Onan BGE User manual

RV Electric Generating Set
Thismanualmust be given tothecustomer,
along withtheOperator’s Manual
Manual
GenSets
u LISTED
0
Installation
965-0630
10-86
Printed in USA

Safety Precautions
This symbol warns of immediate
hazards which will result in severe
personal injury or death.
This symbol refers
to a hazard or
- AW*R"'G i unsafepractice which can result in
Severe personal injuryor death.
This symbol refers to a hazard or
*'AUT''' j unsafepractice which can result in
personal injury orproduct
or property damage.
Fuels,electrical equipment,batteries,exhaustgasesandmoving
partspresentpotentialhazardsthatcould result inserious, per-
sonalinjury.Takecareinfollowingtheserecommendedprocedures.
Do not work on this equipment when mentally or physically
fatigued.
UseExtremeCautionNearFuel. A constantpotential explosive
or firehazardexists.
Do not fill fuel tank near unitwith enginerunning. Do notsmoke
or use openflamenearthe unit orthe fuel tank.
Be sure all fuel supplieshavea positiveshutoffvalve.
Usea non-metallic, non-conductive,flexible section of fuel line
betweenthe generator setandstationaryfuel lineinvehicle.
LPG: The propane fuel supply lines MUST comply with all
requirementsofNFPA501CSection3-5.paragraphs 1.1 and 1.2
as well as CanadianGas Association Bulletin 6149.2-78. The
installer must review and comply with all applicable codes
regardingfueltanks, supplylines.and pressuretestingcomplete
systemforleaksafterinstallationiscompleteandPRIOR
to initial
operationof the generatorset
Havea fireextinguishernearby. Besureextinguisherisproperly
maintainedand be familiar with its proper use. Extinguishers
rated ABC by the NFPA are appropriate for all applications.
Consultthe local fire department for the correcttype
of extin-
guisherfor various applications.
GuardAgainst Electric
Shock
Remove electric power before removing protective shields or
touching electrical equipment Use rubber insulative mats
placedon dry woodplatfqrmsover floors
that aremetalor con-
crete when around electrical equipment
Do not wear damp
clothing (particularly wet shoes)
or allow skin surfaces to be
dampwhen handlingelectricalequipment
Jewelryisagoodconductorofelectricityandshouldberemoved
when working
on electricalequipment
DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY
BUlLDlNGELECTRICALSYSTEM.Hazardoevoltages
can flow
fromthegeneratorsetintotheutilityiine.Thiscreates apotential
forelectrocutionor propertydamage.
Connect onlythroughan
approveddeviceandafterbuilding mainswitch isopen. Consult
an electrician
in regard to emergency power use.
Use extremecaution when working onelectrical components.
Highvoltages causeinjuryordeath.
Follow all state and local electrical codes. Have all electrical
installationsperformedby a qualified licensed electrician.
rr
Do Not SmokeWhile ServicingBatteries
6
Batteries emit a highly-explosive gas that can be ignited by
electrical arcing or by smoking.
Exhaust Gases Are Toxic
Neversleepinthe vehiclewiththe generator set running unless
the vehicle is equipped with an operating carbon monoxide
detector.
Provide an adequate exhaust system to properly expel dis-
charged gases. Check exhaust system regularly for leaks.
Ensure that exhaustmanifoldsare secureand notwarped.
Besurethe unitis well ventilated.
Keep the UnitandSurroundingArea Clean
Removeall oil deposits. Removeall unnecessarygreaseand oil
fromtheunit.Accumula:ed greaseand
oil cancaussoverheating
andsubsequentenginedamageandmaypresentapotentialfire
hazard.
When cleaning generatorset. providecoveror other protection
so thatcleaningandrinsewater, andothercontaminantsarenot
allowedintothe generator. aircleaner,control box,fuelsolenoid,
or electrical connec:ors. Generator set operation and internal
components can beadverselyaffected.
Do NOTcleanthegeneratorsetwhileunitisoperating.This can
resultin personalinjury
or product or propertydamage.
Do NOT use high pressure air. water, or steam for cleaning
generatorsetandcompartmentDirtandotherforeignmattercan
beforced intogenerator, engineandcontrol housings.Genera-
tor set operation and internal componentscan be adversely
aff9cted.
Do NOTuse highstrengthsolvents. They candamageelectrical
connectors.
Do NOTstoreanythinginthegeneratorcompartmentsuchasoil
orgascans,oilyrags,chains, wooden blocksportablepropane
cylinders,etc.
A fire couldresult orthe generatorset operation
[cooling, noise andvibration) may be adversely affected. Keep
thecompartmentfloor clean anddry.
Protect AgainstMoving Parts
Avoid movingpartsof the unitLoosejackets, shirts or sleeves
should not be permitted becauseof the danger of becoming
caught
in movingparts.
Makesureallnutsandboltsaresecure. Keeppowershieldsand
guardsinposition.
If adjustments must be made while the unit is running, use
extremecautionaroundhotmanifo!ds. movingparts, etc.
General
Do not work on this equipment when mentally or physically
fatigued, orafterconsuminganyalcohol or drugthat makesthe
operationof equipmentunsafe.
RV-G.LP-4
4-
*-
,
e
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by any means, is strictly prohibited.

Table of Contents
'.
..
