Onan 12.0 RDJC Series User manual

Onon
INSTALLATIONGUIDE
FOR
12.0 RDJC, RV DIESELSERIES
ELECTRIC GENERATING SETS
974-0610
Printed inU.S.A.'
JUNE 1980

I i
SAFETY PRECAUTIONS
Thefollowingsymbolsinthismanualsignalpoten-
tiallydangerousconditionstotheoperatororequip-
ment.Readthismanualcarefully.Knowwhenthese
conditionscanexist.Then,takenecessarystepsto
protectpersonnelaswellasequipment.
WARNINGlOnanusesthissymbol
~~,,~,,,~Jthroughoutthismanualto
warnofpossibleseriouspersonalinjury.
Thissymbolreferstopossible
equipmentdamage.
Fuels, electricalequipment,batteries,exhaustgases
andmovingpartspresentpotentialhazardsthatcould
resultinserious,personalinjury.Takecareinfollow-
ingtheserecommendedprocedures.
•UseExtremeCautionNearFuel.A constant
potentialexplosiveorfirehazardexists.
Donotfillfueltanknearunitwithenginerunning.
Donotsmokeoruseopenflameneartheunitor
thefueltank.
Besureallfuelsupplieshavea positiveshutoff
valve.
Usesteelfuellines,adequatelysecuredandfree
ofleaks.Usea flexiblesectionoffuellinebe-
tweengeneratorsetandstationaryfuellineinthe
vehicle.Thisflexiblesectionmustbe100%NON-
METALLICtopreventelectricalcurrentsfrom
usingitasa conductor.
Havea fireextinguishernearby.Besureex-
tinguisherisproperlymaintainedandbefamiliar
withitsproperuse.ExtinguishersratedABCby
theNFPAareappropriateforallapplications.
Consultthelocalfiredepartmentforthecorrect
typeofextinguisherforvariousapplications.
•GuardAgainstElectricShock
Removeelectricpowerbeforeremovingprotec-
tiveshieldsortouchingelectricalequipment.Use
rubberinsulativematsplacedondrywoodplat-
formsoverfloorsthataremetalorconcretewhen
aroundelectricalequipment.Donotweardamp
clothing(particularlywetshoes)orallowskin
surfacestobedampwhenhandlingelectrical
equipment.
Jewelryisa goodconductorofelectricityand
shouldberemovedwhenworkingonelectrical
equipment.
Alwaysuseanappropriatelysized,approved
double-throwtransferswitchwithanystandby
generatorset.DONOTPLUGPORTABLEOR
STANDBYSETSDIRECTLYINTOA HOUSE
RECEPTACLETOPROVIDEEMERGENCY
POWER.Itispossibleforcurrenttoflowfrom
generatorintotheutilityline.Thiscreatesex-
tremehazardstoanyoneworkingonlinesto
restorepower.
Useextremecautionwhenworkingonelectrical
components.Highvoltagescauseinjuryordeath.
Followallstateandlocalelectricalcodes.Haveall
electricalinstallationsperformedbya qualified
licensedelectrician.
•DoNotSmokeWhileServicingBatteries
Leadacidbatteriesemita highlyexplosive
hydrogengasthatcanbeignitedbyelectrical
arcingorbysmoking.
•ExhaustGasesAreToxic
Provideanadequateexhaustsystemtoproperly
expeldischargedgases.Checkexhaustsystem
regularlyforleaks.Ensurethatexhaustmanifolds
aresecureandnotwarped.
Besuretheunitiswellventilated.
•KeepTheUnitAndSurroundingAreaClean
Removealloildeposits.Removeallunnecessary
greaseandoilfromtheunit.Accumulatedgrease
andoilcancauseoverheatingandsubsequent
enginedamageandmaypresenta potentialfire
hazard.
DoNOTstoreanythinginthegeneratorcompart-
mentsuchasoilcans,oilyrags,chains,wooden
blocksetc.A firecouldresultorthegeneratorset
operationmaybeadverselyaffected.Keepthe
floorcleananddry.
•ProtectAgainstMovingParts
Avoidmovingpartsoftheunit.Loosejackets,
shirtsorsleevesshouldnotbepermittedbecause
ofthedangerofbecomingcaughtinmoving
parts.
Makesureallnutsandboltsaresecure.Keep
powershieldsandguardsinposition.
Ifadjustmentsmustbemadewhiletheunitis
running, useextremecautionaroundhot
manifolds,movingparts,etc.
Donotworkonthisequipmentwhenmentallyor
physicallyfatigued.

