Westerbeke 12.5 BTDA - Generator Break-In Procedure; Break-In Description and Importance; Break-In Checks and Load Management; Generator Adjustments During Break-In

GENERATOR BREAK·IN PROCEDURE
DESCRIPTION
Although your engine has experienced a minbnum 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 oper-
ated 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 generator 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.
A CAUTION: Do not attempt to break-in your
generator by running without a load.
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 ratif!.g •. Since the· gen~rator operates
at 1800 rpm to produce 60 hertz (or at 1500 ipm to produce
50 Hertz), control of the generator's break-in is governed by
the current drawn from the generator.
CHECK THE FOLLOWING
0 Monitor the control panel gauges.
0 Check for leaks of fuel and engine oil.
0 Check for abnonnal noise such as knocking, friction,
vibration and blow-back sounds.
0 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.
To protect against unintentional overloading .of the generator,
the generator's output leads should be routed through a cir-
cuit breaker that is rated at the rated output of the generator.
NOTE: 8e aware of motor starting loads and the high current
draw required for starting motors. This starting amperage
draw can be 3 to 5 times nonnal running amperage. See
GENERATOR INFORMATION in this manual.
GENERATOR ADJUSTMENTS
Once the generator has been placed in operation, there may
be adjustments required for engine speed. (hertz) during the
engine's break-in period (first 50 hours) or after this period.
A no-load voltage adjustment may also be required in con-
junction with the engine's speed adjustment. See
GENERATOR INFORMATION in this manuaL
Engines & Generators
10