Onan CCK User manual

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.