Onan CCK Series Instruction Manual

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.