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KVKVCKVDPrinted in U.S.A.Begin Spec C Model KV, Spec A, Models KVC & KVD11-04981-0518E

WARNING: The engine exhaust from this productcontains chemicals known to the Stateof California to cause cancer, birthdefects or other reproductive harm.AWARNING ADo not use this genset on a boatSuch use may violate U. S. Coast Guardregulations and can result Insevere personal Injury or death fromfire, electrocution, orcarbon monoxide poisoninggasoline warnings

Table of ContentsSECTIONPAGESAFETY PRECAUTIONS.1. INTRODUCTION2. SPECIFICATIONS.3. CLEARANCES4. TORQUEiii1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AND DIMENSIONS.SPECIFICATIONS.2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15. PREPARINGFORSERVICE5-1Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1Special Tools.5-1Safety Considerations5-2Removing the Genset5-3Reinstalling the Genset5-86. TROUBLESHOOTINGTroubleshooting6-1Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3Troubleshooting Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15Troubleshooting Engine Primary Systems7. CONTROLControl6-187-1Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ControlOperationControlComponentTests8. ENGINEPRIMARYSYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . ionSystemCrankcaseVentilation8-88-10Governor8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gasoline Fuel System8-13LPG Fuel System8-21Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

SECTIONPAGE9. GENERATOR9-1Generator Description9-1Generator Operation9-2VoltageRegulatorTests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3Field Voltage Tests9-4GeneratorTests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4GeneratorService9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brushes and Slip Rings9-12Rotor Bearing Replacement9-1310. ENGINE BLOCK ASSEMBLy10-1Introduction10-1Leak Down Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1Oil Pan and Oil Level Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2Head Cover10-3Cylinder Head10-3Valve System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4Crankcase Cover10-7Camshaft and Tappet Removal10-7Governor10-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Assembly Removal and Service10-8Crankshaft10-13Cylinder Block10-14Timing Gears10-16Bearings10-16Oil Seal10-16Compression Release System10-1711. SERVICE CHECK LIST11-112. WIRING DIAGRAMS12-1ii

SAFETY PRECAUTIONSThoroughly read the OPERATOR'S MANUALmoving or electrically live parts can cause severe personal injury or death.before operating the genset. Safe operation andtop performance can be obtained only whenequipment is operated and maintained properly.· Used engine oil has been identified by somestate and federal agencies as causing canceror reproductive toxicity. Do not ingest, inhale, orcontact used oil or its vapors.The following symbols in this manual alert you to potential hazards to the operator, service person andequipment.r!"'., mC:1:t:.· Benzene and lead in some gasolines havebeen identified by some state and federalagencies as causing cancer or reproductivetoxicity. Do not to ingest, inhaleor contactgasoline or its vapors.alerts you to an immediate hazardwhich will result in severe personal injury ordeath.IAWARNINGI alerts you to a hazard or unsafepractice which can result in severe personal injury or death.· Keep multi-class ABC fire extinguishers handy.Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires,combustible and flammable liquid fuels andgaseous fuels; Class C fires, live electricalequipment. (ref. NFPA No.1 0)IA CAUTIONI alerts you to a hazard or unsafepractice which can result in personal injury orequipment damage.· Genset installation and operation must complywith all applicable local, state and federal codesand regulations.Electricity, fuel, exhaust, moving parts and batteriespresent hazards which can result in severe personalinjury or death.GENERATOR VOLTAGE IS DEADLYIGENERAL PRECAUTIONS· Disable the automatic genset starting feature ofan inverter-charger or other automatic startingdevice before servicing the genset.· Keep children away from the genset.· Do not use evaporative starting fluids. They arehighly explosive.· Generator electrical output connections must· To prevent accidental or remote starting whileworking on the genset, disconnect the negative (-) battery cable at the battery.be made by a trained and experienced electrician in accordance with applicable codes.· The genset must not be connected to shorepower or to any other source of electrical power. Back-feedto shore power can cause electricshock resulting in severe personal injury ordeath and damage to equipment. An approvedswitching device must be used to prevent interconnections.· Keep the genset and its compartment clean.Excess oil and oily rags can catch fire. Dirt andgear stowed in the compartment can restrictcooling air.· Make sure all fasteners are secure and torquedproperly.· Do not work on the genset when mentally orphysically fatigued or after consuming alcoholor drugs.· Use caution when working on live electricalequipment. Remove jewelry, make sure clothing and shoes are dry, stand on a dry woodenplatform or rubber insulating mat and use toolswith insulated handles.· You must be trained and experienced to makeadjustments while the genset is running-hot,iii

