CUMMINS Microlite 2.5 KV Installation guide

Brand: CUMMINS

Model: Microlite 2.5 KV

Category: Power generators

Type: Installation guide

This manual is also suitable for

Installation Manual

RV Generator Set

KV (Spec A−M)

Microlite t 2800 Series

English − Original Instructions 2−2012 981−0604 (Issue 6)

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

Table of Contents

SECTION TITLE PAGE

Safety Precautions iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Precautions iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Voltage is Deadly! iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Gas is Explosive iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moving Parts Can Cause Severe Personal Injury or Death iv . . . . . . . . . . . . .

Engine Exhaust is Deadly! iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Hazards of Carbon Monoxide iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Only You Can Protect Yourself From CO Poisoning! iv . . . . . . . . . . . . . . . . . . .

Substances Hazardous to Health iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Is Flammable and Explosive iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propane iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazardous Reactions v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protective Measures v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage/Transport v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Action v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Petrol (UK) / Gasoline vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazardous Reactions vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protective Measures vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage/Transport vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Action vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Oil − Premium Blue E 15W40 vii . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazardous Reactions vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protective Measures vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage/Transport vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set Warning Labels viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Introduction 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Component Locations 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Specifications 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Step-By-Step Installation Outline 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compartment Mounting 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Under-Floor Mounting 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting to Vehicle Systems 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Systems 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Mounting 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compartment Mount 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Under-Floor Mount 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION TITLE PAGE

5 Ventilation and Acoustics 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Acoustics 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Exhaust System 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Muffler Recommendations 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Installation Guidelines 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tailpipe Recommendations 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Fuel System 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gasoline Fuel System 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evaporative System Installation 7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LPG Fuel System 7-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Electrical Connections 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Wiring 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DC Wiring 8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries 8-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Initial Start and Checks 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Review 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-start Checks 9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Starting and Checks 9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

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 proper-

ly.

Only trained and experienced service person-

nel with knowledge of fuels, electricity, and me-

chinery hazards shall remove, dismantle and

dispose of the generator set. See Service manu-

al.

Some generator set installation procedures

present hazards that can result in severe per-

sonal injury or death. Only trained and experi-

enced personnel with knowledge of fuels, elec-

tricity, and machinery hazards should perform

generator set installation procedures.

The following symbols in this manual alert you to

potential hazards to the operator, service person

and equipment.

Used to alert you to a lethal hazard

against which you must take steps to prevent

severe personal injury or death, as when you

are in the vicinity of High Voltage equipment.

WARNING

Used to alert you to a hazard or un-

safe practice which can result in severe person-

al injury or death.

CAUTION

Used to alert you to a hazard or un-

safe practice which can result in personal injury

or equipment damage.

Electricity, fuel, exhaust, moving parts and batteries

present hazards which can result in severe person-

al injury or death.

GENERAL PRECAUTIONS

 Keep 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 gas-

oline 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.

 Use personal protective equipment when per-

forming maintenance operations such as

glasses, gloves, etc.

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.

BATTERY GAS IS EXPLOSIVE

 Wear splash−proof safety glasses.

 Do not smoke or permit flames or sparks to oc-

cur near the battery at any time.

 To reduce arcing when disconnecting or recon-

necting battery cables, always disconnect the

negative (−) battery cable first and reconnect it

last.

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.

ENGINE EXHAUST IS DEADLY!

 Learn the symptoms of carbon monoxide poi-

soning in this manual and never occupy the ve-

hicle while the genset is running unless the ve-

hicle is equipped with a working carbon mon-

oxide detector.

 Prior to every startup and after every eight

hours of running, all carbon monoxide detec-

tors must be tested and confirmed to be work-

ing in accordance with the manufacturer’s in-

structions or owners manual.

 The exhaust system must be installed in accor-

dance with the genset Installation Manual. En-

gine 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 oper-

ating the genset in a confined area.

THE HAZARDS OF CARBON MONOXIDE

Engine−driven generators can produce harm-

ful level of carbon monoxide that can injury or

kill you.

ONLY YOU CAN PROTECT YOURSELF

FROM CO POISONING!

 Watch constantly for people near the exhaust

of the generator set while it is running.

 Make sure exhaust cannot enter the living

quarters through a window, vent or door.

 Make sure all CO detectors or audible alarms

are working properly.

