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oPERATOR`S / SERVICE ffiANUAL

1. WHEN GOVERNOR IS PROPERLY ASSEMBLED THE DIMENSION SHOWN ON DRAWING WILL BE AS INDICATED CAMSHAFT GEAR CENTER PIN SNAP RING GOVERNOR CUP GOVERNOR FLYBALL FIGURE 11 GOVERNOR CUP the cup against the flyballs when measuring If the distance is less the engine may race especially at no load remove the center pin and press a new pin in only the required amount Otherwise grind off the hub of the cup as required The camshaft center pin cannot be pulled outward nor removed without damage If the center pin extends out too far the cup will not hold the flyballs properly TIMING GEARS If replacement of either the crankshaft gear or the camshaft gear becomes necessary install both gears THESE MARKS MUST ALIGN WHEN INSTALL ING TIMING GEARS FIGURE 12 TIMING GEAR REMOVAL AND INSTALLATION new never one only Use a gear pulling ring Onan tool number 420 0248 to remove the crankshaft gear Be sure to remove the snap ring first See Figure 12 The camshaft gear is pressed on and keyed to the camshaft Remove the camshaft and gear as an assembly after first removing the crankshaft gear lock ring and washer Before removing the camshaft and gear assembly remove the cylinder head and valve assemblies Remove the operating plunger for the breaker points Remove the fuel pump and tappets Press the camshaft out of the gear by use of a hollow tool or pipe which will fit over the camshaft center pin Do
2. After the rear bearing end plate has been tightened using the torque recommended in ASSEMBLY TOR QUES section check the crankshaft endplay as shown in Figure 28 If there is too much endplay see DIMENSIONS AND CLEARANCES section for minimum and maximum endplay remove the rear bearing endplate and replace the gasket with a thinner gasket from the gasket kit For too little endplay remove the rear bearing end plate and MEASURE ENDPLAY HERE FIGURE 28 MEASURING CRANKSHAFT ENDPLAY replace the gasket with a thicker one Reinstall the end plate making sure the thrust washer notches line up with the lock pins Torque and recheck endplay of the crankshaft OIL PUMP Check the oil pump thoroughly for worn parts Oil the pump to prime it before reinstalling Figure 29 Except for gaskets the component parts of the pump are not available individually The suction cup is available separately Install a new pump assembly if required See the O L SYSTEM section for description of the oil bypass relief valve and cleaning instruction if normal oil pressure 30 psi or higher is in doubt A REIS E ci OIL PUMP INTAKE CUP CRANKCASE TURNED ON LEFT SIDE UNSCREW OIL PUMP SSEMBLY FROM INTAKE CUP AT THIS POINT To reassemble reverse the procedure E OIL PUMP ASSEMBLY FIGURE 29 OIL PUMP OIL SYSTEM The CCKA engine has pressure lubrication to all working parts The oil system includes Oil intake cu
3. Always use a steel key for mounting the flywheel TRANSMISSION DRIVE GEARS A standard gear puller is required to remove the drive gears from the crankshaft If unusual resistance is encountered remove the puller and heat the gears with a torch CAUTION Take care not to overheat and cause the temper to be drawn from the gears Excessive heat can damage the rear oil seal Reinstall the puller and proceed as before until the gears come loose Take care not to burn yourself with the torch or hot gears when removing or reinstalling To reinstall the gears heat the gears in oil at 400 F 205 C and place them on the shaft with the shaft keys in place Seta collar on the shaft such as a pipe coupling place a heavy washer over the end and turn the shaft screw in until the gears are properly seated See Figure 9 SHAFT m0 a MEAVY WASHER PIPE COUPLING FIGURE 9 DRIVE GEAR INSTALLATION GEAR COVER After removing the flywheel key and mounting screws tap the gear cover gently with a soft faced hammer to loosen it GOVERNOR CUP ROLL PIN ROTATE GOVERNOR CUP SO THAT ROLL PIN FITS INTO THE METAL LINED HOLE IN THE CuP DEE SE SC ze GOVERNOR y SHAFT YOKE Smooth Side Toward Cup 4 IF FEELER WILL ENTER HOLE 21N 12 7MM BALL HAS FALLEN OUT FIGURE 10 GEAR COVER ASSEMBLY When installing the gear cover make sure that the pin in the gear cover engages the gover nor cup
4. DRILL BIT THIS DIMENSION SHOULD BE 5 16 IN 7 9mm GASKET FS 1076 FIGURE 33 FLOAT LEVEL SETTING tank If the line is open and no fuel comes through the pump is defective Failure of the pump is usually due to a leaking diaphragm valve or valve gasket a weak or broken spring or wear in the drive linkage Oil diluted with gasoline may indicate a faulty diaphragm If the operator chooses to repair the pump rather than install a new one the use of a complete repair kit is recommended Fuel Pump Reconditioning 1 Remove fuel lines and mounting screws holding pump to engine See Figure 34 2 Make an indicating mark with a file across a point at the union of the fuel pump bolt and cover This mark will assure proper reassembly Remove assembly screws and remove upper pump body 3 Turn pump body over and remove valve plate screw and washer Remove valve retainer valves valve springs and valve gasket noting their position Discard valve springs valves and valve retainer gasket 4 Clean pump body thoroughly with solvent and a fine wire brush 5 Holding the pump cover with the diaphragm surface up place the new valve gasket into the cavity Assemble the valve spring and valves in the cavity Reassemble the valve retainer Lock in position by inserting and tightening fuel pump valve retainer screw 6 Place pump body assembly in a clean place and rebuild the lower diaphragm section 7 Holding mounting bracket
5. controlled at any given point between minimum and maximum by simply shifting the throttle lever on the 25 CARBURETOR THROTTLE PLATE GOVERNOR CONTROL LINKAGE CONNECTOR GOVERNOR SPRING GOVERNOR ARM AND SHAFT LINKAGE BRACKET GOVERNOR CUP GOVERNOR SHAFT YOKE FIGURE 35 GOVERNOR LINKAGE dash panel until the desired speed is reached The design of the variable speed governor gives an automatic decrease in sensitivity when the speed is increased and the result is good stability at all speeds Before making governor adjustment run the engine about 15 minutes to reach normal operating temperature If the engine is being run with the throttle wide open either the governor is not properly adjusted or the engine is overloaded After long usage it is difficult to determine if the governor spring has become fatigued Replace the spring if governor regulation is still erratic after making proper ad justments See Figure 35 A reliable instrument for checking engine speed is required for accurate governor adjustment Engine speed can be checked with a tachometer Check the governor arm linkage throttle shaft and lever for binding condition or excessive slack and wear at connecting points A binding condition at any point will cause the governor to act slowly and regulation will be poor Excessive looseness will cause a hunting condition and regulation will be erratic Work the arm back and forth seve
6. nuts and screws often with the engine cold Other 5 16 Cylinder Block Tighten as needed to prevent them from working A SE 10 12 1 38 1 66 loose Flywheel Capscrew 35 40 4 84 5 53 Cylinder Head Nuts 29 31 4 01 4 29 Valve Cover Capscrews 4 8 0 55 1 11 Manifold iii 15 20 2 07 2 77 Fuel Pump Mounting Screws 5 6 0 69 0 83 Carburetor Mounting Stud vU DEE 8 12 1 11 1 66 TROUBLESHOOTING GASOLINE ENGINE TROUBLESHOOTING GUIDE CAUSE STARTING SYSTEM Loose or Corroded Battery Connection Low or Discharged Batter Faulty Starter Faulty Start Solenoid IGNITION SYSTEM Ignition Timing Wrong Wrong Spark Plug Gap Worn Points or improper Gap Settin Bad Ignition Coil or Condenser Faulty Spark Plug Wires FUEL SYSTEM Out of Fuel Check ean Fuel Mixture Readjust Rich Fuel Mixture or Choke Stuck Engine Flooded Poor Quality Fuel O lt Dirty Air Cleaner Dirty Fuel Filter Defective Fuel Pump INTERNAL ENGINE Wrong Valve Clearance Broken Valve Sprin Valve or Valve Seal Leakin iston Rings Worn or Broken Wrong Bearing Clearance COOLING SYSTEM AIR COOLED Poor Ait Circulation Dirty or Oily Cooling Fins Biown Head Gasket COOLING SYSTEM WATER COOLED Insufficient Coolant Faulty Thermostat Worn Water Pump or Pump Seal Water Passages Restricted Defective Gaskets Blow Head Gasket LUBRICATION SYSTEM Defective Oi Gauge Relief Valve Stuck Faulty Oil Pump Dirty Oil of Filter Oil Too Light or
7. 0316 1 Plate Bearing Excludes Bearing 12 101 0367 2 Bearing Camshaft Front or Rear Precision 13 509 0041 1 Seal Bearing Plate 14 516 0072 4 Pin Main Bearing Stop 15 110 0445 5 Mut Rear Bearing Plate Key 1 2 3 4 5 8 37 REF PART QTY PART NO NO USED DESCRIPTION tb 110 0904 4 Rutocap Valve 17 851 0005 5 Washer Lock Rear Bearing Plate Special 18 120 0386 1 Tube Crankcase Oil 19 VALVE 110 1037 2 Intake 110 0880 2 Exhaust 20 INSERT VALVESEAT 110 0872 2 Exhaust Standard 110 0872 02 2 Exhaust 002 Oversize 110 0872 05 2 Exhaust 005 Oversize 110 0872 10 2 Exhaust 010 Oversize 110 0872 25 2 Exhaust 025 Oversize 110 1000 2 Intake Standard 110 1000 02 2 Intake 002 Oversize 110 1000 05 2 Intake 005 Oversize 110 1000 10 2 Intake 010 Oversize 110 1000 25 2 Intake 025 Oversize 21 110 0902 4 Guide Valve 22 110 0539 4 Spring Valve 23 110 0639 8 Lock Valve and Spring Retaining 24 TAPPET VALVE 115 0006 4 Standard 115 0006 05 4 005 Oversize 25 SCREW CAP HEX HEAD 110 0879 8 5 16 18 x 1 1 4 Ig Special 114 0022 10 5 16 x 1 3 4 Ig Special 26 526 0122 18 Washer Flat Cylinder Head Mounting 11 32 I D x 23 32 O D x 10 Ga Thk 27 516 0011 2 Pin Dowel Gearcase Alignment 28 517 0090 1 Plug Wet Hole Plastic Parts included in Cylinder Block Assembly VALVE COVER AND OIL BY PASS NO 1 2 3 erf N 000 0n 13 14 16 17 1
8. 8 2 191 0400 1 Rotor Charging Alternator 3 305 0478 1 Regulator Rectifier 4 305 0477 1 Spacer Regulator Mounting 5 323 0488 4 Socket Connecting 6 323 0789 1 Housing Connecting Sockets 7 321 0165 1 Holder Fuse 8 321 0162 1 Fuse 30 Amp 9 332 0529 1 Terminal Faston 10 332 1338 2 Clamp Loop Type 11 332 1358 1 Bracket Connector Mounting 12 191 0793 1 Clip Wiring Harness 13 812 0156 6 Screw Machine Round Head Rotor Mounting 1 4 20 x 1 1 2 Ig 14 813 0109 3 Screw Machine Round Head Stator Mounting 10 32 x 1 3 4 Ig 15 850 0040 9 Washer Lock Spring 1 4 16 850 0030 3 Washer Lock Spring 10 17 800 0006 2 Screw Cap Hex Head 1 4 20 x 7 8 18 800 0009 1 Screw Cap Hex Head 1 4 20 x 1 1 2 19 800 0047 2 Screw Cap Hex Head 3 8 16 x 5 8 Parts included in Charging Alternator Stator STARTER MOTOR REF PART QTY PART NO NO USED DESCRIPTION 1 MOTOR STARTING For Components see Separate Group 191 0511 1 Key 1 191 0790 1 Key 3 4 5 191 0734 1 Key 2 191 1052 1 Key 6 7 8 2 191 1104 1 Flange Starter Motor Mounting 3 E 1 Bracket Starter Motor Mounting Key 2 4 800 0050 2 Screw Cap Hex Head Starter Motor to Bracket 3 8 16 x 1 Ig 5 102 0455 3 Screw Cap Hex Head Starter Bracket Mounting 3 8 16 x 1 Ig 6 850 0050 5 Washer Lock Spring Starter Motor Mounting 3 8 7 191 1103 2 Spacer Starter Mounting 8 191 1108 1 Seal Air Refer to factory giving c
