Doosan DX22 Manual

950106-106013EN
DX22
GENERATOR ENGINE
Operation &
Maintenance Manual

• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
WARNING: Breathing diesel engine exhaust exposes you
to chemicals known to the State of California to cause
cancer and birth defects or other reproductive harm.
For more information go to
www.P65warnings.ca.gov/diesel.

Preface
This Operation and Maintenance Manual provides information on engine management and maintenance techniques to
customers and technicians of Hyundai Doosan Infracore's DX22 electronically controlled diesel engine for generators.
To provide the best engine to our customers, the DX22 electronically controlled diesel engine for generators is designed to satisfy
all requirements for low noise, economic fuel consumption, high speed and durability with the latest technology and quality.
The engine must be operated and maintained both precisely and appropriately in order to maintain the engine in its optimal
condition and performance over long periods of time. This Operation and Maintenance Manual contains detailed specifications,
reference values, diagnostic techniques, part information and figures for easier and more accurate understanding, maintenance
and troubleshooting.
Performing the service work recommended by Hyundai Doosan Infracore properly and in the correct order can ensure greater
effectiveness of service techniques and protect the safety of workers. Hence, make sure to familiarize yourself with the contents
of this Operation and Maintenance Manual thoroughly before handling the engine.
Hyundai Doosan Infracore strives to develop and invest continuously in order to ensure the best performance and quality as
well as to enhance maintenance techniques. The design of our product may be changed without prior notice and Hyundai
Doosan Infracore shall not be held liable for the failure of this manual to contain all the design changes made to improve the
product.
We will continue striving tirelessly to satisfy the needs of customers and to provide customers with information on safe and
convenient maintenance techniques.
Please do not hesitate to contact us regarding misprints or inquiries concerning the contents of this Operation and Maintenance
Manual.
Thank you for purchasing a Hyundai Doosan Infracore engine. We hope that this Operation and Maintenance Manual will be
useful.
2022. 07
950106-106013EN
Hyundai Doosan Infracore
*Items exempted from warranty coverage
• Malfunctions resulting from failing to comply with the proper handling instructions, regular inspections, and machine storage
techniques specified in the user manual
• Malfunctions resulting from failing to have the machine repaired at a designated dealer or center, or resulting from the use of
non-genuine parts
• Malfunctions resulting from unauthorized modifications, changes, or external hardware
• Malfunctions resulting from incorrect operation by the user, delayed repairs, accidents, and natural disasters
*The contents of this operation and maintenance manual are the exclusive property of Hyundai Doosan Infracore. Any unau-
thorized reproduction, printing and distribution thereof are strictly prohibited.

Table of Contents
1. Introduction ...............................................................................................................................1
General Information ................................................................................................................................... 3
Danger, Warning, Caution, and Notes ....................................................................................................... 4
Engine Care ............................................................................................................................................... 7
2. Operation and Maintenance .....................................................................................................9
Starting and Stopping the Engine ............................................................................................................ 11
Engine Break-In ....................................................................................................................................... 12
Running the Engine in Winter .................................................................................................................. 13
Engine Inspections and Maintenance ...................................................................................................... 14
3. Performance and Specifications ............................................................................................17
Engine Specifications and Performance .................................................................................................. 19
Outside Drawing of the Engine ................................................................................................................ 22
Engine Serial Number .............................................................................................................................. 25
4. Regular Inspections ................................................................................................................27
General Information ................................................................................................................................. 29
Maintenance Schedule ............................................................................................................................ 30
Cautions for Using Biodiesel .................................................................................................................... 31
Cooling System ........................................................................................................................................ 32
Lubrication System .................................................................................................................................. 36
Fuel System ............................................................................................................................................. 40
Intake/Exhaust System ............................................................................................................................ 42
Cylinder Block/Head ................................................................................................................................ 44
Other/Driving System ............................................................................................................................... 47
5. General Engine Information ...................................................................................................49
Method of Indicating Units ....................................................................................................................... 51
Tightening Torque .................................................................................................................................... 52
Engine Disassembly ................................................................................................................................ 55
Engine Assembly ..................................................................................................................................... 65
6. Cooling System .......................................................................................................................87
Overview and Specifications .................................................................................................................... 89
Thermostat ............................................................................................................................................... 91
Causes of Faults and Troubleshooting .................................................................................................... 92
Air Heater (Optional) ................................................................................................................................ 93

