Cummins/Onan CHG-4 — Battery Charger DC and Alarm Wiring Installation

For the Cummins/Onan CHG-4.

Applies to: Cummins Onan Chg 4

Procedure

1. Connect 3/4-inch thin wall conduit between the charger DC Output connector and the generator battery case.
2. If an alarm is used, connect 1/2-inch thin wall conduit between the charger Alarm Output connector and the alarm.
3. Connect a #12 AWG or larger ground wire between the grounding stud on the charger and the generator set frame (common ground).
4. Remove the access cover from the battery charger.
5. Pull battery leads (positive [+] and negative [-]) through the 3/4 inch thin wall conduit, using wire size that will offer low resistance for the wire length required.
6. Pull alarm leads through the 1/2-inch thin wall conduit using 16 AWG or larger wire.
7. Connect the battery positive (+) and negative (-) leads to the charger output terminals observing correct polarity.
8. Tighten the lug screws securely.
9. Connect the alarm leads to the terminal board TB1, selecting either the normally-open (NO) or normally-closed (NC) terminals depending on the alarm system requirements.
10. Connect the DC output wires to the battery, connecting the negative [-] lead last.
11. Replace the access cover on the battery charger.
12. Plug the power cord into the AC receptacle and place the on/off switch in the On position.
13. Observe charger operation. The DC ammeter should show a charge condition depending upon the battery state-of-charge.

Source: manual:901-0604 Onan 305-0856 Charger Install Manual.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.