965 0631 Onan BGM NHM Marquis Series RV Genset Installation Manual (05 1992)

User Manual: 965-0631 Onan BGM NHM Marquis series RV Genset Installation manual (05-1992)

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Installation
Manual
RV GenSets

RV Electric Generating Sets

965-0631
5-92
Printed in U.S.A.

The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.

Redistribution or publication of this document,
by any means, is strictly prohibited.

Table of Contents
SECTION

TITLE

PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Installation Codes and Safety Recommendations . . . . . . . . . . . . . . . . . . . . 1-1

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Compartment Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Under-Floor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

VENTILATION AND ACOUSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailpipe Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1
5-1
5-1
5-3

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Gasoline Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
LPG Liquid Withdrawal Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1
7-1
7-4
7-6

INITIAL START AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Initial Start-Up/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Installation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

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by any means, is strictly prohibited.

Safety Precautions
Thoroughly read the INSTALLATION MANUAL
before installing the genset. Safe operation and
top performance can be obtained only with
proper genset installation.

• Use caution when making adjustments while
the genset is running—hot, moving or electrically live parts can cause severe personal injury or death.

The following symbols in this Manual alert you to
potential hazards to the operator, service person
and equipment.

• 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.

Alerts you to an immediate hazard
which will result in severe personal injury or
death.

• Benzene and lead in some gasolines have
been identified by some state and federal
agencies as causing cancer or reproductive
toxicity. Do not ingest, inhale or contact gasoline or its vapors.

WARNING Alerts you to a hazard or unsafe
practice which can result in severe personal injury or death.

• 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.

Alerts you to a hazard or unsafe
practice which can result in personal injury or
equipment damage.
CAUTION

Electricity, fuel, exhaust, moving parts and batteries
present hazards which can result in severe personal injury or death.

GENERATOR VOLTAGE IS DEADLY!
• Generator output connections must be made
by a qualified electrician in accordance with applicable 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, damage to equipment and fire. An approved switching device must be used to prevent interconnections.
• Use caution when working on live electrical
equipment. Remove jewelry, make sure clothing and shoes are dry and stand on a dry wooden platform on the ground or floor.

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 prevent starting.

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by any means, is strictly prohibited.

FUEL IS FLAMMABLE AND EXPLOSIVE

MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH

• Keep flames, cigarettes, sparks, pilot lights,
electrical arc-producing equipment and
switches and all other sources of ignition well
away from areas where fuel fumes are present
and areas sharing ventilation.
• Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
• Use approved non-conductive flexible fuel
hose for fuel connections at the genset.

• Do not wear loose clothing or jewelry near moving parts such as PTO shafts, fans, belts and
pulleys.
• Keep hands away from moving parts.
• Keep guards in place over fans, belts, pulleys,
etc.

ENGINE EXHAUST IS DEADLY!
• Learn the symptoms of carbon monoxide poisoning in this Manual.
• Never sleep in the vehicle while the genset is
running unless the vehicle has a working carbon monoxide detector.
• The exhaust system must be installed in accordance with the genset Installation Manual.
• Do not use engine cooling air to heat the vehicle interior.
• Make sure there is ample fresh air when operating the genset in a confined area.

BATTERY GAS IS EXPLOSIVE
• Wear safety glasses and do not smoke while
servicing batteries.
• When disconnecting or reconnecting battery
cables, always disconnect the negative (- ) battery cable first and reconnect it last to reduce
arcing.

MBL-1

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iii

1. Introduction
operation of RV generator sets. The address of
each agency is listed so that copies of the codes
may be obtained for reference. Installation codes
and recommendations are subject to change, and
may vary by location or over time. The RV manufacturer and the genset installer bear sole responsibility for following all applicable codes and regulations.

GENERAL
This manual provides installation guidelines for the
Onan BGM and NHM generator sets. A genset
cannot be operated reliably, quietly, and safely unless it is installed correctly. Read this entire manual
before starting installation.
For operation and maintenance procedures, see
the Operator’s Manual, publication 965-0131, that
accompanies each set.

1. ANSI-A119.2
FMVSS 301

When properly installed, this generator set meets or
exceeds the following requirements:
• National Electrical Code, Article 551
• ANSI/RVIA EGS-1 - 1986, Generator Set Standard
• ANSI A119.2/NFPA 501C Standard for Recreational Vehicles
• CSA Electrical Bulletin 946

2. NFPA 70 (N.E.C.) National Fire Protection
NFPA-501C
Association
NFPA 58
470 Atlantic Avenue
Boston MA 02210

The RV manufacturer and/or the set installer must
comply with local codes such as California administrative Code Title 25, which applies to generator set
installation. The RV installer bears sole responsibility for the selection of the appropriate generator set,
installation design, and installation.
Consider the following requirements before installing the set. Each topic is covered in the following
text.
•
•
•
•
•
•
•
•

Recreational Vehicle
Industry Association
14650 Lee Road
Chantilly VA 22021

Level and supportive mounting surface
Adequate cooling air
Adequate fresh induction air
Discharge of circulated air
Electrical connections
Fuel installation
Accessibility for maintenance and service
Noise levels

3. CSA Electrical
Bulletin #946

Canadian Standards
Association, Housing and
Construction Materials
Section
178 Rexdale Blvd.
Rexdale, Ontario, Canada
M9W 1R3

4. California
Administrative
Code - Title 25
Chapter 3

State of California
Documents Section
P.O. Box 1015
North Highlands CA
95660

This manual contains information that is subject to
change. For this reason, use only the installation
manual supplied with the generator set for the installation.

WARNING Incorrect installation, service, or replacement of parts can result in severe personal
injury, death and/or equipment damage. Service personnel must be qualified to perform electrical and/or mechanical component installation.

INSTALLATION CODES AND SAFETY
RECOMMENDATIONS
The following list of Installation Codes and Safety
Recommendations applies to the installation and

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1-1

SPARK PLUGS (TOP ACCESS
TO FRONT AND REAR PLUG)

SUMMER/WINTER
ADJUSTMENT
OIL FILTER
FUSE
MUFFLER
AC CIRCUIT
BREAKERS
NEGATIVE (-) BATTERY
CABLE CONNECTION
START/STOP
SWITCH
FUEL PUMP (FUEL SOLENOID,
LPG GENSETS)
AC OUTPUT LEADS
60 INCHES (1.5 M)
LONG
NAMEPLATE
FUEL INLET
.25 INCH HOSE (GASOLINE)
.25 INCH NPTF (LPG)

OIL FILL AND
CHECK

GOVERNOR
CONTROLLER

OIL DRAIN VALVE
POSITIVE (+) BATTERY
CONNECTION
REMOTE CABLE
CONNECTOR

.50 INCH FLEXIBLE
CONDUIT CONNECTION
VOLTAGE
REGULATOR

FIGURE 1-1. MARQUIS GENERATOR SET

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1-2

2. General Specifications
MODEL

BGM

NHM

5000

6000

6800 (gasoline)
6500 (LPG)

Frequency (Hertz)

