ASTM D7468-22

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: D7468 − 22
Standard Test Method for
Cummins ISM Test
This standard is issued under the fixed designation D7468; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope*
Section
Intake Manifold Temperature Sensor 6.1.7
1.1 The test method covers a heavy-duty diesel engine test
Barometric Pressure Sensor 6.1.8
procedure conducted under high soot conditions to evaluate oil Turbocharger Controller 6.1.9
Power Supply Voltage 6.1.10
performance with regard to valve train wear, top ring wear,
Air Compressor and Fuel Pump 6.1.11
sludgedeposits,andoilfilterplugginginanEGRenvironment.
Engine Block Preparation 6.1.12
Test Stand Configuration 6.2
This test method is commonly referred to as the Cummins ISM
Engine Mounting 6.2.1
Test.
Intake Air System 6.2.2
Aftercooler 6.2.3
1.2 The values stated in SI units are to be regarded as
Exhaust System 6.2.4
standard. No other units of measurement are included in this
Exhaust Gas Recirculation System 6.2.5
standard.
Fuel System 6.2.6
Coolant System 6.2.7
1.2.1 Exception—The only exception is where there is no
Pressurized Oil Fill System 6.2.8
direct SI equivalent such as screw threads, national pipe
External Oil System 6.2.9
threads/diameters, tubing sizes, or where there is a sole source
Crankcase Aspiration 6.2.10
Blowby Rate 6.2.11
of supply equipment specification.
System Time Responses 6.3
1.3 This standard does not purport to address all of the Oil Sample Containers 6.4
Mass Balance 6.5
safety concerns, if any, associated with its use. It is the
Engine and Cleaning Fluids 7
responsibility of the user of this standard to establish appro-
Test Oil 7.1
priate safety, health, and environmental practices and deter-
Test Fuel 7.2
Engine Coolant 7.3
mine the applicability of regulatory limitations prior to use.
Pentane 7.4
See Annex A1 for general safety precautions.
Solvent 7.5
1.4 Table of Contents: Preparation of Apparatus 8
Cleaning of Parts 8.1
Section
General 8.1.1
Scope 1
Engine Block 8.1.2
Referenced Documents 2
Cylinder Head 8.1.3
Terminology 3
Rocker Cover and Oil Pan 8.1.4
Summary of Test Method 4
External Oil System 8.1.5
Significance and Use 5
Crosshead Cleaning and Measurement 8.1.6
Apparatus 6
Rod Bearing Cleaning and Measurement 8.1.7
Test Engine Configuration 6.1
Ring Cleaning and Measurement 8.1.8
Test Engine 6.1.1
Injector Adjusting Screw Cleaning and Measurement 8.1.9
Oil Heat Exchanger, Adapter Blocks, Block Off Plate 6.1.2
Engine Assembly 8.2
Oil Filter Head Modification 6.1.3
General 8.2.1
Oil Pan Modification 6.1.4
Parts Reuse and Replacement 8.2.2
Engine Control Module (ECM) 6.1.5
Build-Up Oil 8.2.3
Engine Position Sensor 6.1.6
Coolant Thermostat 8.2.4
Oil Thermostat 8.2.5
Fuel Injectors 8.2.6
New Parts 8.2.7
This test method is under the jurisdiction of ASTM Committee D02 on
Operational Measurements 8.3
Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of
Units and Formats 8.3.1
Subcommittee D02.B0 on Automotive Lubricants.
Instrumentation Calibration 8.3.2
Current edition approved July 1, 2022. Published July 2022. Originally approved Temperatures 8.3.3
in 2008. Last previous edition approved in 2021 as D7468 – 21. DOI: 10.1520/ Pressures 8.3.4
Flow Rates 8.3.5
D7468-22.
Intake and Exhaust CO Measurement 8.3.6
Until the next revision of this test method, the ASTM Test Monitoring Center 2
Engine/Stand Calibration and Non-Reference Oil Tests 9
will update changes in this test method by means of Information Letters. Informa-
General 9.1
tionlettersmaybeobtainedfromtheASTMTestMonitoringCenter,203Armstrong
New Test Stand 9.2
Drive, Freeport, PA 16229, Attention: Director. This edition incorporates revisions
New Test Stand Calibration 9.2.1
in all information letters through No. 22-1.
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D7468 − 22
Section Section
Stand Calibration Period 9.3 Determination of Operational Validity Annex A11
Stand Modification and Calibration Status 9.4 Exhaust CO Sampling Probe Annex A12
Test Numbering System 9.5 ISM Merit Rating Calculation Annex A13
General 9.5.1 Appendix
Reference Oil Tests 9.5.2 Typical System Configurations Appendix X1
Non-Reference Oil Tests 9.5.3
1.5 This international standard was developed in accor-
Reference Oil Test Acceptance 9.6
dance with internationally recognized principles on standard-
Reference Oil Accountability 9.7
Last Start Date 9.8
ization established in the Decision on Principles for the
Donated Reference Oil Test Programs 9.9
Development of International Standards, Guides and Recom-
Adjustments to Reference Oil Calibration Periods 9.10
mendations issued by the World Trade Organization Technical
Procedural Deviations 9.10.1
Parts and Fuel Shortages 9.10.2
Barriers to Trade (TBT) Committee.
