Onan CCK Series - Adjustment, Electric Choke; Disassembly and Repair; Assembly

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Table of Contents3
General Information4
How to Interpret MODEL and SPEC. NO.4
Typical Model CCK4
Specifications5
Model Series5
Assembly Torques6
Torque Specifications (Foot Pounds)6
Dimensions and Clearances7
Service and Maintenance8
Crankcase Oil8
Speed Booster8
Air Cleaner8
Fuel Sediment9
Gasoline Fuel9
Operator Maintenance Schedule9
Critical Maintenance Schedule9
Troubleshooting10
Adjustments11
Check Breaker Points11
Carburetor11
Ignition Timing11
Electric Choke Adjustment12
Governor and Speed-Booster Adjustments12
Electric Choke13
Governor and Booster13
Governor13
Voltage Chart for Checking Governor Regulation13
Linkage14
Speed Adjustment14
Sensitivity Adjustment14
Speed-Booster14
Engine Disassembly15
General15
Disassembly15
Assembly (Use Genuine ONAN Parts)15
Testing and Adjusting Plants16
Preparation16
Operation16
Fuel System17
Choke17
Fuel Inlet Valve17
Automatic Electric Choke17
Adjustment, Electric Choke18
Disassembly and Repair18
Assembly18
Ignition System19
Magneto Stator Installation19
Ignition Coil Installation (Engines Without Spark Advance Mechanism)19
Timing Ignition (Engines Without Spark Advance Mechanism)19
Timing Ignition (Engines with Spark Advance Mechanism)20
Timing Marks on Flywheel20
Timing Marks on Gear Cover20
Timing Marks on both Gear Cover and Flywheel20
Spark Advance Mechanism21
Testing Ignition Coil21
Timing Ignition (Vacu-Flo Units)21
Spark Advance Mechanism (Vacu-Flo Units)21
Condenser22
Coil22
Spark Plugs22
Governor System23
Cleaning Speed Booster23
Valves24
Valve Grinding and Adjusting24
Tappet Adjustment25
Internal Disassembly26
Gear Cover26
Governor Cup26
Timing Gears26
Pistons and Rings27
Removing Crankshaft Gear27
Timing Marks27
Fitting Piston Rings to the Cylinder27
Connecting Rods28
Crankshaft28
Dressing Conecting Rod Cap Ends28
Crankshaft Endplay28
Bearings29
Camshaft and Crankshaft Bearings29
Gear Cover and Rear Bearing Plate Oil Seals29
Oil Pump30
Oil Pressure Relief Valve Adjustment30
Cylinder30
Cylinder Heads30
Head Bolt Tightening Order31
Manual Starter32
Readi-Pull Starter32
Installing the Starter32
Units Prior to Spec. D32
Installing Starter on Engine (Prior Spec D)33
Units Beginning Spec. D34
Installing Starter Kit (Spec D and Later)34
Generator Maintenance35
Brushes and Springs35
Brush Rig Position35
Collector Rings35
Exception - Generators with 4 Slip Rings36
Generator Disassembly36
Undercutting Commutator Mica36
Test Circuit36
Armature Short Circuit Test37
Testing Field Windings37
Testing Field Winding for Grounds37
Testing Field Windings for Open Circuit37
Control System38
Wiring Diagrams39
Generator Wiring Diagrams40
Revolving Armature 2-Wire, Single Phase40
Revolving Armature 3-Wire, Single Phase40
Revolving Armature Reconnectible for 120, 240 or 120-240 Volts, Single Phase (CCK-3CR)40
Typical Wiring Diagram of Magneto Ignition Used on Manual and Portable Type Plants41
#611B244 #611B276 Wiring Diagram 250-Volt - DC Magnet Service 12-Volt Starter41
Wiring Diagram #602B144 Portable Type Plant with Carrying Frame - 120-Volt AC. 1-Phase. 3-Wire42
Wiring Diagram #602B147 Portable Type Plant with Carrying Frame, Alternating Current, 240-Volt, 3-Phase, 3-Wire42
Wiring Diagram #611C164 Remote Type Plant, Alternating Current 120/240-Volt, 3-Wire, 1-Phase43
Wiring Diagram #602B164 250-Volt, Direct Current 6-Volt Starter Vacu Flo Magnet Service43
Wiring Diagram No. 611C234 Dual Purpose Type Plant 120-Volt AC, 32-Volt DC44
Wiring Diagram #602B165 Portable Type Plant 115-Volt DC44
Wiring Diagram #611C176 Remote Type Plant, Alternating Current 120-Volt 2-Wire, and 240-Volt 2-Wire, 1-Phase45
Wiring Diagram #602B143 Manual Type Plant, Not in Carrying Frame Alternating Current, 1-Or 3-Phase, 2-Or 3-Wire45
Wiring Diagram #611C178 Remote Type Plant, Alternating Current 240-Volt, 3-Wire, 3-Phase46
Wiring Diagram #602B146 Portable Type Plant with Carrying Frame - 120/240-Volt AC. 1-Phase, 3-Wire46
#602A166 #602A174 Wiring Diagram 250-Volt, DC Magnet Service Manual Start47
Wiring Diagram #602B145 Portable Type Plant with Carrying Frame - 240-Volt AC, 4-Phase, 2-Wire47
Wiring Diagram 611C206 Remote Type Plant, Alternating Current, 120/208-Volt, 4-Wire, 3-Phase48
Wiring Diagram #602B160 120/208 Volt AC, 3-Phase 4 Wire48
Wiring Diagram #611C235 32-Volt Remote Start 120/240 Volt Remote Start 120/240 Volt AC, 750 Watt49
Wiring Diagram #611C236 Reconnectible, 120/240 Volt AC, 4-Wire50

Onan CCK Series - Adjustment, Electric Choke; Disassembly and Repair; Assembly

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