Onan MCCK Mode d’emploi

—

^“N

/"’N—

—

'“'

)

MANUAL

AND

CATALOG

ONAN

2515

UNIVERSITY

AVE.

S.E.

MINNEAPOLIS,

MINN.

55414

DIVISION

OFSTUDEBAKER

CORPORATION

CANADA:

ONAN

GENERATORS

CANADA

LTD.,

P.O.

BOX

652,

GUELPH,

ONTARIO

TABLE

CONTENTS

TITLE

PAGE

Installation

Operation

Adjustments

Maintenance

Trouble

Shooting

Parts

Catalog

ONAN

ELECTRIC

GENERATING

PLANTS

MCCK

927-350

SERIES

5AC68

PERFORMANCE

CERTIFIED

certify

that

when

properly

installed

and

operated

this

Onan

electric

plant

will

deliver

the

full

power

and

the

voltage

and

frequency

regulation

promised

its

nameplate

and

published

specifications.

This

plant

has

undergone

several

hours

running-in

and

testing

under

realistic

load

conditions,

accordance

with

procedures

certified

independent

testing

laboratory.

2010

UNIVERSITY

AV«.

S.E.

■

MINNEAPOLIS,

MINN.

BB4U

£>l

1/tStOH

SrUDH^KM

CORPORATE

IMPORTANT...RETURN

WARRANTY

CARD

ATTACHED

UNIT

GENERAL

INFORMATION

THIS

OPERATOR’S

MANUAL

PROVIDES

INFORMATION

FOR

PROPER

INSTALLATION,

OPERATION,

AND

MAINTENANCE

PROCEDURES

YOUR

ONAN

UNIT.

APPLICABLE

WIRING

DIAGRAM

WAS

ALSO

IN¬

CLUDED

TIME

SHIPMENT.

RETAIN

FOR

FUTURE

REFERENCE!

SUGGEST

THIS

MATERIAL

KEPT

HANDY

THAT

CAN

READILY

REFERRED

WHEN

NECESSARY,

EITHER

FOR

ORDERING

PARTS

MAKING

EQUIPMENT

ADJUSTMENTS.

FOR

MAJOR

REPAIR

INFORMATION

SERVICE

MANUAL

AVAIL¬

ABLE.

MAJOR

SERVICE

MANUAL,

ADDITIONAL

OPERATORS

MANUAL,

AND/OR

WIRING

DIAGRAM

REQUIRED,

CONTACT

YOUR

NEAREST

ONAN

DISTRIBUTOR.

THERE

WILL

CHARGE

FOR

THIS

MATERIAL.

SURE

INCLUDE

COMPLETE

ONAN

MODEL,

SPEC.,

AND

SERIAL

NUMBER

SHOWN

ONAN

NAMEPLATE

ATTACHED

UNIT.

THIS

ESSENTIAL

FURNISHING

YOU

WITH

THE

PROPER

INFORMATION.

INTRODUCTION

When

instructions

this

manual

refer

specific

model

generating

plant,

identify

the

model

referring

the

MODEL

AND

SPECIFICATION

NO.

shown

the

plant

nameplate.

Electrical

character¬

istics

are

shown

the

lower

portion

the

plant

nameplate.

How

interpret

MODEL

and

SPEC.

NO.

605MCCK-3R

Factory

code

for

general

identification.

Specific

Type:

MANUAL.

Manually

cranked.

For

permanent

portable

installations.

ELECTRIC.

Electric

starting

the

plant

only.

REMOTE.

Electric

starting.

For

permanent

installation,

can

connected

optional

acces¬

sory

equipment

for

remote

automatic

control

starting

and

stopping.

Factory

code

for

optional

equipment.

Specification

(Spec.)letter

(advances

when

factory

makes

production

modifications).

TYPICAL

MODEL

MCCK

MANUFACTURER'S

WARRANTY

The

Manufacturer

warrants,

the

original

user,

that

each

product

its

manufacture

free

from

defects

material

and

factory

workmanship

properly

installed,

serviced

and

operated

under

normal

conditions

according

the

Manu¬

facturer's

instructions.

Manufacturer's

obligation

under

this

warranty

limited

correcting

without

charge

its

factory

any

part

parts

thereof

which

shall

returned

its

factory

one

its

Authorized

Service

Stations,

transportation

charges

prepeiu,

within

one

year

after

being

put

into

service

the

original

user,

and

which

upon

examination

shall

disclose

Manufacturer’s

satisfaction

have

been

originally

defective.

Correction

such

defects

repair

to,

supplying

replacements

for

defective

parts,

shall

constitute

fulfillment

all

obligations

original

user.

