Onan KVC Series User manual

1
Table of Contents
SAFETY PRECAUTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Codes and Standards for Safety 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Genset 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION, MOUNTING AND ENCLOSURE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL CONNECTIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL CONNECTIONS 11.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION REVIEW AND STARTUP 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Review 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAMS—120V A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAMS—100V A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety Precautions
Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can be obtained only when
equipment is operated and maintained properly.
The following symbols in this manual alert you to po-
tential hazards to the operator, service person and
equipment.
alerts you to an immediate hazard
which will result in severe personal injury or
death.
WARNING alerts you to a hazard or unsafe
practice which can result in severe personal
injury or death.
CAUTION alerts you to a hazard or unsafe
practice which can result in personal injury or
equipment damage.
Electricity, fuel, exhaust, moving parts and batteries
present hazards which can result in severe personal
injury or death.
GENERAL PRECAUTIONS
•Keep ABC fire extinguishers handy.
•Make sure all fasteners are secure and torqued
properly.
•Keep the genset and its compartment clean.
Excess oil and oily rags can catch fire. Dirt and
gear stowed in the compartment can restrict
cooling air.
•Before working on the genset, disconnect the
negative (–) battery cable at the battery to pre-
vent starting.
•Use caution when making adjustments while
the genset is running—hot, moving or electri-
cally live parts can cause severe personal inju-
ry or death.
•Used engine oil has been identified by some
state and federal agencies as causing cancer
or reproductive toxicity. Do not ingest, inhale, or
contact used oil or its vapors.
•Benzene and lead in some gasolines have
been identified by some state and federal
agencies as causing cancer or reproductive
toxicity. Do not to ingest, inhale or contact gaso-
line or its vapors.
•Do not work on the genset when mentally or
physically fatigued or after consuming alcohol
or drugs.
•Carefully follow all applicable local, state and
federal codes.
GENERATOR VOLTAGE IS DEADLY!
•Generator output connections must be made
by a qualified electrician in accordance with ap-
plicable codes.
•The genset must not be connected to the public
utility or any other source of electrical power.
Connection could lead to electrocution of utility
workers and damage to equipment. An ap-
proved switching device must be used to pre-
vent interconnections.
•Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth-
ing and shoes are dry and stand on a dry wood-
en platform.
ENGINE EXHAUST IS DEADLY!
•Learn the symptoms of carbon monoxide poi-
soning in this manual and never sleep in the
vehicle while the genset is running unless the
vehicle is equipped with a working carbon mon-
oxide detector.
•The exhaust system must be installed in accor-
dance with the genset Installation Manual.
Engine cooling air must not be used for heating
the working or living space or compartment.
•Inspect for exhaust leaks at every startup and
after every eight hours of running.
•Make sure there is ample fresh air when operat-
ing the genset in a confined area.
FUEL IS FLAMMABLE AND EXPLOSIVE
•Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equip-
ment. Keep flame, sparks, pilot lights, arc-pro-
ducing equipment and switches and all other
sources of ignition well away.
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3
•Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
•Leaks can lead to explosive accumulations of
gas. Natural gas rises when released and can
accumulate under hoods and inside housings
and buildings. LPG sinks when released and
can accumulate inside housings and base-
ments and other below-grade spaces. Prevent
leaks and the accumulation of gas.
BATTERY GAS IS EXPLOSIVE
•Wear safety glasses and do not smoke while
servicing batteries.
•When disconnecting or reconnecting battery
cables, always disconnect the negative (–) bat-
tery cable first and reconnect it last to reduce
arcing.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
•Do not wear loose clothing or jewelry near mov-
ing parts such as PTO shafts, fans, belts and
pulleys.
•Keep hands away from moving parts.
•Keep guards in place over fans, belts, pulleys,
etc.
MOBILE 6
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Introduction
ABOUT THIS MANUAL
This manual is a guide for the installation of the KVC
Series of generator sets (gensets). Proper installa-
tion is essential for safe, reliable and quite opera-
tion. Read through this manual before starting the
installation. Keep this manual and the Operator’s
Manual with the other vehicle manuals.
This manual addresses the following aspects of the
installation:
•Location, Mounting and Enclosure
•Exhaust System
•Fuel Connections
•Electrical Connections
•Startup
WARNING Improper installation can result in
severe personal injury, death and equipment
damage. The installer must be qualified to per-
form the installation of electrical and mechani-
cal equipment.