Reference Oil Test Data Flow 9.10.3
Special Use of the Reference Oil Calibration System 9.10.4
2. Referenced Documents
Test Procedure 10
Engine Installation and Stand Connections 10.1
2.1 ASTM Standards:
Coolant System Fill 10.2
D86 Test Method for Distillation of Petroleum Products and
Oil Fill for Break-in 10.3
Engine Build Committed 10.3.3 Liquid Fuels at Atmospheric Pressure
Fuel Samples 10.4
D93 Test Methods for Flash Point by Pensky-Martens
Engine Warm-up 10.5
Closed Cup Tester
Shutdown During Warm-up 10.5.1
Engine Break-in 10.6
D97 Test Method for Pour Point of Petroleum Products
Shutdown and Maintenance 10.7
D130 Test Method for Corrosiveness to Copper from Petro-
Normal Shutdown 10.7.1
leum Products by Copper Strip Test
Emergency Shutdown 10.7.2
Maintenance 10.7.3
D235 Specification for Mineral Spirits (Petroleum Spirits)
Downtime 10.7.4
(Hydrocarbon Dry Cleaning Solvent)
200-h Test Procedure 10.8
D287 Test Method for API Gravity of Crude Petroleum and
Oil Fill for Test 10.8.2
Operating Conditions 10.8.4
Petroleum Products (Hydrometer Method)
Injection Timing Change 10.8.5
D445 Test Method for Kinematic Viscosity of Transparent
Mass % Soot Validity 10.8.6
and Opaque Liquids (and Calculation of Dynamic Viscos-
Test Timer 10.8.7
Operational Data Acquisition 10.8.8
ity)
Oil Sampling 10.8.9
D482 Test Method for Ash from Petroleum Products
Oil Addition 10.8.10
D524 Test Method for Ramsbottom Carbon Residue of
End of Test (EOT) 10.9
Engine Disassembly 10.9.3
Petroleum Products
Calculations, Ratings and Test Validity 11
D613 Test Method for Cetane Number of Diesel Fuel Oil
Crosshead Mass Loss 11.1
D664 Test Method for Acid Number of Petroleum Products
Crosshead Mass Loss Correction Factor 11.1.7.1
Injector Adjusting Screw Mass Loss 11.2
by Potentiometric Titration
Injector Adjusting Screw Correction Factor 11.2.5
D976 Test Method for Calculated Cetane Index of Distillate
Ring Mass Loss 11.3
Fuels
Sludge Ratings 11.4
Oil Filter Plugging 11.5
D1319 Test Method for Hydrocarbon Types in Liquid Petro-
Oil Analyses 11.6
leum Products by Fluorescent Indicator Adsorption
Oil Consumption 11.7
D2274 Test Method for Oxidation Stability of Distillate Fuel
Fuel Analyses 11.8
Additional Analysis 11.8.1
Oil (Accelerated Method)
Assessment of Operational Validity 11.9
D2500 Test Method for Cloud Point of Petroleum Products
Assessment of Test Interpretability 11.10
and Liquid Fuels
Test Report 12
Report Forms 12.1
D2622 Test Method for Sulfur in Petroleum Products by
Reference Oil Test 12.2
Wavelength Dispersive X-ray Fluorescence Spectrometry
Electronic transmission of Test Results 12.2.1
Precision and Bias 13 D2709 Test Method for Water and Sediment in Middle
Precision 13.1
Distillate Fuels by Centrifuge
Intermediate Precision Conditions 13.1.1
D4052 Test Method for Density, Relative Density, and API
Reproducibility Conditions 13.1.2
Gravity of Liquids by Digital Density Meter
Bias 13.2
Keywords 14
D4175 Terminology Relating to Petroleum Products, Liquid
Annexes
Fuels, and Lubricants
Safety Precautions Annex A1
Intake Air Aftercooler Annex A2 D4294 Test Method for Sulfur in Petroleum and Petroleum
Engine Build Parts Kit Annex A3
Products by Energy Dispersive X-ray Fluorescence Spec-
Sensor Locations, Special Hardware, and Engine Block Annex A4
trometry
Modifications
External Oil System Annex A5
Cummins Service Publications Annex A6
Specified Units and Formats Annex A7
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Report Forms and Data Dictionary Annex A8
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Sludge Rating Worksheets Annex A9
Standards volume information, refer to the standard’s Document Summary page on
Oil Analyses Annex A10
the ASTM website.
D7468 − 22
D4485 Specification for Performance of Active API Service using different test equipment, applying different equipment
Category Engine Oils assembly procedures, or using modified operating conditions.
D4737 Test Method for Calculated Cetane Index by Four D4175
Variable Equation
3.1.9 reference oil, n—an oil of known performance
D4739 Test Method for Base Number Determination by
characteristics, used as a basis for comparison. D4485
Potentiometric Hydrochloric Acid Titration
3.1.10 sludge, n—in internal combustion engines, a deposit,
D5185 Test Method for Multielement Determination of
principally composed of insoluble resins and oxidation prod-
Used and Unused Lubricating Oils and Base Oils by
uctsfromfuelcombustionandthelubricant,thatdoesnotdrain
Inductively Coupled Plasma Atomic Emission Spectrom-
from engine parts but can be removed by wiping with a cloth.
etry (ICP-AES)
D4175
D5453 Test Method for Determination of Total Sulfur in
3.1.11 test oil, n—any oil subjected to evaluation in an
Light Hydrocarbons, Spark Ignition Engine Fuel, Diesel
Engine Fuel, and Engine Oil by Ultraviolet Fluorescence established procedure. D5967
D5967 Test Method for Evaluation of Diesel Engine Oils in
3.1.12 valve train, n—in internal combustion engines, the
T-8 Diesel Engine
series of components, such as valves, crossheads, rocker arms,
E29 Practice for Using Significant Digits in Test Data to
push rods, and camshaft, that open and close the intake and
Determine Conformance with Specifications
exhaust valves.
