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Qnan

ELECTRIC

POWER

PLANTS

FOR

RECREATIONAL

VEHICLES

SERIES

CCK

ONAN

1400

73RD

AVENUE

N.E.

•

MINNEAPOLIS,

MINNESOTA

55432

4

DIVISION

Of

ONAN

CO/tPOHAriON

N.Y.

INTERNATIONAL

OFFICE:

Empire

State

Bldg,

927-310

6AP71

GENERAL

INFORMATION

This

manual

includes

instructims

for

the

installation,

operation,

and

maintenance

of

the

CCK

electric

generating

plants

used

in

mobile

applications.

Identify

the

model

by

referring

to

the

MODEL

AND

SPECIFI¬

CATION

NUMBER

as

shown

on

the

ONAN

nameplate.

Electrical

characteristics

are

shown

on

the

lower

portion

of

the

nameplate.

How

to

interpret

MODEL

and

SPEC

NO.

5.0CCK

.

lR/6000

P

1

2

3

4

1.

Factory

code

for

general

identification.

2.

Specific

type;

M-MANUAL.

Manually

cranked.

For

permanent

or

portable

installations.

R-REMOTE.

Electric

starting.

For

permanent

installation

can

be

connected

to

optional

accessory

equipment

for

remote

or

automatic

control

of

starting

and

stopping.

3.

Factory

code

for

optional

equipment.

4.

Specification

(Spec)

letter

(advances

when

factory

makes

production

modifications).

Electric

plants

ate

given

a

complete

running

test

under

various

load

conditions

and

thoroughly

checked

before

leaving

the

factory.

Inspect

the

plant

closely

for

loose

or

missing

parts

and

any

damage

which

may

have

occurred

in

shipment.

Tighten

loose

parts,

replace

missing

parts

and

repair

any

damage

before

putting

plant

in

operation.

TABLE

OF

CONTENTS

title

page

General

Information.

1

Specifications.

2

Troubleshooting.

3

Installation.

4

Operation.

g

Adjustments.

10

Service

and

Maintenance.J5

Parts

Catalog.jg

TYPICAL

CCK

FOR

MOBILE

APPLICATIONS

SPECIFICATIONS

ENGINE

Number

of

Cylinders.2

Cubic

Inch

Displacement.49.8

Cylinder

Bore..3

1/4

Piston

Stroke..3

Compression

Ratio...5.5

;

l

RPM...1800

Ignition

Type.Battery

Battery

Voltage.12

Battery

Size

'

SAE

Group

IH.2

in

series

SAE

Rating-20Hour

(nominal).105amp/hr

Battery

Charge

Rate

(maximum).6

amp

Ventilation

Required

(cfm)

Engine.

750

cfm

Generator

.

.

V

.75

cfm

Combustion.32

cfm

GENERATOR

AC

Voltage

Regulation.

.

±

4

%

AC

Frequency

Regulation.5%

Rating

(output

in

watts)

4.0

CCK

5.0

CCK

60

Hertz

AC

Mobile

Service.

.

4000

5000

PLANT

DIMENSIONS

Model

4.0

CCK.

Single

Phase.

2

Wire

Length.

29

3/8

Width.

.20

1/2

Height

.

.22

Weight

.339

Model

5.0

CCK,

Single

Phase,

2

Wire

Length.

32

7/8

Width.20

1/2

Height

.

.22

Weight.397

FEATURES

Battery

Ignition

/

Exciter

Cranking

Rotating

Exciter

Revolving

Armature

Output

Rated

at

Unity

Power

Factor

Load

NOTE:

Hertz

is

a

unit

of

frequency

equal

to

one

cycle

per

second.

TROUBLE-SHOOTING

GUIDE

INSTALLATION

(

If

the

mobile

electric

power

plant

is

to

operate

properly,

it

must

be

correctly

installed.

This

manual

gives

some

of

the

more

important

aspects

of

installation.

For

more

details,

a

Technical

Bulletin

(T-OIS)

is

available

from

Onan.

Ventilation

is

the

most

important

factor

to

be

consid¬

ered.

The

unit

must

have

enough

cooling

air

to

operate

safely

and

efficiently.

