Onan CCK Series User Manual

Keep the manual available for quick reference.

How to request service information, specifying necessary details.

Details the manufacturer's warranty terms and limitations.

States the purpose of the manual and its applicability to CCK series plants.

Defines the designation of the engine end, left, and right sides of the plant.

Describes different types of plants: portable, manual, and remote control.

Describes the engine's configuration: 2-cylinder, air-cooled, 4-stroke, L-head.

Explains the governor's function and its external adjustability.

Details the generator as revolving armature, self-excited, and two primary sizes.

Outlines manual controls for manual and portable plants.

Details controls for AC remote type plants, including electric choke and start switch.

Describes kits for converting the plant to use gaseous fuels like Butane or Propane.

Controls for automatic start/stop and power transfer during outages.

Details underground fuel tank options, lines, and two-wheel dollies.

Details a day tank for quick starting and cold weather shutters.

Warning about poisonous exhaust gases and operating the plant safely.

Guidance on selecting an optimal location based on temperature and ensuring ventilation.

Instructions for securely mounting the plant in a vehicle with safety notes.

Provides instructions for ensuring adequate ventilation for pressure-cooled plants.

Details requirements for installing a permanent mounting base for the plant.

Instructions for positioning and installing the mounting base and cushions.

Guidance on piping exhaust gases safely outside the enclosure.

Instructions for exhaust pipe installation, including condensation traps.

Describes the installation of an oil drain extension for cleaner oil changes.

Instructions for connecting a 12-volt battery for AC remote control plants.

Instructions for connecting a 12-volt battery for magnet service plants.

Details the connection of start and ignition switches for magnet service plants.

Instructions for connecting load wires for magnet service plants.

Instructions for connecting load wires to AC remote plants.

How to connect load wires for single-phase, two-wire AC remote plants.

Diagrams and instructions for single-phase, two-wire connections.

Diagrams and instructions for single-phase, three-wire connections.

Diagrams and instructions for three-phase, three-wire connections.

How to connect load wires for single-phase, three-wire AC remote plants.

How to connect load wires for three-phase, three-wire AC remote plants.

Describes the 4-wire plant for single and three-phase current.

Instructions for connecting load wires on AC manual plants.

Instructions for connecting load wires on AC portable plants.

Guidance on grounding the generator plant and branch circuits for safety and code compliance.

Instructions for connecting remote control switches for starting/stopping plants.

Instructions for installing the separate 5-gallon fuel tank.

Compliance with local codes for underground fuel tank installations.

Details the installation of an auxiliary gravity feed fuel tank.

Describes the optional welded tubular steel frame and two-wheel dolly.

Refers to a separate section for Readi-Pull starter installation and maintenance.

Instructions for installing the gas regulator and its components.

Details the installation of Vacu-Flo cooling for small enclosures.

Instructions for checking and maintaining the crankcase oil level.

Warning not to start or operate until properly prepared with oil and fuel.

Guidance on using detergent oils and recommended SAE numbers for lubrication.

Note on using SAE 5W oil diluted with kerosene for temperatures below 0°F.

Instructions for lubricating the governor arm ball joint.

Instructions for adding oil to the air cleaner cup.

Guidance on filling the fuel tank with clean, fresh gasoline, with safety warnings.

Instructions for gas fuel operation, including spark plug gap and regulator adjustment.

Steps to perform before the initial start, including cleaning spark plugs.

Procedure for starting AC remote control plants, including priming.

Instructions for starting magnet service plants using the ignition switch.

How to start a remote control plant manually if the battery is low.

Procedure for starting manual and portable plants, including choke adjustment.

Guidance on applying load to the plant, including warming up and step-by-step application.

Instructions for adjusting the rheostat for magnet service plants.

Explanation of automatic battery charge rate control and adjustment.

Procedures for stopping manual, portable, and AC remote control plants.

Steps to switch engines from gas to gasoline operation.

Explains the function of controls during remote plant starting using a flowchart.

Details operation of dual purpose plants, including charge rate and load limits.

Precautions and maintenance for operating in low temperatures.

Specific lubrication advice for cold weather conditions.

Fuel recommendations for cold weather starting.

Air cleaner maintenance when frost forms.

Ignition system preparation for cold weather starting.

Battery care and charging for cold weather to prevent freezing.

Readjustment of electric choke for easier starting at lower temperatures.

Ensuring proper airflow for cooling, with caution against overheating.

Maintenance and operational considerations for high temperatures.

Lubrication advice for continuous operation in high temperatures.

Ensuring proper cooling airflow and component condition in high heat.

Modifying battery electrolyte for high temperatures to lengthen life.

Maintenance practices to combat dust and dirt contamination.

Keeping the engine and generator clean in dusty conditions.

Adjusting oil change intervals for dusty operating conditions.

Reminder to provide model and serial numbers for service information.

Daily service tasks to be performed if operated more than 8 hours daily.

Checking fuel supply frequently to avoid running out.

Instructions for checking and maintaining the crankcase oil level.

Instructions for servicing the air cleaner cup.

Importance of keeping the plant clean for better service.

Services to perform each 100 hours of operation if operated over 50 hours weekly.

Guidelines for changing crankcase oil based on usage and fuel type.

Detailed instructions for cleaning the air cleaner element and cup.

Lubrication instructions for the governor linkage and ball joint.

