Onan KVC Series - User Manual

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Table of Contents

SAFETY PRECAUTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Codes and Standards for Safety 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical Genset 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION, MOUNTING AND ENCLOSURE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST SYSTEM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL CONNECTIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION REVIEW AND STARTUP 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Review 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OUTLINE DRAWING A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAMS—120V A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAMS—100V A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Summary

Safety Precautions

General Safety Precautions

General safety guidelines for operation and maintenance.

Generator Voltage Hazards

Warnings and precautions related to generator electrical hazards.

Engine Exhaust Hazards

Warnings and precautions regarding engine exhaust dangers.

Fuel Flammability and Explosiveness

Safety guidelines for handling flammable fuels.

Battery Gas Explosiveness

Safety warnings about explosive gases from batteries.

Moving Parts Hazards

Hazards associated with moving parts and safety measures.

Introduction to the Manual

About This Manual

Overview of the manual's purpose and scope.

Installation Safety Codes and Standards

Discusses relevant safety codes and standards for installation.

Typical Genset Installation Overview

Location, Mounting, and Enclosure Guidelines

Exhaust System Installation Procedures

Electrical Connections and Wiring

Generator Output Connections

Details on connecting the generator's AC output.

Wiring Methods and NEC Compliance

Guidelines for electrical wiring methods according to NEC.

Connecting to Utility Power

Procedures for connecting to external utility power safely.

Remote Control Connections Guide

Battery Connections and Requirements

Battery Compartment Requirements

Requirements for the battery compartment installation.

Battery Cable Sizing and Routing

Guidance on sizing and routing battery cables.

Installation Review and Startup

Installation Review Checklist

Checklist for reviewing installation steps before startup.

Genset Startup Procedure

Procedures for starting the genset after installation review.

This document describes the installation, operation, and maintenance of the KVC Series of engine generator sets (gensets). These gensets are designed for recreational vehicles (RVs) and work vehicles, providing electrical power from an internal combustion engine. Proper installation is crucial for safe, reliable, and quiet operation, and installers must be qualified to handle electrical and mechanical equipment.

Function Description:

The KVC Series genset is a self-excited, 1-phase, electronically regulated generator powered by a 1-cylinder, 4-stroke cycle, spark-ignited, OHV, air-cooled, mechanically governed engine. It converts fuel (gasoline) into electrical energy to power appliances and systems in an RV or work vehicle. The genset is designed for installation within a steel compartment that forms its cooling air plenum, with both cooling air inlet and hot air discharge openings located at the bottom. It features mounting flanges for secure attachment to the vehicle frame. The genset is equipped with an exhaust system that includes a muffler/tailpipe assembly with a U.S. Forest Service approved spark-arrestor to prevent fire and comply with regulations. Electrical connections include AC power output leads and provisions for remote control, allowing for convenient operation from within the vehicle. Battery connections are also detailed, emphasizing the need for proper sizing and ventilation to ensure safe starting and operation.

Important Technical Specifications:

Generator Type: 2-Pole Revolving Field, Self-Excited, 1-Phase, Electronically Regulated
Power Output: 2800 watts
Frequency: 60 Hertz
Voltage Options: 120 volts (23.3 amperes) or 100 volts (28 amperes)
Speed: 3600 rpm
Engine Type: 1-Cylinder, 4-Stroke Cycle, Spark-Ignited, OHV, Air Cooled, Mechanically Governed
Bore: 2.64 inches (67 mm)
Stroke: 2.2 inches (56 mm)
Displacement: 12 cubic inches (197 cc)
Compression Ratio: 8.5:1
Oil Capacity: 1 quart (0.95 L)
Valve Lash (Cold): Intake 0.002 inches (0.05 mm), Exhaust 0.002 inches (0.05 mm)
Spark Plug Gap: 0.025 inches (0.64 mm)
Spark Plug Tightening Torque: 13 lbs-ft (17 N-m)
Ignition Timing: 25° BTDC, non-adjustable (magneto type ignition)
DC System Nominal Battery Voltage: 12 volts
Minimum Battery Rating (CCA @ 0°F): 360/450
Control Fuse: 5 amperes
Weight of Genset (with engine oil): 100 lbs (45 kg)
Minimum Compartment Size (H x D x W): 15.5 inches x 17.5 inches x 20.2 inches (394 mm x 445 mm x 512 mm)
Minimum Free Air Inlet Area: 40 square inches (258 cm²)
Muffler Outlet Collar O.D.: 1.13 inches
Fuel Connection: 1/4 inch barb fitting for gasoline hose
Fuel Consumption (Gasoline):
- No load: 0.16 gph (0.6 l/h)
- Half load: 0.28 gph (1.1 l/h)
- Full load: 0.46 gph (1.7 l/h)

Usage Features:

The genset is designed for ease of use with various remote control options:

Remote Start/Stop Switch with Indicator Lamp: Basic control for starting and stopping the genset.
Remote Start/Stop Switch with Indicator Lamp and Hour Meter: Adds an hour meter to track operational time, useful for maintenance scheduling.
Remote Start/Stop Switch with Indicator Lamp and DC Voltmeter: Includes a DC voltmeter to monitor battery voltage. Remote control wiring harnesses are available in different lengths to suit various installation needs. The genset's AC power output leads are 28 inches (715 mm) long, housed in a 1/2 inch flexible steel conduit. It is crucial to ensure that the genset is not connected to the public utility or any other power source without an approved switching device to prevent dangerous interconnections. The fuel system requires a separate fuel pickup tube or tank, and the fuel line pressure must not exceed 1-1/2 psi to prevent flooding and fire.

Maintenance Features:

Regular maintenance is essential for the genset's longevity and safe operation. The manual emphasizes checking the engine oil level before starting and performing pre-start checks as instructed in the Operator's Manual. Key maintenance-related aspects include:

Accessibility: The control panel, engine oil check/add points, spark plug, and air filter should be easily accessible for routine maintenance.
Exhaust System Inspection: Inspect for exhaust leaks at every startup and after every eight hours of running. Ensure all tailpipe connections are tight and support straps are secure.
Cleanliness: Keep the genset and its compartment clean to prevent fire hazards from excess oil and oily rags, and to ensure proper cooling air circulation.
Battery Maintenance: Batteries must be mounted in a separate, ventilated compartment to prevent the accumulation of explosive hydrogen gas. Battery cables should be inspected and replaced as needed, protected from damage and secured to prevent chafing due to vibration.
Fuel System Inspection: Regularly inspect fuel lines for leaks and ensure they are secured and protected from damage, sharp edges, and vibration.
Airflow: Ensure the air inlet and outlet openings are free of obstructions to maintain proper cooling.
Seal Integrity: The genset compartment must form a good seal against foam seal strips to prevent warm air recirculation. All wiring openings into the vehicle interior must be sealed to keep out exhaust gas.

The manual strongly advises against unauthorized modifications to fuel, exhaust, air intake, or speed control system components, as these are prohibited by law in California and can compromise safety and emissions compliance.