Onan MCCK Instruction Manual

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MANUAL
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CATALOG
ONAN
2515 UNIVERSITY AVE. S.E.
MINNEAPOLIS, MINN. 55414
A DIVISION OFSTUDEBAKER CORPORATION
IN CANADA: ONAN GENERATORS CANADA LTD., P.O. BOX 652, GUELPH, ONTARIO

TABLE OF CONTENTS
TITLE PAGE
Installation 7
Operation
Adjustments 17
Maintenance 20
Trouble Shooting 22
Parts Catalog 25
ONAN
ELECTRIC GENERATING PLANTS
MCCK
927-350 SERIES 5AC68
PERFORMANCE
CERTIFIED
We certify that when properly installed and operated
this Onan electric plant will deliver the full power and the
voltage and frequency regulation promised by its nameplate
and published specifications. This plant has undergone several
hours of running-in and testing under realistic load conditions,
in accordance with procedures certified by an independent
testing laboratory.
2010 UNIVERSITY AV«. S.E. ■ MINNEAPOLIS, MINN. BB4U
A £>l 1/tStOH OF SrUDH^KM CORPORATE
IMPORTANT...RETURN WARRANTY CARD ATTACHED TO UNIT
*
i
£

GENERAL INFORMATION
THIS OPERATOR’S MANUAL PROVIDES INFORMATION FOR PROPER
INSTALLATION, OPERATION, AND MAINTENANCE PROCEDURES OF
YOUR ONAN UNIT. AN APPLICABLE WIRING DIAGRAM WAS ALSO IN¬
CLUDED AT TIME OF SHIPMENT. RETAIN FOR FUTURE REFERENCE!
WE SUGGEST THIS MATERIAL BE KEPT HANDY SO THAT IT CAN BE
READILY REFERRED TO WHEN NECESSARY, EITHER FOR ORDERING
PARTS OR MAKING EQUIPMENT ADJUSTMENTS.
FOR MAJOR REPAIR INFORMATION A SERVICE MANUAL IS AVAIL¬
ABLE. IF A MAJOR SERVICE MANUAL, ADDITIONAL OPERATORS
MANUAL, AND/OR WIRING DIAGRAM IS REQUIRED, CONTACT YOUR
NEAREST ONAN DISTRIBUTOR. THERE WILL BE A CHARGE FOR
THIS MATERIAL.
BE SURE TO INCLUDE COMPLETE ONAN MODEL, SPEC., AND SERIAL
NUMBER AS SHOWN ON ONAN NAMEPLATE ATTACHED TO UNIT. THIS
IS ESSENTIAL IN FURNISHING YOU WITH THE PROPER INFORMATION.
2

INTRODUCTION
When instructions in this manual refer to a specific
model of generating plant, identify the model by
referring to the MODEL AND SPECIFICATION NO.
as shown on the plant nameplate. Electrical character¬
istics are shown on the lower portion of the plant
nameplate.
How to interpret MODEL and SPEC. NO.
605MCCK-3R /
--
1 2
B
3 4
1. Factory code for general identification.
2. Specific Type:
M - MANUAL. Manually cranked. For permanent or
portable installations.
E - ELECTRIC. Electric starting at the plant
only.
R - REMOTE. Electric starting. For permanent
installation, can be connected to optional acces¬
sory 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).
TYPICAL MODEL MCCK
MANUFACTURER'S WARRANTY
The Manufacturer warrants, to the original user, that each
product of its manufacture is free from defects in material
and factory workmanship if properly installed, serviced and
operated under normal conditions according to the Manu¬
facturer's instructions.
Manufacturer's obligation under this warranty is limited to
correcting without charge at its factory any part or parts
thereof which shall be returned to its factory or one of its
Authorized Service Stations, transportation charges prepeiu,
within one year after being put into service by the original
user, and which upon examination shall disclose to U le
Manufacturer’s satisfaction t o have been originally defective.
Correction of such defects by repair to, or supplying of
replacements for defective parts, shall constitute fulfillment
of all obligations to original user.
This warranty shall not apply to any of the Manufacturer's
products which must be replaced because of normal wear
which have been subject to misuse, negligence or aeciden
or which shall have been repaired or altered outside of the
Manufacturer's factory unless authorized by the Manufacturer,
Manufacturer shall not be liable for loss, damage or expense
directly or indirectly from the use of its product or from any
cause.
The above warranty supersedes and is in lieu of all other
warraotiea, expressed or implied, and of all other liabilities
or obligations on part of Manufacturer. No person, agent or
dealer is authorized to give any warranties on behalf of the
Manufacturer nor to assume for the Manufacturer any other
liability in connection with any of ita products unless made
in writing and signed by an officer of the Manufacturer.
DATED AUGUST I, 1943
t
3

