Onan CCK User manual

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Table of contents

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Orion

Service

Manual

Engines

927-0754

3-86

(Spec

A-J)

Replaces

9-84

(Spec

A-J)

Printed

in

USX

Safety

Precautions

It

is

recommended

that

you

read

your

engine

manual

and

become

thoroughly

acquainted

with

your

equipment

be¬

fore

you

start

the

engine.

This

symbol

Is

used

throughout

this

manual

to

warn

of

possible

serious

persons!

injury.

This

symbol

refers

to

possible

equip¬

ment

damage.

Fuels,

electrical

equipment,

batteries,

exhaust

gases

and

moving

parts

present

potential

hazards

that

could

result

in

serious,

personal

injury.

Take

care

in

following

these

recommended

procedures.

’

Safety

Codes

•

All

local,

state

and

federal

codes

should

be

consulted

and

complied

with.

•

This

engine

is

not

designed

or

intended

for

use

in

aircraft.

Any

such

use

is

at

the

owner’s

sole

risk.

General

•

Provide

appropriate

fire

extinguishers

and

install

them

in

convenient

locations.

Use

an

extinguisher

rated

ABC

by

NFPA.

•

Make

sure

that

all

fasteners

on

the

engine

are

secure

and

accurately

torqued.

Keep

guards

in

position

over

fans,

driving

belts,

etc.

•

If

It

is

necessary

to

make

adjustments

while

the

engine

is

running,

use

extreme

caution

when

close

to

hot

ex¬

hausts.

moving

parts,

etc.

Protect

Against

Moving

Parts

•

Do

not

wear

loose

clothing

in

the

vicinity

of

moving

parts,

such

as

PTO

shafts,

flywheels,

blowers,

coup¬

lings,

fans,

belts,

etc.

•

Keep

your

hands

away

from

moving

parts.

Batteries

•

Before

starting

work

on

the

engine,

disconnect

batter¬

ies

to

prevent

inadvertent

starting

of

the

engine.

•

DO

NOT

SMOKE

white

servicing

batteries.

Lead

acid

batteries

give

off

a

highly

explosive

hydrogen

gas

which

can

be

ignited

by

flame,

electrical

arcing

or

by

smoking.

•

Verify

battery

polarity

before

connecting

battery

cables.

Connect

negative

cable

last.

Fuel

System

•

DO

NOT

fill

fuel

tanks

while

engine

is

running.

•

DO

NOT

smoke

or

use

an

open

flame

in

the

vicinity

of

the

engine

or

fuel

tank.

Internal

combustion

engine

fuels

are

highly

flammable.

«

Fuel

lines

must

be

of

steel

piping,

adequately

secured,

and

free

from

leaks.

Piping

at

the

engine

should

be

approved

flexible

line.

Do

not

use

copper

piping

for

flexible

lines

as

copper

will

work

harden

and

become

brittle

enough

to

break.

•

Be

sure

all

fuel

supplies

have

a

positive

shutoff

valve.

Exhaust

System

•

Exhaust

products

of

any

internal

combustion

engine

are

toxic

and'can

cause

injury,

or

death

if

inhaled.

All

engine

applications,

especially

those

within

a

confined

area,

should

be

equipped

with

an

exhaust

system

to

discharge

gases

to

the

outside

atmosphere.

•

Do

not

use

exhaust

gases

to

heat

a

compartment.

•

Make

sure

that

your

exhaust

system

is

free

of

leaks.

Ensure

that

exhaust

manifolds

are

secure

and

are

not

warped

by

botts

unevenly

torqued.

Exhaust

Gas

is

Deadly!

Exhaust

gases

contain

carbon

monoxide,

a

poisonous

gas

that

might

cause

unconsciousness

and

death.

It

is

an

odorless

and

colorless

gas

formed

during

combustion

of

hydrocarbon

fuels.