CAUTION Unauthorized modifications or re-
placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in the State of
California.
See the Operator’s Manual for operation and main-
tenance and the Service Manual for service.
Note: Manuals are updated from time-to-time to re-
flect changes in the equipment and its specifica-
tions. For this reason, only the copy of the installa-
tion manual supplied with the genset should be used
as a guide for the installation.
INSTALLATION CODES AND STANDARDS
FOR SAFETY
The builder of the RV or work vehicle bears sole re-
sponsibility for the selection of the appropriate gen-
set, for its proper installation and for obtaining ap-
provals from the authorities (if any) having jurisdic-
tion over the installation. These sets meet the basic
requirements of the Standard for Safety for Engine
Generator Sets for Recreational Vehicles, ANSI/
RVIA EGS-1. They are suitable for installation in ac-
cordance with:
•NFPA No. 70, Article 551—Recreational
Vehicles and RV Parks
•ANSI A119.2 (NFPA No. 501C)—Recreational
Vehicles
•CSA Electrical Bulletin 946—Requirements for
Internal Combustion Engine-Driven Electric
Generators for Use in Recreational Vehicles
Federal, State and local codes, such as the Califor-
nia Administrative Code—Title 25 (RV installation),
might also be applicable. Installation codes and rec-
ommendations can change from time-to-time and
are different in different countries, states and mu-
nicipalities. Obtain the standards in Table 1 for refer-
ence.
TABLE 1. REFERENCE CODES AND STANDARDS
NFPA No. 70
NFPA N0. 501C
National Fire Protection Association
470 Atlantic Avenue
Boston, MA 02210
ANSI A119.2
ANSI/RVIA-EGS-1
FMVSS 301
Recreational Vehicle Industry Association
14650 Lee Road
Chantily, VA 22021
California Adminis-
trative Code—Title
25, Chapter 3
State of California Documents Section
P.O. Box 1015
North Highlands, CA 95660
CAN/CSA-Z240
Recreational
Vehicles
Bulletin 946
Canadian Standards Association
Housing and Construction Materials Section
178 Rexdale Blvd.
Rexdale, Ontario, Canada M9W 1R3
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TYPICAL GENSET
Figure 1 illustrates a typical genset installation. For
clarity, the genset compartment door and front pan-
els (provided by the vehicle manufacturer) are not
shown. See OUTLINE DRAWING (Page A-1) for
installation details: mounting bolt hole locations,
connection points (fuel, battery, remote control, AC
output and exhaust), sizes and types of fittings, inlet
and outlet air openings, weight and overall dimen-
sions, etc. See your Onan dealer for large-scale
copies of the drawings.
CAUTION Do not tip the genset forward or oil
will spill into the breather.
COOLING
AIR HOT AIR
DISCHARGE
MUFFLER/TAILPIPE
ASSEMBLY
STEEL ENCLOSURE AND COOLING AIR PLENUM THAT SEALS TIGHT
AROUND SIDES, TOP AND FRONT TO PREVENT AIR RECIRCULATION. FRONT
ACCESS COVER MUST ALSO SEAL TIGHT (COACH MANUFACTURER)
AIR SEAL
PANEL
THE DOTS REPRESENT
LOCATIONS REQUIRING
ACCESS FOR OPERATION AND
PERIODIC MAINTENANCE
VEHICLE FRAME, GENSET OUTRIGGERS
AND 2 OF 4 MOUNTING BOLTS
FIGURE 1. TYPICAL GENSET INSTALLATION
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Location, Mounting and Enclosure
These gensets are designed for installation inside a
steel compartment that forms the cooling air plenum
of the genset (Figure 1). The cooling air inlet and hot
air discharge openings are both in the bottom of the
genset. The genset has mounting flanges and is
meant to be lifted up to the bottom of the vehicle
frame outriggers and bolted.
1. The location must be such that the tailpipe
clears the back of the coach body by at least
1 inch (25.4 mm) when installed (Figure 3).
2. Support the genset on a structure able to resist
the dynamic weight of the genset: cyclic forces
of at least 300±lbs (±3 g-force) vertical and
100 ± lbs (±1 g-force) horizontal.