9. Diluted Oi Level Low Qil Too Heavy Dirty Crankcase Breather Valve THROTTLE AND GOVERNOR Linkage Our of Adjustment Linkage Worn or Disconnected Governor Soring Sensitivity Too Great Linkage Binding D OPERATION BEFORE STARTING Crankcase Oil Be sure the crankcase has been filled with oil to the full mark on the oil level indicator Refer to the PERIODIC MAINTENANCE section for the recommended oil changes and complete lubricating oil recommendations Recommended Fuel The engine will perform most satisfactory on non leaded or regular grade gasoline However nonlead ed gasoline is better for the engine If a situation arises when you must use the tractor and these fuels are not available premium or highly leaded gasoline will work in the engine Before switching to a nonleaded gasoline from leaded gasoline take this precaution Remove the cylinder heads and remove all the lead deposits from the engine It lead deposits are not removed from the engine before switching from leaded to non leaded gasoline preignition can occur and cause engine damage STARTING Refer to tractor manual for location setting and operation of electric start choke and throttle con trols APPLYING LOAD If practical allow the engine to warm up before applying heavy loads Continuous overloading can cause engine heating and eventual engine damage Break In Procedure Controlled break in with the proper oil and a con scien
10. Key 8 Carburetor Inlet CARBURETOR See Separate Group for Components 142 0482 1 Key 1 2 3 4 142 0593 1 Key 5 6 7 8 CONNECTOR FUEL LINE 502 0020 1 Key 1 2 3 4 5 Fuel Pump Inlet 502 0313 1 Key 6 7 Fuel Pump Inlet MUFFLER EXHAUST 155 1065 1 Keys 1 2 3 155 0480 1 Key 4 5 6 7 8 154 0360 2 Gasket Muffler 141 0078 1 Gasket Carburetor Mounting 153 0263 1 Bracket and Clip Choke Cable 154 0356 1 Manifold Intake 154 0013 2 Gasket Intake Manifold 149 0045 1 Spacer Fuel Pump Mounting 420 0169 1 Wrench Carburetor Adjusting BASE AIR CLEANER 140 1054 1 Key 1 2 3 4 5 140 1206 1 Key 6 7 8 41 REF NO 17 18 19 20 21 22 23 24 25 27 28 31 32 526 0063 526 0008 800 0028 850 0045 800 0004 149 0136 PART DESCRIPTION Seal O Ring Air Cleaner Element Air Cleaner Cover Air Cleaner Nut Wing Air Cleaner Clamp Fuel Hose Screw Cap Hex Head Carburetor Mounting 1 4 20 x 1 1 2 Ig Screw Cap Hex Head Intake Manifold Mounting 3 8 16 x 2 Ig Screw Machine Fillister Head Fuel Pump Mounting 1 4 20 x 1 1 4 Ig Washer Lock Spring Carburetor Mounting 1 4 Washer Lock Spring Intake Manifold Mounting 3 8 Washer Flat Fuel Pump Mounting 17 64 ID x 7 16 OD x 1 32 Thk Washer Flat Air Cleaner Cover Mounting 13 64 ID x 7 16 OD x 1 32 Thk Screw Cap Hex Head 5 16 18 x 1 Washer Lock Spring 5 15 Screw Cap Hex Head 1 4
11. Kit Complete Engine 160 0836 1 ignition Tune Up Kit 168 0095 1 Carbon Removal Gasket Kit 522 0259 1 Kit Overhaul 47 WIRING DIAGRAMS 9 298229 obey lero Ur wi Mura mirte JOLUJOJSNI Aq POYSIUIN SUBA K OA J9IjNIBY 10 e nbay K alla 18 1 pm 4 1 1 I Li l l U PELBZ SIN VADO DLLLZ SN VNADO DEPOZ SW VADO D6PEL SW V DD DL68L SIN WAIDO 9L 822o 0928229 mira WHINOD 11 mi rain Sita i A 7999 KIROLSNT AB GistiNeni SITA E EEN lt A _ 3901904 871211978 WELL VU Wie SB RS _ AVOMISSY va git Se eur ginas et It mu VOLSISIY SI t DH DE vi Wim asna ig du a j ati Oifivis 0928229 SLEBL SIN VHOD IA gt er wm TT ggf ug CO a i Sg HARDWARE IDENTIFICATION illustrated hardware items are only for identification purposes All hardware items listed throughout this parts catalog are steel SAE grade five 5 or lower zinc plated with clear chromate dip unless parts description indicates differently All dimensions are in inches WASHER TYPES ZO o EXTERNAL TOOTH INTERNAL TOOTH EXTERNAL INTEANAL COUNTERSUNK SPRING FLAT LOCK ET LOCK IT TOOTH LOCK EIT EXTERNAL TOOTH LOCK LOCK Flat washer dimensions given are Inside Diameter 1D Outside Diameter OD and Thickness Thk BOLT AND SCREW TYPES CARRIAGE BOLT
12. Tune Up Specifications Breaker Point Gap full separation 0 020 0 508 mm Spark PUTA nr ER EE 0 025 0 635 mm ro AA ip PP tt 19 BTC Carburetor Float Clearance between float bowl gasket A AS 5 16 7 9 mm DIMENSIONS AND CLEARANCES All clearances given at room temperature of 70 F 21 C All dimensions in inches unless otherwise specified metric equivalents in parentheses where applicable Tappets EWEN ee AR ARA lt AA Valve Stem in Guide OREA AREA AAA ES AAA AAA A Valve Seat Interference Width ooooooomoo Valve Face Anglo ia irse valve RN Lee Valve Interference Angle GCrankshart Mal DOUN ve scena cuart apere Sa emisor KEEN GCrankshalt Eno Play ege KEREN i n CAMA DORNO ARRE Camat ENA PIY is cree ROG Bearing EE EE AAA Connecting Rod End Play iia PUD AGM TT DEENEN Oil Pump Gear Backlash Piston to Cylinder Conformatic Type measured below Minimum Maximum 0 006 0 152 mm 0 015 0 381 mm 0 008 0 203 mm 0 017 0 432 mm 0 0010 0 025 mm 0 0025 0 064 mm 1 32 0 792 mm 44 45 1 o 0 0025 0 064 mm 0 0038 0 096 mm 0 006 0 152 mm 0 012 0 305 mm 0 0015 0 038 mm 0 0030 0 076 mm 0 003 0 076 mm 0 0005 0 013 mm 0 0023 0 058 mm 0 002 0 051 mm 0 016 0 406 mm 0 002 0 051 mm 0 003 0 076 mm 0 002 0 051 mm 0 005 0 127 mm 0 0025 0 064 mm 0 0040 0 102 mm 3 64 1 189 mm oil controlling ring 90 from pin
13. and batteries in a well charged condition 4 Partially restrict cool airflow but use care to avoid overheating EXTREMELY DUSTY AND DIRTY CONDITIONS Keep unit clean Keep cooling surfaces clean Service air cleaner as frequently as necessary Change crankcase oil every 20 operating hours Keep oil and gasoline in dust tight containers Keep governor linkage clean HIGH ALTITUDE OPERATION For operation at altitudes of 2500 feet 762 meters above sea level close carburetor main jet adjustment slightly to maintain proper air to fuel ratio refer to the Fuel System section Maximum power will be reduced approximately four percent for each 1000 feet 305 meters above sea level after the first 1000 feet 305 meters oO wn OUT OF SERVICE PROTECTION Protect an engine which is to be out of service for more than 30 days as follows 1 Run engine until thoroughly warm 2 Turn off fuel supply and run until the engine stops 3 Drain oil from oil base while still warm Refill and attach a warning tag stating oil viscosity used 4 Remove each spark plug Pour 1 ounce two tablespoons of rust inhibitor oil or SAE number 50 oil into each cylinder Crank engine slowly by hand several times Install spark plugs Service air cleaner Plug exhaust outlet to prevent entrance of moisture dirt bugs etc Provide a suitable cover for the entire unit If battery is used disconnect and fol
14. can be filed as necessary to obtain the correct gap but do not use rings which require too much filing Standard size rings can be used on 0 005 inch 0 127 mm oversize pistons Other oversize rings must correspond with the oversize pistons Rings of the tapered type are usually marked top on one side or identified in some other manner Install the ring with this mark toward the closed end of the piston Space each ring gap one third of the way around the piston from the preceding one with no gap directly in line with the piston pin The bottom piston ring groove CYLINDER WALL PISTON RING lt lt S IMPROPER N RING CONTACT N FIGURE 20 NEW RING IN WORN PISTON RING GROOVE 1 FIGURE 21 FITTING PISTON RINGS TO CYLINDER should be fitted with an expander and an oil control ring and the two upper grooves fitted with compres sion rings If a chrome faced ring is used it will be in the top groove The oil control ring is selected for best performance in regard to the correct unit pressure characteristics The piston is fitted with a full floating type piston pin The pin is kept in place by two lock rings in the piston one at each side Be sure these lock rings are properly in place before installing the piston and connecting rod in the engine Refer to DIMENSIONS AND CLEARANCES section for the correct piston to cylinder clearance CONNECTING RODS Service the connecting rods at the same time the pistons or r
15. hy AO CO PO S d K KL RRN es GA REF PART QTY PART NO NO USED DESCRIPTION 1 CRANKSHAFT 104 0710 1 Key 1 238 4 104 0774 1 Key 5 104 0885 1 Key 6 7 8 2 515 0001 1 Key Crankshaft Gear Mounting 3 190 0284 1 Gear Transmission Drive 3 3 16 Key 4 4 190 0285 1 Gear Transmission Drive 2 5 16 Key 4 5 526 0128 1 Washer Flywheel Mounting 6 515 0098 1 Key Flywheel Mounting 7 104 0170 1 Screw Flywheel Mounting Special 8 134 1889 1 Screen Flywheel 9 518 0014 1 Lock Crankshaft Gear Washer 10 104 0043 1 Washer Crankshaft Gear Retaining 11 134 2556 1 Flywheel Includes Ring Gear 12 134 0673 1 Gear Ring Flywheel 13 515 0094 2 Key Transmission Drive Gears Key 4 14 812 0125 3 Screw Roundhead 12 29 x 1 2 Guard Mounting 15 526 0006 3 Washer Flat 12 Guard Mounting 16 850 0035 3 Washer Lock 12 Guard Mounting 17 104 0032 1 Gear Crankshaft Order these parts from the tractor manufacturer REF NO 12 13 14 15 16 FUEL SYSTEM PART QTY PART NO USED DESCRIPTION 149 0693 1 Pump Fuel Key 1 2 3 4 5 6 7 See Separate Group for Components 140 1058 1 Clamp Air Cleaner GASKET 149 0003 2 Key 1 2 3 4 5 6 7 149 0003 1 Key 8 LINE FUEL 149 0611 1 Key 1 2 3 4 5 503 0694 1 Key 6 7 CONNECTOR FUEL LINE 502 0002 2 Key 1 2 3 4 5 1 Fuel Pump Outlet 1 Carburetor Inlet 502 0395 2 Key 6 7 1 Fuel Pump Outlet 1 Carburetor Inlet 502 0395 1
16. not press on the center pin or otherwise CAUTION damage it in any way The governor ball spacer is a press fit to the camshaft gear When pressing a camshaft gear onto the camshaft be sure the gear is started straight and that the key is properly in place Install the governor cup assembly before installing the camshaft and gear in the engine Each timing gear is stamped with an O mark near the 14 edge The gear teeth must mesh so that these marks coincide exactly when the gears are installed in the engine Figure 12 Be sure when installing the camshaft gear and shaft assembly that the thrust washer is properly in place behind the camshaft gear Replace the camshaft retaining washer and lock ring to the crankshaft CYLINDER HEADS Tighten the cylinder head in the order designated per Figure 13 to a torque of 5 foot pounds 0 69 kg m then 10 foot pounds 1 38 kg m etc until all are torqued 29 to 31 foot pounds 4 01 to 4 29 kg m NO 1 CYLINDER NO 2 CYLINDER FIGURE 13 HEAD BOLT TIGHTENING SEQUENCE VALVES Properly seated valves are essential to good engine performance The cylinder head is removable for valve servicing Do not use a pry to loosen the cylinder head Rap sharply on the edge with a soft faced hammer taking care not to break any cooling fins A conventional type valve spring lifter may be used when removing the valve spring locks which are of the split type Clean all carbon deposits from th
17. on breaker box and move it left to advance or right to retard the timing IGNITION COIL To check ignition coil Figure 37 first place ohmmeter leads on small terminals Resistance should read 1 2 to 1 1 2 ohms Next place ohmmeter leads inside of spark plug cable holes Resistance should read 10 800 to 13 200 ohms SPARK PLUGS The only service of spark plugs is cleaning gapping or replacing See the PERIODIC MAINTENANCE section VOLTAG REG RECT TO BATTERY BATTERY CHARGING FLYWHEEL ALTERNATOR The flywheel alternator is a permanent magnet alter nator and uses a solid state voltage regulator rectifier for controlling output Figure 38 A 30 ampere fuse is included in the battery charging system to protect the alternator in case the battery cables are accidently reversed Replace the fuse with Onan Fuse 321 0162 Buss AGC30 or equivalent Weak ignition spark or a discharged battery indicate trouble in the charging system But before testing the engine s charging system always check the battery for serviceability Keep these points in mind when testing or servicing the flywheel alternator 1 Be sure the output plug connector is inserted properly The plug must bottom in receptacle eliminates any resistance due to a poor connec tion Keep clean and tight 2 Be sure regulator rectifier output control has a good ground connection Mating surface for mounting must be clean and fasteners tightened pr
