ASTM D5862 Standard Test Method for Evaluation of Engine Oils in Two-Stroke Cycle Turbo-Supercharged 6V92TA Diesel Engine
9. Measurement Instrumentation
9.1 Temperature Measurement - Use iron-constantan (Type J) thermocouples or platinum resistance thermocouples for temperature measurement. Other temperature sensors that give the same results may be used, provided that they are approved by the ASTM Test Monitoring Center.
9.1.1 Thermocouple Location - Locate the sensing tip of all thermocouples in the center of the stream of the medium involved, unless otherwise specified.
9.1.2 Oil Gallery - Locate thermocouple on the right front of block in turbocharger oil feed line, flush with block face. See Fig.2, location No.2.
9.1.3 Fuel In - Locate thermocouple at the fuel filter. See Fig.3, location No.3.
9.1.4 Coolant In - Locate thermocouple at coolant inlet to coolant pump. See Fig.3, location No.4.
9.1.5 Coolant Out - Locate thermocouple after right and left thermostat housing outlets join. See Fig.4, location No.5.
9.1.6 Air Inlet - Locate thermocouple before compressor. See Fig.1, location No.7.
9.1.7 Air Box - Locate thermocouple right bank, rear air box cover. Tip of thermocouple should be 32 mm (1 1/4 in.) inside air box cover.
9.1.8 Oil Sump - Locate thermocouple in left side of oil sump, 50 to 120 mm (2 to 5 in.) from back and 50 to 100 mm (2 to 4 in.) from bottom of oil pan. See Fig.5, location No.11.
9.1.9 Exhaust - Locate thermocouple as shown in Fig.1, location No.13.
9.2 Pressure Measurement - Use pressure sensors such as pressure gages or manometers, or electronic transducers, located as indicated, and following the established guidelines.
9.2.1 Pressure Sensor Location - Locate pressure sensors in the center of flow unless otherwise specified.
9.2.2 Oil Gallery - Locate pressure sensor on the left front of block. See Fig.2, location No 1.
9.2.3 Air Inlet - The air inlet restriction sensor (4-hole piezometer) is located in the air inlet, 150 +/- 25 mm (6 +/- 1 in.) from turbocharger as shown in Fig.1, location No.6.
9.2.4 Exhaust Back Pressure - Locate 4-hole piezometer in exhaust stream as shown in Fig.1, location No.8.
9.2.5 Air Box - Locate sensor in right bank, rear air box cover.
9.2.6 Crankcase Pressure - The sensor may be located in the front dipstick hole on the left side of the engine as shown in Fig.2, location No.12. This measurement is optional.
10. Reagents and Materials
10.1 Test Fuel - Use ASTM 2D Fuel or equivalent. It shall have the specific properties shown in Annex A4 (Table A4.1). (Warning - Combustible. Health hazard.)
10.1.1 Make certain that all tanks used for transportation and storage are clean before they are filled with test fuel.
10.1.2 Verify that at least 11 300 L (3000 gal) of test fuel is available before starting the test.
10.2 Test Oil:
10.2.1 Selection - The supplier of the test oil sample shall determine that it is representative of the lubricant formulation being evaluated and that it is not contaminated.
10.2.2 Quantity - The supplier of the test oil shall provide approximately 100 L (25 gal) of the test oil sample.
10.2.3 Identification - The oil sample shall be clearly identified with the name of the test sponsor, the oil formulation, and the batch code. The code number from the container is to be entered on the test report.
10.2.4 Storage Prior to Test - The test laboratory shall store the test oil sample in a covered building to prevent both contamination by rainwater and excessive heat exposure.
10.3 Coolant Composition - A 50 % concentration of regular grade ethylene glycol type antifreeze in distilled water is to be used. (Warning - Combustible. Health hazard.)
10.4 Sealing and Anti-seize Compounds - The following sealing and anti-seize compounds are required for this test method:
10.4.1 For All Bolts Under Specified Torque - Use International Compound No.2 to achieve proper fastener torque. Use minimum quantities and remove all excess, as discussed in 8.5.5.