TABLE OF CONTENTS
TITLEPAGE
INTRODUCTION2
GENERALSPECIFICATIONS3
PRE-STARTCHECKS4
COMPARTMENTSIZEANDLOCATION6
VENTILATIONANDACOUSTICS7
FUELSYSTEM8
EXHAUSTSYSTEM9
ELECTRICALLOADSANDCONNECTIONS10
BATTERIES13
WARNING
TO PREVENT FIRE OR ACCIDENT HAZARD . . .
THIS UNIT MUST BE INSTALLED ACCORDING
TO THE MANUFACTURER'S DETAILED IN-
STALLATION PROCEDURES OBSERVING ALL
MINIMUM CLEARANCES.
TO AVOID POSSIBLE PERSONAL INJURY OR
EQUIPMENT DAMAGE, ANY INSTALLATION
AND ALL SERVICE MUST BE PERFORMED BY
QUALIFIED PERSONNEL.

INTRODUCTION
This manualcoversdetailedinstallationprocedures
forthe_ULListed/Onanmodel12.0 RDJC-3CR
recreationalvehicleelectricgeneratingset. Each
Onan RVelectricgeneratingsetMUSTbeinstalled
properlyifitistooperatereliably,quietlyandmost
important safely,eventhoughthesetitselfmeetsor
exceeds allListingRequirements.BeingListed
means thiselectricgeneratingsetmeetsorexceeds
allrequirementsofANSI/NFPA501C-1977Chapter4
(Electrical Systems)andChapter5 (FireandLife
Safety)and ANSI/RVIA-EG1-1976as wellasUL Sub-
ject 1248.
AllRVinstallationsMUSTcomply with thesespecifi-
cations aswellasArticleS51,ANSIC1-1975/NFPA
No. 70-1978 ofthe National ElectricalCode.TheRV
Manufacturerand/orthegeneratorsetinstaller
MUSTcomply with above codes andanylocalcodes
which pertaintothegeneratorsetinstallation.
This manualprovidesdetailedinstallationguidelines
forthisOnanmodelONLY.Foroperationandmain-
tenance procedures,refertotheindividualOpera-
tor's Manual which accompanies each set. TheOper-
ator's manualis #974-0124.
AIRCLEANER
ELEMENT(INSIDE)
FUEL
INLET
AIRRESTRICTION
INDICATOR
EXHAUST
MUFFLER
FUELSEDIMENT
BOWL
GENERATOR
GENERATOR
AIRINLET
OUCT
ACJUNCTION
BOX
LOADCIRCUIT
PROTECTORS PRE-HEAT
SWITCH
AIROUTLETDUCT
(THROUGHBASEPLATE)
START-STOP
SWITCH
REMOTESTART-
STOPTERMINAL
BLOCK(INSIDE)
CONTROL
BOX
FIGURE 1. TYPICAL RDJC FOR RECREATIONAL VEHICLES

GENERAL SPECIFICATIONS
ENGINE
Onanverticalinline4-cylinder,4-cycle,watercooled,dieselfueledengine
rated26.5bhpat1800rpm.Remotestart,negativeground,12-volt,solenoid
shiftstarter.Preheatswitch(glowplugsandmanifoldheater).
ALTERNATOR
Onan-built,four-pole,revolvingfieldpermanentlyalignedtoengine.Genera-
torproduces120/240volts,52ampseachleg,60hertz,singlephaseAC,
12,000wattoutput.
CONTROL
Shockmountedcontrolfeaturingchargerateammeter,fusedbatterycharg-
ingandStartStopcontrolswithremotestartcapability.
RV ELECTRIC GENERATING SET
Somegeneralspecificationsarelistedbelowforreferencepurposes.
SPECIFICATIONS
Height28.50in.(724mm)
Length43.0in.(1092mm)
Width44.0in.(1118mm)
Weight(Approx)1100lbs.(499kg)
AirRequirements
Total(CFM)Approx.2250(637.2m3/min)
FuelInletConnection
Size1/4"InvertedFlare
RecomendedFuel#1or#2Diesel
BatteryVoltage12Volts
BatteryAMP-HR
Minimum(2)SAEGroup2D-560ColdCrankingAmps
BatteryGroundNegative
RPM(Atratedload60Hz)1800
NOTE: Metricvaluesareshowninparentheses.

