMTC

OoviWfie.4o K^g//c
3_. P0_v^rt_4r/:fc_ J:o_£i>JL_LJlk4A-
-Q<
J.- U-^efea^-L^l^-yLco>A»v<.CT''&V"/
-6^1-
WARNING \ ^^ttlSiesJeadlng to thejnslde of
-.....-••.•.-rwraaJ thetruck cabifSFSfecirlcal wi'r-
theOwcks^^rlif^irlcal wir-
ing mustrbe-sealeiiFto prevent poisonous exhaust
gases from entering the cab Interior.
CoJo-n.^aeo^t.Bgaaiso.
f?, V\^1Q>V oWtg.-hpsfcoc*^
4Uc-bi
WARNING Do NOT Install remote starting
panel without the remote control
box housing. A potential shock hazard
exists because of the exposed terminals of the AC
receptacle.
Remote cable I* NOT supplied due to variation In length
requirement between truck makes and models. Color coded
bulk cable (6-conduclor, 16-gauge type SO multistrand wire In
aneoprene jacket) Is available from Onan aspart of the separ-
ate optional ' ._pontrol wiring kit referenced in the
beginning of the Electrical Loads and Connections section.
This kit Includes all necessary wiring and hard-
ware to Interconnect the remote starling panel (with duplex
receptacle) to the generator set control
panel. Step-by-step Installation Instructions ^provided with
each kit, FJ-K<-
CAUTION Do NOT use so//d wire or wire
smaller than 16-gauge in size. Solid
wire will fatigue due to vibration and break. Wire
smallerthan 16-gauge will result Inpoor starting from
remote panel and short service life.
GENSET
TerminalNo.!;
i
REMOTEPANEL/•
7TerminalNo. cmcuiT
\FUNCTION WftlNCCOLOR CODE
GENSET
TerminalNo.!;
i 7*. Ground White
2 Stop Red
3 3 Start Green
« 9- RemoteAlarm
Signnl Orange
5 Diesel
Preheat
Blue
i
8 RunningTime
MeterandSw.tchSt
IntegralRunningLight
Black
FIGURE£,REMOTESTARTINGPANELINSTALLATION.
1/SINCH
CONNECTORS
REMOTECONTROLBOX
TT
ACDUPLEX
RECEPTACLE
II
15FOOT.3-CONOUCTOR.
14-GAUGE(TYPESO)
ACCABLE

RemoteStartingPanelInstallation
MOUNTINGRE!
Aremotecontrol pe
driver to startthe g
area of the.truck. Th
fpreheat " rocker
IOTE PANEL
iel is providedwhichallowsthe
leratorsetfromwithinthe cab
kpanelcontainsstart-stopand
'itches,runningtimemeter,
buzzeralarmandoneACduplexreceptacle.
Remotepanelhasthree1/16inchmountingholes in
bottompanel for shelfmounting andtwo7/8 inch
holes in backpanel forDK controlharnessand AC
supplyconductorforreceptacle.Use14-20screwsof
suitablelength to securel\boltpanel in desired
location.
Exactlocation of remotepanelvariesWcordlng to ownerprefer-
enceandsetlocationaswellastypeofftuck chassis.Remotepanel
isusuallylocatedneardriver'sseat iiacaborina convenient
locationwithinsleepercab.Generator wt canbestarted at com-
partmentlocation if desired.HousinAfrontcovermust
beremoved for access tos\t control
CONNECTINGREMOTEPAINELTO
GENERATORSET
A 6-conductor, 16-gauge (typeSlD) neoprene-
jacketedmultistrand wire cableisrequiredfor
connectingthe. remotecontrolStarting'
paneltothe generator setcontrolpanel.
Thecablemustbefabricated,duringthe
installation, cuttorequiredlengthand
hand wired, totheremoteterminalA)lock
insidetheremotepanelandinside\he
generator setcontrolpanel.RingiWpe
terminalsshouldbe used toconnectqpmote
cabletoterminalblocksinsideboth
controls.
RoutetheDCcontrolcablealongthein3
side ofthetruckframerailswhere
possible.
Securecableevery18inchesalongtherun^vith
insulatedhold-downclamps(closertooeffher in
bends or nearhighheatsources).Us^nylon tie
wrapsasrequired in between cia
Someslackshouldbeallowed In v^mg for movementfrom
vibration ,
A 1/2inch straiiyfcliefconnectororRomex
connectorshould be used onDC cablewhere
cableentersremote)anel.Remotepanellocation
andmethodofynounting(wall or shelf)deter-
mineswhichconnector to use.SeeFigure
Oncab-over^enginetypetruckchassis,allrouting of
anywiring,regardless of type or functionMUST be
longenoughandrouted in suchfashionthatraising
andlowering of cab for access to enginewill NOT
interferewithwiring.Allowslackatthenose(hinged
point) of thecab for raisingcabasrequired.
Refer to interconnectionwiringdiagramshown in
Figure _ andremotepanelwirinqconnections
according to circuitfunction,terminalblock no.
andsuggestedcolorcodeillustratedinHgure (see
chart). UseHeycostrainreliefsorRomexconnectors
•>ncablewhenroutingthrougj^erffryholes in remote
panel to securewiringappealanyentryholes.
All holes leading to the Inside of the
truck cab for electrical wiring must
be^dSled to prevent poisonous exhaust gases from
terlng the cab Interior.
21

NEUTRAL
GENSET
Terminal No.L
i
REMOTEPANEL //?
JTerminal N/.
\ CIRCUIT
1 VUNCTION
WIRING COLOR
CODE
GENSET
Terminal No.L
i /
/
Vjround White
2
StSc
Red
3 Start
\
Green
4
/^•
RemoteAlarm \
Signal *
Orange
5 /
Diesel
Preheat
\Blue
6X
4 RunningTime
Meter and Switch SI
IntegralRunningLight
VJIack
15FOOT.3-CONDUCTOR.
14-GAUGE(TYPE SO)
ACCABLE
FIGURE REMOTESTARTINGPANELINSTALLATU
73

MCbR UU-EDISOIU
InstaBlatioii
Guide
3.0RDJA P/BSEL
MM
GenSet
•AuxHjaryPowerGenerators
ForTmcks
OverTlieRailrvlounti^Cr/
IMPORTANT
Read Through Entire Installation Guide
Prior To Actual Installation
974-0625
4-82
r'ftmeoin U.S.A.