iii SAFETY PRECAUTIONS Thoroughly read the OPERATOR’S MANUAL before operating the genset. Safe operation and top performance can be obtained only when equipment is operated and maintained properly. The following symbols in this manual alert you to po- tential hazards to the operator, service person and equipment. DANGER alerts you to an immediate hazard which will result in severe personal injury or death. WARNING alerts you to a hazard or unsafe practice which can result in severe personal in- jury or death. CAUTION alerts you to a hazard or unsafe practice which can result in personal injury or equipment damage. Electricity, fuel, exhaust, moving parts and batteries present hazards which can result in severe personal injury or death. GENERAL PRECAUTIONS S Keep children away from the genset. S Do not use evaporative starting fluids. They are highly explosive. S To prevent accidental or remote starting while working on the genset, disconnect the nega- tive (−) battery cable at the battery. S Keep the genset and its compartment clean. Excess oil and oily rags can catch fire. Dirt and gear stowed in the compartment can restrict cooling air. S Make sure all fasteners are secure and torqued properly. S Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs. S You must be trained and experienced to make adjustments while the genset is running—hot, moving or electrically live parts can cause se- vere personal injury or death. S Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale, or contact used oil or its vapors. S Benzene and lead in some gasolines have been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not to ingest, inhale or contact gaso- line or its vapors. S Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible ma- terials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 10) S Genset installation and operation must comply with all applicable local, state and federal codes and regulations. GENERATOR VOLTAGE IS DEADLY! S Disable the automatic genset starting feature of an inverter-charger or other automatic starting device before servicing the genset. S Generator electrical output connections must be made by a trained and experienced electri- cian in accordance with applicable codes. S The genset must not be connected to shore power or to any other source of electrical pow- er. Back-feed to shore power can cause electric shock resulting in severe personal injury or death and damage to equipment. An approved switching device must be used to prevent inter- connections. S Use caution when working on live electrical equipment. Remove jewelry, make sure cloth- ing and shoes are dry, stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles.
iv ENGINE EXHAUST IS DEADLY! S Inspect for exhaust leaks at every startup and after every eight hours of running. S Learn the symptoms of carbon monoxide poi- soning in this manual. S Never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon monoxide detector. S Make sure there is ample fresh air when operat- ing the genset in a confined area. S Disable the automatic genset starting feature of an inverter-charger or other automatic starting device before storing the vehicle or parking it in a garage or other confined space. S The exhaust system must be installed in accor- dance with the genset Installation Manual. S Engine cooling air must not be used for heating the working or living space or compartment. FUEL IS FLAMMABLE AND EXPLOSIVE S Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip- ment. Keep flame, sparks, pilot lights, arc-pro- ducing equipment and switches and all other sources of ignition well away. S Fuel lines must be secured, free of leaks and separated or shielded from electrical wiring. S Leaks can lead to explosive accumulations of gas. Natural gas rises when released and can accumulate under hoods and inside housings and buildings. LPG sinks when released and can accumulate inside housings and base- ments and other below-grade spaces. Prevent leaks and the accumulation of gas. BATTERY GAS IS EXPLOSIVE S Wear safety glasses. S Do not smoke. S To reduce arcing when disconnecting or recon- necting battery cables, always disconnect the negative (−) battery cable first and reconnect it last. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH S Disable the automatic genset starting feature of an inverter-charger or other automatic starting device before servicing the genset. S Do not wear loose clothing or jewelry near mov- ing parts such as PTO shafts, fans, belts and pulleys. S Keep hands away from moving parts. S Keep guards in place over fans, belts, pulleys, and other moving parts. MOBILE 7