18. press down on the diaphragm to compress spring under it then turn bracket 90 degrees to unhook diaphragm so it can be removed 8 Clean mounting bracket with a solvent and a fine wire brush UPPER PUMP BODY NOT SERVICEABLE o VALVE GASKET O VALVE AND CAGE VALVE CAGE RETAINER TERN PUMP ROO SPRING MOUNTING GASKET LOWER SIDE DIAPHRAGM GASKET ROCKER ARM o ROCKER ARM o SPRING ROCKER ARM LINK 4320 Po PARTS INCLUDED IN REPAIR KIT FIGURE 34 FUEL PUMP ASSEMBLY 9 Replace the diaphragm fuel pump rod spring diaphragm gasket stand new spring in casting position diaphragm compress spring and turn 90 degrees to reconnect diaphragm 10 Hold bracket then place the pump cover on it make sure that indicating marks are in line and insert the four screws DO NOT TIGHTEN With the hand on the mounting bracket only push the pump lever to the limit of its travel and hold in this position while tightening the four screws CAUTION 11 Mount the fuel pump on engine using new mounting gaskets Connect the fuel lines GOVERNOR ADJUSTMENT Engine speed is governor controlled and preset at the factory Proper governor adjustment is one of the most important factors in maintaining the power and speed desired from the engine This is important to prevent stretching the diaphragm These engines are adapted for use where a wide range of speed settings is desired Engine speed is
19. the front bracket FIGURE 44 STARTER BRUSHES FIGURE 46 INSTALLING SHIFT LEVER INSPECTION OF PARTS Testing Armature for Short Circuits Place the armature in a growler and hold a thin steel blade parallel to the core and just above it while slowly rotating the armature in the growler Figure 47 A shorted armature will cause the blade to vibrate and be attracted to the core Replace shorted armature FIGURE 47 ARMATURE SHORT CIRCUIT TEST Testing Armature for Grounds Touch armature shaft or core and the end of each commutator bar with a pairofohmmeter leads Figure 48 If the ohmmeter reading is low it indicates a grounded armature Replace grounded armature Testing Armature for Open Circuit The most likely place for an open to occur is at the commutator riser bars Inspect the points where the FIGURE 48 ARMATURE GROUND TEST 31 conductors are joined to the commutator bars for loose connections Testing Commutator Runout Place armature in a test bench and check runout with a dial indicator Figure 49 When commutator runout exceeds 0 004 inch 0 102 mm reface the com mutator FIGURE 49 CHECKING COMMUTATOR RUNOUT Testing Armature Shaft Runout The armature shaft as well as the commutator may be checked See Figure 50 A bent armature often may be straightened but if the shaft is worn a new armature is required FIGURE 50 CHECKING ARMATURE SHAFT RUNOUT Testing Field Coils for
20. 20 x 5 8 Plate Fuel Pump Hole Key 8 FUEL PUMP PARTS REF PART QTY PART NO NO USED DESCRIPTION 149 0693 1 Pump Fuel Key 1 2 3 4 5 6 7 149 0526 1 Repair Kit Includes Parts Marked 1 1 Body Not Sold Separately 2 815 0148 4 Screw Self Tapping 48 32 x 7 8 3 815 0147 2 Screw Phillips Self Tapping 6 32 x 5 8 Retainer 4 149 0096 2 Valve and Cage 5 149 0095 2 Gasket Valve 6 149 0582 1 Diaphragm Assembly 7 149 0672 1 Spring 8 149 0539 1 Retainer Valve Cage 9 149 0675 1 Spring 10 516 0113 1 Pin Rocker Arm 11 1 Body Not Sold Separately 12 149 0710 1 Link and Arm Rocker Sold Only as a Set 13 149 0858 1 Diaphragm Lower ide 14 149 0551 1 Lever Primer 15 509 0065 2 Seal O Ring 16 149 0404 1 Spring Primer Lever 17 149 0003 1 Gasket Pump Mounting 18 518 0129 1 Ring Retainer Primer Lever Parts Included in 149 0526 Repair Kit CARBURETOR PARTS REF PART QTY PART NO NO USED DESCRIPTION CARBURETOR 142 0482 1 Key 1 2 3 4 142 0593 1 Key 5 6 7 8 142 0371 1 Repair Kit Carburetor includes Parts Marked 142 0033 1 Gasket Kit Carburetor Includes Parts Marked 1 815 0103 1 Screw Bowl Cover 1 815 0109 2 Screw Bowl Cover 2 815 0091 2 Screw Choke Fly e 4 40 x 3 16 5 3 142 0055 1 Fly Choke 4 142 0205 1 Sleeve Assembly Choke Cover 5 SHAFT ASSEMBLY CHOKE 142 0420 1 Key 1 2 3 4 142 0530 1 Key 5 6 7 8 6 142 0039 1 Shaft Float 7 1
21. 42 0031 1 Gasket Body to Bowl 8 148 0017 2 Gasket 1 Float Valve Seat 1 Main Adjusting Needle 9 142 0049 1 Valve and Seat Assembly 10 142 0032 1 Gasket Nozzle d 11 142 0285 1 Nozzle Assembly pap 12 12 142 0361 1 Float and Lever Assembly 13 145 0008 1 Lever Idle Stop 14 142 0040 1 Needle idle Adjusting 15 142 0282 1 Spring Idle Needie Adjusting 16 142 0035 1 Spring Throttle Stop Adjusting Screw 17 812 0063 1 Screw Throttle Stop Adjusting 4 32 x 1 2 18 815 0072 2 Screw Throttle Fly 4 40 x 1 4 19 142 0369 1 Fly Throttle 20 142 0368 1 Shaft Assembly Throttle 21 142 0370 1 Nut and Jet Nozzle 8 22 142 0046 1 Retainer Main Adjusting e EL 18 Needle 29 22 23 142 0206 1 Packing Main Adjusting 23 9 Needle 24 8 24 142 0045 1 Retainer Main Adjusting 26 Needle Packing 25 25 516 0027 1 Pin Main Adjusting Needle 26 142 0041 1 Needle Main Adjusting 27 1 Body Assembly Not Sold Separately 28 505 0008 1 Plug Gas Inlet 29 142 0042 1 Needle Assembly includes Packing Nut and Retainer 30 142 0343 2 Bushing Throttle Shaft 31 870 0053 1 Nut Throttle Stop 32 813 0103 1 Screw Throttle Stop Clamp 33 142 0227 1 Pin Choke Stop Parts contained in 142 0033 Gasket Kit Parts contained in 142 0371 Repair Kit 43 FLYWHEEL ALTERNATOR 12 REF PART QTY PART NO NO USED DESCRIPTION Ga 1 STATOR CHARGING ALTERNATOR Includes Parts Marked 191 0739 1 Key 1 2 3 4 191 0892 1 Key 5 6 7
22. 5 0238 150 0075 105 0332 150 1257 150 0077 150 1519 150 1520 CAMSHAFT i i d d E A A i hb web PART DESCRIPTION Ring Camshaft Center Pin Kit Governor Cup Ball Fly Governor Washer Camshaft Gear Thrust Key Camshaft Gear Mounting Camshaft Includes Pin Pin Camshaft Center Gear Camshaft Includes Parts Marked Spacer Flyball Plate Flyball Hub Governor Cup Cup Governor Parts included in 105 0332 Camshaft Gear PISTON AND CONNECTING ROD 39 REF PART QTY PART NO NO USED DESCRIPTION 1 PISTON amp PIN Includes Retaining Rings 112 9136 2 Standard 112 0136 05 2 005 Oversize 112 0136 10 2 010 Oversize 112 0136 20 2 020 Oversize 112 0136 30 2 030 Oversize 112 0136 40 2 040 Oversize 2 PIN PISTON 112 0069 2 Standard 3 112 0003 4 Ring Piston Pin Retaining 4 114 0203 2 Rod Assembly Connecting Forged Includes Bushing and Place Bolts 5 RING SET PISTON 113 0153 2 Standard 113 0153 05 2 005 Oversize 113 0153 10 2 010 Oversize 113 0153 20 2 020 Oversize 113 0153 30 2 030 Oversize 113 0153 40 2 040 Oversize 6 805 0010 4 Bolt Place Connecting Rods 5 16 24 x 1 4 Ig 7 BEARING CONNECTING ROD 114 0145 4 Standard 114 0145 02 4 002 Undersize 114 0145 10 El 010 Undersize 114 0145 20 4 020 Undersize 114 0145 30 4 030 Undersize B 114 0036 2 Bushing Piston Pin Connecting Rod 9 114 0059 4 Washer Connecting Rod Screw Lock CRANKSHAFT
23. 7 8 12 526 0006 1 Washer Flat Throttle Control 15 64 ID x 1 2 OD x 3 64 Thk 13 862 0001 1 Nut Hex Throttle Control 1 4 20 14 850 0040 1 Washer Lock Spring Throttle Control 1 4 15 870 0053 1 Nut Hex Governor Control 10 32 16 870 0131 1 Nut Keps Governor Contrl Includes Washer amp 10 32 17 150 1269 1 Spacer Throttie Control Bracket Key 4 5 6 7 8 46 GEAR COVER GROUP REF PART QTY PART NO NO USED DESCRIPTION 1 509 0008 1 Seal Oil Governor Shaft 2 510 0013 1 Bearing Governor Shaft Upper 3 150 0377 1 Shaft and Arm Assembly Governor Sg 4 150 0620 1 Yoke Governor Shaft 5 518 0129 1 Ring Yoke Retainer 6 516 0130 1 Pin Governor Cup Stop 7 510 0008 1 Bearing Governor Shaft Lower 8 510 0014 1 Ball Bearing Governor Shaft 9 103 0332 1 Cover Assembly Gear Includes parts marked 10 103 0011 1 Gasket Gear Cover 11 BRACKET GOVERNOR LINKAGE 150 0635 1 Key 1 2 3 150 1297 1 Key 4 5 6 7 8 12 509 0040 1 Seal Gear Cover 13 516 0011 2 Pin Gear Cover 5 16 x 1 1 8 14 850 0045 5 Washer Lock Spring Gearcover Mounting 5 16 15 SCREW CAP HEX HEAD GEARCOVER MOUNTING 800 0032 4 5 16 18 x 1 3 4 Ig 800 0034 1 5 16 18 x 2 1 4 Ig Parts Included in Gear Cover Assembly SERVICE KITS AND MISCELLANEOUS NOTE For other kits refer to the group for the part in question REF PART QTY PART NO NO USED DESCRIPTION 168 0109 1 Gasket
24. 8 PART QTY PART NO USED DESCRIPTION 123 0398 1 Valve Oil By Pass 120 0140 1 Spring Oil By Pass Valve 526 0066 1 Washer Fiat Oil Pressure Relief Valve 25 64 ID x 9 16 OD x 1 16 Thk 120 0187 1 Stud Oil By Pass Adjustment Includes Nuts Keys 1 2 3 4 801 0050 1 Screw Cap Hex Head Oil By Pass Adjustment Key 5 3 8 24 x 1 Ig 801 0048 1 Screw Cap Hex Head Oil By Pass Adjustment 5 16 18 x 1 lg Key 6 7 8 120 0704 1 Spacer Oil By Pass Key 5 Only 123 0953 1 Tube Breather 123 0958 2 Screen Breather Tube 123 0865 1 Baffle Breather Tube 123 0951 1 Clamp Breather Cap 509 0117 1 Seal O Ring Breather Tube 123 0954 1 Cap Breather Tube TUBE BREATHER 503 0574 1 Keys 1 2 3 4 5 123 1264 1 Key 6 7 8 809 0035 1 Screw Cap Hex Head Breather Cap Clamp 8 x 3 4 Ig 110 0667 2 Gasket Valve Cover 110 0666 2 Cover Valve Cover 526 0063 2 Washer Flat Valve Cover Mounting 17 64 ID x 7 16 OD x 1 32 Thk 800 0012 2 Screw Cap Hex Head Valve Cover Mounting 3 8 16 x 2 Iq 503 0170 1 Clamp Breather Hose OIL SYSTEM m A wo 0 DH SLAM za 11 12 13 14 16 PART NO 123 1102 123 0191 102 0158 102 0655 122 0320 122 0323 122 0321 193 0005 120 0491 120 0663 120 0161 120 0689 505 0056 501 0003 502 0017 309 0237 QTY USED si si eh mb hb zb ep BI eh sch zb sch zb z PART DESCRIPTION Cap 4 Indicator oil Fill Gasket O
25. Clearance 0 0025 0 0635 mm 0 0045 0 1143 mm Piston PIN in PISTOL ces ER sate eth AER E ENN Thumb Push Fit Piston Fan ROO EE EE 0 0002 0 005 mm 0 0007 0 018 mm Piston Aing aap in Cylinder iii 0 010 0 254 mm 0 023 0 584 mm Crankshaft Main Bearing Journal Standard Size 1 9992 5 0779 mm 2 0000 5 0800 mm Crankshaft Rod Bearing Journal Standard Size 1 6252 4 1280 mm 1 6260 4 1300 mm Cylinder Bore Standard Size Honed 3 249 8 252 mm 3 250 8 2550 mm Tune Up Specifications Breaker Point Gap full separation 0 020 0 508 mm Spark PUGAD ama 0 025 0 635 mm O EEGEN 19 BTC Carburetor Float Clearance between float bowl gasket Ir EU EEN 5 16 7 9 mm m HI ASSEMBLY TORQUES TORQUES TORQUE SPECIFICATIONS Ft Lb kg m Assembly torques as given here require the use of a Connecting Rod Bolt 27 29 3 73 4 01 torque wrench These assembly torques will assure CHP PUN ore ceeace cca 7 9 0 97 1 24 proper tightness without danger of stripping the Oil Base Mounting Screws 43 48 5 95 6 64 threads If a torque wrench is not available you will Rear Bearing Plate 20 25 2 77 3 46 have to estimate the degree of tightness necessary for Gear Case Cover 10 13 1 38 1 80 the stud nut or screw being installed and tighten Starter Mounting Bracket to accordingly Be careful notto strip the threads Check Oil Base Screws 43 48 5 95 6 64 all studs
26. Grounds Place one lead on the connector and the other on a clean spot on the frame after unsoldering the shunt field coil wire Figure 51 If the ohmmeter reading is low the fields are grounded either at the connector or in the windings Inspection for Brush Spring Tension Measure brush spring tension with a tension meter as shown in Figure 54 Push the brush and take a reading just as the brush projects a little from the brushholder On a new brush the spring tension should be 49 to 59 ounces 1390 to 1670 grams for begin Spec J CCKA engines 29 to 38 ounces 820 to 1075 grams for Spec G engines FIGURE 51 FIELD COIL GROUND TEST Testing Field Coils for Open Circuit Place one lead on the connector and the other ona clean spot on the brushholder Figure 52 If the FIGURE 54 MEASURING BRUSH SPRING TENSION ohmmeter reading is high the field coil is open Check the other three brushholders in the same manner e INSPECTION AFTER OVERHAUL 1 For no load test the starting motor is wired as shown in Figure 55 and run The value of the meter reading at this condition should be as follows Begin Spec J Spec G Only Voltage 10 5 11 5 RPM 5000 3700 Max Current Draw Amp 53 60 The conductor for this test should be large enough and as short as possible If anything is wrong in the above test SWITCH AMMETER FIGURE 52 FIELD COIL OPEN CIRCUIT TEST Inspection of Brushes When brushes are worn to the wear limit