Voltage

120

Current (amperes)

41.7

56.7 (gasoline)
54.2 (LPG)

1800 RPM

3.5 quarts (3.8 l)

Gasoline

Gasoline, LPG

1/4 in. barb fitting

1/4 in. barb fitting
1/4 in. NPTF

0.4 gph (1.5 Lph)

0.7 gph (2.6 Lph)

0.6 gph (2.27 Lph)

1.0 gph (3.8 Lph)

1.3 gph (4.9 Lph)

0.4 gph (1.5 Lph)
0.5 gph (1.9 Lph)
0.7 gph (2.6 Lph)
1.0 gph (3.78 Lph)
1.3 gph (4.9 Lph)
1.6 gph (6.06 Lph)

GENERATOR DETAILS
Power (watts)

ENGINE DETAILS
Engine Speed
Oil Capacity (with filter)
Fuel
Fuel Inlet Connection (gasoline)
(LPG)
Average Fuel Consumption:
No Load
(gasoline)
(LPG)
Half Load
(gasoline)
(LPG)
Full Load
(gasoline)
(LPG)
LPG Vapor Supply Pressure
(Range)-V apor-Withdrawal
Models Only
Battery Requirements:
Battery
Cold Cranking Amps
Cold Cranking Amps
below 32° F (-0° C)

9 to 13 inch
(229 to 330 mm)
W. C. (water column)
One, 12-volt
360

One, 12-volt
360

450

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2-1

MODEL

BGM

NHM

Weight

258 lb (116 kg)

272 lb (123 kg0

Height

15.5 in. (394 mm)

Length

33.6 in. (854 mm)

Width

22.3 in. (566 mm)

Control Fuse

10 Ampere

Fuel Pump/Autochoke Fuse

10 Ampere

Air Requirement

450 ft3/min
12.6 m3/min

0.025 in. (0.64 mm)

12° BTDC

0.005 in. (0.13 mm)
0.013 in. (0.33 mm)

75-115 psi
(517-793 kPa)

GENERATOR SET DETAILS

TUNE-UP SPECS
Spark Plug Gap
Timing (non-adjustable)
Valve Lash:

Intake
Exhaust

Cylinder Compression (hot)

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2-2

3. Mounting
tor, control, choke, and governor areas. Use baffles
to protect certain areas. (See Ventilation and
Acoustics section.)

GENERAL
Marquis generator sets are designed for compartment and underfloor mounting. Both methods use
the set tray for support. Choose the appropriate
manual section and carefully follow the instructions.
Read this entire manual and exhaust kit and other kit instructions before installing the genset.

Compartment Construction
1. Install the generator set in its own compartment. See Figures 3-1 and 3-2.
2. If any part of the compartment is above the vehicle floor, separate the compartment from the
vehicle interior and fuel supply with a vaportight wall.
3. Line the compartment walls with 26-gauge galvanized steel or a material of comparable
strength and fire resistance (see NFPA 70,
NEC and California Title 25 for complete details).

COMPARTMENT MOUNT
In a compartment mount, the set is installed on a
frame that is part of the vehicle. This frame must be
constructed according to safety-approved specifications (see Compartment Construction in this section).
Unless the set will be removed from underneath the
vehicle, make the access opening large enough to
remove the set. Allow extra clearance to access the
following components:
•
•
•
•
•
•
•
•
•
•

Exhaust gases present the hazard of severe personal injury or death.
Make the compartment walls vapor-tight to
the interior of the vehicle to prevent exhaust fumes from entering.
WARNING

Oil fill
Oil drain
Oil filter
Oil dipstick
Air cleaner element
Spark plugs
Carburetor
Start/Stop switch
Circuit breaker
DC fuse

4. Construct the compartment floor to prevent oil,
fuel or water accumulation. Provide openings
in the compartment floor according to the
Compartment Floor Plan, Figure 3-2.
Do NOT use absorbent soundproofing material on
the compartment floor. The floor should have
as few openings as possible, to reduce the
noise level.
5. Secure the set mounting tray to the support
frame, using four 3/8-16 UNC grade 5 screws
(bottom mounting) or eight 5/16-18 UNC grade
5 screws (side mounting). The mounting bolts
must not extend more than 1/4 inch (6 mm)
through the mounting nut. See Figures 3-1 and
3-2. Torque 3/8” mounting screws to 35 ft lbs
(47 N•m). Torque 5/16” mounting screws to 25
ft lbs (34 N•m).

Minimum compartment dimensions are shown in
Figure 3-1. Clearances between the generator set
and the compartment are included in these dimensions.
To minimize noise, line the entire genset compartment with a 1/2 to 1 inch (12.7 to 25.4 mm) thickness
of self-extinguishing acoustical material, rated for
250° F (121° C) minimum. Adjust the compartment
height, width and depth dimensions to fit the acoustical material. See Figures 3-1 and 3-2.

CAUTION If the unit mounting plate is not
fastened securely to the vehicle compartment, road vibrations can damage the generator set components. Use screws long
enough for at least 1-1/2 threads to extend
through the weld nut. The mounting bolts
must not extend more than 1/4 inch (6 mm)
through the weldnut.

Allow for air intake and discharge at the bottom of
the generator set. Air inlets to the set compartment
must not allow dirt, rocks, water, or slush to reach
the set. Minimize dust and salt entrance into the
compartment. Make certain to protect the genera-

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3-1

SEE NOTE 1

NOTE 1: MINIMUM
UNIT CLEARANCE
FROM COMPARTMENT SURFACES

SEE NOTE 1
RIGHT END VIEW

LEFT END VIEW

TOP VIEW

FIGURE 3-1. COMPARTMENT MOUNT OUTLINE
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3-2

3-3
FIGURE 3-2. COMPARTMENT FLOOR PLAN

compartment must be minimized. Baffles may be
needed to protect certain areas. See the Ventilation
section of this manual for more detailed information.

UNDER-FLOOR MOUNT
In an under-floor installation, the genset is mounted
below the floor and outside the passenger compartment of the vehicle. This type of installation must
comply with the Installation Codes and Safety Recommendations (see Introduction section). Read
this section for general application information, and
study the proper under-floor housing/exhaust kit instructions for more information on under-floor
installations.

Access Opening: Provide an access opening to
the generator set on the side of the vehicle. Make it
large enough to check the following:
•
•
•
•
•
•
•
•
•
•

The vehicle structure must be able to support the
weight of the generator set (see Specifications section) when subjected to road vibrations. The vehicle
manufacturer and/or the installer must provide a
structurally sound support frame, using tubing,
angle brackets, or steel-reinforced plywood or other
composition board. Plywood or particle board can
be reinforced with 3-inch (76 mm) or larger washers
or a full metal plate.

See Figure 3-1 for size and Figure 3-3 for locations.

Mounting Clearance: The compartment door
must open the full width of the generator set in
compartment mounts. Under-floor installations require that access be made from the bottom, or
through a side door. Refer to the correct outline
drawing when installing the set.

