
GENERATOR
BREAK-IN
PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum
of
one
hour
of
test operations at the factory
to
make sure accurate
assembly procedures were followed and that the engine
operated properly, a break-in time is required. The service
life
of
your engine is dependent upon how the engine is
operated and serviced during its initial hours
of
use.
Breaking-in a new engine basically involves seating the
piston
rings
to
the
cylinder walls. Excessive oil
consumption
and smoky operation indicate that the cylinder walls are
glazed
or
scored, which is caused
by
overloading the
engine during the break-in period.
Your new engine requires approximately 50 hours
of
initial
conditioning operation to break in each moving part in order
to maximize the performance and service life
of
the engine.
Perform this conditiOning carefully, keeping in mind the
following:
Start the engine according to the STARTING PROCEDURE
section. Run the engine while checking that all systems (raw
water pump, oil pressure,.battery charging) are functioning.
AFTER
START·UP
Once the generator has been started, check for proper opera-
tion and then encourage a fast warm-up. Run the generator
between 20% and 60%
of
full-load for the first
10
hours.
After the first
10
hours
of
the generator's operation, the load
can be increased to the full-load rated output, then periodi-
cally vary the load.
Avoid overload at all times. An overload is signaled by smoky
exhaust with reduced output voltage and frequency. Monitor
the current being drawn from the generator and keep it within
the generator's rating. Since the generator operates at 1800
rpm to produce 60 hertz (or at 1500 rpm
to
produce 50
Hertz), control
of
the generator's break-in is governed by the
current
drawn
from
the
generator.
NOTE:
Be aware
oImotor
starting loads andthe high current
draw requiredfor starting motors. This starting amperage
draw can
be
3 to 5 times normal running amperage. See
GENERATOR INFORMATION in this manual.
GENERATOR
ADJUSTMENTS
Once the generator has been placed in operation, there may be
governor adjustments required for engine speed (hertz) during
the engine's break-in period (first 50 hours) or after this
period see ENGINE SPEED (HERTZ) ADJUSTMENT) under
ENGINEADJUSTMENTS
..
A no-load voltage adjustment
may also be required in conjunction with the engine's speed
adjustment see GENERATOR INFORMATION.
THE
DAILY
ROUTINE
CHECK
LIST
Follow this check list each day before starting your generator.
• Check that all generator circuit breakers (power panel) are
in the
off
position before starting.
• Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule.)
Any deficiency
or
problems in the following items must
be
corrected before start up.
• Visually inspect the engine for fuel, oil, or water leaks.
• Check the oil level (dipstick).
• Check the coolant level in the coolant recovery tank.
• Check your fuel supply.
• Check the starting batteries (weekly).
• Check drive belts for wear and proper tension (weekly).
CHECK WITH THE ENGINE RUNNING.
• Check for abnormal noise such as knocking, vibrating and
blow-back sounds.
• Confirm exhaust smoke:
When the engine is cold -White Smoke.
When the engine is warm -almost Smokeless.
When the engine is overloaded -some Black Smoke.
NOTE:
Some unstable running may occur in a coldengine.
This condition should abate
as
normal operating temperature
is reached andloads are applied.
A
CAUTION:
00
not
operate
the
generator
for
long
periods
of
time
without
a
load
being
placed
on
the
generator.
STOPPING
THE
GENERATOR
Remove the
AC
loads from the generator one at a time.Allow
the generator to run for 3-5 minutes to stabilize the operating
temperature, then momentarily depress the stop button and
release. The generator
wiII
automatically shut down.
Tum
off
the
DC
circuit breaker to prevent unintentional starts
as
a
safety precaution.
-.,.y-
WESTERBEKE
Engines & Generators
9