PRE-START CHECKS
ThisRVgeneratorsetiscompletelyassembledas
receivedexceptforsparkarresterandanyoptional
accessoryitemsshippedloosewitheachsetfor
installationlater.Aftertheinitialinstallationiscom-
pletedthefollowingstepsarenecessarybefore actu-
allystartingthegeneratorsetforthefirsttime.
1. Installtheexhaustsystem.
2. Addoiltotheengine.
3.Connectfuellineandreturnlinetoenginefrom
fuelsupplytank.
4. ConnectACloadcircuits.
5.Connectthestartstopremoteswitches.
6.Connectbatteryleadsbetweensetandbattery.
Connectgroundleadlast.
7.Fillradiatorwithcoolant.
Vehiclechassis(frame)groundandthebatteryandgenerator
setgroundshouldallbeelectricallyconnectedtobeat0
groundpotential.AllOnanunitsaredesignedfornegative
groundapplication.
WARNING Donotsmokewhileservicingbatteries.
Leadacidbatteriesgiveoffexplosive
gaseswhilebeingcharged.
FUEL SYSTEM
Withsetrunning,checkforleaks.Checkaround
injectorandfuelpumpinletsforanyleaks.Makesure
fuellinesarenotrubbingagainstanythingwhich
couldcausebreakage.RefertoFuelSystemSection.
ELECTRICAL
AC Output
AllACleads(Tl,T2,T3,andT4)terminateatthemain
circuitbreakeringeneratorset'sjunctionbox.Gen-
eratormaincircuitbreakerloadwiringshouldbe
connectedtodistributionboxwithmultistandwire
enclosedinaflexibleconduit.Checkallwires(toand
fromthegeneratorset)forfrayingandlooseconnec-
tions. Forinformationonloadconnectionsreferto
ELECTRICALLOADSANDCONNECTIONSsec-
tion.
Battery Connections
Batterypositive(+)connectstostartermotor.Battery
negative(-)connectstolocationonrearofgenerator.
Checkterminalsonsetforcleanandtightconnec-
tions.
WARNINGl
ENGINE EXHAUST GAS (CARBON MONOXIDE)IS DEADLY!
Carbonmonoxideisanodorless,colorlessgasformedbyIncomplete
combustionofhydrocarbonfuels.Carbonmonoxideisa dangerousgasthat
cancauseunconsciousnessandispotentiallylethal.Someofthesymptomsor
signsofcarbonmonoxideinhalationare:
•Dizziness
•IntenseHeadache
•WeaknessandSleepiness
Vomiting
MuscularTwitching
ThrobbinginTemples
Ifyouexperienceanyoftheabovesymptoms,getoutintofreshair
immediately.
Thebestprotectionagainstcarbonmonoxideinhalationisa regularinspection
ofthecompleteexhaustsystem.Ifyounoticea changeinthesoundor
appearanceofexhaustsystem,shuttheunitdownimmediatelyandhaveit
inspectedandrepairedatoncebya competentmechanic.

MAINTAIN THEFOLLOWING MINIMUM INSTALLATION CLEARANCES:
1.ExhaustPipe to Top of Compartment - 2"
2. ExhaustPipe to Side of Compartment - 3-1/2"
3.Top of GeneratorEnd of Set to Top of Compart- '
ment - 2"
4.RadiatorCap to Top of Compartment - 2-1/2"
5.DriveBeltGuide to CompartmentDoor - 0"
6. Muffler To Side of Compartment - 2-1/4"
7. Muffler To Top of Compartment - 1/4"
8.Rear of Engine(AboveGenerator) To Back of
Compartment-1/2"
LOUVERED
METALDOOR
•264SQ.IN.
MINIMUM
ENGINECOOLING
AIR IN
GENERATORCOOLING
AIR IN
ENTIRESURFACE
MUST BE METAL
FIGURE 2.COMPARTMENT SIZE AND MINIMUM DIMENSIONS

