GENERATOR
BREAK-IN
PROCEDURE
DESCRIPTION
Although your engine has experienced a minimum
of
one
hour oftest 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 ofyour 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
ofinitial
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%
offull-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 ofthe generator's break-in
is
governed
by
the
current drawn from the generator.
NOTE:
Be
aware
of
motor starting loads and the
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
(HER7Z) ADJUSTMENT) under
ENGINEADJUSTMENTS
..
Ano-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 cold
engine.
This
condition should
abate
as normal operating
temperature
is
reached
and
loads
are
applied.
A
CAUTION:
Do
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 turn the key to the offposition.
Once
the
generator
is
shutdown, close down all circuit breakers
as
a
safety precaution.
CAUTION
(WESTERLINK
or
NMEA-2000):
The electronic components in the
Digital Diesels draw a very small amount
of
amperage (milli-amps) from
the generator's starting battery when the unit is in a static state. This
maybe
as
much
as
50
milli-amps
for
the system
ECU
and 50 mi/li·amps
for
each display. This can be as much as
72
amp·hours in a months time
with no generator use. It is not necessary to be concerned with this slight
amperage draw during normal seasonal use. However,
if
the generator
set is not to be used
for
a number
of
nwnths, such as winter storage, it is
best
10
disconnect the
DC
power to the generator with a NMEA-2000
system
or
shut
off
the DC breaker on the generator's control boxfor a
WESTERLINK system.
.
NOTE:
Keep
in
mindthat the Westerbeke generator maybe the DC power
supply
for
the vessel's NMEA-2000 network.
Engines
&
Generators
9