._
SAFETY PRECAUTIONS ................................ Inside Front Cover
INTRODUCTION ....................................................... 2
GENERALSPECIFICATIONS ........................................... 4
MOUNTING ............................................................ 5
ConventionalCompartmentMount ..................................... 5
Under-Floor Mount .................................................. 8
VENTILATION AND ACOUSTICS ....................................... 10
Ventilation
......................................................... 10
Acoustics .......................................................... 11
EXHAUSTSYSTEM ................................................... 13
General ............................................................ 13
Muffler Recommendations ........................................... 13
Exhaust Installation Guidelines
....................................... 13
Tailpipe Recommendations
.......................................... 13
FUEL SYSTEM ....................................................... 16
General
............................................................. 16
Gasoline
Fuel System ............................................... 16
ELECTRICALCONNECTIONS
......................................... 19
DC Wiring .......................................................... 23
Pre-Start Checks
................................................... 26
Initial Start-upInspection ............................................ 26
Installation Review
.................................................. 28
.. Propane (LPG) Fuel System 17
AC Wiring .......................................................... 19
..........................................
INSTALLATION CHECKSAND START-UP .............................. 26
1
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by any means, is strictly prohibited.

Introduction
Each RV generatorset must be installedproperly if it is
to operatereliably,quietly,and most importantly - safely.
Therefore,readtheentiremanual and housing/exhaust
.kit instructions before starting the installation. This
manual details installation procedures for the Onan
BGE and BGELgeneratorsets.For operationand main-
tenance procedures, refer to the Operator’s Manual
.* which accompanieseach unit.
Listed and certified, this generatorsetmeetsorexceeds
all requirements of the National ElectricalCode,Article
551 (NFPA 70) as well asANSI/RVIA Standard EGS-1.
UL Standard 1248,and CSA Bulletin 946. Recreational
vehicleinstallationsMUST comply
with thesespecifica-
tions aswell asANSI 11
9.2, Standardfor Recreational
Vehicles. The recreational vehicle manufacturer and
generatorsetinstaller
MUST alsocomply with anylocal
codes such as CaliforniaAdministrativeCode
Title 25,
which pertainsto the generatorset installation.
UL listing and CSA certification applies to60 Hz models only.
Requirements fo be considered prior to the installation
are
listed below. Each is covered in thefollowingtext or
associated kit instructions.
0 Level and supportive mounting surface.
0 Adequate cooling air.
0 Discharge of circulatedair.
0 Discharge of exhaust gases.
0 Electrical connections.
0 Fuel installation.
0 Accessibilityfor maintenanceand service.
0 Noise levels.
The
following list of installation codes and safe.,
recommendationspertainstotheinstallation
and opera-
tion
of this RV generator set. The address of each
agency
is listed so that you can obtain a copy for your
own use.
‘
INSTALLATION CODES AND
SAFETY RECOMMENDATIONS
I
i
1. ANSI-Al19.2 Recreational Veh.
ANSI/RVIA-EGS-1
Industry Assoc.
14650 Lee Road
Chantilla
VA 22021
2.
NFPA 70 (N.E.C.)
National Fire
470 Atlantic Ave.
Boston
MA 0221 0
NFPA-501 C Protection Assoc.
3. CSA Electrical Canadian Standards
Bulletin
#946
Assoc. - Housing &
Const. Materials Section
178 Rexdale Blvd.
Rexdale Ont. Canada
M9W
1 R3
4. UL Standard 1248
Underwriters Lab Inc.
333 Pfingsten Road
Northbrook
IL 60062
5. California Stateof California
Administrative DocumentsSection
Code
- Title 25
Chapter
3 North Highlands CA
P.O. Box 101 5
95660
I AWARNING I
Incorrect installation, service, or replacement of parts can result in severe
personal injury and/or equipmentdamage. Servicepersonnel must be qualified
to perform electrical
and mechanicalcomponentinstallation.
2
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by any means, is strictly prohibited.

'.
.*
._
BGE
GOVERNOR
SPARK ADJUSTMENTS
SUMMER/WINTER
CARGURETOR ADJUSTMENT
ADJUSTMENTS
FUELPUMPINLET
AC CIRCUITBREAKERS
REMOTESTART
CABLECONNECTION
LOCATIONOP~ONAL
SPARK
BGEL PLUG
VAPORIZER
\\
ADJUSTMENTS
AC CIRCUITBREAKER
FUELFILTERAND
SOLENOIDASSEMBLY
NEGATIVE
(-) BA'K
CABLECONNECTl POSITIVE (+) BATTERY
TO PLATE CABLECONNECTION
LOCATIONOPTIONAL REMOTESTART
CABLECONNECTION
.
M-1604-1
FIGURE 1. BGEAND BGEL GENERATOR SETS
3
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by any means, is strictly prohibited.

General Specifications
.-
ENGINE
Onan opposed2-cylinder,4-cycle,air-cooled,gasoline-fueled forthe BGE model
and propane-fueled for
the BGEL model. Remotestart,negative ground,12-volt,
automotive-type
starter.
'
GENERATOR
Onan-built,four-pole,revolving field,permanentlyaligned to engine.
Frequency ....................... -50 Hz.. ........................ 60 Hz
'Watts.. .......................... .3500 ............................ 4000
Volts.. .................... .11.0/220 or 1201240.. .................... 120
Amps.. .................. .31.8/15.9 or 29.2114.6.. .................. .33.3
Phase .............................. 10 ............................. .10
c
.
..
CONTROL
Front-mountedcontrolfeaturesfixed battery charger and remote start capability.
. GENERATOR SET
Dimensions*
..
Height .............. :. ................................ 14.0 in. (356 mm)
Length.. .............................................. 25.0 in. (635 mm)
Width.. ............................................... 18.8 in. (478 mm)
60 Hz. ................................................... 218 Ib (99 kg)
SO Hz.. .................................................. 228 Ib (104 kg)
60 Hz ......................................... -480 ft3/min (1 3.6 m3/min)
50 Hz ......................................... .400 ft3/min (1 1.3m3/min)
BGE ... 1 ............................................. 1 /4 in. barbfitting
BGEL..
