Onan CCK Bedienungsanleitung

Orion

Service

Manual

Engines

927-0754

3-86

(Spec

A-J)

Replaces

9-84

(Spec

A-J)

Printed

USX

Safety

Precautions

recommended

that

you

read

your

engine

manual

and

become

thoroughly

acquainted

with

your

equipment

be¬

fore

you

start

the

engine.

This

symbol

used

throughout

this

manual

warn

possible

serious

persons!

injury.

This

symbol

refers

possible

equip¬

ment

damage.

Fuels,

electrical

equipment,

batteries,

exhaust

gases

and

moving

parts

present

potential

hazards

that

could

result

serious,

personal

injury.

Take

care

following

these

recommended

procedures.

’

Safety

Codes

•

All

local,

state

and

federal

codes

should

consulted

and

complied

with.

•

This

engine

not

designed

intended

for

use

aircraft.

Any

such

use

the

owner’s

sole

risk.

General

•

Provide

appropriate

fire

extinguishers

and

install

them

convenient

locations.

Use

extinguisher

rated

ABC

NFPA.

•

Make

sure

that

all

fasteners

the

engine

are

secure

and

accurately

torqued.

Keep

guards

position

over

fans,

driving

belts,

etc.

•

necessary

make

adjustments

while

the

engine

running,

use

extreme

caution

when

hot

ex¬

hausts.

moving

parts,

etc.

Protect

Against

Moving

Parts

•

not

wear

loose

clothing

the

vicinity

moving

parts,

such

PTO

shafts,

flywheels,

blowers,

coup¬

lings,

fans,

belts,

etc.

•

Keep

your

hands

away

from

moving

parts.

Batteries

•

Before

starting

work

the

engine,

disconnect

batter¬

ies

prevent

inadvertent

starting

the

engine.

•

NOT

SMOKE

white

servicing

batteries.

Lead

acid

batteries

give

off

highly

explosive

hydrogen

gas

which

can

ignited

flame,

electrical

arcing

smoking.

•

Verify

battery

polarity

before

connecting

battery

cables.

Connect

negative

cable

last.

Fuel

System

•

NOT

fill

fuel

tanks

while

engine

running.

•

NOT

smoke

use

open

flame

the

vicinity

the

engine

fuel

tank.

Internal

combustion

engine

fuels

are

highly

flammable.

Fuel

lines

must

steel

piping,

adequately

secured,

and

free

from

leaks.

Piping

the

engine

should

approved

flexible

line.

not

use

copper

piping

for

flexible

lines

copper

will

work

harden

and

become

brittle

enough

break.

•

sure

all

fuel

supplies

have

positive

shutoff

valve.

Exhaust

System

•

Exhaust

products

any

internal

combustion

engine

are

toxic

and'can

cause

injury,

death

inhaled.

All

engine

applications,

especially

those

within

confined

area,

should

equipped

with

exhaust

system

discharge

gases

the

outside

atmosphere.

•

not

use

exhaust

gases

heat

compartment.

•

Make

sure

that

your

exhaust

system

free

leaks.

Ensure

that

exhaust

manifolds

are

secure

and

are

not

warped

botts

unevenly

torqued.

Exhaust

Gas

Deadly!

Exhaust

gases

contain

carbon

monoxide,

poisonous

gas

that

might

cause

unconsciousness

and

death.

odorless

and

colorless

gas

formed

during

combustion

hydrocarbon

fuels.

Symptoms

carbon

monoxide

poi¬

soning

are:

•

Dizziness

•

Vomiting

•

Headache

•

Muscular

Twitching

•

Weakness

and

Sleepiness

•

Throbbing

Temples

you

experience

any

these

symptoms,

get

out

into

fresh

air

immediately,

shut

down

the

unit

and

not

use

until

has

been

inspected.

The

best

protection

against

carbon

monoxide

inhalation

proper

installation

and

regular,

frequent

inspections

the

complete

exhaust

system.

you

notice

change

the

sound

appearance

exhaust

system,

shut

the

unit

down

immediately

and

have

inspected

and

repaired

once

competent

mechanic.

Cooling

System

•

Coolants

under

pressure

have

higher

boiling

point

than

water.

NOT

open

radiator

pressure

cap

when

coolant

temperature

above

212°

(100°C)

while

engine

running.

Keep

the

Unit

and

Surrounding

Area

Clean

•

Make

sure

that

oily

rags

are

not

left

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

potential

fire

hazard.

E-4

Table

Contents

Genera!

Information..

Specifications

...

Dimensions

and

Clearances.4

Assembly

Torques

and

Special

Tools.

Engine

Troubleshooting.7

Starting..

Installation

Guidelines

Oil

System

Governor

System..

Fuel

System.21

Ignition

System..

Battery

Charging

System

...

Starting

System..

Manual

Starter.

Engine

Disassembly.53

Special

Equipment..

WAKNINO

INCORRECT

SERVICE

REPLACEMENT

PARTS

MIGHT

RESULT

SEVERE

PERSONAL

INJURY

AND/OR

EQUIPMENT

DAMAGE.

