Generator Break-In Procedure - Westerbeke 7.6 kw EDT 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 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 of motor starting loads and the high current
draw required for 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 (HER'lZ) ADJUSTMENT) under
ENGINE ADJUSTMENTS .. A no-load voltage adjustment
may also be requirad in conjunction with the engine's speed
adjustment see GENERATOR INFORMATION.
THE DAILY ROUTINE
CHECKLIST
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 hourrneter reading in your log (engine hours
relate to me 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 abnonual noise such as knocking, vibrating imd
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 IIOrmIll operating temperature
is reached and loads 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 rnn for 3-5 minutes to stabilize the operating
temperature, then tum the key to the off position. Once the
generator is shutdown, close down all circuit breakers as a
safety precaution.
Engines
&
Generators
9