COMPARTMENT SIZE ANDLOCATION
COMPARTMENT SIZE ANDLOCATION
Compartmentlocationisdeterminedlargelyby:
1. Physicalsize.
2. Accessopening.
3.Mountingsupport—mostimportantofall.
Physical Size
Theareainthevehiclefortheelectricgeneratingset
mustbelargeenoughforthecompartment,with
specifiedminimumclearancebetweentheelectric
generatingsetandcompartmentwallsorceiling(and
acousticalmaterial,ifused.)SeeFigure2.
ACCESS OPENING
Planthelocationforanaccessopeninglargeenough
topermitsetremoval.Compartmentdoorshouldbe
designedforeasyremovalorforeasyaccessfor
operatororservicepersonal.
MOUNTING SUPPORT
Becauseofcompartmentweight,themostdesirable
mountinglocationisbetweenthemainframe
membersoftherecreationalvehicle.However,thisis
seldompossible.Mostcommoninstallationsareon
thesideofthevehicleandmostdifficultto.reinforce.
Onesideofthecompartmentisfastenedtotheframe
andtheoppositesidesecuredtothebody.Compart-
mentfloormustbemetal.
Channel, boxorangleironcanbeusedfora com-
partmentframewitha sheetmetalcover.
COMPARTMENT
WARNING
J
1. Compartmentorinstallationareamustbesepar-
atedfromlivingquartersbya vapor-tight wall.
WARNINGI Separateinstallationareaorcompart-
•MMBM^HJI mentfromlivingquartersbya vapor-
tightwalltoprevententranceofnoxiousfumestointeriorand
possibleasphyxiationhazard.
2. Linethecompartmentorseparatefromliving
quarterswitha firebarrierofsheetmetalorother
noncombustiblematerial.Thecompartmentcan
alsobereadilysealedandlendsitselfeasilyto
soundoraccousticaltreatment.
Donotuseflammablematerialdirectly
aboveoraroundtheelectricgenerating
setcompartment.Heattransferredthroughthesheetmetal
compartmentstructureorothermaterialcanbeHOTenough
todiscolor,charorignitefiberboard,seatcushions,etc.Use
ofasbestosorothernoncombustibletemperatureinsulating
materialinhightemperatureareasmaybenecessary.
SeeFigure2 forminimumclearancesandcom-
partmentsize.
DONOTuseabsorbentsoundproofingmaterial
oncompartmentfloor.Thefloorshouldhave min-
imumopeningstoreduceentranceofroaddirt.
Compartmentfloormustbesoconstructedasto
preventaccumulationofoil,fuelorwaterinany
corner.Drainagecanbeaccomplishedthrough
theuseofa 1/2"diameterholeneareachcorner
orothersuitablemeans.
WARNING 1 Besureholesarenotdirectlyabove
mufflertopreventfirehazard.
VIBRATION ISOLATORS
RubbervibrationisolatorsarefurnishedwithallOnan
recreationalvehiclemodels.
1/16"MINIMUM
CLEARANCE
— TOALLOWUNIT
TO ROCKONITS
MOUNTS
B75
FIGURE3.VIBRATIONISOLATORS
1. Onanmountsarea "throughbolt"typewhich
preventthesetfrombreakinglooseiftheyare
damaged.
2. Vibrationisolatorsofthetypeshown(withsnub-
bingwashers)inFigure3 mustbeinstalledprop-
erlytominimizevibration.Leave 1/16-inch min-
imum' clearancebetweenthesnubbingwashers
asshowninFigure3.