Line the floor above the set with 26-gauge galvanized steel or a material of comparable strength and
fire resistance (see NFPA 70, NEC and California
Title 25 for complete details).

Generator Set Location
Figure 3-3 shows the most common mounting
areas for an underfloor mount. If the set is mounted
on the curb side, location 1 or 2, protect its generator end from road splash and debris. If mounted on
the driver’s side, location 3 or 4, protect its engine
end. If possible, drive the vehicle through mud and
slush to test the installation. Refer to shaded areas
of Figure 3-3.

CAUTION Failure to meet Onan review for
modifications of mounting kits or for non-Onan
kit installations can void the intent of NCTI/CSA
approval. Liability for damage or injury and
warranty expenses becomes the responsibility
of the person making the modifications.

Exhaust Kit: Review the exhaust system kit installation instructions and check the components supplied in the kit. Plan clearances for shifting or removing exhaust components when the set is removed for inspection or maintenance.

The bottom air inlet opening to the generator set
compartment must not admit dirt, rocks, water or
slush. The entrance of dust and salt into the

Oil fill
Oil drain
Oil filter
Oil dipstick
Air cleaner element
Spark plugs
Carburetor
Start/Stop switch
Circuit breaker
DC fuse

3
1

FIGURE 3-3. COMMON GENSET MOUNTING AREAS
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3-4

4. Ventilation and Acoustics
Air ducting must provide a direct free-airflow path to
the generator set, with minimal bends. The duct
must be smooth and non-restrictive to airflow.

VENTILATION
Ventilation of the Marquis genset requires:
• Sufficient incoming air (for combustion and
cooling)
• Adequate exhaust of heated air

Fuel and fuel leakage present the
hazard of fire or explosion, which can cause severe personal injury or death. The ventilation
system should provide a constant flow of air to
expel any accumulation of fuel vapor. The generator set compartment must be vapor-tight to
the vehicle interior, to keep fumes from entering
the vehicle.
WARNING

A centrifugal fan in a scroll housing on the engine
(Figure 4-1) draws air from under the set into the
generator end of the compartment, and through the
generator (which has its own cooling fan) over the
cooling surfaces of the engine. Then it discharges
the heated air through the bottom outlet on the engine end of the set.

ACOUSTICS

Make certain that nothing obstructs or restricts air
intake and discharge. Air recirculation must be
minimized.

For maximum noise reduction, line the entire generator compartment with 1 inch (25.4 mm) thickness
of sound absorbing material. Use the following
guidelines to construct the housing.

Exhaust gas presents the hazard of
severe personal injury or death. Because discharged cooling air can contain exhaust gas,
never use discharged cooling air to heat the vehicle.
WARNING

• Make certain that all joints and corners of the
compartment are vapor-tight to the interior/ cab
of the vehicle. Lining the compartment is less
effective if openings, cracks, doors and joints
are not sealed. Seal the compartment door
edge to eliminate noise leaks around the door
perimeter.
• Cover the back, top and sides of the compartment (not the compartment base) with fiberglass or another self-extinguishing, sound-absorbent material. Sound insulation and adhesive should be rated at 200° F (90° C) minimum. See Figure 4-2 to design the set
compartment for optimum noise reduction.

AIR
OUTLET

• A combination of materials can reduce noise
more than a single material can. For instance,
a sheet of lead combined with a layer of acoustical material is more effective than either
alone.

BOTTOM AIR
INLET

FIGURE 4-1. COOLING SYSTEM

When designing the air inlet and outlet for the set
compartment (see Figure 3-2), allow for the restriction of grilles and ductwork: some expanded metal
grilles provide as little as 60 percent free air inlet
area per square foot. The most efficient grille provides only 90 percent free inlet area per square foot.
Obtain the free inlet area of the grille material from
the material supplier. Multiply the grille area by the
free area percentage to get the free inlet area.

High temperatures in the compartment can present the hazard of fire, which can
result in severe personal injury or death. To
meet ANSI and CSA temperature rise requirements for vehicles, the layer of insulation must
not reduce the minimum compartment size specified in Figure 3-1.
WARNING

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4-1

SERVICE SIDE ACCESS
PANEL

SELF-EXTINGUISHING ACOUSTICAL MATERIAL
1/2 TO 1 INCH (12.7 TO 25.4 MM THICK)

FIGURE 4-2. NOISE REDUCTION-COMPARTMENT DESIGN RECOMMENDATION

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4-2

5. Exhaust System
ature of any combustible material more than 117° F
(65° C) above the ambient air inlet temperature.

GENERAL
Plan the exhaust system carefully. The exhaust
system must be vapor-tight. Check all applicable
standards, local codes and regulations. Study the
following recommendations. See the instructions
supplied with the exhaust kit for specific mounting
procedures.

The exhaust system must extend a minimum 1 inch
(25 mm) beyond the perimeter of the vehicle. If the
generator set tailpipe is on the same side of the
coach as the compartment, terminate the tailpipe
aft of the generator set air intake, or reduce the possibility of exhaust recirculation by directing the exhaust down and to the rear.

MUFFLER RECOMMENDATIONS
The Onan-installed spark arrester muffler is U.S.
Forest Service-approved, and meets code requirements. Failure to provide and maintain a spark arrester may violate the law.
Liability for damage or injury, and warranty expenses due to use of unapproved mufflers or installation modifications becomes the responsibility of
the person installing the substitute muffler or performing the modifications. Contact an Onan distributor for approved exhaust system parts.

LAST TAILPIPE HANGER AS
CLOSE TO END AS PRACTICAL

EXHAUST INSTALLATION GUIDELINES
The exhaust system must be placed no closer than
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 temper-

1 INCH (25 mm)
MINIMUM

FIGURE 5-1. TERMINATING THE EXHAUST
TAILPIPE

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5-1

To reduce the chance of damaging the tailpipe and
emitting exhaust gases under the vehicle, make
certain that no part of the exhaust system intrudes
into the departure angle or approach angle of the
vehicle, unless it is protected by a skid bar or other
protection device. The shaded areas in Figure 5-2
illustrate typical mounting locations.

Do not terminate the exhaust tailpipe under the vehicle. Be aware that any vent, window or opening
that can be opened and that is not permanently
sealed from the vehicle living space can be an avenue for carbon monoxide. Do not terminate the tailpipe such that it is closer than 6 inches (153 mm) to
any opening into the vehicle interior (door, window,
vent). See Figure 5-2.

WARNING Exhaust gas presents the hazard of
severe personal injury or death. Do not mount
any portion of the exhaust system into the approach or departure angle unless it is adequately protected. Use only Onan-specified exhaust
equipment with the generator set. Use a sufficient number of hangers to prevent dislocation
of the system.

