CUMMINS ONAN KV KVC KVD Series RV Generator Workshop Manual

Printed in U.S.A. 1/05 981-0238G (KV Spec A-L) (KVC Spec A-C) (KVD Spec A-B) Parts Catalog Genset KV Replaces 5-02 (KV Spec A-K KVC Spec A-C and KVD) KVD KVC

The following symbols are used in Onan manuals to alert users to the potentially dangerous condi- tions relating to maintenance of equipment and replacement of parts. Please read and observe. This symbol warns of immedi- ate hazards which will result in severe personal injury or death. This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. This symbol refers to a hazard or unsafe practice which can result in severe personal injury or product or property damage. To avoid errors or delay in filling your parts order, always give the MODEL, SPEC NO. and SERIAL NO. from the Onan nameplate. For handy reference, insert your nameplate infor- mation in the spaces below. MODEL AND SPEC NO. SERIAL NO. DIGITAL CONTROL SOFTWARE VERSION AND DATE (IF APPLICABLE) Contact with USED ENGINE OILS has been identified by a United States federal agency and some USA state agencies as causing CANCER or REPRODUCTIVE TOXICITY. When checking or changing engine oils take all necessary precautions not to ingest, breathe the fumes or contact the used oil. Contact with ASBESTOS has been identified by a United States federal agency and some USA state agencies as causing CANCER or REPRODUCTIVE TOXICITY. When handling engine gaskets take all necessary precautions not to ingest, breathe or contact the dust from the gaskets! Use adequate ven- tilation and wear protective gloves, masks and clothing! Contact with BENZINE and LEAD, found in gasoline, fuel additives and solvents has been identified by a United States federal agency and some USA state agencies as causing CANCER or REPRODUC- TIVE TOXICITY. When checking, draining or adding gasoline and fuel additives or using solvents take all necessary precautions not to ingest, breathe the fumes or contact the liquids. Use adequate ventila- tion and wear protective gloves, masks and protective clothing! PSP-1 Service and repair of Onan equipment must be performed by trained, experienced personnel only. Im- proper service or repair may result in property damage, severe personal injury or death. Do not use this catalog as a guide to servicing your equipment. Read and follow the IMPORTANT SAFETY IN- STRUCTIONS in the Service Manual appropriate for the equipment you are working on.

1 Introduction This manual applies to the standard Recreational Vehicle Generator Sets as listed in the Generator Set Data Table. Parts are arranged in groups of related items and each illustrated part is identified by a reference number correspond- ing to the same reference number in the parts list. Parts illustrations are typical. Using the model and specification number from your generator set nameplate, select parts that apply to your set. Right and left sides are determined by facing the engine end (front) of the set. Generator Set Data Table MODEL AND WIRING SPECIFICATION VOLTS HERTZ FUEL DIAGRAM 1.7KV-FU/29236A,B 240 50 Gasoline 610-0376 2.0KV-FR/26119B 230 50 LP 610-0376 2.0KV-FR/26119,C,D,E 230 50 LP 610-0383 2.0KV-FR/26119F,G,H,J 230 50 LP 610-0389 2.0KV-FR/26119K,L 230 50 LP 610-0389 2.0KV-FR/33742B 220 50 Gasoline 610-0376 2.0KV-FR/33742C,D,E 220 50 Gasoline 610-0383 2.0KV-FR/33742F,G 220 50 Gasoline 610-0389 2.0KV-FR/37544A,B 110/220 50 Gasoline 610-0380 2.0KV-FR/51844C,E 220 50 Gasoline 610-0384 2.0KV-FR/51844F,G 220 50 Gasoline 610-0390 2.2KV-FA/26100A,B 120 60 Gasoline 610-0375 2.3KV-FR/33742F,G,J,K 220 50 Gasoline 610-0389 2.3KV-FR/51844F,G,J,K 220 50 Gasoline 610-0390 2.5KV-FR/11540F,G,H,J 100 60 LP 610-0394 2.5KV-FR/11540K,L 100 60 LP 610-0394 2.5KV-FA/26120B 120 60 LP 610-0379 2.5KV-FA/26120C,D,E 120 60 LP 610-0382 2.5KV-FA/26120F,G,H,J 120 60 LP 610-0388 2.5KV-FA/26120K,L 100 60 LP 610-0388 2.8KV-FR/11351C,E 100 60 Gasoline 610-0386 2.8KV-FR/11351F,G,J,K 100 60 Gasoline 610-0394 2.8KV-FA/11574F,G,J,K 120 60 Gasoline 610-0388 2.8KV-FA/26100A,B 120 60 Gasoline 610-0375 2.8KV-FA/26100C,E 120 60 Gasoline 610-0382 2.8KV-FA/26100F,G,J 120 60 Gasoline 610-0388 3.0KVC-83A,B,C 120 60 Gasoline 610-0395 3.0KVC-84A,B,C 100 60 Gasoline 610-0396 2.5KVD-2089A,B 120 60 LP 625-4345 2.0KVD-3730B 230 50 LP 625-4562 2.8KVD-2090A 120 60 Gasoline 625-4345 2.3KVD-3729A 230 50 Gasoline 625-4562 Note - The diagonal line (/) or dash (-) in the model and specification number separates generator set characteristics from the specification number and letter. The specification number denotes customer requested options or deviations from a standard model. The specification letter advances (A to B, B to C, etc.) with major manufacturing changes.