VENTILATION AND ACOUSTICS
Themostimportantfactorsofventilationforanair-
cooledJWelectricgeneratingsetaresufficientin-
coming'coolingairandexhaustingheatedair.Before
consideringtheinstallationproblems,knowledgeof
howanOnanunitcoolsitselfisneeded.SeeFigure4.
WARNING Neverusedischargedcoolingairforheating
sinceitcancontainpoisonousgases.
FIGURE5. RADIATORAIRREQUIREMENTS
FIGURE4.TYPICALONANRVCOOLINGSYSTEM
AIR REQUIREMENTS
The12.0RDJCrunningat1800rpmrequiresa min-
imumradiatorairinletopening17.5"widex 17.75"
highwithnorestrictions.Thecoolingairthroughthe
floordischargeductis160cubicfeetperminute.See
Figure4 and5.
WARNING Insulationmustnotreducetheminimum
clearancesasspecifiedInFigure 2, tocomply
withtemperatureriseandsafetyrequirementsofrecreational veh-
icles, topreventfirehazard.
RESTRICTED AIR OPENINGS
Sheetmetalwithlouverscanbeusedoverinletareas.
However,someprovideonly60percentfreeinletarea
persquarefoot.Eventhemostefficientgrilleonly
providesabout90percentfreeinletareapersquare
foot.Thefreeinletareaofthematerialcanbe
obtainedfromthemanufacturer.Unrestrictedair
inletrequirementsforthissetis264squareinches
(1.8squarefeet).SeeFigure5.
COMPARTMENT ACOUSTICAL LINING
1. Besurealljointsandcornersofthecompartment
arevaportighttocoachinteriorbeforeliningwith
acousticalmaterial.
Liningthecompartmentdoeslittleifopening,
cracks,doorandjointsarenotsealed.Alsomake
surecompartmentdooredgeissealedtoelimi-
natenoise-airleaksaroundthedoorperimeter.
2. Coverthesoundreflectivesurfaces,back,top
andsides(notcompartmentbase)withfiberflass
orothernoncombustibleacousticalmaterial.It
shouldbenolessthanoneinchthickandapprox-
imatelytwopoundspersquarefootindensity.Be
sureadhesiveusedisalsononcombustible.Test
acousticalmaterialandadhesiveforheateffects
beforeusing.
3.Ratherthanusingonesinglematerialoftwo
poundpersquarefootdensity, a combinationof
materialscanreducenoiseevenmore.Forexam-
ple, a sheetofleadorvisoelasticmaterialofone-
halftoonepoundpersquarefootdensityanda
layerofoneinchacousticalmaterialoftwopound
persquarefootdensity,respectively,isfarmore
superior.
WARNING Separateinstallationareaorcompart-
mentfromlivingquartersbya vapor-
tightwalltoprevententranceofnoxiousfumestointeriorand
possibleasphyxiationhazard.
WARNING Insulationmustnotreducethe
min-
imumclearancesasspecifiedinFigure2
tocomplywithtemperatureriseandsafetyrequirementsfor
recreationalvehiclestopreventfirehazard.

FUEL SYSTEM
RECOMMENDED FUEL
UseASTM2-Dor1-Dfuelwitha minimumCetane
numberof'45*.Number2 dieselfuelgivesthebest
economyformostoperatingconditions;however,
useASTM1-Dfuelduringthefollowingconditions:
1. Whenambienttemperaturesarebelow32°F
(0oC)
2. Duringlongperiodsoflightengine load; orno
load.
*NOTE: FuelswithCetanenumbershigherthan45maybe
neededinhigheraltitudesorwhenextremelylowambient
temperaturesareencounteredtopreventmisfires.
Uselowsulfurcontentfuelhavinga pourpoint
(abilitytofilter)ofatleast10oF(60C)belowthe
lowestexpectedtemperature.Keepthefuelclean
andprotectedfromadverseweather.Leavesome
roomforexpansionwhenfillingthefueltank.
Duetotheprecisetolerancesofdieselinjec-
tionsystems,itisextremelyimportantthe
fuelbekeptclean.Dirtinthesystemcancauseseveredamageto
boththeinjectionpumpandtheinjectionnozzle.
CAUTION
-ION)
WARNING Leakageoffuelinoraroundthecompart-
mentisa seriousfirehazard.Theventilation
systemshouldprovidea constantflowofairtoexpelanyaccumu-
lationoffuelvaporwhilethevehicleisintransit.Compartments
mustbevaportighttotheinteriortokeepfumesfromwithinthe
vehicle.
FUEL CONSUMPTION
Itshouldbenotedthatundervaryingelectricalloads,
fuelconsumptionofenginesforrecreationalvehicle
generatorsetsvariesaccordingly.Averagefuel con-
sumptionatratedloadis1.30gallonsperhour.
2.
clefuelsystemmustbeinaccordancewithchas-
sis(vehicle)manufacturers'detailedinstallation
instructions.
Installanapprovedflexiblenon-metallicand
non-organicfuellinebetweenthevehiclefuel
systemandtheenginetoabsorbvibration.
3.Useofseamlesssteeltubingandflaredconnec-
tionsarerecommendedforlongrunsbetween
thefueltankandtheflexibleconnectortothe
generatorset.
4. Runfuellinesatthetopleveloftanktoa pointas
closetotheengineaspossibletoreducedanger
offuelsiphoningoutoftankifthelineshould
break.
5.Keepfuellinesawayfromhotengineorexhaust
areas.
Connect7/16inchfuelreturnlinefrombleeder
valveoninjectionpumptotopoffuelsupplytank.
Whensharingthefueltankwithvehicleengine,
usea separatefuellineforeachenginetoavoid
starvingthegeneratorset.Keepfueltankpick-up
offthebottomofthetanktoreducethechanceof
contaminantscloggingthefuelline.
8.Flexiblelinemustbelongenoughtoallowfor4"
ofsetmovementtopreventbinding,stretchingor
breakingbecauseofsetmovement.
9.Installlinessotheyareaccessibleandprotected
fromdamage.
10. Usemetalstrapswithoutsharpedgestosecure
thefuellines.
11. Donotrunfuellineinconjunctionwithelectrical
wiring.
12. Forservicing,installa shut-offvalveatthefuel
tank.
6.
7.
FUEL LINES, RETURN LINE AND
FUELFILTERS
FuelLines
1. Mostelectricgeneratingsetinstallationsare
designedtosharethevehiclefuelsupplytank
withthevehicleengine.Allconnectionsto vehi-
Fuel Filters
Thisgeneratorsetisequippedwitha primaryand
secondaryin-linefuelfilters.
Operatingthegeneratorsetfroma teeinthemainfuellinecan
causeerraticoperationwhenvehicleisoperatedathighway
speeds.Theset'sfuelpumphasneitherthecapacitynorthepower
toovercomethedrawofvehicleenginefuelpump.