Symptoms

of

carbon

monoxide

poi¬

soning

are:

•

Dizziness

•

Vomiting

•

Headache

•

Muscular

Twitching

•

Weakness

and

Sleepiness

•

Throbbing

in

Temples

If

you

experience

any

of

these

symptoms,

get

out

into

fresh

air

immediately,

shut

down

the

unit

and

do

not

use

until

it

has

been

inspected.

The

best

protection

against

carbon

monoxide

inhalation

is

proper

installation

and

regular,

frequent

inspections

of

the

complete

exhaust

system.

If

you

notice

a

change

in

the

sound

or

appearance

of

exhaust

system,

shut

the

unit

down

immediately

and

have

it

inspected

and

repaired

at

once

by

a

competent

mechanic.

Cooling

System

•

Coolants

under

pressure

have

a

higher

boiling

point

than

water.

DO

NOT

open

a

radiator

pressure

cap

when

coolant

temperature

is

above

212°

F

(100°C)

or

while

engine

is

running.

Keep

the

Unit

and

Surrounding

Area

Clean

•

Make

sure

that

oily

rags

are

not

left

on

or

near

the

engine.

•

Remove

all

unnecessary

grease

and

oil

from

the

unit

Accumulated

grease

and

oil

can

cause

overheating

and

subsequent

engine

damage

and

present

a

potential

fire

hazard.

E-4

Table

of

Contents

Genera!

Information..

Specifications

...

Dimensions

and

Clearances.4

Assembly

Torques

and

Special

Tools.

6

Engine

Troubleshooting.7

Starting..

Installation

Guidelines

.9

Oil

System

.

1

4

Governor

System..

Fuel

System.21

Ignition

System..

Battery

Charging

System

...

4

1

Starting

System..

Manual

Starter.

5

9

Engine

Disassembly.53

Special

Equipment..

WAKNINO

|

INCORRECT

SERVICE

OR

REPLACEMENT

OF

PARTS

MIGHT

RESULT

IN

SEVERE

PERSONAL

INJURY

AND/OR

EQUIPMENT

DAMAGE.

SERVICE

PERSONNEL

MUST

BE

QUALIFIED

TO

PERFORM

ELECTRICAL

AND/OR

MECHANICAL

SERVICE.

1

General

Information

mi-

introduction

ENGINE

MODEL

REFERENCE

This

manual

deals

with

specific

mechanical

and

elec¬

trical

information

needed

by

engine

mechanics

for

troubleshooting,

servicing,

repairing,

or

overhauling

the

engine.

Use

the

table

of

contents

for

a

quick

reference

to

the

separate

engine

system

sections.

The

troubleshooting

guide

is

provided

as

a

quick

reference

for

locating

and

correcting

engine

trouble.

The

illustrations

and

procedures

presented

in

each

section

apply

to

the

engines

listed

on

the

cover.

The

flywheel

end

of

the

engine

is

the

front

end

so

right

and

left

sides

are

determined

by

viewing

the

engine

from

the

front.

The

disassembly

section

contains

major

overhaul

procedures

for

step

by

step

removal,

disassembly,

inspection,

repair

and

assembly

of

the

engine

components.

If

a

major

repair

or

an

overhaul

is

necessary,

a

compe¬

tent

mechanic

should

either

do

the

job

or

supervise

and

check

the

work

of

the

mechanic

assigned

to

do

the

job

to

ensure

that

alt

dimensions,

clearances

and

torque

values

are

within

the

specified

tolerances.

A

parts

catalog

(available

at

the

dealer

level)

contains

detailed

exploded

views

of

each

assembly

and

the

individual

piece

part

numbers

and

their

proper

names

for

ordering

replacement

parts.

Use

only

Genuine

Onan

replacement

parts

to

ensure

quality

and

the

best

possible

repair

and

overhaul

results.

When

ordering

parts,

always

use

the

com¬

plete

Model

and

Spec

number

as

well

as

the

Serial

number

shown

on

the

nameplate.

