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Cummins/Onan CCK Engine

The Cummins/Onan CCK is a 0.5 L 2-cylinder natural engine rated at 1800 rpm. It powers generator sets from Cummins/Onan, including the 3.5CCK, 4.0 CCK-3R, 4.0CCK and 4.0CCK-3CR. It holds 2.8 L (0.7 gal) of oil.

Also known as: Onan CCK

0.498 L
Displacement
2
Cylinders
1800 rpm
Rated speed
2.8 L
Oil capacity

Engine specifications

Oil capacity2.8 L
Displacement0.498 L
Cylinders2
Aspirationnatural
Rated speed1800 rpm

Common problems

15
  • Voltage drops under heavy load
    Cause: Engine lacks power
    Fix: See remedies for engine misfires under heavy load.
  • Hot crank
    Cause: Lack of fuel or faulty carburetion
    Fix: Refill tank. Check fuel system. Clean, adjust, as necessary.
  • Low oil pressure
    Cause: Defective gage
    Fix: Replace.
  • Excessive oil consumption, light blue smoky exhaust
    Cause: Oil leaks from oil base or connections. This does not cause smoky exhaust.
    Fix: Replace gaskets. Tighten screws and connection. Check breather valve.
  • Pinging sound when engine is suddenly or heavily loaded
    Cause: Wrong spark plug
    Fix: Install correct spark plug.
  • High oil pressure
    Cause: Defective gage
    Fix: Replace.
  • Engine will not start when cranked
    Cause: Battery discharged
    Fix: Refill tank. Check fuel system. Clean, adjust, as necessary.
  • Engine overheating
    Cause: Insufficient cooling air
    Fix: Check air entrance and exit.
  • Engine misfires at light load
    Cause: Spark plug gap too narrow
    Fix: Adjust to correct gap
  • Engine misfires at heavy load
    Cause: Spark plug gap too wide
    Fix: Adjust gap
  • Black, smoky exhaust, excessive fuel consumption, fouling of spark plug with soot, possible lack of power under heavy load
    Cause: Fuel mixture too rich
    Fix: Adjust carburetor or choke. Install needed carburetor parts.
  • Out of Fuel
    Fix: Check fuel
  • Loose or Corroded Battery Connection
    Cause: Faulty Starter
  • Fails to crank
    Cause: Bad battery connection
    Fix: Clean and tighten all battery and cable connections.
  • Cranks but won't start F2
    Cause: Blown fuse (F2)
    Fix: Replace fuse (F2) on control.

Compiled from service & troubleshooting documentation across every generator set that uses the Cummins/Onan CCK.

Maintenance schedule

ItemSpecCapacityPart #Interval
Air filter140B495500 hr Amazon eBay $22.91
Fuel filter149-202 Amazon eBay
Oil filter122-37 Amazon eBay $16.95 NAPA $17.50
Battery—
BeltBelt, Alternator511-76 Amazon eBay
Coolant—
FuelFuel system and pump—
OilAPI SE or SE/CC4.0 liters—100 hr
Spark plug0.025' GASOLINE167-242100 hr eBay

Pooled from every document that names this exact engine — confirm the interval and part number against your unit's serial number.