 Pay attention to the signs of CO poisoning.

SUBSTANCES HAZARDOUS TO HEALTH

Generator sets use substances, and emit and

create wastes that can cause health risks. Genera-

tor set operators must use appropriate personal

protective equipment (such as clothing, gloves,

protective glasses/goggles, and respiration equip-

ment) when exposed to fuel, oil, coolant, wet batter-

ies, grease, cleaning agents, or other substances

exposed to lungs, eyes, or skin. use appropriate

containers for transport, storage, and disposal of

waste substances. Follow local regulations for dis-

posal and recycling.

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.

 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.

PROPANE

This product is also known as C

or liquified pro-

pane gas. It consists of predominantly C

Hydrocar-

bons (propane and prepane) with typically < 50 ppm

of ethyl mercaptan or other odorizing agent added

to assist leak detection. Contains <0.1% 1, 3 buta-

deine. Hazardous components include c3−4 rich,

petroleum distillate.

The substance has an initial boiling point of −42.1

C flash point of −104 C (PMCC), and a vapor pres-

sure of 7.5 bar at 15 C.

Keep the container below 50C. The substance

should not be used for any other purpose without

contacting the manufacture or supplier. Installers,

operators and maintainers are likely to encounter

this substance. When doubt exists as to correct

handling procedure, contact supplier.

HAZARDOUS REACTIONS

This liquid is extremely flammable (F+). Readily

forms an explosive air−vapor mixture at ambient

temps. Avoid smoking, heat sources, such as weld-

ing and naked flames, sparks and static electricity

build−up. Thermal decomposition products are

hazardous, containing CO

compounds.

The vapor is explosive. High vapor concentrations

can cause respiratory irritation, dizziness, nausea,

and loss of consciousness. Excessive and pro-

longed exposure to the mist can cause chronic in-

flammatory reaction of the lungs and form of pulmo-

nary fibrosis.

Vapor is heavier than air and may travel to remote

sources of ignition. Liquid leaks generate large vol-

umes of flammable vapor (approx 250:1).

Avoid strong oxidizing agents, e.g. chlorates which

may be used in agriculture

Cold burns (frost bite) will result from skin/eye con-

tact with liquid. Toxicity following single exposure to

high level of propane is of low order.

PROTECTIVE MEASURES

Ensure good ventilation and avoid heat sources.

Observance of good housekeeping rules will en-

sure general safety. Do not smoke.

When working on, or testing, injection equipment,

special care is required. Use eye protection at all

times.

Adopt a high standard of personal hygiene. In the

case of skin contact, flush with water to normalize

temperature. Use gloves and overalls, and eye

protection goggles. Use oil impervious gloves and

avoid contamination inside the gloves. If overalls

become contaminated, discontinue use and clean

thoroughly. Contaminated clothing should be re-

moved, soaked with water, and laundered before

reuse.

STORAGE/TRANSPORT

Store and transport only in correctly marked con-

tainers. Keep containers closed when not in use.

Keep cool, out of sunlight and away from naked

flames. Electrical continuity is required between the

transport and storage vessels during product trans-

fer.

In case of leak clear people away from area to a

safe place. DO NOT operate electrical equipment

unless flame proof. Summon emergency services

and treat or refer casualties as necessary.

Extinguish all naked lights − AVOID MAKING

SPARKS! Try to stop flow of product. Cover drains

and dispense vapor with water spray. Note: Vapor

may collect in confined spaces.

EMERGENCY ACTION

 Fire

Extinguishing media:

Large fire − None. Product flow must be

stopped and container cooled by water spray.

Water fog should be used to assist approach to

source of the fire.

Small fire − foam/dry powder, CO

Avoid making sparks. Fire fighters to sue self−

contained breathing apparatus. Keep fire ex-

posed containers cool, using water fog/spray.

Prevent run−off from entering waterway, drains

and drinking water supplies. Every precaution

must be taken to keep containers cool to avoid

the possibility of a boiling liquid expanding va-

por explosion (BLEVE).

 Ingestion: Not applicable

 Inhalation (of vapor)

Remove from further exposure. Obtain medi-

cal assistance immediately.

 Eyes

Cold burns should be flushed with water to

normalize temperature. Cover burns with ster-

ile dressings. Do not use ointments or pow-

ders. Obtain medical assistance as necessary.