Index 2 Arm, Governor Adjust, 11 Arm, Rocker, 8 Armature, Starter, 47, 49 Baffle, Air, 26 Baffle, Inlet (KV, KVD, Gasoline), 23 Baffle, Inlet (KV, KVD, LP), 25 Baffle, Seal, 26 Base Mounting KV, 38 Base Mounting KVD, 39 Base, Housing (KV), 34 Base, Housing (KVC), 36 Base, Housing (KVD), 35 Base, Mounting (KV), 34 Base, Mounting (KVC), 36 Base, Mounting (KVD), 35 Base, Oil, 10 Bearing, Ball, 7 Bearing, Choke Flange (KV Begin Spec C), 13 Bearing, Choke Flange (KVC, KVD, Gasoline), 14 Bearing, Crankshaft Ball, 7 Bearing, Generator Rotor Ball, 51 Block, Cylinder, 6 Block, Generator Brush, 45 Boot, Inlet Baffle Insulation (KV, KVD, Gasoline), 23 Boot, Inlet Baffle Insulation (KV, KVD, LP), 25 Boot, Spark Plug (KV), 34 Boot, Spark Plug (KVC), 54 Boot, Spark Plug (KVD), 35 Box, Control (KV Spec A-F), 52 Box, Control (KVD and KV Begin Spec G), 53 Brace, Generator, 43 Bracket, Choke Mounting (KV Spec A, B), 12 Bracket, Fuel Regulator (KV Begin Spec L and KVD Begin Spec B), 21 Bracket, Lifting, 6 Bracket, Muffler (KV Spec A-G), 29 Bracket, Muffler (KVD), 32 Bracket, Muffler Hanger (KVC), 31 Bracket, Regulator, 19 Bracket, Solenoid, 51 Bracket, Starter, 45 Bracket, Underfloor Mounting, 43 Breaker, Circuit (KV Spec A-F), 52 Breaker, Circuit (KVC), 54 Breaker, Circuit (KVD and KV Spec Begin Spec G), 53 Breather, Cylinder Head, 6 Brush, Generator Brush Block, 45 Bushing, Inlet Baffle Strain Relief (KV, KVD, Gasoline), 23 Bushing, Inlet Baffle Strain Relief (KV, KVD, LP), 25 Camshaft, 8 Cap, Choke Dome (KV Begin Spec C), 13 Cap, Choke Dome (KVC, KVD, Gasoline), 14 Cap, Starter Drive, 47, 49 Cap, Starter End, 47, 49 Capacitor (KV Spec A-F), 52 Carburetor (LP), 19 Carburetor, Gasoline, 16 Choke (KV Begin Spec C), 13 Choke (KV Spec A, B), 12 Clamp, Loop, 19 Clamp, Muffler (KVD), 32 Clip, ”J”, 9 Clip, Choke ”U” (KV Spec A, B), 12 Clip, Governor Retainer, 11 Clip, Rod End (KV Spec A, B), 12 Clutch, Starter, 47 Coil, Ignition (KV), 34 Coil, Ignition (KVC), 54 Coil, Ignition (KVD), 35 Collar, Governor Control Lever, 11 Components, Carburetor, 17 Components, Starter (Begin Spec K), 49 Components, Starter (Spec A-J), 47 Conduit (KVC), 54 Connector, Barbed Hose (KV, KVD, LP), 25 Connector, Conduit (KVC), 54 Connector, Plug (8 Pin) (KVC, KVD and KV begin Spec F), 67 Connector, Receptacle (8 Pin) (KVC, KVD and KV begin Spec F), 67 Connector, Receptacle (8 Pin) (KVC, KVD and KV begin Spec F), 67 Control (KVC), 54 Coupling, Anchor (KV, KVD, LP), 25 Cover, Air Filter Element, 46 Cover, Choke (KV Begin Spec C), 13 Cover, Choke (KV Spec A, B), 12 Cover, Choke (KVC, KVD, Gasoline), 14 Cover, Choke Thermostat Element (KV Begin Spec C), 13 Cover, Choke Thermostat Element (KVC, KVD, Gasoline), 14 Cover, Cylinder Head, 9 Cover, Housing (KV), 40 Cover, Housing (KVD), 41 Cover, Mounting Base (KVC), 36 Cover, Rocker Switch (KV Spec C-F), 52 Cover, Rocker Switch (KVC), 54 Cover, Rocker Switch (KVD and KV Spec Begin Spec G), 53 Cover, Starter Spring, 47 Cover, Switch (KVC), 54 Crankshaft, 7 Diaphragm, Pull Off (KV Spec A, B), 12 Diode, Remote Panel (KV Spec A-E), 55 Door, Generator Scroll Preheat, 46 Duct, Endbell Air, 45 Edging, Underfloor Mounting , 43 Elbow, Fuel Pump (KVC), 27 Elbow, Inlet Baffle (KV, KVD, Gasoline), 23 Elbow, Inlet Baffle (KV, KVD, LP), 25 Elbow, Intake (Gasoline), 16 Elbow, Male (KV, KVD, LP), 25

