ASTM D6681 Standard Test Method for Evaluation of Engine Oils in a High Speed, Single-Cylinder Diesel Engine - Caterpillar 1P Test Procedure
6. Apparatus and Installation
6.1 The test engine is an electronically controlled, direct injection, in-head camshaft, single-cylinder diesel engine with a four-valve arrangement. The engine has a 137.2 mm bore and a 165.1 mm stroke resulting in a displacement of 2.4 L.
6.1.1 The electronic control module (ECM) defines the desired engine fuel timing, monitors and limits maximum engine speed, maximum engine power, minimum oil pressure, and, optionally, maximum engine crankcase pressure. The ECM also controls the fuel injection duration that defines the engine fuel rate based on set conditions from the test cell feedback control systems. The oil pressure is also set by the ECM with signals to the 1Y3867 engine air pressure controller (Mamac) to modulate the facility air supply to the 1Y3898 Johnson Controls relief valve.
6.1.2 The 1Y3700 engine arrangement also consists of inlet air piping and hoses from the cylinder head to the air barrel and exhaust piping and bellows from the cylinder head to the exhaust barrel that are specifically designed for oil testing. See the Caterpillar Service Manual.
6.2 Equip the engine test stand with the following accessories or equipment:
6.2.1 Intake Air System - The intake air system components from the cylinder head to the air barrel are a part of the basic 1Y3700 engine arrangement. These components consisting of an adapter, elbow, hose, clamps, and flanged tube can be found in the 1Y3700 Parts Book.
6.2.1.1 Purchase the 1Y3978 intake air barrel (which is almost identical to the exhaust barrel except for the top cover) that has been specifically designed from one of the three approved manufacturers. 10,11 Install the intake air barrel at the location shown in Annex A7. Do not add insulation to the barrel.
6.2.1.2 Paint the inside of the intake air piping with Caterpillar yellow primer or red Glyptal prior to installation.
6.2.1.3 Install the air heater elements in the intake air barrel as specified in AnnexA7 (even ifthey will not be supplied with electricity).
6.2.1.4 Use an air filter capable of filtering particles 10 µ (or smaller).
6.2.1.5 Use a Sierra Model 780 airflow meter with Feature 1 = F6, Feature 2 = CG and calibration temperature = 60 °C to measure intake airflow for each calibration test. Annex A4 shows the piping requirements for the installation of the Sierra Model 780 airflow meter.
6.2.1.6 Measure the inlet air temperature at the location shown in Annex A2. Measure the inlet air pressure at the air barrel as shown in Annex A7. The location of the 1Y3977 humidity probe is shown in Annex A8. The sample line might require insulation to prevent dropping below dew point temperature and shall not be hygroscopic. Drain taps may be installed at the low points of the combustion air system.
6.2.1.7 Use feedback-equipped controls to maintain filtered, compressed, and humidified inlet air at the conditions specified in Annex A12.
6.2.2 Exhaust System - The exhaust system components from the cylinder head to the exhaust barrel are part of the basic 1Y3700 engine arrangement. These components consisting of an adapter, elbow, bellows, flange, and clamps can be found in the 1Y3700 Parts Book.
6.2.2.1 Purchase the 1Y3976 exhaust barrel (which is almost identical to the intake barrel except for the top cover) that has been specifically designed from one of the three approved manufacturers. Install the exhaust barrel at the location shown in Annex A7. Do not add insulation to the barrel.
6.2.2.2 Install a restriction valve downstream from the exhaust barrel. The distance between the valve and barrel is not specified. The location of the exhaust thermocouple is shown in Annex A2. Measure the exhaust pressure at the exhaust barrel shown in Annex A7.
6.2.2.3 Use feedback-equipped controls to maintain the exhaust gases at the pressure specified in Annex A12.
6.2.3 Fuel System - The fuel system schematic is shown in Annex A5. Desired fuel injection timing is controlled by the engine computer at 13° BTC. Measure the fuel rate using micro motion device with a maximum range of 90 kg/h scaled to the 1P operation range specified in Annex A12. Use the day tank specified in Annex A5. Measure fuel temperature at the fuel filter base as shown in Annex A2 and control it using the cell facility feedback system. Use the required fuel heat exchanger(s) and arrange them as specified in Annex A5. Use the Fisher regulator specified in Annex A5.