7. Lubrication System .................................................................................................................95
Overview and Specifications .................................................................................................................... 97
8. Fuel System .............................................................................................................................99
General Information ............................................................................................................................... 101
Fuel System Components ...................................................................................................................... 102
9. Intake/Exhaust System .........................................................................................................123
General Information ............................................................................................................................... 125
Turbocharger ......................................................................................................................................... 125
10. Cylinder Block/Head .............................................................................................................135
General Information ............................................................................................................................... 137
Cylinder Block ........................................................................................................................................ 138
Inspecting the Cylinder Head ................................................................................................................. 140
Rocker Arms .......................................................................................................................................... 144
Tappet and Pushrod .............................................................................................................................. 145
Camshaft ................................................................................................................................................ 146
11. Electrical System ...................................................................................................................149
Electronic Components .......................................................................................................................... 151
Circuit Diagram ...................................................................................................................................... 153
Switches and Sensors ........................................................................................................................... 161
Engine Control Unit (ECU) ..................................................................................................................... 166
TMS 3.0 (Option) ................................................................................................................................... 169
Starter Motor .......................................................................................................................................... 174
Alternator ............................................................................................................................................... 176
12. Other/Driving System ............................................................................................................179
General Information ............................................................................................................................... 181
Crankshaft .............................................................................................................................................. 182
Pistons ................................................................................................................................................... 185
Injectors ................................................................................................................................................. 188
Miscellaneous ........................................................................................................................................ 189
13. Installation Guidelines ..........................................................................................................193
Fuel Lines .............................................................................................................................................. 195

1
1. Introduction
General Information ..............................................................................................................3
General Information ..................................................................................................................................... 3
Danger, Warning, Caution, and Notes ..................................................................................4
General Information ..................................................................................................................................... 4
General Precautions .................................................................................................................................... 5
Cautions for Starting the Engine .................................................................................................................. 5
Cautions for Inspections and Maintenance.................................................................................................. 5
General Information ..................................................................................................................................... 6
Other Safety Instructions and Environmental Pollution................................................................................ 6
Use of Genuine Parts................................................................................................................................... 7
Engine Care ..........................................................................................................................7
Preventing Damage and Wear..................................................................................................................... 7
Preventing Pollution ..................................................................................................................................... 8
Handling Engine Oil ..................................................................................................................................... 8
HVO (Hydro treated Vegetable Oil) ............................................................................................................. 8
GTL (Gas To Liquids) .................................................................................................................................. 8

2

1. Introduction
3
General Information
General Information
This Operation and Maintenance Manual provides the most
efficient methods for engine maintenance as well as quick,
efficient methods to determine the cause of engine faults to
ensure that any actions taken by professionally certified
maintenance technicians are performed in the most efficient
and safest way possible. In the event that the engine is
serviced by an untrained technician or in facilities which are
not equipped with the specified tools and equipment, the
operator and/or others around the engine may sustain
life-threatening physical injuries and severe faults may occur
in engine performance.
Regular inspections and maintenance are required to maintain
long-term optimal engine conditions and performance.
In the event that a part must be replaced, only genuine parts
as defined by the parts on the list (PARTS BOOK) should be
used. Using non-genuine imitation parts or recycled parts
may cause critical damage and faults in engine performance.
Hyundai Doosan Infracore shall not be held liable for any
damage or faults resulting from the use of such parts.
The maintenance methods stated in this Operation and
Maintenance Manual are the most efficient and safest work
procedures. Some work procedures require special tools.
For questions about genuine parts and special tools, please
contact us.
This Operation and Maintenance Manual includes 'Danger,'
'Warning' and 'Caution' items intended to reduce the risk of
possible injuries during operation of the engine. Failing to
heed this information may lead to severe faults in engine
performance and operation, as well as severely injuring
workers. Hence, make sure to heed the 'Danger,' 'Warning'
and 'Caution' items. Please note that it is not possible for this
Operation and Maintenance Manual to include information
about every possible danger or unanticipated risk which may
occur while handling and servicing the engine.

