Onan CCK User manual

Orton
Operators
Manual
case
GenSet
4 kW and 5 kW
Mobile Models
927-0120
(SPEC U)
(Reprinted 5-82)
Printed in U.S.A.

Safety Precautions
Before operating the generator set, read the Operator's
Manual and become familiar with it and the equipment. Safe
and efficient operation can be achieved only if the unit is
properly operated and maintained. Many accidents are
caused by failure to follow fundamental rules and precautions.
The following symbols, found throughout this manual, alert you
to potentially dangerous conditions to the operator, service per¬
sonnel, or tne equipment.
A DANGER This symbol warns of Immediate haz¬
ards which will result in severe personal injury or
death .
lAWARNiNGl This symbol refers to a hazard or unsafe
practice which can result in severe personal injury
or death .
1A caution] This symbol refers to a hazard or unsafe
practice which can result in personal injury or prod¬
uct or property damage .
FUEL AND FUMES ARE FLAMMABLE. Fire, explosion, and
personal injury can result from improper practices.
• DO NOT fill fuel tanks while engine is running. Fuel contact
with hot engine or exhaust is a potential fire hazard.
• DO NOT SMOKE OR USE AN OPEN FLAME near the gen¬
erator set or fuel tank.
• Fuel lines must be adequately secured and free of leaks.
Fuel connection at the engine should be made with an ap¬
proved flexible, non-conductive line. Do not use copper pip¬
ing on flexible lines as copper will work harden and Become
brittle.
• Be sure all fuel supplies have a positive shutoff valve.
GASOLINE AND LPG FUEL MAY BE ACCIDENTALLY IG¬
NITED BY ELECTRICAL SPARKS, presenting the hazard of
fire or explosion, which can result in severe personal in¬
jury or death. When installing the generator set:
• Do not tie electrical wiring to fuel lines.
• Do not run electrical lines and fuel lines through the same
compartment openings.
• Keep electrical and fuel lines as far apart as possible.
• Place a physical barrier between fuel lines and electrical
lines wherever possible.
• If electrical and fuel lines must pass through the same com¬
partment opening, make certain that they are physically
separated by running them through individual channels, or
by passing each line through a separate piece of tubing.
• DO NOT SMOKE while servicing batteries. Lead acid bat¬
teries emit a highly explosive hydrogen gas that can be ig¬
nited by electrical arcing or by smoking.
EXHAUST GASES ARE DEADLY
♦ Never sleep in the vehicle with the generator set running un¬
less vehicle is equipped with an operating carbon monoxide
detector.
♦ Provide an adequate exhaust system to properly expel dis¬
charged gases. Inspect exhaust system daily for leaks per
the maintenance schedule. Ensure that exhaust manifolds
are secure and not warped. Do not use exhaust gases to
heat a compartment.
♦ Be sure the unit is well ventilated.
MOVING PARTS CAN CAUSE SEVERE PERSONAL IN¬
JURY OR DEATH
• Before starting work on the generator set, disconnect batter¬
ies. This will prevent accidental arcing.
• Keep your hands away from moving parts.
• Make sure that fasteners on the generator set are secure.
Tighten supports and clamps, keep guards in position over
fans, drive belts, etc.
• Do not wear loose clothing or jewelry while working on gen¬
erator sets. Loose clothing and jewelry can become caught
in moving parts. Jewelry can short out electrical contacts
and cause shock or burning.
• If adjustment must be made while the unit is running, use ex¬
treme caution around hot manifolds, moving parts, etc.
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL
INJURY OR DEATH
• Disconnect starting battery before removing protective
shields or touching electrical equipment. Use rubber insuia-
tive mats placed on dry wood platforms over floors that are
metal or concrete when around electrical equipment. Do not
wear damp clothing (particularly wet shoes) or allow skin sur¬
faces to be damp when handling electrical equipment.
• Use extreme caution when working on electrical compo¬
nents. High voltages can cause injury or death.
• Follow all state and local electrical codes. Have all electrical
installations performed by a qualified licensed electrician.
Tag open switches to avoid accidental closure.
• DO NOT CONNECT GENERATOR SET DIRECTLY TO
ANY BUILDING ELECTRICAL SYSTEM. Hazardous volt¬
ages can flow from the generator set into the utility line. This
creates a potential for electrocution or property damage.
Connect only through an approved device and after building
main switch is open. Consult an electrician in regard to
emergency power use.
GENERAL SAFETY PRECAUTIONS
• Have a fire extinguisher nearby. Maintain extinguisher prop¬
erly and become familiar with its use. Extinguishers rated
ABC by the NFPA are appropriate for all applications. Con¬
sult the local fire department for the correct type of extin¬
guisher for various applications.
• Hot coolants under pressure can cause severe personal in¬
jury. DO NOT open a radiator pressure cap while the engine
is running. Stop the engine and carefully bleed the system
pressure.
• Benzene and lead, found in some gasoline, have been iden¬
tified by some state and federal agencies as causing cancer
or reproductive toxicity. When checking, draining or adding
gasoline, take care not to ingest, breathe the fumes, or con¬
tact gasoline.
• Used engine oils have been identified by some state or fed¬
eral agencies as causing cancer or reproductive toxicity.
When checking or changing engine oil, take care not to in¬
gest, breathe the fumes, or contact used oil.
• Remove all unnecessary grease and oil from the unit. Accu¬
mulated grease and oil can cause overheating and engine
damage, which presents a potential fire hazard.
• DO NOT store anything in the generator compartment such
as oil or gas cans, oily rags, chains, wooden blocks, portable
propane cylinders, etc. A fire could result or the generator
set operation* (cooling, noise and vibration) may be ad¬
versely affected. Keep the compartment floor clean and dry.
• Do not work on this equipment when mentally or physically
fatigued, or after consuming any alcohol or drug that makes
the operation of equipment unsafe.
RV-9

