Breaking in your Generator
Breaking in a generator is when you run it for a time, several times, and then change the oil, several times, between runs.The goal is to get the engine rods to seat properly against the engine cylinders with this process of running the generator scraping tiny metal shavings off of both parts and depositing them in the oil (which is why you change the oil)
This process is well known to engine aficionados and enthusiasts but is not something most people are aware of because it’s a process usually carried out by the manufacturers However, whether it was carried out by the manufacturers of your machine or not, it’s worth doing yourself again to make one hundred percent sure that it’s happened It’s worth the cost
For some people, this process shows results very clearly, with the oil that they remove during the breaking in process being noticeably darker due to all the small metal fragments These fragments can cause damage to your generator and will severely lessen its lifespan The first step of breaking in a generator is to top up the oil.This includes getting some oil (or oil conditioner if you want to go the extra step) into the cylinders, which involves removing the spark plug and pouring some down into the cylinder Then you crank the starter cable a few times to get the oil around the system.
The next step is to then run the generator for about an hour without any load at all Of course, you have to add some fuel before you can run the generator. If a generator is run at full throttle without being broken in, the heat produced can negatively affect the seal in the cylinders, causing oil to be slowly lost over time that wouldn’t otherwise have been, as well as affecting the potential highest power output of the generator.
After the initial run with no load for an hour, it’s important to drain out the oil completely and refill it with new, clean oil. Check the manual of your specific generator as to what variety of oil it is designed to take For instance, the Hyundai HY6500SEi 6 5kW Inverter Generator manual says that this model of generator requires SAE 30 or 15w40 Engine Oil Then the advice goes that you should run your generator for a further hour with no load and once again replace the oil, to make sure that all the debris and any metal is fully and completely cleaned out of the engine
The final step is to run your generator under load for a further hour.This step is to bring the temperature up now that the cylinders should be seating the rods properly It is said this process is the final step to setting up the best seal possible in the cylinders After this, it is not necessary to replace the oil a final time. From then on, refer to the manual. In the case of the Hyundai HY6500SEi 6 5kW Inverter Generator manual, it suggests after every 100 hours of use (or if it is contaminated)
Following the Manual
While a lot of manuals these days are all about stating the obvious, like having burn risk signs on toasters, amongst this anti-liability language are some useful tips and tricks. For instance,
using genuine, original equipment manufacturer (OEM) parts is suggested by the manual because they can’t be held liable for non original parts.This can be useful to know because it means if anything goes wrong and you want to chase up the manufacturer for some customer support, they can’t use the excuse you used non-original parts as a way to dismiss your claims.
That said, the equipment dealers you purchased from are far more likely to be, first off, understanding about this but also are easier to get in touch with and want to maintain good relationships with their customers than the global businesses are.
Another good tip found in the manual is that petrol can damage some types of plastic on your generator, so ensure that no petrol splashes or leaks onto plastic parts while refilling the fuel tank This is the sort of thing that some people may not be aware of because you could assume that all the parts of a generator would be designed so they don’t take damage when coming into contact with fuel, but it’s these little details which make it worthwhile checking the manual for your specific machine so you know the peculiarities and particularities of your generator
The Hyundai HY6500SEi 6.5kW Inverter Generator manual has a handy reference chart for maintenance operations, defining how frequently each type of check should be performed For instance, it suggests checking the oil before each and every use, as well as after the first month (or the twenty-hour mark) and repeatedly every six months after that.
Of course, this is a reference chart only and it is worth altering it to fit with your specific use case scenarios. For instance, if you use your generator every day for several hours, it’s better to check the oil more frequently On top of this, the chart contains some checks that you may not be aware of, such as the check on the muffler screen which is recommended every 12 months This screen is part of the exhaust system and needs to be cleaned or possibly replaced if necessary whenever it gets too clogged up
Air Filter
There are several filters on your generator, including oil and air filters, each of which have to be cleaned or replaced over time In the case of the air filter, the cover is removed, the filter and element are removed, the filter is cleaned with soapy water and then left to dry.Then, the filter is oiled with the same oil used in the engine and squeezed to remove the excess, left wet but not dripping with oil.Then the element is reinserted into the filter, which is also reinserted into the machine and the cover replaced.All of this is a long process but, without a proper air supply, the engine in your generator will suffer lower power and without clean air supply the engine can become far more worn far more quickly.
Spark plugs
Similarly, the spark plugs need to be changed out, checking for carbon deposits or discolouration An important part of the spark plug is the gap This also needs to be checked and if either of these issues can’t be fixed with a little cleaning or minor reshaping then the spark
plug simply needs to be replaced The manual has this information relevant to your machine and in the case of the Hyundai HY6500SEi 6.5kW Inverter Generator the correct type of spark plug is the tan coloured F6RTC (TORCH) variety which has a spark plug gap of 0 6 to 0 7mm (or 0.024 to 0.028 inches).
Muffler
The muffler screen was mentioned earlier and is not too difficult to check and clean It’s important to know the muffler will be hot after the generator has been used for any reasonably lengthy time so make sure either to ideally let it cool or if you’re in a rush try not to touch it If you decide to put together a list for yourself when you perform maintenance and checks on your generator, then it’s worth doing this before running the generator to avoid the issue For the HY6500SEi generator, the cover is unscrewed and removed, the muffler screen is removed, then the spark arrester is pried out from the muffler. Both the spark arrestor and muffler screen can be cleaned with a wire brush and then reinstalled, along with the cover
Fuel Filter
Another important filter is the fuel tank filter In the case of the HY6500SEi model, this filter is secured just inside the fuel tank opening where the tank cap screws on It is a cylinder which is removed from the tank and then needs to be cleaned with solvent such as isopropyl alcohol. Then it’s a matter of cleaning off the solvent and replacing the filter back into the tank, as long as the filter itself is not damaged
If it’s damaged, it will simply need to be replaced as a hole in the filter makes the filter almost pointless.Again, any particulate matter that gets into the fuel the engine runs off of will cause damage and shorten the life of your generator The more or the larger the particulate matter, the worse the damage is going to be.As you might be aware by now, the list of items you need to keep your generator maintained starts to grow when you consider the long term requirements, like cleaning out the air filter
Equipment Needed for Maintenance
So far, we have Phillips head screw drivers for removing covers and flat head screw drivers for prying the spark arrestor, soap for cleaning the air filter, engine oil and a solvent for cleaning fuel The solvent is a good item to have on hand when using a generator anyway, because it’s almost certain that you are going to be storing fuel as well
It is recommended to run your generator each week to keep the components properly cleaned and lubricated For most people who run a generator only for backup power purposes, this often more realistically occurs once per month and sometimes only twice a year. In the case of
backup power, where the generator is used less frequently, the costs of not having it when you need it can be higher than for Hyundai generators that are used every day, because in the latter case contingencies have been put in place
Storing Fuel
Another problem faced by generator owners who don’t run their Hyundai generatorsAustralia frequently to maintain them is they end up needing a generator and their supply of fuel has gone bad. Diesel fuel lasts up to a year when stored properly in a tightly sealed container in a cool environment Petrol lasts from three up to six months Ethanol can last from as little as a single month up to a maximum of three months.As fuel degrades, it becomes less combustible and causes damage to the engine as well as possibly causing a gummy residue in fuel lines which can block them up entirely
Overview
If you follow the instructions in your manual for maintaining your generator on a weekly, monthly, and yearly cycle, as well as breaking it sufficiently on its first use, your generator can last you for thousands of hours Making sure you keep your generator clean and maintained makes the world of difference when you have to rely on it to provide power, whether that’s backup power or just for everyday use.