ENGINE EXHAUST IS DEADLYI·· Inspect for exhaust leaks at every startup andafter every eight hours of running.· Learn the symptoms of carbon monoxide poisoning in this manual.· Never sleep in the vehicle while the genset isrunning unless the vehicle is equipped with aworking carbon monoxide detector.BATTERY GAS IS EXPLOSIVE· Make sure there is ample fresh air when operating the genset in a confined area.· Wear safety glasses.· Do not smoke.· Disable the automatic genset starting feature ofan inverter-charger or other automatic startingdevice before storing the vehicle or parking it ina garage or other confined space.· To reduce arcing when disconnecting or reconnecting battery cables, always disconnect thenegative (-) battery cable first and reconnect itlast.· The exhaust system must be installed in accordance with the genset Installation Manual.MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH· Engine cooling air must not be used for heatingthe working or living space or compartment.· Disable the automatic genset starting feature ofan inverter-charger or other automatic startingdevice before servicing the genset.FUEL IS FLAMMABLE AND EXPLOSIVE· Do not smoke or tum electrical switches ON orOFF where fuel fumes are present or in areassharing ventilation with fuel tanks or equipment. Keep flame, sparks, pilot lights, arc-producing equipment and switches and all othersources of ignition well away.· Fuel lines must be secured, free of leaks andseparated or shielded from electrical wiring.MOBILELeakscan lead to explosiveaccumulationsofgas. Natural gas rises when released and canaccumulate under hoods and inside housingsand buildings. LPG sinks when released andcan accumulate inside housings and basements and other below-grade spaces. Preventleaks and the accumulation of gas.· Do not wear loose clothing or jewelry near moving parts such as PTO shafts, fans, belts andpulleys.· Keep hands away from moving parts.· Keep guards in place over fans, belts, pulleys,and other moving parts.7iv

1. IntroductionThis is the service manual for the KV, KVC, KVD series of generator sets (gensets). Read and carefullyobserve all of the instructions and safety precautions in this manual.IAWARNINGIMODEL KV I KVDImproper service or parts replace-ment can lead to severe personal injury or deathand to damage to equipment and property. Service personnel must be qualified to performelectrical and mechanical service.IAWARNINGI Unauthorized modifications or replacement of fuel, exhaust, air intake or speedcontrol system components that affect engineemissions are prohibited by law in the State ofCalifornia.IAWARNINGIIMPORTANT ENGINE ItFORMATION POWER GENERATION oLPG (liquified petroleum gas) is0Model No:flammable and explosive and can cause asphyxiation. NFPA 58, Section 1.6 requires allpersons handling LPG to be trained in properhandling and operating procedures.MOO 73rd Ave. NE.MiMeIlpOis,MN 66432MIIde n u.s.A.PH: IN:AC Va1t8:kVA:kW:AqI8:RPM:Fuel:II8t:OptIons:See the Operator's Manual for instructions conceming operation, maintenance and storage and for recommendations concerning engine lubricating oiland fuel.nsuI8tIan lEMA CIaa FAnIbIent40' C[The engine family designation, engine displacement, statement of compliance with the applicable EPA and / or Califomiaemissions regulations, including the compliance period orcategory, appear in this block on the actual nameplate on thegenset.}See the Installation Manual for important recommendations concerning the installation and for a listof the installation codes and standards for safetywhich may be applicable.See the Parts Manual for parts identification numbers and required quantities and for exploded viewsof the genset subassemblies. Genuine Onan@ replacement parts are recommended for best results.When contacting Onan for parts or product information, be ready to provide the model and serial numbers on the genset nameplate. Figure 1-1 illustratesthe nameplate and its location. Every character inthese numbers is significant. (The last character ofthe model number is the specification letter, which isimportant for obtaining the right parts.)MODEL KVCFIGURE 1-1. TYPICAL NAMEPLATE1-1