WARNING The genset can fall from the
vehicle if the supporting structure is too
weak and cause severe personal injury or
death. Design the structure carefully, follow
applicable mounting kit instructions and
torque mounting bolts properly.
3. The genset compartment must be sized
according to the outline drawing (Page A-1).
Construction must be such that the compart-
ment forms a good seal against the foam seal
strips shown in Figure 2, to prevent warm air off
the engine from recirculating back into the
blower inlet. The air seal panel (Figure 1) pre-
vents air recirculation in front. It must be
removed (two screws) before the genset can
be installed or removed from the compartment.
4. The genset must be isolated from the vehicle
living space to prevent the entrance of engine
exhaust, gasoline vapors and noise. The gen-
set compartment must therefore be vapor-tight
and fire resistive. Do not duct genset cooling
air, which can include exhaust gases, into the
vehicle for heating.
WARNING EXHAUST GAS AND FIRE ARE
DEADLY! — Install a vapor-tight and fire-re-
sistive barrier of approved materials
between the genset and the vehicle interior.
— Do not duct genset cooling air into the
vehicle for heating.
5. The cooling air inlet and hot air discharge open-
ings in the bottom of the genset must not be
obstructed by other components.
6. Acoustic insulation and adhesive should be
Classified as “Self-Extinguishing” at not less
than 200°F (90°C). Acoustic insulation can
absorb spilled fuel and oil and therefore should
not be used underneath the genset. Insulation
thickness must be such that it does not interfere
with the governor mechanism (on top) or touch
hot exhaust components.
SEALING
STRIPS
SEALING
STRIPS
FIGURE 2. AIR SEALING STRIPS
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Exhaust System
This genset must be installed with the muffler/tail
pipe assembly and mounting hardware shipped
with the genset (Figure 3). The muffler has a U.S.
Forest Service approved spark-arrestor. Failure to
provide and maintain a spark arrestor can be a vio-
lation of the law.
Liability for damage or injury, and warranty ex-
penses due to use of unapproved mufflers becomes
the responsibility of the person installing the muffler.
Contact an Onan distributor or dealer for approved
exhaust system parts.
WARNING EXHAUST GAS IS DEADLY! Keep
exhaust gases from entering the vehicle. Do not
terminate the exhaust tailpipe underneath the
vehicle or closer than 6 inches (153 mm) to
openings into the vehicle or route it such that it
is not protected. Use approved materials only.
MUFFLER CLAMP
HERE
MUFFLER HANGARS
HERE
MUFFLER/TAILPIPE
ASSEMBLY
FIGURE 3. EXHAUST SYSTEM
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Use the hardware in the muffler kit to install the muf-
fler/tailpipe assembly in the orientation shown in
Figure 3:
1. Be careful not to damage the flexible exhaust
tube. Secure the two hangers, one on each end
of the muffler so that the flexible pipe lines up
exactly with the engine outlet.
2. Do not route the tail pipe near fuel lines or fuel
tanks.
3. Do not mount the muffler or tailpipe closer than
3 inches (76 mm) to combustible material
(wood, felt, cotton, organic fibers, etc.) unless
it is insulated or shielded. The temperature rise
(above ambient) on adjacent combustible
material must not exceed 117° F (65° C).
4. To keep the tailpipe from being damaged, do
not route it such that it protrudes into the ap-
proach or departure angles of the vehicle or
below the axle clearance line (Figure 4).
5. Do not terminate the tailpipe underneath the
vehicle. Extend it a minimum of 1 inch (25 mm)
beyond the perimeter of the vehicle (Figure 5).
Support the end of the tailpipe such that it can-
not be pushed inward and up under the skirt of
the vehicle.
6. Do not terminate the tailpipe such that it is clos-
er than 6 inches (153 mm) to any opening, such
as a door, window, vent or unsealed compart-
ment, into the vehicle interior (Figure 6)
DEPARTURE
ANGLE
APPROACH
ANGLE
AXLE CLEARANCE
LINE
FIGURE 4. VEHICLE DEPARTURE ANGLE
1 INCH (25 mm)
MINIMUM
LAST TAILPIPE HANGER AS
CLOSE TO END AS
PRACTICAL
FIGURE 5. TERMINATING THE EXHAUST TAILPIPE
NO OPENING INTO THE VEHICLE INTERIOR MAY
BE CLOSER THAN 6 INCHES (153 mm) TO THE
END OF THE TAIL PIPE (WITHIN SHADED AREA)
6 in
153 mm
TAILPIPE
FIGURE 6. MINIMUM DISTANCES TO OPENINGS
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9
Fuel Connections
See the Operator’s Manual for recommended fuels
and Specifications for fuel consumption rates.