1. Introduction
4
Danger, Warning, Caution, and Notes
General Information
Instructions which require absolute compliance while
performing the inspection, service and troubleshooting
procedures provided in this Operation and Maintenance
Manual are classified more specifically as 'Danger,'
'Warning' and 'Caution' items. In addition, Note) is used to
provide additional descriptions and information required for
maintenance technicians to successfully operate our
engines. Complying with the proper service methods and
'Danger,' 'Warning' and 'Caution' items recommended by
Hyundai Doosan Infracore can both enhance the
effectiveness of engine maintenance and prevent physical
injuries to workers. However, not every possible danger can
be anticipated.
Note) Additional descriptions, information, and references
are provided for ease of understanding.
DANGER
Make sure to comply with these instructions; failure to
do so may result in life-threatening physical injuries to
workers and/or people around the engine.
WARNING
Make sure to comply with these instructions; failure to
do so may result either in physical injuries to workers
and/or people around the engine or severe environ-
mental pollution.
CAUTION
Make sure to comply with these instructions; failure to
do so may result in severe faults in engine performance
and operation.
Safety sign Reference Location
Fan
Operation &
Maintenance manual
V-belt
Turbocharger
Exhaust manifold
(Heat screen)
Emergency stop
device
WARNING
• While running the engine, be careful not to touch the
safety guard on the cooling fan. Otherwise, the spin-
ning cooling fan may cause severe injury, such as
severing fingers.
• While running the engine, be careful not to touch the
safety guard on the V-belt. Otherwise, the spinning
V-belt may cause severe injury, such as severing
fingers.
• The V-belt safety guard is an optional item for
customers. The V-belt safety guard must be installed
in order to prevent accidents. In the event that the
V-belt safety guard is not installed, do not approach
the engine while it is running. Hyundai Doosan Infra-
core is not responsible for accidents or injuries
which occur without the V-belt safety guard installed.
• Be careful not to touch the turbocharger components
immediately after stopping the engine or while the
engine is running. Otherwise, the heated turbo-
charger may cause severe injury. In the event that a
heated turbocharger must be handled for the sake of
maintenance or repairs, wait for the turbocharger to
cool sufficiently before handling it.
• Be careful not to touch the exhaust manifold or heat
shield components immediately after stopping the
engine or while the engine is running. Otherwise, this
may cause severe injury. The heat shield installed on
the exhaust manifold becomes especially hot, so
take care not to touch it.
• In the event that emergency engine maintenance
must be performed, use the mechanism installed on
the generator first. It may be difficult to operate the
'manual emergency stop device' installed on the fuel
pump, and touching the exhaust manifold may cause
severe injury. Hence, use the 'manual emergency
stop device' after installing a separate auxiliary
cable. Hyundai Doosan Infracore is not responsible
for accidents or injuries which occur without a sepa-
rate auxiliary cable installed.