10.4.2 All bolts, plugs, fittings or fasteners, (including studs) that intersect with a through hole and come in contact with oil, fuel or coolant shall have a sealer applied to the threads. It is recommended that Loctite J26558-92 Pipe Sealant with Teflont be used, as discussed in 8.5.5.
10.5 Cleaning Materials - The following cleaning materials are required in the procedure. The use of alternative materials requires approval by the ASTM TMC.
10.5.1 For Block Cleaning - Use Penetone (specifically Penmul L-460), as discussed in 8.3.1.
10.5.2 For Head Cleaning - Use an aliphatic carbon, as discussed in 8.3.2.
10.5.3 For Piston Ring Cleaning - Use Oakite Rust Stripper OF, as discussed in 8.3.3.
10.5.4 For Coolant System Cleaning - Use Nalprep 2001, as discussed in 13.1.2.
11. Hazards
11.1 General - The environment involved with any engine test is inherently hazardous. Serious injury of personnel and damage to facilities can occur if adequate safety precautions are not taken. However, as evidenced by the fact that many thousands of engine tests are successfully conducted each year it is possible to take adequate precautions.
11.2 Caveat - The following paragraphs do not cover all possible safety-related problems associated with 6V92TA testing.
11.3 Personnel - Carefully select and train personnel who will be responsible for the design, installation, and operation of 6V92TA test stands. Make certain that the test operators are capable of handling the tools and facilities involved and in observing all safety precautions, including avoiding contact with either moving or hot test parts.
11.4 Personnel Protection Facilities - Provide the following personnel protection facilities:
11.4.1 Provide safety shower and eye-rinse equipment in close proximity to the facilities used for parts cleaning, engine assembly, engine test operation, and parts rating.
11.4.2 Provide, and require the use of, appropriate face masks, eye protection, chemical breathers, gloves, and so forth, in all aspects of 6V92TA testing.
11.4.3 Provide dry chemical fire extinguishers for putting out fires.
11.4.4 Advise personnel not to use water to attempt to extinguish fires involving fuel, oil, or glycol.
11.4.5 Equip test stands with automatic fire extinguishing equipment.
11.4.6 Install suitable guards around all external moving parts, or hot parts.
11.4.7 Advise personnel not to work alongside the engine and coupling shaft when the engine is operating at high speeds.
11.4.8 Provide barrier protection between the engine and coupling shaft, and operating personnel.
11.4.9 Prohibit the wearing of loose or flowing clothing by personnel working near a running engine.
11.5 Safety Equipment and Practices - Observe the following in order to establish and maintain safe working conditions for 6V92TA testing:
11.5.1 Provide the proper tools for conducting the 6V92TA test.
11.5.2 Require regular inspection and approval by the laboratory safety department of the facilities used for 6V92TA testing.
11.5.3 Properly install all fuel lines, oil lines, and electrical wiring. Maintain them in good condition.
11.5.4 Select and install coolant hoses and clamps with special care in order to prevent coolant leaks and possible fires.
11.5.5 Do not permit tripping hazards to exist in any of the areas involved with 6V92TA testing.
11.5.6 Keep the outer surfaces of the engine, other equipment, and the floor area free from fuel and oil.
11.5.7 Do not allow the accumulation of containers of oil or fuel in 6V92TA areas.
11.5.8 Demand that personnel be alert for leaking fuel, exhaust gas, oil, or coolant, and that they take action to stop such leaks.
11.5.9 Equip the test stand with an automatic fuel shutoff valve designed to turn off the fuel supply to the engine whenever the engine is not running.
11.5.10 Make provision for manual, remote operation of the fuel shutoff valve.
11.5.11 Install suitable interlocks to shut down the engine when any of the following develop: loss of dynamometer field current, engine overspeeding, loss of engine oil pressure, failure of the exhaust system, failure of the room ventilation, activation of the fire protection system, excessive vibration, and so forth.