The

heated

air

must

be

disposed

of

to

keep

the

engine

from

overheating

and

losing

power.

For

the

CCK

electric

plant

running

at

1800

rpm,

the

——unt

of

air

discharged

is

750

efm.

The

minimum

free

air

inlet

with

no

filter

or

restriction

is

140

sq.

in.

Onan

Vacu-Flo

cooled

units

are

specifically

designed

for

mounting

in

small

compartments

(where

proper

cooling

is

difficult)

and

are

equipped

to

provide

suf¬

ficient

cooling

air

and

adequate

disposition

of

heated

air.

With

this

type

of

cooling,

a

centrifugal

fan

in

a

scroll

housing

pulls

cooling

air

into

the

compartment

and

over

the

cooling

fins

and

surfaces

of

the

engine.

Heated

air

is

expelled

through

a

single

discharge

and

away

from

the

unit

and

installation

area.

TYPICAL

-SLIDE

OUT

"

TRAY

FOR

COMPARTMENT

MOUNTING

EXHAUST

CONNECTION

BEVEL

MUST

BE

BACK

PAR

ENOUGH

SO

AS

NOT

TO

LET

TRAY

BOCK

WHEN

IN

POSITION.

LOCATION

The

compartment

itself

should

be

of

vapor

tight

design

and

completely

independent

of

living

quarters.

A

sheet

metal

covered

compartment

may

be

readily

sealed

and

lends

itself

easily

to

treatment.

The

plant

may

have

to

be

removed

for

service,

so

make

the

door

large

enough

to

facilitate

removal

of

the

unit.

The

compartment

location

is

determined

by

physical

size,

access

opening

and

most

important,

best

mounting

support.

Allow

2"

clearance

on

all

sides

of

the

plant

for

rocking

on

mounts.

POSITIONING

The

following

should

be

considered

for

accessibility

when

mounting

the

unit

in

a

compartment.

(Position

so

operating

instructions

and

nameplate

are

visible

and/or

install

an

accessible

nameplate,

data

decal

or

sticker.)

1.

Make

air

discharge

duct

as

short

as

possible.

Position

so

exhaust

heated

ait

is

not

drawn

into

cool

air

inlet.

2.

Ait

cleaner

should

be

easy

to

remove

and

service.

3.

Battery

or

batteries

roust

be

accessible

for

service.

4.

Oil

fill

tube

cap

should

be

easy

to

reach.

5.

The

control

box

switch

should

be

visible.

6.

Provide

space

for

muffler.

7.

Oil

drain

should

be

readily

accessible.

8.

Cylinder

head

readily

accessible

for

service.

9.

Rope

start

sheave

should

be

accessible.

MOUNTING

The

best

method

of

mounting

is

to

attach

the

plant

to

a

mounting

platform

using

Onan

vibration

isolators.

See

Figure

2.

The

vibration

isolators

must

be

properly

installed

to

minimize

vibration.

The

Onan

mounts

are

a

“fail-safe"

type

with

mounting

bolts

that

prevent

the

unit

from

breaking

loose

if

the

mounts

are

damaged.

The

mounting

base

should

be

fastened

directly

to

the

supporting

frame.

Channel,

box

or

angle

iron

can

be

used

for

a

mounting

base

frame.

This

will

provide

the

greatest

support

plus

a

base

sealed

against

ait,

dirt

and

sound.

Do

not

use

sheet

metal

or

thin

plate

without

a

supporting

frame.

Plywood

of

sufficient

thickness

for

strength

can

be

used,

but

unless

it

is

suitably

sealed,

it

is

vulnerable

to

climatic

elements,

will

tend

to

become

oil

soaked,

and

is

not

fireproof.

The

supporting

base

or

platform

must

be

strong

enough

to

withstand

the

shock

from

sharp

turns,

bumps,

holes,

etc.

which

accompany

mobile

applications.

Brace

the

mounting

platform

to

eliminate

any

chance

of

the

platform

bowing

or

bending.

It

is

desirable

to

mount

the

unit

on

a

pullout

tray

to

facilitate

service

and

repair.