1. Introduction
5
General Precautions
1. To use the engine safely and with optimal performance over
long periods of time, engine operators must familiarize them-
selves with the contents of this Operation and Maintenance
Manual and perform both daily and routine inspections.
2. We have divided the contents of this manual into causes
of bodily injury, property damage, and causes of pollu-
tion. Make sure to comply with all instructions concerning
the specified regulations and mounting locations.
Cautions for Starting the Engine
1. Before starting the engine, make sure to read this Opera-
tion and Maintenance Manual carefully and familiarize
yourself with the 'Danger.' 'Warning' and 'Caution' items.
Please contact Hyundai Doosan Infracore if there is any
uncertainty regarding the contents of this manual or if you
have any questions.
2. For the sake of safety, attach a warning to the engine
prohibiting anyone but workers from approaching the
engine while it is in operation. Make sure to notify the
engine operators that the safety of the engine room is
their responsibility.
3. Only authorized personnel may start and operate the
engine. Never allow an unauthorized person to handle
the engine.
4. Do not approach rotating or moving parts while the
engine is in operation.
5. Be careful not to touch or come in contact with the engine
while it is running since it becomes hot during operation.
6. Exhaust gas is poisonous. Before starting the engine,
ventilate the workspace sufficiently; when working in an
enclosed space, check to ensure that the space is venti-
lated.
Cautions for Inspections and Maintenance
1. Make sure to perform inspections and service work only
with the engine stopped. If it is absolutely necessary to
perform inspections or service work with the engine
running, be careful of any possible accidents and
scalding.
2. If performing inspections or service work while the engine
is running cannot be avoided, do not get too close to any
rotating parts.
3. When draining engine oil, make sure to prepare a container
of sufficient size to ensure that engine oil does not overflow.
4. When replacing or refilling engine coolant, open the
coolant cap after cooling the engine sufficiently.
5. Fuel is highly flammable. Smoking or using an open
flame near the engine may cause a fire.
6. Label and store coolant containers separately to avoid
confusion with beverage containers. If coolant is
ingested, seek medical assistance immediately.
7. Follow the instructions provided by the battery manufac-
turer when checking or handling batteries.
WARNING
While starting the engine or during inspections and
maintenance, if skin accidentally comes in contact with
corrosive acid or fuel, you are burnt by hot oil, or fuel or
antifreeze gets in your eyes, seek medical assistance
immediately.
DANGER
Severe injuries may occur if gloves or accessories such
as necklaces, rings or watches are caught in rotating
parts during service work while the engine is running.
WARNING
Do not replace or disconnect any pipes or hoses (engine
fuel circuit, engine oil circuit, coolant circuit and
compressed air circuit, etc.) while the engine is running.
Spurting fluid may cause physical injuries.
WARNING
If the coolant cap is opened while the engine is still hot,
hot coolant will spurt out and may cause burns. Open the
coolant cap only after cooling the engine sufficiently.
WARNING
When fuel needs to be refilled, make sure to add fuel
while the engine is stopped.
WARNING
Battery fluid is toxic, corrosive and explosive. Hence, it
should be handled by trained technicians.

1. Introduction
6
8. Only certified service technicians should service and
handle the engine.
9. Use proper tools only according to their intended use.
Using a worn wrench with a split tip may lead to injuries
due to slipping of the tool while working.
10. When lifting the engine with a crane, never allow anyone
to stand or pass beneath it. Make sure to check the
surroundings and ensure that there is enough safe space
to work before lifting the engine.
11. Before inspecting and replacing parts in electrical
systems, disconnect the battery ground cable first. To
prevent a short circuit, connect the battery ground cable
only after all other work is complete.
12. Before performing arc welding, stop the engine, shut off
the power source and disconnect the wire harness
connected to the engine control unit (ECU).
13. Do not apply any form of electric or mechanical shock or
perform welding on electrical systems or the engine
control unit (ECU).
General Information
1. Working on the engine while it is hot may cause burns, so
make sure to perform work on the engine only after it has
cooled sufficiently.
Before working on fuel lines, use a diagnostic device to
check the common rail pressure and engine temperature
first.
2. Disconnect the ground cable from the battery to prevent
damage to wires and sensors resulting from short circuits.
3. Engine oil and coolant may damage painted surfaces, so
label and store them separately in appropriate containers.
4. Store removed parts in a designated area to avoid
damaging or contaminating them.
5. For the sake of efficient and safe service work, use the
specified tools and special tools.
6. When replacing parts, make sure to replace them with
genuine Hyundai Doosan Infracore parts. Using imitation
or recycled parts may cause severe faults with an impact
on engine performance.
7. During service work, replace all parts such as cotter pins,
gaskets, O-rings, seal rings, oil seals and washers with
new ones. Reusing parts may cause faults in the engine
and hinder normal engine performance.
8. To reassemble parts after removing them, make sure to
store them in groups in their order of disassembly. In
particular, bolts and nuts have different strengths, shapes
and tightening torques depending on their mounting loca-
tions, so make sure to organize and store them properly.
9. Make sure to clean removed parts in order to remove any
foreign matter before inspecting or reassembling them.
Use compressed air to clean out oil holes and other holes.
10. Before assembling parts, apply a thin layer of suitable oil
or grease to rotating parts or parts requiring lubrication.
11. If necessary, use a designated adhesive when installing
gaskets in order to prevent oil or coolant leakage.
12. Tighten bolts and nuts to their specified tightening torque.
13. After completing service work, perform a final inspection
and test run to check whether all service work was
performed correctly.
Other Safety Instructions and Environmental
Pollution
Make sure to comply with the following instructions during
engine service work to protect the safety of workers and
prevent environmental pollution.
1. The workspace must have low humidity and be
well-ventilated.
2. The workspace must be clean, well-organized and free of
any open flames.
3. Smoking within the workspace is strictly prohibited.
4. Workers must wear work clothes, protective glasses and
safety shoes.
5. Workers may not wear any accessories such as neck-
laces, rings, watches or earrings.
6. When the engine must be started, ventilate the area suffi-
ciently to prevent carbon monoxide poisoning; then, start
the engine in a well-ventilated area.
7. Working on the engine while it is hot may cause burns, so
make sure to perform work on the engine only after it has
cooled sufficiently.
8. During service work while the engine is running, avoid
working on any rotating or moving parts.
9. Dispose of used oil according to the regulations of local
public institutions.
10. Spilling or allowing engine oil or fuel to leak into the
ground may cause severe environmental pollution of
seas, rivers and groundwater.
11. Dispose of anticorrosive agents, antifreeze, filter
elements, cartridges, etc. which cannot be diluted, as
special waste.
12. Dispose of coolant and special waste according to the
regulations of local public institutions.

