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Cummins/Onan — How To Use This Manual

For these Cummins/Onan models: KVC Spec A, N/A.

Applies to: Cummins/Onan KVC Spec A, Cummins/Onan N/A Engine

Procedure

  1. Determine the actual work performed: −Obtain this information from the work description on the repair order.
  2. Determine the Accessibility Code: −Determine the application from the repair order. −Look in the “Accessibility Code Listing” on page to determine the accessibility code for the application involved in the repair. If the application is not shown, assume the accessibility code is “B”. −Write down the code.
  3. Determine applicable SRCT: −Find the Contents Page for Group 99 − Standard Repair Combined Times. −Compare the titles to the work performed to determine if a SRCT will apply. −If there is a SRCT that seems to apply, find that SRCT and compare the SRT within the SRCT to the work performed. If you are not sure of the work included in the SRT, read that SRT and compare the procedure listin ---CHUNK BREAK--- g with the work performed. −If a SRCT applies to all or part of the work performed, find the column that contains the same accessibility code determined in Step 2 above. −Move down the column to the line containing the SRCT code and title and pick out the ap- propriate time. −If all the work in the SRCT is performed and additional steps were taken, use the SRCT and continue to Step 4 to cover the additional work. − If there is NOT an appropriate SRCT, move to Step 4.
  4. Determine the appropriate repair SRT: −Use the information from the repair order to identify the parts involved. −Use the contents page at the front of the manual or the alphabetical index in the back of the manual to determine the appropriate SRT group for the parts and/or work involved. −Find the contents page for that group. −Read the contents page for procedure titles that seem to correspond to the work performed. −Find the SRT within the group. −Read the SRT procedure listing to determine the work included. Redistribution or publication of this document by any means, is strictly prohibited. − xi − −If the work performed and the work included in the SRT are the same, all or in part, determine and record the time. −Repeat the steps in this paragraph until you have determined a SRT for all the work per- formed.
  5. Determine the appropriate troubleshooting SRT: −Read the repair order to determine what troubleshooting work was performed. −Find the contents page for Group 00. −Read the contents page for procedure to determine the work included in each step. −If the work performed and the work included in the troubleshooting SRT are the same, all or in part, determine and record the time of the SRT step. Remember that troubleshooting SRT are cumulative.
  6. Determine the appropriate miscellaneous SRT: −Read the repair order to determine if any application hardware was removed and installed in order to access the engine or generator set. −Find the contents page for Group 17. −Read the contents page for procedure titles that seem to correspond to the work performed. −Find the SRT within the group. −Read the SRT procedure to determine the work included in the SRT. −If the work performed and the work included in the SRT are the same, all or in part, determine and record the time. −If the work required to application hardware is not given in the SRT manual, determine the time for ONLY this work from the repair order. Record the time for possible use as “99−999” or “Non−SRT Time”.
  7. Determine the appropriate administrative SRT: −Both of the administrative SRT are shown at the beginning of Group 00. −Determine the appropriate SRT. −Record the time.