.................................................. -1 /4 in. NPTF
Battery Voltage .................................................. .12 volts
Recommended Battery Capacity'.
................
.360 cold cranking amperes
Cranking Current
............................................. 100 amperes
rlmin at:
60 Hertz .......................................................... 7800
50 Hertz ......................................................... 1500
Weight
Air Requirements:
Fuel Inlet Connection
*Under-Floormountgeneratorsetwith compartment
housing has slightlylarger
dimensions. See Mounting section.
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by any means, is strictly prohibited.

Mounting
Read the entire manual and housing/exhaust kit
instructions before installingthe generator set The
generatorsetisdesignedfortwovery differenttypes
of
installations;conventionalcompartmentmountinstalla:
tions and under-floor mount installations. Choosethe
appropriatesectiondescribingeach and carefully fol-
lowthe instructionsgiven.
CONVENTIONAL
COMPARTMENT MOUNT
Ina conventional installationthe generator set isactu-
ally installedon aframeworkthat ispart of the recrea-
tionalvehicle
(RV). Thisframeworkmustbeconstructed
inaccordancewiththe safety-approvedspecifications
contained inthe following CompartmentConstruction
section..
Unlessgeneratorset
is toberemovedfromunderneath,
plan the locationfor an access opening to be large
enough
to permitset removal. Allow additional clear-
ance for easy access
to the oil fill, drain, filter and oil
dipstick as well as the air cleaner element, circuit
breaker,governoradjustments,carburetoradjustments,
Start/Stop switch, and DCfuse. The locations of each
are shown in Figure 1.
Designthecompartmentlargeenoughforthegenerator
set, with
0.6 inch (15 mm) minimumclearancebetween
the generator set and compartment walls and ceiling
(andacousticalmaterial,if used). See Figures
2 and 3.
Compartment Construction
1. Installthe generator set in its own compartment.
Separatethecompartmentareafromthelivingquar-
tersandanyfuelsupply(gasoline
or propane)witha
vapor-tight wall. See Figures
2 and 3 for minimum
clearancesand compartmentsize.
2. Linethecompartmentwallswith26-gaugegalvan-
izedsteel or amaterialofcomparablestrength,dur-
ability andfire resistance (see NFPA
70, NEC and
CaliforniaTitle
25 for completedetails).
3. Constructthecompartmentfloor inamanner so as
to prevent oil, fuel or water accumulation. Com-
partment drainage can be accomplished
by 1 /2
inch (13 mm) diameterholesasshown on thecom-
partmentfloordrawings, Figure 3.
Fire presents the hazard of
* jaWAR"G1 severepersonalinjury or death.
To prevent a fire hazard, do not position the
muif/er directlybelow
a drain hole.
Do NOT useabsorbentsoundproofingmaterialon
compartmentfloor. The floor should have minimal
openingsto reducesound level.
4. Equipbasewith an oil drain holeto the outsideof
compartment.
Do not mountthe muffler belowthe
oil drainvalve.
Exhaustgases present the haz-
ard of severepersonal injury or
death. Make thecomparfmentwallsvapor-tightto
theinteriorof thevehicletopreventexhaustfumes
fromentering ihe vehicle coach.
5. Securethegeneratorsetmountingplatetosupport
frameusing
318-1 E UNC, grade 5 screws.Theback
two mountingholesaresuppliedwith weld nutsto
facilitateinstallingscrews.Thefront
two holescan
be secured with 318-1
6 screws, lockwashersand
nuts. The front holes are square to allow use of
3/8-16 cage nutsif desired.
See Figure 3.
1-1 Road vibrationscan causecom-
ponent damage
to generator set
if unit mounting plate is not fastened securely
to
vehicle compartment, Use screws of sufficient
length
to allow a minimum of 1-1f2 threads to
extend through nut to ensure maximum holding
power.
5
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by any means, is strictly prohibited.

;E, ym &:: OIL FILTER REMOVAL
*-AIR FILTER
FUELINLET
- 114 INCH
1317.0 1 DISCHARGE
(
OPTIONAL EXHAUST OUTLET
NOTES:
1. DIMENSIONING INCLUDES 0.6 INCH (15
mm) MINIMUM CLEARANCEREQUIRED
BEMlEENSETANDlNSUIATlONORCOM-
PARTMENTWALLS.
IMUMSHOWN. ALLOW
EXTRA SPACEAT
OIL FILL SIDE AND EQUALLY ON BOTH
ENDS.
3. ALLOW MINIMUM OF 0.6 INCH (15 mm)
CLEARANCEBETWEENTOP OF SET AND
INSULATlON
OR COMPARTMENT
CEILING. MINIMUMHEIGHT
14.60 INCHES.
4. WEIGHT - 218 LBS. (99 kg). 50 Hz-228
5. DIMENSIONS IN ( ) INMILLIMETRES.
2. IF COMPARTMENT IS LARGERTHANMIN-
Lb1104 kg.
I
OIL DRAIN VALVE FOL
.62 1.0. HOSE
“L FUEL INLET
\
0 25 nos€ ¶4RB
ALT FUEL PUMP
.75 INCHCONDUITWITH
AC. PIGTAILS
36.0 INCHES
(0.92 m) LONG
VIEW A-A
500-2126
FIGURE 2.
BGElBGEL COMPARTMENT MOUNT OUTLINE (BGE SHOWN)
6
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by any means, is strictly prohibited.