SERVICE

PERSONNEL

MUST

QUALIFIED

PERFORM

ELECTRICAL

AND/OR

MECHANICAL

SERVICE.

General

Information

mi-

introduction

ENGINE

MODEL

REFERENCE

This

manual

deals

with

specific

mechanical

and

elec¬

trical

information

needed

engine

mechanics

for

troubleshooting,

servicing,

repairing,

overhauling

the

engine.

Use

the

table

contents

for

quick

reference

the

separate

engine

system

sections.

The

troubleshooting

guide

provided

quick

reference

for

locating

and

correcting

engine

trouble.

The

illustrations

and

procedures

presented

each

section

apply

the

engines

listed

the

cover.

The

flywheel

end

the

engine

the

front

end

right

and

left

sides

are

determined

viewing

the

engine

from

the

front.

The

disassembly

section

contains

major

overhaul

procedures

for

step

removal,

disassembly,

inspection,

repair

and

assembly

the

engine

components.

major

repair

overhaul

necessary,

compe¬

tent

mechanic

should

either

the

job

supervise

and

check

the

work

the

mechanic

assigned

the

job

ensure

that

alt

dimensions,

clearances

and

torque

values

are

within

the

specified

tolerances.

parts

catalog

(available

the

dealer

level)

contains

detailed

exploded

views

each

assembly

and

the

individual

piece

part

numbers

and

their

proper

names

for

ordering

replacement

parts.

Use

only

Genuine

Onan

replacement

parts

ensure

quality

and

the

best

possible

repair

and

overhaul

results.

When

ordering

parts,

always

use

the

com¬

plete

Model

and

Spec

number

well

the

Serial

number

shown

the

nameplate.

Identify

your

model

referring

the

MODEL

and

SPEC

(specification)

NO.

shown

the

unit

nameplate.

Always

use

this

number

and

the

engine

serial

number

when

making

referencetoyourengine.

How

interpret

MODEL

and

SPEC

NO.

generator

set

engines.

CCK

Indicates

kilowatt

rating.

Series

identification.

Voltage

code

the

generator.

Method

starting:

A-automatic,

R-remote

elect¬

ric

starting,

and

E-electric

starting.

Factory

code

for

designating

optional

equipment,

any.

Specification

letter

which

advances

when

the

fac¬

tory

makes

production

modifications.

How

interpret

MODEL

and

SPEC

NO.

industrial

engines.

CCK

3199

Factory

code

for

general

identification

purposes.

Specific

Type*

MS-ELECTRIC

starting

with

stub

shaft,

starter

and

generator.

Factory

code

for

optional

equipment

supplied.

Specification

(Spec

Letter)

advances

with

factory

production

modification.

Specifications

This

manual

contains

metric

equivalents

that

immediately

parentheses

after

the

U.S.

customary

units

measure.

SPECIFICATION

Number

Cylinders

Bore

Stroke

Displacement

Compression

Ratio_

Rated

Speed

(Maximum)

Power

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

MEASURE

3.000

(76.2)

49.8

(816)

5.5

2700

12.9

(9.6)

Full

Flow

3.0

(2.8)0

3.5

(3.3)©

Clockwise

Mechanical

SERIES

CCKA

3.250

(82.55)

49.8

(816)

7.0

3600

Full

Flow

3.0

(2.8)0

Clockwise

Mechanical

0.007

(0.18)

0.016

(0.41)

CCKB

3.000

(76.2)

49.8

(816)

7.0

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

0.020

(Full

Separation

and

Engine

Cold)

(mm)

(0.51)

Ignition

Timing

All

Models

BTC

19°

Gaseous

Fuel

BTC

Gasoline

Fuel

BTC

24°

Gasoline

Fuel

(Static)

ATC

1°®

Gasoline

Fuel

(Static

Running)

BTC

20°

Gasoline

Fuel

Running

BTC

24°®®

24°

Add

0.5

quart

(0.47

litre)

for

electric

start

modeis.

Magneto

Ignition

With

Spark

Advance

Battery

Ignition

Magneto

Ignition

with

Spark

Advance

Dimensions

and

Clearances

All

clearances

given

room

temperature

70°F

(21

°C).

All

dimensions

Inches

(approximate

millimetre

dimensions

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

Bushing

Bore

{Without

bearing).

Piston

Bushing

Bore

with

Bearing,

0.8115

(20.61)

0.8125

(20.64)

(Finished

bore).

Bearing

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

Cylinder

0.300

(7.62)

Measure

90°

0.10

inch

below

oil

ring...

Clearance

Cylinder

(CCKB

with

112-0073

piston)

0.0025

(0.064)

0.0045

(0.114)

Measure

90°

0.10

inch

below

oil

ring..

0.0060

(0.150)

0.0080

(0300)

Piston

Bore.......

Ring

Groove

Width

0.7502

{19.055)

0.7506

(19.065)

Top

Compression

Ring

0.0960

{2.438)

0.0970

(2.464)

No.

Compression

Ring..

0.0955

{2.426)

0.0965

(2.451)

No.

Oil

Control

Ring...