Identify

your

model

by

referring

to

the

MODEL

and

SPEC

(specification)

NO.

as

shown

on

the

unit

nameplate.

Always

use

this

number

and

the

engine

serial

number

when

making

referencetoyourengine.

How

to

interpret

MODEL

and

SPEC

NO.

on

generator

set

engines.

CCK

2

F

T

1.

Indicates

kilowatt

rating.

2.

Series

identification.

3.

Voltage

code

of

the

generator.

4

Method

of

starting:

A-automatic,

R-remote

elect¬

ric

starting,

and

E-electric

starting.

5.

Factory

code

for

designating

optional

equipment,

if

any.

6

Specification

letter

which

advances

when

the

fac¬

tory

makes

production

modifications.

How

to

interpret

MODEL

and

SPEC

NO.

on

industrial

engines.

CCK

MS

/

3199

1

2

3

T

4

t.

Factory

code

for

general

identification

purposes.

2

Specific

Type*

MS-ELECTRIC

starting

with

stub

shaft,

starter

and

generator.

3,

Factory

code

for

optional

equipment

supplied.

4.

Specification

(Spec

Letter)

advances

with

factory

production

modification.

2

Specifications

This

manual

contains

Si

metric

equivalents

that

follow

immediately

in

parentheses

after

the

U.S.

customary

units

of

measure.

SPECIFICATION

Number

of

Cylinders

Bore

Stroke

Displacement

Compression

Ratio_

Rated

Speed

(Maximum)

Power

at

Rated

Speed_

Oil

Filter

Oil

Capacity

Without

Filter

_

Oil

Capacity

With

Filter

Change

Crankshaft

Rotation

(viewed

from

flywheel)

Governor

Valve

Clearance

(Cold)

Intake

Exhaust

Spark

Plug

Gap

(Gas)

Spark

Plug

Gap

(Gasoline)

UNIT

OF

MEASURE

3.000

(76.2)

49.8

(816)

5.5

to

1

2700

12.9

(9.6)

Full

Flow

3.0

(2.8)0

3.5

(3.3)©

Clockwise

Mechanical

SERIES

CCKA

2

3.250

(82.55)

49.8

(816)

7.0

to

1

3600

Full

Flow

3.0

(2.8)0

Clockwise

Mechanical

0.007

(0.18)

0.016

(0.41)

CCKB

2

3.000

(76.2)

49.8

(816)

7.0

to

1

3900

20.0

(14.9)

Full

Flow

3.5

(3.3)

Clockwise

Mechanical

0.007

(0.18)

0.016

(0.41)

Breaker

Point

Gap

-

Static

in

0.020

0.020

0.020

(Full

Separation

and

Engine

Cold)

(mm)

(0.51)

(0.51)

(0.51)

Ignition

Timing

All

Models

BTC

19°

Gaseous

Fuel

BTC

Gasoline

Fuel

BTC

24°

24°

Gasoline

Fuel

(Static)

ATC

1°®

o

^

1°®

Gasoline

Fuel

(Static

or

Running)

BTC

20°

©

20°

®

Gasoline

Fuel

Running

BTC

24°®®

24°

©

Q'

-

Add

0.5

quart

(0.47

litre)

for

electric

start

modeis.

©

-

Magneto

Ignition

®

-

With

Spark

Advance

©

-

Battery

Ignition

©

-

Magneto

Ignition

with

Spark

Advance

3

Dimensions

and

Clearances

All

clearances

given

at

room

temperature

of

70°F

(21

°C).

All

dimensions

In

Inches

(approximate

millimetre

dimensions

in

parentheses)

unless

otherwise

specified.

DESCRIPTION

MINIMUM

MAXIMUM

CYLINDER

BLOCK

Inches

(mm)

Indies

(mm)

Cylinder

Bore

Honed

Diameter...

Maximum

Allowable

.

3.2490

(82.525)

3.2500

(82.550)

Taper.

0.005

(0.127)

Out-of-Round

.

