8-2
Assembly
Assemble cooling system in reverse order of disas-
sembly. Follow the generator assembly instructions
(Section
9. Generator
) for installing the fan hub as-
sembly.
CAUTION
Overheating can result in engine
damage. To avoid overheating, never operate
the genset with any of the cooling system com-
ponents removed.
EXHAUST SYSTEM
The condition of the exhaust system is extremely
critical on RV gensets because of the possibility of
exhaust gases entering the vehicle. The exhaust
system must not have any leaks and it must be well
supported. The tailpipe must extend 1 inch (25.4
mm) beyond the the perimeter of the vehicle and it
must not terminate so exhaust can enter the ve-
hicle.
WARNING
Exhaust gasses contain carbon
monoxide, an odorless and colorless gas that
can cause severe personal injury or death.
Make certain that the exhaust components are
in good condition and that there are no leaks.
The exhaust system consists of the muffler, the ex-
haust pipe, and the clamps and hangers needed for
installation of the exhaust pipe. On Begin Spec B,
the muffler has a flexible inlet pipe. On Spec A, the
muffler has a flexible outlet pipe. Figure 8-2 on Page
8-3 shows a typical exhaust system for a compart-
ment mount genset. The following section covers
the service procedures for the exhaust system.
The exhaust system must be serviced immediately
if inspection reveals leaking joints or connections,
loose fasteners, or broken or damaged compo-
nents.
Always replace worn components with new original
equipment replacement parts. Do not attempt to re-
pair a broken exhaust pipe or manifold by welding
and do not replace worn out components with parts
that do not meet factory specifications.
The muffler is a spark arrester type muffler that is
US Forest Service Approved and meets code re-
quirements. Failure to provide and maintain a spark
arrester muffler can be in violation of the law. Con-
tact an Onan distributor for approved replacement
exhaust parts.
WARNING
Inhaling exhaust gases can cause
severe personal injury or death. Modifying the
exhaust system may let poisonous exhaust
gases enter the vehicle. Use only Onan replace-
ment parts to service the exhaust system. Un-
authorized modifications will void the Onan
warranty. Liability for injury or damages due to
unauthorized modifications becomes the re-
sponsibility of the person making the modifica-
tion.
Muffler Disassembly
1. Allow the exhaust system to cool down before
servicing.
2. Loosen the exhaust pipe clamp securing the
exhaust pipe to the genset.
3. Remove exhaust pipe hanger(s) and lower ex-
haust pipe.
4. Remove the genset from the vehicle and re-
move the outer housing. See
Set Removal
Guideslines
on Page 5-2.
Spec A:
5. Remove the bolts securing the muffler flange to
the engine and the muffler outlet pipe to the
base.
6. Remove the hardware securing the muffler
bracket to the engine bracket. Remove the
muffler and the exhaust gasket.
Begin Spec B:
5. Remove the bolts securing the flexible exhaust
manifold to the muffler.
6. Remove the screws securing the muffler to the
base. Remove the muffler and the exhaust
gasket.
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