ASTM D5862 Standard Test Method for Evaluation of Engine Oils in Two-Stroke Cycle Turbo-Supercharged 6V92TA Diesel Engine
13. Test Procedure
13.1 Pre-Test Procedure:
13.1.1 Oil Charging - Test severity can be affected by the volume of oil maintained in the engine during this test. Additionally, oil consumption is a condition of test validity.
13.1.1.1 Oil filling is accomplished with the use of an electric or air driven gear pump suitable for this purpose. Reasonable care should be exercised to ensure that the test oil, as delivered from the pump, is clean and free of contamination. Previous test oils shall be thoroughly flushed from the pump and delivery lines.
13.1.1.2 The recommended location for oil filling is at the remote oil cooler filter adapter. See Annex A2 (Fig.A2.2). This location also may be used for oil sampling.
13.1.1.3 For dry engine oil charge, pump 22.0 +/- 0.3 kg (48.5 +/- 0.7 lb) of test oil into the engine through the oil filter adapter.
13.1.1.4 Start the engine and idle for 10 min or until the oil gallery temperature reaches 60°C (140°F).
13.1.1.5 Stop the engine and wait 25 min.
13.1.1.6 Set the full mark on the adjustable dipstick to the oil level. The adjustable dipstick is described in Annex A2 (Fig.A2.4). Remove the dipstick and place in a location where this setting will not be altered. Cap the dipstick tube opening.
13.1.1.7 Complete the break-in as described in 13.1.2.
13.1.1.8 For wet engine oil charge, pump 18 kg (40 lb) of test oil into the engine.
13.1.1.9 Start the engine and idle for 10 min or until the oil gallery temperature reaches 60°C (140°F).
13.1.1.10 Stop the engine and wait 25 min.
13.1.1.11 Add additional test oil until the oil level reaches the full mark. This represents the initial oil charge.
13.1.1.12 Oil additions are made at the end of each test cycle after the engine has stopped for 25 min. Determine the approximate oil volume needed to return to the full mark indicated on the adjustable dipstick using the intermediate scribe lines.
13.1.1.13 Weigh the oil make-up and add to the engine. Record the weight in the test log.
13.1.1.14 At the end of the test, estimate the weight of oil needed to return to the full mark, but do not add fresh oil at this point.
13.1.1.15 The total oil consumed in the test is determined by the sum of the oil additions, included the estimated addition described in 13.1.1.14. It does not include the initial oil charge or the final quantity of oil in the engine. Record as grams per hour (g/h) on Forms 2 or 3 (see Annex A5) as appropriate.
13.1.2 Coolant Flush Procedure - Fill the engine coolant system with cleaning agent just previous to start-up for engine break-in. (Warning - Health hazard.)
13.1.2.1 At the start of break-in, fill the coolant system as follows:
(1) Check that all drain cocks are closed.
(2) Fill the coolant system (approximately 45 L) with clean water and add 1 L of Nalprep 2001 to the surge pot as it is filling up.
(3) Fill the system until the coolant level is to the top of the sight glass.
(4) Install the red cap.
13.1.2.2 Flush the cleaning agent from the coolant system prior to start-up for a test. Proceed as follows:
(1) Drain the cleaning solution from the engine.
(2) Fill and drain the cooling system two times with clean water.
(3) Fill the cooling system with clean water.
(4) Run the engine to do oil leveling at idle until the oil sump temperature is >60°C; then shut down the engine.
(5) Drain the water from the engine.
(6) Fill the coolant system with a premixed 50/50 solution of ethylene glycol type antifreeze in distilled water.
13.1.3 Engine Break-in - Perform engine conditioning using the test oil, reference or non-reference. Make an oil and filter change following break-in. The specific engine operating conditions for break-in are provided in Table 3.
13.1.4 Power Check - At the conclusion of break-in, but before shutting down engine, verify that engine output is adequate by performing a power check. Increase engine speed to 2300 r/min and increase torque until a nominal fuel flow rate of 90 kg/h is obtained. Observe and record engine power, which shall be at least 373 kW. If the engine fails to reach this power level, and repairs cannot remedy the power loss, the test should not be started. The duration of the power check should be only long enough to determine engine power output.
13.1.5 Air Box Inspection - At the conclusion of break-in and after the power check, an air box inspection shall be made. See 13.3.2.
13.2 Engine Operating Procedure:
13.2.1 Test Procedure:
13.2.1.1 At the completion of break-in and following service to the lubricant and filters, start the engine and allow it to warm up for 10 min, maintaining an idle. Increase engine speed to 1200 r/min. Apply load and adjust fuel flow until the conditions for Mode 1 (Torque), as is shown in Table 4, are set. Maintain this setting for 8 h.