X
19.75
(501.6)
I
so sa. HOLE
(127) 2 PLACES
NOTES.
CONVENTIONALCOMPARTMENT MOUNT BGE-BGEL
WlTH END-MOUNTEDMUFFLER
CUT-OUT
FOR COOLING
1. DIMENSIONS INCLUDE 0.6 INCH (15 mm)
AIR DISCHARGE MINIMUM CLEARANCE REQUIRED
BETWEENSETANDiNSUWTlON
OR COM-
PARTMENTWALLS.
IMUMSHOWN. ALLOW EXTMSPACE AT
OIL FILLSIDES AND EQUALLY ON
BOTH
ENDS.
3. ALLOW MINIMUM OF 0.6 INCH (15 mm)
CLEARANCEBETWEENTOPOF SET AND
ING. MlNiMUMHEIGHT- 14.60 INCHES(371
mm).
.
2. IFCOMPARTMENTISLARGERMANMIN-
INSULATION
OR COMPASTMENT CEIL-
4. DIMEF.!SIDNS ( ]ARE IN MILUMETRES.
5. SWAREHOLES (5.5il/127) ARESUITABLE
FOR
USE OF 38 IWCH CASE MU.
.JOBDRAINHOLE
(127) 2 PLACES
FIGURE 3. COMPARTMENT FLOOR PLAN .
7
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by any means, is strictly prohibited.

UNDER-FLOOR MOUNT
Foran under-floormountinstallation,thegeneratorset
ismountedinahousingbelowthefloorandoutsidethe
coachof therecreationalvehicle.Thishousingassem-
bly should be as supplied
or approved by Onan, and
must be installedin accordancewith safety approved
specifications. Review the following text for general
applicationinformation,andreviewtheproperhousing/
exhaust kit instructionsfor further specificsregarding
under-floormountinstallations.
The vehicle constructionmust be ableto supportthe
weight
of thegeneratorset (seeGeneralSpecifications).
It is the vehicle manufacturer’s and the installer’s
responsibilitytoprovideandassure
a structurallysound
supportframe, by usingtubing, anglebrackets, or with
steel reinforced plywood
or other compositionboard.
Reinforcementof plywood
or particleboardcanbewith
3 inch (76 mm) or largerwashers or afull metalplate.
.-
General
Generator SetLocation: Whenchoosingalocationfor
mountingtheunder-floormountgeneratorset,consider
thefollowingnotonlyformounting,butforprotection
of
the generatorset as well.
Figure
4 showsthe mostcommonmountingareas of a
RV generatorsetinarecreationalvehicle. If thegenera-
tor set is mounted
on the curb side, location l or 2,
protectthegeneratorendofthegeneratorsetfromroad
splashanddebris.
If mountedonthedriver’sside, loca-
tion 3 or 4, protect the engine end of the generator.
(Installationshouldbeverifiedbyaroadtestinmudand
slush). Referto shadedareasof Figure
4.
Leave an area between the generator set and the
recreationalvehicleskirtfor anair inlet if
it is notsub-
jected to road splash. See
V€NTlLATlON for more
detailedinformation.
Air inlet openings to thegeneratorsetcompartment must notallow
dirt, rock, water, orslushtodirectly hit the generator
set. Oustand
saltentrance into the compartment must
be minimized. Payspecial
attentiontoprotection
of thegenerator, control, choke,andgovernor
Access Opening: Provide an access opening og the
side of the recreationalvehicle for the generator set.
Makeitlargeenoughtoallowforchecking
or addingoil,
foradjustinggovernorandcarburetor,andforaccessto
the control paneland
AC circuit breaker.The opening
shouldalsoprovideaccessfor oilandairfilter replace-
ment
so that the generator set does not have to be
lowered for these procedures. See Figure
1 for
locations.
Mounting Clearance: Ifthecompartmentdoordoesnot .
openthefullwidthofthegeneratorsetandtothebottom
of thevehicleskirt, provide
2 inches (51 mm) minimum
betweenthetrayandtheskirtoftherecreationalvehicle.
Thisdistanceallowsloweringthegenerator setwithout
hittingthe vehicle skirt. Figure
5 shows basicdimen-
sions
of the under-floormount generator set.
8
Y
Housing Assembly
Therecreationalvehiclemustbeadaptedfortheunder-
floor housing.Theconstructionofthevehiclemustsup-
port the weight of the generator set. It is the vehicle
manufacturer‘sresponsibilityto provide a structurally
soundframe and carriagebolts
or equal to attachthe
housingkit.
failure to meet Onan approval for
modifications
of housing kits or for
non-Onan kit housing installationsmay void intent
of
ULKSA approval. Liability for damage or injury and
warranty expenses
becomes the responsibility of the
person making themodifications.
Use template suppliedwith housing kit to insurethat
panels are installed square to each other. Failureto
mountpanelssquaremayresultinsparkplugbreakage.
Reviewthe exhaustsystem kit installationinstructions
andcomponentparts. Planclearancesformovementor
removalof exhaustcomponentswhen generatorsetis
loweredfor inspection/maintenancepurposes.
areas. Baffi& might berequired to protectcertain areas.
~
REFER TO INSTRUCTIONS
EXHAUST KIT
INSTRUCTIONS
FIGURE 4. COMMON MOUNTING AREAS OF GENERATOR s
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by any means, is strictly prohibited.

OIL FILL AM0 CHECK
r
8
NOTES
ALT NELPUMP
1. DIMENSIONS INCLUDE 0.E INCH (15 mm)
MIN REQUIRED CLEAWNSE BETWEEN
MENTWALLS.