1. Introduction
7
Use of Genuine Parts
The engine is a mechanically balanced assembly comprising
a large number of parts. Accordingly, regular maintenance
and replacement of consumable parts are essential for
preventing engine failure and maintaining long-term optimal
performance.
We recommend using genuine Hyundai Doosan Infracore
parts when replacing parts. Using imitation or recycled parts
may cause severe engine faults and damage for which
Hyundai Doosan Infracore shall not be held liable.
Engine Care
Preventing Damage and Wear
Using the engine for any purpose other than that for which it
was designed may cause severe faults in the engine for which
Hyundai Doosan Infracore shall not be held liable. For details
regarding the intended uses and purposes of the engine,
please contact our sales department. Do not adjust, convert or
change the engine control unit (ECU) without the authorization
of Hyundai Doosan Infracore.
When a problem occurs in the engine, locate the cause and
resolve the issue immediately to prevent any severe faults.
We recommend using genuine Hyundai Doosan Infracore parts
when replacing parts. Using imitation or recycled parts may
cause severe engine faults and damage for which Hyundai
Doosan Infracore shall not be held liable.
Make sure to maintain the engine according to the following
instructions.
1. Only use clean fuel with the specified grade. Please use
the fuel recommended in this Operation and Mainte-
nance Manual.
2. Do not operate the engine without lubricant or coolant. Use
only the products (engine oil, coolant, anticorrosive
agents, etc.) recommended by Hyundai Doosan Infracore.
3. Always keep the engine and its surroundings clean.
4. Make sure to use the fuel recommended in this Operation
and Maintenance Manual.
5. Use the maintenance schedule to perform inspections
and replacements at the specified intervals.
6. Do not stop the engine immediately while it is hot.
Instead, idle it for at least 5 minutes so that the engine
temperature drops sufficiently.
7. Check the engine oil level on flat, level ground. Do not fill
oil past the upper limit mark on the oil level gauge.
WARNING
Failing to comply with the regulations of local public
institutions may result in legal sanctions for violating
regulations on the disposal of environmental contami-
nants.
CAUTION
Using imitation or unspecified fuel may cause severe
faults in the engine.
WARNING
If the radiator cap is opened to add or replace coolant
while the engine is overheated, hot coolant will spurt out
and may cause serious burns.
CAUTION
Add engine oil immediately if the engine oil level falls
below the lower limit mark on the oil level gauge.