 Skin

Cold burns should be flushed with water to

normalize temperature. Cover burns with ster-

ile dressings. Do not use ointments or pow-

ders. Obtain medical assistance as necessary.

 Spillage: See Storage/Transport

PETROL (UK) / GASOLINE

This product is also known as petrol (UK) or gaso-

line. It can be clear liquid with slight tan or yellow col-

or with a characteristic mild odor. It is a complex

combination of hydrocarbons consisting of primari-

ly of paraffins, napthlenes, aromic and olefinic hy-

drocarbons having carbon numbers predominantly

between C4 and C12.

The substance has an initial boiling point of

25−220C, a flash point greater than <−40C, and a

vapor pressure between 0.5 − 1 bars and has neg-

ligible solubility in water.

It is used as a fuel for off−road petrol powered ve-

hicles and stationary engines, and can be found in

fuel tanks, pipes and injection systems. The sub-

stance should not be used for any other purpose

without contacting the manufacture or supplier. In-

stallers, operators and maintainers are likely to en-

counter this substance.

HAZARDOUS REACTIONS

This liquid is extremely flammable. Avoid smoking,

heat sources, such as welding and naked flames,

sparks and static electricity build−up. Thermal de-

composition products are hazardous, containing

, NO

and SO

compounds.

The vapor is explosive. High vapor concentrations

can result in central nervous system and respiratory

depression with subsequent loss of consciousness.

Where ventilation is poor or temperature high, va-

por production may be a hazard. Excessive and

prolonged exposure to the mist can cause chronic

inflammatory reaction of the lungs and form of pul-

monary fibrosis.

Avoid strong oxidizing agents, e.g. chlorates which

may be use in agriculture.

Petrol is slightly irritating to the skin and has a de-

fatting action. Toxicity following single exposure to

high level of petrol is of low order. Prolonged, re-

peated skin contact may DE−fat the skin resulting in

possible skin irritation and dermatitis. In some

cases warty, cancerous growths have occurred.

This product contains benzene (<1%) which is clas-

sified as a carcinogen. Exposure to Benzene may

result in blood disorders such as anaemia and leu-

kemia. Toxic to aquatic organisms, may cause

long−term adverse effects in aquatic environment.

PROTECTIVE MEASURES

Ensure good ventilation and avoid heat sources.

Observance of good housekeeping rules will en-

sure general safety. Do not smoke. Avoid breathing

mist.

When working on, or testing, injection equipment,

special care is required to avoid perforation of skin

by high pressure fuel. Use eye protection in the

event of suspected high pressure leak.

Adopt a high standard of personal hygiene. In the

case of skin contact, wash well with soap and water.

Use glove and overalls, and eye protection goggles

if there is a risk of splashing. Use oil impervious

gloves and avoid contamination inside the gloves. If

overalls become contaminated, discontinue use

and clean thoroughly. Contaminated clothing

should be removed, soaked with water, and laun-

dered before use.

No special respiratory precautions are necessary in

normal use.

DO NOT use as a solvent for removing dirt/grease

etc., from skin.

STORAGE/TRANSPORT

Store and transport only in correctly marked con-

tainers. Keep containers closed when not in use.

Keep cool, out of sunlight and away from naked

flames. Electrical continuity is required between the

transport and storage vessels during product trans-

fer.

Contain leak/spill with sand, earth or other suitable

material, and prevent entry of substance into drain-

age/sewerage system, water−courses and land.

Dispose of unwanted or absorbed substance

through unauthorized contractor to a licensed site.

Inform local and fire authorities should the product

reach waterways, drains etc.

EMERGENCY ACTION

 Fire

Extinguishing media:

Large fire − Foam/water fog. Never use water

jet.

Small fire − foam/dry powder, AAAF,CO

sand,

earth.

Avoid making sparks. Fire fighters to sue self−

contained breathing apparatus. Keep fire ex-

posed containers cool, using water fog/spray.

vii

Prevent run−off from entering waterway, drains

and drinking water supplies.

 Ingestion

Do not induce vomiting. Wash the mouth out

with water, and send to hospital immediately.

 Inhalation (of vapor)

Remove from further exposure. Obtain medi-

cal assistance immediately.

 Aspiration (inhalation of liquid)

If, following ingestion of gas oil, vomiting oc-

curs, there is danger of aspiration into the

lungs. This would cause intense local irritation

and chemical pneumonitis that can be fatal.

