Onan MCCK - BREAK-IN PROCEDURE

The RESET button must be pressed before re-starting.
A one minute time limit is necessary before the RESET
button can be pressed after an emergency stop. If the
plant is under automatic control, a re-start will be at¬
tempted automatically.
PLANT EXERCISE
Infrequent use results in hard starting. Operate plant
one 30-minute period each week. Run longer if battery
needs charging, or keep battery charged with a separate
charger.
EMERGENCY OPERATION IF BATTERY FAILS
The remote-type revolving-armature plant needs a battery
for electric choke, ignition and limiting exciter voltage.
If the battery fails completely and the plant must be oper¬
ated during an emergency, a battery can be shared with
other equipment having an alternator. Do not disconnect
the plant charging circuit, as damage will occur to the
ignition relay from the increased voltage. Instead, con¬
sider disconnecting other equipment and using that bat¬
tery.
BREAK-IN PROCEDURE
No matter how carefully engine parts are manufactured
or expertly assembled, there are always microscopic
variations in fit between metal parts such as pistons,
rings, main and connecting rod bearings.
Break-in or ideal fitting of all internal moving metal
parts can best be achieved by maintaining proper cooling
and correct lubrication during the running-
BREAK-IN PROCEDURE
No matter how carefully engine parts are manufactured
or expertly assembled, there are always microscopic
variations in fit between metal parts such as pistons,
rings, main and connecting rod bearings.
Rrea*-/n,or ideal fitting of all internal moving metal
parts can best be achieved by maintaining proper cooling
and correct lubrication during the running-in period.
Break-in can take as little as ten operating hours or it
may take many hundreds of hours. Extended periods of
very heavy engine loading (above rated horsepower or
electrical output)during this initial service period can
cause severe cylinder scoring or bearing galling. On the
other hand, extended periods of very light loading during
initial break-in may cause cylinder wall glazing and/or
poor piston ring seating. Engine parts damage can also
be caused by using the wrong type or viscosity of oil,
and allowing the engine to run at too high a temperature
during break-in.
All engines use more oil than normal during the first
hours of operation. As internal moving parts are run-in by
controlled operation, oil consumption should gradually
decrease until the rate of consumption is stabilized. It
is extremely rare that oil consumption drops to zero. AH
engines use some oil, even when in perfect condition and
properly broken-in. Oil consumption varies according to
engine design, engine (piston) speed, size of engine,
type of oil, oil viscosity, length of operating periods,
operating temperatures, engine loading, etc. As engine
operation is continued, clearances between moving parts
increase slightly due to normal wear of piston rings,
cylinder walls, valve guides, oil seals, etc.These clear¬
ances increase until oil consumption is excessive, and
engine parts have to be replaced and/or refitted. This
usually takes thousands of hours.
Each Onan engine is run-in at the Onan factory for a
minimum of three hours. This is not enough running time
to completely break-in the engine. Proper completion ot
the break-in period is the customer’s responsibility.
Generator sets manufactured by Onan can be loaded to
full nameplate rated output (not until they bog down) as
soon as they are put into operation. It is recommended
during this first few hours of operation that generator
sets be loaded to 80% of rated capacity. Initial heavy
loading helps seat piston rings and brings oil consump¬
tion to normal in the shortest time.
During break-in, check oil level at least every eight (8)
operating hours. Add oil if the level is at low on the
dipstick. Never over-fill. This may cause oil to foam and
enter the breather system.
Drain the initial oil fill after 50 hours of operation while
the engine is hot.
Controlled break-in with consistent use of proper oil
from a reputable supplier and a conscientiously-applied
maintenance program will help assure satisfactory serv¬
ice for thousands of hours from your Onan electric plant.
OUT-OF-SERVICE PROTECTION
Protect a plant that is to be out of service for more than
30 days as follows:
1. Run plant until thoroughly warm.
2. Turn off fuel supply and run until plant 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 oz. (two tablespoons)
of rust inhibitor (or SAE #50 oil) into each cylinder.
Crank engine slowly (by hand) several times. Install
spark plugs.
5. Service flame arrester.
6. Clean governor linkage and protect by wrapping with
a clean cloth.
7. Plug exhaust outlet to prevent entrance of moisture,
dirt, bugs, etc.
8. Wipe generator brushes, slip rings, etc. DO NOT AP¬
PLY LUBRICANT OR PRESERVATIVE TO BRUSHES
AND RINGS.
9. wipe entire unit. Coat parts that can rust with a bright
film of grease or oil.
10. Provide a suitable cover for the entire unit.
11. Drain cooling system if danger of freezing exists
during storage.
12. If battery is used, disconnect and follow standard bat¬
tery storage procedure. Do not allow batteries to be¬
come fully discharged.
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