1. Introduction
8
8. If gauges for the battery, oil pressure, coolant tempera-
ture, etc. are installed in the machine, always check
whether the gauges indicate normal levels.
9. Do not operate the engine without coolant.
Preventing Pollution
Note the following instructions to prevent environmental
pollution during engine maintenance.
1. Drain used oil and coolant, etc. into suitable containers.
2. Dispose of used oil and coolant according to the regula-
tions of local public institutions.
3. Be especially careful to ensure that drained oil and
coolant do not spill onto the ground or into drains. Other-
wise, drinking water sources may be severely contami-
nated.
4. Set aside oil, filters, filter cartridges, etc. as environ-
mental contaminants and handle and dispose of them
according to the specified procedures.
5. Handle and dispose of antifreeze, coolant, and anticorro-
sive agents as hazardous waste.
Handling Engine Oil
If engine oil comes into contact with skin repeatedly over long
periods of time, the skin contracts and dries out, possibly
leading to skin irritation. Engine oil contains harmful
substances. Hence, make sure to comply with the following
safety rules when handling engine oil.
1. Do not come into contact with used engine oil repeatedly
over long periods of time.
2. Always wear work clothes and gloves.
3. If engine oil comes into contact with skin, use water and
soap or hand cleaner to wash it off immediately.
4. Do not use gasoline, fuel, thinners, solvents, etc. to wipe
skin.
5. Wipe off oil and put on protective skin cream.
6. Do not keep oily gloves or rags in pockets.
HVO (Hydro treated Vegetable Oil)
HVO is a synthetic diesel which is manufactured through the
hydrogenation of plants and animal fats.
To the user, HVO is reminiscent of diesel in accordance with
EN590, apart from HVO having a somewhat lower density.
Hyundai Doosan Infracore approves the use of up to 100%
HVO for engines in accordance with the EU standard
EN15940.
GTL (Gas To Liquids)
GTL is a synthetic fuel that is often refined from natural gas.
To the user, GTL is reminiscent of diesel in accordance with
EN590, apart from GTL having a somewhat lower density
and less odour.
Hyundai Doosan Infracore approves the use of up to 100%
GTL in accordance with the EU standard EN15940.
CAUTION
Use a mixture of antifreeze and coolant. Using regular
water in winter causes coolant flow paths in the cylinder
block to freeze, possibly leading to engine damage.
CAUTION
Do not spray high-pressure water directly on the engine.
It may damage engine parts, electronic parts, and wiring.
WARNING
Dispose of used oil according to the regulations of local
public institutions. Engine oil can cause severe environ-
mental pollution if it is spilled on the ground, in drains,
sewers, rivers, or seas. Failing to dispose of engine oil
properly according to disposal regulations is punish-
able by law.

9
2. Operation and Maintenance
Starting and Stopping the Engine .......................................................................................11
Preparing to Start....................................................................................................................................... 11
When Starting the Engine .......................................................................................................................... 11
Immediately after Starting the Engine........................................................................................................ 11
During Operation........................................................................................................................................ 11
When Stopping .......................................................................................................................................... 11
Engine Break-In ..................................................................................................................12
General Information ................................................................................................................................... 12
Breaking in New Engines........................................................................................................................... 12
Inspection Items......................................................................................................................................... 12
Operation after Break-In Period ................................................................................................................. 12
Inspection after Starting the Engine........................................................................................................... 12
Engine Oil Pressure ................................................................................................................................... 13
Coolant Temperature ................................................................................................................................. 13
Engine Speed (rpm)................................................................................................................................... 13
Running the Engine in Winter .............................................................................................13
Prevention of Coolant Freezing ................................................................................................................. 13
Preventing Engine Overcooling ................................................................................................................. 13
Engine Oil .................................................................................................................................................. 13
Running the Primary Fuel Filter (Oil-Water Separator) Heater .................................................................. 13
Engine Inspections and Maintenance .................................................................................14
Checking Engine Parts after Prolonged Operation .................................................................................... 14
Turbocharger Inspections and Maintenance.............................................................................................. 14
Intake System ............................................................................................................................................ 15
Exhaust System ......................................................................................................................................... 15
Lubrication System .................................................................................................................................... 15
Fuel System Inspections and Maintenance ............................................................................................... 15