27. NSTALLED ws FOR AND SHIFT BOX APPROXIMATE TIMING LO ADVANCE OR RETARD FIGURE 3 IGNITION TIMING Ignition Timing Engine Running Always check timing after replacing ignition points or if moticing poor engine performance Proceed as follows 1 To accurately check the ignition timing use a timing light when engine is running Connect the timing light according to its manufacturer s in structions Either spark plug can be used as they fire simultaneously 2 Place a white chalk or paint mark on the timing mark 3 Start the engine and check the timing 19 BTC 4 If timing needs adjustment loosen the mounting screws on breaker box and move it left to advance or right to retard the timing 5 Tighten the screws on the breaker box and recheck timing 6 Replace breaker box cover and any other hardware removed Ignition Timing Engine Not Running 1 Connect a continuity test lamp set across the ignition breaker points Touch one test prod to the breaker box terminal to which the coil lead is connected and touch the other test prod to agood ground on the engine 2 Turn crankshaft against rotation coun terclockwise until the points close Then slowly FLYWHEEL IGNITION TIMING OHMMETER FIGURE 37 TESTING IGNITION COIL turn the crankshaft with rotation clockwise 3 The lamp should go out just as the points break 19 BTC 4 If timing needs adjustment loosen the mounting screws
28. OIL When changing oil fill the crankcase to the FULL mark Figure 1 with an SE American Petroleum Institute designation oil of the viscosity specified on the nameplate If SE oil is not available SD or SD CC oil may be used USE THESE SAE VISCOSITY GRADES Oil consumption may be higher with a multigrade oil than with a single grade oil if both oils have com parable viscosities at 210 F 99 C Therefore single grade oils are generally more desirable unless an ticipating a wide range of temperatures Use the proper grade oil for the expected conditions Check oil level every 8 operating hours Change oil every 40 operating hours under normal operating conditions When operating in extremely dusty or dirty conditions change oil every 20 operating hours TEMPERATURE RANGE YOU EXPECT BEFORE NEXT OIL CHANGE CAP AND OIL LEVEL INDICATOR KEEP OIL AT THIS LEVEL a FULL NEVER OPERATE ENGINE WITH OIL BELOW THIS LEVEL Low ALWAYS REPLACE CAP TIGHTLY OR OIL LEAKAGE MAY OCCUR FIGURE 1 OIL LEVEL INDICATOR Change the crankcase oil filter every other oil change 80 operating hours Remove the filter by turning counterclockwise using a filter wrench Add the air seal over the filter to prevent air loss around the housing Figure 2 Coat rubber gasket on filter with film of oil before installing Install the filter finger tight plus 1 4 to 1 2 turn If oil becomes so dirty that the markings on th
29. OPERATOR S SERVICE MANUAL AND PARTS CATALOG FOR SERIES CCKA INDUSTRIAL ENGINES MODELS CCKA MS 1831G CCKA MS 1897G CCKA MS 1949G wal CCKA MS 2043G CCKA MS 2111G CCKA MS 2567G CCKA MS 2813J CCKA MS 3110J CCKA MS 3612J ISSUE DATE FORM NUMBER 12 79 927 1103 SPEC G J SAFETY PRECAUTIONS The following symbols in this manual signal poten tially dangerous conditions to the operator or equip ment Read this manual caretully Know when these conditions can exist Then take necessary steps to protect personnel as wall as equipment WARNING Onan uses this symbol throughout this manual to warn of possible serious personal injury This symbol refers to possible equipment damage Fuels electrical equipment batteries exhaust gases and moving parts present potential hazards that could result in serious personal injury Take care in follow ing these recommended procedures Use Extreme Caution Near Gasoline A constant potential explosive or fire hazard exists Do not fill fuel tank near unit with engine running Do not smoke or use open flame near the unit or the fuel tank Be sure all fuel supplies have a positive shutoff valve Fuel lines must be of steel piping adequately secured and free of leaks Use a flexible section of fuel line between generator set and stationary fuel line in the vehicle This flexible section must be 100 NON METALLIC to prevent electrical currents from using it as
30. PLUG GAP ENGINE DISASSEMBLY If engine disassembly is necessary observe the following order i e flywheel gear cover As disassembly progresses the order may be changed as will be self evident The engine assembly procedure is the reverse of disassembly Any special assembly instructions for a particular group are included in the applicable section When reassembl ing check each section for these special assembly instructions or procedures FLYWHEEL Removing the flywheel is a relatively simple process but the following procedure must be followed to avoid damage to the gear case and possible injury to the operator 1 Turn the flywheel mounting screw outward about two turns Do not remove the screw completely WARNING since it acts as a restrainer when the flywheel snaps loose 2 Install a puller bar Onan tool number 420 0100 on the flywheel as shown in Figure 8 BLOWER WHEEL WHEEL PULLER BLOWER WHEEL MOUNTING SCREW FIGURE 8 BLOWER WHEEL PULLER 12 3 Turn the puller bar bolts in alternately until the wheel snaps loose on the shaft Do notuse a screwdriver or similar tool to pry behind the flywheel against the gear case cover The gear case cover is die cast material and will break if too much pressure is applied in this manner 4 Unscrew the puller from the flywheel remove the flywheel mounting screw and washer and pull the flywheel off the shaft Take care not to drop the wheel
31. RTANI ALWAYS GIVE ABOVE NOS WHEN ORDERING PARIS HORSEPOWER 165 OIL CAPACITY 2 QUARTS CHECK OIL LEVEL DAILY BELOW 30 F SAL 5W20 ABOVE 30 PF SAE 30 CHANGE OIL AFTER FIRST 5HOURS CHANGE O11 EVERY 40 OPERATING HOURS EVERY 20 HOURS DUST Y CONDITIONS FUEL REGULAR GASOLINE BATTERY i2VNEGGNOD DO NOT REVERSE BATTERY CONNEC TIONS VALWES COLD IN 010 EXH 012 SPARK PLUG GAP 025 POINT GAP 020 MANUFACTURED BY DIVISION OF ONAN CORPORATION MINNEAPOLIS MINNESOTA USA 99411135 For handy reference insert YOUR engine nameplate information in the spaces above 2 Do not order by reference number or group number always use part number and description 3 Give the part number description and quantity needed of each item If an older part cannot be identified return the part prepaid to your dealer or nearest AUTHORIZED SERVICE STATION Print your name and address plainly on the package Write a letter to the same address stating the reason for returning the part 4 State definite shipping instructions Any claim for loss or damage to your unit in transit should be filed promptly against the transportation company making the delivery Shipments are complete unless the packing list indicates items are back ordered Prices are purposely omitted from this Parts Catalog due to the confusion resulting from fluctuating costs import duties sales taxes exchange rates etc For current parts prices consult your Onan Dealer Distributor or Parts an
32. TRUSS HEAD BINDER HEAD PAN HEAD HEXAGON HEAD FILLISTER HEAD FLAT HEAD B i ee bl a eee Espa eee ROUND HEAD HEXAGON WASHER OVAL HEAD SQUARE HEAD SOCKET HEAD TWELVE POINT SLOTTED SOCKET HEAD f CAP SET SET E E TE 157 L Measure length between these points INTERNAL DRIVE TYPES Nominal size fractions diameter or screw number S IS SLOTTED CROSS RECESSED SIX POINT TWELVE POINT PHILLIPS SOCKET SOCKET 1 4 20 x 4 4 NUT TYPES FULL HEXAGON JAM HEXAGON HEXAGON WASHER SQUARE
33. a conductor Have a fire extinguisher nearby Be sure ex tinguisher is properly maintained and be familiar with its proper use Extinguishers rated ABC by the NFPA are appropriate for all applications Consult the local fire department for the correct type of extinguisher for various applications Guard Against Electric Shock Remove electric power before removing protec tive shields or touching electrical equipment Use rubber insulative mats placed on dry wood plat forms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surfaces to be damp when handling electrical equipment Jewelry is a good conductor of electricity and should be removed when working on electrical equipment Always use an appropriately sized approved double throw transfer switch with any standby generator set DO NOT PLUG PORTABLE OR STANDBY SETS DIRECTLY INTO A HOUSE RECEPTACLE TO PROVIDE EMERGENCY POWER It is possible for current to flow from generator into the utility line This creates ex treme hazards to anyone working on lines to restore power Use extreme caution when working on electrical components High voltages cause injury or death Follow all state and local electrical codes Have all electrical installations performed by a qualified licensed electrician Do Not Smoke While Servicing Batteries Lead acid batteries emit a highly explosive hydrogen gas
34. ance with the procedure described in Inspection of Parts Make any repair necessary Reassembly is the reverse of disassembly Take the following precautions 1 Clean all of the parts carefully with a dry cloth and compressed air if it is available Do not use steam or high pressure water to CAUTION clean the starter Otherwise water particles are entrapped in the starter after reassembly Do not immerse bearing equipped parts in cleaning fluid Clean these parts with a brush dipped in Varsol or any other compara ble mineral spirits Do not immerse overrunning clutch in cleaning solvent Thoroughly dry any parts that come into contact with the cleaning fluid Apply SAE 20 oil to the armature shaft and splines Apply grease Shell Albania No 2 or equivalent sparingly on the shift lever pin the joint of the shift lever and plunger the plunger and spacing washers at the end of the shaft To mount the overrunning clutch first insert the pinion stopper into the armature shaft then apply the ring to the groove of the shaft rigidly For the insertion of the ring use a tool as shown in Figure 45 and pull the pinion stopper up FIGURE 45 MOUNTING OVERRUNNING CLUTCH Use spacing washers to adjust the armature to give end play of 0 004 to 0 02 inch 0 102 to 0 51 mm Tighten the through bolts to a torque of 35 to 44 in Ibs 0 40 to 0 51 kg m Insert the shift lever as shown in Figure 46 into
35. and connect the meter leads to the two terminals of the female plug with the yellow wires Meter should read less than 0 8 ohms if stator has continuity If meter shows no reading winding is open and stator should be replaced 3 Touch red meter lead to yellow wire plug terminal and other meter lead to metal core of stator If meter doesn t read infinity the stator winding is grounded Replace the stator Fiywheel Magnet Group or Rotor To test the magnet group or rotor lay a piece of ferrous iron material up against the magnets to be sure they are charged If not replace the rotor If the rotor is removed and replaced use ap proximately 5 ft lb torque 0 69 kg m on the moun ting bolts STARTING SYSTEM ELECTRIC STARTER Normally the starter will require little or no service other than possible brush replacement See Figure 39 However if through accident or misuse the starter requires service or overhaul the following procedures will provide the information necessary to perform this service FIGURE 39 STARTER ASSEMBLY STARTER DISASSEMBLY 1 Loosen the M terminal nut on the solenoid switch and remove the connector to the starter assembly Then unscrew attaching screws and remove the solenoid switch Figure 40 The packings for the solenoid switch are mounted so that the steel packing is located in the front bracket side SOLENOID SWITCH FIGURE 40 SOLENOID SWITCH REMOVAL 2 After removing the throu