Exhaust gas presents the hazard of
severe personal injury or death. Do not terminate an exhaust pipe under the vehicle. The tailpipe must not terminate so that any vent, window, or opening into the living area is within the
area shown in Figure 5-2. Keep all openings
closed when the generator set is running.
WARNING

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

SEALED WINDOW
TAILPIPE
(RV REAR VIEW)

DEPARTURE
ANGLE
GROUND
SKID BARS

SHADED ZONE IS AREA OF
RECOMMENDED TAILPIPE
INSTALLATION

AXLE LOWER
CLEARANCE
LINE

APPROACH
ANGLE

FIGURE 5-2. TAILPIPE INSTALLATION

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5-2

steel exhaust tailpipe (not supplied) can be slid
over the exhaust tube and clamped in place
with a U-bolt type automotive muffler clamp,
marked 1-3/8 inch.

TAILPIPE RECOMMENDATIONS
An exhaust tailpipe is not supplied with the genset,
because length requirements vary between vehicle
manufacturers. Refer to the following recommendations for information and safety considerations.

Place the exhaust gasket (supplied) between the
exhaust flanges. Use 5/16-18 x 1 inch grade 5 bolts
with a flat washer to connect the exhaust flanges.
Tighten the flange mounting bolts to 25 ft-lbs (34
N•m).

Exhaust gas presents the hazard of
severe personal injury or death. Do not use flexible exhaust tailpipe, because it can leak or
break from road shock or vibration. Do not terminate the exhaust system under the vehicle.
Direct exhaust gases away from any window,
door, or compartment openings. Do not operate
the generator set without an exhaust tailpipe.
WARNING

Use double rubber, U-shaped, shock-mounted
hangers to support the exhaust system. If the tailpipe extends beyond 1-1/2 feet (0.46 m) from the
genset, attach an automotive tailpipe hanger for
additional support. Support the exhaust system at
or near the perimeter of the vehicle to prevent the
pipe from being damaged and pushed up under the
vehicle skirt. Attach hangers to steel framework,
not wood or other floor materials.

The exhaust pipe can leave the generator set in one
of three directions (see Figures 3-1 and 5-3):
• Straight down through the bottom of the set
(the most common configuration)
• Out the left side of the set (by rotating the exhaust tube on the muffler 90 degrees)
• Straight out the back of the set (with the use of
an optional exhaust kit)

CAUTION Angular mounting of muffler and
tailpipe hanger brackets can result in exhaust
system damage. Properly mounted hanger
brackets will absorb much road shock vibration
and prolong the use of exhaust system components. Mount muffler and tailpipe hanger brackets directly above the component supported,
not at an angle. Do not twist the rubber sections
of any hangers.

If the exhaust exits the side or the rear of the generator set, discard the original exhaust opening cover
plate and install the appropriate optional cover
plates that enclose the opening around the tailpipe.
Cover plates are included with the optional exhaust
kit, or they may be ordered separately.

The exhaust back pressure under full load must not
exceed 2 inches (51 mm) water column (WC) as
measured within 6 inches (154 mm) of the muffler
outlet flange.

The exhaust tailpipe can be attached to the set by
two methods:
• An exhaust tailpipe can be constructed by
welding a 1/4 inch plate steel mounting flange
(see Figure 3-1 for flange dimensions) onto a
minimum 1-3/8 inch O.D. 18-gauge rigid steel
exhaust tailpipe.
• An optional exhaust tube kit, with a mounting
flange welded to one end, can be bolted to the
exhaust pipe on the set (or directly to the muffler when exhausting out the back of the set).
The optional exhaust tube can be cut to the desired length. A 1-1/2 inch O.D. 18-gauge rigid

CAUTION Excessive exhaust back pressure
can cause engine damage. If a tailpipe deflector
is used, make sure it is large enough to prevent
back pressure.

Do not connect the genset to the vehicle engine exhaust system.
CAUTION Interconnecting the engine exhaust
systems will allow exhaust condensates and
soot to migrate into the engine that is idle, causing engine damage.

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5-3

MUFFLER

TAILPIPE NOT
SUPPLIED

TAILPIPE COVER

EXHAUST PIPE
FOR BOTTOM OR
SIDE EXHAUST

TAILPIPE NOT
SUPPLIED

OPTIONAL EXHAUST PIPE
FOR REAR EXHAUST
TAILPIPE COVER

CLAMP

MUFFLER

TAILPIPE NOT SUPPLIED
USE ADDITIONAL HANGERS IF
TAILPIPE EXCEEDS 3 FT (914 mm)
HANGER BRACKET
AT PERIMETER OF
VEHICLE

FIGURE 5-3. TYPICAL EXHAUST INSTALLATIONS
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5-4

6. Fuel System
line manual fuel shutoff valve, to close the fuel line if
the set is removed for service.

GENERAL
This section describes fuel system installations for
recreational vehicles.

Recommended Fuel

WARNING Fuel presents the hazard of fire or
explosion which can result in severe personal
injury or death. Do not smoke or allow any
flame, spark, pilot light, arc-producing equipment or other ignition sources around fuel or
fuel components, or in the installation area.
Keep a type ABC fire extinguisher nearby. The
ventilation system must provide a constant flow
of air to expel any accumulation of fuel vapor
while the vehicle is in transit. Compartments
must be vapor-tight to the vehicle interior to
prevent any fumes from entering these areas.

Use clean, fresh unleaded gasoline having a minimum octane rating (Anti-Knock Index) of 87.
During some times of the year only mandated “oxygenated” gasolines may be available. These are acceptable for use, but not preferable. Leaded gasoline may be used but will result in the extra maintenance required for removing combustion chamber
and spark plug deposits. Do not use gasoline or
gasoline additives (de-icers) containing methanol
because methanol can be corrosive to fuel system
components.
CAUTION Do not use gasoline or gasoline additives containing methanol because methanol
can be corrosive to fuel system components.

GASOLINE FUEL SYSTEM
Fuel System Provisions
On some vehicles, the genset can share the vehicle
fuel supply tank with the vehicle engine. Connection to the vehicle fuel tank must be made according
to the chassis (vehicle) manufacturer’s detailed instructions. See Fuel Line Installation, in this section.

Fuel presents the hazard of fire or
explosion that can cause severe personal injury
or death. Never fill the fuel tank when the engine
is hot or is running. Do not permit any flame,
spark, pilot light, cigarette or other ignition
source near the fuel system.

Onan recommends a separate fuel pickup tube or a
separate fuel tank. Connection with the vehicle fuel
line is not recommended.

Lead deposits can cause engine
damage if they are not removed before using
unleaded gasoline. Do not alternate between
leaded (regular) and unleaded gasoline.

WARNING

CAUTION

The genset has a fuel shutoff valve as a safety feature. If the vehicle fuel tank becomes pressurized (3
psi maximum), the positive fuel shutoff prevents the
set from being flooded when the set is not running.

Fuel Consumption
Generator set fuel consumption varies proportionately to differing electrical loads. Refer to the Specifications section for approximate fuel consumption
at no load, half load, and full load.

If contaminated fuel is possible, Onan recommends
an in-line fuel filter. Onan also recommends an in-

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6-1

Install an approved flexible non-metallic (non-conductive) fuel line between the vehicle fuel system
and the generator set, to absorb vibration. Flexible
fuel line must be long enough to allow generator set
movement, to prevent binding, stretching or breaking. Onan recommends seamless steel tubing and
flared connections for long runs between the fuel
tank and the flexible connector to the generator set.