Service intervals

40
ItemActionHoursMonthsNotes
Air cleaner oil levelCheck8 hrDaily service; add oil same SAE number as crankcase.
Crankcase oil levelCheck8 hrDaily service; add oil as necessary to full mark.
Fuel supplyCheck8 hrDaily service; perform each 8 hours if operated more than 8 hours daily.
GeneralInspect8 hr
General inspectionInspect8 hr
Oil levelCheck8 hrDuring break-in, check at least every 8 operational hours.
Plant cleanlinessClean8 hrDaily service; wipe off dirt and spilled oil.
Air cleanerClean100 hrPerform more often in extremely dusty conditions; replace element every 500 hours
Battery electrolyteCheck200 hr
Engine oilChange50 hrFirst service — Change crankcase oil after first 50 hours of operation
Governor linkageClean50 hr
Governor linkageLubricate100 hrClean joints and lubricate every 50 hours
OilChange50 hrChange crankcase oil after first 50 hours; every 50 hours or sooner in dusty conditions
Spark arrester/muffler, screen typeClean50 hrRemove and scrape clean or replace screen; may be blown clean with compressed air. Every 50 operating hours.
Spark arrester/muffler, spin-out typeClean50 hrRemove pipe plug in bottom of muffler and run set for 5 minutes; replace plug. Every 50 hours of set operation.
Spark arrestersClean50 hrSpark arresters should be cleaned every 50 to 100 hours; routine cleaning during servicing is good safety practice.
BatteryInspect100 hrKeep connections tight and clean; check electrolyte.
Crankcase oilChange100 hrFirst service — Normal conditions; every 50 hours if using diluted oil, highly leaded gasoline, or severely dusty conditions.
Dolly wheel bearingsLubricate100 hrUse approved wheel bearing lubricant through Zerk fittings.
Fuel filterClean100 hrEvery 100 hours or sooner, drain fuel pump and check filter element
Reduction gear boxDrain100 hr6 moFirst service — every six months thereafter or every 100 hours
Reduction gear box oilChange100 hr6 moevery six months thereafter or every 100 hours
Reduction gear box oilDrain100 hrFirst service — after first 100 hours
Reduction gear drive oilDrain100 hr6 moFirst service — Drain after first 100 hours, then every six months or every 100 hours, whichever is first.
Spark plugsCheck100 hr
Spark plugsClean100 hrClean and reset gap; replace defective plug.
Spark plugsReplace100 hrif not changed within last 100 hours
Breaker pointsAdjust200 hrInspect, dress or replace; adjust gap to 0.020 inch at full separation.
Breaker pointsChange200 hrChange every 200 hours of operation.
Breaker pointsCheck200 hrCritical maintenance schedule
Crankcase breatherClean200 hr
Exhaust systemInspect200 hrMonthly service; inspect all connections.
Fuel system/filterClean200 hrMonthly service; drain tank, clean filter screen, empty fuel filter bowl.
Generator brushes/commutatorInspect200 hrMonthly service; replace brushes worn to 5/8 inch or less.
Oil filterReplace200 hrnormally
Air cleaner cartridgeReplace500 hrContractor model; install new cartridge every 500 hours.
Air cleaner elementReplace500 hrBegin Spec R
BrushesCheck500 hrCritical maintenance schedule
Commutator & collector ringsClean500 hrCritical maintenance schedule
Stainless steel spark arrester screenReplace500 hrFor units using specially designed stainless steel screens.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Service specifications