10

2. Operation and Maintenance
11
Starting and Stopping the Engine
Preparing to Start
Inspect the following before starting the engine for the first time
after purchasing it.
1. Check the fuel, coolant and oil levels before starting the
engine; add as necessary.
2. Check whether the engine oil level lies between the
upper and lower limit lines on the oil level gauge. The
upper and lower limit lines on the oil level gauge indicate
the maximum and minimum engine oil levels.
3. When adding fuel, oil or coolant, take care not to allow
foreign matter to enter the engine; store them in a clean
place when not in use in order to prevent contamination.
Use only fuel, oil, coolant, etc. recommended by Hyundai
Doosan Infracore. Otherwise, severe engine faults may
occur.
When Starting the Engine
Follow the instructions below when starting the engine.
1. For cold starts, start the engine after preheating it suffi-
ciently with the glow plug.
2. If the engine is started abruptly, oil cannot reach the
turbocharger as well as the various parts of the engine;
this lack of lubrication can lead to abnormal wear or
seizure of the bearings. Hence, before starting the
engine, it is necessary to run it with the starter motor to
check for a rise in hydraulic pressure (until the needle on
the hydraulic pressure gauge installed in the machine
moves or the pressure indicator comes on).
3. Oil flow in pipes worsens after the engine has been
stopped for a prolonged period of time or in cold weather.
Hence, after changing the oil, replacing the oil filter
cartridge or parts of the lubrication system or leaving the
engine stopped for an extended period of time or in cold
weather, undo the oil pipe connection at the inlet of the
turbocharger and run the starter motor until oil flows out
of it. Once this step is complete, make sure to retighten
the pipe connection and start the engine.
Immediately after Starting the Engine
1. After starting the engine, do not increase the engine rpm
suddenly when the engine and turbocharger are not yet
rotating smoothly. The engine may be overloaded,
leading to seizure in parts not yet sufficiently lubricated
by oil. Hence, idle the engine after starting it to enable
enough oil to reach the turbocharger.
2. Oil, air and gas leakage reduces hydraulic pressure. Oil
leakage in particular may cause bearings to seize.
Hence, in the event of an oil, air or gas leak, check the
leaking part, locate the cause and resolve the issue.
During Operation
1. If the oil pressure is excessively low, it can lead to
abnormal wear or seizure of bearings; if it is excessively
high, it can cause oil leaks.
2. Continuing to run the engine with abnormal noise or
vibrations may cause severe damage to the engine.
Hence, in the event of abnormal noise or vibrations, lower
the engine rpm slowly; then, stop the engine and deter-
mine the cause.
When Stopping
Do not stop the engine abruptly after running it at a high rpm
for an extended period of time. If heat transferred from the
hot turbine blades reaches the bearings and causes oil to
burn, it may lead to seizure of the metal bearing and rotating
shaft. Hence, after operating the engine at a high rpm for a
prolonged period of time, idle the engine sufficiently before
stopping it.
CAUTION
Do not fill engine oil past the upper limit line on the oil
level gauge. Overfilling oil can damage the engine.

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.
CAUTION
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.
CAUTION
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.
CAUTION
Replace the engine oil and oil filter with engine oil and a
genuine part recommended by Hyundai Doosan Infra-
core.