2.SpecificationsKV MODELSLPGGASOLINE2.8KVGENERATOR:2.3KV2.0KV2-Pole Revolving Field, Self-Excited,Electronically2.5KV2.0KVRegulated, 1-Phase2800 watts2000 watts2300 watts2500 watts2000 wattsFrequency60 Hertz*50 Hertz50 Hertz60 Hertz*50 HertzVoltage120 volts220 volts230 volts120 volts220/230 voltsCurrent23.3 amperes9.1 amperes10 amperes20.8 amperes9.1/8.7 amperesSpeed3600 rpm3000 rpm3000 rpm3600 rpm3000 rpm0.16 gph (0.61/h)0.28 gph (1.1 Vh)0.46 gph (1.7 I/h)0.16 gph (0.6 I/h)0.23 gph (0.9 Vh)0.32 gph (1.2 I/h)0.16 gph (0.6 Vh)0.23 gph (0.9 l/h)0.32 gph (1.2 I/h)1.0 Ibs/h (0.44 kg/h)1.5 Ibs/h (0.68 kg/h)2.5 Ibs/h (1.1 kg/h)0.9 Ibs/h (0.40 kg/h)1.3 Ibs/h (0.59 kg/h)2.1 Ibs/h (0.92 kg/h)PowerFUEL CONSUMPTION:No loadHalf loadFull loadENGINE: 1-Cylinder, 4-Cycle, Spark-Ignited,BoreOHV, Air Cooled2.64 inch (67 mm)2.64 inch (67 mm)Stroke2.2 inch (56 mm)2.2 inch (56 mm)Displacement12 inch3 (197 cc)12 inch3 (197 cc)CompressionRatio8.5: 18.5: 1Oil Capacity**1 quart (0.95 I)1 quart (0.95 I)Intake ValveClearance (Cold)0.002 inch (0.05 mm)0.002 inch (0.05 mm)Exhaust ValveClearance (Cold)0.002 inch (0.05 mm)0.002 inch (0.05 mm)Spark Plug Gap0.025 inch (0.64 mm)0.020 inch (0.51 mm)Spark PlugTorque13lbs-ft13lbs-ft (17 N-m)Ignition Timing(magneto typeignition)250 BTDC, non-adjustable(17 N-m)250 BTDC, non-adjustable-9 to 13 inch (229 to 330 mm)W.C. (water column)12 volts12 volts360 amperes360 amperes5 amperes5 amperesLPG Vapor Supply PressureDC SYSTEM:Nominal BatteryVoltageMin. Battery ColdCranking CapacityControl Fuse*-60 Hertzmodelsare Listed** -See Periodic Maintenanceby CSA and the U.S. Testingin the Operator'sCompany.Manual for oil filling instructions.2-1

KVC MODELSGENERATOR:2-Pole Revolving Field, Self-Excited,1-Phase, ElectronicallyPowerRegulated2800 watts2800 wattsFrequency60 Hertz*60 HertzVoltage120 volts100 voltsCurrent23.3 amperes28 amperesSpeed3600 rpm3600 rpmGasolineGasoline0.16 gph (0.61/h)0.28 gph (1.1 I/h)0.46 gph (1.71/h)0.16 gph (0.6 I/h)0.28 gph (1.1 I/h)0.46 gph (1.71/h)FUEL CONSUMPTION(GASOLINE):No loadHalf loadFull loadENGINE: 1-Cylinder, 4-Stroke Cycle, Spark-Ignited,OHV, Air Cooled, MechanicallyGovernedBore2.64 inch (67 mm)2.64 inch (67 mm)Stroke2.2 inch (56 mm)2.2 inch (56 mm)Displacement12 inch3 (197 cc)12 inch3 (197 cc)8.5: 18.5: 11 quart (0.95 I)1 quart (0.95 I)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 Gap0.025 inch (0.64 mm)0.025 inch (0.64 mm)CompressionRatioOil CapacitySpark Plug Tightening TorqueIgnition Timing (magneto type ignition)13lbs-ft(17 N-m)13lbs-ft25 BTDC, non-adjustable(17 N-m)25 BTDC, non-adjustableDC SYSTEM:12 volts12 volts360/450above/below 32 F (0 C)360/450above/below 32 F (0 C)5 amperes5 amperesNominal Battery VoltageMin. Battery Rating: Cold Cranking Amps (CCA)@ 0 F (-18 C)Control FuseINSTAllATION:Weight of Genset (with engine oil)Minimum Compartment(H x D x W)**100 Ibs (45 kg)15.5 inch x 17.5 inch x 20.2 inch(394 mm x 445 mm x 512 mm)SizeMinimum Free Air Inlet Area40 inch2 (258 cm2)Muffler Outlet Collar O. D.1.13 inchFuel Connection1/4 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.2-2