60
TypeItemValueUnitCondition
ClearanceArmature End Play0.004-0.020in
ClearanceArmature end play.004 to .020inch (0.102 to 0.508 mm)
ClearanceCamshaft Bearing0.0015 min / 0.0030 maxinches (0.04-0.08 mm)at room temperature 70°F
ClearanceCamshaft Bearing to Camshaft Clearance.0015-.0030in.
ClearanceCamshaft End Play.003in.
ClearanceCamshaft End Play0.003 mininches (0.08 mm)at room temperature 70°F
ClearanceCamshaft bearing0.003in
ClearanceCamshaft bearing clearance0.0015-0.0030in
ClearanceCamshaft bearing journal diameter1.3740-1.3745in
ClearanceCamshaft bearing to camshaft clearance.0015 - .0030in
ClearanceCamshaft end play0.0020-0.0033inat 70 F
ClearanceCamshaft end play0.0030-0.0120in
ClearanceCarburetor float clearance (between float bowl gasket and float).312inches (7.938 mm)
ClearanceCommutator Runout Maximum0.004in
ClearanceConnecting Rod End Play.002-.016in.
ClearanceConnecting Rod End Play (Ductile Iron)0.002 min / 0.016 maxinches (0.05-0.41 mm)at room temperature 70°F
ClearanceConnecting rod end play.002 - .016in
ClearanceConnecting rod end play (aluminum rod)0.002-0.016in
ClearanceConnecting rod end play (forged rod)0.002-0.003in
ClearanceConnecting rod journal diameter1.6252-1.6260in
ClearanceConnecting rod side clearance0.0020-0.0160in
ClearanceCrankshaft End Play.006-.012in.
ClearanceCrankshaft End Play0.0020-0.012in
ClearanceCrankshaft End Play0.006 min / 0.012 maxinches (0.15-0.30 mm)at room temperature 70°F
ClearanceCrankshaft Main Bearing0.0024 min / 0.0042 maxinches (0.061-0.10 mm)at room temperature 70°F
ClearanceCrankshaft Main Bearing - Journal to Bearing Clearance.0025-.0038in.
ClearanceCrankshaft Main Bearing Journal - Standard Size1.9992 min / 2.000 maxinches (50.779-50.8 mm)
ClearanceCrankshaft Rod Bearing Journal - Standard Size1.6252 min / 1.6260 maxinches (41.280-41.300 mm)
ClearanceCrankshaft Rod Journal to Rod Bearing Clearance.0020-.0033in.
ClearanceCrankshaft end play.006 - .012in
ClearanceCrankshaft end play0.0015-0.003inat 70 F
ClearanceCrankshaft end play0.0025 to 0.0035inch
ClearanceCrankshaft end play0.006-0.012in
ClearanceCrankshaft main bearing - journal to bearing clearance.0025 - .0038in
ClearanceCrankshaft main bearing clearance, aluminum alloy flanged prior Spec F0.002 to 0.003inch
ClearanceCrankshaft rod journal to rod bearing clearance.0020 - .0033in
ClearanceCylinder Bore - Standard Size3.2490 min / 3.2500 maxinches (82.525-82.550 mm)
ClearanceCylinder Bore Honed Diameter3.2490-3.2500in
ClearanceCylinder bore - honed3.249 - 3.250in
ClearanceExhaust Valve Stem Diameter0.3410-0.3415in
ClearanceExhaust valve stem clearance in guide0.0025 to 0.004inch
ClearanceExhaust valve stem to guide clearance0.0025-0.004in
ClearanceFront gear cover oil seal installation depth1-1/32inrear spring side of casing from gear cover mounting face
ClearanceFuel injection pump installation dimension3.260innew camshaft; instead of 3.254
ClearanceGear lash at oil pumpapproximately .005in
ClearanceGovernor cup in-and-out travel7/32incup held against flyballs
ClearanceIntake Valve Stem Diameter0.3425-0.3430in
ClearanceIntake valve stem clearance in guide0.001 to 0.0025inch
ClearanceIntake valve stem to guide clearance0.0010-0.0025in
ClearanceMain bearing clearance0.0025-0.0038in
ClearanceMain bearing inside diameter CCK (installed)2.0020-2.0030in
ClearanceMain bearing inside diameter CCKA/CCKB (installed)2.0015-2.0040in
ClearanceMain bearing journal diameter1.9992-2.0000in
ClearanceMaximum Allowable Taper0.005in
ClearanceOil Pump Gear Backlash.002-.005in.
ClearanceOil Pump Gear Backlash0.002 min / 0.005 maxinches (0.05-0.13 mm)at room temperature 70°F
ClearanceOil by-pass valve plunger diameter.3365 to .3380inches (8.55 to 8.59 mm)
ClearanceOil by-pass valve spring free length2-5/16inches (58.74 mm)
ClearanceOil pump gear backlash.002 - .005in
ClearanceOil pump gear backlash0.0005-0.0015in