TO THE OWNER
Welcome to the growing family of Onan Power users
.. . We are proud to have you as a customer.
Read this manual carefully and observe all safety
rules within. Operating instructions, adjustments and
periodic maintenance procedures are given so that
you . . . the owner, can keep your unit running like
new and expect many years of dependable service
from it. Remember . . . any machine, regardless of
design or type, will perform only in relation to the
services it receives.
If your generator set needs special attention, ask your
Onan dealer for assistance; the Onan Parts and
Service Organization has been factory-trained to
provide up-to-date know-how for keeping your RV
electric generating set “on the road.” A complete
Parts Catalog is available at nominal cost and may be
ordered under #927-0220.
TABLE OF CONTENTS
General Information. 2
Specifications. 3
Installation Checks. 4
Operation.. 6
Engine Troubleshooting Guide. 11
Maintenance. 12
Periodic Maintenance Schedule. 16
Adjustments. 17
Control Troubleshooting. 21
Generator Set Schematic. 22
Remote Accessories. 23
Parts Information. 25
1 warningX
TO PREVENT FIRE OR ACCIDENT HAZARD. . .
THIS UNIT MUST BE INSTALLED ACCORDING
TO THE MANUFACTURERS DETAILED IN¬
STALLATION PROCEDURES OBSERVING ALL
MINIMUM CLEARANCES.
TO AVOID POSSIBLE PERSONAL INJURY OR
EQUIPMENT DAMAGE, ANY INSTALLATION
AND ALL SERVICE MUST BE PERFORMED BY
QUALIFIED PERSONNEL.
1

GENERAL INFORMATION
YOUR MANUAL
This manual contains operation and other informa¬
tion to properly maintain, service, and make ad¬
justments on you r generator set. Study and follow the
instructions carefully. A well-planned service and
maintenance program will result in longerunit life and
better performance. Because the most important part
of repair is diagnosis, a troubleshooting chart is
included.
Throughout the manual, engine end of the generator
set is the front. Left and right sides are determined
when facing the engine (front) end.
When contacting yourOnan dealer, distributor, orthe
factory about the generator set, always supply the
complete model number and serial number as shown
on the nameplate (see Model Designation preceding).
This information is necessary to identify your
generator set among the many types manufactured
by Onan.
FIGURE 1.
TYPICAL. CCK FOR RECREATIONAL VEHICLES
RE AKER POINT
BOX
EXHAUST.
START-STOP
SWITCH
SOLID STATE
CONTROL
UNIT
NAMEPLATE'
GENERATOR
COOLING AIR
■ E L ECTRIC
FUEL PUMP
OIL DRAIN
VIBRATION
ISOLATOR
2