This

warranty

shall

not

apply

any

the

Manufacturer's

products

which

must

replaced

because

normal

wear

which

have

been

subject

misuse,

negligence

aeciden

which

shall

have

been

repaired

altered

outside

the

Manufacturer's

factory

unless

authorized

the

Manufacturer,

Manufacturer

shall

not

liable

for

loss,

damage

expense

directly

indirectly

from

the

use

its

product

from

any

cause.

The

above

warranty

supersedes

and

lieu

all

other

warraotiea,

expressed

implied,

and

all

other

liabilities

obligations

part

Manufacturer.

person,

agent

dealer

authorized

give

any

warranties

behalf

the

Manufacturer

nor

assume

for

the

Manufacturer

any

other

liability

connection

with

any

ita

products

unless

made

writing

and

signed

officer

the

Manufacturer.

DATED

AUGUST

1943

SPECIFICATIONS

Nominal

dimension

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

Amp/hr.

SAE

rating,

20-hr.

(nominal)

Battery

charge

rate,

amperes

Ventilation

required

(cfm

1800

rpm)

Generator

Combustion

Output

rated

unity

power

factor

load

Rating

(output

watts)

50-cycle

AC,

intermittent

service

50-cycle

AC,

continuous

service

60-cycle

AC,

intermittent

service

60-cycle

AC,

continuous

service

voltage

regulation

frequency

regulation

Revolving

armature-type

generator

120/240-

volt

single

phase

model.reconnectible

Rotating

type

exciter

Model

Series

4MCCK

605MCCK

49.8

3-1/4

qts

1800

1500

13.0

two,

series

105

2-3

low

2-3

low

5-8

high

5-8

high

1-phase

3500

5500

3500

5000

4000

6500

4000

6500

Yes

OPTIONAL

EQUIPMENT

REMOTE

START-STOP

SWITCH

SPDT,

momentary

contact,

center-off

type.

SWITCH80ARD

Instruments

read

amperes,

and

volts,

and

break

overloaded

circuit.

Desirable

information

for

operator.

For

wall

mounting.

INSTRUMENT

PANEL

Part

plant

control

box

assembly.

Instruments

read

amperes

and

volts,

and

break

overloaded

circuit.

Desirable

information

for

operator.

Plants

with

instrument

panel

have

room

for

optional

receptacles.

RECEPTACLES

Convenience

for

plugging

loads.

Plants

with

receptacles

have

room

for

optional

instrument

panel.

AUTOMATIC

DEMAND

CONTROL

Starts

and

stops

plant

automatically.

CONTROL-O-MATIC

^-function

automatic

control

which

automatically

starts

and

stops

plant,

supplies

current

demand

and

automatically

runs

bilge

blower.

LOAD

TRANSFER

CONTROL

Controls

running

plant

and

transfers

load.

HEAT

EXCHANGER

COOLING

Closed

system

using

fresh

water

plant.

LOAD

TRANSFER

SWITCH

Three-pole,

three-position

select

generator

shore

power.

AQUA

LIFT

MUFFLER

High-efficiency

silencer

for

plants

which

discharge

cooling

water

into

exhaust.

able

for

above

below

water-line

installation.

Suit-

11.

SEPARATE

FUEL

TANK

Various

sizes.

12.

EXHAUST

LINE

TEMPERATURE

SWITCH

Shuts

down

plant

water

flow

fails.

13.

OTHER

See

your

dealer.

SUPPORTS.

WATER

LINE

FROM

MANIFOLD

WATER

OUTLET

HIGH

WATER

TEMP.

CUT-

OFF

SWITCH

-RUBBER

HOSE

ENGINE

GENERATOR

RUBBER

HOSE.

.PITCH

■

pooT

RUBBER

HOSE

VENTILATED

BATTERY

BOX

SEA

COCK^SC"

RAW

WATER

LINE

-FILTER

WARNING:

not

u*e

scoop

type

water

inlet

fitting*

electric

plant*

using

Aqualift

muffler

system*.

WATER

LINE

Recommended

flush

type

ttwu-hull

fitting

and

water

filter.

ELECTRIC

PLANT

AQUALIFT

SIPHON

BREAK

HANGER

STRAPS

-VACUUM

RELIEF

VALVE

"ADAPTER

''''ELBOW

(2)

—

RUBBER

HOSE

■

•—WATER

OUTLET

■

XHAUST

WATER

INJECTION

ELBOW

EXHAUST

OUTLET

TYPICAL

BELOW

WATER

LINE

INSTALLATION

WATER

FILTER

STRAINER

FLUSH

THRU-

HULL

FITTING

CAUT/OA/

,CLAMP

EXHAUST

XHA{J

vnz?

