ASTM D6483 Standard Test Method for Evaluation of Diesel Engine Oils in T-9 Diesel Engine
8. Preparation of Apparatus at Rebuild
8.1 Cleaning of Parts:
8.1.1 Engine Block - Thoroughly spray the engine with solvent (see 7.4) to remove any oil remaining from the previous test, and air dry.

8.1.2 Rocker Covers and Oil Pan - Remove all sludge, varnish, and oil deposits. Rinse with solvent, and air dry.

8.1.3 Auxiliary Oil System - Flush all oil lines, galleries, and external oil reservoirs with solvent to remove any previous test oil, and then air dry.

8.1.4 Oil Cooler and Oil Filter - Flush the oil cooler and filter lines with solvent to remove any previous test oil, and then air dry.

8.1.5 Cylinder Head - Clean the cylinder heads, using a wire brush to remove deposits, and rinse with solvent to remove any sludge and oil, and then air dry.

8.2 Valves, Seats, Guides, and Springs:
8.2.1 Visually inspect valves, seats, and springs for defects or heavy wear and replace if necessary. Replacement of the valves, guides, and seat inserts for each test is recommended, but not required.

8.2.2 Replace and ream guides to 0.9525 +/- 0.0013 cm (0.3750 +/- 0.0005 in.).

8.3 Cylinder Liner, Piston, and Piston Ring Assembly:
8.3.1 Cylinder Liner Fitting - For proper heat transfer, fit cylinder liners to the block in accordance with the procedure outlined in the Mack Service Manual.

8.3.2 Piston and Rings - Cylinder liners, pistons, and rings are provided as a set and should be used as a set. Examine piston rings for any handling damage. Record pretest measurements, as detailed in 11.1.

8.4 Injectors and Injection Pump:
8.4.1 Injectors - Servicing of injectors is recommended every 500 h. Resetting of injector opening pressure is recommended if pressure is below specification.

8.4.2 Injection Pump - The removal of the injection pump is not recommended unless a problem is noted during a test. Should a problem occur, replacement with a new injection pump that has never been serviced or rebuilt is recommended. High pressure flow calibration equipment such as a Bacharach No. 72-7010 standard injector tester is available from Mack approved dealers. Kent-Moore tool numbers J29539 (top dead center indicator) and J37077 (position sensor) are recommended for setting the injection timing.

8.5 Assembly Instructions:
8.5.1 General - The test parts specified for this test method are intended to be used without material or dimensional modification. Exceptions, for example, a temporary parts supply problem, shall be approved by the Test Monitoring Center (TMC) and noted in the test report. All replacement test engine parts shall be genuine Mack Truck Inc. parts. Assemble all parts as illustrated in the Mack Service Manual except where otherwise noted. Target all dimensions for the means of the specifications. Use EF-411 (see Annex A3) for lubricating parts during assembly.
8.5.1.1 Thermostat - Block the thermostat wide open.

8.5.1.2 Rod Bearings - Install new rod bearings for each test. See 11.1 for pretest measurements to be recorded.

8.5.1.3 Main Bearings - Install new main bearings for each test.

8.5.1.4 Piston Undercrown Cooling Nozzles - Particular care shall be taken in assembling the piston undercrown cooling nozzles to ensure proper piston cooling (as outlined in the Mack Service Manual).

NOTE 1 - Proper oil pressure is also important to ensure sufficient oil volume for proper cooling.

8.5.2 New Parts - Use test parts on a first-in/first-out basis. Install the following new parts for each rebuild (see Table A3.1 for part numbers):
8.5.2.1 Cylinder liners.

8.5.2.2 Pistons.

8.5.2.3 Piston rings.

8.5.2.4 Overhaul gasket set.

8.5.2.5 Oil filters.

8.5.2.6 Engine coolant conditioner.

8.5.2.7 Primary fuel filter.

8.5.2.8 Secondary fuel filter.

8.5.2.9 Valve stem seals.

8.5.2.10 Connecting rod bearings.

8.5.2.11 Main bearings.

8.6 Measurements:
8.6.1 Calibrations - Calibrate thermocouples, pressure gages, speed, and fuel flow measuring equipment prior to each reference test or at any time readout data indicates a need. Conduct calibrations with at least two points that bracket the normal operating range. Make these calibrations part of the laboratory record. During calibration, connect leads, hoses, and read-out systems in the normally used manner and calibrate with necessary standards. Immerse thermocouples in calibration baths. Calibrate standards with instruments traceable to the National Institute of Standards and Technology (NIST) on a yearly basis.