SPECIFICATIONS
(Dimensions in parenthesis are metric values)
ENGINE DETAILS
Manufacturer.
Number of Cylinders.
Displacement (in )...
Cylinder Bore.
Piston Stroke.
Compression Ratio ..
Engine Speed.
Engine Design.
Starting Method.
. Onan
. T wo
. 49 8 (816 cm )
. 3.25 inch (82.5 mm)
... 3.00 inch (76.2 mm)
.. 5.5 to 1
... 1800 i pm
Four Cycle, Air Cooled, L-Head, Horizontally Opposed
. Exciter Cranking (Generator)
GENERATOR DETAILS
Manufacturer. Onan
Generator Design. Revolving Armature, Four Pole. 1800 rpm
Rating (Watts)
4.0 CCK. 4000
5.0 CCK. 5000
Voltage (AC). 120/240 Volts
Current Rating (Amperes)
4.0 CCK
120 Volts. 33.3
240 Volts. 16.7
5.0 CCK
120 Volts. 41.6
240 Volts. 20.8
Phase. Single
Output Wires. Four Wire, Reconnectible
Output Rating. Unity Power Factor
Cranking Current.. 75-100 Amperes
Break-away Current. 300-350 Amperes
CAPACITIES AND REQUIREMENTS
Oil Capacity.
Recommended Battery.
Battery Charged Rate Fixed .
Average Fuel Consumption @ Rated Load
4.0 CCK.
5.0 CCK.
Air Inlet Size Required (Minimum)
4.0 CCK.
5.0 CCK.
. 4 Quarts (3.78 Litres)
12 Volt, 74 Amp/hr (266.40 kC)
. 1-1-1/2 amperes
.0.88 gph
.1 05 gph
. 100 in 2 (645 cm 2 )
. 100 in 1 ' (645 cm 2 )
TUNE-UP SPECIFICATIONS
Spark Plug Gap.
Breaker Point Gap.
Ignition Timing.
Valve Tappet Adjustment
Intake.
Exhaust.
.025 inch (0.64 mm)
.020 inch (0.51 mm)
. 19° BTC
.007 inch (0.18 mm)
.016 inch (0.41 mm)
3

INSTALLATION CHECKS
INSTALLATION
Nearly all Onan electric generating sets are installed
by the motor home manufacturer. Although the
manufacturer must follow safety codes when install¬
ing, certain installation problems could arise after the
unit is installed and subjected to vibration. There are a
few areas that you as the operator should be concern¬
ed with. If in doubt about any aspect of your generator
set’s operation or safety, contact your nearest
authorized Onan Service Center. A daily inspection of
your installation should include the following:
EXHAUST
Check for leaks around manifolds, gaskets, and
welds. Make sure exhaust lines are not heating
surrounding areas excessively. If so, have corrected
immediately. Remember EXHAUST GASES CON¬
TAIN DEADLY CARBON MONOXIDE. Be sure all
holes to the inside of RV from set compartment are
sealed to prevent poisonous exhaust gases from
entering vehicles.
WARNING Ail exhaus * shielding supplied with unit
MUST be properly installed to prevent
overheating of compartment walls or the possibility of fire.
FUEL SYSTEM
With set running, check for leaks. Raw fuel will cause
fumes which could EXPLODE. Check around car¬
buretor and fuel pump inlets. Make sure fuel lines are
not rubbing against anything which could cause
breakage.
ELECTRICAL
AC Output: All AC leads (Ml, M2, M3 and M4)
terminate in generator sets junction box. These wires
should be connected to distribution box witi. mul¬
tistrand wire enclosed in a flexible conduit. Check all
wires (to and from the generator set) for fraying and
loose connections. For information on load connec¬
tions refer to operation section following.
Battery Connections: Battery positive (+) connection
connects to start solenoid. Battery negative connects
to location on rear of generator. Check terminals on
set and battery for clean and tight connections.
WARNING I Separate installation area or compartment
from living quarters by a vapor-tight wall to
prevent entrance of noxious fumes to interior.
3 MOUNTING HOLES FOR
4 MOUNTING HOLES FOR
MOUNTING PLATE
EXH MANIFOLD AND EXTENSION
Pf>E OPTIONAL LOCATION
REMOTE TERM BLOCK
iNTROL PANEL
-AIR CLEANER
OUTPUT BOX
a KNOCKOUTS
■ 8ATT POS TERM
-FUEL INLET Vq NPTF
AIR
-BATT NEG TERM
MODEL NO.
MODEL NC.W/PLATE
DIM A DRY WT.
4L0CCK-3CR/I6000S
4.0CCK-3CR/
29.06(738) 290 LBS (131 kg)
5.0CCK-3CR/I6000S
5.0CCK-3CR/
31.44(799)
315 LBS (142 kg)
ARE MILLIMETRES
FIGURE 2. INSTALLATION OUTLINE
4