2. IF COMPARTMENT IS LARGER THAN MIN
SHOWN.
ALLOW !EXTRA SPACE AT OIL
FILL SIDE AND EQUALLYON BOTH ENDS.
Lb1104 kg.
SET AND INSULATION OR COMPART-
NEL $NET
m 2: WE 8410
3. WEIGHT 213 LB (93 kg) 50 Hz-228
4. DIMENSIONS IN ( ) ARE IN mm.
.75 INCHCONDUITWITH
AC. PIGTAILS
36.0 INCHES
A.C. CIRCUIT BREAKERS
RU.a 159LOl YIN
CLCkUNCC rOR UIT 5WW .
'\
VIEW A-A
'w
500-2135
FIGURE 5. UNDER-FLOOR MOUNT BGEIBGEL(BGE SHOWN)
9
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by any means, is strictly prohibited.

Ventilation and Acoustics
VENTILATION
The most importantfactors of ventilationfor an RV air-
cooled generator set are sufficient incoming air (for
combustionand cooling) and adequateexhausting of
heatedair.
All Onangeneratorsetsforrecreationalveh-
icles useVacu-Flo@cooling.
Acentrifugalfan inascrollhousingontheengine(Fig-
ure
6) drawsairfromthegenerator endof thecompart-
ment,throughthegenerator(generatoralsohasacool-
ing fan), and over the cooling surfaces of the engine,
thendischargesthe heated air outthrough theVacu-
Floe dischargeopening.
Make sure nothing obstructs or restricts discharged
airflowandthatrecirculation
of airisminimal. A dustor
noisedeflector
if added mustbeaminimumof 6 inches
(150 mm) belowthe generatorset and open on three
sides.
Exhaust gas presenfsthe hazard of
(BWARNINGI severe personal injury or death.
Since discharged cooling air can contain some
exhaust gas, never use discharged cooling air for
heating.
Thefree airinletareaiscritical for propergenerator set
operation and cooling.
A minimumfree air inletarea of
85 in2 (548 cm2)with no restrictionsisrequired. Refer-
ence: thegenerator set airdischargerateis
480 ft3/min
(1 3.6 m3/min).
-
FIGURE 6. VACU-FLO@ COOLING SYSTEM
Whenplanningtheairinlettothegeneratorset,allowfor
airflow restrictions caused by grilles and duct work.
Some expanded metal grillesprovideonly
60 percent
freeairinletareapersquarefoot. Eventhemostefficient
grilleonlyprovidesabout
90 percentfreeinletareaper
squarefoot The free inletarea of the materialcan be
obtainedfrom the material supplier. Multiplythe grille
area times thepercent
of free area of thegrillto obtain
thefree inletarea.
Inletairductingshouldprovideadirectfree-airflowpath
togeneratorset,withminimalbends;andmaterialsused
shouldbesmoothand non-restrictiveto airflow.
Air inletopeningsshouldbelocatedas highaspossible
to allow for convection coolingof heatedair from the
generator set compartmentafter unitshutdown.Other-
wise, hard starting might result due to vapor locking
(gasolinefuel), hotcombustionair, etc.
Fuel or fuel leakage presents the
IBWAR”G1 hazardoffire or explosionwhichcan
causeseverepersonalinjuryor death. The ventilation
system shouldprovide a constant flowofair
to expel
anyaccumulation offuelvapor. Compartmentsmust
be vapor-tight to the vehicle interior to keep fumes
fromentering the vehicle.
To obtainthe 85 in2 (548 cm2) freeair inletarea, Onan
recommendsbringingincoolingairthtoughtherecrea-
tionalvehicleskirt. This canbeaccomplishedbyusing
theaccessdoor,ductingintothegeneratorendfromthe
side wall, or using the horizontal area between the
recreationalvehicleskirt and the generatorset along
withtheverticalarea(if roadsplash
is notaproblem -
seetheMOUNTINGsection).SeeFigure7forreference
totheseareas. Iftheskirtofthevehicledoes notextend
toorbelowthe
top ofthegeneratorsetdriptray,provide
an extension.
You can bring air from under the coach for cooling.
However,runtestswhiletherecreationalvehicle
is both
parked and while the vehicle is moving at highway
speedsto ensure proper cooling with this method.
A
temperature rise of 8°F (4.4OC) between the outside
ambient and
air in the top openings of the generator
housing
is acceptable.
I
..
..
,
b
..
10
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I I
Duct
MINIMUMFREEAIRFLOWTO
GENERATOR
SET COMPARTMENT
(MAY
BE CUMULATIVE):
85 IN2 (548 cmt)
Skirt
RV Floor7 1
,Skirt
Air In
AIR INLET ACCESS DUCTFROM
BETWEEN RV SKIRT Air Out DOORAIR SIDEWALL
AND GENERATOR SET INLET TO GENERATOR
FIGURE 7. AIR INLET ALTERNATIVES FOR UNDER-FLOOR
, MOUNT GENERATOR SET.
ACOUSTICS
The Onanhousingkitfortheunder-floormountgenera-
tor set containsacoustical materialto minimizenoise.
Additionalinsulationisnot necessary. If, however,you
are constructing your own compartment or housing,
usethefollowingguidelines.
Forthe conventionalcompartmentmount, if compart-
ment penetratesfloor, besure alljointsand comersof
the compartmentare vapor-tightto the interior. Lining
the compartmentis less effectiveif openings, cracks,
doors,andjointsarenotsealed.Also,sealcompartment
door edge to eliminate noise leaks around the door
perimeter.