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Recommended fluids

FluidGradeStandardAmbientCapacityNotes
CoolantEthylene glycol base anti-freeze mixed with waterDo NOT use straight 100% ethylene glycol. Normal mixture approximately 50% anti-freeze and 50% water; ratio varies with ambient temperature.
Coolantcoolant under pressureDo not open radiator pressure cap when coolant temperature is above 212°F (100°C) or while engine is running.
Engine oilAPI designation SE or SE/CCUse oil with API designation SE or SE/CC. Do not use an oil with designation CD unless it is also designated SE and the oil manufacturer certifies it will perform satisfactorily in gasoline engines. For gaseous operation, use an ashless or low-ash detergent oil specifically made for gaseous-fueled engines.
Engine oilAPI SE or SE/CCAPI SE or SE/CCFor gaseous operation, use ashless or low-ash detergent oil specifically made for gaseous-fueled engines. Do not use CD unless also designated SE.
Engine oilAshless or low-ash detergent oilFor gaseous operation
Engine oilSAE 10WAPI MS or MS/DG4.0 U.S. quarts0°F to 30°F
Engine oilSAE 30API MS or MS/DG4.0 U.S. quartsAbove 30°F
Engine oilSAE 30 above 30°F; SAE 10W or 5W-20 from 0°F to 30°F; SAE 5W-20 below 0°FSE or SE/CC; MS or MS/DG; MIL-L-2104B4.0 U.S. quartsDo not mix brands or grades.
Engine oilSAE 5W (5W-20 if 5W not available)Service MS or MS/DG4.0 U.S. quartsBelow 0 F; do not mix brands or grades; oil consumption usually higher with multi-viscosity all-weather oil
Engine oilSAE 5W or SAE 10W plus 10% keroseneAPI Service DG or MS/DG detergent oilbelow -18°C4.0 U.S. QuartBelow 0°F (-18°C). Use 40 ounces kerosene to each quart of oil if SAE 5W not available; mix thoroughly before pouring.
Engine oilSAE 5W-20API MS or MS/DG4.0 U.S. quartsBelow 0°F
Engine oilSE or SE/CCAPI SE or SE/CC (MS sequence / ASTM G-IV; MIL-L-2104B)4.0 U.S. quartsAbove 30 F use SAE 30; 0 F to 30 F use SAE 10W or 5W-20; below 0 F use SAE 5W-20. Do not mix brands or grades.
Engine oilSAE 50API Service DG or MS/DG detergent oilabove 32°C4.0 U.S. QuartAbove 90°F (32°C). Capacity 4 U.S. Quart typical; dimensional table lists 3 Quart for 305CCK.
FuelASTM 2-D or 1-D diesel fuelCetane number 45Use Number 1-D diesel fuel when ambient temperatures are below 32 F (0 C) or during long periods of light load/cyclic operation.
FuelClean, fresh, regular grade automotive gasolineDo not use highly leaded premium types.
FuelRegular automotive type gasoline, at least 68 octane4.0 U.S. GallonPortable type plant has 4 gallon rectangular tank mounted over generator. Do not use highly leaded premium gasoline.
FuelRegular grade automobile gasolineDo not use highly leaded premium types; never fill tank while engine is running; leave space for fuel expansion
Fuelclean, fresh, regular grade, automotive gasolineDo not use highly leaded premium types.
Fuelregular grade automotive gasolineDo not use highly leaded premium types.
Fuelunleaded or regular grade gasolineUse clean, fresh, unleaded or regular grade gasoline. Do not use highly leaded premium fuels. Use regular gasoline for the first 25 hours, then use unleaded gasoline thereafter.
Gear oilSAE 50 motor oil or SAE 90 mineral gear oil1.0 pintGear box holds 1/2 pint U.S. measure (.24 litre). Do not use extreme pressure or hypoid lubricants.
GreaseApproved wheel bearing lubricantDolly wheel bearings through Zerk fittings.
GreaseFibrous grease or stiff cup greaseFill space between oil seal lips; use cup grease to hold bearing thrust washers and to lubricate sheave hub bearing and spring pawls
GreasePowdered graphite or light non-gummy oilGovernor arm ball joint.
OtherLPGGaseous fuel optional. LPG vaporizer regulator reduces LPG tank pressure to a uniform outlet pressure of 7 psi (48.3 kPa).
OtherpropaneLPG is heavier than air and settles in low places.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

12
Adjust Breaker Points adjustment

Tools: flat thickness gauge

  1. Remove cover screws
  2. Remove spark plugs
  3. Turn flywheel clockwise about 1/4 turn after top center
  4. Loosen screws A and turn cam B until gap is .020 in.
  5. Retighten screws and recheck gap
  6. Replace spark plugs and cover
Adjust Carburetor Idle Jet adjustment