6.2.4 Oil Consumption System - Use an oil scale system to accurately measure oil consumption (see Fig.A6.2 and Fig.A6.3). The oil scale system shall have a resolution as listed in AnnexA2. Use flexible hoses similar to Aeroquip flexible hose, FC352-08, to-and-from the oil scale reservoir to eliminate measurement errors. Use No.5 TFE-fluorocarbon, steel-braided hoses to and from the oil scale pumps. The hose length to-and-from the oil scale cart shall not exceed 2.7 m. Use the special oil pan adapter described in Fig.A6.4.
6.2.5 Engine Oil System - A schematic of the oil system is shown in Fig.A6.1. Measure oil pressure at the engine oil manifold (see Annex A2). An engine oil pressure sensor transmits a signal to the ECM that maintains oil pressure at 415 kPa. The ECM transmits a signal to an engine-mounted Mamac air pressure controller. The Mamac modulates the facility air pressure of 280 kPa to levels that vary between (0 to 140) kPa and directs it to the normally closed Johnson Controls relief valve. Because the engine oil pressure sensor calibration might vary from the cell data acquisition transducer, vary the oil pressure adjust signal to the ECM to maintain the oil pressure at the test specifications. See the Electronic Installation and Operation manual for additional information. The ECM maintains the oil pressure regardless of engine speed. Measure the oil temperatures at locations shown in Annex A2.
6.2.5.1 Oil Heating System - Use an external oil heating system provided by the test facility to maintain the engine oil manifold temperature specified in Annex A12. An example system is shown in Appendix X1. A special 1Y3908 oil cooler bonnet has been designed to allow separate fluids to the engine coolant tower arrangement (see Fig.A6.9). Plug the 1Y3660 oil cooler adapter and 1Y3908 heat exchanger bonnet as shown in Annex A6. Use Paratherm NF for the heating fluid. The temperature of the Paratherm NF is measured by the thermocouple shown in Annex A2.
6.2.5.2 Oil Sample Valve - Refer to Annex A2 for the installation location and component makeup of the oil sample valve. Use of alternate equivalent components for the sample valve is permitted.
6.2.6 Engine Coolant System - The coolant system schematic is shown in Annex A3. Control the coolant temperature out of the engine using a cell facility feedback system. Use a 1Y3898 Johnson Controls valve or equivalent fail-open valve to regulate the coolant temperature out of the engine as shown by the schematic in Annex A3. If the 1Y3898 Johnson valve is used, supply facility air pressure at 280 kPa to the controller that regulates air pressure to the valve at (0 to 140) kPa. Install a feedback-equipped control system to pneumatically adjust the valve. Remove the 1Y3832 hose originally supplied with the engine and install a sight glass using the components shown in Annex A3.
6.2.7 Engine Instrumentation - Use feedback-equipped systems to control the engine operating temperatures, pressures, and flow rates. Measure the engine operating conditions at the locations shown in Annex A2. For temperature measurements, use thermocouples 1Y468 (intake air), 1Y467 (engine exhaust) and 1Y466 (fluids-water, oil, and fuel) or equivalent thermocouples as specified in AnnexA2. Instrument measurement and reporting resolutions are shown in Annex A2.
6.2.8 A dynamometer with feedback control to maintain engine torque and speed. Use a starting system capable of at least breakaway torque of 136 N·m and sustained torque of 102 N·m at 200 r/min.
6.2.9 Compressed air at 35 kPa to the top of the coolant tower as specified in Annex A3 to ensure water does not boil out of the antifreeze mixture and result in less heat rejection from the engine.
6.2.10 Measure engine blowby downstream of the engine breather housing by measuring the delta pressure across an orifice or an equivalent device.