The

load

wires,

control

wires

and

fuel

lines

must

have

enough

slack

and

be

flexible

so

the

unit

can

slide

out

without

disconnecting

them.

When

using

a

pull-out

tray,

pipe

the

exhaust

gases

into

the

air

outlet.

The

air

outlet

duct

may

face

the

botttxn,

side

or

top

of

the

enclosure,

depending

on

bow

the

unit

is

installed.

FUfil.

SUPPLY

(GASOLINE)

Install

a

separate

fuel

tank

for

the

unit.

If

the

plant

has

to

be

connected

to

the

vehicle

supply

tank,

do

not

tee

off

the

vehicle

supply

line.

The

generating

unit

must

have

a

separate

fuel

line

because

the

more

powerful

vehicle

fuel

pump

will

starve

the

generating

unit

for

gasoline.

FUEL

LINES

Use

annealed

copper

or

seamless

steel

tubing

and

flared

connections.

Run

fuel

lines,

at

the

top

level

of

the

tank

to

a

point

as

close

to

the

engine

as

pos¬

sible,

to

reduce

the

danger

of

fuel

siphoning

out

of

the

tank

if

the

line

should

break.

Install

lines

so

they

are

accessible

at

all

times

and

protected

from

mechanical

injury.

Use

nonferrous

metal

straps,

without

sharp

edges,

to

secure

the

fuel

lines.

EXHAUST

If

the

unit

is

permanently

mounted,

pipe

the

exhaust

to

a

muffler

mounted

under

the

floor.

If

the

unit

is

mounted

on

a

slide-out

tray,

vent

the

exhaust

through

the

air

discharge

duct.

Flexible

exhaust

tubing

(used

between

the

unit

and

the

muffler)

absorbs

unit

vibration.

If

the

exhaust

line

passes

through

a

flamiSable

floor

or

partition,

insulate

with

asbestos

backed

metal

collars

where

it

passes

through

these

barriers.

Exhaust

lines

may

be

asbestos

wrapped

to

reduce

heat

radiation

within

the

compartment.

However,

care

should

be

taken

to

see

that

flexible

exhaust

sections

that

are

wrapped

still

retain

their

flexibility.

When

installing

mufflers,

other

than

those

supplied

with

plant

or

if

the

exhaust

system

is

excessively

complicated,

the

exhaust

back

pressure

should

be

checked.

Exhaust

back

pressure

at

rated

load,

mea-

sured

at

the

exhaust

manifold,

should

not

exceed

2

in.

Hg.

(Mercury

column).

Where

a

tapped

hole

is

not

provided,

the

manifold

and/or

a

pipe

coupling

may

be

drilled

and

tapped.

After

measurement

is

made,

plug

the

hole

with

an

ordinary

pipe

plug.

I

i^aRNINO

\

discharged

Vacu-FIo

air

for

heatmg

since

it

may

contain

carbon

monoxide

or

other

poisortoua

gases.

BATTERY

CONNECTION

Connect

the-positive

battery

cable

to

the

start

solenoid

(located

in

the

control

box).

See

Figures.

Connect

the

negative

battery

cable

to

a

good

ground

on

the

generator.

Do

not

disconnect

the

starting

bat-

terfes

while

the

engine

is

running.

The

resulting

overvoltage

will

damage

the

electric

choke

and

other

control

components.

In

mobile

applications

where

the

generator

is

normally

operated

in

ambient

temperatures

above

0°F

and

the

battery

is

kept

charged

by

frequent

tunning

of

the

unit,

a

single

12

volt

battery

of

72amp/hr

capacity

minimum

is

sufficient.

WIRING

All

wiring

must

meet

applicable

local

electrical

codes.

Wires

must

be

of

adequate

size,

properly

insulated

and

supported

in

an

approved

manner.

Have

a

qualified

electrician

install

and

inspect

the

wiring.

Mount

switches

and

controls

securely

to

prevent

damage

from

vibration

and

road

shocks.

All

switches

should

be

vibration

proof

to

prevent

accidental

opening

or

closing

while

the

vehicle

is

in

motion.

Protect

load

circuits

and

generator

output

circuits

by

proper

size

fuses

or

circuit

breakers

to

prevent

severe

overload

conditions

from

damaging

the

generator.