13.2.1.2 At the end of Mode 1 (Torque) increase engine speed to 2300 r/min. Adjust the fuel flow to obtain the fuel flow range specified in Table 4. Maintain this condition for 8 h. Upon completion of this mode, return engine to idle for 5 min, then stop engine. Oil sampling shall be done during this 5-min period. See 13.3.1 for oil sampling procedure and schedule.
13.2.1.3 The third mode is a heat soak period and is an integral portion of the test procedure. During this period however, airbox inspections, oil sampling and oil leveling may be performed. This mode of the test may be longer, but cannot be shorter than 3 h. Heat soak after the seventh cycle is not necessary.
13.2.1.4 Table 5 summarizes the 100-h test sequence by segment.
13.3 Periodic Measurements and Functions :
13.3.1 Oil Additions and Used Oil Sampling:
13.3.1.1 Take samples of the test oil according to the schedule shown in Table 6 as a means of test quality control and possible problem diagnosis. Where applicable, ASTM test methods are recommended for this analysis and are identified in Table 6.
13.3.1.2 Take oil samples from the oil filter adapter of the remote oil cooler, Annex A2 (Fig.A2.2), while the engine is idling. This shall be done during the 5-min cool down after completion of a test mode. (Warning - In addition to other precautions, oil samples taken in this manner will be hot and can cause severe burns. Proper safety precautions to avoid skin contact, including the use of gloves, apron and safety glasses, are recommended.)
13.3.1.3 Take oil samples by first purging the sample line of 100 mL (approximately 3.4 fl oz) of test oil. This purge oil is immediately returned to the engine before oil leveling. Then draw the sample into the appropriate clean, engine oil compatible container as required by the analytical laboratory. All sample volumes should be within 10 % of 100 mL, except for a 500-mL sample taken at 96 h.
13.3.1.4 Take samples prior to any oil leveling or makeup.
13.3.2 Air Box Inspections:
13.3.2.1 Perform airbox inspections by removing small covers on the engine block exposing the liner port area. With the use of a bore scope or similar device, a limited inspection of the ring faces and liner inside diameter are possible. Such inspections are useful as a diagnostic tool to provide interim test part conditions and identify impending engine failure. It is not intended for prediction of failing oil performance.
13.3.2.2 An airbox inspection for liner and ring distress is required after break-in. Make an estimate of cylinder liner scuffing and report on Form 16 (see Annex A5). Exercise extreme care when removing the airbox covers and working in the liner port area so as not to disturb any soot accumulation in the liner parts, which, if accidentally spilled into the cylinder, can cause ring and liner scuffing. Use a bore scope for this inspection. Excessive liner scuffing after break-in could be indicative of a test problem. A test may be aborted at the discretion of the laboratory.
13.3.2.3 Due to the potential of introducing soot and combustion debris, which can initiate liner and ring scuffing, airbox inspections are not recommended during the test unless one or more of the following conditions exist:
(1) A sudden increase in crankcase pressure or blowby occurs.
(2) Used oil iron content exceeds 500 ppm.
(3) Power output is below 364 kW (488 bhp) during the power mode immediately preceding the inspection.
13.3.2.4 Report all airbox inspections on Form 16 (see Annex A5). Note the cause for the inspection in the appropriate area of the form.
13.4 Diagnostic Data Review - This section outlines significant characteristics of specific engine operating parameters. The parameters can directly influence the test or may be used to indicate normalcy of other parameters.
13.4.1 Exhaust Temperatures - Deviations for individual exhaust temperatures are used to indicate incorrect combustion, a sign of injector malfunctioning.
13.4.2 Crankcase Pressure - Higher crankcase pressure than normal can indicate scuffed cylinders, a leak in the seal between the piston dome and skirt, or a blower seal failure.
13.4.3 Airbox Pressure - Low boost pressure can indicate a damaged turbocharger (either broken vanes or a bearing failure), exhaust system leaks or blower malfunction.
13.5 End of Test Procedure:
13.5.1 Estimate the amount of oil necessary to bring oil to full mark, and add this amount to the cumulative oil make-up for a final oil consumption figure. Do not actually add the oil to the engine.
13.5.2 After taking end-of-test oil sample, drain oil, fuel, and water from the engine.
13.5.3 Remove engine to cleaning area and clean all surfaces as necessary to remove loose dirt, etc. before removing sub-assemblies.
13.5.4 Mount engine on overhaul stand and remove all required subassemblies, cleaning each individual part after removal. Pistons, rings, and liners, and bearings shall be cleaned as outlined in 8.3. Take care to identify and maintain all locations for test parts. Cut liners as exactly in half as possible, along the crankshaft center line, taking special care not to disturb deposits. This is accomplished by use of a suitable saw and done after cleaning with Varsol 3139 and before rating.
