ASTM D6987 Standard Test Method for Evaluation of Diesel Engine Oils in T-10 Exhaust Gas Recirculation 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. Additionally, follow use of an engine parts washer by a solvent wash.
8.1.2 Rocker Covers and Oil Pan - Remove all sludge, varnish, and oil deposits. Rinse with solvent (see 7.4) and air-dry. Additionally, follow use of an engine parts washer by a solvent wash.
8.1.3 Auxiliary Oil System - Flush all oil lines, galleries, and external oil reservoirs first with a solvent (see 7.4) 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 first with a solvent (see 7.4) to remove any previous test oil and then air-dry. Additionally, follow use of an engine parts washer by a solvent wash.
8.1.5 Cylinder Head - Clean the cylinder heads using a wire brush to remove deposits and rinse with a solvent (see 7.4) to remove any sludge and oil and then air-dry. Additionally, follow use of an engine parts washer by a solvent wash.
8.1.6 Intake Manifold - Clean the intake manifold before each test. Scrub the manifold using a nylon brush and a solvent, and then wash the manifold using an engine parts cleaner.
8.1.7 EGR Coolers - Clean the EGR coolers before each test by flushing with a solvent and then air-drying (see 7.4).
8.1.8 EGR Venturi Unit - Clean the venturi before each test. Spray with a solvent and scrub with a nylon brush.
8.2 Valves, Seats, Guides, and Springs - 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.
8.2.1 Replace and ream guides to 0.9525 cm +/- 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 according to 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 pre-test measurements as detailed in 11.1.
8.4 Injectors and Injection Pumps:
8.4.1 Injectors - Check the injector opening pressure at the start of each calibration period. Reset the injector opening pressure if it is outside the specification of 36900 kPa to 37900 kPa [5350 to 5500 psi].
8.4.2 Injection Pumps - The electronic unit pumps (EUP) may be changed at any time using the procedure specified in the Mack Service Manual. Be sure to enter the EUP's four digit calibration code into the engine control unit (ECU). The calibration code can be found on the EUP label.
8.5 Assembly Instructions:
8.5.1 General - The test parts specified for this test are intended to be used without material or dimensional modification. Exceptions, for example, is approval of a temporary parts supply problem by the TMC, and noting this approval 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 Bulldog Premium EO-M+ Oil for lubricating parts during assembly; see A2.10, Annex A2.
8.5.1.1 Thermostat - Block the thermostat wide open.
8.5.1.2 Rod Bearings - Install new rod bearings for each test. See 10.1 for pre-test measurements to be recorded.
8.5.1.3 Main Bearings - Install new main bearings for each test.
8.5.1.4 Piston Under Crown Cooling Nozzles - Take particular care in assembling the piston under crown 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.
8.5.1.5 Thrust Washers - Install new thrust washers for each test.
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 A2.1 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 Valve guides.
8.5.2.11 Connecting rod bearings.
8.5.2.12 Main bearings.
8.5.2.13 Thrust washers.
8.6 Measurements:
8.6.1 Calibrations:
8.6.1.1 Calibrate thermocouples, pressure gages, speed, and fuel flow measuring equipment prior to each reference oil 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. For controlled temperatures, immerse thermocouples in calibration baths. Calibrate standards with instruments traceable to the National Institute of Standards and Technology on a yearly basis.
8.6.1.2 Oxygen Sensor - Calibrate the oxygen sensor prior to every test in accordance with Annex A4.
8.6.2 Temperatures:
8.6.2.1 General - Measure temperatures with thermocouples and conventional readout equipment or their equivalent. For temperatures in the 0 °C to 150 °C [32 to 300°F] range, calibrate temperature-measuring systems to +/- 0.5 °C for at least two temperatures that bracket the normal operating range. 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 m 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.A1.6. Locate the coolant-in thermocouple anywhere between the heat exchanger and the coolant pump inlet (upstream of the junction with the EGR coolant return). Refer to Fig.A1.7.
8.6.2.4 Oil Gallery - Locate thermocouple at the center port on the filter housing. Insertion depth shall be 98 mm [3.875 in.] Refer to Fig.A1.8.
8.6.2.5 Oil Sump Temperature - Using a front sump oil pan configuration, locate thermocouple on the exhaust side of the oil pan, 178 mm [7 in.] from the front and 178 mm [7 in.] from the top of the pan. Thermocouple length shall be 102 mm [4 in.]. Refer to Fig.A1.4.