Fuel Line Installation
Vehicle fuel systems operate at a specified fuel
pressure. For this reason, do not change or remove
the fuel fill tube, fill limiter vent, vapor canister, vapor
lines, filler cap and all parts of the fuel system without the approval of the vehicle manufacturer.
Check the filler cap to make sure that the pressure
vacuum relief valve functions properly: replace it if
necessary.

Run fuel lines at the same height as the top level of
the tank, to a point as close to the engine as possible. This reduces the danger of fuel siphoning out
of the tank if the line should break.

If a separate connection is not supplied for the generator, add a second fuel pickup in the tank. This
pickup should not extend below the bottom 1/4 of
the tank, so the vehicle will run after the generator
runs out of fuel.

Keep fuel lines away from hot engine or exhaust
areas, to reduce the chance of vapor lock. Fuel
lines should be accessible and protected from damage. Use metal straps without sharp edges to secure fuel lines. Do not run fuel lines where they may
contact sharp or rough surfaces, or where they may
be kinked, pinched, chaffed, or struck.

Do not connect directly to the vehicle fuel line. This
may cause the genset or the vehicle engine to run
poorly. Consult the vehicle manufacturer for information on shared fuel supplies. Unauthorized fuel
system modifications may cause dangerous operating conditions.

WARNING Gasoline and LPG fuel may be accidentally ignited by electrical sparks, presenting
the hazard of fire or explosion, which can result
in severe personal injury or death. For this reason, when installing the generator set:

WARNING Gasoline presents the hazard of explosion or fire, which can result in severe personal injury or death. Do not connect the generator set fuel line to the pressurized part of the
vehicle fuel system. Flooding of the generator
set engine and compartment can occur, resulting in a fire hazard.

• Do not tie electrical wiring to fuel lines.
• Do not run electrical lines and fuel lines
through the same compartment openings.
• Keep electrical and fuel lines as far apart as
possible.
• Place a physical barrier between fuel lines
and electrical lines wherever possible.
• If electrical and fuel lines must pass
through the same compartment opening,
make certain that they are physically separated by running them through individual
channels, or by passing each line through a
separate piece of tubing.

The generator set may starve for
fuel when the vehicle is operated at highway
speeds, if its fuel line is connected to the main
fuel line with a tee. The generator set fuel pump
has neither the capacity nor the power to overcome the draw of the vehicle engine fuel pump.
For this reason, use a separate fuel line to the
generator set, or a separate fuel tank.
CAUTION

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6-2

LPG LIQUID WITHDRAWAL FUEL SYSTEM

NOTE: THESE
COMPONENTS ARE
MOUNTED HORIZONTALLY
ON THE MARQUIS
GENERATOR SET.

Fuel System Provisions
On liquid withdrawal LPG gensets, the fuel solenoid
valve contains a filter cartridge and a magnet, to
trap dirt and contaminants. The solenoid valve and
filter are shown in Figure 6-1. Figure 6-2 is a flow
diagram of LPG fuel system components.

FUEL
SOLENOID

Recommended Fuel
Use clean, fresh HD-5 grade liquified petroleum gas
or equivalent product consisting of at least 90 percent propane. Commercial liquified petroleum gas
fuels may contain more than 2.5 percent butane
which can result in poor fuel vaporization and poor
engine starting in low ambient temperatures (below
32° F (0° C).
Satisfactory performance requires that the LPG vapor (vapor-withdrawal models only) be supplied at a
pressure within the range indicated in Specifications.

FUEL
FILTER
BODY

High LPG supply pressure (vapor
withdrawal models only) can cause gas leaks
which can lead to fire and severe personal injury or death. LPG supply pressure must be adjusted to Specifications by qualified personnel.
WARNING

FIGURE 6-1. FUEL SOLENOID VALVE AND
FILTER

Propane Fuel Lines and Supply Tank
WARNING LP gas (Propane) presents the hazard of fire or explosion that can cause severe
personal injury or death. Do not permit any
flame, spark, pilot light, cigarette, or other ignition source near the fuel system. Keep an ABC
type fire extinguisher nearby.
Review all codes that apply to LPG generator set
installation. Refer to paragraph 2-11 (LP-Gas Engine Fuel Installations) of NFPA Pamphlet 501C
and paragraph 3-6.2.5 of NFPA 58 (Piping, Hose
and Fittings). These sections deal with fuel tanks
and lines, but do not cover all applicable codes and
regulations. Obtain this pamphlet by writing to the
address listed in the beginning of this manual.

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6-3

noid valve and filter assembly. This relief valve protects the fuel line from pressure buildup if the fuel
tank manual shutoff valve and the fuel solenoid
valve are closed at the same time.

When installing the fuel lines, keep these factors in
mind:
• Install LPG fuel lines to be accessible, but protected from damage.

Testing Fuel System for Leaks

• Use metal straps without sharp edges to secure fuel lines.

Before operating the set, test the LPG fuel system
for leaks. Refer to NFPA 501C, paragraph 2-4.18.2.
Energize the fuel solenoid from a separate 12-volt
DC source before testing the fuel system. Testing
must conform to procedures listed in NFPA-58, or to
the UL recommended test procedure, as follows:

• Keep fuel lines away from hot engine or exhaust areas.
• Do not run fuel lines next to electrical wiring.
Ensure that the LP tank is appropriately matched to
the genset and other appliances if applicable.

After assembly and before initial operation, all fuel
system connections, hose valves, regulators, and
fittings must be tested and proven free of leaks using a soap-and-water (or equivalent) solution while
the system is under gas or air pressure of at least 90
pounds per square inch (620 kPa).

An excess flow valve must be mounted internally to
the LPG fuel supply tank(s), per NFPA 501C, Paragraph 2-2.7.7. This valve and the fuel lines must be
sized so that the excess flow valve will close if the
fuel line is completely severed (broken). For operation at the lowest ambient temperature, use a valve
rated at 2.6 gallons per hour (9.9 l/hr) flow rate and
6.5 pounds per square inch (45 kPa) differential
pressure. Consult the Natural LP Gas Association
for information on the limits of excess flow valves.

Other approved methods of detecting leaks can be
used if appropriate. This test shall NOT be made
with a flame.

LPG fuel presents the hazard of explosion or fire which can result in severe personal injury or death. Do not smoke or allow
any flame, spark, pilot light, arc-producing
equipment or other ignition sources around fuel
or fuel components.
WARNING

Install an approved flexible non-metallic (non-conductive) fuel line between the vehicle fuel system
and the genset, to absorb vibration. Seamless steel
tubing and flared connections are best for long runs
between the fuel tank and the flexible connector to
the genset.

WARNING LPG leaks inside a garage or other
inadequately ventilated space or near a pit or
basement or other below-grade space can lead
to explosive accumulations of gas because
LPG “sinks” when it is released into the air.
Check for and comply with all local ordinances
regarding the garaging of vehicles with LPG engine fuel systems.