E178 Practice for Dealing With Outlying Observations
3.1.13 wear, n—the loss of material from a surface, gener-
2.2 Other ASTM Document:
ally occurring between two surfaces in relative motion, and
ASTM Deposit Rating Manual 20 (Formerly CRC Manual
4 resulting from mechanical or chemical action or a combination
20)
of both. D4175
2.3 National Archives and Records Administration:
3.2 Definitions of Terms Specific to This Standard:
Code of Federal Regulations Title 40 Part 86.310-79
3.2.1 crosshead, n—an overhead component, located be-
3. Terminology
tween the rocker arm and each intake valve and exhaust valve
pair, that transfers rocker arm travel to the opening and closing
3.1 Definitions:
of each valve pair.
3.1.1 blind reference oil, n—a reference oil, the identity of
3.2.1.1 Discussion—Each cylinder has two crossheads, one
which is unknown by the test facility. D4175
for each pair of intake valves and exhaust valves.
3.1.2 blowby, n—in internal combustion engines, that por-
3.2.2 de-rate protocols, n—protocols in the engine control
tion of the combustion products and unburned air/fuel mixture
module that cause the engine to reduce power output when
that leaks past piston rings into the engine crankcase during
certain operating parameters are exceeded.
operation.
3.1.3 calibrate, v—todeterminetheindicationoroutputofa 3.2.3 overhead, n—in internal combustion engines, the
device (e.g., thermometer, manometer, engine) with respect to components of the valve train located in or above the cylinder
that of a standard. head.
3.1.4 exhaust gas recirculation (EGR), n—a method by
3.2.4 overfuel, v—to cause the fuel flow to exceed the
which a portion of the engine exhaust is returned to the standard production setting.
combustion chambers through the intake system.
4. Summary of Test Method
3.1.5 heavy-duty, adj—in internal combustion engine
operation, characterized by average speeds, power output, and
4.1 ThistestmethodusesaCumminsISM500dieselengine
internal temperatures that are close to the potential maximum.
with a specially modified engine block.Test operation includes
D4485
a 25 min warm-up,a2h break-in, and 200 h in four 50 h
3.1.6 heavy-duty engine, n—in internal combustion engine stages. During stages A and C the engine is operated with
types,onethatisdesignedtoallowoperationcontinuouslyator retarded fuel injection timing and is overfueled to generate
close to its peak output. excess soot. During stages B and D the engine is operated at
conditions to increase valve train wear.
3.1.7 non-reference oil, n—anyoilotherthanareferenceoil,
suchasaresearchformulation,commercialoilorcandidateoil.
4.2 Prior to each test, the engine is cleaned and assembled
D4175
with new cylinder liners, pistons, piston rings and overhead
valve train components. All aspects of the assembly are
3.1.8 non-standard test, n—a test that is not conducted in
specified.
conformance with the requirements in the standard test
method; such as running in an non-calibrated test stand or
4.3 A forced oil drain, an oil sample and an oil addition,
equivalent to an oil consumption of 0.064 g/MJ, is performed
4 at the end of each 25 h period.
For stock #TMCMNL20, visit the ASTM website, www.astm.org, or contact
ASTM Customer Service at service@astm.org.
4.4 The test stand is equipped with the appropriate instru-
Available from Superintendent of Documents, Attn: New Orders, P.O. Box
mentation to control engine speed, fuel flow, and other oper-
371954, Pittsburgh, PA 15250-7954. Charge orders may be telephoned to the
Government Printing Office order desk. ating parameters.
D7468 − 22
4.5 Oil performance is determined by assessing crosshead disable the engine protection protocols, the test lab shall have
wear, top ring mass loss, injector adjusting screw mass loss, a signed confidentiality agreement in place with Cummins.
sludge deposits, and oil filter plugging. Contact the TMC to obtain the identification of the current
ECM calibration file and current communication protocol file.
5. Significance and Use
Obtain calibration and communication protocol files from
Cummins.
5.1 This test method was developed to assess the perfor-
6.1.6 Engine Position Sensor—When using the CM870
mance of an engine oil to control engine wear and deposits
ECM, disable the secondary engine position sensor measure-
under heavy-duty operating conditions selected to accelerate
ment coil by cutting the two outside wires colored red and
soot generation, valve train wear, and deposit formation in a
black.TheredandblackwiresarelabeledAandDrespectively
turbocharged, aftercooled four-stroke-cycle diesel engine
on the engine position sensor plug (Fig. A4.4).
equipped with exhaust gas recirculation hardware.
6.1.7 Intake Manifold Temperature Sensor—Substitute a
5.2 This test method can be used for engine oil specification
1.8 kΩ resistor or potentiometer for the intake manifold tem-
acceptance when all details of this test method are in compli-
perature sensor. The Cummins engineering tool shall indicate
ance. Applicable engine oil service categories are included in
65.6 °C (150 °F) after the intake manifold temperature sensor
Specification D4485.
has been replaced with the appropriate resistance.
