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7

A

L

/

MANUAL

AND

CATALOG

ONAN

2515

UNIVERSITY

AVE.

S.E.

MINNEAPOLIS,

MINN.

55414

A

DIVISION

OFSTUDEBAKER

CORPORATION

IN

CANADA:

ONAN

GENERATORS

CANADA

LTD.,

P.O.

BOX

652,

GUELPH,

ONTARIO

TABLE

OF

CONTENTS

TITLE

PAGE

Installation

7

Operation

Adjustments

17

Maintenance

20

Trouble

Shooting

22

Parts

Catalog

25

ONAN

ELECTRIC

GENERATING

PLANTS

MCCK

927-350

SERIES

5AC68

PERFORMANCE

CERTIFIED

We

certify

that

when

properly

installed

and

operated

this

Onan

electric

plant

will

deliver

the

full

power

and

the

voltage

and

frequency

regulation

promised

by

its

nameplate

and

published

specifications.

This

plant

has

undergone

several

hours

of

running-in

and

testing

under

realistic

load

conditions,

in

accordance

with

procedures

certified

by

an

independent

testing

laboratory.

2010

UNIVERSITY

AV«.

S.E.

■

MINNEAPOLIS,

MINN.

BB4U

A

£>l

1/tStOH

OF

SrUDH^KM

CORPORATE

IMPORTANT...RETURN

WARRANTY

CARD

ATTACHED

TO

UNIT

*

i

£

GENERAL

INFORMATION

THIS

OPERATOR’S

MANUAL

PROVIDES

INFORMATION

FOR

PROPER

INSTALLATION,

OPERATION,

AND

MAINTENANCE

PROCEDURES

OF

YOUR

ONAN

UNIT.

AN

APPLICABLE

WIRING

DIAGRAM

WAS

ALSO

IN¬

CLUDED

AT

TIME

OF

SHIPMENT.

RETAIN

FOR

FUTURE

REFERENCE!

WE

SUGGEST

THIS

MATERIAL

BE

KEPT

HANDY

SO

THAT

IT

CAN

BE

READILY

REFERRED

TO

WHEN

NECESSARY,

EITHER

FOR

ORDERING

PARTS

OR

MAKING

EQUIPMENT

ADJUSTMENTS.

FOR

MAJOR

REPAIR

INFORMATION

A

SERVICE

MANUAL

IS

AVAIL¬

ABLE.

IF

A

MAJOR

SERVICE

MANUAL,

ADDITIONAL

OPERATORS

MANUAL,

AND/OR

WIRING

DIAGRAM

IS

REQUIRED,

CONTACT

YOUR

NEAREST

ONAN

DISTRIBUTOR.

THERE

WILL

BE

A

CHARGE

FOR

THIS

MATERIAL.

BE

SURE

TO

INCLUDE

COMPLETE

ONAN

MODEL,

SPEC.,

AND

SERIAL

NUMBER

AS

SHOWN

ON

ONAN

NAMEPLATE

ATTACHED

TO

UNIT.

THIS

IS

ESSENTIAL

IN

FURNISHING

YOU

WITH

THE

PROPER

INFORMATION.

2

INTRODUCTION

When

instructions

in

this

manual

refer

to

a

specific

model

of

generating

plant,

identify

the

model

by

referring

to

the

MODEL

AND

SPECIFICATION

NO.

as

shown

on

the

plant

nameplate.

Electrical

character¬

istics

are

shown

on

the

lower

portion

of

the

plant

nameplate.

How

to

interpret

MODEL

and

SPEC.

NO.

605MCCK-3R

/

--

1

2

B

3

4

1.

Factory

code

for

general

identification.

2.

Specific

Type:

M

-

MANUAL.

Manually

cranked.

For

permanent

or

portable

installations.

E

-

ELECTRIC.

Electric

starting

at

the

plant

only.

R

-

REMOTE.

Electric

starting.

For

permanent

installation,

can

be

connected

to

optional

acces¬

sory

equipment

for

remote

or

automatic

control

of

starting

and

stopping.

3.

Factory

code

for

optional

equipment.

4.

Specification

(Spec.)letter

(advances

when

factory

makes

production

modifications).