13. Test Procedure
13.1 Pre-Test Procedure:
13.1.1 Oil Charging - Test severity can be affected by the volume of oil maintained in the engine during this test. Additionally, oil consumption is a condition of test validity.
13.1.1.1 Oil filling is accomplished with the use of an electric or air driven gear pump suitable for this purpose. Reasonable care should be exercised to ensure that the test oil, as delivered from the pump, is clean and free of contamination. Previous test oils shall be thoroughly flushed from the pump and delivery lines.
13.1.1.2 The recommended location for oil filling is at the remote oil cooler filter adapter. See Annex A2 (Fig.A2.2). This location also may be used for oil sampling.
13.1.1.3 For dry engine oil charge, pump 22.0 +/- 0.3 kg (48.5 +/- 0.7 lb) of test oil into the engine through the oil filter adapter.
13.1.1.4 Start the engine and idle for 10 min or until the oil gallery temperature reaches 60°C (140°F).
13.1.1.5 Stop the engine and wait 25 min.
13.1.1.6 Set the full mark on the adjustable dipstick to the oil level. The adjustable dipstick is described in Annex A2 (Fig.A2.4). Remove the dipstick and place in a location where this setting will not be altered. Cap the dipstick tube opening.
13.1.1.7 Complete the break-in as described in 13.1.2.
13.1.1.8 For wet engine oil charge, pump 18 kg (40 lb) of test oil into the engine.
13.1.1.9 Start the engine and idle for 10 min or until the oil gallery temperature reaches 60°C (140°F).
13.1.1.10 Stop the engine and wait 25 min.
13.1.1.11 Add additional test oil until the oil level reaches the full mark. This represents the initial oil charge.
13.1.1.12 Oil additions are made at the end of each test cycle after the engine has stopped for 25 min. Determine the approximate oil volume needed to return to the full mark indicated on the adjustable dipstick using the intermediate scribe lines.
13.1.1.13 Weigh the oil make-up and add to the engine. Record the weight in the test log.
13.1.1.14 At the end of the test, estimate the weight of oil needed to return to the full mark, but do not add fresh oil at this point.
13.1.1.15 The total oil consumed in the test is determined by the sum of the oil additions, included the estimated addition described in 13.1.1.14. It does not include the initial oil charge or the final quantity of oil in the engine. Record as grams per hour (g/h) on Forms 2 or 3 (see Annex A5) as appropriate.
13.1.2 Coolant Flush Procedure - Fill the engine coolant system with cleaning agent just previous to start-up for engine break-in. (Warning - Health hazard.)
13.1.2.1 At the start of break-in, fill the coolant system as follows:
(1) Check that all drain cocks are closed.
(2) Fill the coolant system (approximately 45 L) with clean water and add 1 L of Nalprep 2001 to the surge pot as it is filling up.
(3) Fill the system until the coolant level is to the top of the sight glass.
(4) Install the red cap.
13.1.2.2 Flush the cleaning agent from the coolant system prior to start-up for a test. Proceed as follows:
(1) Drain the cleaning solution from the engine.
(2) Fill and drain the cooling system two times with clean water.
(3) Fill the cooling system with clean water.
(4) Run the engine to do oil leveling at idle until the oil sump temperature is >60°C; then shut down the engine.
(5) Drain the water from the engine.
(6) Fill the coolant system with a premixed 50/50 solution of ethylene glycol type antifreeze in distilled water.
13.1.3 Engine Break-in - Perform engine conditioning using the test oil, reference or non-reference. Make an oil and filter change following break-in. The specific engine operating conditions for break-in are provided in Table 3.
13.1.4 Power Check - At the conclusion of break-in, but before shutting down engine, verify that engine output is adequate by performing a power check. Increase engine speed to 2300 r/min and increase torque until a nominal fuel flow rate of 90 kg/h is obtained. Observe and record engine power, which shall be at least 373 kW. If the engine fails to reach this power level, and repairs cannot remedy the power loss, the test should not be started. The duration of the power check should be only long enough to determine engine power output.
13.1.5 Air Box Inspection - At the conclusion of break-in and after the power check, an air box inspection shall be made. See 13.3.2.
13.2 Engine Operating Procedure:
13.2.1 Test Procedure:
13.2.1.1 At the completion of break-in and following service to the lubricant and filters, start the engine and allow it to warm up for 10 min, maintaining an idle. Increase engine speed to 1200 r/min. Apply load and adjust fuel flow until the conditions for Mode 1 (Torque), as is shown in Table 4, are set. Maintain this setting for 8 h.
