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MCCK Series
Onan MCCK Series User Manual
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Service
Manual
Engine
927-0752
RCCK
SPEC
A
WCCK
Spec
A-H
5-a4
Prinled
in
U.S.A.
Redistribution or publication of this document
by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
2
Table of Contents
Safety Precautions
2
Table of Contents
3
General Information
4
Engine Model Reference
4
Specifications
5
Dimensions and Clearances
6
Assembly Torques
8
Special Tools
8
Engine Troubleshooting
9
Mounting
10
Ventilation
10
Connect to the Load
10
RCCK Installation
10
Clutch Installation
11
Flexible Coupling
11
Battery Connections
12
Gasoline Carburetors
13
Checking Float Level
13
RCCK Fuel System
13
Thermal Magnetic Choke
14
Fuel Pump
15
Fuel Pump Reconditioning
15
Fuel Pump Assembly
15
Adjustable Governor
16
Linkage
16
Speed Adjustment
16
Sensitivity Adjustment
16
Adjusting Sidedraft Carburetor
17
Carburetor Adjustments
17
Throttle Stop Screw Setting
18
Float Adjustment
18
Carburetor Overhaul
20
Downdraft Lua Carburetor Assembly
20
Mixture Needle Inspection
21
Fuel Pump Test
22
Electric Fuel Pump
22
Fuel Pump Repair
22
Removal of Plunger Assembly
22
Mechanical Fuel Pump
23
Exploded View of Pump
23
Fuel Filter
24
Automatic Chokes
24
Thermo-Magnetic Chokes Assembly
25
Thermo-Magnetic Chokes
25
Thermo-Magnetic Chokes Settings and Adjustments
25
Electric Choke
26
Choke Specifications
26
Fixed Speed Governor
28
Vacuum-Booster Adjustment
29
Ignition Coil
30
Breaker Points
30
Ignition Timing
30
Ignition System
30
Spark Plugs
31
Ignition Timing - Engine Not Running
31
Battery Charging, Alternators
32
15 Amp Flywheel Alternator System
32
Battery Care
32
Battery Charging System
32
Testing Phelon 15 Amp System
33
20 Amp Flywheel Alternator System
33
Testing Alternator
34
Testing Regulator Assembly
34
No Output- Stator Assembly
34
Checking Rectifier Assembly
34
Oil System
35
Oil Bypass Valve
35
Oil Pressure
35
Oil Pressure Pump Assembly
35
Crankcase Breather Rcck and Mock
36
Crankcase Breather Mock
36
RCCK Cooling System
37
MCCK Cooling System
38
High Water Temperature Cut-Off Switch
39
Water Pump
39
Starter
43
Solenoid-Shift Starter
43
Gear-Drive Starter
43
Starting System
43
Pinion Clearance
44
Drive Pinion
44
Electric Starter Inspection and Troubleshooting
46
Field Coil Ground Test
47
Test for Open Field Coil
47
Brush Wear Limits
47
Measuring Brush Spring Tension
47
Gear Cover
48
Flywheel
48
Engine Disassembly
48
Governor Cup
49
Timing Gears
49
Cylinder Heads
50
Valves
50
Cylinder Head Bolt Torque Sequence
50
Timing Gear Removal and Installation
50
Tappet Adjustment
51
Piston and Rings
51
Valve Face and Seat Angles
51
Wear Ridge on Cylinder Wall
52
Cleaning Piston Ring Grooves
52
Inspecting Ring Lands
52
Fitting Piston Rings to Cylinder
53
New Ring in Worn Piston Ring Groove
53
Connecting Rods
53
Cylinder Block Inspection
54
Cylinder Bore Measurement
54
Honing Procedure
55
Honing Cylinder
55
Correct Hone Finish
55
Bearings
56
Oil Seals
56
Camshaft
56
Crankshaft Endplay
57
Oil Pump
57
Measuring Crankshaft Endplay
57
Wiring Diagram
58
4
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Onan MCCK Series Specifications
General
Cylinders
2
Fuel Type
Gasoline
Governor Type
Mechanical
Starting
Electric
Lubrication System
Pressure
Rotation
Counterclockwise
Bore
3.25 in. (82.6 mm)
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