Run-in has to be Moderately Hard The initial oil fills is seldom the same formulation that is used for
subsequent fills, though it may be similar in most respects. It will
probably have less detergency, to allow whatever running-in needed, as
a start point.
The purpose of running-in engines is to reduce the severity of the
surface roughness of critical mating surfaces (journals / bearings,
rings / liners, etc.) thus increasing the contact area. Defects on
these surfaces, in new or re-built engines, have the effect of
reducing the actual contact areas (values of 1/1000 of the specified
design area have been measured). Improvement is achieved by
controlling the initial wear that takes place. The benefits include
reduced long-term wear and energy losses due to friction. Plateaux
honeing is one mechanical means of increasing the initial surface
contact area while significantly reducing the metal loss to oil. In
this case the inverted V shaped peaks in the surface metal have their
tops lopped off during manufacture rather than during the stage1 of
bedding-in.
Running-in occurs in two stages: Stage 1: Removal of surface roughness. This surface roughness
is less pronounced, though still present in the best of newly built
engines. Stage 2: Correction of surface imperfections (poor machining
tolerances and distortion)
After assembly most *diesel* engines are initially run up to full load
for periods which may last as long as 2.5 hours on test beds. Most of
the time, despite this severe running period Stage 1 is very often
incomplete. Note that this early bench running is at or near full
load. It therefore follows that Stage 2 will not have been reached by
the time the unit has been put into service. Unless this is properly
controlled, engine failures can result if the loading is increased too
fast or too slow. Many petrol engines are not bench run-in, but benefit equally from moderately hard early use but are least likely to achieve an effective first stage due to the mistaken and historic belief in an excessively gentle running-in. Such gentle treatment was needed historically
because of very wide production tollerances, which could mean that
bearing surfaces could have little effective clearance and could heat
and seize when stressed. There is still a concern here in the first
few hundred miles, hence the almost universal recommendation to allow
the engine to heat thoroughly before loading and not to rev
excessively in the first few hundred miles.... until stage 2 has been
well established.
Symptoms of failure, which some people mistakenly attribute to factors
other than the actual cause, include:
· Lack of power
· High oil consumption
· Oil exiting from the exhaust (breathing)
· Cylinder bore glazing
These are usually evident before 5000 miles or approximately 200 hours
have been completed if they are ever to become evident. *It is well documented that if new or re-built engines are operated under conditions of low load / constant speed, running-in can be prevented and bore glazing is the most likely outcome. This mode of operation is usually associated with cars, commercial vehicles, agricultural / plant equipment and generators.*
*Cylinder bore glazing is caused by a combination of iron oxides,
graphite and lubricant additives that form a hard chemical layer that
prevents the running-in process from taking place. The process occurs
before the piston rings generate load carrying surface plateaux or
optimum oil control capability.*
Bore glazing afflicts normally aspirated engines more than
turbo-charged versions that generate higher load factors and piston
ring pressures.
*Most piston rings are chrome plated and the best lubricant choice for
running-in would be a straight mineral oil. However, combustion
by-products coupled with high running temperatures have to be
effectively dealt with and require detergency and dispersancy
additives to provide engine protection.* With thanks to Moris oil for the bones of this summary which has been substantially added to by a certain Mr. Huw for clarity
EXPERTS ARE ALL SAYING PUSH THAT ENGINE
kb
Last edited by kb100 : 7th March 2006 at 15:17.
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