Do NOT use maintenance free, unvented
batteries with this generator set. Malfunction
of the starting-charging system can produce high charging
currents, causing excessive gassing. An unvented battery can build
up sufficient pressure to explode.
Grounding: Generator must be effectively bonded to
recreational vehicle chassis.
Vehicle chassis (frame) ground and the battery and generator set
ground should all be electrically connected to be at 0 ground
potential. All Onan units are designed for negative ground
application.
Mount the battery in a separate compartment
from the set or any spark-producing device to
prevent fire or explosion.
VENTILATION
The biggest enemy of electric generating sets in¬
stalled in motor homes is excessive heat. Make sure
the set’s air inlet and outlet are not plugged with dust,
dirt, bugs, leaves or anything that could restrict
cooling air.
Don’t use discharged cooling air for compart¬
ment heating since it could contain
poisonous exhaust gases.
Do not terminate exhaust under vehicle, as
carbon monoxide gas is poisonous. Direct
exhaust gases away from window and door openings.
I wad|ji||/; On all listed models with exhaust shielding
supplied with unit, shielding MUST be
property installed to prevent overheating of compartment walls or
the possibility of fire. Refer to appropriate installation guide for
each model for details.
DO NOT DISCONNECT BATTERY CABLES
FROM BATTERY WHILE GENERATOR SET
IS CRANKING OR RUNNING; SPARKS MAY CAUSE AN EXPLO¬
SION.
FIGURE 3. BATTERY AND GROUND CONNECTION
5

OPERATION
[BEFORE STARTING
[Crankcase Oil
Oil capacity of the CCK generator set is 4 U.S. quarts
(3.79 lit). Fill the crankcase until the oil reaches the
“FULL” mark on the oil level indicator (Fiqure 4) DO
NOT OVERFILL.
WARNING | Do NOT check oil whi *e t he generator set is
hhhhmhJ operating. Hot oil could cause bums by
: blowing out of oil fill tube due to crankcase pressure.
CAP AND OIL
LEVEL INDICATOR;
KEEP OIL
AT THIS LEVEL
NEVER OPERATE
ENGINE WITH OIL
BELOW THIS LEVEI_
ALWAYS REPLACE
CAP TIGHTLY, OR
OIL LEAKAGE MAY
OCCUR.
Check oil level daily and change oil every 100 normal
operating hours. See Figure 5 for location of oil drain.
If operating in extremely dustyordirtyconditions, the
oil might have to be changed sooner. When adding oil
between changes, use the same brand as in the
crankcase. Various brands of oil might not be com¬
patible when mixed.
TEMPERATURE fiBinc
Below 0°F (-18° C) .5W or 5W-30
0° to 32° F (-18° C to 0°C) .lOW or 10W-40
Above 32° F (0°C) . 30
Oil consumption may be higher with a multigrade oil
than with a single-grade oil if both oils have com¬
parable viscosities at 210°F (99° C). Therefore, single
grade oils are generally more desirable unless an¬
ticipating a wide range of temperatures. Use the
proper grade oil for the expected conditions.
Use of the same grade and quality oil as that used in
your recreational vehicle engine is acceptable as long
as unit is serviced regularly and oil meets API
designation SE or SE/CC. Other factors (primarily
temperature) should also be considered when selec¬
ting appropriate engine oil.
FIGURE 4. CHECKING OIL LEVEL
Use a heavy duty oil with the API (American
Petroleum Institute) designation SE or SE/CC
(gasoline operation only). If this oil is not available,
SD or SD/CC designated oil can be used.
FIGURE 5. OIL DRAIN AND FILL
Recommended Fuel
All Onan AC electric generating sets for recreational
vehicles use gasoline fuel. Because any AC electric
generating set runs at a constant speed, lead deposits
tend to build up in the combustion chambers. Forthis
reason, use clean, fresh, lead free or low-lead gas¬
oline. Regular grade gasoline may also be used, but
DO NOT use highly leaded premium types of fuel.
For new engines, the most satisfactory results are
obtained by using nonleaded gasoline. For older
engines that have previously used leaded gasoline,
the cylinder heads must be taken off and all lead
deposits removed from engine before switching to
nonleaded gasoline.
leaded gasoline, if
damage.
Lead deposits must be removed from an
engine before switching from leaded to non-
not, preignition can occur causing engine
| WARNING \ ^ a so * s n e leakage to or around the compart-
ment is a definite hazard. The ventilation
system should provide a constant flow of air to expei any
accumulation of fuel vapor while the vehicle is in transit. Com¬
partments must be vapor tight to the interior to keep fumes from
within the vehicle.
8