9. Measurement Instrumentation
9.1 Temperature Measurement - Use iron-constantan (Type J) thermocouples or platinum resistance thermocouples for temperature measurement. Other temperature sensors that give the same results may be used, provided that they are approved by the ASTM Test Monitoring Center.
9.1.1 Thermocouple Location - Locate the sensing tip of all thermocouples in the center of the stream of the medium involved, unless otherwise specified.
9.1.2 Oil Gallery - Locate thermocouple on the right front of block in turbocharger oil feed line, flush with block face. See Fig.2, location No.2.
9.1.3 Fuel In - Locate thermocouple at the fuel filter. See Fig.3, location No.3.
9.1.4 Coolant In - Locate thermocouple at coolant inlet to coolant pump. See Fig.3, location No.4.
9.1.5 Coolant Out - Locate thermocouple after right and left thermostat housing outlets join. See Fig.4, location No.5.
9.1.6 Air Inlet - Locate thermocouple before compressor. See Fig.1, location No.7.
9.1.7 Air Box - Locate thermocouple right bank, rear air box cover. Tip of thermocouple should be 32 mm (1 1/4 in.) inside air box cover.
9.1.8 Oil Sump - Locate thermocouple in left side of oil sump, 50 to 120 mm (2 to 5 in.) from back and 50 to 100 mm (2 to 4 in.) from bottom of oil pan. See Fig.5, location No.11.
9.1.9 Exhaust - Locate thermocouple as shown in Fig.1, location No.13.
9.2 Pressure Measurement - Use pressure sensors such as pressure gages or manometers, or electronic transducers, located as indicated, and following the established guidelines.
9.2.1 Pressure Sensor Location - Locate pressure sensors in the center of flow unless otherwise specified.
9.2.2 Oil Gallery - Locate pressure sensor on the left front of block. See Fig.2, location No 1.
9.2.3 Air Inlet - The air inlet restriction sensor (4-hole piezometer) is located in the air inlet, 150 +/- 25 mm (6 +/- 1 in.) from turbocharger as shown in Fig.1, location No.6.
9.2.4 Exhaust Back Pressure - Locate 4-hole piezometer in exhaust stream as shown in Fig.1, location No.8.
9.2.5 Air Box - Locate sensor in right bank, rear air box cover.
9.2.6 Crankcase Pressure - The sensor may be located in the front dipstick hole on the left side of the engine as shown in Fig.2, location No.12. This measurement is optional.
10. Reagents and Materials
10.1 Test Fuel - Use ASTM 2D Fuel or equivalent. It shall have the specific properties shown in Annex A4 (Table A4.1). (Warning - Combustible. Health hazard.)
10.1.1 Make certain that all tanks used for transportation and storage are clean before they are filled with test fuel.
10.1.2 Verify that at least 11 300 L (3000 gal) of test fuel is available before starting the test.
10.2 Test Oil:
10.2.1 Selection - The supplier of the test oil sample shall determine that it is representative of the lubricant formulation being evaluated and that it is not contaminated.
10.2.2 Quantity - The supplier of the test oil shall provide approximately 100 L (25 gal) of the test oil sample.
10.2.3 Identification - The oil sample shall be clearly identified with the name of the test sponsor, the oil formulation, and the batch code. The code number from the container is to be entered on the test report.
10.2.4 Storage Prior to Test - The test laboratory shall store the test oil sample in a covered building to prevent both contamination by rainwater and excessive heat exposure.
10.3 Coolant Composition - A 50 % concentration of regular grade ethylene glycol type antifreeze in distilled water is to be used. (Warning - Combustible. Health hazard.)
10.4 Sealing and Anti-seize Compounds - The following sealing and anti-seize compounds are required for this test method:
10.4.1 For All Bolts Under Specified Torque - Use International Compound No.2 to achieve proper fastener torque. Use minimum quantities and remove all excess, as discussed in 8.5.5.