13.2.1.2 At the end of Mode 1 (Torque) increase engine speed to 2300 r/min. Adjust the fuel flow to obtain the fuel flow range specified in Table 4. Maintain this condition for 8 h. Upon completion of this mode, return engine to idle for 5 min, then stop engine. Oil sampling shall be done during this 5-min period. See 13.3.1 for oil sampling procedure and schedule.
13.2.1.3 The third mode is a heat soak period and is an integral portion of the test procedure. During this period however, airbox inspections, oil sampling and oil leveling may be performed. This mode of the test may be longer, but cannot be shorter than 3 h. Heat soak after the seventh cycle is not necessary.
13.2.1.4 Table 5 summarizes the 100-h test sequence by segment.
13.3 Periodic Measurements and Functions :
13.3.1 Oil Additions and Used Oil Sampling:
13.3.1.1 Take samples of the test oil according to the schedule shown in Table 6 as a means of test quality control and possible problem diagnosis. Where applicable, ASTM test methods are recommended for this analysis and are identified in Table 6.
13.3.1.2 Take oil samples from the oil filter adapter of the remote oil cooler, Annex A2 (Fig.A2.2), while the engine is idling. This shall be done during the 5-min cool down after completion of a test mode. (Warning - In addition to other precautions, oil samples taken in this manner will be hot and can cause severe burns. Proper safety precautions to avoid skin contact, including the use of gloves, apron and safety glasses, are recommended.)
13.3.1.3 Take oil samples by first purging the sample line of 100 mL (approximately 3.4 fl oz) of test oil. This purge oil is immediately returned to the engine before oil leveling. Then draw the sample into the appropriate clean, engine oil compatible container as required by the analytical laboratory. All sample volumes should be within 10 % of 100 mL, except for a 500-mL sample taken at 96 h.
13.3.1.4 Take samples prior to any oil leveling or makeup.
13.3.2 Air Box Inspections:
13.3.2.1 Perform airbox inspections by removing small covers on the engine block exposing the liner port area. With the use of a bore scope or similar device, a limited inspection of the ring faces and liner inside diameter are possible. Such inspections are useful as a diagnostic tool to provide interim test part conditions and identify impending engine failure. It is not intended for prediction of failing oil performance.
13.3.2.2 An airbox inspection for liner and ring distress is required after break-in. Make an estimate of cylinder liner scuffing and report on Form 16 (see Annex A5). Exercise extreme care when removing the airbox covers and working in the liner port area so as not to disturb any soot accumulation in the liner parts, which, if accidentally spilled into the cylinder, can cause ring and liner scuffing. Use a bore scope for this inspection. Excessive liner scuffing after break-in could be indicative of a test problem. A test may be aborted at the discretion of the laboratory.
13.3.2.3 Due to the potential of introducing soot and combustion debris, which can initiate liner and ring scuffing, airbox inspections are not recommended during the test unless one or more of the following conditions exist:
(1) A sudden increase in crankcase pressure or blowby occurs.
(2) Used oil iron content exceeds 500 ppm.
(3) Power output is below 364 kW (488 bhp) during the power mode immediately preceding the inspection.
13.3.2.4 Report all airbox inspections on Form 16 (see Annex A5). Note the cause for the inspection in the appropriate area of the form.
13.4 Diagnostic Data Review - This section outlines significant characteristics of specific engine operating parameters. The parameters can directly influence the test or may be used to indicate normalcy of other parameters.
13.4.1 Exhaust Temperatures - Deviations for individual exhaust temperatures are used to indicate incorrect combustion, a sign of injector malfunctioning.
13.4.2 Crankcase Pressure - Higher crankcase pressure than normal can indicate scuffed cylinders, a leak in the seal between the piston dome and skirt, or a blower seal failure.
13.4.3 Airbox Pressure - Low boost pressure can indicate a damaged turbocharger (either broken vanes or a bearing failure), exhaust system leaks or blower malfunction.
13.5 End of Test Procedure:
13.5.1 Estimate the amount of oil necessary to bring oil to full mark, and add this amount to the cumulative oil make-up for a final oil consumption figure. Do not actually add the oil to the engine.
13.5.2 After taking end-of-test oil sample, drain oil, fuel, and water from the engine.
13.5.3 Remove engine to cleaning area and clean all surfaces as necessary to remove loose dirt, etc. before removing sub-assemblies.
13.5.4 Mount engine on overhaul stand and remove all required subassemblies, cleaning each individual part after removal. Pistons, rings, and liners, and bearings shall be cleaned as outlined in 8.3. Take care to identify and maintain all locations for test parts. Cut liners as exactly in half as possible, along the crankshaft center line, taking special care not to disturb deposits. This is accomplished by use of a suitable saw and done after cleaning with Varsol 3139 and before rating.