EXHAUST SYSTEM
Planeachindividualexhaustsystemcarefully. A
properInstallation isnot only gas tight, but usually
quieter,"too. Be sure to check all applicablerecrea-
tionalvehiclestandards,localcodes and regulations.
WARNING
CAUTION
Plan the exhaustsystemcarefully.Exhaust
gases are deadly!
Do not connect the electricgenerating set
exhaust tothe vehiclesystem.Watervapor
from one engine can damage the otherengine.
1. The exhaustsystemmust beno closerthan 2
inchesfrom any combustiblematerial, orbeso
located, insulated or shielded soit does not raise
thetemperature ofany combustiblematerial by
morethan 117°F (65°C)above the ambient air
inlettemperature.
2. The exhaustsystemmustextend a minimum of
oneinchbeyond the perimeter ofthe vehicle. If
thegenerator set tailpipe isonthe sameside of
thecoach asthe compartment, it shouldtermi-
nate aftoftheair intake to preventrecirculation of
exhaustfumes.
WARNING Do
not terminatepoisonouscarbon
monoxideexhaust gas undervehicle.
Directexhaustgasesawayfromwindow and dooropenings.
Keep all openingsabove ortothe rear of exhaustpipesclosed
whengenerator setis operating.
3.Exhaustpipemustterminate a minimum of three
feetfrom the vehiclefuelfillerspout(moredis-
tance if required by localcodes).
4. Use automotivetypetailpipehangers for hang-
ing the exhaustsystemfromvehicleunder-
carriage.
CAUTION Iftailpipedeflector
is used, be sure itis
largeenough to preventexcessiveback
pressure.
EXHAUST SPARK ARRESTERS
Exhaustsparkarresters are necessary for SAFE
OPERATION. All requireperiodicclean-out(every 50
to 100 operatinghours) to maintainmaximum effi-
ciency.Somestate and federalparksrequirethem.
Tocleansparkarresterremovepipeplug in bottom of
muffler. Runset underload for5 minutes.Replace
plug.
WARNING Allexhaustshieldingsuppliedwithunit
MUST be properlyinstalled to preventover-
heating of compartmentwalls orthe possibility of fire.
WARNING Checkexhaustsystem(visually
and audibly)
forleaksdaily (at leastevery 8 hours of run-
ningtime).Excessiveexhaustnoise may indicate on exhaustline
leak.
Modifications of exhaustsystemwillvoid theUL listing and Onan
warranty.Liability for damage or injury and warrantyexpenses due
to any changesbecome the responsibility ofthe personmaking
suchchanges.
IMPORTANT:Certainstates(particularlyCalifornia)havestate
ordinancespertaining tothe type and usage of exhaustmuffler/
sparkarresters on internalcombustionengines or enginedriven
equipmentwhenused ina recreationalvehiclesuch as electric
generatingsets. Be sureyourInstallationmeets all Federal,State
andlocalcodespertaining to yourunit.Failure to provide and
maintain a sparkarrester maybein violation ofthelaw.