6.2.11 The crankcase pressure is above atmospheric pressure with this engine arrangement. Measure it at the location shown in Annex A2.
6.3 Obtain information concerning the test engine, engine electronics system, new engine parts, replacement parts, and permissible substitution or replacement parts from Caterpillar,Inc.
6.4 Engine and parts warranty information can be found in Annex A1. Use the form listed in Annex A9 for returning defective parts.
7. Reagents and Materials
7.1 Purity of Reagents - Reagent grade chemicals shall be used in all tests. Unless otherwise indicated, it is intended that all reagents conform to the specifications of the Committee on Analytical Reagents of the American Chemical Society where such specifications are available. Other grades may be used, provided it is first ascertained that the reagent is of sufficiently high purity to permit its use without lessening the accuracy of the determination.
7.2 Diesel Piston Rating Booth, as described by ASTM Deposit Rating Manual 20.
7.3 Diesel Piston Rating Lamp, as described by ASTM Deposit Rating Manual 20.
7.4 Dispersant Engine Cleaner.
7.5 Engine Coolant - Use a 50/50 mixture of mineral-free water and Caterpillar brand coolant (P/N 8C684 for 3.8 L or 8C3686 for 208 L drum) for engine coolant. Mineral-free water is defined as water having a mineral content no higher than 34.2 mg/kg total dissolved solids. The coolant mixture may be reused for up to 1600 h. Keep the mixture at a 50:50 ratio as determined by using either Caterpillar testers 5P3514 or 5PO957 or an equivalent tester. Keep the coolant mixture contamination free. Total solids shall remain below 5000 mg/kg. Keep the additive level correct using Caterpillar test kit P/N 8T5296.
7.6 Lead Shot, commercial grade, approximately 5 mm in diameter.
7.7 Light Grease.
7.8 Mobil EF-411, available from ExxonMobil for engine assembly and calibration of the oil scale pump flow rates.
7.9 Paratherm NF, as supplied by Paratherm and used as the fluid to heat the engine oil.
7.10 Pentane (Solvent), purity > 99 %, high-performance, liquid chromatography grade.
7.11 Reference Oil, as supplied by the TMC for calibration of the test stand.
7.12 REO 217, as supplied by the CRC and used when any copper components are changed.
7.13 Sodium Bisulfate (NaHSO4), commercial grade.
7.14 Solvent - Use only mineral spirits meeting the requirements of Specification D235, Type II, Class C for Aromatic Content (0 to 2 vol %), Flash Point (61 °C, min) and Color (not darker than + 25 on Saybolt Scale or 25 on Pt-Co Scale). (Warning - Combustible. Health hazard.) Obtain a Certificate of Analysis for each batch of solvent from the supplier.
7.15 Fuel - Obtain the required test fuel from Chevron Phillips as PC-9-HS Reference Diesel Fuel (see Annex A14).
7.16 Test Oil - The total amount of oil needed for each lubricant test is approximately 42 L.
7.17 Trisodium Phosphate (Na3PO4), commercial grade.
7.18 5.4000 in. Ring Bore Standard Class Z Master.
8. Oil Samples
8.1 Take purge samples of 250 mL at (48, 72, 120, 144, 168, 192, 216, 264, 312, 336) h. Following removal of each purge sample, remove a 30 mL sample, then add (317 +/- 10) g of new oil. It is not necessary to perform analysis on these samples of 30 mL. Use the purge sample to return to the full mark.
8.1.1 Take purge samples of 250 mL at 0 h (new) and (24, 96, 240, 288, 360) h. Following removal of each purge sample, remove a 90 mL sample and add (370 +/- 10) g of new oil.
8.1.2 Analyze all 90 mL samples for viscosity by Test Method D445 at (100 and 40) °C, TBN by Test Method D4739, TAN by Test Method D664, and the wear metals Al, Cr, Cu, Fe, Pb, Si by Test Method D5185. Analyze the samples for fuel dilution taken at (24, 240, 360) h by Test Method D3524. See Fig.A6.7 and Fig.A6.8 for two graphical examples and a sample worksheet.