Coverthesoundreflectivesurfaces,back,topandsides
(not compartment base) with fiberglassor other self-
extinguishing acoustical material. Acoustical material
and adhesiveshouldberatedfor useat
2OOOF (90°C)
minimum.
Ratherthan usingonesinglematerial,
a combination of
materialscan reducenoiseconsiderably. Forinstance,
a sheet of lead or viscoelastic materialand a layer of
acousticalmaterialsismoreeffectivethaneitheralone.
To reduce line of sight noise, a sound panel (baffle)
shouldbeaddedbehindtheairinlet. Thepanelmustbe
spaced
to allowfor minimumfreeairinlet of 85 in2 (548
cm2).
RefertoFigure
8 toaidyourgeneratorsetcompartment
design and noise reduction plans. Size ducting to
ensurethat minimumfreeairflowof
85 in2 (548 em*) is
still attainedafter acousticalmaterial isadded.
High temperatures in the compart-
l3iE@@I ment can present the hazard of fire
which canresulfinseverepersonal injury or death. To
meet UL, ANSl and CSA femperafureriserequirements
for recreational vehicles, insulafion must not reduce
fhe
0.6 inch (15 mm) clearance specified.
11
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12
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Exhaust System
GENERAL
Plan eachindividual exhaustsystemcarefully. A proper
installation
is not only vapor-tight, but usually quieter
and safertoo.Be sureto checkall applicablestandards,
local codesand regulations.
Refer to the following
text for recommendationsto fol-
low when installing the exhaust system.Then refer
to
the installation instructions supplied with the exhaust
system
kit for specific mounting procedures.%ee Fig-
ures 9 and 10 for exhaust kit options.
..
.-
MUFFLER RECOMMENDATIONS
Onan supplied mufflerisparkarresters are forest ser-
vice approved and meet coderequirements.(Failure
to
provideand maintain asparkarrestercan be in violation
of
the law.) Use only ONAN UL/CSA tested mufflers.
Liability for damage or injury and warranty expenses
duetouse
of unapprovedmufflers or installationmodifi-
cationsbecomes
the responsibilityof theperson instal-
ling substitute muffler or performing the modifications.
Contactan Onan distributorfor approvedexhaustsys-
tem parts and installation instructions.
EXHAUST INSTALLATION GUl DELlN ES
Theexhaustsystem must be no closerthan 3 inches (76
mm) from combustible material (wood, felt, cotton,
organic fibers, etc.),
or be so located, insulated or
shielded,that it does not raise the temperature of any
combustiblematerialmorethan
117OF (65OC)abovethe
ambient air inlet temperature.
The exhaust system must extend a minimum 1 inch (25
mm) beyondtheperimeterof the vehicle. If thegenerator
set tailpipe
is on the same side of the coach asthe
compartment.
try to terminate the tailpipe aft of the
generator set air intake to reduce the possibility of
exhaust recirculation,
by directing the exhaust down
and to the rear.
Exhaust gas presents the hazard of
severepersonal injury
or death. Use
only Onanspecifiedexhaustequipment withgenerator
setand supportthesystemper
kit instructions.
Exhaustgas presents thehazardof
iAWARNiNG 1 severepersonal inibry or death. Do
notterminateexhaustgasunder vehicle. Do nottermi-
nateexhaustsystemdirectly under any vent, window,
or opening which can be opened and which is not
pennanenilysealedfromthevehiclelivingspace. Keep
allopeningsclosedwhenthegeneratorsetisrunning.
Excessive exhaust back
pressure
cancauseenginedamage. If tai/pipe
deflector is
used, makesureitislargeenougbtopre-
vent backpressure.
Water vapor cancauseenginedam-
-/ age. Do notconnectthegeneratorset
exhaust to the vehicle exhaust.system since water
vapor from one enginecandamagethe other.
TAILPIPE RECOMMENDATIONS
An exhausttailpipe is NOT supplied because of varia-
tion
in lengthrequirementsbetween motor homemanu-
facturers.After muffler
is installed and prior to installing
exhaust tailpipe, refer to
the following recommenda-
tions for additional tips and safetyconsiderations.
Use
1-318 inch I.D. 18 gauge rigid steel tubing for
tailpipe.
I Exhaustgas presents the hazard oi
~AWARNING severepersonal injury or death. Do
not use flexible exhaust tailpipe since it can leak or
break dueto roadshock or vibration.
Do notterminate
exhaust sysiem under the vehicle. Direct exhaust
gases away from any window, door, or compartment
openings.
Do notoperatethegenerator set withoutan
exhausttailpipe.
Use U-bolt type automotive muffler clamps marked 1 -
318 and double rubber, U-shaped shock mounted
hangers for supporting the exhaust system. If tailpipe
extendsbeyond
1-1 /2 feet (0.46 m) from muffler.attach
an automotive tailpipe hanger for additional support
The exhaustsystemshould be supportedat or nearthe
perimeter ofthe vehicleto prevent the pipe from being
damaged and pushed
up under the skirt.
Angularmounting of muifierand tail-
exhaust system damage. Properly mounted hanger
brackets wili absorb much road
shock vibration and
prolongtheusefulnessofexhaustsystemcomponents.
Mount muffler and iailpipe hanger brackets directly
abovethecomponentsupported,notatanangle. Do not
twist therubbersectionsof any hangers.
: igCAUT'oN pipe hanger brackets can result in
13
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..
HANGER BRACKET
(3 FOOTll METRE
FROMDOWNPIPE.
OR AT
PERIMETER OF VEHICLB
.
..
EXHAUST ACCESSORY
KIT 542-0471 SHOWN
us-1146
EXS1147
f IGURE 9.