10.4.2 All bolts, plugs, fittings or fasteners, (including studs) that intersect with a through hole and come in contact with oil, fuel or coolant shall have a sealer applied to the threads. It is recommended that Loctite J26558-92 Pipe Sealant with Teflont be used, as discussed in 8.5.5.
10.5 Cleaning Materials - The following cleaning materials are required in the procedure. The use of alternative materials requires approval by the ASTM TMC.
10.5.1 For Block Cleaning - Use Penetone (specifically Penmul L-460), as discussed in 8.3.1.
10.5.2 For Head Cleaning - Use an aliphatic carbon, as discussed in 8.3.2.
10.5.3 For Piston Ring Cleaning - Use Oakite Rust Stripper OF, as discussed in 8.3.3.
10.5.4 For Coolant System Cleaning - Use Nalprep 2001, as discussed in 13.1.2.
11. Hazards
11.1 General - The environment involved with any engine test is inherently hazardous. Serious injury of personnel and damage to facilities can occur if adequate safety precautions are not taken. However, as evidenced by the fact that many thousands of engine tests are successfully conducted each year it is possible to take adequate precautions.
11.2 Caveat - The following paragraphs do not cover all possible safety-related problems associated with 6V92TA testing.
11.3 Personnel - Carefully select and train personnel who will be responsible for the design, installation, and operation of 6V92TA test stands. Make certain that the test operators are capable of handling the tools and facilities involved and in observing all safety precautions, including avoiding contact with either moving or hot test parts.
11.4 Personnel Protection Facilities - Provide the following personnel protection facilities:
11.4.1 Provide safety shower and eye-rinse equipment in close proximity to the facilities used for parts cleaning, engine assembly, engine test operation, and parts rating.
11.4.2 Provide, and require the use of, appropriate face masks, eye protection, chemical breathers, gloves, and so forth, in all aspects of 6V92TA testing.
11.4.3 Provide dry chemical fire extinguishers for putting out fires.
11.4.4 Advise personnel not to use water to attempt to extinguish fires involving fuel, oil, or glycol.
11.4.5 Equip test stands with automatic fire extinguishing equipment.
11.4.6 Install suitable guards around all external moving parts, or hot parts.
11.4.7 Advise personnel not to work alongside the engine and coupling shaft when the engine is operating at high speeds.
11.4.8 Provide barrier protection between the engine and coupling shaft, and operating personnel.
11.4.9 Prohibit the wearing of loose or flowing clothing by personnel working near a running engine.
11.5 Safety Equipment and Practices - Observe the following in order to establish and maintain safe working conditions for 6V92TA testing:
11.5.1 Provide the proper tools for conducting the 6V92TA test.
11.5.2 Require regular inspection and approval by the laboratory safety department of the facilities used for 6V92TA testing.
11.5.3 Properly install all fuel lines, oil lines, and electrical wiring. Maintain them in good condition.
11.5.4 Select and install coolant hoses and clamps with special care in order to prevent coolant leaks and possible fires.
11.5.5 Do not permit tripping hazards to exist in any of the areas involved with 6V92TA testing.
11.5.6 Keep the outer surfaces of the engine, other equipment, and the floor area free from fuel and oil.
11.5.7 Do not allow the accumulation of containers of oil or fuel in 6V92TA areas.
11.5.8 Demand that personnel be alert for leaking fuel, exhaust gas, oil, or coolant, and that they take action to stop such leaks.
11.5.9 Equip the test stand with an automatic fuel shutoff valve designed to turn off the fuel supply to the engine whenever the engine is not running.
11.5.10 Make provision for manual, remote operation of the fuel shutoff valve.
11.5.11 Install suitable interlocks to shut down the engine when any of the following develop: loss of dynamometer field current, engine overspeeding, loss of engine oil pressure, failure of the exhaust system, failure of the room ventilation, activation of the fire protection system, excessive vibration, and so forth.