36. ast the ignition plunger hole Crankshaft New crankshaft main bearings are precision type which do not require line reaming or line boring after installation See PARTS CATALOG section for stan dard size and undersizes available Before putting in the main bearings expand the bearing bore by placing the casting in hot water or in an oven heated to 200 F 93 C If practical cool the precision bearing to shrink it For putting in either the front or rear main bearing using instructions following always align the oil hole s in the bearing with the oil hole s in the bearing bore The oil passage must be at least 1 2 open The cold oiled precision bearing should require only light taps to position it Install the bearing flush with the inside end of the bore If the head of alock pin is damaged use side cutters or Easy Out tool to remove pin Then install a new lock pin Apply oil to the thrust washers to hold in place when the PRECISION TYPE DO NOT LINE REAM OR BORE rd 7 32 IN MV an eg WITH HOLE IN BEARING BORE CAMSHAFT BEARING LOCK PIN ALIGN HOLE IN BEARING le D E ALIGN BEARING HOLES WITH OIL K HOLES IN BEARING BORE THRUST WASHER BEARING PRECISION TYPE DO NOT LINE REAM OR BORE CRANKSHAFT RIN FIGURE 26 INSTALLATION OF CAM AND CRANKSHAFT BEARINGS crankshaft is installed The oil grooves in the thrust washer bearings must face the crankshaft Be sure two notches fit over lock pi
37. cket Coil Mounting Key 4 5 6 7 8 Screw Cap Socket Head Nut Coil Terminal 10 32 Washer Coil Terminal 10 Screw Resistor Mounting 10 32 x 2 1 2 Washer Lock Resistor Mounting 10 Washer Centering Resistor Mounting Washer Lock Spring 1 4 Screw Machine Round Head with ET 8 32 x 3 8 Screw Cap HWH 10 32 x 5 16 Lead Coil BLOWER HOUSING GROUP 4 REF PART QTY PART NO NO USED DESCRIPTION 1 134 0589 1 Housing Cylinder Air Left 2 HOUSING BLOWER 134 2025 1 Key 1 2 3 134 2199 1 Key 4 5 134 2951 1 Key 6 7 8 3 HOUSING CYLINDER AIR RIGHT 134 2032 1 Key 1 134 2094 1 Key 2 3 4 5 134 2954 1 Key 6 7 8 4 321 0169 1 Clip Cylinder Air Housing 5 815 0261 5 Screw Tapping HWH 1 4 20 x 1 2 6 821 0010 2 Screw Cap HWH 1 4 20 x 1 2 GOVERNOR GROUP REF PART QTY PART NO NO USED DESCRIPTION 1 SPRING GOVERNOR 150 0698 1 Key 1 2 3 150 1264 1 Key 4 5 6 7 8 2 150 0639 1 Joint Ball 3 150 0629 1 Link Throttle 4 518 0006 1 Clip Link End 5 152 0155 1 Swivel Throttle Cable Connector Key 4 5 6 7 8 6 150 1310 4 Bracket Throttle Control Key 4 5 6 7 8 7 145 0412 1 Connector Throttle Bracket Key 4 5 6 7 8 9 815 0104 1 Screw Machine Fillister Head Throttle Control Swivel Key 4 5 6 7 8 8 32 x 5 16 Ig 10 815 0241 1 Screw Machine Truss Head Throttle Control Bracket Key 4 5 6 7 1 4 20 x 1 2 Ig 11 516 0059 1 Key Cotter Throttle Control Key 4 5 6
38. correctly see following Turn the governor cup so that the metal lined hole is at the three o clock position The smooth side of the governor yoke must ride against the governor cup Turn the governor arm and shaft clockwise as far as possible and hold in this position until the gear cover is installed flush against the crankcase SAUTION Adjust the roll stop pin to protrude to a point 3 4 inch 19 05 mm from the cover mounting surface See Figure 10 GOVERNOR CUP With the gear cover removed the governor can be taken off after removing the snap ring from the camshaft center pin Catch the flyballs while sliding the cup off See Figure 11 Be careful not to damage the gear cover oil seal If damaged it will have to be replaced Replace any flyball that is grooved or has a flat spot If the arms of the ball spacer are worn or otherwise damaged replace the entire timing gear set The governor cup must spin freely on the camshaft center pin without excessive looseness or wobble If the race surface of the cup is grooved or rough replace it with a new one When installing the governor cup tilt the engine so the gear is up put the flyballs in place and install the cup and snap ring on the center pin Figure 11 The camshaft center pin extends out 3 4 inch 19 05 mm from the end of the camshaft This distance provides an in and out travel distance of 7 32 inch 7 55 mm for the governor cup as illustrated Hold 13
39. crank the engine over one complete revolution and again line up the correct timing marks Then follow the adjustment given for the valves of the left hand cylinder INTAKE AND EXHAUST VALVES SEE TABLE OF CLEARANCES OF FIGURE 16 ADJUSTING TAPPETS PISTONS AND RINGS Whenever there is a noticeable wear ridge at the top of each cylinder remove the ridge with a ridge reamer before removing the pistons If not the rings can catch the ridge when pushing out the pistons and cause a ring land fracture Figure 17 To remove the piston and connecting rod assemblies turn the crankshaft until a piston is at the bottom of the stroke Remove the nuts from the connecting rod bolts Lift the rod bearing cap from the rod and push the rod and piston assembly out the top of the cylinder with the handle end of a hammer Be careful not to scratch the crankpin or the cylinder wall when removing these parts WEAR RIDGE RING LAND CYLINDER WALL PISTON REMOVING PISTON WITH LARGE WEAR RIDGE COULO BREAK RING OR RING LAND FIGURE 17 WEAR RIDGE ON CYLINDER WALL 16 Keep the connecting rod bearing caps and bearings with their respective rods The pistons are fitted with two compression rings on top and one oil control ring on bottom with an expander Remove these rings from the piston using a piston ring spreader Clean the piston ring grooves with a groove cleaner Figure 18 Clean all passages with a non caustic solv
40. d Service Center En esta lista de partes los precios se omiten de proposito ya que bastante confusion resulto de fluctuaciones de los precios derechos aduanales impuestos de venta cambios extranjeros etc Consiga los precios vigentes de su distribuidor de productos ONAN 34 This catalog applies to the CCKA Engines listed below Parts are arranged in groups of related items Each illustrated part is identified by a reference number corresponding to the same reference number following the illustration Parts illustrations are typical Using the MODEL and SPEC NO from the engine nameplate select the PARTS KEY NO 1 2 etc in the last column that applies to your Engine Model and Spec No This PARTS KEY NO represents parts that differ between models Unless otherwise mentioned in the description parts are interchangeable between models Right and left engine sides are determined by FACING the blowerend front of the engine MODEL AND SPEC NO PARTS KEY NO a II Mn E Mi AC eem AC Mn A DG SE E CCKA MS 2813J CCKA MS 3110J CCKA MS 3612J The Specification Letter Advances A to B B to C etc with manufacturing changes CCKA MS 2567G is replacement engine for CCKA MS 2111G and is identical INDEX GROUP TITLE PAGE NUMBER INTRODUCTION Serre dE oana EEN RTE NEEN aa cutia adela e oi Ke AR 35 DATA TABLE iia RECAE lea dacia aaa a d 35 A lomator fiel vd ee NNN EE oa asics ccs sce
41. e cylinder head piston top valves guides etc If a valve face is burned or warped or the stem worn install a new valve Worn valve stem guides may be replaced from inside the valve chamber See Figure 14 A seal is provided behind the intake valve guides only The smaller diameter ofthe tapered valve guides must face toward the valve head Tappets are also replaceable from the valve chamber after first removing the valve assemblies The valve face angle is 44 The valve seat angle is 45 This 1 interference angle results in a sharp seating surface between the valve and the top of the valve seat The interference angle method of grinding valves minimizes face deposits and lengthens valve life Figure 15 NOTE USE A STANDARD AUTOMOTIVE TYPE WRENCH TO ADJUST THE TAPPETS NOTE SEE VALVE TAPPET CLEARANCES IN TEXT VALVE iber SCREW FIGURE 14 CCKA VALVE SYSTEM ASS Do not hand lap the valves H at all avoidable CAUTION since the sharp contact can be destroyed This is especially important where stellite faced valves and seats are used Finish the valve faces in a machine to 44 Grind the valve seats with a 45 stone Width of the seat band should be 1 32 to 3 64 0 792 to 1 189 mm of an inch wide Grind only enough to assure proper seating Remove all grinding compound from engine parts and place each valve in its proper location Check each valve for a tight seat using an air pressure type testing
42. e oil level indicator cannot be seen change the filter and shorten the filter service period AIR SEAL 69 i FIGURE 2 OIL FILTER AND AIR SEAL AIR FILTER The CCKA engine is equipped with a paper cartridge automotive type air filter Figure 3 Under normal usage change the filter every 200 operating hours WING NUT COPPER WASHER COVER ELEMENT BREATHER O RING HOSE CLAMP FIGURE 3 AIR CLEANER ASSEMBLY Extremely dusty conditions may require a change every 50 operating hours Inspect the filter more frequently if the engine appears to be losing power or idles roughly To service the air filter remove the wing nut and washer at the top If the filter element is dirty clean by tapping gently on a flat surface When cleaning do not dent the sealing surfaces Clean the sealing surfaces pan and cover before reassembly Check to see that the pan is assembled firmly onto the carburetor air intake The O ring in the pan neck should make a tight seal around the air intake Tighten the clamp on the air intake See Figure 3 Reassemble the air filter and replace the washer and wing nut tighten the wing nut finger tight only CRANKCASE BREATHER Begin Spec J Clean the crankcase breather cap valve assembly and the breather tube baffle in a petroleum base solvent every 200 operational hours To remove breather cap and valve assembly remove the breather hose clamp and breather tube clamp Figu
43. ent Clean the rod bore and the back of the connecting rod bearings thoroughly FIGURE 18 CLEANING RING GROOVES Mark each piston to make sure the rod will be assembled on the piston from which it was removed Remove the piston pin retainer from each side and push the pin out Inspect the pistons for fractures at the ring lands skirts and pin bosses Check for wear at the ring land using new rings and a feeler gauge as shown in Figure 19 See DIMENSIONS AND CLEARANCES section for proper side clearance measurement and ring groove widths Improper width rings or excessive ring side clearance can result in ring breakage New rings in worn ring grooves don t have good cylinder wall contact Figure 20 Replace pistons showing signs of bad scoring or burring excessive skirt clearance wavy or worn ring lands fractures or damage from detonation Replace piston pins showing fractures scored bores or bores out of round more than 0 002 inch 0 051 mm Use a new piston pin to check the pin bushing in the FIGURE 19 INSPECTING RING LANDS connecting rod for wear The clearance should be as shown in DIMENSIONS AND CLEARANCES section Before installing new rings on the piston check the ring gap by placing each ring squarely in its cylinder at a position corresponding to the bottom of its travel see Figure 21 The gap between the ends of the ring is given in DIMENSIONS AND CLEARANCES section Rings which are slightly oversize