Some

special

precautions

must

be

taken

when

installing

AC

load

wires

to

Onan

electric

plants

if

the

plant

is

single

phase

but

has

3

output

wires

(120/240

volt

output).

Balance

the

120

volt

loads

between

the

two

legs

of

the

generator

windings.

This

means

connecting

half

of

the

vehicle's

120volt

load

to

each

leg

of

(he

generator

output.

The

average

running

load

would

be

approximately

equal

for

each

side

of

the

generator

output.

Attempting

to

take

the

full

load

off

only

one

leg

couto

damage

the

generator

output

windings.

Connect

any

240

volt

load

across

both

windings.

To

control

the

plant

from

several

locations,

install

separate,

switches

and

wire

them

in

parallel

(Figure

5).

Any

number

of

switches

may

be

used.

OPERATION

BEFORE

STARTING

Be

sure

the

crankcase

has

been

filled

with

oil

to

the

"FULL”

mark

on

the

oil

level

indicator.

Refer

to

the

Maintenance

Section

for

the

recommended

oil

changes

and

complete

lubricating

oil

recommendations.

ELECTRIC

STARTING

Push

the

START-STOP

switch

to

its

"START”

posi¬

tion.

Release

the

switch

as

soon

as

the

engine

starts.

If

the

engine

fails

to

start

at

first

try,

inhibitor

oil

used

at

the

factory

may

have

fouled

the

spark

plug.

Remove

the

plug,

clean

in

a

suitable

solvent,

dry

thoroughly

and

install.

Heavy

exhaust

smoke

when

the

engine

is

first

started

is

normal

and

is

caused

by

the

inhibitor

oil.

If

the

battery

charge

condition

is

too

low

to

crank

the

engine,

the

plant

can

be

started

manually.

Set

the

control

box

switch

(located

inside

the

control

box)

to

its

manusl

start

position.

Pull

the

rope

with

a

fast,

steady

pull

to

crank

the

engine.

Do

not

jerk.

After

starting,

return

the

control

box

switch

to

the

electric

start

position

to

avoid

discharging

the

battery.

APPLYING

LOAD

If

practical,

allow

plant

to

warm

up

before

connecting

a

heavy

load.

Continuous

generator

overloading

may

cause

high

operating

temperatures

that

can

damage

the

wlDdings.

Keep

the

load

within

nameplate

rating.

STOPPING

1.

Push

start-stop

switch

to

stop

position.

2.

Release

switch

when

plant

stops.

If

stop

circuit

fails,

close

fuel

valve.

BREAK-IN

PROCEDURE

Controlled

break-in

with

the

proper

oil

and

a

con¬

scientiously

applied

maintenance

program

will

help

to

assure

satisfactory

service

from

your

Onan

electric

plant.

When

operating

engine

for

the

first

time,

use

the

following

sequence

using

MS/DG

oil:

1.

One

half

hour

at

1/2

load.

2.

One

half

hour

at

3/4

load.

3.

Full

load.

4.

Change

crankcase

oil

after

the

first

50

hours

of

operation.

BATTERY

CHARGING

The

battery

charge

rate

is

automatically

controlled

by

a

voltage

regulator.

The

high

charge

rate

was

set

at

the

factory

for

average

operating

conditions.

If

frequent

starts

and

short

operating

periods

require

an

increased

charge

rate,

adjust

by

moving

the

slide

clip

on

the

adjustable

resistor

in

the

control

box.

Do

not

exceed

Samps.

INFREQUENT

SERVICE

If

the

plant

is

used

infrequently,

extended

shutdown

periods

can

result

in

difficult

starting.

Run

the

plant

at

least

30

minutes

every

week

to

eliminate

hard

starting.

HIGH

TEMPERATURES

1.

See

that

nothing

obstructs

air

flow

to

and

from

the

plant.

2.

Keep

cooling

fins

clean.

Air

housing

should

be

properly

installed

and

undamaged.

3.

Kee|^

ignition

timing

properly

adjusted.

LOW

TEMPERATURES

1.

Use

correct

SAE

No.

oil

for

temperature

conditions.