8.6.2.6 Intake Air Temperature - Locate the intake air thermocouple in center of air stream at the turbocharger inlet as shown in Fig.A1.9. The temperature thermocouple is to be approximately 102 mm [4 in.] upstream of the compressor inlet connection. It is not necessary to control intake air humidity, but measurements are required.
8.6.2.7 Fuel In - Locate thermocouple at the fitting on the outlet side of the fuel transfer pump as shown in Fig.A1.10.
8.6.2.8 Pre-Turbine Exhaust - Locate one thermocouple in each side of exhaust manifold section; see Fig.A1.11. The thermocouple shall be downstream of the pre-turbine exhaust pressure sensor.
8.6.2.9 Exhaust Tailpipe - Locate thermocouple in exhaust pipe downstream of turbine in accordance with Fig.A1.12.
8.6.2.10 Intake Manifold - Locate thermocouple at tapped fitting on intake air manifold as shown in Fig.A1.13.
8.6.2.11 EGR Cooler Inlet - Distinct EGR cooler inlet temperature measurements are not necessary. Use the pre-turbine exhaust temperatures instead (see 8.6.2.8).
8.6.2.12 EGR Cooler Outlet - Locate thermocouple as shown in Fig.A1.14.
8.6.2.13 EGR Pre-Venturi - Locate thermocouple as shown in Fig.A1.15. Be aware that the EGR pre-venturi thermocouple shall be downstream of the pressure sensor.
8.6.2.14 Additional - Monitor any additional temperatures that the test laboratory regards as helpful in providing a consistent test procedure.
8.6.3 Pressures:
8.6.3.1 Before Oil Filter - Locate pickup at tapped hole on oil cooler fitting; see Fig.A1.16.
8.6.3.2 After Oil Filter (Main Oil Gallery) - Locate pickup at the left port of the filter housing; see Fig.A1.8.
NOTE 2 - The E7 engine has only one oil gallery, and it serves as both a main gallery and piston-cooling gallery.
8.6.3.3 Pre-Turbine Exhaust - Locate pickup in each side of exhaust manifold section (tap shall be upstream of the preturbine temperature thermocouple); see Fig.A1.11. This measurement is not mandatory but is recommended for diagnostic and safety purposes.
8.6.3.4 Intake Manifold (Air Boost) - Take measurement at tapped fitting provided on intake manifold as illustrated in Fig.A1.17.
8.6.3.5 Intake Air Pressure (Intake Air Restriction) - Measure with a Keil probe (p/n KDF-8-W required) located approximately 203 mm [8 in.] upstream of the compressor inlet (see Fig.A1.9). The probes may be obtained from the supplier shown in A2.9.
8.6.3.6 Exhaust Back - Locate pickup in exhaust pipe after turbocharger in center of exhaust stream. Measure exhaust backpressure in a straight section of pipe, 30.5 cm to 40.6 cm [12 to 16 in.] downstream of the turbo with a pressure tap hole as shown in Fig.A1.12.
8.6.3.7 Crankcase Pressure - Locate pickup at any location in the auxiliary oil system vent line, such as between the dipstick tube fitting and the top of the auxiliary oil sump bucket.
8.6.3.8 Compressor Discharge - Locate pickup within 15.2 cm [6 in.] of the second compressor.
8.6.3.9 Coolant System - Locate pickup at the top of the coolant system expansion tank.
8.6.3.10 Barometric Pressure - Locate barometer approximately 1.2 m [4 ft] above ground level in convenient location in the laboratory.
8.6.4 Exhaust Oxygen Sensor - Locate the oxygen sensor at the 12 o'clock position, 35.6 cm to 43.2 cm [14 to 17 in.] downstream of the turbine. Countersink the sensor coupling and install the sensor so that the sensor threads are flush with the inside diameter of the exhaust pipe. Do not expose threads to the flow stream. Refer to Fig.A1.12.
8.6.5 Intake Carbon Dioxide Sensor - Measure intake CO2. Locate the probe as shown in Fig.A1.8.
8.6.6 Engine Blowby - Connect the metering instrument to the filter element canister on the engine front cover.
8.6.7 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 unit injection pumps. Never plug fuel return lines. Accurate fuel consumption measurements require proper accounting of return fuel.
8.6.8 Humidity - Place the measurement equipment between the inlet air filter and compressor in such a manner as not to affect temperature and pressure measurements. Do not condition the intake air downstream of the humidity sensor. Report humidity on the appropriate form.
8.6.9 System Time Responses - The maximum allowable system time responses are shown in Table 1. Determine system time responses in accordance with the Data Acquisition and Control Automation II (DACA II) task force report.