Tools: idle adjustment tool

  1. Run engine at no load
  2. Turn idle needle in until engine slows considerably
  3. Turn out until engine runs smoothly
Adjust Carburetor Main Jet adjustment

Tools: main adjustment wrench

  1. Connect full load
  2. Turn main needle out about two turns
  3. Turn in slowly until engine loses power
  4. Turn out slowly until smooth at full power
  5. Do not open more than 1/2 turn beyond maximum power
Adjust Electric Choke adjustment
  1. Loosen two cover retaining screws
  2. Turn cover clockwise for less choking action
  3. Turn counterclockwise for more choking action
  4. Retighten cover screws
Adjust Sisson Choke adjustment

Tools: 1/16 in. diameter rod

  1. Insert 1/16 in. rod through shaft hole into mounting flange notch
  2. Loosen choke lever clamp screw
  3. Adjust choke lever so plate is closed or not more than 5/16 in. open
  4. Tighten screw and remove rod
Adjust anti-dieseling solenoid adjustment
  1. With set stopped, turn lever counterclockwise; set screw so plates are closed but not binding.
  2. Check lever has approximately 30 degrees travel counterclockwise from vertical.
  3. Start set; lever should rotate approximately 60 degrees clockwise from stopped position.
  4. Check solenoid plunger is fully seated.
  5. If not, adjust distance between plunger and lever arm; repeat steps.
Adjusting the Gas Pressure Regulator adjustment

Tools: Manometer reading up to 14 inches water column

  1. Use a manometer which reads up to 14 inches (355.6 mm) water column.
  2. Shut off gas supply. Temporarily remove the 1/8-inch pipe plug at regulator inlet for testing pressure.
  3. Connect manometer to read gas supply line pressure.
  4. Open gas supply line valve. Alternately cover and uncover the regulator outlet with your palm. Watch manometer. If regulator closes completely, manometer holds steady reading.
  5. If manometer reading drops slightly each time you remove your hand, regulator is leaking. Turn adjusting screw inward just enough so reading remains constant.
  6. Close gas supply line valve. Remove manometer. Bleed air from gas supply line. Install test-hole plug in regulator. Open gas supply line valve.
  7. See that vent fitting is installed in the regulator hole.
  8. Secure hose between regulator outlet nipple and carburetor inlet with clamps on each end.
  9. Operate engine to assure quick starting results.
Breaker Point Gap Adjustment adjustment

Tools: thickness gage

  1. Crank engine to fully open breaker points (1/4 turn after top center).
  2. Loosen and move stationary contact to correct gap.
  3. Set breaker point gap at 0.020 in.
  4. Secure points and check for correct gap.
Breaker Points Adjustment adjustment

Tools: Flat thickness gauge, File or fine stone

  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.
  3. Turn flywheel clockwise approximately 1/4 turn after top center (TC).
  4. Loosen screws (A) and turn cam (B) until point gap measures .020 in with a flat thickness gauge.
  5. Retighten screws (A) and recheck gap.
  6. If points are slightly burned, dress smooth with a file or fine stone; if burned and pitted, replace with a new set.
  7. Replace spark plugs and breaker box cover.
Carburetor Adjustment adjustment

Tools: Onan carburetor wrench 420B169

  1. Turn main adjusting needle out about two full turns.
  2. Turn main needle slowly in until engine begins to lose power and speed.
  3. Then turn out very slowly until engine runs smoothly at full power.
  4. Adjust idle jet needle with engine at normal temperature and no load.
  5. Turn idle needle in until engine loses considerable speed.
  6. Turn idle needle out until engine runs smoothly.
  7. Adjust float level by bending float near shaft.
Carburetor Adjustment (Gasoline) adjustment

⚠ Forcing mixture screws tight damages needle and seat.