KVD MODELSGASOLINEGENERATOR:Power2-Pole Revolving Field, Self-Excited,LPG1-Phase, Electronically Regulated2800 wattsFrequency2500 watts60 Hertz60 HertzVoltageCurrent120 volts120 volts23.3 amps20.8 ampsSpeed3600 rpm3600 rpmFUEL CONSUMPTION:GasolineLPGNo loadHalf loadFull load0.20 gph (0.76 Vh)0.30 gph (1.14 Vh)0.43 gph (1.63 Vh)ENGINE: 1-Cylinder, 4-Stroke Cycle, Spark-Ignited,BoreOHV, Air Cooled, Mechanically0.85 Ibs/h (0.39 kg/h)1.45 Ibs/h (0.66 kg/h)2.35 Ibs/h (1.07 kglh)Governed2.64 in (67 mm)2.64 in (67 mm)Stroke2.2 in (56 mm)2.2 in (56 mm)Displacement12 in3 (197 cc)8.5: 112 in3 (197 cc)8.5: 1CompressionRatioOil Capacity1 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 Gap0.025 in (0.64 mm)0.020 inch (0.51 mm)13lbs-ftSpark Plug Tightening TorqueIgnition Timing (magneto type ignition)(17 N-m)13lbs-ft25 BTDC, non-adjustable(17 N-m)25 BTDC, non-adjustableDC SYSTEM:12 voltsNominal Battery VoltageMin CCA RatingControl Fuse-360/450 above/below 32 F (0 C)SAE @ 32 F (0 C)5 ampINSTAllATION:Noise71 dB(A)*Weight of Genset (with muffler)111.6 Ibs (50.6 kg)Weight of Genset (without muffler)107.21bs (48.6 kg)Minimum Compartment Size (H x D x W)**Minimum Free Air Inlet Area12.52 in x 18.20 in x 20.46 in (317.9 mm x 462.2 mm x 519.8 mm)24 in2 (155 cm2)Muffler Outlet Collar O. D.Maximum Exhaust Back Pressure1.13 in (28.3 mm)20 in WCGasoline Fuel Connection1/4 in Hose Barb3 ft (1 m)Maximum Gasoline Fuel Pump Lift1/4 in NPTFLPG Vapor Fuel ConnectionLPG Vapor Connection9-13 in (228-330 mm) WCPressure* 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.2-3

3. Clearances and 0/100.0(18-24 ftelb)(25-33 Nem)CYLINDER HEADCylinder Head Deformation LimitTorqueVALVEValve Face AngleIntake44.5 -45 Exhaust44.5 -45 IntakeValve Stem ustValve Guide Inside DiameterClearance BetweenValve and Guide StemReference ValveAllowable LimitValve Clearance (Lash)0.02-0.0800.02-0.080IntakeOpeningValve OpeningClosing Timing(when cool)78 (58 -70 before top dead center)Closing118 (98 -110 after bottom dead center)Opening118 (98 -110 after bottom dead center)78 (58 -70 before top dead center)ExhaustClosingValve SpringReference ValueFree HeightLoad and HeightAllowable LimitReference ValueAllowable Limit33.0-33.51.28732.712.94 Ib/0.8858 in11.64 Ib/0.8858 in5.87 kgf/22.5 m5.28 kgf/22.5 m1.50.0591Allowable Squareness LimitValve SeatValve Seat Angle1.299-1.319Intake45 Exhaust45 Reference Valve0.0394-0.05121.0-1.30.05911.5Valve Seat WidthAllowable Limit3-1