Obtain immediate medical assistance.

 Eyes

Irrigate copiously with water or preferably eye−

wash solution for at least five minutes. If irrita-

tion persists seek medical advice.

 Skin

Wash thoroughly with soap and water. Change

clothing if necessary.

If high pressure injection has occurred prompt

surgical attention is required.

 Spillage

Absorb using sand, earth or other suitable ma-

terial. Dispose of unwanted or absorbed flam-

mable material as directed under Storage/

Transport (Section 5.7.3). In the event of a ma-

jor spillage, only trained personnel wearing self

contained breathing apparatus should handle

the spill. Any spillage or leak should be treated

as a major fire/explosion hazard. If vehicles

present, switch off engines.

LUBRICATION OIL − PREMIUM BLUE E

15W40

Also known as oil, lube oil, sump oil, new oil is dark,

viscous liquid with a slight, characteristic odor. The

base oil contains: distillates (petroleum), solvent−

dewaxed heavy paraffinic. It is not classified as dan-

gerous according to Directive 1999/45/EC and its

amendments, and is not classified according to the

EU regulations.

It has a boiling point greater than 150C, a flash

point Open Cup of 220C (Cleveland), and is insolu-

ble in cold water.

It is used in engine lubricant oil systems, sump pan

and filters, make−up tanks and piping systems as a

lubrication oil for use in wide range of diesel engines

operating under severe conditions. Installers, oper-

ators and maintainers are likely to encounter this

product.

HAZARDOUS REACTIONS

This product is stable although slightly re−active

with oxidizing agents. Results of decomposition are

carbon oxides (CO, CO

) and water.

Although harmful if swallowed or aspirated

(breathed in), repeated or prolonged exposure is

not know to aggravate medical conditions.

Used oil may contain harmful combustion by−prod-

ucts and unburnt fuel that will cause skin reactions

as detailed for fuel. Particular care must be taken if

oil form a severely overheated engine is handled −

use impervious gloves, lab coat and safety glasses.

Do not breath vapor/spray.

PROTECTIVE MEASURES

Ensure good ventilation and avoid heat sources.

Adopt a high standard of personal hygiene. In case

of skin contact, wash thoroughly with soap and wa-

ter.

Use safety glasses, impervious gloves and lab coat.

Avoid contamination inside the gloves. If overalls

become contaminated, discontinue use and clean

thoroughly.

No special respiratory precautions are necessary in

normal use. Do not breath vapor/spray when han-

dling hot materials.

STORAGE/TRANSPORT

Store and transport only in correctly marked con-

tainers. Keep containers tightly sealed when not in

use. Keep in cool, well ventilated area, out of sun-

light and away from naked flames. Store well away

from food − stuffs and drinking water.

Wear splash goggles, full suit, boots and gloves.

Absorb leak/spill with inert material and dispose of

unwanted or absorbed substance through an au-

thorized contractor to a licensed site. Finish clean-

ing by spreading water on the contaminated surface

and allow to evacuate through the sanitary system.

viii

GENERATOR SET WARNING LABELS

Warning signs are provided on the generator set at

or near the point of risk. To avoid injury, always take

the necessary precautions − as indicated on the

sample signs shown below.

Caution / Warning.

Indicates a risk of personal injury.

Caution / Warning of Temperature Hazard.

Indicates a risk of personal injury from high temperature.

Caution / Warning of High Voltage Hazard.

Indicates a risk of personal injury from electric shock/electrocution.

Caution / Warning.

Indicates a risk of personal injury from equipment that may be subject to

automatic starting or remote starting.

Caution / Warning.

Indicates to read Operator manual for additional information.

Caution / Warning of Belt and Rotating Part Hazard.

Indicates a risk of personal injury from entanglement in moving parts.

Caution / Warning of Pressure Hazard.

Indicates a risk of personal injury from pressurized fluids.

1-1

1. Introduction

GENERAL

This manual provides installation guidelines for the

MicroLite

(KV) generator set (referred to as gen-

set). The genset must be installed properly to oper-

ate reliably, quietly, and safely. Read this entire

manual before starting the installation.

For operation and maintenance procedures, see

the Operator’s Manual (981-0136) that accompa-

nies each genset.