0.188

(4.775)

0.189

(4.801)

DESCRIPTION

MINIMUM

MAXIMUM

PISTON

Inches

(mm)

inches

(mm)

Clearance

Piston.

Thumb

Push

Fit

Clearance

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

Cylinder.

INTAKE

VALVE

0.010

(0.254)

0.020

(0.508)

Stem

Diameter...

0.3425

(8.70)

0.3430

(8-71)

Clearance

(Stem

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

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

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)........

........

ib.

(17

kg)

ib.

(19

kg)

Spring

Load

@1.125

inch

(Valve

Open).

GEAR

BACKLASH

(32

kg)

(36

kg)

Timing

Gear.

0.002

(0.051)

0.003

(0.076)

Oil

Pump

Gear.....

0.002

(0.051)

0.005

(0.127)

Assembly

Torques

The

torque

values

given

Table

have

been

deter¬

mined

for

the

specific

applications.

Standard

torque

values

must

not

used

where

those

listed

Table

apply.

The

engine

assembly

torques

given

here

will

assure

proper

tightness

without

danger

stripping

threads.

All

threads

must

clean

and

lubricated

with

new

engine

oil

before

torquing.

Check

all

studs,

nuts,

and

capscrews,

and

tighten

required

keep

them

from

working

loose.

Refer

the

PARTS

MANUAL

for

the

location

washers

and

capscrews.

TABLE

TORQUE

DESCRIPTION

SPECIFICATION

Ft-Lb.

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

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

Guide

arid

Driver

Combination

Bearing

Remover

(Main

and

Cam)

Combination

Bearing

Driver

(Main

and

Cam)

Ffywheet

Putter

Engine

roubleshooting

Starting

PRE-STARTING

Preparations

for

the

initial

and

each

additional

star¬

ting

operation

should

include

careful

checks

the

oil,

fuel,

cooling,

and

electrical

systems.

The

cylinder

air

housing

door

should

closed

withal!

airshrouds

place.

Crankcase

Oil:

sure

the

crankcase

has

been

filled

with

oil

the

“FULL”

mark

the

oil

level

indicator,

Figure

Use

oil

with

the

API

(American

Petroleum

Institute)

designation

SE/CC.

not

use

oil

with

the

designation

unless

also

designated

and

the

oil

manufacturer

certifies

will

perform

satisfactorily

gasoline

engines.

For

gaseous

operation,

use

ashless

low-ash

detergent

oil

specifically

made

for

gaseous-fueled

engines.

CAP

AND

OIL

LEVEL

INDICATOR

KEEP

OIL

THIS

LEVEL.

NEVER

OPERATE

ENGINE

WITH

OIL

BELOW

THIS

LEVEL.

A874

-FULL

ALWAYS

REPLACE

CAP

TIGHTLY,

OIL

LEAKAGE

HAY

OCCUR.

FIGURE

OIL

LEVEL

INDICATOR

WARNING

)

Crankcase

pressure

could

blow

out

and

cause

serious

burns.

NOT

check

oil

while

the

engine

operating.

OIL

CAPACITIES

Electric

Start

3-1/2

qts.

(3.31

litre)

qts.

(3.8

litre

with

filter)

Manual

Start

qts.

(2.8

litre)

3-1/2

qts.

(3.3

litre

with

filter)

Engine

oil

should

always

bedrained

when

the

engine

warm.

Remove

pipe

plug

drain

engine

oil.

Recommended

Fuel:

Use

clean,

fresh,

regular

grade,

automotive

gasoline.

not

use

highly-leaded

premium

types.

For

new

engines,

the

most

satisfactory

results

are

obtained

using

nonleaded

gasoline.

For

older

engines

that

have

previously

used

leaded

gasoline,

heads

must

taken

off

and

all

lead

deposits

removed

from

engine

before

switching

nonleaded

gasoline.

I^CAUTION^

lead

deposits

are

not

removed

—*~*-^*-*~&

irom

engine

before

switching

from

leaded

nonleaded

gasoline,

pre-ignition

could

occur

causing

severe

damage

the

engine.

WARNING

Spilled

fuel

might

Ignite

and

cause

serious

personal

Injury

death.

Never

fill

the

fuel

tank

when

the

engine

running.

STARTING

Electric

Start

Move

the

ignition

switch

ON.

Push

the

START

button

crank

the

engine.

Manual

Start

Engine

priming

before

starting

shown

Figure

(manual

start

only).

Pull

the

choke

control

about

3/4

the

way

closed

necessary

according

temperature

con¬

ditions.

Pull

the

start

rope

with

fast

steady

pull

crank

the

engine.

not

jerk

let

rope

snap

back

under

its

own

power.

the

engine

warms

up,

adjust

the

choke

gradually

its

fully

open

position.

APPLYING

LOAD

Apply

load

new

reconditioned

engine

gradual¬

about

four

steps;

not

less

than

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

setting

the

ignition

switch

the

off

position.

Open

the

fuel

line

valve

(when

used)

and

operate

primer

assure

fuel

supply

after

filling

empty

tank.

Engines

equipped

with

magneto

ignition

are

stopped

pushing

the

stop

button

(located

the

blower

housing).

Hold

until

engine

completely

stops.

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