AND

HOS

COOLING

WATER

OUT

CLAMP

WARNING:

Install

Siphon

Break

Kit

M155K950

exhaust

injection

elbow

below

load

water

line.

Locate

the

Siphon

Break

least

12”

above

load

water

line

and

vertical

position.

Remote

mounting

the

siphon

break

permissible

within

radius

water

injection

exhaust

elbow.

Vertical

position

and

height

valve

must

maintained.

"I"

BRACKET-

'BOLT

ABOVE

WATER

LINE

INSTALLATION

Figure

Typical

Installation

INSTALLATION

GENERAL

Proper

installation

very

important.

Give

attention

the

following

points:

Adequate

generator

cooling

air,

discharge

circulated

air,

adequate

fresh

air,

adequate

engine

cooling

water,

discharge

circulated

water,

dis¬

charge

exhaust

gases,

electrical

connections,

fuel

connection,

sturdy

and

flat

floor

and

accessibility

for

operation

and

service.

Use

this

manual

guide

help

with

the

installation.

Refer

Typical

Installation,

Figures

and2.

For

complete

instructions,

request

Onan

Technical

Bulletin

T-021.

Installations

must

considered

individually,

and

ex¬

ecuted

compliance

with

all

regulations

which

may

affect

the

installation.

The

advice

and

guidance

con¬

tained

the

booklet,

Fire

Protection

Standard

for

Motor

Craft:

(NFPA

No.302)

offered

the

National

Fire

Pro¬

tection

Association

International,

Boston

10,

Mass¬

achusetts,

will

helpful

the

installer

equipment

vessels.

Figure

Mounting

Dimensions

LOCATION

Select

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

the

crankcase

lubricating

oil

and

the

cooling

system.

2-1/2”

clearance

around

the

unit

required

permit

rock

its

mounts

without

restraint.

Use

flexible

exhaust

line,

fuel

line,

battery

cables,

and

electrical

wires.

install

cone-type

mounting

cushions

(Fig.3).

position

the

plant

the

drip

pan

and

place

the

cushions

under

the

oil

base

and

generator

support.

Always

use

cushions

with

highest

part

number

(part

number

shown

the

cushion)

the

generator

end.

Secure

the

plant,

the

drip

pan

with

the

associated

hardware

(Fig.3).

Add

thin

flat

washers

maintain

approximately

1/16”

clearance

between

snubber

washer

and

flat

washer.

Cushion

de¬

flection

under

load

should

approximately

3/16”.

CAPSCREW

LOCK

WASHER

FLAT

WASHER

SNUBBER

GENERATOR

OIL

BASE

MOUNT¬

ING

FOOT

CUSHION

MOUNTING

SPACER

BUSHING

DRIP

PAN

Figure

Cone-Type

Mounting

Cushion

Install

two

hold-down

clamps

the

drip

pan

(front

and

rear

both

sides).

Secure

the

clamps

the

mounting

base.

FUEL

TANK

AND

LINES

separate

fuel

tank

used,

install

the

bottom

the

tank

will

less

than

feet

below

the

fuel

pump.

prevent

siphoning

system

leak

occurs,

position

the

tank

below

the

level

the

engine

pump,or

use

siphon

break

system.

fuel

tank

shared,

not

connect

existing

line

point

above

the

fuel

supply

level.

This

avoids

starving

the

plant

(See

Fig.4

and

5).

MOUNTING

The

floor

should

flat,

and

give

support

directly

under

the

plant

mounting

points.

vertical

fuel

lift

exceeds

feet,

vapor

lock

occurs,

install

auxiliary

electric

fuel

pump

near

the

fuel

sup¬

ply-

Figure

Fuel

System

Figure

Fuel

System

Use

approved

flexible

rubber

fuel

line

the

engine.

Install

the

fuel

supply

line

from

near

the

bottom

the

supply

tank

the

1/8"

pipe-tapped

inlet

the

fuel

pump

(see

Fig.6).

shut-off

valve

the

tank

and

near

the

plant

recom¬

mended

for

service

convenience

(Fig.6).

OIL

DRAIN

The

oil

drain

may

extended

suit

the

installation.

The

oil

base

has

1/2”

pipe-tapped

hole.

Figure

Fuel

Shut-Off

Valve

VENTILATION

Generating

plants

require

fresh

air

for

combustion

and

generator

cooling.

Onan

recommends

that

the

ventilation

system

able

deliver

1-1/2

times

the

air

re¬

quired

the

plant.