44. gh bolts the starting motor can be divided into three parts the front bracket housing and rear bracket The spacing 29 5 washers shown in Figure 41 are used for adjust ment of the thrust gap of the armature shaft and are placed between the rear bracket and the commutator These washers are inserted so the steel washer is located in the commutator side CAPSCREW FOR BRUSH RING FIGURE 41 REMOVING THROUGH BOLTS The armature can easily be removed from the front bracket Be careful not to miss a small steel washer used in the end of the armature shaft The shift lever can be removed along with the ar mature when it is removed In this case the spring holder lever springs and retainer can be taken out before the lever See Figure 42 LEVER ASSEMBL Y LEVER SPRINGS TS SPRING MOLDER Ke ARMATURE FIGURE 42 ARMATURE REMOVAL Remove the ring after driving the pinion stopper toward the pinion gear using a cylindrical tool as shown in Figure 43 The overrunning clutch and the pinion stopper should be removed simultaneously Two of the four brushes have been soldered to the brushholder Figure 44 The brush springs can be removed from the brushholder FIGURE 43 RING REMOVAL brush springs can be removed from the brushholder 6 The pole shoes may be removed if necessary by removing the flat head machine screws from the frame STARTER REASSEMBLY Inspect the parts carefully in accord
45. il Fill Cap Gasket Oil Base Mounting Base Oil Adapter Oil Fill Filter Oil Spin On Gasket Oil Filter Adapter Gauge Oil Pressure Key 1 2 3 Pump Oil Complete NOTE Internal parts not sold separately Intake Oil Pump Includes Cup and Screen Gasket Kit Oil Pump Line Oil Pump Intake Plug Oil Drain Line Oil Gauge Flexible Connector Oil Line Switch Low Oil Pressure Key 4 5 6 7 8 38 REF NO 7 18 19 20 21 22 23 24 25 26 27 28 SS PART NO 502 0058 123 0674 141 0078 122 0347 800 0005 800 0007 800 0028 102 0455 850 0040 850 0040 850 0050 526 0065 122 0352 815 0194 J PART DESCRIPTION Tee Low Oil Pressure Switch Key 4 5 6 7 8 Tube Oil Fill Gasket Oil Fill Tube Mounting Seal Air Oil Filter Screw Cap Hex Head Oil Fill Tube Mounting 1 4 20 x 3 4 Ig Screw Cap Hex Head Oil Pump Mounting 1 4 20 x 1 lg Screw Cap Hex Head Oil Filter Adapter Mounting 5 16 18x 1 ig Screw Cap Hex Head Ou Base Mounting 3 8 16 x 1 Ig Washer Lock Spring Ou Fill Tube Mounting 1 4 Washer Lock Spring Oil Pump Mounting 1 4 Washer Lock Spring Oil Base Mounting 3 8 Washer Flat Oil Filter Adapter Mounting 21 64 1Dx9 16 00x1 16 Imi Pan Oil Drain Screw Tapping Hex Head with ET 10 32 x 3 8 REF NO DD AO NA Y za 9 10 11 12 PART NO 150 0078 150 1695 510 0015 105 0004 515 0001 10
46. inding Invert the carburetor body and measure the float level CARBURETOR ASSEMBLY 1 Install the throttle shaft and plate using new screws and lockwashers Install the bevel mated FLOAT rw FUEL INLET VALVE SEAT BODY TO BOWL GASKET FIGURE 32 CARBURETOR DISASSEMBLY to the carburetor body On plates marked with the letter C install with the mark on the side toward the idle port when viewed from the flange end of the carburetor To center the plate back off the top screw close the throttle lever and seat the plate by tapping it with a small screwdriver Then tighten the two screws 2 Install the choke shaft and plate Center the plate in the same manner as the throttle plate Step 1 Use new screws and lockwashers 3 Install the fuel inlet valve seat and valve 4 Install the float and float pin Center the pin so the float bowl does not ride against it 5 Check the float level with the carburetor casting inverted See Figure 33 6 Install the carburetor body with the gasket align ed properly 7 Install the fuel adjustment screws finger tight Then back out 1 to 1 1 2 turns 8 Reconnect the choke linkage FUEL PUMP A diaphragm type fuel pump is used If fuel does not reach the carburetor check the fuel pump To do this disconnect the fuel line at the carburetor and while cranking the engine slowly by hand observe whether fuel comes through the line Be sure there is fuel in the 24 MEASURE WITH
47. ings or a new crankshaft should be installed If a worn main bearing journal cannot be fitted with an available precision type undersize bearing then refinish it to the next under size If a worn rod journal cannot be fitted by installing new bearing inserts then refinish it to take the corresponding undersize bearing insert available Whenever making major repairs on the engine always inspect the drilled passages of the crankshaft Clean them to remove any foreign material and to assure proper lubrication of the connecting rods BEARINGS Removal of the camshaft or crankshaft bearings requires complete disassembly of the engine Use a press or a Suitable drive plug to remove the bearings Support the casting to avoid distortion and avoid damaging the bearing bore during removal and installation Use oil on the bearings to reduce friction when installing and again lubricate with oil after installing see Figure 26 Use Onan combination bearing driver 420 0324 to install the camshaft bearings Camshaft Replacement camshaft bearings are precision type which do not require line reaming or line boring after installation Coat the bearing with lubricating oil to reduce friction Place the bearing on the crankcase over the bearing bore with the lubricating hole front only in proper position Be sure to start the bearing Straight Press the front bearing in flush with the outside end of the bearing bore Press the rear bearing in until p
48. low standard battery storage procedure PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE Regularly scheduled maintenance is the key to lower operating costs and longer service life for the unit Use the following schedule as a guide However actual operating conditions under which a unit is run should be the determining factor in establishing a maintenance schedule When operating in very dusty or dirty conditions reduce some service periods SERVICE THESE ITEMS Inspect Engi Check Oil Level _ Clean Governor Linkage Service Air Cleaner Change Crankcase Oil Replace Oil Filter Replace Spark Plugs Clean Breather Valve _ Check Breaker Points Check Battery Electrolyte Level Clean Fuel System _ Replace Air Cleaner Element Remove Carbon amp Lead Deposits Check Valve Clearance x1 Perform more often in extremely dusty conditions Check the condition of the crankcase oil the filters etc frequently until the proper service time periods can be established For any abnormalities in operation unusual noises from engine or accessories loss of power overheating etc contact your Onan dealer NOTE If tractor is out of service for more than 30 days between seasons for example see Out of Service Protection in the OPERATION section WARNING All exhaust system connections MUST be checked regularly for any leaks and tightened as necessary Do NOT terminate exhaust pipe under tractor CRANKCASE
49. nce ee RE NNN da NN de STEEN 44 Block Cylinder co ooooncornrorsccrocor carr roca rra os 36 37 COBH s n mmmeie s rc 39 Carburetor Parts CATAS AAA IATA 49 Crankshaft AAA ARALAR 40 Fuel System EA E SER RRS Ce ee 41 Gear Cover e a arc 47 DIEN OR rT RAEE CERA NAAA 46 Housing Blower ooooooooooosociocoro rocoso di 46 AAA NAAA NN 45 DEDO oscar criar dara 38 Piston and Connecting Rod sccceosneeaease ra 39 Purnp Porte A RAE RR NA 42 Service Kits and Miscellaneous eee e nee eeeeeeees Seege 47 Starter Motor EREET De ERECTA A ARL EE 44 Valve Cover and Oil By Pass RANA KR ele loiale EEN ER 37 CYLINDER BLOCK CYLINDER BLOCK REF PART QTY PART HO NO USED DESCRIPTION 1 BLOCK ASSEMBLY 110 1770 1 Key 1234 110 1911 1 Key 5 6 7 8 2 517 0048 1 Plug Camshaft Expansion 3 800 0512 5 Screw Cap Hex Head Rear Bearing Plate Mounting 516 18 x 1 4 502 0020 1 Elbow Street Ou Line Keys 1 2 3 4 amp 5 5 110 0892 2 Gasket Cylinder Head 6 110 0884 1 Head Cylinder Right 2 Cylinder 7 110 0883 1 Head Cylinder Left 1 Cylinder 8 BEARING CRANKSHAFT 101 0450 2 Standard 101 0450 02 2 002 Undersize 101 0450 10 2 010 Undersize 101 0450 20 2 020 Undersize 101 0450 30 2 030 Undersize 9 104 0575 2 Washer Crankshaft Bearing Thrust 10 GASKET KIT BEARING PLATE 101 0413 1 Key 1 2 3 4 101 0115 1 Key 5 6 7 8 11 101
50. nd Sleepiness e Throbbing in Temples if you experience any of the above symptoms get out into fresh air immediately The best protection against carbon monoxide inhalation is a regular inspection of the complete exhaust system If you notice a change in the sound or appearance of exhaust system shut the unit down immediately and have it inspected and repaired at once by a competent mechanic SPECIFICATIONS All clearances given at room temperature of 70 F 21 C All dimensions in inches unless otherwise specified metric equivalents in parentheses where applicable RK EE E EE E 4 cycle Air Cooled a a A A Gasoline Rated Power GH 000 Meri 16 5 HP 12 3 kw Ne ERNEST RON RR SRI RE RE REN RARA 2 oe re nn ia 0 000020610 RAE AREA Esa 49 8 in 816 cm SUOKG Shi corer TATS EE EE 3 000 inches 76 2 mm OG is 5 ae EE EE SEENEN do Ee 3 250 inches 82 6 mm Compression sea level 100 120 psi 7 03 8 44 kg sq cm CIMIENTO AAC Horizontal Ductile Iron A A RR RI CORONINI EE Mechanical A AAA Sleeve Oil Capacity including 1 2 qt 0 47 1 for filter 2 1 2 U S Quarts 3 31 litres LUDFICATION System ii iia ale EE EE Ee EEN e Es Full Pressure cl ee REA AAA ARALAR A DAA AAA Battery Cooling Air Volume at 3600 rpM oooooooooomccrcororoo 830 ctm 23 5 m min A EN Adjustable mechanical flyball PUG PUD VDO ooo cozi si ocoale oa ai oa aaa AICA a Diaphragm Fuel Rom EE aa 4 feet 1 22 m
51. ns OIL SEALS The bearing plate must be removed to replace its oil seal Drive the oil seal out from the inside using Onan bearing plate driver 420 0181 and gear cover driver 420 0313 Before installing the seals fill the space between seals with a fibrous grease or stiff cup grease This will improve sealing see Figure 27 When installing the gear cover oil seal tap the seal inward until it is 1 inch 25 4 mm from the mounting face of the cover Install new style thin open face seal 1 7 64 inches 28 2 mm from mounting face of cover When installing the bearing plate oil seal tap the seal into the bearing plate bore to bottom against the shoulder in the plate bore Use a seal expander or place a piece of shim stock around the end of the crankshaft when replacing the bearing plate to avoid damaging the seal Remove the shim stock as soon as the plate is in place Use heavy fiber or cup grease in space between seals improve seal MOUNTING FACE OF GEAR COVER New style thin open face seal dimension is REAR BEARING PLATE THIS SURFACE SHOULD BE CLEANED OF ALL OLD SEALING COMPOUND BE FORE INSTALLING SEAL 1 7 64 28 2 MM THIS SURFACE SHOULD BE CLEANED OF ALL OLD SEALING COMPOUND BE INSTALLING SEAL FORE A877 GEAR COVER OIL SEAL DRIVE OR PRESS OIL SEAL TO SHOULDER OF THE PLATE BORE REAR BEARING PLATE OIL SEAL FIGURE 27 GEAR COVER AND REAR BEARING PLATE OIL SEALS CRANKSHAFT ENDPLAY