6. Apparatus and Installation
6.1 The test engine is an electronically controlled, direct injection, in-head camshaft, single-cylinder diesel engine with a four-valve arrangement. The engine has a 137.2 mm bore and a 165.1 mm stroke resulting in a displacement of 2.4 L.
6.1.1 The electronic control module (ECM) defines the desired engine fuel timing, monitors and limits maximum engine speed, maximum engine power, minimum oil pressure, and, optionally, maximum engine crankcase pressure. The ECM also controls the fuel injection duration that defines the engine fuel rate based on set conditions from the test cell feedback control systems. The oil pressure is also set by the ECM with signals to the 1Y3867 engine air pressure controller (Mamac) to modulate the facility air supply to the 1Y3898 Johnson Controls relief valve.
6.1.2 The 1Y3700 engine arrangement also consists of inlet air piping and hoses from the cylinder head to the air barrel and exhaust piping and bellows from the cylinder head to the exhaust barrel that are specifically designed for oil testing. See the Caterpillar Service Manual.
6.2 Equip the engine test stand with the following accessories or equipment:
6.2.1 Intake Air System - The intake air system components from the cylinder head to the air barrel are a part of the basic 1Y3700 engine arrangement. These components consisting of an adapter, elbow, hose, clamps, and flanged tube can be found in the 1Y3700 Parts Book.
6.2.1.1 Purchase the 1Y3978 intake air barrel (which is almost identical to the exhaust barrel except for the top cover) that has been specifically designed from one of the three approved manufacturers. 10,11 Install the intake air barrel at the location shown in Annex A7. Do not add insulation to the barrel.
6.2.1.2 Paint the inside of the intake air piping with Caterpillar yellow primer or red Glyptal prior to installation.
6.2.1.3 Install the air heater elements in the intake air barrel as specified in AnnexA7 (even ifthey will not be supplied with electricity).
6.2.1.4 Use an air filter capable of filtering particles 10 µ (or smaller).
6.2.1.5 Use a Sierra Model 780 airflow meter with Feature 1 = F6, Feature 2 = CG and calibration temperature = 60 °C to measure intake airflow for each calibration test. Annex A4 shows the piping requirements for the installation of the Sierra Model 780 airflow meter.
6.2.1.6 Measure the inlet air temperature at the location shown in Annex A2. Measure the inlet air pressure at the air barrel as shown in Annex A7. The location of the 1Y3977 humidity probe is shown in Annex A8. The sample line might require insulation to prevent dropping below dew point temperature and shall not be hygroscopic. Drain taps may be installed at the low points of the combustion air system.
6.2.1.7 Use feedback-equipped controls to maintain filtered, compressed, and humidified inlet air at the conditions specified in Annex A12.
6.2.2 Exhaust System - The exhaust system components from the cylinder head to the exhaust barrel are part of the basic 1Y3700 engine arrangement. These components consisting of an adapter, elbow, bellows, flange, and clamps can be found in the 1Y3700 Parts Book.
6.2.2.1 Purchase the 1Y3976 exhaust barrel (which is almost identical to the intake barrel except for the top cover) that has been specifically designed from one of the three approved manufacturers. Install the exhaust barrel at the location shown in Annex A7. Do not add insulation to the barrel.
6.2.2.2 Install a restriction valve downstream from the exhaust barrel. The distance between the valve and barrel is not specified. The location of the exhaust thermocouple is shown in Annex A2. Measure the exhaust pressure at the exhaust barrel shown in Annex A7.
6.2.2.3 Use feedback-equipped controls to maintain the exhaust gases at the pressure specified in Annex A12.
6.2.3 Fuel System - The fuel system schematic is shown in Annex A5. Desired fuel injection timing is controlled by the engine computer at 13° BTC. Measure the fuel rate using micro motion device with a maximum range of 90 kg/h scaled to the 1P operation range specified in Annex A12. Use the day tank specified in Annex A5. Measure fuel temperature at the fuel filter base as shown in Annex A2 and control it using the cell facility feedback system. Use the required fuel heat exchanger(s) and arrange them as specified in Annex A5. Use the Fisher regulator specified in Annex A5.
