Cummins/Onan 4.0 BFA Generator Set

Tools: voltmeter, double-pole double-throw switch, separate ground cable

1. Remove spark plug wires so set will not start when cranked.
2. Connect voltmeter to battery terminals, battery side of start solenoid, and set frame.
3. Crank engine and measure voltage at battery.
4. Then measure voltage from start solenoid to set frame; do not allow more than five seconds between readings.
5. Subtract voltage at set from measured battery voltage during cranking; difference should not exceed 0.6 volt.
6. If difference exceeds 0.6 volt, check all connections; a separate ground cable may be needed.
7. Alternate test: remove spark plug wires, crank engine and measure cranking speed.
8. Connect separate ground cable from battery to set frame, crank engine and again measure speed.
9. If cranking speed increased more than ten percent, check connections and consider permanent ground cable.

⚠ Do not use flammable material directly above or around the generator set compartment.

⚠ Be sure drain hole is not directly above muffler to prevent fire hazard.

⚠ Separate installation area or compartment from living quarters by a vapor-tight wall to prevent entrance of noxious fumes to interior.

1. Install generator set in its own compartment separated from living quarters and fuel supply by a vapor-tight wall.
2. Line compartment or separate set from living quarters with fire barrier of galvanized steel (22 gauge minimum) or equivalent noncombustible material.
3. Seal compartment vapor tight to prevent noxious fumes entering motor home interior.
4. Leave clearance as specified in individual installation guide; maintain one inch minimum for generator cooling air inlets on generator end.
5. Compartment bottom must have minimal openings; use sheet metal base plate or plywood covered with sheet metal.
6. Equip base with oil drain hole to outside of compartment, not directly above muffler.
7. Do not use absorbent material on inside compartment floor.
8. Construct compartment floor to prevent accumulation of oil, fuel or water in corners; use 1/2 inch diameter hole near each corner or other suitable drainage.

⚠ Insulation must not reduce minimum clearances required to meet ANSI 198.1 and CSA #946 temperature rise requirements for recreational vehicles.

1. Ensure all joints and corners of compartment are vapor tight to coach interior before lining.
2. Cover sound reflective surfaces (back, top, sides, not base) with fiberglass or other noncombustible acoustical material.
3. Use acoustical material no less than one inch thick and approximately two pounds per square foot in density.
4. Use noncombustible adhesive; test acoustical material and adhesive for heat effects before using.
5. A combination of materials, such as lead or viscoelastic material plus acoustical material, can reduce noise even more.
6. To prevent line-of-sight noise, add a sound panel (baffle) behind louvered air inlet, spaced to allow minimum free air inlet.

⚠ Do not connect generator set exhaust to vehicle exhaust system.

⚠ Do not terminate poisonous carbon monoxide exhaust gas under vehicle.

⚠ Direct exhaust gases away from window and door openings.

1. Where exhaust passes through base or floor, leave adequate clearance; turn up metal around hole or use collar.
2. Keep exhaust system no closer than 1-1/2 inches from combustible material, or insulate/shield so temperature does not rise more than 117°F (65°C) above ambient after full load for one hour.
3. Extend exhaust system a minimum of one inch beyond perimeter of vehicle.
4. Terminate tailpipe aft of air intake if on same side as compartment to prevent recirculation.
5. Terminate exhaust pipe a minimum of three feet from vehicle gasoline filler spout.
6. Use largest possible radius elbows and as few elbows as possible.
7. Use automotive type tail pipe hangers for hanging exhaust system from vehicle undercarriage.
8. If tail pipe deflector is used, ensure it is large enough to prevent excessive back pressure.
9. Clean spark arrester muffler every 100 hours of operation.
10. Check exhaust system visually and audibly for leaks daily, at least every 8 hours of running time.

⚠ Leakage of gasoline in or around compartment is a definite hazard.

⚠ Because of fire hazard, do not tie electrical wiring to fuel line.

1. Follow chassis manufacturer's detailed installation instructions for all connections to vehicle fuel system.
2. Install approved flexible non-metallic and non-organic fuel line between vehicle fuel system and engine to absorb vibration.
3. Use seamless steel tubing and flared connections for long runs between fuel tank and flexible connector.
4. Run fuel lines at top level of tank to a point as close to engine as possible.
5. Keep fuel lines away from hot engine or exhaust areas to reduce chance of vapor lock.
6. Flexible line must be long enough to allow for 4 inches of set movement.
7. Install lines so they are accessible and protected from damage.
8. Use metal straps without sharp edges to secure fuel lines.
9. Do not run fuel line in conjunction with electrical wiring.

⚠ Use only the vibration isolators provided with the electric generating set, as they are designed to support unit's weight.

1. Read the individual installation guide for the model before mounting.
2. Ensure air cleaner is easy to remove.
3. Make battery or batteries accessible.
4. Ensure oil fill, drain and oil dipstick are easy to reach and service.
5. Leave sufficient clearance around exhaust system.
6. Use only vibration isolators provided with the electric generating set.

⚠ Do not smoke while servicing batteries. Lead acid batteries give off explosive gases while being charged.

Tools: terminal puller

1. Keep battery case clean and dry.
2. Make sure battery cable connections are clean and tight; use a terminal puller when removing cables.
3. Coat battery terminals with mineral grease or petroleum jelly to reduce corrosion and oxidation.
4. Identify each battery cable as positive or negative before making any connection; always connect ground (negative) cable last.
5. Maintain electrolyte level by adding water (drinking quality or better) as needed to split level marker.
6. Avoid overcharging when recharging; stop boost charge when specific gravity is 1.260 and electrolyte is 80°F (26.7°C).