When properly installed, this genset meets or ex-

ceeds the following requirements:

 National Electrical Code, NFPA 70-Article 551

 ANSI/RVIA EGS-1 - 1986, Generator Set

standard

 ANSI A119.2/NFPA 501C Standard for

Recreational Vehicles

 NFPA 58 Standard for the Storage and

Handling of Liquefied Petroleum Gases

 CSA Electrical Bulletin 946

The RV manufacturer and/or the genset installer

must comply with local codes such as California ad-

ministrative Code title 25, which applies to genset

installation. The RV installer bears sole responsibil-

ity for the selection of the appropriate genset, instal-

lation design, and installation.

Consider the following requirements before install-

ing the genset. Each topic is covered in the following

text.

 Level and supportive mounting surface

 Adequate cooling air

 Adequate fresh induction air

 Discharge of circulated air

 Noise levels

 Accessibility for maintenance and service

 Exhaust connections

 Fuel supply

 Electrical connections

MicroLite is a trademark of the Onan Corporation.

INSTALLATION CODES AND SAFETY

RECOMMENDATIONS

The following list of Installation Codes and Safety

Recommendations applies to the installation and

operation of RV gensets. The address of each

agency is listed so that copies of the codes may be

obtained for reference. Installation codes and rec-

ommendations are subject to change, and may vary

by location or over time. The RV manufacturer and

the genset installer bear sole responsibility for fol-

lowing all applicable codes and regulations.

1. ANSI-A119.2 Recreational Vehicle

FMVSS 301 Industry Association

14650 Lee Road

Chantilly, VA 22021

2. NFPA 70 (N.E.C.) National Fire Protection

NFPA 501C Association

NFPA 58 470 Atlantic Avenue

Boston, MA 02210

3. CSA Electrical Canadian Standards

Bulletin #946 Association, Housing and

Construction Materials

Section

178 Rexdale Blvd.

Rexdale, Ontario,

Canada M9W 1R3

4. California State of California

Administrative Documents Section

Code - Title 25 P.O. Box 1015

Chapter 3 North Highlands, CA

95660

This manual contains information that is subject to

change. For this reason, use only the installation

manual supplied with the genset for the installation.

Keep this manual along with the Operator’s manual

in the RV or near the genset for future reference.

WARNING

Incorrect installation, service, or re-

placement of parts can result in severe personal

injury, death and/or equipment damage. Ser-

vice personnel must be qualified to perform

electrical and/or mechanical component instal-

lation.

1-2

WARNING

This genset is not a life support sys-

tem. It can stop without warning. Children, per-

sons with physical ore mental limitations, and

pets could suffer personal injury or death. A

personal attendant, redundant power or an

alarm system must be used if genset operation

is critical.

WARNING

This generator set is not “ignition

protected” and shall not be used in a flammable

vapor environment.

COMPONENT LOCATIONS

The standard control panel and routine mainte-

nance items are located behind the access cover

(Figure 1-1).

To remove the access cover: Slide the latches up

and pull the cover outward from the bottom. Lower

the cover to remove it from the housing.

To secure the access cover: Position the tabs on

the top of the access cover in the openings on the

housing. Slide the latches up and push the bottom

of the cover in place. Hold the cover in place firmly

while releasing the latches to secure the cover.

WARNING

Operation of the genset with the ac-

cess cover removed can result in severe per-

sonal injury or equipment damage. Hot compo-

nents are exposed when the access cover is re-

moved and genset cooling air does not circulate

properly. Do not operate the genset with the ac-

cess cover removed.

MUFFLER

(INSIDE COVER)

CONTROL

FUSE (NOT

SHOWN)

START/STOP

SWITCH

OIL DRAIN

BOTTOM CENTER

(NOT SHOWN)

AIR FILTER

COVER

SPARK

PLUG

ACCESS

GASOLINE

FUEL FILTER

GASOLINE

CARBURETOR

MAIN ADJUST

CIRCUIT BREAKER

(NOT SHOWN)

OIL FILL

AND CHECK

LATCHES

REMOVABLE

ACCESS

COVER

PREHEAT CONTROL

(NOT USED ON LP

MODELS)

FIGURE 1-1. MICROLITE KV COMPONENT LOCATIONS

2-1

2. Specifications

TABLE 2-1. SPECIFICATIONS FOR GASOLINE-FUELED MODELS

MODEL 2.3 KV MODEL 2.8 KV

GENERATOR: 2-Pole Revolving Field, Self-Excited, Electronically Regulated, 1-Phase