5.3 The design of the engine used in this test method is
6.1.8 Barometric Pressure Sensor—Disconnect the baro-
representativeofmany,butnotall,moderndieselengines.This
metric pressure sensor. Replace the sensor with a 200 Ω
factor, along with the accelerated operating conditions needs to
resistor or potentiometer from power to ground (pins 1 and 2)
be considered when extrapolating test results.
and an 800 Ω resistor or potentiometer from signal to ground
(pins 2 and 3). The Cummins engineering tool shall indicate
6. Apparatus
101.2 kPa (29.9 in. Hg) after the barometric pressure sensor
6.1 Test Engine Configuration:
has been replaced with the appropriate resistance.
6.1.1 Test Engine—The Cummins ISM 500 is an in-line
6.1.9 Turbocharger Controller—Supply nominal 550 kPa
six-cylinder heavy-duty diesel engine with 11 L of displace-
air pressure to the turbocharger controller.
ment and is turbocharged and aftercooled. The engine has an
6.1.10 Power Supply Voltage—The nominal power supply
overhead valve configuration and EGR hardware. It features a
(battery) voltage is 12 Vdc, as displayed on the Cummins
2002 emissions configuration with electronic control of fuel
engineering tool.
metering and fuel injection timing. Obtain the test engine and
6.1.11 Air Compressor and Fuel Pump—The engine-
the engine build parts kit from the central parts distributor
mounted air compressor is not used for this test method.
(CPD). The components of the engine build parts kit are
Remove the air compressor and install the fuel injection pump
shown in Table A3.1. Non-kit parts are shown in Table A3.2.
in its place (Fig.A4.5). The fuel injection pump is driven with
6.1.2 Oil Heat Exchanger, Adapter Blocks, and Block-off
Cummins coupling P/N 208755.
Plate—The oil heat exchanger is relocated from the stock
6.1.12 Engine Block Preparation—Verify the oil capacitors
position with the use of adapter blocks as shown in Fig.A4.1. havebeendisabled.Iftheoilcapacitorshavenotbeendisabled,
Install an oil cooler block-off plate on the back of the coolant
use the following procedure.
thermostat housing (Fig.A4.1). Control the oil temperature by 6.1.12.1 Modifyanominal25mmholesawbyreplacingthe
directing process water through the oil heat exchanger (Fig.
drillbitfromthedrivearborwitharodprotrudingfromthesaw
A4.1).
cutting surface (Fig. A4.16). The rod prevents damage to the
6.1.3 Oil Filter Head Modification—Modify the oil filter
engine block as the hole saw breaks through the block.
head by plugging the filter bypass return to sump line and the
6.1.12.2 Insert the modified hole saw arbor into the cast oil
engineoilthermostat(Fig.A4.2).Blockthethermostatpassage
drain back hole in the bottom of the capacitor.
to route all of the engine oil into the oil cooler. The casting
6.1.12.3 Saw through the bottom of the capacitor wall (Fig.
shown in Fig. A4.2 is available from Cummins in assembly
A4.17) and remove the core produced by the hole saw.
P/N 3895946.
6.1.12.4 Remove all burrs and debris from the area around
6.1.4 Oil Pan Modification—Modify the oil pan as shown in
the hole.
Fig. A4.3.
6.2 Test Stand Configuration:
6.1.5 Engine Control Module (ECM)—Obtain the ECM
6.2.1 Engine Mounting—Install the engine so that it is
from the CPD. The ECM programming is modified, using the
upright and the crankshaft is horizontal.
Cummins engineering tool, to provide retarded injection
6.2.1.1 Configure the engine mounting hardware to mini-
timing, increasing soot generation and valve and injector train
mize block distortion when the engine is fastened to the
wear. Some engine protection protocols are disabled to allow
mounts. Excessive block distortion may influence test results.
test conditions to be attained. Before a test lab can obtain the
6.2.2 Intake Air System—With the exception of the intake
Cummins engineering tool and instructions describing how to
air tube, the intake air system is not specified. A typical
Available from Test Engineering Inc., 12758 Cimmaron Path, Suite 102, San
Antonio, TX 78249-3417. Available from the ASTM Test Monitoring Center, 203 Armstrong Drive,
Available from Southwest Research Institute, P.O. Drawer 28510, SanAntonio, Freeport, PA 16229, Attention: Director.
TX 78228. Available from a Cummins parts distributor.
D7468 − 22
TABLE 1 200 h Test Sequence TABLE 2 Maximum Allowable System Time Responses
Stage Time Response
Measurement
Parameter Unit
(s)
AB C D
Speed 2.0
Stage Length h 50 50 50 50
Temperature 3.0
Speed r/min 1800 ± 5 1600 ± 5 1800 ± 5 1600 ± 5
Pressure 3.0
Power kW record record record record
A Flow 45
Torque (typical) N·m 1220 1830 1220 1830
Fuel Flow kg/h 58 ± 1 64.4 ± 1 58 ± 1 64.4 ± 1
Intake Manifold Temp. °C 80 65.5 80 65.5
Blowby Flow L/min record record record record
Coolant Out Temp. °C 65.5 ± 2 65.5 ± 2 65.5 ± 2 65.5 ± 2
Coolant In Temp. °C record record record record
Coolant Delta Temp. °C record record record record
of the expansion tank. The system should have a sight glass to
Fuel In Temp. °C 40 ± 2 40 ± 2 40 ± 2 40 ± 2
detect air entrapment.