Mount a manual shutoff valve on the fuel supply
tank. This valve must be fully open when operating
the generator set, so that the excess flow valve will
close if the fuel line is severed.
Install a hydrostatic pressure relief valve between
the fuel tank manual shutoff valve and the fuel sole-

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6-4

CARBURETOR
Venturi type.

REGULATOR
Two stage design that will ONLY
flow fuel when carburetor provides
suction to fuel outlet

VAPORIZER
Changes propane fuel from a liquid
state to a gas using exhaust
manifold heat on generator set.

SOLENOID VALVE
A “Normally Closed” valve which allows fuel
flow ONLY when engine is cranking or running.
FUEL FILTER
Protects engine and fuel system components from
contaminates. An internal magnet stops all
magnetic particles that may collect on fuel lock
solenoid plunger and foul its action or plug fuel filter.

HYDROSTATIC RELIEF VALVE
Must be located after manual
shutoff valve. Relief pressure
between 400 and 500 PSIG
MUST be properly maintained.

Customer Supplied and Installed
Hardware Customer Must Satisfy
UL 1248 NFPA 58. , CSA946
CAN1-B149.2-78 and Any Local
Codes That Apply

FUEL TANK (Generator Set and
Other Vehicle Appliances)
Must conform to ASME or DOT
and CTC standards. (Working
pressure between 240 and 375
psi, depending on tank selected)l

MANUAL SHUTOFF VALVE
Must Be Mounted On Tank

INTERNAL EXCESS FLOW VALVE
Must Close with Complete Line Breakage.
Consult National LP Gas Association Publication
113-78 For Limitations.

FIGURE 6-2. FLOW DIAGRAM OF LIQUID LPG FUEL SYSTEM

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6-5

7. Electrical Connections
• Do not tie electrical wiring to fuel lines.

GENERAL

• Do not run electrical lines and fuel lines
through the same compartment openings.

Installing the genset electrical system means:
• Connecting the load
• Connecting the battery
• Connecting a remote control (if used)

• Keep electrical and fuel lines as far apart as
possible.
• Place a physical barrier between fuel lines
and electrical lines wherever possible.

Connect the battery last, to avoid accidentally starting or short-circuiting the set during installation.
Connect the positive (+) battery cable first and the
negative (-) battery cable last to reduce the risk of
arcing.

• If electrical and fuel lines must pass
through the same compartment opening,
make certain that they are physically separated by running them through individual
channels, or by passing each line through a
separate piece of tubing.

WARNING Accidentally starting the generator
set during installation can cause severe personal injury or death. Do not connect the starting battery until instructed to do so in the Installation Checks and Start-Up section.

AC WIRING
Wire Types

All wiring must meet local electrical codes. For this
reason, a qualified electrician should install and inspect the wiring.

The leads attached to the genset output must have
a current rating not less than 115 percent of the
nameplate current rating of the genset. The Onansupplied AC feeder conductor insulation is rated at
125°C. Wires connected to the Onan feeder conductors must either meet this insulation rating, or be
a larger size (see National Electrical Code, NFPA
70).

Mount switches and controls securely, to prevent
damage from vibration and road shocks. All
switches must be vibration-proof to prevent accidental opening or closing while the vehicle is in motion.
WARNING Gasoline and LPG fuel can be accidentally ignited by electrical sparks, presenting
the hazard of fire or explosion, which can result
in severe personal injury or death. For this reason, when installing the generator set:

Use stranded wire for all load connections. Load
wiring must be appropriately sized and insulated for
the specified current rating. Grounding must comply with all codes.

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7-1

Conduit

Line Circuit Breaker

Install the generator load conductors in a flexible
metallic conduit. Cut the conduit to length, leaving
extra wire for the junction box connections. Connecting wires must be correctly sized and insulated
for the current rating. Round off or cover the ends of
the conduit, to prevent its sharp edges from cutting
the insulation.

The generator set has line circuit breakers mounted
on the side of the control panel. The breakers provide short circuit and overload protection for the
generator.

Load Connections
The generator output voltage and maximum current
rating are specified on the generator nameplate.

Run the conduit so that it does not interfere with the
movement of the set.
Use waterproof conduit
wherever it is exposed to the elements.

Load wiring must be appropriately sized and insulated for the specified current rating. Grounding
procedure must comply with codes.

Seal all openings made for conduit, so exhaust or
fuel vapor cannot enter the living quarters. Flexible
metal conduit must be sealed internally at the end
where it terminates inside the junction box or panel
board (flexible conduit is not vapor-tight along its
length).

A lead to be connected to an output feeder conductor shall not be more than two AWG sizes smaller
than the output lead conductor and the insulation
shall be:
• Rubber (with braid), neoprene, or thermoplastic, with a wall thickness of at least 0.030 inch
(0.76 mm).
• Other material having the same or better electrical and mechanical properties.

Exhaust gas and fuel fumes present
the hazard of severe personal injury or death.
To prevent exhaust gas and fuel fumes from entering the vehicle interior, seal all openings
made for conduit, wiring, etc. Also seal the wiring within the conduit itself. Use a silicone/rubber based sealant.
WARNING

WARNING Electrical shock can cause severe
personal injury or death. Use only approved
power supply assemblies. Never remove the
grounding pin from assemblies. Incorrect
ground or no ground can cause the vehicle to
become electrically ”hot”. Equip the vehicle
with adequate Ground-Fault Circuit Protection
devices to meet the National Electrical Code
(NFPA 70, 551-9[C]) and for personal safety.

Wiring Disconnect Method
There must be no chance that an outside power
source might be connected to the generator set.
Feeder conductors from the set compartment must
terminate in a 120-volt double-pole, double-throw,
positive-off switching device mounted ahead of the
vehicle distribution panel: or they must connect to a
generator set receptacle box. Figures 7-1 and 7-2
show examples of the wire connection. Figure 7-3
shows the genset wiring diagram.

WARNING Gasoline fuel presents the hazard of
fire or explosion, which can result in severe personal injury or death. Do not tie electrical wiring
to fuel lines.

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7-2

VEHICLE
WIRING

JUNCTION
BOX
FLEXIBLE
CONDUIT

DOUBLE POLE
DOUBLE THROW
SWITCHING
DEVICE

VEHICLE AC
DISTRIBUTION PANEL

SET MOUNTED BREAKERS (60 HZ)
(1) 30 AMP
(1) 20 AMP
OR
(2) 30 AMP

MAIN
BREAKER(S)
HACR
BREAKERS
FOR AIR
CONDITIONER(S)
GFCI*
BREAKER

*IMPORTANT!

POWER
SUPPLY CORD

GROUND-FAULT CIRCUIT INTERRUPTERS (GFCIs) ARE
REQUIRED BY THE NATIONAL ELECTRICAL CODE (NFPA 70,
551-9 [C]) IN ALL EXTERNAL AND SOME INTERNAL OUTLETS.
TO PROPERLY EQUIP YOUR RECREATIONAL VEHICLE WITH
THESE PROTECTION DEVICES, CONTACT YOUR RV
MANUFACTURER OR DEALER FOR RECOMMENDATIONS.