ELECTRICAL LOADS ANDCONNECTIONS
Allofthefollowingdescriptionpertainstoalternating
currrenLOnanelectricgeneratingsetsforrecrea-
tionalvehicles.
1. Allwiringmustmeetapplicablelocalelectrical
codes.Havea qualifiedelectricianinstalland
inspectthewiring.
2. Wiresmustbeadequatesize,properlyinsulated
andsupportedinanapprovedmanner.
3.Mountswitchesandcontrolssecurelytoprevent
damagefromvibrationandroadshocks.All
switchesmustbevibration-prooftopreventac-
cidentalopeningorclosingwhilethevehicleisin
motion.
4. Installanapprovedjunctionboxforfeeder con-
ductorsfromtheelectricgeneratingset.Itmust
havea blankcoverandbeinsidecompartment
(notonset).
WARNING Topreventnoxiousgasesfromentering
vehicleinterior,sealanyopeningsmade
intheset'scompartmentforconduit,wiring,etc.Sicknessor
asphyxiationmayresult.
WIRE TYPES
Usemultistrandwirewhichmeetsallapplicable
codesasfeederconductors,fromelectricgenerating
settocompartmentjunctionbox.Manyinstallersuse
multistrandwirethroughoutthevehicletoreducethe
dangerofbreakagefromvibration.
Theconductorsoftheelectricgeneratingsetshall
haveanampacitynotlessthen115percentofthe
nameplatecurrentratingofthegenerator.Neutral
conductorsshallbethesamesizeastheconductors
oftheoutsidelegs.
Supplyconductorsfromtheelectricgeneratingsetto
thejunctionboxonthecompartmentwallmustbe
installedinflexiblemetalicconduit.
CAUTION Donotusesolidmetalconductorsincom-
partment.Theymaydevelopmetalfatigue
fromsetmovementandeventuallybreak.
RECONNECTIBLE, SINGLE-PHASE
GENERATOR
Voltageselectiononreconnectiblesingle-phase
generatorsisforuseas120/240volts,3-wire;or120
volts, 2 wire.Balancetheloadwhenconnectingfor
threewireservice.Currentforanyoneoutputlead
mustnotexceednameplaterating.Whentwoormore
single-phasecircuitsareavailable,dividetheload
equallybetweenthem.SeeFigure6.
SAFETY DISCONNECT
Thefeederconductorsfromthesetcompartment
mustterminateina three-pole,double-throw, posi-
tiveoff,switchingdevicefor120/240operationahead
ofthevehicledistributionpanel.Thisassuresthe
outsidepowersourcecannotbeconnectedsimul-
taneouslywiththeelectricgeneratingset.Neutral
mustbeswitched.
WARNING
WARNING Becauseoffirehazard,donottieelectrical
wiringtofuelline.
Useonlyapprovedpowersupplyassemblies.
Neverremovegroundingpinfrompower
supplyassembly.Incorrectornogroundmaycausetherecrea-
tionalvehicletobeelectrically"hot."Thisisa potentialshock
hazard.
Onrecreationalvehicleswhichhaveprovisionsfor
usingoutsideACutilitypower(separatefromthe
electricgeneratingset)theneutralaswellasthe
"HOT"leadMUSTbecompletelyisolatedfromthe
RVwhenloadorpowerisswitched.
Theoperationofa typicaltransferdeviceisshownin
Figure7.In additiontothetransferdevice,anover
currentprotectiondevice(circuitbreakerorfuse)
shallbeprovidedbetweenthetransferdeviceandthe
ACcircuitinRV.A groundfaultcircuitinterrupter
shouldbeinstalledinthewiringsystemtoprotectall
branchcircuits.
STARTING CONTROLS
RemotecontrolOnanelectricgeneratingsetsare
designatedbyan"R"inthemodelnumberandallow
theoperatortostartthesetinsidethevehicle.Referto
operator'smanualforspecificinformation.
10

POWER REQUIREMENTS FOR APPLIANCES
Appliance or Approximate
ToolRunning Wattage
Refrigerator600-1000
Electricbroom200-500
Coffeepercolator550-700
Electricfrying pan 1000-1350
Hairdryer350-500
Electricstove (per element)350-1000
Electriciron500-1200
Radio 50-200
Electricwaterheater1000-1500
Spaceheater1000-1500
Electricblanket50-200
Television 200-600
Electric drill 250-750
Batterycharger Upto800
Electricwaterpump500-600
AirConditioner1400-2200
Converter300-350
Microwaveoven700-1500
Tl
G
E
N
E
R
A
T
O
R
L
E
A
D
S
T2
T3
T4
L0
CBI
L2
UNGROUNDEDLOADWIRE
GROUNDEDLOADWIRE
T
120 V
240 V
120V
i
UNGROUNDEDLOADWIRE
FIGURE 6. SINGLE-PHASE,"3C"VOLTAGECODEGENERATORCONNECTIONS
11