SPECIFICATIONS
Nominal dimension of plant (inches)
Height
Width
Length
Number cylinders
Displacement (cubic inch)
Cylinder bore (inches)
Piston stroke (inches)
Oil capacity
RPM (for 60-cycle)
RPM (for 50-cycle)
Compression ratio
B.H.P (1800 rpm)
Battery voltage
Battery size
SAE group 1H
Amp/hr. SAE rating, 20-hr. (nominal)
Battery charge rate, amperes
Ventilation required (cfm 1800 rpm)
Generator
Combustion
Output rated at unity power factor load
Rating (output in watts)
50-cycle AC, intermittent service
50-cycle AC, continuous service
60-cycle AC, intermittent service
60-cycle AC, continuous service
AC voltage regulation in i %
AC frequency regulation in %
Revolving armature-type generator
120/240- volt single phase model.reconnectible
Rotating - type exciter
Model Series
4MCCK 605MCCK
24
24
22
22
30
33
2
2
49.8
49.8
3-1/4
3-1/4
3
3
4 qts
4 qts
1800
1800
1500 1500
7: 1
7: 1
13.0
13.0
12 V
12 V
two, in
two, in
series
series
105
105
2-3 low
2-3 low
5-8 high
5-8 high
75
75
32
32
1-phase
1-phase
3500
5500
3500
5000
4000
6500
4000
6500
3
3
5
5
Yes
Yes
Yes
Yes
Yes
Yes
4

OPTIONAL EQUIPMENT
1. REMOTE START-STOP SWITCH
SPDT, momentary contact, center-off type.
2. SWITCH80ARD w , _ . .
Instruments to read ac amperes, and ac volts, and to break overloaded ac circuit.
Desirable information for operator. For wall mounting.
3. INSTRUMENT PANEL .
Part of plant control box assembly. Instruments to read ac amperes and ac volts,
and to break overloaded ac circuit. Desirable information for operator. Plants with
instrument panel have no room for optional ac receptacles.
4. AC RECEPTACLES
Convenience for plugging in ac loads. Plants with ac receptacles have no room for
optional instrument panel.
5. AUTOMATIC DEMAND CONTROL
Starts and stops plant automatically.
6. CONTROL-O-MATIC j ..
A ^-function automatic control which automatically starts and stops plant, supplies
current on demand and automatically runs bilge blower.
7. LOAD TRANSFER CONTROL
Controls running of plant and transfers load.
8 . HEAT EXCHANGER COOLING
Closed system using fresh water in plant.
9. LOAD TRANSFER SWITCH
Three-pole, three-position to select generator or shore power.
10 .
AQUA LIFT MUFFLER t ,
High-efficiency silencer for plants which discharge cooling water into exhaust.
able for above or below water-line installation.
Suit-
11. SEPARATE FUEL TANK
Various sizes.
12. EXHAUST LINE TEMPERATURE SWITCH
Shuts down plant if water flow fails.
13. OTHER
See your dealer.
r
5

SUPPORTS.
I MU FI
WATER LINE FROM
MANIFOLD WATER
OUTLET
HIGH WATER \
TEMP. CUT- \ Q
OFF SWITCH
-RUBBER
HOSE
_ ENGINE
GENERATOR
RUBBER
HOSE.
.PITCH
I '
■ ' - pooT RUBBER
r pE * HOSE
VENTILATED
BATTERY BOX
SEA COCK^SC"
RAW WATER LINE
-FILTER
WARNING: Do not u*e scoop type water inlet fitting*
on electric plant* using Aqualift muffler
system*.
WATER LINE
Recommended flush type
ttwu-hull fitting and water
filter.
TO
ELECTRIC
PLANT
AQUALIFT
SIPHON
BREAK
HANGER STRAPS
-VACUUM RELIEF
VALVE
"ADAPTER
''''ELBOW (2)
— RUBBER HOSE
■ •—WATER OUTLET
■ E XHAUST WATER
INJECTION ELBOW
EXHAUST OUTLET
TYPICAL
BELOW WATER LINE
INSTALLATION
L V WATER
FILTER
3^ STRAINER
V FLUSH THRU-
HULL FITTING
CAUT/OA/ /
,CLAMP ^
EXHAUST \ £ XHA{J * T
vnz? AND
HOS . E , COOLING
\ J ' WATER
^ / OUT
CLAMP -
WARNING: Install Siphon Break Kit M155K950 if exhaust
injection elbow is below load water line. Locate the Siphon
j Break at least 12” above load water line and in a vertical
i position. Remote mounting the siphon break is permissible
within a 5' radius oi water injection exhaust elbow. Vertical
position and height oi valve must be maintained.
"I" ^
BRACKET-
'BOLT
ABOVE WATER LINE
INSTALLATION
Figure I. Typical Installation
6