FIGURE 7-1. SWITCHING DEVICE WIRING FOR
UTILITY POWER

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7-3

VEHICLE
WIRING

JUNCTION
BOX
FLEXIBLE
CONDUIT

DISCONNECTING
DEVICE

VEHICLE AC
DISTRIBUTION PANEL

30 AMP
MAIN
BREAKER
HACR
BREAKER
FOR AIR
CONDITIONER

SET
MOUNTED
BREAKERS

GFCI*
BREAKER
*IMPORTANT!
GROUND-FAULT CIRCUIT INTERRUPTERS
(GFCIs) ARE REQUIRED BY THE NATIONAL
ELECTRICAL CODE (NFPA 70, 551-9 [C]) IN ALL
EXTERNAL AND SOME INTERNAL OUTLETS. TO
PROPERLY EQUIP YOUR RECREATIONAL
VEHICLE WITH THESE PROTECTION DEVICES,
CONTACT YOUR RV MANUFACTURER OR
DEALER FOR RECOMMENDATIONS.

POWER
SUPPLY CORD

FIGURE 7-2. USING UTILITY POWER CORD FOR SWITCHING

GENERATOR

FIGURE 7-3. 60 HZ GENERATOR SET WIRING DIAGRAM
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7-4

DC WIRING
Remote Control (Option)
INDICATOR
LAMP

Onan offers optional remote control kits that can be
connected to the genset. There are three models
available:

START/STOP
SWITCH

• Remote panel with start/stop switch and indicator lamp only (see Figure 7-4).

• Remote panel with start/stop switch, indicator

FIGURE 7-4. REMOTE PANEL WITH START/STOP
SWITCH ONLY

lamp, and hour (elapsed time) meter (see Figure 7-5).

• Remote panel with start/stop switch, indicator
lamp, and battery DC voltmeter (see Figure
7-6).

START/STOP
SWITCH
INDICATOR
LAMP

The location of the remote control panel can vary by
application. Refer to the instructions supplied with
the remote control kit for more installation information and important safety precautions.

HOUR
METER

Be sure to seal all openings made for wiring so exhaust or fuel vapors cannot enter the living quarters.
If flexible metal conduit is used, it must be sealed internally at the end where it terminates. Flexible metal conduit is not vapor-tight along its length due to its
construction.

FIGURE 7-5. REMOTE PANEL WITH START/STOP
SWITCH AND HOUR METER

START/STOP
SWITCH
INDICATOR
LAMP

Inhalation of exhaust gas or ignition
of fuel vapor can cause severe personal injury
or death. Be sure to vapor-seal flexible metal
conduit and all openings made during installation of the genset with a silicone/rubber based
sealant.
WARNING

BATTERY DC
VOLTMETER

A remote control connector is located inside the
housing (see Figure 1-2). Keep the connector inside the genset housing to keep it clean. Contact an
Onan dealer for the proper remote connector plug
and wiring harness assembly.

FIGURE 7-6. REMOTE PANEL WITH START/STOP
SWITCH AND DC VOLTMETER

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7-5

Mount the battery on a rigid support structure,
where leaks and accidental spills cannot damage
the genset, fuel lines, and wiring.

BATTERIES
To prevent accidental starting of the genset during
installation, do not connect the battery cables at the
battery until so instructed in the Initial Start and
Checks section.

Batteries present the hazard of explosion, which can result in severe personal injury. Because batteries give off explosive gas,
install the battery in a separate compartment
from the genset and away from all flames, pilot
light, arcing, or spark-producing devices.
WARNING

WARNING Accidental starting of the genset
can can cause severe personal injury or death.
Do not connect the starting battery until so
instructed in the Initial Start and Checks section.

Battery Cables
Because of the high cranking currents involved, it is
highly recommended that a negative (-) battery
cable be run with the positive (+) battery cable between the battery and the genset. Size the cables
according to Table 7-2. Total cable length is the sum
of the lengths of the positive (+) and negative (-)
cables. In other words, total cable length will be
approximately twice the distance between the battery and the genset.

Onan does not recommend that the vehicle starting
battery be used to operate the genset. Doing this
can discharge the battery under some operating
conditions.

Battery Capacity
The genset has a 12 VDC, negative-ground control
and starting system. See Table 7-1 for minimum
battery capacity requirements.

BELOW 32° F
(0° C)

Alternatively, use rated cranking current as the basis for calculating battery cable size. Rated cranking current for these gensets is 180 amperes at 0F
(-18 C). The cables should be sized so that voltage
across the cranking motor terminals will be within 1
volt of the voltage across the battery terminals.

450 Cold Cranking
Amps
(Approx. 95 amp/hour)

TABLE 7-2. CABLES FOR COLD WEATHER
STARTING TO -20°F (-29°C)

TABLE 7-1. COLD CRANKING AMPS FOR MINIMUM
12-VOLT BATTERY
ABOVE 32° F
(0° C)
360 Cold Cranking
Amps
(Approx. 70 amp/hour)

Battery Recharging
The genset is equipped with a 10-amp, regulatedvoltage battery charger if electrical option B183 was
ordered. If the option was not ordered, other means
will have to be provided for recharging the genset
battery.

*CABLE LENGTH
IN FEET (METERS)

CABLE
SIZE

0-10 (0-3)
11-15 (3-4.5)
16-20 (4.5-6)

2
0
000**

* Total battery cable length including both positive (+) and negative (-) cables.
** #2 cable is acceptable up to 20 feet (6.1 m) if
the battery capacity exceeds 1000 CCA.

Battery Compartment
Mount the battery in its own compartment, away
from the genset and any spark-producing device.
For ventilation, provide the battery compartment
with an opening of at least 1.7 in2 (11 cm2) at the top
and 1.7 in2 (11 cm2) at the bottom.

Negative (-) Battery Connection. Connect one
end of the negative (-) battery cable to the genset
ground. Tighten the ground connection securely
(see Figure 7-7).

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7-6

Alternate Negative (-) Battery Connection. In
cases where the distance from the battery to the
genset is quite long, the vehicle frame (ground) can
be used for the return cranking current:

tected from damage and secured to prevent chafing
due to vibration.

Routing battery cables with fuel
lines can lead to fire and severe personal injury
or death. Keep battery cables away from fuel
lines.
WARNING

1. Connect one end of a short, negative (-) battery cable (of the same size as the positive (+)
battery cable) to the vehicle frame near the battery. (Do not connect the other end to the battery at this time.)

CAUTION Failure to secure the battery cable
terminals can result in personal injury and/or
equipment damage from an electrical short. See
that terminal connections are secure. If necessary, secure cables to prevent abrasion.

2. Connect one end of a short, negative (-) battery cable (of the same size as the positive (+)
battery cable) to the vehicle frame near the
genset. Connect the other end to the genset
ground. See Figure 7-7.