TYPICAL

MODEL

MCCK

MANUFACTURER'S

WARRANTY

The

Manufacturer

warrants,

to

the

original

user,

that

each

product

of

its

manufacture

is

free

from

defects

in

material

and

factory

workmanship

if

properly

installed,

serviced

and

operated

under

normal

conditions

according

to

the

Manu¬

facturer's

instructions.

Manufacturer's

obligation

under

this

warranty

is

limited

to

correcting

without

charge

at

its

factory

any

part

or

parts

thereof

which

shall

be

returned

to

its

factory

or

one

of

its

Authorized

Service

Stations,

transportation

charges

prepeiu,

within

one

year

after

being

put

into

service

by

the

original

user,

and

which

upon

examination

shall

disclose

to

U

le

Manufacturer’s

satisfaction

t

o

have

been

originally

defective.

Correction

of

such

defects

by

repair

to,

or

supplying

of

replacements

for

defective

parts,

shall

constitute

fulfillment

of

all

obligations

to

original

user.

This

warranty

shall

not

apply

to

any

of

the

Manufacturer's

products

which

must

be

replaced

because

of

normal

wear

which

have

been

subject

to

misuse,

negligence

or

aeciden

or

which

shall

have

been

repaired

or

altered

outside

of

the

Manufacturer's

factory

unless

authorized

by

the

Manufacturer,

Manufacturer

shall

not

be

liable

for

loss,

damage

or

expense

directly

or

indirectly

from

the

use

of

its

product

or

from

any

cause.

The

above

warranty

supersedes

and

is

in

lieu

of

all

other

warraotiea,

expressed

or

implied,

and

of

all

other

liabilities

or

obligations

on

part

of

Manufacturer.

No

person,

agent

or

dealer

is

authorized

to

give

any

warranties

on

behalf

of

the

Manufacturer

nor

to

assume

for

the

Manufacturer

any

other

liability

in

connection

with

any

of

ita

products

unless

made

in

writing

and

signed

by

an

officer

of

the

Manufacturer.

DATED

AUGUST

I,

1943

t

3

SPECIFICATIONS

Nominal

dimension

of

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

1H

Amp/hr.

SAE

rating,

20-hr.

(nominal)

Battery

charge

rate,

amperes

Ventilation

required

(cfm

1800

rpm)

Generator

Combustion

Output

rated

at

unity

power

factor

load

Rating

(output

in

watts)

50-cycle

AC,

intermittent

service

50-cycle

AC,

continuous

service

60-cycle

AC,

intermittent

service

60-cycle

AC,

continuous

service

AC

voltage

regulation

in

i

%

AC

frequency

regulation

in

%

Revolving

armature-type

generator

120/240-

volt

single

phase

model.reconnectible

Rotating

-

type

exciter

Model

Series

4MCCK

605MCCK

24

24

22

22

30

33

2

2

49.8

49.8

3-1/4

3-1/4

3

3

4

qts

4

qts

1800

1800

1500

1500

7:

1

7:

1

13.0

13.0

12

V

12

V

two,

in

two,

in

series

series

105

105

2-3

low

2-3

low

5-8

high

5-8

high

75

75

32

32

1-phase

1-phase

3500

5500

3500

5000

4000

6500

4000

6500

3

3

5

5

Yes

Yes

Yes

Yes

Yes

Yes

4

OPTIONAL

EQUIPMENT

1.

REMOTE

START-STOP

SWITCH

SPDT,

momentary

contact,

center-off

type.

2.

SWITCH80ARD

w

,

_

.

.

Instruments

to

read

ac

amperes,

and

ac

volts,

and

to

break

overloaded

ac

circuit.

Desirable

information

for

operator.

For

wall

mounting.

3.

INSTRUMENT

PANEL

.

Part

of

plant

control

box

assembly.

Instruments

to

read

ac

amperes

and

ac

volts,

and

to

break

overloaded

ac

circuit.

Desirable

information

for

operator.

Plants

with

instrument

panel

have

no

room

for

optional

ac

receptacles.

4.

AC

RECEPTACLES

Convenience

for

plugging

in

ac

loads.

Plants

with

ac

receptacles

have

no

room

for

optional

instrument

panel.

5.

AUTOMATIC

DEMAND

CONTROL

Starts

and

stops

plant

automatically.