EXHAUST SYSTEM KK EXAMPLES FOR CONVENTIONAL
COMPARTMENTMOUNT GENERATOR
SET
14
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EXHAUST ACCESSORY
KIT 542-0482 SHOWN
TAILPIPE NOT
FURNISHED BY ONAN
EXHAUSTACCESSORY
KIT 542-0469 SHOWN
EXHAUSTACCESSORY
KIT 542-0470 SHOWN
Exs-1149
TAILPIPE NOT
%-- FURNISHED BY ONAN
FIGURE 10. EXHAUST SYSTEM KIT EXAMPLES FOR UNDER-FLOOR MOUNT
15
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Fuel System
Model
60 Hz
50 Hz
GENERAL
This installation manual covers gasoline and LPG
(liquid-propane gas) fuel systems. The Onan BGE
model is gasoline-fueled,and the Onan BGEL model is
liquid LPG fueled. Separate procedures are given for
each.
No Load Half Load Full Load
0-4 gallhr 0.6 gal/hr 0.8 gallhr
(1.5 Ilhr) (2.3 I/hr) (3.0 Ilhr)
0.35 gal/hr 0.53 gallhr
0.73 gal/hr
(1.3 Ilhr) (2.0 Ilhr) (2.8 Ilhr)
*
b.
Fuel presents the hazard of fire or
explosionwhichcanresultin severe
personal injury or death.
Do not smoke or allow any
ignition sources in the installation area. Keep a type
ABC fireextinguishernearby. Theventilationsystemof
theinstallationareamustprovideaconstantflowof air
toexpelanyaccumulationof fuel vaporwhilethevehi-
cleis intransit. Compartmentsmust be vapor tight to
fhevehicleinterior topreventanyfumes fromentering
the vehicleinterior.
GASOLINE FUEL SYSTEM .
Fuel System Provisions
Generatorsetinstallationsmay
be designedtosharethe
vehicle fuel
supply tank with the vehicle engine. AI1
connections to the vehicle fuel tank must be done in
accordance with chassis (vehicle) manufacturer's
detailed installation instructions. See Fuel
Line In-
stallation.
The generator set includes a
fuel shut-off valve as a
safety feature and
is an integral part of the fuel pump.
Should the vehicle fueltank become pressurized, the
positivefuel shut-off prevents floodingof the generator
set
when the set is not operating.
Forlhe possibility of contaminatedfuel,Onanrecommendsanin-line
luel filter.
.
Recommended Fuel
Use clean,fresh, unleaded or regular grade gasoline.
Using unleaded gasoline results in extended periods
between service, longer spark
plug life, and reduced
carbon.clean-out maintenance.
If regular gasoline is
used,lead deposits must be removed from the cylinder
heads as required
to 'alleviate engine power loss.
Unleaded gasolinemay
be safely used after lead depos-
its have been removed. . .
Do not alternate between leaded
k&%!@l (regular) and unleaded gasoline.
Lead deposits can cause engine damage if
not
removedbefore usingunleadedgasoline.
Fuel Consumption
It should be noted that under varying electrical loads,
fuel consumption of engines for recreational vehicle
generator
sets variesaccordingly.
Fuel
Line Installation
Recreationalvehicle
fuel systems aredesignedto oper-
ate
in a criticalpressure range.It is very important dur-
ing the installation of the generatorsetthat the vehicle
fuel
supply design NOT be altered. The fuel fill tube, fill
limitervent, vapor canister,vapor lines and gas fill cap
should
never be changed,removed or replaced without
PRIOR approval from thevehicle manufacturer. Check
thefiller
cap to ensure thatthe pressure vacuum relief
valve is functioningproperly.Replace if required.
If separateconnection is not suppliedforthegenerator,
addasecondfuelpickup inthetank.Thispickupshould
not extend belowthebottom 1 /4 of tank so thevehicle
can
still be run, after generator runs out of fuel.
.
Do NOTtee off thevehiclefuel line, doing so may cause
poor operation of thegenerator or
the vehicle. Consult
with vehicle manufacturerforfurtherspecificsregard-
ing asharedfuel supply. Unauthorizedfuelsystemmod-
ifications could
result in dangerous operating con-
ditions.
ACA~ON
Connecfingfhegeneratorsetfuelline
a with a fee to the main fuel.line can
resun in fhe generafor set starving for fuel when ihe
vehicle is operatedat highway speeds. Thegenerafor
setfuelpumphasneitherthe
capacity nor thepower to
overcomefhe
draw ofthevehicleenginefuelpump. Use
a separafe fuel line for thegeneraforset.
Gasolinepresentsthehazardofexplo-
[-I sion or firewhich can resulf insevere
personalinjuryordeath.
Do not connectthegenerator
setfuel line tothepressurizedpart of thevehiclefuel
system. Flooding of thegeneratorsetengineand com-
partmenf can occur,resulfingina firehazard.
tnstall an approved, flexible non-metallic (non-
conductive)andnon-organicfuel
line betweenthe veh-
ickfuel system and thegenerator set to absorbvibra-
tion. Onan recommends using a seamlesssteeltubing
and flared connectionsfor long
runs between the fuel
tank and the flexible connectorto the generatorset.
Run fuel linesatthe same height asthetop level of tank
toa point asclosetothe
engine aspossible. This redu-
cesthedangeroffuelsiphoningoutofthetankiftheline
should break.
.
16
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Keep fuel linesawayfrom hot engine or exhaustareas.
This reduces chance of vaporlock. Install lines so that
they are accessible and protected from damage. Use
metal strapswithout sharp edges
to securethem.