Genset Bonding Terminal
The genset ground, as shown in Figure 7-7, is also
the bonding terminal for grounding the genset to the
vehicle frame (ground) when a continuous negative
(-) battery cable is used from the battery directly to
the genset. Connect an 8 AWG grounding wire from
the vehicle frame to the genset ground.

NOTE: Make sure that the frame (ground) connections (to major frame members, if possible) are secure enough to minimize electrical resistance. Avoid
making these connections at welds or mechanical
joints.

Positive (+) Battery Connection. Connect one
end of the positive (+) battery cable to the B+ post.
Tighten the B+ connection securely (see Figure
7-7).

Route battery cables away from fuel lines and hot
engine exhaust components. Battery cable should
be accessible for inspection and replacement, pro-

WARNING Failure to ground the genset properly can result in injury or death. The genset
must be grounded to the vehicle frame.

Redistribution or publication of this document,
by any means, is strictly prohibited.

7-7

8. Initial Start and Checks
EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, an odorless and colorless gas.
Carbon monoxide is poisonous and can cause unconsciousness and death.
Symptoms of carbon monoxide poisoning can include:
• Dizziness
• Nausea
• Headache
• Weakness and Sleepiness

• Throbbing in Temples
• Muscular Twitching
• Vomiting
• Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET
OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired.
Never sleep in vehicle with the generator set running unless the vehicle interior is equipped with an operating carbon monoxide detector. Protection
against carbon monoxide inhalation also includes proper exhaust system
installation and visual and audible inspection of the complete exhaust system at the start of each generator set operation.
1-RV

4. See the Operator’s Manual, and note the features of the individual system. Open the fuel
supply valves to the generator set.

PRE-START CHECKS
Before starting the generator set, perform these
steps:
1. Perform the Installation Review described in
this section.
2. Add oil to the engine. See the Operator’s
Manual (publication 965-0131) for the oil type
and quantity.
3. Check that battery terminals and cable connectors are clean and dry. Connect the positive (+)
battery cable to the POS (+) battery post first,
then connect the negative (-) battery cable to
the NEG (-) battery post. Always connect the
negative (-) battery cable last to reduce the risk
of arcing.
WARNING Batteries present the hazard of explosion, which can result in severe personal injury. Because batteries produce explosive gas,
do not smoke or allow any arc-producing devices in the battery area. Do not disconnect
cables from the battery while the generator set
is cranking or running. This causes arcing and
can result in an explosion.

INITIAL START-UP/INSPECTION
Start Generator Set at Unit Control
WARNING Exhaust gas presents the hazard of
severe personal injury or death. Do not operate
the generator set inside any room or building.

1. Move the Start/Stop switch to the START position. The engine should crank and start. The
unit may need more cranking at initial start than
at subsequent starts, to prime the fuel system.
If the genset fails to start, see the Troubleshooting Guide in the Operator’s Manual.

Redistribution or publication of this document,
by any means, is strictly prohibited.

8-1

2. After the set starts, check for fuel leaks. If any
leaks are found, stop the set immediately, close
off the fuel supply and have the leak(s) repaired. Make sure that the fuel lines do not
touch anything that can damage them.

Start Generator Set at Remote Control
1. Move the Remote Start/Stop switch to the
START position. The engine should crank and
start. If it does not, see the Troubleshooting
Guide in the Operator’s Manual. Check all remote control connections, repair if necessary,
and restart the set.
2. After the genset starts, check the battery condition meter (if equipped) to confirm its proper operation.
3. See the Operator’s Manual for procedures to
test set operation.
4. Operate the set with a normal load, monitoring
fuel supply connections, exhaust system, set
performance, and quality of noise reduction. If
set performance is not acceptable, see the Service Manual for adjustment procedures, or
contact an authorized Onan service center for
assistance. If any genset systems require adjustment, disconnect the starting battery to prevent accidental start-up.

WARNING Fuel presents the hazard of explosion or fire which can result in severe
personal injury or death. If a fuel leak is
found, stop the generator set , and have the
leak repaired immediately.
WARNING A hot generator set can cause
severe burns. Always allow the generator
set to cool before performing service.

3. Examine the exhaust system for leaks. If any
leaks are found, stop the set and have the exhaust system repaired immediately.
WARNING Exhaust gas presents the hazard of severe personal injury or death. Do
not operate the generator set if it is excessively noisy. Have it inspected and repaired
immediately by an authorized Onan service
center.

Accidental starting of the generator set during maintenance procedures
can cause severe personal injury or death.
Disconnect the generator set starting battery, negative (-) cable first, before performing maintenance.
WARNING

4. Perform the Break-In Procedure described in
the Operator’s Manual.
5. Move the unit Start/Stop switch to the STOP
position to stop the genset.

Redistribution or publication of this document,
by any means, is strictly prohibited.

8-2

7. Does the installation allow 1/2 inch (13 mm)
free movement of the generator set on its
mounts ?

INSTALLATION REVIEW
Incorrect installation, service, or
parts replacement can result in severe personal
injury, death, and/or equipment damage. Installing personnel must be qualified to perform
electrical and mechanical component installations and service.
WARNING

8. Are all fuel connections and hose clamps tight?
9. Are air inlet and exhaust openings clear and
sufficiently sized (see Mounting section) for
proper airflow ?
10. Is the generator set protected from direct road
splash from vehicle wheels ?

Prior to initial start up of the generator set, check
each of the following items. For a proper installation, each answer must be yes: if not, that aspect of
the installation should be reworked or provision
made to satisfy the requirement.

11. Can the following routine maintenance items
be performed ?
• Change oil and filter

1. If the exhaust system is run into the angle of approach or departure (see Figure 5-1), is it protected from bottoming out by use of skid bars,
rollers, etc. ?
2. Does the exhaust system extend to the perimeter of the vehicle, and does it not terminate below an openable window, door, or vent ?
3. Are all required exhaust clamps, hangers, and
support straps in place per the Exhaust System
section of this manual and the kit instructions ?
4. Do the hanger straps located at the perimeter
and along the center line of the generator set
have double U-shaped rubber isolators ?
5. Is the compartment metal-lined and sealed
around all edges ?
6. Is a flexible section of non-conducting fuel line
installed between the fuel inlet and the fuel line
from the tank ?

• Adjust carburetor
• Start/stop the unit
• Change air filter
• Operate AC circuit breakers
• Change spark plugs
12. Are fuel lines and electrical wires run separately ?
13. Are wiring holes into the inside of coach (including the inside of AC conduit) sealed to prevent passage of exhaust gases ?
14. Has a rubber boot been installed on battery
plus (+) lead at the start solenoid connection in
the control ?
15. Are all electrical leads connected and protected, and is the conduit adequately supported ?

Redistribution or publication of this document,
by any means, is strictly prohibited.

8-3

Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-528-7229
Cummins and Onan are registered trademarks of Cummins Inc.

Redistribution or publication of this document,
by any means, is strictly prohibited.

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965 0631 Onan BGM NHM Marquis Series RV Genset Installation Manual (05 1992)

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