Power 2,300 watts 2,800 watts

Frequency 50 Hertz 60 Hertz*

Voltage 230 volts 120 volts

Current 10.0 amperes 23.3 amperes

Speed 3,000 RPM 3,600RPM

FUEL CONSUMPTION: Gasoline

No load gph (l/h)

Half load gph (l/h)

Full load gph (l/h)

0.20 (0.8)

0.23 (0.9)

0.40 (1.5)

0.20 (0.8)

0.30 (1.1)

0.43 (1.6)

ENGINE: 1-Cylinder, 4-Cycle, Spark-Ignited, OHV, Air Cooled

Bore 2.64 inches (67 mm)

Stroke 2.2 inches (56 mm)

Displacement 12 inches

(197 cc)

Compression Ratio 8.5 : 1

Oil Capacity** 1 quart (0.95 l)

Intake Valve

Clearance (Cold)

0.002 inches (0.05 mm)

Exhaust Valve

Clearance (Cold)

0.002 inches (0.05 mm)

Spark Plug Gap 0.025 inches (0.64 mm)

Spark Plug Tightening Torque 13 lbs-ft (17 N-m)

Ignition Timing (Breakerless elec-

tronic magneto ignition)

25 BTDC, non-adjustable

CONTROL AND CRANKING SYSTEM: 12 VDC

Nominal Battery Voltage 12 volts

Minimum Required Battery Cold

Cranking Capacity (amperes)

360

Control Fuse 5 amp

* − The 60 Hertz models are Listed by CSA and the U.S. Testing Company.

** −See Periodic Maintenance for oil filling instructions.

2-2

TABLE 2-2. SPECIFICATIONS FOR LPG-FUELED MODELS

MODEL 2.0 KV MODEL 2.5 KV

GENERATOR: 2-Pole Revolving Field, Self-Excited, Electronically Regulated, 1-Phase

Power 2,000 watts 2,500 watts

Frequency 50 Hertz 60 Hertz*

Voltage 230 volts 120 volts

Current 8.7 amperes 20.8 amperes

Speed 3,000 RPM 3,600RPM

FUEL CONSUMPTION: LPG

No load gph (l/h)

Half load gph (l/h)

Full load gph (l/h)

0.20 (0.8)

0.30 (1.14)

0.45 (1.7)

0.20 (0.8)

0.34 (1.29)

0.55 (2.08)

ENGINE: 1-Cylinder, 4-Cycle, Spark-Ignited, OHV, Air Cooled

Bore 2.64 inches (67 mm)

Stroke 2.2 inches (56 mm)

Displacement 12 inches

(197 cc)

Compression Ratio 8.5 : 1

Oil Capacity** 1 quart (0.95 l)

Intake Valve

Clearance (Cold)

0.002 inches (0.05 mm)

Exhaust Valve

Clearance (Cold)

0.002 inches (0.05 mm)

Spark Plug Gap 0.025 inches (0.64 mm)

Spark Plug Tightening Torque 13 lbs-ft (17 N-m)

Ignition Timing (Breakerless elec-

tronic magneto ignition)

25 BTDC, non-adjustable

CONTROL AND CRANKING SYSTEM: 12 VDC

Nominal Battery Voltage 12 volts

Minimum Required Battery Cold

Cranking Capacity (amperes)

360

Control Fuse 5 amp

* − The 60 Hertz models are Listed by CSA and the U.S. Testing Company.

** −See Periodic Maintenance for oil filling instructions.

3-1

3. Step-By-Step Installation Outline

INTRODUCTION

This section provides a step-by-step overview of a

typical installation. This section includes:

 Preparation

 Compartment Mounting

 Under-Floor Mounting

 Connecting to Vehicle Systems

 Exhaust System

Review this section, then refer to the detailed in-

structions in sections four through nine for specific

procedures and important safety precautions. The

installer is responsible for complying with all appli-

cable installation codes and safety requirements.

PREPARATION

1. Remove the shipping carton by cutting the

banding around the bottom. Unfold the flaps at

the bottom of the carton and lift the carton off

the genset.

Collect all loose shipped items, like the Opera-

tor’s Manual, and add them to the vehicle docu-

mentation package.