WARNING Gasoline is flammable and explo-
sive and can cause severe personal injury or
death. Do not smoke or allow any flame, spark,
pilot light, arc-producing equipment, switches
or other ignition sources around fuel or fuel
components, or in areas sharing ventilation.
Keep an ABC fire extinguisher handy.
Onan recommends a separate fuel pickup tube or a
separate fuel tank for the genset. The genset must
never be connected to the fuel supply line of the
vehicle engine—either to a high-pressure system
(pump in tank), which can overpressurize the gen-
set fuel system, or to a vacuum system (pump on
engine), which can cause the genset to starve for
fuel. Some vehicle chassis manufacturers allow
connections to the fuel return line on high pressure
fuel systems. Contact the vehicle chassis manufac-
turer for approval. Fuel line pressure at the point
where the genset is connected must not exceed
1-1/2 psi under any condition.
WARNING Excessive fuel pressure can flood
the genset causing a fire. Genset fuel supply
line pressure must not exceed 1-1/2 psi under
any condition.
For separate fuel pickup tube installations:
1. Contact the vehicle chassis manufacturer
regarding installation of the second fuel pickup.
Do not change or remove the fuel fill tube, fill
limiter vent, vapor canister, vapor lines, filler
cap or any other part of the fuel system without
the approval of the vehicle chassis manufac-
turer. Doing so could affect vehicle engine
operation or vehicle emissions regulation com-
pliance.
2. Terminate the genset pickup above the vehicle
pickup to prevent the genset from running the
vehicle out of fuel.
Note: Federal standards for vehicle fuel tanks may
require the installation of an automatic shutoff valve
at the genset fuel tank pickup to prevent leakage in
the event of a roll-over. Federal standards for vehicle
impact, roll-over and emmisions may also apply to a
separate genset fuel tank. Check with the vehicle
chassis manufacture regarding these standards.
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For long runs use copper or hot dip coated
seamless steel tubing (ASTM A-254) with double-
flared fittings. See Figure 7 for the connection at the
genset. Use 1/4 inch I. D. fuel hose (SAE 30-R7)
and stainless steel hose clamps.
Run the fuel line at or above the top of the fuel tank to
reduce the risk of siphoning fuel out of the tank if the
line should break. The maximum fuel pump lift is 36
inches (914 mm).
Route gasoline fuel lines away from electrical wiring
and hot engine exhaust components. (Heat can
cause fuel vapor lock.) Fuel lines should be
accessible for inspection and replacement,
protected from damage and secured to prevent
kinking, contact with sharp edges and chafing due
to vibration.
WARNING Sparks can ignite gasoline, leading
to severe personal injury or death. Do not run
electrical wiring and fuel lines together. Sepa-
rate them with conduit or tubing if run through
the same opening. Do not tie them together.
FIGURE 7. FUEL CONNECTION
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Electrical Connections
Do not connect the battery cables to the battery until
Installation Review and Startup (Page 17) to pre-
vent accidental starting of the genset during
installation.
WARNING Accidental starting of the genset
can cause severe personal injury or death. Do
not connect the starting battery until Installa-
tion Review and Startup (Page 17).
GENERATOR CONNECTIONS
The genset is equipped with 28 inch (715 m) long
AC power output leads in 1/2 inch flexible steel con-
duit (Figure 8). See Figure 9 for typical connections.
If these leads must be replaced by longer leads,
make sure their ampacity, as determined by the
appropriate chart in the National Electrical Code
(NEC), is at least 115 percent of the amps marked
on the genset circuit breaker. (Unless 125°C rated
wiring is available, heavier gauge wiring may be
required to obtain the required ampacity.)
Wiring Methods
Follow the National Electrical Code, especially not-
ing the following:
1. Have a qualified electrician supervise and in-
spect the installation of all AC wiring.
