2. Operation and Maintenance
12
Engine Break-In
General Information
In order to provide only engines of the highest quality, Hyundai
Doosan Infracore ensures that engines undergo a final
acceptance test before releasing them from the factory.
However, since the engines are not run for an extended period
of time, they must complete a break-in procedure during the
initial 50 hours of operation after being delivered. Proper engine
break-in ensures long-term optimal engine performance.
Breaking in New Engines
As the bearings in a new engine are not sufficiently broken in
initially, they tend to break easily due to overload or running
at a high speed, thereby shortening the engine life as well.
Hence, make sure to follow the instructions below during the
initial 50 hours of operation after receiving the engine.
1. Before running the engine, make sure to warm it up suffi-
ciently until the engine temperature is suitable for normal
operating conditions.
2. Avoid running the engine at a high rpm under overloaded
conditions or for a prolonged period of time.
3. Do not run the engine at a high speed without a load.
4. Do not start or stop the engine abruptly.
5. Do not exceed 70% of the maximum engine load.
6. Inspections, maintenance and service work must be
performed by certified technicians at accredited service
centers according to the applicable standards.
Inspection Items
Check and inspect the following during the break-in period of
a new engine.
1. Check periodically whether the engine oil lies within the
specified range between the upper and lower limit lines
on the oil level gauge.
2. In the event that the oil warning lamp installed in the
machine turns on or blinks, it means that the oil pressure
is too low. Hence, check the oil level and refill if neces-
sary. When refilling engine oil, do not exceed the upper
limit line on the oil level gauge. If the oil level is normal,
check related parts, such as the oil pressure sensor, oil
pump and oil lines.
3. Check the coolant temperature gauge installed in the
machine and check whether coolant is circulating prop-
erly. If the coolant level in the auxiliary tank is too low, the
needle on the coolant temperature gauge may vibrate.
4. Replace the engine oil and oil filter after the break-in
period.
Operation after Break-In Period
When starting the engine in extremely cold regions, the
engine must be warmed up slowly. Do not increase the
engine rpm abruptly before the engine has been preheated
sufficiently. Oil consumption is higher until the piston rings
are seated properly and the engine is running normally.
Hence, the engine oil level must be checked periodically
during the initial 50 hours of the break-in period.
Inspection after Starting the Engine
While the engine is in operation, always check the pressure
in the engine lubrication system with the engine oil pressure
gauge installed in the machine. If low oil pressure is indicated
on the engine oil pressure gauge, stop the engine
immediately. In addition, make sure to check whether the
charge warning indicator of the generator is turned off while
the engine is in operation.
1. Connect the positive (+) and negative (-) battery termi-
nals securely to ensure that they do not come loose. The
sheath on battery connector cables should not be torn or
ripped.
2. If the battery charge warning indicator blinks or turns on
and the engine stops suddenly while driving, check the
electrical system for malfunctions.
3. If an abnormal condition, such as an abnormal emission
color or odor, occurs while driving, stop the engine, locate
the cause, and correct the issue.
In the event that the oil level cannot be checked accu-
rately on the oil level gauge, rotate the oil level gauge
180° and stick the guide tube back in the oil level gauge;
then, remove it and check the oil level again.
The oil pressure may increase and decrease along with
the engine speed (rpm). In addition, cold oil generally
indicates a higher oil pressure at certain engine speeds
(rpm) than warm oil—a phenomenon which occurs even
in normal engine operating conditions.
Replace the engine oil and oil filter with engine oil and a
genuine part recommended by Hyundai Doosan Infra-
core.
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