6.

CONTROL-O-MATIC

j

..

A

^-function

automatic

control

which

automatically

starts

and

stops

plant,

supplies

current

on

demand

and

automatically

runs

bilge

blower.

7.

LOAD

TRANSFER

CONTROL

Controls

running

of

plant

and

transfers

load.

8

.

HEAT

EXCHANGER

COOLING

Closed

system

using

fresh

water

in

plant.

9.

LOAD

TRANSFER

SWITCH

Three-pole,

three-position

to

select

generator

or

shore

power.

10

.

AQUA

LIFT

MUFFLER

t

,

High-efficiency

silencer

for

plants

which

discharge

cooling

water

into

exhaust.

able

for

above

or

below

water-line

installation.

Suit-

11.

SEPARATE

FUEL

TANK

Various

sizes.

12.

EXHAUST

LINE

TEMPERATURE

SWITCH

Shuts

down

plant

if

water

flow

fails.

13.

OTHER

See

your

dealer.

r

5

SUPPORTS.

I

MU

FI

WATER

LINE

FROM

MANIFOLD

WATER

OUTLET

HIGH

WATER

\

TEMP.

CUT-

\

Q

OFF

SWITCH

-RUBBER

HOSE

_

ENGINE

GENERATOR

RUBBER

HOSE.

.PITCH

I

'

■

'

-

pooT

RUBBER

r

pE

*

HOSE

VENTILATED

BATTERY

BOX

SEA

COCK^SC"

RAW

WATER

LINE

-FILTER

WARNING:

Do

not

u*e

scoop

type

water

inlet

fitting*

on

electric

plant*

using

Aqualift

muffler

system*.

WATER

LINE

Recommended

flush

type

ttwu-hull

fitting

and

water

filter.

TO

ELECTRIC

PLANT

AQUALIFT

SIPHON

BREAK

HANGER

STRAPS

-VACUUM

RELIEF

VALVE

"ADAPTER

''''ELBOW

(2)

—

RUBBER

HOSE

■

•—WATER

OUTLET

■

E

XHAUST

WATER

INJECTION

ELBOW

EXHAUST

OUTLET

TYPICAL

BELOW

WATER

LINE

INSTALLATION

L

V

WATER

FILTER

3^

STRAINER

V

FLUSH

THRU-

HULL

FITTING

CAUT/OA/

/

,CLAMP

^

EXHAUST

\

£

XHA{J

*

T

vnz?

AND

HOS

.

E

,

COOLING

\

J

'

WATER

^

/

OUT

CLAMP

-

WARNING:

Install

Siphon

Break

Kit

M155K950

if

exhaust

injection

elbow

is

below

load

water

line.

Locate

the

Siphon

j

Break

at

least

12”

above

load

water

line

and

in

a

vertical

i

position.

Remote

mounting

the

siphon

break

is

permissible

within

a

5'

radius

oi

water

injection

exhaust

elbow.

Vertical

position

and

height

oi

valve

must

be

maintained.

"I"

^

BRACKET-

'BOLT

ABOVE

WATER

LINE

INSTALLATION

Figure

I.

Typical

Installation

6

INSTALLATION

GENERAL

Proper

installation

is

very

important.

Give

attention

to

the

following

points:

Adequate

generator

cooling

air,

discharge

of

circulated

air,

adequate

fresh

air,

adequate

engine

cooling

water,

discharge

of

circulated

water,

dis¬

charge

of

exhaust

gases,

electrical

connections,

fuel

connection,

sturdy

and

flat

floor

and

accessibility

for

operation

and

service.

Use

this

manual

as

a

guide

to

help

with

the

installation.

Refer

to

Typical

Installation,

Figures

1

and2.

For

more

complete

instructions,

request

Onan

Technical

Bulletin

T-021.

Installations

must

be

considered

individually,

and

ex¬

ecuted

in

compliance

with

all

regulations

which

may

affect

the

installation.

The

advice

and

guidance

con¬

tained

in

the

booklet,

Fire

Protection

Standard

for

Motor

Craft:

(NFPA

No.302)

offered

by

the

National

Fire

Pro¬

tection

Association

International,

Boston

10,

Mass¬

achusetts,

will

be

helpful

to

the

installer

of

equipment

in

vessels.