0.002

(0.051)

Main

Bearing

Inside

Diameter

{Without

bearing)..

.

2.187

(55.55)

2.188

(55.58)

Main

Bearing

Inside

Diameter

CCK

(Installed).

.

2.0020

(50.85)

2.0030

(50.88)

Main

Bearing

Inside

Diameter

CCKA/CCKB

(Installed)

.

.

2.0015

(50.84)

2.0040

(50.90)

Camshaft

Bearing

Bore

(Bearing

installed)....

CRANKSHAFT

.

1.3760

(34.95)

1.3770

(34,98)

Main

Bearing

Journal

Diameter...

.

1.9992

(50.78)

2.0000

(50.80)

Main

Bearing

Clearance.

.

0.0025

(0.064)

0.0038

(0.097)

Connecting

Rod

Journal

Diameter.

.

1.6252

(4138}

1.6260

(41.30)

Crankshaft

End

Play.

CONNECTING

ROD

Large

Bore

Diameter

(Without

bearing

installed

.

0.006

(0.152)

0.012

(0305)

and

rod

bolts

property

torqued]

....

.

1.7505

(44.46)

1.7510

(44.48)

Connecting

Rod

Side

Clearance......,

.

0.0020

(0.051)

0.0160

(0.406)

Piston

Pin

Bushing

Bore

{Without

bearing).

Piston

Pin

Bushing

Bore

with

Bearing,

.

0.8115

(20.61)

0.8125

(20.64)

(Finished

bore).

Bearing

to

Crankshaft

Clearance

.

0.7504

(19.05)

0.7508

(19.07)

Nodular

Iron

Rod...

.

0.0005

(0.013)

0.0023

(0.058)

Aluminum

Rod.

CAMSHAFT

......

0.0020

(0.051)

0.0033

(0.084)

Bearing

Journal

Diameter.

.

13740

{34.90}

13745

(34.91)

Bearing

Clearance.

.

0.0015

(0J038)

0.0030

(0.076)

End

Play.

......

0.0030

(0.076)

0.0120

(0305)

Camshaft

Lift.

PISTON

Clearance

in

Cylinder

0.300

(7.62)

Measure

90°

to

pin

0.10

inch

below

oil

ring...

Clearance

in

Cylinder

(CCKB

with

112-0073

piston)

.

0.0025

(0.064)

0.0045

(0.114)

Measure

90°

to

pin

0.10

inch

below

oil

ring..

.

0.0060

(0.150)

0.0080

(0300)

Piston

Pin

Bore.......

Ring

Groove

Width

.

0.7502

{19.055)

0.7506

(19.065)

Top

1

Compression

Ring

.

.

0.0960

{2.438)

0.0970

(2.464)

No.

2

Compression

Ring..

.

0.0955

{2.426)

0.0965

(2.451)

No.

3

Oil

Control

Ring...

..

0.188

(4.775)

0.189

(4.801)

4

DESCRIPTION

MINIMUM

MAXIMUM

PISTON

PIN

Inches

(mm)

inches

(mm)

Clearance

in

Piston.

Thumb

Push

Fit

Clearance

in

Connecting

Rod

...

*...

........

0.0002

(0.005)

0.0007

(0.018)

Diameter.

PISTON

RINGS

Clearance

..

0.7500

(19.05)

0.7502

(19.06)

Top

Groove....

.

0.002

(0.051)

0.008

(0.203)

Ring

End

Gap

in

Cylinder.

INTAKE

VALVE

.

0.010

(0.254)

0.020

(0.508)

Stem

Diameter...

.

0.3425

(8.70)

0.3430

(8-71)

Clearance

(Stem

to

Guide)

.

Valve

Face

Angle.

INTAKE

VALVE

SEAT

.

0.0010

(0.025)

0.0025

44°

(0.064)

Valve

Seat

Width.

Valve

Seat

Angle.

EXHAUST

VALVE

.

0.031

(0.787)

0.047

45°

(1.194)

Stem

Diameter.