Procedure for cleaning and resetting spark plugs.

Battery connection, electrolyte level, and checking charge condition.

Lubrication of dolly wheel bearings.

Services to perform each 200 hours of operation if operated over 200 hours monthly.

Draining fuel tank, cleaning shut-off valve and filter screen.

Inspecting, dressing, and adjusting breaker points.

Inspecting exhaust line connections for leaks or damage.

Importance of regular carbon removal for engine efficiency.

When valve grinding is needed and how to check compression.

Service instructions for the crankcase breather valve.

Generator maintenance: checking commutator, collector rings, and brushes.

Importance of brush rig position to prevent arcing and ensure proper operation.

Information about the pre-lubricated and sealed generator bearing.

States that satisfactory performance depends on correct adjustments.

Explains governor and booster adjustments for speed control.

Steps for making final governor adjustments after warming up the plant.

Brief steps for governor and carburetor adjustments.

Adjusting the linkage between the governor arm and throttle shaft.

Adjusting governor spring tension for rated speed and voltage.

Chart for checking governor regulation by voltage for DC plants.

Chart for checking governor regulation by speed for DC plants.

Chart for checking AC governor regulation by voltage.

Chart for checking AC governor regulation by speed.

Adjusting sensitivity for closest regulation without hunting.

Setting the throttle idle stop screw to prevent hunting.

Adjusting the speed booster for stable output voltage under load.

Adjusting oil pressure using the relief valve adjustment screw.

Carburetor adjustments for best stability at full load and idle.

Carburetor adjustments for gas fuel operation.

Adjusting the electric choke setting for optimal starting.

Table providing approximate choke plate settings for various temperatures.

General advice on engine and generator repair by competent mechanics.

A table listing minimum and maximum clearances for engine parts.

Table of assembly torques for various engine components.

Covers carburetor maintenance and magneto stator installation.

Carburetor maintenance, including cleaning and float level adjustment.

Instructions for mounting and connecting the magneto stator.

Coil connections for magneto and battery ignition plants.

Procedure for setting ignition timing for magneto and battery ignition.

Instructions for removing and handling the flywheel.

Procedures for valve servicing, including grinding and replacement.

How to adjust valve tappets for proper clearance.

Instructions for removing and installing the gear cover.

Instructions for removing, inspecting, and installing the governor cup.

Procedures for replacing crankshaft and camshaft gears.

Cylinder wear, rebore, and piston/ring replacement.

Inspecting, cleaning, and installing pistons and rings.

Servicing connecting rods, bearing surfaces, and clearance.

Removal, installation, and types of camshaft and crankshaft bearings.

Instructions for replacing oil seals in the gear cover and bearing plate.

Inspecting crankshaft journals and refinishing for bearing fit.

Procedure for removing, checking, and priming the oil pump.

Checking, repairing, or replacing the diaphragm fuel pump.

Importance of using new gaskets during reassembly.

How to test the ignition coil using a tester.

General generator care and when to seek professional help.

Step-by-step procedure for disassembling the generator.

Inspecting and replacing worn brushes and springs.

Checking and aligning the brush rig for proper operation.

Refinishing collector rings when grooved or rough.

Undercutting mica on the commutator for proper brush contact.

Using test lamps and growlers to test windings.

Procedure for testing the armature for grounded conditions.

Testing AC and DC windings for open circuits.

Testing the armature for short circuits using a growler.

General procedure for testing field windings.

Testing field windings for ground faults.

Testing field windings for open circuits.

Replacing armature ball bearings.

Reassembling the generator, ensuring proper fit and torque.

Replacing defective control equipment and checking connections.

Instructions for servicing the Readi-Pull starter assembly.

Caution regarding potential injury from unwinding recoil spring.

Instructions for installing the complete starter kit for units prior to Spec. D.

Instructions for installing the starter for units beginning Spec. D.

Possible causes and remedies for stiff engine cranking.

Causes and remedies for slow electric cranking.

Common causes and solutions for failure to start after cranking.

Causes and remedies for voltage not building up.

Causes and remedies for unsteady voltage.

Causes and remedies for generator overheating.

Causes and remedies for engine overheating.

Causes and remedies for voltage drops under heavy load.

Causes and remedies for engine misfires at light load.

Causes and remedies for engine misfires at heavy load.

Causes and remedies for misfires under all load conditions.

Causes and remedies for low oil pressure.

Causes and remedies for high oil pressure.

Causes and remedies for engine backfiring at the carburetor.

Causes and remedies for excessive oil consumption and light blue exhaust.

Causes and remedies for black smoke, high fuel use, and low power.

Continued causes and remedies for smoke, fuel use, and power issues.

Causes and remedies for light pounding knocks.

Causes and remedies for the engine stopping unexpectedly.

Causes and remedies for dull metallic thuds.

Causes and remedies for sharp metallic thuds, especially on cold starts.

Causes and remedies for pinging sounds under load.

Causes and remedies for tapping sounds.

Causes and remedies for hollow clicking sounds on cool engines.

Causes and remedies for low voltage at the far end of the line.

Causes and remedies for motor issues related to line distance.

Causes and remedies for noisy brushes.

Causes and remedies for excessive brush arcing.

Causes and remedies for spark plugs fouling quickly on gasoline.

Causes and remedies for starting and operational issues on gas fuel.