1-1 1. Introduction This is the service manual for the KV, KVC, KVD se- ries of generator sets (gensets). Read and carefully observe all of the instructions and safety precau- tions in this manual. WARNING Improper service or parts replace- ment can lead to severe personal injury or death and to damage to equipment and property. Ser- vice personnel must be qualified to perform electrical and mechanical service. WARNING Unauthorized modifications or re- placement of fuel, exhaust, air intake or speed control system components that affect engine emissions are prohibited by law in the State of California. WARNING LPG (liquified petroleum gas) is flammable and explosive and can cause as- phyxiation. NFPA 58, Section 1.6 requires all persons handling LPG to be trained in proper handling and operating procedures. See the Operator’s Manual for instructions concern- ing operation, maintenance and storage and for rec- ommendations concerning engine lubricating oil and fuel. See the Installation Manual for important recom- mendations concerning the installation and for a list of the installation codes and standards for safety which may be applicable. See the Parts Manual for parts identification num- bers and required quantities and for exploded views of the genset subassemblies. Genuine Onan® re- placement parts are recommended for best results. When contacting Onan for parts or product informa- tion, be ready to provide the model and serial num- bers on the genset nameplate. Figure 1-1 illustrates the nameplate and its location. Every character in these numbers is significant. (The last character of the model number is the specification letter, which is important for obtaining the right parts.) MODEL KVC MODEL KV / KVD [THE ENGINE FAMILY DESIGNATION, EN- GINE DISPLACEMENT, STATEMENT OF COM- PLIANCE WITH THE APPLICABLE EPA AND / OR CALIFORNIA EMISSIONS REGULATIONS, INCLUDING THE COMPLIANCE PERIOD OR CATEGORY, APPEAR IN THIS BLOCK ON THE ACTUAL NAMEPLATE ON THE GENSET.] FIGURE 1-1. TYPICAL NAMEPLATE
2-2 Min. Battery Cold Cranking Capacity 360 amperes 360 amperes Control Fuse 5 amperes 5 amperes * − 60 Hertz models are Listed by CSA and the U.S. Testing Company. ** −See Periodic Maintenance in the Operator’s Manual for oil filling instructions.
2-3 KVC MODELS GENERATOR: 2-Pole Revolving Field, Self-Excited, 1-Phase, Electronically Regulated Power 2800 watts 2500 watts Frequency 60 Hertz* 60 Hertz Voltage 120 volts 120 volts Current 23.3 amperes 20.8 amperes Speed 3600 rpm 3600 rpm FUEL CONSUMPTION (GASOLINE): Gasoline LPG No load Half load Full load 0.16 gph (0.6 l/h) 0.28 gph (1.1 l/h) 0.46 gph (1.7 l/h) 1.0 lbs/h (0.44 kg/h) 1.5 lbs/h (0.68 kg/h) 2.5 lbs/h (1.1 kg/h) ENGINE: 1-Cylinder, 4-Stroke Cycle, Spark-Ignited, OHV, Air Cooled, Mechanically Governed Bore 2.64 inch (67 mm) 2.64 inch (67 mm) Stroke 2.2 inch (56 mm) 2.2 inch (56 mm) Displacement 12 inch 3 (197 cc) 12 inch 3 (197 cc) Compression Ratio 8.5 : 1 8.5 : 1 Oil Capacity 1 quart (0.95 l) 1 quart (0.95 l) Intake Valve Lash (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm) Exhaust Valve Lash (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm) Spark Plug Gap 0.025 inch (0.64 mm) 0.020 inch (0.51 mm) Spark Plug Tightening Torque 13 lbs-ft (17 N-m) 13 lbs-ft (17 N-m) Ignition Timing (magneto type ignition) 25° BTDC, non-adjustable 25° BTDC, non-adjustable DC SYSTEM: Nominal Battery Voltage 12 volts 12 volts Min. Battery Rating: Cold Cranking Amps (CCA) @ 0° F (−18° C) 360/450 above/below 32° F (0° C) 360/450 above/below 32° F (0° C) Control Fuse 5 amperes 5 amperes INSTALLATION: Weight of Genset (with engine oil) 100 lbs (45 kg) Minimum Compartment Size (H x D x W)** 15.5 inch x 17.5 inch x 20.2 inch (394 mm x 445 mm x 512 mm) Minimum Free Air Inlet Area 40 inch 2 (258 cm 2 ) Muffler Outlet Collar O. D. 1.13 inch Fuel Connection 1/4 inch barb fitting for gasoline hose * Listed by CSA and the U. S. Testing Company. ** See the Installation Manual for additional considerations when sizing the genset compartment.