Figure

2.

Mounting

Dimensions

LOCATION

Select

a

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

of

the

crankcase

lubricating

oil

and

the

cooling

system.

A

2-1/2”

clearance

around

the

unit

is

required

to

permit

it

to

rock

on

its

mounts

without

restraint.

Use

flexible

exhaust

line,

fuel

line,

battery

cables,

and

electrical

wires.

To

install

cone-type

mounting

cushions

(Fig.3).

position

the

plant

on

the

drip

pan

and

place

the

cushions

under

the

oil

base

and

generator

support.

Always

use

cushions

with

highest

part

number

(part

number

is

shown

on

the

cushion)

on

the

generator

end.

Secure

the

plant,

to

the

drip

pan

with

the

associated

hardware

(Fig.3).

Add

thin

flat

washers

to

maintain

approximately

1/16”

clearance

between

snubber

washer

and

flat

washer.

Cushion

de¬

flection

under

load

should

be

approximately

3/16”.

CAPSCREW

LOCK

WASHER

FLAT

WASHER

SNUBBER

GENERATOR

OR

OIL

BASE

MOUNT¬

ING

FOOT

CUSHION

MOUNTING

SPACER

BUSHING

DRIP

PAN

Figure

3.

Cone-Type

Mounting

Cushion

Install

two

hold-down

clamps

to

the

drip

pan

(front

and

rear

or

both

sides).

Secure

the

clamps

to

the

mounting

base.

FUEL

TANK

AND

LINES

If

a

separate

fuel

tank

is

used,

install

it

so

the

bottom

of

the

tank

will

be

less

than

4

feet

below

the

fuel

pump.

To

prevent

siphoning

if

a

system

leak

occurs,

position

the

tank

below

the

level

of

the

engine

pump,or

use

a

siphon

break

system.

If

a

fuel

tank

is

shared,

do

not

connect

to

an

existing

line

at

a

point

above

the

fuel

supply

level.

This

avoids

starving

the

plant

(See

Fig.4

and

5).

MOUNTING

The

floor

should

be

flat,

and

give

support

directly

under

the

plant

mounting

points.

If

vertical

fuel

lift

exceeds

4

feet,

or

vapor

lock

occurs,

install

an

auxiliary

electric

fuel

pump

near

the

fuel

sup¬

ply-

Figure

4.

Fuel

System

Figure

5.

Fuel

System

Use

an

approved

flexible

rubber

fuel

line

next

to

the

engine.

Install

the

fuel

supply

line

from

near

the

bottom

of

the

supply

tank

to

the

1/8"

pipe-tapped

inlet

of

the

fuel

pump

(see

Fig.6).

A

shut-off

valve

at

the

tank

and

near

the

plant

is

recom¬

mended

for

service

convenience

(Fig.6).

OIL

DRAIN

The

oil

drain

may

be

extended

to

suit

the

installation.

The

oil

base

has

a

1/2”

pipe-tapped

hole.

Figure

6.

Fuel

Shut-Off

Valve

VENTILATION

Generating

plants

require

fresh

air

for

combustion

and

generator

cooling.

Onan

recommends

that

the

ventilation

system

he

able

to

deliver

1-1/2

to

2

times

the

air

re¬

quired

by

the

plant.

When

the

ventilation

system

depends

on

wind

or

boat

motion,

use

powered

exhausters

to

pro¬

vide

ventilation

when

the

boat

is

not

in

motion.

For

more

information,

refer

to

Onan

Technical

Bulletin

T-021.

EXHAUST

See

Installation,

Fig.l

and

2.

The

engine

exhaust

con¬

nection

is

1”,

pipe-tapped.

Pipe

exhaust

gases

outside

of

the

hull

-

exhaust

gases

are

deadly

poisonous

’

Install

a

separate

exhaust

line

as

follows:

1.

Above

vessel

load

water

line.

2.

Pitched

downward

to

prevent

water

backflow.

3.

Shield

line

near

combustible

material.

4.

Use

flexible

hose

or

tubing

(see

Fig.l

and

2).

5.

For

turns,

use

sweeping

(long

radius)

elbows.

6.

Increase

one

pipe

size

for

every

10'

increase

in

pipe

length.