When

the

ventilation

system

depends

wind

boat

motion,

use

powered

exhausters

pro¬

vide

ventilation

when

the

boat

not

motion.

For

information,

refer

Onan

Technical

Bulletin

T-021.

EXHAUST

See

Installation,

Fig.l

and

The

engine

exhaust

con¬

nection

1”,

pipe-tapped.

Pipe

exhaust

gases

outside

the

hull

exhaust

gases

are

deadly

poisonous

’

Install

separate

exhaust

line

follows:

Above

vessel

load

water

line.

Pitched

downward

prevent

water

backflow.

Shield

line

near

combustible

material.

Use

flexible

hose

tubing

(see

Fig.l

and

2).

For

turns,

use

sweeping

(long

radius)

elbows.

Increase

one

pipe

size

for

every

10'

increase

pipe

length.

Provide

tee

for

water

line

connection

for

wet

exhaust

(Fig.7).

Refer

Water

Discharge

Line.

Raise

the

dry

portion

the

exhaust

line

high

enough

prevent

water

back-flowing

into

the

engine.

Onan

recommends

using

the

Aqua

Lift

muffler

for

maximum

silencing

efficiency

and

ease

installation.

Figure

Water

Outlet

Connections

The

recommended

Neoprene

muffler

(silencer)

Elasto-Muffle

brand,

size

mark

O.and

two

bushings,size

(fits

1-5/8”

O.D.).

cast

iron

stainless-steel

muffler

also

available.

Provide

recommended

(or

equal)

silencer

and

install

near

the

end

the

wet

exhaust

line.

Caution:

Dry

exhaust

will

damage

the

neoprene

silencer.

WATER

SUPPLY

LIME

continuous

supply

cooling

water

required.

The

water

pump

inlet

hose

fitting

for

1/2”

I.D.

hose

(see

Fig.8).

Use

section

non-collapsible

hose

near

the

plant

(or

for

the

entire

run)

absorb

vibrations.

The

inside

diameter

the

plumbing

must

least

1/2”.

Use

Permatex

other

pipe

sealer

all

pipe

fittings

supply

line

pump.

Normally,

the

pump

should

de¬

liver

3.5

gallons

cooling

water

per

minute.

Measure

the

discharged

water

flow

after

thermostat

opens,

sure

the

supply

line

large

enough.

Reduce

resis¬

tance

pipe

runs

longer

than

5’

using

larger

in¬

side

diameter

plumbing.

prove

suction

line

air¬

tight,

see

that

bubbles

appear

discharged

water.

air

teak

reduces

lubrication

and

shortens

pump

im¬

peller

life.

Install

strainer

the

water

suction

line

inlet

where

accessible

for

cleaning.

Figure

Water

Pump

Inlet

Ho*e

WATER

DISCHARGE

LIME

The

1/2”

I.D.

water

outlet

hose

fitting

the

ex¬

haust

manifold

the

exhaust

outlet

(see

Fig.7).

Use

plumbing

least

large

the

supply

line.

Use

section

hose

near

the

plant

the

entire

run.

Con¬

nect

the

line

discharge

the

heated

water

into

the

ex¬

haust

line

several

feet

ahead

the

Aqualift

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

fresh

water

cooling

heat

exchanger

cooling.

Water

circulated

through

the

engine

called

fresh

water,

hot

water

efc.

Water

circulated

through

the

heat

exchanger

only

called

raw

water,

sea

water,

cold

water,

dis¬

charged

water,

etc.

This

system

with

antifreeze

cool¬

ant

recommended

where

freezing

conditions

exist,

where

the

owner

wants

prevent

the

possibility

salt

water

problems.

Caution:

not

use

the

existing

neoprene

impeller

water

pump

the

hot

water

side

the

cooling

system

Heat

soluble

oil

(in

many

rust

inhibitors

and

anti¬

freeze

wifi

damage

the

impeller.

Instead,

connect

the

neoprene

impeller

pump

the

cold

water

side.

Use

metal

impelter,

centrifugal-type

water

pump

(Oberdorfer

1-GP,

equal)

the

fresh

water

side.

Drive

with

belt

from

the

plant

power

take-off

(see

Fig-9).

FRESH

WATER

FROM

MANIFOLD

HEAT

EXCHANGER

RAW

WATER

EXHAUST

MANIFOLD

CYLINDER

HEAD

DETAIL

DRAIN

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

PUMP

RAW

WATER

ENGINE

PUMP

HEAT

EXCHANGER

(INSIDE

FITTING)

HEAT

EXCHANGER

(REAR

FITTING)

Figure

Cooling

System

Details

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