2-4 KVD MODELS GASOLINE LPG GENERATOR: 2-Pole Revolving Field, Self-Excited, 1-Phase, Electronically Regulated Power 2800 watts 2500 watts Frequency 60 Hertz 60 Hertz Voltage 120 volts 120 volts Current 23.3 amps 20.8 amps Speed 3600 rpm 3600 rpm FUEL CONSUMPTION: Gasoline LPG No load Half load Full load 0.20 gph (0.76 l/h) 0.30 gph (1.14 l/h) 0.43 gph (1.63 l/h) 0.85 lbs/h (0.39 kg/h) 1.45 lbs/h (0.66 kg/h) 2.35 lbs/h (1.07 kg/h) ENGINE: 1-Cylinder, 4-Stroke Cycle, Spark-Ignited, OHV, Air Cooled, Mechanically Governed Bore 2.64 in (67 mm) 2.64 in (67 mm) Stroke 2.2 in (56 mm) 2.2 in (56 mm) Displacement 12 in 3 (197 cc) 12 in 3 (197 cc) Compression Ratio 8.5 : 1 8.5 : 1 Oil Capacity 1 quart (0.95 liter) 1 quart (0.95 liter) Intake Valve Lash (Cold) 0.002 in (0.05 mm) 0.002 in (0.05 mm) Exhaust Valve Lash (Cold) 0.002 in (0.05 mm) 0.002 in (0.05 mm) Spark Plug Gap 0.025 in (0.64 mm) 0.020 inch (0.51 mm) Spark Plug Tightening Torque 13 lbs-ft (17 N-m) 13 lbs-ft (17 N-m) Ignition Timing (magneto type ignition) 25° BTDC, non-adjustable 25° BTDC, non-adjustable DC SYSTEM: Nominal Battery Voltage 12 volts Min CCA Rating − SAE @ 32° F (0° C) 360/450 above/below 32° F (0° C) Control Fuse 5 amp INSTALLATION: Noise 71 dB(A)* Weight of Genset (with muffler) 111.6 lbs (50.6 kg) Weight of Genset (without muffler) 107.2 lbs (48.6 kg) Minimum Compartment Size (H x D x W)** 12.52 in x 18.20 in x 20.46 in (317.9 mm x 462.2 mm x 519.8 mm) Minimum Free Air Inlet Area 24 in 2 (155 cm 2 ) Muffler Outlet Collar O. D. 1.13 in (28.3 mm) Maximum Exhaust Back Pressure 20 in WC Gasoline Fuel Connection 1/4 in Hose Barb Maximum Gasoline Fuel Pump Lift 3 ft (1 m) LPG Vapor Fuel Connection 1/4 in NPTF LPG Vapor Connection Pressure 9-13 in (228-330 mm) WC * In a typical RV installation at half load and distance of 10 ft (3 m). ** See the Installation Manual for additional considerations when sizing the genset compartment.
Cummins Onan KV/KVC/KVD RV Mobile Generator Sets OEM Service & Repair Manual
Models covered:
Cummins Onan KV
Cummins Onan KVC
Cummins Onan KVD
The Cummins Onan KV/KVC/KVD RV Mobile Generator Sets Service & Repair Manual is a comprehensive technical guide designed for maintaining and repairing these specific generator models. It covers all critical systems, including engine, fuel, electrical, and control components, providing detailed, step-by-step procedures to ensure repairs meet factory standards.
The manual includes precise technical diagrams, troubleshooting instructions, and comprehensive repair guidelines, making it suitable for addressing routine maintenance tasks as well as complex diagnostic issues. Whether you're dealing with engine tune-ups, electrical repairs, or fuel system servicing, this guide ensures accuracy and reliability throughout the repair process.
Available in digital format for convenient access, this manual serves as an essential resource for technicians and RV owners alike, ensuring that your Cummins Onan KV, KVC, or KVD generator set operates efficiently and reliably in mobile applications. Whether in the shop or on the road, this manual helps ensure optimal performance and longevity.
Printable: Yes Language: English Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc. Requirements: Adobe Reader (free)
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Cummins Onan KV/KVC/KVD RV Mobile Generator Sets OEM Service & Repair Manual