  8. Determine the total appropriate SRT time: −Check to be sure that there is no duplication of tasks within the SRT procedures selected. If there is work duplicated by some of those selected, use other information contained in the manual to reduce the time of one of the SRT accordingly. If the information is not available, make an estimate. −Total all the times obtained during performance of Steps 2 through 7. Redistribution or publication of this document by any means, is strictly prohibited. − xii − Standard Repair Times Review Procedure Onan Corporation makes every effort to be sure the SRT published in this manual are credible and equitable. It will be necessary to review the published times when one or more of the following changes occur: −Design changes to special service tools or equipment required to perform the repair −Changes to the repair procedure A formal SRT review procedure is available for any Cummins/Onan Authorized Repair Location that believes the SRT shown in this manual are incorrect. To be sure prompt attention and an accurate appraisal is given to your request, the following guide- lines must be met: 1. Be sure the technician has followed all the procedures and used all the service tools re- ferred to in the appropriate service manuals. 2. Be sure a journeyman technician performed the repair, one who has completed the repair a sufficient number of times to become familiar with the procedure. 3. Be sure all the SRT, including supplemental SRT, appropriate for the repair are being used. 4. Include as much detail as possible about the specific repair. NOTE: It is NOT the intent of this procedure to provide a forum for appealing or disputing the amount of time or the SRT judged appropriate on a particular warranty claim. Communication of this sort must follow the processes shown in the Onan Warranty Administration Manual. 5. Provide photographs of the installation. 6. Provide copies of all repair orders applicable to the SRT involved, the technicians time cards, and any other information related to the repair that will aid in the review process. 7. Be sure to provide the correct name of the repairing location, a phone number, and point of contact. Company Action Upon receipt of the request for an SRT review, the following action will be taken: 1. The person signing the request will be contacted to acknowledge the receipt of the request. 2. All the information provided will be analyzed and compared with the history files of the spe- cific operation. 3. All information will be analyzed to determine if an error has been made in the procedure, the operations description, or the published repair time. 4. If it is determined the published repair time is incorrect, additional studies/analysis will be performed to establish the correct time. The requester will be notified of the results, and the results will be published in the next SRT update. 5. If it is determined that the time and procedure is correct, recommendations and assistance will be offered as needed. Redistribution or publication of this document by any means, is strictly prohibited. 1 Group 00 − Complete Engine Contents Page Administrative Time 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open/Close Repair Order (Shop) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove and Install (Gas Engine) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rebuild (Gas Engine) 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set, Mobile 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove and Install 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshoot 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cranks But Will Not Start (Genset) 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Overfueling (Genset) 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Unstable ---CHUNK BREAK--- (Hunts) (Genset) 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Will Not Crank (Genset) 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High/Low AC Output (Genset) 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starts But Stops When Switch Released 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redistribution or publication of this document by any means, is strictly prohibited. 2 Standard Repair Times Removed From Chassis In-Chassis Service Accessibility Codes Special Procedure Number and Description R A B C D S 00−901 Administrative Time − Open/Close Repair Order (Shop) 0.4 - - - - - Includes: −Clock on and off the job −Move equipment to and from work area −Clean work area and write repair at the end of −each shift and when job has been com- pleted −Record the following: −Generator Set model number −Generator Set serial number −Customer name and address −Original date of purchase −Hours of operation 00−101 Engine − Remove and Install (Gas Engine) - - 4.0 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Mounting tray and mounts −Exhaust tube −Generator end −Air cleaner assembly −Carburetor/Intake manifold assy −Air deflector −Starter −Exhaust manifold −Test run engine Redistribution or publication of this document by any means, is strictly prohibited. 