Provide

a

tee

for

water

line

connection

for

wet

exhaust

(Fig.7).

Refer

to

Water

Discharge

Line.

Raise

the

dry

portion

of

the

exhaust

line

high

enough

to

prevent

water

back-flowing

into

the

engine.

Onan

recommends

using

the

Aqua

Lift

muffler

for

maximum

silencing

efficiency

and

ease

of

installation.

8

Figure

7.

Water

Outlet

Connections

The

recommended

Neoprene

muffler

(silencer)

is

an

Elasto-Muffle

brand,

size

mark

O.and

two

bushings,size

AB

(fits

1-5/8”

O.D.).

A

cast

iron

or

stainless-steel

muffler

is

also

available.

Provide

a

recommended

(or

equal)

silencer

and

install

it

near

the

end

of

the

wet

exhaust

line.

Caution:

Dry

exhaust

will

damage

the

neoprene

silencer.

WATER

SUPPLY

LIME

A

continuous

supply

of

cooling

water

is

required.

The

water

pump

inlet

is

a

hose

fitting

for

1/2”

I.D.

hose

(see

Fig.8).

Use

a

section

of

non-collapsible

hose

near

the

plant

(or

for

the

entire

run)

to

absorb

vibrations.

The

inside

diameter

of

the

plumbing

must

be

at

least

1/2”.

Use

Permatex

or

other

pipe

sealer

on

all

pipe

fittings

in

supply

line

to

pump.

Normally,

the

pump

should

de¬

liver

3.5

gallons

of

cooling

water

per

minute.

Measure

the

discharged

water

flow

after

thermostat

opens,

to

be

sure

the

supply

line

is

large

enough.

Reduce

resis¬

tance

on

pipe

runs

longer

than

5’

by

using

larger

in¬

side

diameter

plumbing.

To

prove

suction

line

is

air¬

tight,

see

that

no

bubbles

appear

in

discharged

water.

An

air

teak

reduces

lubrication

and

shortens

pump

im¬

peller

life.

Install

a

strainer

in

the

water

suction

line

inlet

where

it

is

accessible

for

cleaning.

Figure

B.

Water

Pump

Inlet

Ho*e

WATER

DISCHARGE

LIME

The

1/2”

I.D.

water

outlet

hose

fitting

is

on

the

ex¬

haust

manifold

next

to

the

exhaust

outlet

(see

Fig.7).

Use

plumbing

at

least

as

large

as

the

supply

line.

Use

a

section

of

hose

near

the

plant

or

the

entire

run.

Con¬

nect

the

line

to

discharge

the

heated

water

into

the

ex¬

haust

line

several

feet

ahead

of

the

Aqualift

or

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

to

as

fresh

water

cooling

or

heat

exchanger

cooling.

Water

circulated

through

the

engine

is

called

fresh

water,

hot

water

,

efc.

Water

circulated

through

the

heat

exchanger

only

is

called

raw

water,

sea

water,

cold

water,

dis¬

charged

water,

etc.

This

system

with

an

antifreeze

cool¬

ant

is

recommended

where

freezing

conditions

exist,

or

where

the

owner

wants

to

prevent

the

possibility

of

salt

water

problems.

Caution:

Do

not

use

the

existing

neoprene

impeller

water

pump

in

the

hot

water

side

of

the

cooling

system

Heat

or

soluble

oil

(in

many

rust

inhibitors

and

anti¬

freeze

s)

wifi

damage

the

impeller.

Instead,

connect

the

neoprene

impeller

pump

on

the

cold

water

side.

Use

a

metal

impelter,

centrifugal-type

water

pump

(Oberdorfer

1-GP,

or

equal)

in

the

fresh

water

side.

Drive

it

with

a

belt

from

the

plant

power

take-off

(see

Fig-9).

_

FRESH

WATER

FROM

MANIFOLD

HEAT

EXCHANGER

RAW

WATER

TO

EXHAUST

MANIFOLD

CYLINDER

HEAD

DETAIL

B

DRAIN

J

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

.t

PUMP

RAW

WATER

ENGINE

PUMP

TO

HEAT

EXCHANGER

(INSIDE

FITTING)

TO

HEAT

EXCHANGER

(REAR

FITTING)

Figure

9.

Cooling

System

Details

9