Oil Gallery Temp. °C 115 ± 2 115 ± 2 115 ± 2 115 ± 2
Turbo Inlet Temp. °C record record record record
6.2.7.1 Although the system volume is not specified, an
Intake Manifold Press. kPa abs. $ 300 $ 320 $ 300 $ 320
excessively large volume may increase the time required for
Exhaust Temp. °C record record record record
the engine fluid temperatures to attain specification. A system
Fuel Pressure kPa record record record record
Oil Gallery Pressure kPa record record record record
volume of 45 L or less, including the volume contained in the
Oil Filter Delta Press. kPa record record record record
engine, has proven satisfactory.
Coolant System kPa 99-107 99-107 99-107 99-107
B
Press. 6.2.8 Pressurized Oil Fill System—The oil fill system is not
Exhaust Press. kPa abs. 107 ± 1 107 ± 1 107 ± 1 107 ± 1
specified. A typical configuration includes an electric pump, a
Crankcase Press. kPa record record record record
50 L reservoir, and a transfer hose. The location for the
Inlet Air Press. kPa abs. record record record record
pressurized fill is located on the filter head (Fig. A4.2).
Intake CO % 0.97- 0.97- 0.97- 0.97-1.09
1.09 1.09 1.09
6.2.9 External Oil System—Configure the external oil sys-
A
At standard atmospheric temperature and pressure.
tem in accordance with Fig.A5.1. Use a (10 to 13) Lcontainer
B
Measure the coolant pressure on the top of the expansion tank.
for the external oil reservoir. Use Viking Pump model number
SG053514. Nominal pump motor speed is 1725 r/min.
6.2.9.1 Oil Sample Valve Location—Locate the oil sample
valve on the return line from the external oil system to the
configuration is shown in Fig. X1.1. The air filter should be
engine.Locatethevalveasclosetothereturnpumpaspossible
typical of air filters used for engines in heavy-duty applica-
(Fig. A5.1).
tions. Install the intake air tube (Fig.A4.6) at the intake of the
6.2.9.2 Unacceptable Oil System Materials—Do not use
turbocharger compressor. The system shall allow control of
brass or copper fittings because they can influence used oil
applicable parameters listed in Table 1.
wear metals analyses in the external oil system.
NOTE 1—Difficulty in achieving or maintaining intake manifold pres-
6.2.10 Crankcase Aspiration—Vent the blowby gas at the
sure or intake manifold temperature, or both, may be indicative of
port located on the left side of the valve cover (Fig. A4.8).
insufficient or excessive restriction.
Route the vent line downward from the valve cover port to the
6.2.3 Aftercooler—Use a Modine aftercooler for aftercool-
blowby canister. The line shall be between (1.2 and 1.8) m in
ing. Instructions for obtaining the correct aftercooler are listed
length and 1.5875 cm minimum inside diameter.
in A2.1.
6.2.11 Blowby Rate—The flowrate measurement device is
6.2.4 Exhaust System—Install the exhaust tube (Fig. A4.7)
not specified. The blowby canister shall be 35 L minimum in
atthedischargeflangeoftheturbochargerturbinehousing.The
volume. The outlet of the blowby canister to the flowrate
piping downstream of the exhaust tube is not specified. A
device shall be 3.175 cm minimum inside diameter. The hose
method to control exhaust pressure is required.
connecting the blowby canister to the flowrate device shall be
6.2.5 Exhaust Gas Recirculation System—The EGR system
3.81 cm minimum inside diameter. The length of this hose is
is supplied with the engine. Modify the EGR valve by drilling
not specified.
vent holes in the actuator case (Fig. A4.18). Provide 138 kPa
airtotheEGRvalveactuator.Ventthecoolantfromthecoolant
6.3 System Time Responses—The maximum allowable sys-
ventblocktothebottomoftheexpansiontankasshowninFig.
tem time responses are shown in Table 2. Determine system
X1.3.
time responses in accordance with the Data Acquisition and
6.2.6 Fuel System—The fuel supply and filtration system is
Control Automation II (DACA II) Task Force Report.
not specified. A typical configuration is shown in Fig. X1.2.
6.4 Oil Sample Containers—High-density polyethylene
The fuel consumption rate is determined by measuring the rate
containers are recommended for oil samples. (Warning—
of fuel flowing into the day tank. A method to control the fuel
Glass containers may break and may cause injury or exposure
temperature is required.
to hazardous materials, or both.)
6.2.7 Coolant System—The system configuration is not
specified.Atypicalconfigurationconsistsofanon-ferrouscore 6.5 Mass Balance—A balance is required to measure the
heat exchanger, a reservoir (expansion tank), a temperature massofthecrossheads,rodbearings,injectoradjustingscrews,
control valve, and a vent line from the coolant vent block on and piston rings. An electronic or mechanical balance may be
theenginetothebottomoftheexpansiontankasshowninFig. utilized. The balance shall have a minimum display resolution
X1.3.Pressurizethesystembyregulatingairpressureatthetop of 0.1 mg.
D7468 − 22
7. Engine and Cleaning Fluids 8.1.6.6 If an electronic scale is used for mass measurement,
use the following procedure:
7.1 Test Oil—Approximately 75 L of test oil is required to
(1) Demagnetize (degauss) each crosshead prior to mea-
complete the test.
surement.
7.2 Test Fuel—Approximately 15 500 Lof Chevron Phillips
(2) Measure the crosshead two times. Make the second
PC-9-HS diesel fuel is required to complete the test. Fuel
measurement with the crossheads in an orientation that is 90°
property tolerances are shown in the “PC-9-HS Fuel Specifi-
from the original orientation. If the difference between the two
cation” section of the “TMC-Monitored Test Fuel Specifica-
mass measurements is greater than 0.2 mg, demagnetize the
tions” document maintained by the TMC.
crosshead and repeat the measurement process.