3 Standard Repair Times In-Chassis Service Accessibility Codes Removed From Chassis Special Procedure Number and Description S D C B A R 00−203 Engine − Rebuild (Gas Engine) - - 8.5 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Mounting tray and mounts −Exhaust tube −Generator end −Air cleaner assembly −Carburetor/Intake manifold assy −Air deflector −Starter −Exhaust manifold −Spark plug −Rocker cover −Cylinder head −Oil base −Balance shaft assembly −Gearcase cover −Connecting rod and piston −Crankshaft −Camshaft −Tappets −Bearings −Oil seals −Hone or bore cylinder −Test run engine Redistribution or publication of this document by any means, is strictly prohibited. 4 Standard Repair Times In-Chassis Service Accessibility Codes Removed From Chassis Special Procedure Number and Description S D C B A R 00−1AA Generator Set, Mobile − Remove and Install - - 2.0 - - - Includes: −Disconnect and connect −Battery cables −Main leads and associated wiring −Fuel lines −Exhaust systems −Remove and install −Generator set from mounting location −Test run for proper operation 00−022 Troubleshoot − Engine Cranks But Will Not Start (Genset) - - - - - - −01 −Check: - - 0.3 - - - −Spark plugs −Ignition module −Fuel supply −02 −Perform checks in step 01 - - 0.5 - - - −Check: −Fuel supply fittings −Fuel pump −Carburetor choke −Carburetor adjustments 00−0AC Troubleshoot − Engine Overfueling (Genset) - - - - - - −01 −Check: - - 0.4 - - - −Spark plugs −Fuel pressure at carburetor −Choke heater −02 −Perform checks in step 01 - - 0.6 - - - −Check: −Governor adjustments −Carburetor adjustments (continued on next page) Redistribution or publication of this document by any means, is strictly prohibited. 5 Standard Repair Times In-Chassis Service Accessibility Codes Removed From Chassis Special Procedure Number and Description S D C B A R 00−0AC - - - - - - Troubleshoot − Engine Overfueling (Genset) −03 −Perform checks in step 02 - - 1.0 - - - −Check: −Ignition coil −Ignition module 00−041 Troubleshoot − Engine Unstable(Hunts)(Genset) - - - - - - −01 −Check: - - 0.3 - - - −Fuel supply −Fuel Lines for leakage −Loose wire connection −02 −Perform checks in step 01 - - 0.9 - - - −Check: −Governor linkage for binding −Governor adjustments −Carburetor adjustments 00−0AA Troubleshoot − Engine Will Not Crank (Genset) - - - - - - −01 −Check: - - 0.3 - - - −Low battery voltage −Terminal connections −Battery cable size −02 −Perform checks in step 01 - - 0.8 - - - −Check: −Remote control −Blown fuse −Start solenoid −Start disconnect relay 00−0AD Troubleshoot − High/Low AC Output (Genset) - - - - - - −01 −Check: - - 0.3 - - - −Broken or loose wires (continued on next page) Redistribution or publication of this document by any means, is strictly prohibited. 6 Standard Repair Times In-Chassis Service Accessibility Codes Removed From Chassis Special Procedure Number and Description S D C B A R 00−0AD - - - - - - Troubleshoot − High/Low AC Output (Genset) −Voltage regulator −Engine speed −02 −Perform checks in step 01 - - 1.0 - - - −Check: −Main rotor −Main stator −Adjust engine speed 00−0AB Troubleshoot − Starts But Stops When Switch is Released - - - - - - −01 −Check: - - 0.3 - - - −Oil level −Choke element −Engine speed −02 −Preform checks in step 01 - - 0.5 - - - −Check: −All electrical connections −Start disconnect relay −AC voltage regulator −Control board (Begin Spec C) −03 −Perform checks in step 02 - - 1.0 - - - −Check: −Main rotor −Main stator Redistribution or publication of this document by any means, is strictly prohibited. 7 Group 01 − Cylinder Block Contents Page Camshaft 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove and Install 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove and Install 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Seal, Rear 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace (Horizontal) 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hone or Bore 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Cover 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove and Install 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Cover Gasket 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear, Camshaft 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove and Install 11 . ---CHUNK BREAK--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear, Crankshaft 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove and Install 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor, Mechanical 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove and Install 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove and Install, All 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Rings 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redistribution or publication of this document by any means, is strictly prohibited. 