INSTALLATION
GENERAL
Proper installation is very important. Give attention to
the following points: Adequate generator cooling air,
discharge of circulated air, adequate fresh air, adequate
engine cooling water, discharge of circulated water, dis¬
charge of exhaust gases, electrical connections, fuel
connection, sturdy and flat floor and accessibility for
operation and service. Use this manual as a guide to
help with the installation. Refer to Typical Installation,
Figures 1 and2. For more complete instructions, request
Onan Technical Bulletin T-021.
Installations must be considered individually, and ex¬
ecuted in compliance with all regulations which may
affect the installation. The advice and guidance con¬
tained in the booklet, Fire Protection Standard for Motor
Craft: (NFPA No.302) offered by the National Fire Pro¬
tection Association International, Boston 10, Mass¬
achusetts, will be helpful to the installer of equipment
in vessels.
Figure 2. Mounting Dimensions
LOCATION
Select a dry, properly-ventilated location for the plant,
preferably near the main keel, above low-lying vapors
and free from splash from the bilge. Provide accessibility
for minor servicing operations. draining of the crankcase
lubricating oil and the cooling system.
A 2-1/2” clearance around the unit is required to permit
it to rock on its mounts without restraint. Use flexible
exhaust line, fuel line, battery cables, and electrical
wires.
To install cone-type mounting cushions (Fig.3). position
the plant on the drip pan and place the cushions under
the oil base and generator support. Always use cushions
with highest part number (part number is shown on the
cushion) on the generator end. Secure the plant, to the
drip pan with the associated hardware (Fig.3). Add thin
flat washers to maintain approximately 1/16” clearance
between snubber washer and flat washer. Cushion de¬
flection under load should be approximately 3/16”.
CAPSCREW
LOCK WASHER
FLAT WASHER
SNUBBER
GENERATOR OR
OIL BASE MOUNT¬
ING FOOT
CUSHION
MOUNTING SPACER
BUSHING
DRIP PAN
Figure 3. Cone-Type Mounting Cushion
Install two hold-down clamps to the drip pan (front and
rear or both sides). Secure the clamps to the mounting
base.
FUEL TANK AND LINES
If a separate fuel tank is used, install it so the bottom
of the tank will be less than 4 feet below the fuel pump.
To prevent siphoning if a system leak occurs, position
the tank below the level of the engine pump,or use a
siphon break system.
If a fuel tank is shared, do not connect to an existing
line at a point above the fuel supply level. This avoids
starving the plant (See Fig.4 and 5).
MOUNTING
The floor should be flat, and give support directly under
the plant mounting points.
If vertical fuel lift exceeds 4 feet, or vapor lock occurs,
install an auxiliary electric fuel pump near the fuel sup¬
ply-