.

0.3410

(8.661)

0.3415

(8.674)

Clearance

(Stem

to

Guide).

Valve

Face

Angie.

EXHAUST

VALVE

SEAT

.

0.0025

(0.064)

0.004

44°

(0.102)

Seat

Cylinder

Head

Bore

Diameter.

.

1.1890

(30.20)

1.1900

(30.23)

Seat

Outside

Diameter...

.

1.1920

(30.28)

1.1930

(30.30)

Valve

Seat

Width.

Valve

Seat

Angle.

VALVE

GUIDE

.

0.031

(0.787)

0.047

45°

(1.194)

Inside

Diameter.....

TAPPET

.

0.344

(8.74)

0.346

(8.79)

Body

Diameter.

.

0.7475

(18.99)

0.7480

(19.00)

Bore

Diameter.

........

0.7505

(19.06)

0.7515

(19.09)

Clearance

in

Bore.....

VALVE

SPRINGS

INTAKE

AND

EXHAUST

.

0.0015

(0.038)

0.003

(0.076)

Valve

Spring

Free

Length

(Approx.)...

Valve

Spring

Length

1.662

(42.21)

Valve

Open.....

1.125'

(28.58)

Valve

Closed.

1.375

(34.93)

Spring

Load

@

1.375

inch

(Valve

Closed)........

........

38

ib.

(17

kg)

42

ib.

(19

kg)

Spring

Load

@1.125

inch

(Valve

Open).

GEAR

BACKLASH

.

71

Ib

(32

kg)

79

Ib

(36

kg)

Timing

Gear.

.

0.002

(0.051)

0.003

(0.076)

Oil

Pump

Gear.....

.

0.002

(0.051)

0.005

(0.127)

5

Assembly

Torques

The

torque

values

given

in

Table

1

have

been

deter¬

mined

for

the

specific

applications.

Standard

torque

values

must

not

be

used

where

those

listed

in

Table

1

apply.

The

engine

assembly

torques

given

here

will

assure

proper

tightness

without

danger

of

stripping

threads.

All

threads

must

be

clean

and

lubricated

with

new

engine

oil

before

torquing.

Check

all

studs,

nuts,

and

capscrews,

and

tighten

as

required

to

keep

them

from

working

loose.

Refer

to

the

PARTS

MANUAL

for

the

location

of

washers

and

capscrews.

TABLE

1.

TORQUE

DESCRIPTION

SPECIFICATION

Ft-Lb.

Nm

Cylinder

Head

Capscrews_

29-31

(39-42)

Rear

Bearing

Plate.,.

Connecting

Rod

Bolt

20-25

(27-34)

Iron

Rod

...

27-29

(37-39)

Aluminum

Rod.

24-26

(33-35)

Flywheel

Capscrew.

Starter

Mounting

Bracket

to

35-40

(48-54)

Oil

Base

Screws.

25-35

(34-47)

Gear

Case

Cover..

10-13

(14-18)

Oil

Pump...

7-9

(10-12)

intake

Manifold

..

15-20

(20-27)

Exhaust

Manifold.

14-17

(19-23)

Oil

Base.

43-48

(58-65)

Special

Tools

The

following

special

tools

are

available

from

Onan.

For

further

information

see

TOOL

CATALOG

9(XHmsL

YaNe

Seat

Driver

VaNe

Guide

Driver

OH

Guide

arid

Driver

Combination

Bearing

Remover

(Main

and

Cam)

Combination

Bearing

Driver

(Main

and

Cam)

Ffywheet

Putter

8

Engine

T

roubleshooting

7

Starting

PRE-STARTING

Preparations

for

the

initial

and

each

additional

star¬

ting

operation

should

include

careful

checks

of

the

oil,

fuel,

cooling,

and

electrical

systems.

The

cylinder

air

housing

door

should

be

closed

withal!

airshrouds

in

place.