8 Standard Repair Times Removed From Chassis In-Chassis Service Accessibility Codes Special Procedure Number and Description R A B C D S 01−3AE Camshaft − Replace - - 2.5 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Mounting tray and mounts −Exhaust tube −Rocker cover −Push rods −Oil base −Gearcase cover −Gearcase cover gasket −Camshaft −Torque cylinder head −Test run unit 01−1AA Connecting Rod − Remove and Install - - 2.5 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Mounting tray and mounts −Intake manifold/Carburetor assy. −Cylinder head −Oil base −Gearcase cover −Connecting rod and piston (continued on next page) Redistribution or publication of this document by any means, is strictly prohibited. 9 Standard Repair Times In-Chassis Service Accessibility Codes Removed From Chassis Special Procedure Number and Description S D C B A R 01−1AA - - - 2.5 - - Connecting Rod − Remove and Install −Clean and visually inspect −Crankshaft −Test run unit 01−112 Crankshaft − Remove and Install - - 4.5 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Mounting tray and mounts −Generator end −Starter −Intake manifold/Carburetor assy. −Exhaust manifold −Cylinder head −Oil base −Gearcase cover −Piston −Connecting rod −Crankshaft −Crankshaft gear −Bearings −Oil seals −Test run engine 01−308 Crankshaft Seal, Rear − Replace (Horizontal) - - 3.0 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring (continued on next page) Redistribution or publication of this document by any means, is strictly prohibited. 10 Standard Repair Times In-Chassis Service Accessibility Codes Removed From Chassis Special Procedure Number and Description S D C B A R 01−308 - - - 3.0 - - Crankshaft Seal, Rear − Replace (Horizontal) −Remove and install −Air inlet panel −Mounting tray and mounts −Base cover −Generator end −Generator adapter −Oil seal −Test run engine 01−541 Cylinder Block − Hone or Bore - - 8.0 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Mounting tray and mounts −Base cover −Generator end −Intake manifold/Carburetor assy. −Exhaust manifold −Cylinder head −Oil base −Gearcase cover −Piston and piston rings −Connecting rod −Crankshaft −Camshaft −Valve assembly −Tappets −Bearings −Oil seals (continued on next page) Redistribution or publication of this document by any means, is strictly prohibited. 11 Standard Repair Times In-Chassis Service Accessibility Codes Removed From Chassis Special Procedure Number and Description S D C B A R 01−541 - - - 8.0 - - Cylinder Block − Hone or Bore −Hone or bore and clean cylinder −Install −New piston and rings −New connecting rod −New bearings −Adjust valve lash −Test run unit 01−121 Gear Cover − Remove and Install - - 0.4 - - - Includes: −Remove and install −Gearcase cover and gasket −Test run unit 01−3AB Gear Cover Gasket − Replace - - 0.4 - - - Includes: −Remove and install −Gearcase cover and gasket −Test run unit 01−107 Gear, Camshaft − Remove and Install - - 2.4 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Mounting tray and mounts −Rocker cover −Push rods −Oil base −Gearcase cover −Gearcase cover gasket −Camshaft Redistribution or publication of this document by any means, is strictly prohibited. 12 Standard Repair Times In-Chassis Service Accessibility Codes Removed From Chassis Special Procedure Number and Description S D C B A R 01−107 - - - 2.4 - - Gear, Camshaft − Remove and Install −Test run unit 01−114 Gear, Crankshaft − Remove and Install - - 2.0 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Mounting tray and mounts −Gearcase cover and gasket −Crankshaft gear −Test run unit 01−1AB Governor, Mechanical − Remove and Install - - 2.0 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Gearcase cover and gasket −Governor −Test run unit 01−140 Piston − Remove and Install, All - - 2.3 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Mounting tray and mounts −Base cover −Intake manifold/Carburetor assy. Redistribution or publication of this document by any means, is strictly prohibited. 13 Standard Repair Times In-Chassis Service Accessibility Codes Removed From Chassis Special Procedure Number and Description S D C B A R 01−140 - - - 2.3 - - Piston − Remove and Install, All −Exhaust tube (continued on next page) −Cylinder head −Oil base −Piston −Connecting rod −Adjust valve lash −Test run engine 01−3AC Piston Rings − Replace - - 2.5 - - - Includes: −Disconnect and connect −Choke linkage −Governor linkage −Electrical wiring −Remove and install −Base cover −Mounting tray and mounts −Intake manifold/Carburetor assy. −Exhaust tube −Cylinder Air housing −Cylinder head −Oil base −Piston and rings assembly −Connecting rod −Adjust valve lash −Test run engine Redistribution or publication of this document by any means, is strictly prohibited. 14 Redistribution or publication of this document by any means, is strictly prohibited. 15 Group 02 − Cylinder Head Contents Page Cylinder Head 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove And Install 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Gasket 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace 16 . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source: manual:900-0616B Onan KVC Repair Times.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.