Figure 4. Fuel System
Figure 5. Fuel System
Use an approved flexible rubber fuel line next to the
engine. Install the fuel supply line from near the bottom
of the supply tank to the 1/8" pipe-tapped inlet of the
fuel pump (see Fig.6).
A shut-off valve at the tank and near the plant is recom¬
mended for service convenience (Fig.6).
OIL DRAIN
The oil drain may be extended to suit the installation.
The oil base has a 1/2” pipe-tapped hole.
Figure 6. Fuel Shut-Off Valve
VENTILATION
Generating plants require fresh air for combustion and
generator cooling. Onan recommends that the ventilation
system he able to deliver 1-1/2 to 2 times the air re¬
quired by the plant. When the ventilation system depends
on wind or boat motion, use powered exhausters to pro¬
vide ventilation when the boat is not in motion. For more
information, refer to Onan Technical Bulletin T-021.
EXHAUST
See Installation, Fig.l and 2. The engine exhaust con¬
nection is 1”, pipe-tapped. Pipe exhaust gases outside
of the hull - exhaust gases are deadly poisonous ’
Install a separate exhaust line as follows:
1. Above vessel load water line.
2. Pitched downward to prevent water backflow.
3. Shield line near combustible material.
4. Use flexible hose or tubing (see Fig.l and 2).
5. For turns, use sweeping (long radius) elbows.
6. Increase one pipe size for every 10' increase in pipe
length.
Provide a tee for water line connection for wet exhaust
(Fig.7). Refer to Water Discharge Line. Raise the dry
portion of the exhaust line high enough to prevent water
back-flowing into the engine. Onan recommends using
the Aqua Lift muffler for maximum silencing efficiency
and ease of installation.
8
Figure 7. Water Outlet Connections

The recommended Neoprene muffler (silencer) is an
Elasto-Muffle brand, size mark O.and two bushings,size
AB (fits 1-5/8” O.D.). A cast iron or stainless-steel
muffler is also available. Provide a recommended (or
equal) silencer and install it near the end of the wet
exhaust line.
Caution: Dry exhaust will damage the neoprene silencer.
WATER SUPPLY LIME
A continuous supply of cooling water is required. The
water pump inlet is a hose fitting for 1/2” I.D. hose
(see Fig.8). Use a section of non-collapsible hose near
the plant (or for the entire run) to absorb vibrations. The
inside diameter of the plumbing must be at least 1/2”.
Use Permatex or other pipe sealer on all pipe fittings
in supply line to pump. Normally, the pump should de¬
liver 3.5 gallons of cooling water per minute. Measure
the discharged water flow after thermostat opens, to
be sure the supply line is large enough. Reduce resis¬
tance on pipe runs longer than 5’ by using larger in¬
side diameter plumbing. To prove suction line is air¬
tight, see that no bubbles appear in discharged water.
An air teak reduces lubrication and shortens pump im¬
peller life. Install a strainer in the water suction line
inlet where it is accessible for cleaning.
Figure B. Water Pump Inlet Ho*e
WATER DISCHARGE LIME
The 1/2” I.D. water outlet hose fitting is on the ex¬
haust manifold next to the exhaust outlet (see Fig.7).
Use plumbing at least as large as the supply line. Use
a section of hose near the plant or the entire run. Con¬
nect the line to discharge the heated water into the ex¬
haust line several feet ahead of the Aqualift or neo¬
prene silencer. Make sure water cannot back flow into
the exhaust line. See Optional Heat Exchanger Cooling.
HEAT EXCHANGER COOLING (Optional)
Closed-type cooling systems are commonly referred to
as fresh water cooling or heat exchanger cooling. Water
circulated through the engine is called fresh water, hot
water , efc. Water circulated through the heat exchanger
only is called raw water, sea water, cold water, dis¬
charged water, etc. This system with an antifreeze cool¬
ant is recommended where freezing conditions exist, or
where the owner wants to prevent the possibility of
salt water problems.
Caution: Do not use the existing neoprene impeller
water pump in the hot water side of the cooling system
Heat or soluble oil (in many rust inhibitors and anti¬
freeze s) wifi damage the impeller. Instead, connect the
neoprene impeller pump on the cold water side. Use a
metal impelter, centrifugal-type water pump (Oberdorfer
1-GP, or equal) in the fresh water side. Drive it with a
belt from the plant power take-off (see Fig-9). _
FRESH WATER FROM
MANIFOLD
HEAT
EXCHANGER RAW WATER TO
EXHAUST
MANIFOLD
CYLINDER HEAD
DETAIL B
DRAIN
J
hTOHEAT EXCHANGER
PUMP
‘TO ENGINE PUMP
-EXHAUST OUTLET
GOVERNOR ADJUSTMENT
ENGINE PUMP
OIL PRESSURE
GAGE
LOW OIL PRESSURE
CUT-OFF SWITCH
BELT
HEAT EXCHANGER
PUMP
HIGH WATER
TEMPERATURE
SWITCH
DRAIN
HEAT
EXCHANGER
.t PUMP
RAW WATER
ENGINE PUMP
TO HEAT EXCHANGER
(INSIDE FITTING)
TO HEAT EXCHANGER
(REAR FITTING)
Figure 9. Cooling System Details
9