CAUTION

This genset contains oil. Do not

tip the genset over or oil leakage and genset

damage can result.

2. Remove the shipping bolts that secure the

wooden skid to the ends of the genset base.

FIGURE 3-1. CRATE REMOVAL

FIGURE 3-2. SKID BASE REMOVAL

SHIPPING

CARTON

BANDING

WOOD

SKID

GENSET

SHIPPING

BOLTS

3-2

COMPARTMENT MOUNTING

Install the genset in its own compartment. If any part

of the compartment is above the vehicle floor, sepa-

rate the compartment from the living quarters with

vapor-tight walls. Refer to the Mounting section for

compartment construction details.

WARNING

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 en-

tering the living quarters.

The genset requires an unobstructed air inlet of at

least 24 square inches (155 cm

). Refer to the

Mounting and Ventilation section for details. Pro-

vide an adequate genset access for maintenance

and service removal either through the door or out

the bottom (7.5 x 15 inch [190.5 x 381 mm] minimum

maintenance opening).

1. Carefully measure the compartment size to

make sure there will be proper clearance for

the genset. Figure 3-3 shows the compartment

dimensions. Add 1/2 inch (12.7 mm) to

compartment depth if 1/2-inch (12.7 mm) in-

sulation is used inside the door.

Allowing one to two inches of additional space

on the left side of the compartment will make

electrical and fuel connections easier.

2. Put holes in the bottom of the compartment for

genset mounting, air outlet, oil drain, and spark

plug access (Figure 3-4). If the bottom of the

compartment is wooden, remove the wooden

section under compartment and replace it with

a sheet metal floor and an adequate steel sup-

port frame. (Refer to Onan template number

539-1386).

SPARK PLUG

ACCESS

FIGURE 3-3. MINIMUM COMPARTMENT

DIMENSIONS

FIGURE 3-4. COMPARTMENT FLOOR TEMPLATE

USE TEMPLATE OR SEE FIGURE 4-2

NFPA 70 (NEC) 551-30 (d)

OIL

DRAIN

DRAINAGE

HOLES

GENSET

MOUNTING

HOLES

AIR

OUTLET

3 IN (76 mm)

12.5 IN

(317.5 mm)

17.75 IN

(451 mm)

24.5 IN

(622 mm)

3-3

3. Put holes in the compartment to run connec-

tions for the fuel line, battery cable, remote con-

trol harness and AC conduit. Design holes so

they will not chafe or restrict the lines.

If the remote control harness or AC conduit go

directly into the interior of the vehicle, seal

around and inside the conduit to prevent the

passage of exhaust gases. The fuel line must

not be routed through the interior of the vehicle.

4. Mount the genset in the compartment with four

3/8-16 screws. Screw length must not protrude

more than 1/2 inch (13 mm) through the genset

base.

5. Proceed to Connecting To Vehicle Systems

(page 3-5).

UNDER-FLOOR MOUNTING

An optional kit is required for under-floor mounting.

Support brackets are used to suspend the genset

below the floor of the vehicle. Refer to the instruc-

tions that are supplied with the kit for specific instal-

lation instructions and important safety precau-

tions. For additional under-floor mounting informa-

tion refer to the Mounting section.

1. Use the template supplied with the under-floor

mounting kit to locate the holes in the vehicle

support structure.

WARNING

Failure to provide an adequate

support structure can result in severe per-

sonal injury, death, and/or equipment dam-

age. Carefully follow the Under-Floor Hous-

ing kit installation instructions and provide

an adequate support structure. Use speci-

fied hardware and tighten all mounting

hardware to the recommended torque set-

tings.

1 IN

(25.4 mm)

FIGURE 3-5. GENSET TO VEHICLE SYSTEMS

CONNECTIONS

FIGURE 3-7. UNDER-FLOOR MOUNTING

TEMPLATE

FIGURE 3-6. COMPARTMENT MOUNTING

7/16 IN - HOLES (6) FOR 3/8 IN BOLTS

LOCATE FUEL AND ELECTRICAL LINE

ENTRANCE HOLES IN SHADED AREA

USE TEMPLATE

FROM KIT

3/16-16 SCREW

1/2 IN (13 mm) MAXIMUM

PROTRUSION

SUPPORT

THICKNESS

7.5 IN

(190.5 mm)

5.75 IN

(146 mm)

3-4

2. If the area above the compartment is made of a

wood product, you must install a 26-gauge

(0.02-inch) galvanized metal plate (or equiva-

lent) above the genset.