016-0.05224.65Valve lifterOuter DiameterReference ValueClearance BetweenValve Lifterand GuideCamshaftAllowable LimitStandard Journal DiameterClearance Between CamshaftJournal Bearing (Flywheel Side)IntakeReference ValueCam HeightAllowable llowable Side Clearance Limit24.5524.550.20Allowable Limit0.00790.050.092-0.1410.20Reference Value2.6378-2.638667.00-67.02Allowable .10Bending LimitTiming GearBacklash0.00790.002024.65Reference Value0.0036-0.0056CylinderInner DiameterMinimum ClearanceBetween Cvlinder and PistonPiston.Outer Diameter (Skirt Diameter)Piston RingGapReference ValueAllowable LimitClearance Between RingReference Limitand Ring GrooveAllowable Limit0.00393-20.90

ITEMPiston 90.100.00160.00160.040.0410.1-14.5 ttelb(13.7-19.6 Nem)Reference Value1.1798-1.1804Wear LimitReference 054Allowable Limit0.0039Reference Value0.9835-0.98400.9803Outer DiameterConnecting Rod (Small End)Inner Diameter Reference ValueClearance BetweenSmall end & PistonPinReference ValueAllowable LimitConnecting RodBending LimitTorsion LimitBolt Tightening Torque (10.1-14.5 ttelb)CrankshaftPin DiameterCrank Pin OilClearanceJournal DiaSide ClearanceWear LimitReference ValueAllowable limit0.00790.00080.02-0.100.200.02Reference Value0-0.00390-0.10Allowable Limit0.0079Standard Gap0.0236-0.02760.200.6-0.7Bending LimitAxial PlayIgnition Plug0.0008-0.00390.1024.980-24.99324.93-3

4. Torque SpecificationsMounting screws and nuts must be tightened to the specified torque settings. All threads must be clean andlubricated with new engine oil. The cylinder head mounting bolts must be tightened in the proper sequence,refer to Section 10. Engine Block Assembly.TABLE 4-1. TORQUE N-METERS- 20Connecting Rod10 - 1414Head Cover3.3 - 64.4 - 8Cylinder Head (Cold)18 - 2425 - 33Endbell to StatorHousing Mounting Screws6-98 - 12Engine Cooling Shrouds6-98 -12Fan Mounting Screws6-98 - 12Gearcase Cover11 - 1414 - 19Generator Housing toEngine Mounting Nuts6-78-9Intake Manifold6-87 - 11Carburetor Mounting Nut8 - 1511 - 20Muffler Bkt to Engine10 - 1414 - 20Muffler Flange to Engine5-9Oil Base and GeneratorHousing to Mounting Stud22 - 277 - 1230- 376-98 - 12Oil Drain Plug18 - 2425 - 33Oil Watch Bolt6-98 - 1240-5054 - 68SparkPlug8 - 1810 - 24StarterBkt.to Engine6-98 - 13StarterBktto Starter2.5 - 3.33.4 - erNut16 - 2422 336-87 - 11SpeedAdjustLeverNut8 - 1511 20VibrationIsolators4-6Oil Base to EngineRotorThrough-bolt4-1-5.5 - 8.0

When engine torques are not specified in Table 4-1, tighten the screws and nuts according to Tables 4-2 and4-3. The grade numbers are indicated o

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 .

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(ANSI) A300 standards of limitation on the amount of meristematic tissue (number of buds) removed during any one annual cycle (in general, removing no more than 25% on a young tree). The third circle is the top circle – the reason the other circles exist. We grow and maintain trees for aesthetic and functional values, and pruning properly for structure and biological health helps us achieve .

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2 BETH REVIS helped her lie down in the clear cryo box. It would have looked like a cof-fin, but coffins have pillows and look a lot more comfortable. This looked more like a shoebox. “It’s cold,” Mom said. Her pale white skin pressed flat against the bot-tom of the box. “You won’t feel it,” the first worker grunted. His nametag said dE. I looked away as the other worker, Hassan .