2. Install vibration-proof switches and controls
that won’t open and close circuits when the
vehicle is in motion.
3. Provide ground fault circuit interrupters
(GFCIs)for all convenience power receptacles.
4. Route AC wiring, remote control wiring and fuel
lines separately.
5. Seal all conduit openings into the vehicle inte-
rior to keep out exhaust gas. Apply silicone rub-
ber or an equivalent type of sealant inside and
outside each conduit connector. (Flexible con-
duit is not vapor-tight and will allow exhaust gas
to enter along the wires if not sealed.)
WARNING EXHAUST GAS IS DEADLY!
Seal all wiring openings into the vehicle
interior to keep out exhaust gas.
FIGURE 8. AC OUTPUT LEADS AND CONDUIT
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6. Bond the genset and all connected AC and DC
equipment and controls to a common ground-
ing point in accordance with applicable codes.
WARNING Faulty grounding can lead to
fire and electrocution, resulting in severe
personal injury or death. Grounding must
be in accordance with applicable codes.
Connecting the Vehicle to Utility Power
When the vehicle has provision for connecting utility
power it must have an approved device to keep the
genset and utility from being interconnected. See
Figure 9 for typical connections.
WARNING Interconnecting the genset and the
public utility (or any other power source) can
lead to the electrocution of personnel working
on the utility lines, damage to equipment and
fire. An approved switching device must be
used to prevent interconnections.
TO VEHICLE AC
N
L1L1
N
UTILITY POWER
GNDGND
DISTRIBUTION PANEL
TRANSFER SWITCH
120V120V
L1 N GND
GENSET
GREEN
WHITE
BLACK
FIGURE 9. TYPICAL CONNECTIONS WITH TRANSFER SWITCH AND UTILITY
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REMOTE CONTROL CONNECTIONS
Onan offers three varieties of remote control panel:
•Remote start/stop switch with indicator lamp
only (Figure 10).
•Remote start/stop switch with indicator lamp
and hour meter (Figure11).
•Remote start/stop switch with indicator lamp
and DC voltmeter (Figure12).
The genset has an 8-pin connector for remote con-
trol connections (Figure 13). Remote control wiring
harnesses in several lengths are available sepa-
rately. To make connections to a remote control
panel:
1. Snap the connector together with its mate in the
wiring harness from the remote panel. If the wir-
ing harness is made up by others, insulated 18
AWG copper conductors should be used for
distances up to 30 feet (9 meters) and heavier
gauge conductors for distances that are great-
er. Use flexible sheathing to protect remote
control wiring. Figure 14 is a schematic of typi-
cal remote control connections. It identifies the
function of each connector pin number. The re-
mote panel end of each lead should be marked
to identify the connector pin number.
2. Route control leads separately from AC power
leads to reduce the possibility of erratic opera-
tion due to false induced signals.
3. Seal the opening where the leads enter the
vehicle interior with silicone rubber or an equiv-
alent type of sealant to keep out exhaust gas.
WARNING EXHAUST GAS IS DEADLY!
Seal all wiring openings into the vehicle
interior to keep out exhaust gas.
FIGURE 10. REMOTE CONTROL
FIGURE 11. REMOTE CONTROL / HOUR METER
FIGURE 12. REMOTE CONTROL / DC VOLTMETER
FIGURE 13. REMOTE CONTROL CONNECTOR
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+
–
+
–
CONNECTOR MATEREMOTE CONTROL
PANEL
START
GND
STOP
START/STOP SWITCH
DC VOLTMETER
DC
VOLTMETER
+
–
HOUR METER
HOUR METER
OPTIONAL
OPTIONAL
A
B
C
F
GENSET
CONNECTOR
EFG H
WIRE END
CONNECTOR END
WIRE END
CONNECTOR END
A
B
C
DE
F
G
H
A
A
B
B
WIRE END
(VIEW B–B)
CONNECTOR END
(VIEW A–A)
LED
RUN (SWITCHED B+)
FIGURE 14. SCHEMATIC OF TYPICAL REMOTE CONTROL CONNECTIONS
BATTERY CONNECTIONS
Do not connect the battery cables to the battery until
Installation Review and Startup (Page 17) to pre-
vent accidental starting of the genset during installa-
tion.