8.6.2 Temperatures:
8.6.2.1 General - Measure temperatures with thermocouples and conventional readout equipment, or equivalent. For 0 to 150°C (32 to 300°F) range, calibrate temperature measuring systems to +/- 0.5°C (+/- 1°F) at 100 +/- 1°C (210 +/- 2°F) and to +/- 0.5°C (+/- 1°F) at 0 +/- 1°C (32 +/- 2°F). Insert all thermocouples so that the tips are located midstream of the flow unless otherwise indicated.

8.6.2.2 Ambient Air - Locate thermocouple in a convenient, well ventilated position between 2 and 3 m (approximately 6 and 10 ft) from the engine and hot accessories.

8.6.2.3 Coolant - Locate the coolant-out thermocouple in the water manifold prior to the thermostat housing. Locate in center of water stream (refer to Fig. A2.1). Locate the coolant-in thermocouple within 30.5 cm (12 in.) of the elbow upstream of the oil cooler (refer to Fig. A2.2).

8.6.2.4 Oil - Locate thermocouple on the right side of the engine on the top of the accessory drive, as shown on Fig. A2.5.

8.6.2.5 Intake Air - Locate sensors for dry bulb measurement and humidity in center of air stream at the turbocharger inlet, as shown in Fig. A2.3. It is not necessary to control intake air humidity, but measurements are recommended.

8.6.2.6 Fuel In - Locate thermocouple in center of fuel line between secondary filter and injection pump, as shown in Fig. A2.4.

8.6.2.7 Pre-Turbine Temperatures - Locate one thermocouple in each side of exhaust manifold tee section (see Fig. A2.3). The exhaust manifold (pre-turbine) thermocouples and pressure taps are located on the same tee.

8.6.2.8 Exhaust (Tailpipe) Temperature - Locate thermocouple in exhaust pipe downstream of turbine in accordance with Fig. A2.3.

8.6.2.9 Intake Manifold - Locate thermocouple at tapped fitting on intake air manifold, as shown in Fig. A2.6.

8.6.2.10 Additional - Monitor any additional temperatures that the test lab regards as helpful in providing a consistent test procedure.

8.6.3 Pressures:
8.6.3.1 Before Filter Oil Pressure - Locate pickup at tapped hole on oil cooler fitting (see Fig. A2.2).

8.6.3.2 After Filter/Main Gallery Oil Pressure - Locate pickup at tapped hole on top of oil filter pad above centrifugal oil filter (see Fig. A2.2).

NOTE 2 - The E7 engine has only one oil gallery, that serves as both a main gallery and piston cooling gallery.

8.6.3.3 Pre-Turbine Exhaust Pressure - Locate pickup in each side of exhaust manifold tee section (same tap as pre-turbine temperature), see Fig. A2.3.

8.6.3.4 Intake Air Boost - Take measurement at tapped fitting provided on intake manifold, as illustrated in Fig. A2.6.

8.6.3.5 Intake Air Total Pressure - Measure with a Keil Probe (p/n # KDF-8-W recommended), located at the turbo inlet (see Fig. A2.3).

8.6.3.6 Exhaust Back Pressure - Locate pickup in exhaust pipe after turbocharger in center of exhaust stream. Measure exhaust back pressure in a straight section of pipe, 30.5 to 40.6 cm (12 to 16 in.) downstream of the turbo with a pressure tap hole, as shown in Fig. A2.3.

8.6.3.7 Crankcase Pressure - Locate pickup at dipstick tube fitting or other suitable opening direct to the crankcase.

8.6.3.8 Barometric Pressure - Locate barometer approximately 1.2 m (4 ft) above ground level in convenient location in the lab.

8.6.4 Engine Blowby - Connect the metering instrument to the blowby line coming from the valve cover crossover tube (P/N 191GC418A).

8.6.5 Fuel Consumption Measurements - Place the measuring equipment in the fuel line before the primary fuel filter. Install the primary fuel filter before the fuel transfer pump, and install the secondary filter before the injection pump. Accurate fuel consumption measurements require proper accounting of return fuel. (Warning - Fuel return lines should never be plugged.)

8.6.6 Humidity - Place the measurement equipment between the inlet air filter and compressor in such a manner as not to affect temperature and pressure measurements. Measure humidity at 8 h intervals, and report (see Annex A1).

8.7 System Time Responses - The maximum allowable system time responses are shown in Table 2. Determine system time responses in accordance with the Data Acquisition and Control Automation II (DACA II) Task Force Report.