2. Operation and Maintenance
13
4. Check the state of the engine during operation using the
warning indicators and gauges installed in the machine.
Engine Oil Pressure
If the engine oil pressure is inconsistent while idling or the
engine oil pressure does not reach the specified amount
while driving at a high speed, stop the engine immediately,
check the oil level and check the oil lines for leakage.
Coolant Temperature
Operating the engine with an excessively low coolant
temperature increases fuel consumption and wear of the
cylinder liner, thereby shortening the engine life.
Engine Speed (rpm)
In electronically controlled engines, the engine control unit
(ECU) has a function which prevents the engine from running
at engine speeds (rpm) exceeding the specified amount in
order to protect the engine. A variety of functions—such as
controlling fuel flow, delaying ignition time, and blocking fuel
and ignition—are set by the memory in the engine control
unit (ECU) and cannot be changed arbitrarily by the operator.
Running the Engine in Winter
Prevention of Coolant Freezing
Using only water to add coolant without any antifreeze can
cause corrosion inside the engine, reduce cooling efficiency,
and cause engine freezing in winter. When operating the
engine in a cold area for an extended period of time, make
sure to completely drain coolant from the engine. Frozen
coolant can cause critical damage to the engine. When
adding and replacing coolant, make sure to use coolant
mixed with the specified ratio of antifreeze. Antifreeze
prevents coolant from freezing.
Preventing Engine Overcooling
If the engine is cooled below the normal operating
temperature, thermal efficiency drops and fuel consumption
and wear of the cylinder liner increase. Hence, make sure to
keep the engine running within the normal operating
temperature range. If the coolant temperature remains below
the normal operating temperature range in spite of running
the engine for a sufficient amount of time, check the
thermostat or other parts related to the cooling system.
Engine Oil
If the engine oil viscosity increases due to cold temperatures
in winter or in extremely cold regions, the engine rpm may be
unstable after starting the engine. In order to prevent this
phenomenon, make sure to replace the engine oil with
engine oil intended for use in winter or extreme cold. When
replacing engine oil, please use genuine oil recommended
by Hyundai Doosan Infracore.
Running the Primary Fuel Filter (Oil-Water
Separator) Heater
In winter and in cold temperatures, the paraffin in diesel
forms a gel and blocks the surface of the cartridge in the
primary fuel filter, resulting in restricted fuel flow. In such
cases, engine start-up may be delayed/impossible, the
engine rpm may be unstable after engine start-up, or the
engine may turn off. To prevent this phenomenon, run the
heater mounted on the primary fuel filter (oil-water separator)
five minutes before starting the engine to remove the paraffin
from inside the primary fuel filter and the paraffin gel entering
continuously from the fuel tank.

2. Operation and Maintenance
14
Note) If the heater switch on the generator control panel is
left on while the engine is turned off, the current
consumption resulting from unnecessary operation of
the fuel heater mounted on the primary fuel filter may
cause the battery to discharge. Hence, if the generator
control panel is not connected to a sufficient constant
external charging power source, it is recommended to
turn on the heater switch of the generator set five
minutes before starting the engine.
Engine Inspections and Maintenance
Checking Engine Parts after Prolonged
Operation
The function of engine parts may be degraded by wear,
corrosion, and thermal deterioration in engine parts and
assemblies. In order to maintain optimal engine
performance, check the engine after prolonged operation to
enhance engine durability.
Even if the engine is operated normally, faults may occur in
certain unpredictable and vulnerable parts as the engine is
used over time. In such cases, it is difficult to maintain engine
performance simply by repairing certain parts. In order to
locate the causes of problems more accurately and maintain
optimal engine performance, it is best to replace or repair all
related parts as a whole.
In order to prevent engine malfunction in advance, performing
replacements and inspections periodically enables the
engine to be used safely for a longer period of time.
We recommend performing engine adjustments and preventive
inspections in the spring after winter or cold temperatures have
passed. In doing so, the engine can be used economically and
without faults for extended periods of time.
As the following parts affect the engine output and
performance, these parts should be checked and inspected
periodically.
1. Components that can affect intake and exhaust
•Airfilter
• Intercooler
• Turbocharger, muffler
• Misc.
2. Components that can affect lubrication and cooling
performance
•Airfilter
• Oil Filter
• Antifreeze
• Misc.
3. Components that can affect fuel injection
•FuelTank
• Primary fuel filter and cartridge
• Secondary fuel filter and element
• Common rail, high-pressure pump wiring fasteners
Turbocharger Inspections and Maintenance
As turbocharger performance has a significant impact on
engine performance, it is important to perform periodic
inspections and maintenance, as well as to comply with the
specified instructions for handling the turbocharger.