52. o aie ag RR e ia 22 H BEE MI AR IEA IDA O 23 Ignition and Battery Charging ooooooooocmocm 26 SING SYR rociar rra 29 PIES CIO ai AAA Dic aie AI 34 WINO EE ea a oe 1 GENERAL INFORMATION YOUR MANUAL ENGINE MODEL REFERENCE The manual contains operation maintenance Some instructions in this manual refer to specific troubleshooting service information and a parts models of industrial engines Identify the model by catalog for the CCKA engine Keep the manual in a referring to the model number as shown on the unit handy location and refer to it often nameplate Throughout the text engine end with the flywheel is How to interpret a typical MODEL NUMBER considered engine front Left and right are deter mined when facing the front of the engine CCKA MS 2813 J 1 2 3 4 1 Factory code for general identification purposes 2 Specific Type MS ELECTRIC starting with stub shaft starter and generator 3 Factory code tor optional equipment supplied 4 Specification Spec letter advances with factory production modification ENGINE EXHAUST GAS CARBON MONOXIDE IS DEADLY Carbon monoxide is an odorless colorless gas formed by incomplete combustion of hydrocarbon tuels Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal Some of the symptoms or signs of carbon monoxide inhalation are e Dizziness Vomiting e Intense Headache e Muscular Twitching e Weakness a
53. ods are serviced Remove the rods with the pistons Replaceable bushings and bearings are used See PARTS CATALOG section for available undersize and standard size bearings Proper clearance is obtained by replacing the pin bushing and the bearings The rod bearings are precision size and require no reaming Install the connecting rods and caps with raised lines witness marks aligned and with the caps facing toward the oil base The rod and cap numbered 2 fits on the crankshaft journal nearest the bearing plate Coat the crankshaft journal bearing surfaces with oil before installing the rods Crank the engine by hand to see that the rods are free If necessary rap the connecting rod cap screws sharply with a soft faced hammer to set the rod square on the journal Checking Bearing Clearance With Plastigage Make certain that all parts are marked or identified so that they are reinstalled in their original positions FIGURE 22 MEASURING BEARING CLEARANCE WITH PLASTIGAGE Place a piece of correct size Plastigage in the bearing cap the full width of the bearing insert about 1 4 inch 6 35 mm off center Figure 22 Rotate the crank about 30 from bottom dead center and reinstall the bearing cap Tighten the bolts to the torque specified in the ASSEMBLY TORQUES section Do not turn the crankshaft Remove the bearing cap Leave the flattened Plastigage on the part to which it has adhered and compare the widest point with the grad
54. omplete Model Spec anu Serial Number REF 12 13 14 15 16 z Z Bonvouaunv O IGNITION 24 PART QTY PART NO USED DESCRIPTION 160 0930 1 Cover Breaker Box 160 0150 1 Gasket Breaker Box Cover 160 0075 1 Cam Point Gap Adjusting 160 0002 1 Point Set breaker 304 0610 1 Support Resistor Terminal 312 0069 1 Condenser Breaker Points 167 0188 1 Clip Spark Plug Cables 160 0043 1 Gasket Breaker Box Mounting 304 0060 1 Resistor Ignition 160 0262 1 Plunger Assembly Includes Plunger and Guide CABLE SPARK PLUG RIGHT 167 1594 1 8 1 2 Key 1 2 3 4 5 6 167 1596 1 7 1 4 Key 7 8 166 0346 1 Coil Ignition CABLE SPARK PLUG LEFT 167 1594 1 Key 1 2 3 167 1593 1 17 1 2 Key 4 5 6 167 1595 1 17 Key 7 8 160 0263 1 Diaphragm Breaker Box PLUG SPARK 167 0241 2 Key 1 2 3 4 5 6 167 0237 2 Key 7 8 160 0257 1 Box Breaker Includes Points Condenser Cover and Gasket N VG Ze REF NO 17 18 19 21 22 23 24 27 28 31 32 PART NO 503 0514 160 0558 166 0376 160 0428 160 0349 334 0028 160 0261 166 0562 802 0034 870 0053 854 0010 813 0112 850 0030 304 0014 850 0040 815 0201 821 0004 336 0332 QTY USED Na _ ep zb zg NN PART DESCRIPTION Clamp Coil Nipple Rubber Coil Bracket Coil Mounting Key 1 2 3 Strap Point Set to Terminal Block Block and Terminal Assembly Lead 4 ft piece of wire Wick Breaker Box Oil Drain Bra
55. operly 3 Never reverse the battery leads Regulator Rectifier Tests The following tests for the regulator rectifier require a fully charged battery 1 Connect a voltmeter across the battery Start the engine and operate at 1800 to 3600 rpm 2 Voltmeter should read 13 4 to 14 volts If it does no further testing of the charging system is necessary If not install a new regulator rectifier TO STARTER B CONNECTION TO IGNITION COIL PRIMARY WHITE FUSEHOLDER WITH 30 AMP FUSE BLACK FIGURE 38 FLYWHEEL BATTERY CHARGING ALTERNATOR and retest Be sure it has a good ground connec tion and the connector is properly seated Stator Test Engine Running 1 Before starting the engine disconnect the con nector at the voltage regulator Be sure engine is stopped before perfor BARNES ming step 2 Otherwise personal injury may result from rotating flywheel 2 Insert test connectors from AC voltmeter between the two yellow wires Figure 38 3 Voltage should be 17 volts or higher If not stop engine and check leads to stator If they are okay perform next check Stator Tests Engine Not Running For testing use a Simpson 270 VOM or equivalent Be sure test meter and battery if battery powered are in good condition Check with engine NOT running 1 Set voltage selector switch to DC and zero meter on RX1 scale Zero the meter before each reading and each time scales are changed 2 Unplug the connector
56. ottom of the cylinder must be worked out first because it is smaller Then when the cylinder takes a uniform diameter move the hone up and down all the way through the bore Follow the hone manufacturer s recommendations for wet or dry honing and oiling the hone Check the diameter of the cylinder regularly during honing A dial bore gauge is the easiest method but a telescoping gauge can be used Check the size at six places in the bore measure twice at the top middle and bottom at 90 angles When the cylinder is approximately 0 002 inch 0 051 mm within the desired bore change to fine stones and finish the bore The finish should not be smooth but as shown in Figure 25 The crosshatch formed by the scratching of the stones should form an angle of 23 This can be achieved by moving the hone up and down in the cylinder about 40 cycles per minute Clean the cylinder block thoroughly with soap water and clean rags A clean white rag should not be soiled on the wall after cleaning is complete Do not use a solvent or gasoline since they wash the oil from the walls but leave the metal particles Dry the crankcase and coat it with oil PRODUCE CROSS HATCH SCRATCHES FOR FAST RING SEATING AVOID THIS FINISH FIGURE 25 HONE FINISH CRANKSHAFT Inspect the bearing journals If they are scored and cannot be smoothed out by dressing down the bearing journals should be refinished to use nearest available undersize bear
57. ove capscrew or slotted stud and locknut located behind gear cover and under governor arm Location of the capscrew is the same as shown for the slotted stud and locknut in Figure 30 A LF OIL BYPASS RELIEF VALVE ADJUSTMENT CW INCREASE CCW DECREASE FIGURE 30 BYPASS VALVE ADJUSTMENT 2 Remove spring and plunger with a magnet tool Clean plunger and spring with a suitable solvent and reinstall Bypass Valve Adjustment This adjustment applies to all Spec G models except the CCKA MS 2116G and CCKA MS 2567G models To increase oil pressure loosen the locknut and turn the stud inward Figure 30 To decrease oil pressure loosen the locknut and turn the stud outward Be sure to tighten the locknut securely after making an adjustment The spring and plunger can be removed and cleaned Low oil pressure may indicate worn main or connec ting rod bearings improper clearance at these points a weak or broken bypass spring an improperly adjusted bypass or a defective gauge Check the oil pressure gauge before making any other test it may be defective LOW OIL PRESSURE SWITCH All models except the CCKA MS 1831G have a low oil pressure switch It is generally used to operate alow oil pressure warning light for oil pressure lower than 8 to 10 pounds per square inch 0 56 to 0 70 kg sq cm FUEL SYSTEM GENERAL Satisfactory engine performance is largely depen dent upon correct fuel system adjustments However adjustment
58. p Gear type oil pump Oil pressure gauge Oil passages to deliver oil throughout engine Oil filter The oil pump is located on the front surface of the crankcase and is driven by the crank gear The inlet pipe and screen assembly is attached directly to the pump body A discharge passage in the cover of the pump registers with a drilled passage in the crankcase Parallel passages distribute oil to the front main bearing rear main bearing and pressure control bypass valve Circumferential grooves in the main bearings supply oil to the connecting rod bearings through drilled passages from each journal A drilled passage connects the front main bearing oil supply to the front camshaft bearing The flyball governor is lubricated by a drilled passage in the front camshaft journal The oil overflow from the bypass valve furnishes lubrication to the camshaft drive gears OIL BYPASS VALVE The bypass valve located to the right and behind the gear cover controls oil pressure by allowing excess oil to flow directly back to the crankcase Normally the valve begins to open about 30 psi 2 11 kg sq cm The valve is nonadjustable for all models begin Spec J and models CCKA MS 2111G and CCKA MS 2567G Other Spec G models had an adjustable bypass valve see Bypass Valve Adjustment Normally the valve requires no maintenance To determine if abnormal high or low oil pressure is caused by a sticky plunger inspect as follows 1 Rem
59. ral times by hand while the engine is idle If either of these conditions exists find out where the trouble lies and adjust or replace parts as needed IGNITION AND BATTERY CHARGING IGNITION SYSTEM The engine is equipped with an automotive type battery ignition system Both spark plugs fire simultaneously thus the need for a distributor is eliminated Spark advance is fixed at 19 BTC before top center which should be maintained for best performance Ignition timing should be checked periodically especially after breaker point replace ment BREAKER POINTS 1 Remove the two screws and the cover on the breaker box 2 Remove the two spark plugs so engine can be easily rotated by hand If plugs have not been changed within the last 100 hours replace them with new ones after setting the breaker points 3 Remove the two mounting screws A and pull the points out of the box just far enough so screw B can be removed See Figure 36 Replace points with a new set but do not completely tighten mounting screws A 4 Rotate the engine clockwise facing flywheel by hand until points are fully open Turn screw C until point gap measures 0 020 inch 0 508 mm with a flat thickness gauge 5 Tighten mounting screws and recheck gap 6 Proceed to gnition Timing Each time new breaker points are installed place a drop of oil on the point s pivot point Figure 36 PLACE DROP OF OIL ON PIVOT POINT WHENEVER NEW POINTS ARE I
60. re 4 ra i _ Use extreme care when cleaning with a WARNING petroleum base cleanser due to fire hazard BREATHER HOSE HOSE CLAM CAP AND VALVE BAFFLE BREATHER TUBE FIGURE 4 CRANKCASE BREATHER BEGIN SPEC J Spec G Clean the crankcase breather every 200 operating hours Figure 5 To clean the breather lift off the rubber breather cap Carefully pry the valve from cap Otherwise press hard with both of your thumbs on top of cap and fingers below to release valve from rubber cap Wash this fabric flapper type check valve in a petroleum base solvent Dry and reinstall position ing perforated disc toward engine wae Use extreme care when cleaning with a WARNING petroleum base cleanser due to fire hazard A TUBE FROM AIR CLEANER I BREATHER ay TUBE BAFFLE FIGURE 5 CRANKCASE BREATHER SPEC G 11 GOVERNOR LINKAGE The linkage must be able to move freely through its entire travel Every 40 hours of operation clean the joints and lubricate as shown in Figure 6 Also inspect the linkage for binding excessive slack and wear TO LOOSEN PULL JOINT APART CLEAN AND LUBRICATE WITH GRAPHITE O04 KEEP GOVERNOR LINKAGE LUBRICATED WITH GRAPHITE FIGURE 6 GOVERNOR LINKAGE SPARK PLUGS Each time the spark plugs are removed inspect clean and regap Figure 7 If the plug looks discolored or has fouled replace it SPARK PLUG GAP 0 025 IN 0 635 MM FIGURE 7 CHECKING SPARK