7.3 Engine Coolant—Use premixed 50/50 Fleetguard Com- 8.1.7 Rod Bearing Cleaning and Measurement:
pleat PG. 8.1.7.1 Clean the rod bearings with solvent. Use a nonme-
tallic soft bristle brush if necessary. Avoid handling the rod
7.4 Pentane—(Warning—Flammable. Health hazard.)
bearings with bare hands. Use gloves or plastic covered tongs.
7.5 Solvent—Use a solvent which meets Specification D235
8.1.7.2 Spray the rod bearings with air until dry.
for mineral spirits, Type II, Class C for Aromatic Content
8.1.7.3 Rinse the rod bearings in pentane and dry with air.
(0-2 % vol), Flash Point (61 °C, min), and Color (not darker
8.1.7.4 Measure the mass of each bearing half to a tenth of
than +25 on Saybolt Scale or 25 on Pt-Co Scale). Obtain a
a milligram (xxx.x mg).
Certificate of Analysis for each batch of solvent from the
8.1.8 Ring Cleaning and Measurement:
supplier. (Warning—Combustible. Health Hazard. Use ad-
8.1.8.1 Clean and measure the rings in accordance with the
equate safety precautions with all solvents and cleaners.)
Mack Test Ring Cleaning and Measuring procedure, available
from theTMC. Avoid handling the rings with bare hands. Use
8. Preparation of Apparatus
gloves or plastic covered tongs.
8.1 Cleaning of Parts:
8.1.9 Injector Adjusting Screw Cleaning and Measurement:
8.1.1 General—The preparation of test engine components
8.1.9.1 Clean the injector adjusting screws with solvent.
specific to the Cummins ISM test are indicated in this section.
Use a soft bristle brush if necessary. Avoid handling the
Use the Cummins service publications (Annex A6) for the
injectoradjustingscrewswithbarehands.Useglovesorplastic
preparation of other engine components. Take precautions to
covered tongs.
prevent rusting of iron components.
8.1.9.2 Spraytheinjectoradjustingscrewswithairuntildry.
8.1.2 Engine Block—Disassemble the engine, including re-
8.1.9.3 Rinse the injector adjusting screws with pentane and
moval of the crankshaft, camshaft, piston cooling tubes, oil
dry with air.
pump, and oil gallery plugs.Thoroughly clean the surfaces and
8.1.9.4 Measure injector adjusting screw mass to a tenth of
oil passages (galleries). Use a brush to clean the oil passages.
a milligram (xxx.x mg).
Removal of camshaft bearings is at the discretion of the
8.1.9.5 If an electronic scale is used for mass measurement,
laboratory.
then use the following procedure:
8.1.3 Cylinder Head—Disassemble and clean the cylinder
(1) Demagnetize each injector adjusting screw prior to
head. Use a brush as necessary to remove deposits.
measurement.
8.1.4 Rocker Cover and Oil Pan—Clean the rocker cover
(2) Measure the adjusting screw two times. Make the
and oil pan. Use a brush as necessary to remove deposits.
second measurement with the injector adjusting screw in an
8.1.5 External Oil System—Flush the internal surfaces of
orientation that is 90° from the original orientation. If the
the oil lines and the external reservoir with solvent. Repeat
difference between the two mass measurements is greater than
until the solvent drains clean. Flush solvent through the oil
0.2mg,demagnetizetheinjectoradjustingscrewandrepeatthe
pumps until the solvent drains clean.
measurement process.
8.1.6 Crosshead Cleaning and Measurement:
8.2 Engine Assembly:
8.1.6.1 Handling and Orientation—Avoid handling the
8.2.1 General—Except as noted in this section, use the
crossheads with bare hands; use gloves or plastic covered
procedures indicated in the Cummins service publications
tongs. Orient the crossheads in the engine with the elongated
(Annex A6). Assemble the engine with the components from
slot toward the exhaust valve.
the Engine Build Parts Kit (Annex A3).
8.1.6.2 Clean the crossheads with solvent. Use a nonmetal-
8.2.2 Parts Reuse and Replacement—Engine components
lic soft bristle brush if necessary.
may be reused or replaced at the discretion of the laboratory,
8.1.6.3 Spray the crossheads with air until dry.
except as noted in 8.2.7.
8.1.6.4 Rinse the crossheads in pentane and dry with air.
8.2.3 Build-Up Oil—Use Cummins Premium Blue or test
8.1.6.5 Measure crosshead mass to a tenth of a milligram
oiltolubricatepartsfortheenginebuild.Iftestoilisused,then
(xxx.x mg).
the engine build is valid only for the respective test oil.
8.2.4 Coolant Thermostat—Lock the engine coolant ther-
mostat open.
Available from Chevron Phillips Chemical Company LP, 10001 Six Pines
8.2.5 Oil Thermostat—Remove the oil thermostat and plug
Drive, Suite 4036B, The Woodlands, TX 77387-4910, fuels@cpchem.com.
the oil passage. This will route all of the oil flow through the
AvailablefromtheTMCwebsiteathttp://www.astmtmc.org/ftp/docs/fuel/tmc-
monitored%20test%20fuel%20specifications.pdf. oil cooler (Fig. A4.2).
