Installation 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
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 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.
THE
DAILY
ROUTINE
CHECK
LIST
Follow this check list each day before starting your generator.
D Check that all generator circuit breakers (power panel) are
in the off position before starting.
D Record the hourmeter reading in your log (engine hours
relate to the maintenance schedule.)
D Visually inspect the engine for fuel, oil,
or
water leaks.
D Check the oil level (dipstick).
D Check the coolant level in the coolant recovery tank.
D Check your fuel supply.
D Check the starting batteries (weekly).
D Check drive belts for wear and proper tension (weekly).
CHECK WITH THE ENGINE RUNNING.
D Check for abnormal noise such as knocking, vibrating and
blow-back sounds.
D 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:
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 run 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
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