WARNING Accidental starting of the genset
can cause severe personal injury or death. Do
not connect the starting battery until Installa-
tion Review and Startup (Page 17).
The genset has a 12 VDC, negative-ground engine
control and cranking system. See Specifications for
the requirements for cranking batteries.
Battery Compartment
Batteries must be mounted in a separate compart-
ment from that of the genset and away from spark-
producing equipment. A compartment must have
openings of at least 1.7 square inches (11 square
centimetres) at the top and bottom for ventilation of
battery gasses. It should be mounted such that
spills and leaks will not drip acid on fuel lines, wiring
and other equipment that could be damaged.
WARNING Arcing can ignite the explosive hy-
drogen gas given off by the battery, causing se-
vere personal injury. The battery compartment
must be ventilated and must isolate the battery
from spark-producing equipment.
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15
Battery Cables
Size battery cables according to Table 2. The cur-
rent path between the genset and the negative (–)
battery terminal must also be able to carry full crank-
ing current without causing excessive voltage drop.
It is highly recommended that a full-length cable be
used to connect the genset to the negative (–) bat-
tery terminal (Figure 15). Note also that codes may
require bonding conductors from the genset and the
battery to the vehicle frame.
If a full-length negative (–) cable is not run from the
battery (Figure 16), all vehicle frame members in
the path of battery cranking currents must have sub-
stantial crossections. The electrical resistance of
riveted or bolted frame joints must also be carefully
considered, especially if the joints will be exposed to
corrosive conditions. A cable must be used to con-
nect the frame to the designated negative (–) termi-
nal on the genset (Figure 16). The cable must be
sized according to Table 2. The genset mounting
bolts are not considered adequate means for
bonding the genset to the vehicle frame, either
for the purpose of carrying cranking currents or
for complying with requirements for genset/
system grounding.
Route battery cables away from fuel lines and hot
engine exhaust components. Battery cables should
be accessible for inspection and replacement,
protected from damage and secured to prevent
chafing due to vibration.
WARNING Routing battery cables with fuel
lines can lead to fire and severe personal injury
or death. Keep battery cables away from fuel
lines.
Terminate the battery cables with appropriately
sized eyelet connectors and connect them to the
genset as shown in Figure 17.
TABLE 2. BATTERY CABLE SIZES FOR
TEMPERATURES DOWN TO –20°F (–29° C)
TOTAL CABLE LENGTH*
FEET (METERS)
CABLE SIZE
AWG
0 to 10 (0 to 3) 2**
11 to 15 (3 to 4.5) 0
16 to 20 (4.5 to 6) 000
* – Add the negative battery cable lengths with the positive
battery cable lengths for the total.
** – A total length of up to 20 feet (6 meters) may be used
in warmer climates or when battery capacity totals at least
1000 CCA (Cold Cranking Amps).
GENSET
BAT
–+
–
+
SIZE PER TABLE 2
#8 AWG
MINIMUM
VEHICLE FRAME
FIGURE 15. FULL-LENGTH CABLE FROM
BATTERY NEGATIVE (–) TERMINAL
GENSET
BAT
–+
–
VEHICLE FRAME
+
SIZE PER TABLE 2
FIGURE 16. VEHICLE FRAME AS PATH FROM
BATTERY NEGATIVE (–) TERMINAL
+–
FIGURE 17. BATTERY CABLE CONNECTIONS
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16
Specifications
GENERATOR: 2-Pole Revolving Field, Self-Excited, 1-Phase, Electronically Regulated
Power 2800 watts 2800 watts
Frequency 60 Hertz* 60 Hertz
Voltage 120 volts 100 volts
Current 23.3 amperes 28 amperes
Speed 3600 rpm 3600 rpm
FUEL CONSUMPTION: Gasoline Gasoline
No load
Half load
Full load
0.16 gph (0.6 l/h)
0.28 gph (1.1 l/h)
0.46 gph (1.7 l/h)
0.16 gph (0.6 l/h)
0.28 gph (1.1 l/h)
0.46 gph (1.7 l/h)
ENGINE: 1-Cylinder, 4-Stroke Cycle, Spark-Ignited, OHV, Air Cooled, Mechanically Governed
Bore 2.64 inch (67 mm) 2.64 inch (67 mm)
Stroke 2.2 inch (56 mm) 2.2 inch (56 mm)
Displacement 12 inch3(197 cc) 12 inch3(197 cc)