6.2.4 Oil Consumption System - Use an oil scale system to accurately measure oil consumption (see Fig.A6.2 and Fig.A6.3). The oil scale system shall have a resolution as listed in AnnexA2. Use flexible hoses similar to Aeroquip flexible hose, FC352-08, to-and-from the oil scale reservoir to eliminate measurement errors. Use No.5 TFE-fluorocarbon, steel-braided hoses to and from the oil scale pumps. The hose length to-and-from the oil scale cart shall not exceed 2.7 m. Use the special oil pan adapter described in Fig.A6.4.
6.2.5 Engine Oil System - A schematic of the oil system is shown in Fig.A6.1. Measure oil pressure at the engine oil manifold (see Annex A2). An engine oil pressure sensor transmits a signal to the ECM that maintains oil pressure at 415 kPa. The ECM transmits a signal to an engine-mounted Mamac air pressure controller. The Mamac modulates the facility air pressure of 280 kPa to levels that vary between (0 to 140) kPa and directs it to the normally closed Johnson Controls relief valve. Because the engine oil pressure sensor calibration might vary from the cell data acquisition transducer, vary the oil pressure adjust signal to the ECM to maintain the oil pressure at the test specifications. See the Electronic Installation and Operation manual for additional information. The ECM maintains the oil pressure regardless of engine speed. Measure the oil temperatures at locations shown in Annex A2.
6.2.5.1 Oil Heating System - Use an external oil heating system provided by the test facility to maintain the engine oil manifold temperature specified in Annex A12. An example system is shown in Appendix X1. A special 1Y3908 oil cooler bonnet has been designed to allow separate fluids to the engine coolant tower arrangement (see Fig.A6.9). Plug the 1Y3660 oil cooler adapter and 1Y3908 heat exchanger bonnet as shown in Annex A6. Use Paratherm NF for the heating fluid. The temperature of the Paratherm NF is measured by the thermocouple shown in Annex A2.
6.2.5.2 Oil Sample Valve - Refer to Annex A2 for the installation location and component makeup of the oil sample valve. Use of alternate equivalent components for the sample valve is permitted.
6.2.6 Engine Coolant System - The coolant system schematic is shown in Annex A3. Control the coolant temperature out of the engine using a cell facility feedback system. Use a 1Y3898 Johnson Controls valve or equivalent fail-open valve to regulate the coolant temperature out of the engine as shown by the schematic in Annex A3. If the 1Y3898 Johnson valve is used, supply facility air pressure at 280 kPa to the controller that regulates air pressure to the valve at (0 to 140) kPa. Install a feedback-equipped control system to pneumatically adjust the valve. Remove the 1Y3832 hose originally supplied with the engine and install a sight glass using the components shown in Annex A3.
6.2.7 Engine Instrumentation - Use feedback-equipped systems to control the engine operating temperatures, pressures, and flow rates. Measure the engine operating conditions at the locations shown in Annex A2. For temperature measurements, use thermocouples 1Y468 (intake air), 1Y467 (engine exhaust) and 1Y466 (fluids-water, oil, and fuel) or equivalent thermocouples as specified in AnnexA2. Instrument measurement and reporting resolutions are shown in Annex A2.
6.2.8 A dynamometer with feedback control to maintain engine torque and speed. Use a starting system capable of at least breakaway torque of 136 N·m and sustained torque of 102 N·m at 200 r/min.
6.2.9 Compressed air at 35 kPa to the top of the coolant tower as specified in Annex A3 to ensure water does not boil out of the antifreeze mixture and result in less heat rejection from the engine.
6.2.10 Measure engine blowby downstream of the engine breather housing by measuring the delta pressure across an orifice or an equivalent device.
6.2.11 The crankcase pressure is above atmospheric pressure with this engine arrangement. Measure it at the location shown in Annex A2.