No &ad
Half Load
0.5 gal/hr 0.8 gal/hr
(1.9 I/hr)
(3.0 Vhr)
Flexible line must be long enough to allow for set
movement
in order to prevent binding, stretching or
breaking.
PROPANE (LPG) FUEL SYSTEM
(60 Hz Only)
+- Fuel System Provisions
' .- . Onan liquid LPG generatorsetscontain afiltercartridge
and magnet
in the fuel solenoid valve to protect the
solenoid valve and regulator valves from dirt and con-
taminants. The solenoid valve and
filter is shown in
Figure 11. Figure 12 shows the flow diagram for the
liquid LPG fuelsystem components used on thegenera-
tor
set
Full Load
1.3 gal/hr
(4.0 I/hr)
Generatorsetoperation using liquid LPG is very sensi-
tiveto altitude,temperature,and
BTU contentof the gas.
Variation
in any oneof thesefactorsdirectlyaffectsthe
performanceof thegenerator
set. Becauseof this, minor
adjustments
might be required after the installation,
refertoGeneratorSetService
Manual if adjustmentsare
required.
.,
Recommended Fuel
Use clean,fresh commercial propane or HD-5 grade
liquid propane gas in a mixture of at least 90 percent
propane.Propane
fuels otherthan HD-5 gradecancon-
tain morethan
2.5 percentbutaneand can result in poor
fuel vaporization
and poor engine starting in low
ambienttemperatures(below32°For
OOC).
Fuel Consumption
It should be noted that under varying electrical loads,
fuel consumption of engines for recreational vehicle
generator set varies accordingly. Average fuel con-
sumption
at various loads is shown in thetable below.
LPG FUEL CONSUMPTION
Propane Fuel Lines and Supply Tank .
The installer must review all codes that apply to the
particularinstallation.Paragraph
3-5.1 (Gas Piping Sys-
tems) of NFPA Pamphlet 501C deals specifically with
propanefuel linesbutdoesnotnecessady coverallapplicable
codes and regulations. You
can obtain this pamphlet
from the address listed in thebeginning of this manual.
When installing the fuel lines, keep the following in
mind:
1. Install all propanefuel lines so they areaccessible,
yet protected from damage.
2.
3.
4.
FUEL FILTER
BODY
FIGURE 11. FUEL SOLENOlO VALVE AND FILTER
Use metal straps withoutsharpedgesto securefuel
lines.
Keep fuel lines away from hot engine or exhaust
areas.
Do NOT run fuel lines in conjunction with electrical
wiring.
Most propane (LPG) liquid withdrawal generator set
installationsaredesignedto sharethevehiclepropane
fuel supplytank(s). The vehicle propanefuel supply tank
MUST have a dip tubeto ensure liquid withdrawal.
An excess flow valve MUST be mounted internal to the
propane
fuel supplytank(s) per NFPA 501 C, Paragraph
3-4.4. This excess flow valve and propane fuel lines
MUST besized
so the excess flow valve will close with a
completely
severed (broken)propane fuel line. For
operation at the lowest ambient temperature, a valve
rated at
2.6 gallonsper hour (9.9 Vhr) flow rateand 6.5
pounds per square inch (45 kPa)differential pressure is
recommended. Consultthe Natural LP GasAssociation
for
the limitationsof excess flow valves.
17
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Install an approved flexible non-metallic (non-
conductive)andnon-organicfuel linebetweentheveh-
iclefuel system andthe generatorset to absorbvibra-
tion.Onan recommends usinga seamless steel tubing
and flared connection
for long runs between the fuel
tankandtheflexible connectorto the generator set.
aldotIurV~~)
Mu3 confonn to ASME or doland
CTC slandards. (Working pressure
A manualshut-0%valve MUSTbemountedonthepro-
panefuelsupplytank.Thissupplytankvalve
MUST be
fully open when operatingthe generatorset
to ensure
theexcessflowvalve
will closewithasevered(broken)
propanefuel line.
Must Close with Completeline
Breakage.ConsultNational
LP Gas
AssocialionPublication
113-78
For Limitations.
VblQZ
.-A hydrostatic pressure relief valve MUST be installed
betweenthe propanefuel supplytank manualshut-off
valve and the propane fuel solenoid valve and filter
assembly
.
This relief valve protects the propane fuel line from
pressurebuildupifboththesupplytankmanualshut-off
valveandthefuelsolenoidvalveareclosedatthesame
time.
Testing Fuel System for Leaks
The completedpropanefuel system installationMUST
becheckedandtestedforleaksbeforethegeneratorset
isoperated.ThefuelsolenoidMUST beenergizedfrom
a separate
12 volt DC source beforetesting the fue
systemforleaks.Thetest
MUST conformtoprocedure:
listedin
NFPA-58, Paragraph 318, or ULrecommended
test procedureas follows:
After assemblyandprior lo initialoperation, all iuel system connec-
tions,hose,valves,regulators,andfittingsmust
be testedandproven
free of anyleaks usinga soapand water or equivalentsolutionwhile
thesystem is under a gas or air pressure of not less than 90 pounds
persquare inch
(620 kPa).
Other approved methods of detecting leaks may be
used if appropriate. Test shall
NOT be made with a
flame.
.
..
Liquid LPG fuelpresents fhe hazard
EiSSiEI ' of explosion or firewhich can result
in severe personal injury
or deafh. Do not smoke or
allow any ignitionsources in the installationarea.
CARBURETOR
*l/enluri lype with bolh a"Main"and
!et adjustments.
when carburetorprovides suclion Io fuel outlet.
"
C.
I 'Idle-
.w
FIGURE 12 FLOW DIAGRAM OF UQUID LPG FUEL SYSTEM
18
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