Tools: screwdriver

  1. Warm engine until choke fully open.
  2. With no load, turn idle adjustment out until speed drops slightly.
  3. Turn idle needle in until speed returns to normal.
  4. Apply full load.
  5. Turn main adjustment in until speed drops slightly.
  6. Turn main needle out until speed returns to normal.
Carburetor Adjustment - Gasoline adjustment
  1. Start engine and warm up until choke is fully open.
  2. No load: turn idle adjustment out until speed drops slightly below normal.
  3. Turn needle in until speed returns to normal.
  4. Apply full load.
  5. Turn main adjustment in until speed drops slightly below normal.
  6. Turn needle out until speed returns to normal.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Voltage reconnection

VoltagePhaseConnectionLeadsNotes
1 or 3P, 2 or 3WManual start, Magnet serviceWiring diagrams 602B143, 602A166
115VDCPortableWiring diagram 602B165
12012-wireM1, M3 (join); M2, M4 (join)Ungrounded load wire black; grounded load wire white
1201Two-wire AC remote/manualM1 (ungrounded black), M2 (grounded white)Connect grounded white load wire to M2 and ungrounded black load wire to M1.
120, 240 or 120-240V1PRevolving armature reconnectible (CCK-3CR)Reconnection of generator leads
120/20834-wireM1, M2, M3, M43-phase.
120/2083Four-wire AC remoteM1, M2, M3, M0Single-phase lower voltage from any M1/M2/M3 to M0; three-phase higher voltage M1/M2/M3; M0 is ground load terminal.
120/2083Voltage Code 4120/208V, 3PH
120/208V3P, 4WWiring diagram 611C206
120/208V3P, 4WPortableWiring diagram 602B160
120/24013-wireM1; M2, M3 (join); M4Only half nameplate rating can be taken off each 120 V connection
120/2401Reconnectable for 120 V, 2-wire; 240 V, 2-wire; or 120/240 V, 3-wireApplies to sets marked ** in the Generator Set Data Table.
120/2401Three-wire AC remoteM1, M2, M3Two 120 volt circuits across M1-M2 and M2-M3; one 240 volt circuit across M1-M3; M2 not used with 240 volt circuit.
120/2401Voltage Code 3C120/240V, 1PH
120/2403Voltage Code 5O120/240V, 3PH
120/240V1P, 3WPortableWiring diagram 602B146
120/240V1P, 3WRemote startWiring diagram 611C164
120/240V1P, 4WReconnectibleWiring diagram 611C236
120/240VAC, 32VDCWiring diagram 611C235
120V1P, 2WManual startWiring diagram 611C176
120V1P, 2WPortableWiring diagram 602B144
120VAC, 32VDCWiring diagram 611C234
220/3803Voltage Code 7220/380V, 3PH
24012-wireM1, M4 (join); M2Ungrounded load wire black; grounded load wire white
24033-wireM1, M2, M33-phase.
2403Three-wire AC remoteM1, M2, M3Connect one load wire to each terminal; reverse connections at any two generator terminals if 3-phase motor rotation is wrong.
240V1P, 2WManual startWiring diagram 611C176
240V1P, 2WPortableWiring diagram 602B145
240V3P, 3WWiring diagram 611C178
240V3P, 3WPortableWiring diagram 602B147

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Common questions

What is the oil capacity of the Cummins/Onan CCK?

The Cummins/Onan CCK engine has an oil capacity of 2.8 liters.

What is the displacement of the Cummins/Onan CCK?

The Cummins/Onan CCK has a displacement of 0.498 liters with 2 cylinders.

Which generators use the Cummins/Onan CCK engine?

The Cummins/Onan CCK powers 7 generator set(s), including Cummins/Onan 3.5CCK, Cummins/Onan 4.0 CCK-3R, Cummins/Onan 4.0CCK, Cummins/Onan 4.0CCK-3CR, Cummins/Onan 4CCK.

How often should you change the oil in the Cummins/Onan CCK?

The Cummins/Onan CCK oil change interval is every 100 hours.

What is a common problem with the Cummins/Onan CCK engine?

A commonly reported issue on generators using the Cummins/Onan CCK is: Voltage drops under heavy load. Cause: Engine lacks power. Fix: See remedies for engine misfires under heavy load..