Generator Break-In Procedure; The Daily Routine - Westerbeke 5.0Kw BCDR 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
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.
reach its full rated speed are signs of an overload.
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 generators operation, the
load can be increased to the full-load rated output, then
periodically vary the load.
Avoid overload at all times. An ovefload 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 generators engine break-in is governed by the
current drawn from the generator.
NOTE:
Be aware of motor starting loads and the high
current drawn 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 (HERTZ) ADJUSTMENT under
ENGINE ADJUSTMENTS. A no-load voltage adjustment may
also be required in conjunction with the engine's speed adjust-
ment (see GENERATOR INFORMATION).
THE DAILY ROUTINE
CHECK LIST
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 WITH THE ENGINE RUNNING.
• Check for abnormal noise such as knocking, vibration 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 off position. Once the
generator is shutdown, close down all circuit breakers as a
safety precaution.
Engines & Generators
10