Change

oil

only

when

engine

is

warm.

If

an

unexpected

temperature

drop

causes

an

emergency,

move

the

plant

to

a

warm

location

or

apply

heat

externally.

2.

Use

fresh,

standard

grade

gasoline.

Protect

against

moisture

condensation.

Below

0°F

adjust

carburetor

main

jet

for

slightly

richer

fuel

mixture.

3.

Keep

ignition

system

clean,

properly

adjusted

and

batteries

in

a

well

charged

condition.

4.

Partially

restrict

cool

air

flow,

but

use

care

to

avoid

overheating.

OUT-OF-SERVICE

PROTECTION

Protect

a

plant

that

is

to

be

out-of-service

(or

more

than

30

days

as

follows:

1.

Run

the

plant

until

thoroughly

warm.

2.

Turn

off

fuel

supply

and

run

until

plant

stops.

3.

Drain

oil

from

oil

base

while

still

warm.

Refill

and

attach

a

warning

tag

stating

oil

viscosity

used.

4.

Remove

each

spark

plug.

Pour

loz.

(two

table¬

spoons)

of

rust

inhibitor

(or

SAE

#50

oil)

into

each

cylinder.

Crank

engine

slowly

(byi-hand)

several

times.

Install

spark

plugs.

5.

Service

air

cleaner.

6.

Clean

governor

linkage

and

protect

by

wrapping

with

a

clean

cloth.

7.

Plug

exhaust

outlet

to

prevent

entrance

of

moisture,

dirt,

bugs,

etc.

8.

Wipe

generator

brushes,

slip

rings,

etc.

Do

not

apply

lubricant

or

preservative.

9.

Wipe

entire

unit.

Coat

rustable

parts

with

a

light

film

of

grease

or

oil.

10.

I

f

battery

is

used,

disconnect

and

follow

standard

battery

storage

procedure.

operate

start

switch

Energizes

start

solenoid

Solenoid

contacts

close

Current

fed

to

generator

Current

fed

through

voltage

dropping

Current

fed

to

electric

series

field,

cranks

resistor

energizes

stop

relay

and

choke

operates

car-

engine.

closes

its

contacts.

buretor

choke.

I

Battery

current

fed

to

ignition

coil

through

the

stop

relay

contacts

and

the

resistor.

Engine

starts

I

Operate

start

switch

until

generator

speed

builds

up.

Release

start

switch.

j

Generator

DC

current

pro¬

duced.

AC

output

current

produced

and

fed

to

load.

1

■

‘

J_

1^:_

j

_

Start

solenoid

de-

Takes

over

energizing

Recharges

Takes

over

operating

energized.

of

stop

relay.

battery.

of

choke.

1

The

charge

rate

is

high

when

the

When

the

battery

becomes

fully

battery

is

not

fully

charged

DC

charged,

the

voltage

regulator

re-

current

passes

through

both

the

moves

the

adjustable

resistor

from

adjustable

resistor

and

the

fixed

from

the

circuit

and

current

resistor

which

are

paralleled

by

passes

through

the

fixed

resistor

the

closed

contacts

of

the

two-

step

voltage

regulator.

only.

1

^

L

1

Exciter

voltage

closes

the

reverse

current

relay,

feeding

current

into

the

battery.

DUST

AND

DIRT

1.

Keep

plant

clean.

Keep

cooling

surfaces

clean.

2.

Service

air

cleaner

as

frequently

as

necessary.

3.

Change

crankcase

oil

every

50

operating

hours.

4.

Keep

oil

and

gasoline

in

dust-tight

containers.

5.

Keep

governor

linkage

clean.

6.

Clean

generator

brushes,

slip

rings

and

commutator.

Do

not

remove

normal

(dark

brown)

film.

Do

not

polish.

HIGH

ALTITUDE

For

operation

at

altitudes

of

2500

feet

abc^e

sea

level,

close

carburetor

main

jet

adjustment

slightly

to

maintain

proper

air-to-fuel

ratio

(refer

to

the

Adjustments

Sec¬

tion).

Maximum

power

will

be

reduced

approximately

4%

for

each

1000

feet

above

sea

level,

after

the

first

1000

feet.