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GENERATOR INSTALLATION
IAS Units = 2oO4
Dade foe

Read _all instructions fully before proceeding.

See also Instruction Sheet C537 for the Generator Remote Switch (supplied with vehicle)

and Generator manual (supplied with the Generator)

1. Remove the generator mounting brackets (Figure A).

2. Drop the trunk compartment by removing 6 bolts located inside the
compartment ( Figure A)

3. Seal off the old trunk opening to prevent exhaust gases from entering the

vehicle. Use a piece of 16 ga. sheet metal 20 4” x 30” using plenty of silicone
sealant at the joint and screw the plate securely to the vehicle with 8 x % self
tapping screws.

4. Prepare the generator:

A) Install the quick connect plug supplied with the Onan generator to the 4 wire
harness located along the bumper of the van (Figure B) by butt connecting color
to color.

B) Hook up the fuel line ( 10 ft of 1/4” I.D. meeting SAE 30R7 Standards ) to
the generator fuel supply inlet and forward to the auxiliary fuel supply tap on
the fuel tank (Figure B). It is a 5/16 dia. tube with a black rubber cap.

Use a 4 NPT male x 5/16 hose barb fitting and a %4 NPT female x 44 hose barb
fitting screwed together back to back (Figure C) as an adapter between the fuel
tap and the ‘4” rubber line. A short piece of 5/16 rubber line will be required
between the fuel tap and the 5/16 barb. Hose clamp all fitting to hose joints
being particularly careful on the fuel tap not to over tighten the 5/16 rubber line
to the 5/16 plastic tube.

5. A piece of black liquid-tite conduit passes through the floor (Figure B). Open
up the end under the vehicle and fish the generator wires up to the junction box
located inside the vehicle. Make the appropriate color coded connections.
Remove the reset cover and replace with a 4” square blank,

. Along the back of the van there is another set of wires (Figure B) that are
8 ga. red and 8 ga. white (these are the battery feed wires). The white wire is to
be connected to battery ground and the other end is to be grounded to one of the
generator mounting bolts (we recommend cleaning some of the paint off where
the generator is to be grounded as a good ground connection is absolutely
necessary!). The red wire is to be connected to battery positive and the other
end to the single white wire on the generator ( the two lugs may be nut and
bolted together and then properly protected).

. Attach the generator to the mounting brackets and lift into place with a floor
jack. Re-install all fasteners and washers then tighten.

. Install the generator exhaust pipe (Figure D) so that it extends out past the side
of the vehicle (Figure B) on the passengers side just forward of the battery
compartment (It will require lengthening from it’s stock length) and secure
with exhaust hangers. We recommend Pleasure-Way Industries supply the
modified pipe.

. Prior to operation of the vehicle or the generator make certain that all

connections are proper and secure, all connections are protected, all hoses and
fittings are tight, all fasteners are tight and all hoses and wiring harnesses are
secured out of harms way.

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