Index 3 Element, Air Filter, 46 Element, Thermostat (KV Begin Spec C), 13 Element, Thermostat (KV Spec A, B), 12 Element, Thermostat (KVC, KVD, Gasoline), 14 Endbell, 45 Engine, Replacement, 6 Ferrule, Muffler Hanger Wire Rope (KVC), 31 Filter, Fuel, 15 Flange, Air Cleaner, 21 Flange, Air Cleaner (Gasoline), 16 Flange, Air Cleaner (LP), 19 Flyweight, 8 Foam, Carburetor (KVC, KVD), 16 Foam, Fuel Filter, 15 Fuse (KV Spec A-F), 52 Fuse, Generator Harness (KV Spec C-E), 61 Fuse, Generator Harness (KVC), 63 Fuse, Generator Harness (KVD and KV Begin Spec F), 62 Fuse, Generator Harness (KVD and KV, Begin Spec F), 62 Gasket, Carburetor (Gasoline), 16 Gasket, Carburetor (LP), 19 Gasket, Cylinder Head, 9 Gasket, Drain Plug, 10 Gasket, Exhaust (KVD), 32 Gasket, Gearcase, 6 Gasket, Governor Retainer Clip, 11 Gasket, Head, 6 Gasket, Housing Base (KV), 34 Gasket, Housing Cover (KV), 40 Gasket, Housing Cover (KVD), 41 Gasket, Inlet Baffle Foam (KV, KVD, Gasoline), 23 Gasket, Inlet Baffle Foam (KV, KVD, LP), 25 Gasket, Intake Elbow (Gasoline), 16 Gasket, Muffler (KV Begin Spec H), 30 Gasket, Muffler (KV Spec A-G), 29 Gasket, Muffler (KVC), 31 Gasket, Muffler (KVD), 32 Gasket, Oil Base, 10 Gear, Camshaft, 8 Gear, Crankshaft, 7 Gear, Governor, 8 Gear, Starter, 47 Gearcase, 6 Generator, 51 Governor, 11 Grommet, Generator Harness (KVC), 63 Grommet, Housing Base (KVC), 36 Grommet, Inlet Baffle (KV, KVD, Gasoline), 23 Grommet, Inlet Baffle (KV, KVD, LP), 25 Grommet, Inlet Baffle (KVD, Gasoline), 23 Grommet, Inlet Baffle (KVD, LP), 25 Grommet, Muffler Bracket (KVC), 31 Guard, Housing Cover Air Inlet (KV), 40 Guide, Push Rod, 8 Hanger, Tailpipe (KV), 33 Harness, AC Output (KVC), 54 Harness, Adapter (KVC, KVD and KV Begin Spec F), 67 Harness, DC (Z1, Z2, Z3, Z4) (KV Spec A, B), 60 Harness, DC (Z1, Z4) (KV