3. Assemble the under-floor mounting kit accord-

ing to the instructions provided with the kit.

Note that the side panels can be mounted with

the top flanges toward the genset, as shown in

Figure 3-9, or they can be reversed to point

away from the genset.

WARNING

Dropping the genset can cause

severe personal injury or death. Make sure

no one moves the vehicle during installa-

tion by removing the keys and disconnect-

ing the negative (−) battery cable. Keep feet

and hands clear during installation.

4. Use a forklift to carefully raise the genset into

position in the support frame. Secure the gen-

set to the support frame with the mounting

hardware included in the Under-Floor Housing

kit.

5. Proceed to the next section on connecting to

the vehicle systems.

FIGURE 3-9. UNDER-FLOOR

MOUNTING KIT

FIGURE 3-10. UNDER-FLOOR

INSTALLATION

FIGURE 3-8. UNDER-FLOOR MOUNTING KIT

WITH METAL CEILING (NOT SUPPLIED WITH KIT)

NFPA 70 (NEC) 551-30 (f)

AREA ABOVE SET

(APPROX. 16.5 X 24 IN [419 X 610 mm])

MUST BE METAL

UNDER-FLOOR

MOUNTING KIT

COMPONENTS

3-5

CONNECTING TO VEHICLE SYSTEMS

1. Route fuel line separate from electrical wires or

separate them with conduit or other sheathing.

WARNING

Fuel presents the hazard of fire

or explosion that can result in severe per-

sonal injury or death. Do not smoke or allow

any flame, spark, pilot light, arc-producing

equipment or other ignition sources near

fuel or in the installation area. Read the im-

portant safety precautions in the Fuel Sys-

tems section.

2. Gasoline Fueled Sets: Connect 1/4-inch I.D.

fuel hose (type SAE 30-R7) to the barb fitting

on the genset. Secure fuel hose to barb fitting

with a stainless steel clamp (worm-gear type).

Do not over tighten clamp or hose could be

damaged.

LPG Fueled Sets: Use 1/2-inch I.D. fuel line.

Use a 1/4-inch NPTF thread pipe fitting for fuel

connection to the genset. LPG models are de-

signed to operate on LP vapor at 11 inches of

water column. Refer to the Fuel System section

for instructions and important safety precau-

tions.

3. Install a listed 1/2-inch flexible conduit over the

AC wiring. (Use water-tight conduit for under-

floor mounting.) Secure the conduit to the fitting

on the genset. Make sure lines do not contact

sharp, hot of abrasive surfaces.

WARNING

Accidental starting can cause

severe personal injury or death. Do not con-

nect the battery cables to the genset start-

ing battery until instructed to in the Initial

Start and Checks section.

FIGURE 3-11. FUEL AND ELECTRIC LINES

FIGURE 3-12. FUEL LINE CONNECTION

FIGURE 3-13. AC CONDUIT CONNECTION

AC CONDUIT

BATTERY

POSITIVE (+)

CABLE

FUEL LINE

NFPA 70 (NEC) 551-30 (e)

FUEL

HOSE

CLAMP

AC CONDUIT

REMOTE

CONTROL

CONNECTOR

3-6

4. Connect the battery positive (+) cable to the

wiring harness B+ connection. Tighten the B+

connection securely and cover the connection

with the terminal boot to insulate it. Wire-tie the

terminal boot in place to prevent movement of

the boot.

5. Connect the battery negative (−) cable to any

one of the four genset mounting holes in the

base. Use star (EIT) washers on each side of

the ring terminal when securing the terminal to

base.

6. Connect the remote control harness connector

to the mating connector on the left side of the

genset (Figure 3-16).

7. Proceed to the next section on connecting the

exhaust system.

FIGURE 3-16. REMOTE CONTROL

CONNECTION

FIGURE 3-15. BATTERY NEGATIVE (−)

CONNECTION

REMOTE

CONTROL

CONNECTOR

FIGURE 3-14. BATTERY POSITIVE (+)

CONNECTION

TERMINAL

BOOT

BATTERY

NEGATIVE (−)

CONNECTION

BATTERY

POSITIVE (+)

CONNECTION

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Model: Microlite 2.5 KV

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