D7468 − 22
8.2.6 Fuel Injectors—The fuel injectors may be reused. 8.3.3.5 Oil Gallery Temperature—Install the sensor at the
Dedicate the injectors to a particular cylinder. Install the ⁄4-in. NPT hole on the left rear of the engine (Fig. A4.5 and
injectors in accordance with the torque wrench method as Fig. A4.12).
noted in the Cummins service publications (Annex A6). 8.3.3.6 Intake Air Temperature—Install the sensor (Fig.
8.2.7 New Parts—The parts listed below are contained in
A4.6).
the Engine Build Parts Kit and are not reusable (except as
8.3.3.7 Intake Manifold Temperature—Install the sensor
noted in 10.3.3). Clean the parts prior to use. Replacement of
30 mm from the outside edge of the manifold and 16 mm
any part listed below during a test invalidates the test.
forward from the air inlet to the manifold. (Fig. A4.8, Fig.
8.2.7.1 Pistons (crown, skirt) A4.9).
8.2.7.2 Piston Rings (top, second, oil)
8.3.3.8 Exhaust Temperature—Installthesensor(Fig.A4.7).
8.2.7.3 Cylinder Liners
8.3.3.9 Additional—Monitor any additional temperatures
8.2.7.4 Rocker Lever Shafts
considered to be beneficial.
8.2.7.5 Rocker Levers (exhaust, intake, injector)
NOTE 2—Additional exhaust sensor locations are recommended, such
8.2.7.6 Rocker Lever Sockets (intake and exhaust)
as the exhaust ports and pre-turbine (front and rear). The detection of
8.2.7.7 Valves (intake, exhaust)
changes in exhaust temperature(s) is an important diagnostic. Measure-
8.2.7.8 Valve Stem Guides ment of the EGR cooler gas inlet and outlet temperatures and coolant inlet
and outlet temperatures is recommended.
8.2.7.9 Valve Inserts
8.2.7.10 Piston Cooling Nozzles 8.3.4 Pressures:
8.2.7.11 Valve Crossheads
8.3.4.1 Measurement Location and Equipment—The pres-
8.2.7.12 Connecting Rod Bearings
sure measurement locations are specified in this section. The
8.2.7.13 Adjusting Screws measurement equipment is not specified. Follow the guidelines
detailed in the Data Acquisition and Control Automation II
8.3 Operational Measurements:
Task Force Report for the accuracy and resolution of the
8.3.1 Units and Formats—See Annex A7.
pressure measurement sensors and the complete measurement
8.3.2 Instrumentation Calibration:
system.
8.3.2.1 Fuel Consumption Rate Measurement Calibration—
8.3.4.2 Install a condensation trap at the lowest elevation of
Calibrate the fuel consumption rate measurement system
the tubing between the pressure measurement location and the
before every reference test sequence and at least once every
final pressure sensor for Crankcase Pressure, Intake Air
nine months. Temperature-compensate volumetric systems,
Pressure, and Exhaust Pressure. Route the tubing to avoid
and calibrate them against a mass flow device. The flowmeter
intermediate loops or low spots before and after the conden-
located on the test stand shall indicate within 0.2 % of the
sation trap.
calibration standard. Trace the calibration standard to national
8.3.4.3 Oil Gallery Pressure—Measure the pressure at the
standards.
left-rear of the engine, in the ⁄8-in. NPT port behind ECM, in
8.3.2.2 Calibration of the Temperature Measurement
front of the oil gallery temperature measurement location (Fig.
Systems—Calibrate the temperature measurement systems be-
A4.5 and Fig. A4.12).
fore every reference oil test sequence. Each temperature
8.3.4.4 Oil Filter Inlet Pressure—Measure the pressure at
measurement system shall indicate within 60.5 °C of the
the ⁄8 in.-14 o-ring plug located on the oil filter assembly (Fig.
laboratory calibration standard. Trace the calibration standard
A4.2).
to national standards.
8.3.4.5 Oil Filter Outlet Pressure—Measure the pressure at
8.3.2.3 Calibration of the Pressure Measurement Systems—
the ⁄4-in. NPT port located on the oil filter assembly (Fig.
Calibrate the pressure measurement systems before every
A4.2).
reference oil test sequence. Trace the calibration standard to
8.3.4.6 Intake Manifold Pressure—Measure the pressure at
national standards.
the ⁄4-in. NPT port located on the intake air elbow (Fig.
8.3.3 Temperatures:
A4.13).
8.3.3.1 Measurement Location—The temperature measure-
8.3.4.7 Crankcase Pressure—Measure the pressure at the
ment locations are specified in this section. The measurement
boss on the top-front, left-hand side of the rocker cover (Fig.
equipment is not specified. Install the sensors such that the tip
A4.8).
is located midstream of the flow unless otherwise indicated.
8.3.4.8 Intake Air Pressure—Measure the pressure on the
Follow the guidelines detailed in the Data Acquisition and
intake air tube (Fig. A4.6).
ControlAutomationIITaskForceReport fortheaccuracyand
8.3.4.9 Exhaust Pressure—Measure the pressure on the
resolution of the temperature measurement sensors and the
exhaust tube (Fig. A4.7).
complete measurement system.
8.3.4.10 Fuel Pressure—Measure the pressure at the ⁄16
8.3.3.2 Coolant Out Temperature—Install the sensor in the
in.-18 Compucheck adapter on fuel pump body (Fig. A4.5).
⁄4 in. NPT hole at the top of the coolant out tube (Fig.A4.10).
8.3.4.11 Coolant Pressure—Measure the pressure on top of
8.3.3.3 Coolant In Temperature—Install the sensor on the
right side of the coolant pump intake housing at the 1-in. NPT the expansion tank (Fig. X1.3).
port (Fig. A4.11). 8.3.4.12 Additional Pressures—Monitor any additional
pressures considered to be beneficial.