Compression Ratio 8.5 : 1 8.5 : 1
Oil Capacity 1 quart (0.95 l) 1 quart (0.95 l)
Intake Valve Lash (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm)
Exhaust Valve Lash (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm)
Spark Plug Gap 0.025 inch (0.64 mm) 0.025 inch (0.64 mm)
Spark Plug Tightening Torque 13 lbs-ft (17 N-m) 13 lbs-ft (17 N-m)
Ignition Timing (magneto type ignition) 25°BTDC, non-adjustable 25°BTDC, non-adjustable
DC SYSTEM:
Nominal Battery Voltage 12 volts 12 volts
Min. Battery Rating: Cold Cranking Amps (CCA)
@ 0°F (–18°C)
360/450
above/below 32°F (0°C)
360/450
above/below 32°F (0°C)
Control Fuse 5 amperes 5 amperes
INSTALLATION:
Weight of Genset (with engine oil) 100 lbs (45 kg)
Minimum Compartment Size
(H x D x W)**
15.5 inch x 17.5 inch x 20.2 inch
(394 mm x 445 mm x 512 mm)
Minimum Free Air Inlet Area 40 inch2(258 cm2)
Muffler Outlet Collar O. D. 1.13 inch
Fuel Connection 1/4 inch barb fitting for gasoline hose
* Listed by CSA and the U. S. Testing Company.
** See the Installation Manual for additional considerations when sizing the genset compartment.
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17
Installation Review and Startup
INSTALLATION REVIEW
Before starting the genset inspect the installation
and check (√) each of the following questions if it can
be answered “YES”. If an item cannot be checked
provision must be made to satisfy the requirement.
[ ] Is the control panel on the genset easily acces-
sible for starting and stopping the genset and
resetting the circuit breaker?
[ ] Is there easy access for checking and adding
engine oil, replacing the spark plug and chang-
ing the air filter?
[ ] Is the genset securely bolted in place?
[ ] Are all specified clearances provided?
[ ] Are the air inlet and outlet openings free of ob-
structions?
[ ] Is there access for draining engine oil?
[ ] Are all tailpipe connections tight and all hang-
ers and support straps secure?
[ ] Does the tailpipe terminate at least 1 inch
(25 mm) beyond the perimeter of the vehicle
and at least 6 inches (153 mm) away from any
opening into the vehicle?
[ ] Is the genset located outside the vehicle interior
or separated by approved vapor-tight and fire-
resistive materials?
[ ] Are all openings into the vehicle, such as for AC
wiring, sealed to keep out engine exhaust? Are
AC conduit connectors sealed inside and out-
side?
[ ] Have all AC connections been inspected and
approved?
[ ] Has a properly sized battery(ies) been installed
in a ventilated compartment isolated from the
genset?
[ ] Have properly sized battery cables been
installed and secured at sufficient intervals to
prevent chaffing and contact with sharp edges,
fuel lines and hot exhaust parts?
[ ] Are all fuel connections tight?
[ ] Has the fuel line been secured at sufficient in-
tervals to prevent chaffing and contact with
sharp edges, electrical wiring and hot exhaust
parts?
STARTUP
When all the items on the Installation Review check
list have been checked , connect the battery cables
to the battery, positive (+) cable first.
WARNING Batteries give off explosive gases
that can cause severe personal injury. Do not
smoke near batteries. Keep flames, sparks, pilot
lights, electrical arcs and arc-producing
equipment and all other ignition sources well
away.
Read the Operator’s Manual and perform the main-
tenance and pre-start checks instructed. The gen-
set is shipped from the factory with the proper level
of engine oil, which should nevertheless be checked
before the genset is started. Start and operate the
genset, following all the instructions and safety pre-
cautions in the Operator’s Manual.
WARNING EXHAUST GAS IS DEADLY! Do not
operate the genset when the vehicle is indoors
or where exhaust can accumulate.
Check for fuel and exhaust leaks and unusual
noises while the genset is running under full and in-
termediate loads. Do not place the genset in service
until all fuel and exhaust leaks have been fixed and
operation is satisfactory.
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