6.3 Obtain information concerning the test engine, engine electronics system, new engine parts, replacement parts, and permissible substitution or replacement parts from Caterpillar,Inc.
6.4 Engine and parts warranty information can be found in Annex A1. Use the form listed in Annex A9 for returning defective parts.
7. Reagents and Materials
7.1 Purity of Reagents - Reagent grade chemicals shall be used in all tests. Unless otherwise indicated, it is intended that all reagents conform to the specifications of the Committee on Analytical Reagents of the American Chemical Society where such specifications are available. Other grades may be used, provided it is first ascertained that the reagent is of sufficiently high purity to permit its use without lessening the accuracy of the determination.
7.2 Diesel Piston Rating Booth, as described by ASTM Deposit Rating Manual 20.
7.3 Diesel Piston Rating Lamp, as described by ASTM Deposit Rating Manual 20.
7.4 Dispersant Engine Cleaner.
7.5 Engine Coolant - Use a 50/50 mixture of mineral-free water and Caterpillar brand coolant (P/N 8C684 for 3.8 L or 8C3686 for 208 L drum) for engine coolant. Mineral-free water is defined as water having a mineral content no higher than 34.2 mg/kg total dissolved solids. The coolant mixture may be reused for up to 1600 h. Keep the mixture at a 50:50 ratio as determined by using either Caterpillar testers 5P3514 or 5PO957 or an equivalent tester. Keep the coolant mixture contamination free. Total solids shall remain below 5000 mg/kg. Keep the additive level correct using Caterpillar test kit P/N 8T5296.
7.6 Lead Shot, commercial grade, approximately 5 mm in diameter.
7.7 Light Grease.
7.8 Mobil EF-411, available from ExxonMobil for engine assembly and calibration of the oil scale pump flow rates.
7.9 Paratherm NF, as supplied by Paratherm and used as the fluid to heat the engine oil.
7.10 Pentane (Solvent), purity > 99 %, high-performance, liquid chromatography grade.
7.11 Reference Oil, as supplied by the TMC for calibration of the test stand.
7.12 REO 217, as supplied by the CRC and used when any copper components are changed.
7.13 Sodium Bisulfate (NaHSO4), commercial grade.
7.14 Solvent - Use only mineral spirits meeting the requirements of Specification D235, Type II, Class C for Aromatic Content (0 to 2 vol %), Flash Point (61 °C, min) and Color (not darker than + 25 on Saybolt Scale or 25 on Pt-Co Scale). (Warning - Combustible. Health hazard.) Obtain a Certificate of Analysis for each batch of solvent from the supplier.
7.15 Fuel - Obtain the required test fuel from Chevron Phillips as PC-9-HS Reference Diesel Fuel (see Annex A14).
7.16 Test Oil - The total amount of oil needed for each lubricant test is approximately 42 L.
7.17 Trisodium Phosphate (Na3PO4), commercial grade.
7.18 5.4000 in. Ring Bore Standard Class Z Master.
8. Oil Samples
8.1 Take purge samples of 250 mL at (48, 72, 120, 144, 168, 192, 216, 264, 312, 336) h. Following removal of each purge sample, remove a 30 mL sample, then add (317 +/- 10) g of new oil. It is not necessary to perform analysis on these samples of 30 mL. Use the purge sample to return to the full mark.
8.1.1 Take purge samples of 250 mL at 0 h (new) and (24, 96, 240, 288, 360) h. Following removal of each purge sample, remove a 90 mL sample and add (370 +/- 10) g of new oil.
8.1.2 Analyze all 90 mL samples for viscosity by Test Method D445 at (100 and 40) °C, TBN by Test Method D4739, TAN by Test Method D664, and the wear metals Al, Cr, Cu, Fe, Pb, Si by Test Method D5185. Analyze the samples for fuel dilution taken at (24, 240, 360) h by Test Method D3524. See Fig.A6.7 and Fig.A6.8 for two graphical examples and a sample worksheet.