61. s as shown in Figure 53 replace them See that the brushes move STARTING BATTERY smoothly in the brushholders MOTOR 03 IN A a 7 Grt a RPM a INDICATOR BA BEGIN SPEC T SPEC G FIGURE 53 BRUSH WEAR LIMITS FIGURE 55 WIRING STARTER FOR NO LOAD TESTS 32 inspect the following items 2 To adjust pinion clearance connect the battery to biui the starting motor as shown in Figure 56 This will engems eege ES allow the pinion of the starting motor to slide and insufficient armature endplay stop In this state measure the clearance between oe open or inp ad the end of the pinion and pinion stop when the rounded or open pinion is pushed lightly toward the commutator uuu end Clearance should be 0 02 to 0 06 inch 0 51 to 1 52 mm Adjust for proper clearance by remov ing the solenoid switch attaching screws and select the proper thickness of the fiber packings shown in Figure 57 STARTING MOTOR BATTERY FIGURE 57 ADJUSTING PINION CLEARANCE FIGURE 56 BATTERY CONNECTIONS PARTS CATALOG INSTRUCTIONS FOR ORDERING REPAIR PARTS For parts or service contact the dealer from whom you purchased this equipment or refer to your Nearest Authorized Onan Parts and Service Center To avoid errors or delay in filling your parts order please furnish all information requested Always refer to the nameplate on your unit 1 Always give the MODEL and SPEC NO and SERIAL NO MODEL AND SPEC NO SERIAL NC rl IMPO
62. s cannot fully compensate for low engine power due to wear etc If trouble develops follow an orderly procedure to determine the cause before making any adjustment Adjusting the carburetor is means of obtaining the correct fuel to air mixture for smooth efficient operation Always adjust in two steps first the load adjustment and then the idle adjustment CARBURETOR ADJUSTMENTS Before adjusting the carburetor be sure the ignition system is working properly and the governor is adjusted Allow the engine to warm before starting carburetor adjustments It carburetor is completely out of adjustment so the engine will not start open both adjustment screws counterclockwise 1 to 1 1 2 turns off their seats to permit starting Do not force the needles against their seats This can bend the needle 1 Apply a full load to engine if possible 2 Turn the load adjustment screw clockwise Figure 31 until engine speed drops Then turn screw counterclockwise until engine speed returns to normal LOAD ADJUSTMENT WRENCH IDLE ADJUSTMENT SCREW ba LOAD ADJUSTMENT SCREW CARBURETOR ADJUSTMENTS FIGURE 31 23 3 Remove load from the engine 4 Turn idle adjustment screw counterclockwise until engine speed drops slightly Then turn the screw clockwise until speed returns to normal Alternate Method No load adjustment possible 1 Start the engine and allow it to warm up 2 Push in on the governor mechanism to slow
63. sswise of the block e Reading A compared to B and reading C compared to reading D indicates cylinder taper If cylinder taper exceeds 0 005 inch 0 127 mm rebore and hone to accommodate the next oversize piston Reading A compared to reading C and reading B compared to reading D indicates whether or not the cylinder is out of round If the out of round exceeds 0 002 inch 0 051 mm the cylinders must be rebored and honed for the next oversize piston A reboring machine is used when going to oversize pistons The following repair data covers honing to oversize by use of a hone Repair 1 A hone can be used to rebore a cylinder Figure 24 Remove stock to 0 002 inch 0 051 mm undersize of finish bore with coarse hone 100 grit then complete honing with finish hones 300 grit Anchor the block solidly for either vertical or horizontal honing Use either a drill press or heavy duty drill which operates at approximately 250 to 450 rpm Lower the hone into the cylinder until it protrudes 1 2 to 3 4 inch 12 7 to 19 0 mm past the end of the cylinder Rotate the adjusting nut until the stones come in contact with the cylinder wall at the narrowest point Turn the hone by hand Loosen the adjusting nut until the hone can be turned Connect drill to hone and start drill Move the hone up and down in the cylinder approximately 40 cycles per minute Usually the b
64. that can be ignited by electrical arcing or by smoking Exhaust Gases Are Toxic Provide an adequate exhaust system to properly expel discharged gases Check exhaust system regularly for leaks Ensure that exhaust manifolds are secure and not warped Be sure the unit is well ventilated Keep The Unit And Surrounding Area Clean Remove all oil deposits Remove all unnecessary grease and oil from the unit Accumulated grease and oil can cause overheating and subsequent engine damage and may present a potential fire hazard Do NOT store anything in the generator compart ment such as oil cans oily rags chains wooden blocks etc A fire could result or the generator set operation may be adversely affected Keep the floor clean and dry Protect Against Moving Parts Avoid moving parts of the unit Loose jackets shirts or sleeves should not be permitted because of the danger of becoming caught in moving parts Make sure all nuts and bolts are secure Keep power shields and guards in position If adjustments must be made while the unit is running use extreme caution around hot manifolds moving parts etc Do not work on this equipment when mentally or physically fatigued eg TABLE OF CONTENTS TITLE PAGE Genaral Babich pee A a 2 DEER EELER EEN en EE NA 3 Dimensions and Clearances WEE A 3 arata au ata 3 AGUOMI LONER TE A OP PPR E 5 A WEE 6 1 dE EE EE EE 7 e let lt EE 9 ANOO amb ee E E d KEESS ais 12 a EA E a ga
65. the unit down to about 400 to 500 rpm 3 Release the governor mechanism to allow the engine to accelerate If the engine accelerates evenly and without a lag the load screw setting is correct If not adjust the screw counterclockwise about 1 4 turn and again slow down the engine and release the mechanism Continue until the engine accelerates evenly and without a time lag after releasing the governor 4 Push in on the governor mechanism to slow the unit to 400 to 500 rpm Set the idle screw for even operation so the engine is firing on both cylinders and running smoothly CARBURETOR DISASSEMBLY Remove the choke linkage from the choke cable bracket and clip 2 Remove the main carburetor body from the choke sleeve 3 Remove the float pin and float See Figure 32 4 Lift out the fuel inlet valve and unscrew the valve seat 5 Remove the load and idle adjustment screws 6 Remove the throttle plate screws and the plate and pull out the throttle shaft 7 Remove the choke plate screws and plate and pull out the choke shaft Cleaning and Repair To clean the carburetor soak all components thoroughly in a carburetor cleaner following the cleaner manufacturer s instructions Be sure all car bon is cleaned from the carburetor bore especially in the area of the throttle valve Blow out the passages with compressed air If possible avoid using wire to clean out the passages The float should fit freely on its pin without b
66. tiously applied maintenance program will help to assure satisfactory service While the engine can be loaded to the full nameplate horsepower rating during initial operation apply half load the first few hours of operation with intermittent periods of full load During break in check oil level often Add oil if the level is at low on the dipstick Never overfill This may cause oil to foam and enter the breather system Drain the initial oil fill after five hours of operation while the engine is still hot See the PERIODIC MAINTENANCE section for oil recommendations fe Do NOT check oil while the generating set is WARNING operating Hot oil could cause burns by blowing out of oil fill tube due to crankcase pressure STOPPING Refer to tractor manual for location and operation of Stop control HIGH OPERATING TEMPERATURE CONDITIONS 1 See that nothing obstructs airflow to and from the engine 2 Keep cooling fins clean Air housing should be properly installed and undamaged 3 Keep ignition timing properly adjusted LOW OPERATING TEMPERATURE CONDITIONS 1 Use correct SAE oil for temperature conditions Change oil only when engine is warm If an unexpected temperature drop causes an emergency move the tractor to a warm location 2 Use fresh gasoline Protect against moisture condensation Below 0 F 18 C adjust car buretor main jet for a slightly richer fuel mixture 3 Keep ignition system clean properly adjusted
67. tool If such a tool is not available make pencil marks at intervals across the valve face and observe if FIGURE 15 VALVE FACE AND SEAT ANGLES 15 the marks rub off uniformly when the valve is rotated part of a turn against the seat Lightly oil the valve stems and reassemble all parts removed Adjust the valve clearance see Tappet Adjustment The positive type valve rotocoils serve to prolong valve life and decrease valve repairs Check the rotocoils periodically by removing the cylinder heads and cranking the engine When functioning properly the valve is rotated a fraction of a turn each time it opens If rotocoils are faulty install new ones TAPPET ADJUSTMENT The engine is equipped with adjustable tappets To make a valve adjustment remove the valve covers Crank the engine over slowly by hand until the left hand intake valve when facing the flywheel opens and closes Continue about 1 4 turn until the correct timing marks align This should place the left hand piston at the top of its compression stroke the position it must be in to get proper valve adjustment for the left hand cylinder Clearances are shown in DIMENSIONS AND CLEARANCES section For each valve the gauge should just pass between the valve stem and valve tappet Figure 16 To correct the valve clearance turn the adjusting screw as needed to obtain the right clearance The screw is self locking To adjust the valves on the right hand cylinder
68. uations on the Plastigage envelope to determine bearing clearance CYLINDER BLOCK Inspection 1 Make a thorough check for cracks Minute cracks may be detected by coating the suspected area with a mixture of 25 kerosene and 75 light motor oil Wipe the part dry and immediately apply a coating of zinc oxide white lead dissolv ed in wood alcohol If cracks are present the white coating will become discolored at the defective area 2 Inspect the cylinder bore for scoring Check the Welsh plugs for a tight even fit and the fins for breakage 3 Check the cylinder bore for taper out of round and wear with a cylinder bore gauge telescope gauge or inside micrometer Figure 23 These measurements should be taken at four places the top and bottom of piston ring travel 4 Record measurements taken lengthwise at the top and bottom of the piston travel as follows a Lengthwise of the block measure and record as A the diameter of the cylinder at the top of the cylinder where the greatest ring wear occurs FIGURE 23 METHODS OF CYLINDER INSPECTION 18 FIGURE 24 HONING CYLINDER b Also lengthwise of the block measure and record as B the cylinder diameter at the piston skirt travel c Crosswise of the block measure and record as C the diameter of the top of the cylinder at the greatest point of wear d Measure and record as D the diameter at the bottom of the cylinder bore and cro

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