Crankcase

Oil:

Be

sure

the

crankcase

has

been

filled

with

oil

to

the

“FULL”

mark

on

the

oil

level

indicator,

Figure

1.

Use

oil

with

the

API

(American

Petroleum

Institute)

designation

SE

or

SE/CC.

Do

not

use

an

oil

with

the

designation

CD

unless

it

is

also

designated

SE

and

the

oil

manufacturer

certifies

it

will

perform

satisfactorily

in

gasoline

engines.

For

gaseous

operation,

use

an

ashless

or

low-ash

detergent

oil

specifically

made

for

gaseous-fueled

engines.

CAP

AND

OIL

LEVEL

INDICATOR

KEEP

OIL

AT

THIS

LEVEL.

NEVER

OPERATE

ENGINE

WITH

OIL

BELOW

THIS

LEVEL.

A874

-FULL

ALWAYS

REPLACE

CAP

TIGHTLY,

OR

OIL

LEAKAGE

HAY

OCCUR.

FIGURE

1.

OIL

LEVEL

INDICATOR

WARNING

)

Crankcase

pressure

could

blow

out

fj

0

f

0

/7

and

cause

serious

burns.

Do

NOT

check

oil

while

the

engine

is

operating.

OIL

CAPACITIES

Electric

Start

3-1/2

qts.

(3.31

litre)

4

qts.

(3.8

litre

with

filter)

Manual

Start

3

qts.

(2.8

litre)

3-1/2

qts.

(3.3

litre

with

filter)

Engine

oil

should

always

bedrained

when

the

engine

is

warm.

Remove

pipe

plug

to

drain

engine

oil.

Recommended

Fuel:

Use

clean,

fresh,

regular

grade,

automotive

gasoline.

Do

not

use

highly-leaded

premium

types.

For

new

engines,

the

most

satisfactory

results

are

obtained

by

using

nonleaded

gasoline.

For

older

engines

that

have

previously

used

leaded

gasoline,

heads

must

be

taken

off

and

all

lead

deposits

removed

from

engine

before

switching

to

nonleaded

gasoline.

I^CAUTION^

If

lead

deposits

are

not

removed

—*~*-^*-*~&

irom

engine

before

switching

from

leaded

to

nonleaded

gasoline,

pre-ignition

could

occur

causing

severe

damage

to

the

engine.

WARNING

I

Spilled

fuel

might

Ignite

and

cause

serious

personal

Injury

or

death.

Never

fill

the

fuel

tank

when

the

engine

is

running.

STARTING

Electric

Start

1.

Move

the

ignition

switch

to

ON.

2.

Push

the

START

button

to

crank

the

engine.

Manual

Start

1.

Engine

priming

before

starting

is

shown

in

Figure

5

(manual

start

only).

2.

Pull

the

choke

control

about

3/4

of

the

way

closed

or

as

necessary

according

to

temperature

con¬

ditions.

3.

Pull

the

start

rope

with

a

fast

steady

pull

to

crank

the

engine.

Do

not

jerk

or

let

rope

snap

back

under

its

own

power.

4.

As

the

engine

warms

up,

adjust

the

choke

gradually

to

its

fully

open

position.

APPLYING

LOAD

Apply

load

to

a

new

or

reconditioned

engine

gradual¬

ly

in

about

four

steps;

not

less

than

30

minutes

running

time

for

each

step.

Start

with

1/4

load,

then

1/2,

3/4

and

full-load.

STOPPING

THE

ENGINE

When

possible,

disconnect

all

load

before

stopping

the

engine.

Engines

equipped

with

battery

ignition

are

stopped

by

setting

the

ignition

switch

to

the

off

position.

Open

the

fuel

line

valve

(when

used)

and

operate

primer

to

assure

fuel

supply

after

filling

an

empty

tank.

Engines

equipped

with

magneto

ignition

are

stopped

by

pushing

the

stop

button

(located

on

the

blower

housing).

Hold

in

until

engine

completely

stops.