120 V
OVERCURRENT
PROTECTION
. CBI
ELECTRIC
GENERATING SET
OVERCURRENT
PROTECTION
120 V —CBI
O-
-1—0
3POLE
DOUBLETHROW
POSITIVE OFF
TRANSFERDEVICE
120 V
120 V
120 V
120 V
TOVEHICLE
MAINBREAKERS
CB
OUTSIDE
POWER
CB
-O O
GROUND
FIGURE7.SCHEMATICOFTRANSFERDEVICEANDOVERLOADPROTECTION
12

BATTERIES
BATTERY CARE
Toincreasebatterylife,theoperatorcanperforma
numberofroutinechecksandsomepreventivemain-
tenance.
1. Keepthebatterycasecleananddry.
2. Makesurethebatterycableconnectionsare
cleanandtight.Usea terminalpullerwhenre-
movingcablesforanyreason.
3.Coatthebatteryterminalswitha mineralgrease
orpetroleumjellytoreducecorrosionandoxida-
tion.
4. Identifyeachbatterycabletobepositiveornega-
tivebeforemakinganyconnection.Always con-
necttheground(negative)cablelast.
5.Maintaintheelectrolytelevelbyaddingwater
(drinkingqualityorbetter)asneededforfillingto
splitlevelmarker.(Thewateringredientofthe
electrolyteevaporates,butthesulphuricacid
ingredientremains.Therefore,addwater,not
electrolyte).
6.Avoidoverchargingwhenrecharging.Stopthe
boostchargewhenthespecifcgravityis1.260
andtheelectrolyteis80°F(26.70C).
BATTERIES AND BATTERY CABLES
In orderfortheelectricgeneratingsettocrank effi-
cientlyundervariousoperatingconditions,thebat-
teryandbatterycablesmustbecorrectlychosenand
installed. Beforeselectinga battery,besurethe
installationareaiscompatibleandproperlyde-
signed. Thecompartmentforthebatterymust
provide:
1. Rigidmountingsupport.
2. A locationwhereaccidentalacidspillsorleaks
won'tdamageset,batterycables,etc.
3.Providea minimumof2 squareinchesattopand
2squareinchesatbottomofbatteryforventila-
tionpurposes.
4. Batterycableentrypointsshouldbesealed
(vaportight)iftheyenterorpassthroughliving
area.
CAUTION
WARNING Mountthebatteryinaseparatecompartment
fromthesetoranyspark-producingdeviceto
simultaneously.
Neverdisconnectthebatterywitheither
enginerunningandnevercrankbothengines
BATTERY CABLES
Forreliablestarting,voltagedropfromthebattery
terminalstotheexcitercrankingwindingsofthe gen-
eratorshouldnotexceed0.12voltsper100amperes
ofbreak-awaycurrentwhilecranking.Disconnect
leadtofuelsolenoidduringtesttopreventsetfrom
starting. Measurevoltageatbatteryterminalsandat
startsolenoidterminalwhilecranking.Connectthe
batterynegativetogroundwiththesamesizecable
asusedforbatterypositive.
Besuretheframeconnection(majorframememberif
possible)issufficienttominimizeresistance.Tryto
avoida connectionata weldormechanicaljoint.
Forshortdistances,onenegativebatterycablecan
beusedbetweensetandbatteryratherthenseparate
cablestochassisground.
The12.0RDJCdraws475amperesofcrankingcurrent.
Thebreak-awaycurrentisapproximately715amperes.
Thechargingcurrentvariesfrom2-5amperesdepend-
ingonbatterycondition(stateofcharge).
Foradditionalinformationoninstallationcontact
yourOnanServiceRepresentative.
Onanrecommendsusinga separatebatteryforoperationofthe
generatorinadditiontotheregularvehiclestartingbattery.
^ARNIN^^
Donotdisconnectbatterycablesfrombat-
terywhilegeneratorsetiscrankingor run-
ning; sparksmaycauseanexplosion.
TABLE1.MINIMUM12VOLTBATTERYSIZE*
(ORUSE2-6VOLTBATTERIESINSERIES)
Above32°F(0oC) Above0°F(-18°C)
BCIGroup2
565ColdCrankingAmps BCIGroup5D
800ColdCrankingAmps
preventfireorexplosion. 'Largercapacitybatteriesmayberequiredifbatteryisalsousedto
powerothercoachaccessories.
13