Spec C-E), 61 Harness, DC (Z1, Z4) (KVD and KV Begin Spec F), 62 Harness, Generator (J1, J2)(KVC), 63 Harness, Generator (KV Spec A, B), 60 Harness, Generator (KV Spec C-E), 61 Harness, Generator (KVD and KV Begin Spec F), 62 Harness, Generator (KVD), 64 Harness, PCB, 65 Harness, PCB (KV Spec C-F), 52 Harness, PCB (KVC, KVD and KV Spec 51844), 65 Harness, PCB (KVC), 54 Harness, PCB (KVD and KV Spec Begin Spec G), 53 Harness, Remote Panel (KVD and KV Begin Spec F), 57 Harness, Remote Panel (Switch Only), 58 Harness, Remote Switch Panel (KV Begin Spec F), 56 Harness, Remote Wiring (KV Spec A-E), 59 Harness, Remote Wiring (KVC, KVD and KV Begin Spec F), 67 Harness, Wiring (Z1)(KVC), 65 Head, Cylinder, 6 Holder Assy, Brush, 49 Holder, Fuse (KV Spec A-F), 52 Holder, Generator Harness Fuse (KVC), 63 Holder, Governor Spring, 11 Hose, Breather, 9, 21 Hose, Fuel (Gasoline), 15 Hose, Fuel (LP), 19 Hose, Vacuum (KV Spec A, B), 12 Hose, Vapor, LP, 21 Hose, Vent (LP), 19 Hourmeter (KVD and KV Begin Spec F), 57 Housing, Air Guide, 9 Housing, Choke (KV Begin Spec C), 13 Housing, Choke (KV Spec A, B), 12 Housing, Choke (KVC, KVD, Gasoline), 14 Housing, Scroll, 46 Housing, Stator, 51 Housing, Terminal (KVC, KVD and KV begin Spec F), 67 Hub, Fan, 51 Indicator, Oil Level, 10 Inlet Assy, 26 Insulation, Inlet Baffle (KV), 38 Insulation, Inlet Baffle (KVD), 39 Insulation, Lower Exhaust Baffle (KV), 34 Insulation, Upper Exhaust Baffle (KV), 38 Insulation, Upper Exhaust Baffle (KVD), 39 Insulator, Carburetor (Gasoline), 16 Insulator, Carburetor (LP), 19 Isolator, Vibration (KV Spec A), 51 Isolator, Vibration (KV), 38 Isolator, Vibration (KVC), 36 Isolator, Vibration (KVD), 39 Key, Camshaft, 8

CUMMINS ONAN KV KVC KVD Series RV Generator Workshop Manual

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