Generator Break-In Procedure - Westerbeke 5.5 EGCD Operator's Manual

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
~e.
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
scored, which is caused by overloading the engine during the
break-in period ..
Your new engme 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,
~ing
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 wann-:up. Run the generator
between 20%
and
60% of full load for the fifst 10 hours.
After the first 10 hours of the generators operation, the
load can be increased to the full-load rated output, then
periodically vary the load.
Avoid overload at all times. An overload is signaled by a
smoky exhaust with reduced output voltage and frequency.
Monitor the current being drawn from the generator and keep
it within the generators' rating. Since the generator operates at
1800 rpm to produce 60 hertz, or at .1500 to produce 50 hertz,
control of the
generato~
engine break -in
~
governed by the
current drawn from the generator.
NOTE:
Be aware ofnwtor starting loads OJ7d
the
high
current
drawn
required for starting nwtors. This starting
amperage draw can be 3 to 5 times nonnal
running
amperage. See GENERATOR INFORMATION
in
this manuaL
GENERATOR ACJUSTMENTS
Once the generator
has
been placed into operation, there may be
the need for a AC no-load voltage adjustment before or at the
50 hour break-in service. (see Generator Information).
THE DAILY ROUTINE
CHECKLIST
Follow
this
checklist 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).
• 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 the drive belt for wear and proper tension (weekly)
CHECK Wll'H THE ENGINE RUNNING.
• Check for abnom13l noise such as knocking, vibration and
blow-back sounds.
• Confinn 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 1U1111ing
may
occur
in
a cold engine.
This condition should abate as nonnal operating temperature
is reached .arulloads afe applied.
A
CAUTION: Do not operate the geniJI'Bfor for long
periods of time without
a
load being placed· on the
generator. ·
·STOitflNii'RIE,GENEMTOR:'
. . .·.
~-
.
.
. .
.
.
.·.
. .
Remove the AC amperage loads from the generator one at a
time. Allow the generator to run for 3 - 5 minutes to stabilize
the operating temperatures. Then depress the STOP switch
and hold depressed until the generator comes to a complete
STOP.
NOTE:
This engine is certified to operate at 1800 rpm (60 Hi}
in the
United States. Operating this engine at 1500 rpm
(50
Hz) in
the
'United States may be a" violation
of
Federal
Law. ·
Engines & Generators
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