starting
Push the start-stop switch to the start position.
Release the switch when engine starts. If engine fails
to start, inhibitor oil used at the factory may have
fouled the spark plugs. Remove the plugs, clean in a
suitable solvent, dry thoroughly and re-install. Heavy
exhaust smoke when the engine is first started is
normal and caused by the inhibitor oil.
CONTROL FUSES
A 5 amp. 32 volt fuse (F2) is connected in the ignition circuit of the
control. If unit cranks but fails to start when switch SI is pushed,
ch»*ck fuse F2. It remote battery condition meter does not operate.
< h« c k fuse FI.
STOPPING
Push the start-stop switch to the stop position and
hold until unit stops completely.
BREAK-IN PROCEDURE
Controlled break-in with the proper oil and a con¬
scientiously applied maintenance program will help
to assure satisfactory service from yourOnan electric
generating set. Break-in as follows:
1. O n e half hour at 1/2 load (with one air conditioner
only).
2 One half hour ai3/4 load (with one air conditioner
and approximately 1000 watts additional load).
3. Change crankcase oil after the first 50 hours of
operation.
APPLYING LOAD
If practical, allow set to warm up before connecting a
heavy load. Continuous generator overloading may
cause high operating temperatures that can damage
the windings. Keep the load within nameplate rating.
VOLTAGE SELECTION
Voltage selection on reconnectible single-phase
generators is for use as 120/240 volts, 3 wire; or 120
volts, 2 wire. Use the connection for two-wire service
when one load exceeds one half the rated capacity.
Balance the load when connecting for three wire
service. Current for any one output lead must not
exceed nameplate rating. When two or more single¬
phase circuits are available, divide the load equally
between them. See Figure 6.
LOAD CONNECTIONS
1. Generator set load wires Ml, M2, M3 and M4
terminate within the junction box. Connect and
join wires within junction box in an approved
manner for desired voltage code. See Figure 6.
2. Wires must be adequate size, properly insulated'
and supported.
3. Mount switches and controls securely to prevent
damage from vibration and road shocks. All
switches must be vibration proof to prevent
accidental opening or closing while the vehic e is
in motion.
4. A ll wiring must meet applicable local electrical
codes. Have a qualified electrician install ano
inspect the wiring.
EXERCISE
Infrequent use results in hard starting. Operate the
generator set one 30-minute period each week. Run
longer if battery needs charging. Exercising for one
long period each week is better than several short
periods.
BATTERY CHARGING
The battery charge rate is automatically controlled by
a solid-state voltage regulator. The high charge rate
was set at the factory for average operating con¬
ditions.
HIGH OPERATING TEMPERATURES
1. See that nothing obstructs air flow to and from the
set.
2. Keep cooling fins clean. Air housing should be
properly installed and undamaged.
3. Keep ignition timing properly adjusted.
LOW OPERATING TEMPERA’’ URES
1. Use correct SAE oil for tempera e conditions.
Change oil only when engine is warm. If an
unexpected temperature drop causes an
emergency, move vehicle to a warm location.
2. Use fresh gasoline. Protect against moisture
condensation. Below 0°F (-18°C), adjust car¬
buretor main jet for a slightly richer fuel mixture.
3. Keep ignition system clean, properly adjusted
and batteries in a well charged condition.
4. Partially restrict cool airflow, but use care to avoid
overheating.
OPERATION IN DUST AND DIRT
1. Keep unit 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 com¬
mutator, do not remove normal dark brown film.
Do not polish.
HIGH ALTITUDES
For operation at altitudes of 2500 feet (775 m) above
sea level, close carburetor main jet adjustment slight¬
ly to maintain proper air-to-fue! ratio (refer to the
ADJUSTMENTS section). Maximum power will be
reduced approximately four percent for each 1000
feet (310 m) above sea level after the first 1000 feet.

POWER REQUIREMENTS FOR APPLIANCES
Appliance or Approximate
Tool Running Wattage
Refrigerator.. 600-1000
Electric broom . 200-500
Coffee percolator. 550-700
Electric frying pan. 1000-1350
Hairdryer. 350-500
Electric stove (per element). 350-1000
Electric iron. 500-1200
Radio. 50-200
Electric water heater. 1 0 0 0-1500
Space heater. 1000-1500
Electric blanket. 50-200
Television. 200-600
Electric drill. 250-750
Battery charger. Up to 800
Electric water pump. 500-600
Air Conditioner.1400-2200
Converter. 300-350
FIGURE 6. SINGLE-PHASE, “-3C” VOLTAGE CODE GENERATOR CONNECTIONS