8.3.3.4 Fuel In Temperature—Install the sensor in the fuel
pump inlet fitting (Fig. A4.5). 8.3.5 Flow Rates:
D7468 − 22
8.3.5.1 Flow Rate Location and Measurement Equipment— oneforeachteststart(referenceoilandnon-referenceoil)with
The flow rate measurement locations are specified in this the exception stated in 9.5.2.
section.Theequipmentfortheblowbyrateandthefuelrateare
9.5.2 Reference Oil Tests—A reference oil test conducted
not specified. Follow the guidelines detailed in the Data
subsequent to an unacceptable reference oil test shall include a
Acquisition and ControlAutomation II Task Force Report for
letter suffix after Z. The letter suffix shall begin with A and
the accuracy and resolution of the flow rate measurement
incrementalphabeticallyuntilanacceptablereferenceoiltestis
system.
completed. For example, if two consecutive unacceptable
8.3.5.2 Blowby—The device used to measure the blowby
referenceoiltestswereconductedandthefirsttestnumberwas
flow rate is not specified. See 6.2.11 for blowby measurement
27-4B4607-10, the second test number would be 27-4B4607-
system configuration details.
10A. A third calibration attempt would have the test number
8.3.5.3 Fuel Flow—The fuel consumption rate is deter-
27-4B4607-10B. If the third test was acceptable, then 27-
mined by measuring the fuel flowing to the day tank (Fig.
4B4607-10B would identify the reference oil test in the test
X1.2).
report.
8.3.6 Intake and Exhaust CO Measurement:
2 9.5.3 Non-Reference Oil Tests—Do not add a letter suffix to
8.3.6.1 Sampling Probes—Instructionsforobtaininggeneral
Z for aborted or operationally invalid non-reference oil tests.
specifications and fabrication details for the intake and exhaust
9.6 Reference Oil Test Acceptance:
CO probesareshowninAppendixX1.Theintakeandexhaust
9.6.1 Reference oil test acceptance is determined in accor-
probes may also be obtained from the CPD.
dance with the LTMS.
8.3.6.2 Sampling Probe Locations—Install the intake CO
probe51mmforwardfromthemanifoldpressuresensoronthe
9.7 Reference Oil Accountability:
same centerline (Fig. A4.14). The exhaust CO probe location
9.7.1 Laboratories shall provide a full accounting of the
is shown in Fig. A4.7.
identification and quantities of all reference oils used. With the
8.3.6.3 Sampling Probe Insertion Depths—Insert the intake
exception of the oil analyses required in 11.7, perform no
CO probeuntilittouchesthebottomofthemanifold,andthen
physical or chemical analyses of reference oils without written
back the probe out 12 mm.Adiagram of the insertion depth for
permissionfromtheTMC.Insuchanevent,includethewritten
the exhaust probe is shown in Fig. A4.15.
confirmation and the data generated in the reference oil test
report.
9. Engine/Stand Calibration and Non-Reference Oil Tests
9.7.2 Retain used reference oil samples for 90 days from the
9.1 General—Calibrate the test stand by conducting a test EOT date.
withablindreferenceoil. SubmittheresultstotheASTMTest
9.8 Last Start Date—In order for a non-reference oil test to
Monitoring Center (TMC) for determination of acceptance in
be within a calibration period, crank the assembled engine
accordance with the Lubricant Test Monitoring System
(10.3.3) prior to the expiration of the calibration period (9.3).
(LTMS).
9.9 Donated Reference Oil Test Programs—The surveil-
9.2 New Test Stand—A new test stand is defined as a test
lance panel is charged with maintaining effective reference oil
stand that has never been calibrated.
test severity and precision monitoring. During times of new
9.2.1 New Test Stand Calibration—New stand calibration is
parts introductions, new or re-blended reference oil additions,
determined in accordance with the LTMS.
and procedural revisions, it may be necessary to evaluate the
9.3 Stand Calibration Period—The calibration period is
possible effects on severity and precision levels. The surveil-
12 months. Up to 12 operationally valid, non-reference oil
lance panel may choose to conduct a program of donated
tests, including any non-interpretable tests, may be completed
reference oil tests in those laboratories participating in the
during each calibration period.
monitoring system, in order to quantify the effect of a particu-
9.3.1 The TMC may schedule more frequent reference oil
lar change on severity and precision.Typically the surveillance
tests or extend the calibration period.
panelrequestsitspanelmemberstovolunteerenoughreference
oil test results to create a robust data set. Broad laboratory
9.4 Stand Modification and Calibration Status—Stand cali-
participation is needed to provide a representative sampling of
bration status can be invalidated by conducting any non
theindustry.Toensurethequalityofthedataobtained,donated
standard test or modification of the test and control systems or
tests are conducted on calibrated test stands. The surveillance
both. A non standard test includes any test conducted under a
panel shall arrange an appropriate number of donated tests and
modified procedure, nonprocedural hardware, controller set
ensure completion of the test program in a timely manner.
point modifications, or any combination thereof. Contact the
TMC prior to any changes to determine the effect on the
9.10 Adjustments to Reference Oil Calibration Periods:
calibration status.
9.10.1 Procedural Deviations—On occasions when a labo-
9.5 Test Numbering System: ratory becomes aware of a significant deviation from the test
9.5.1 General—The test number has three parts, X-Y-Z. X method, such as might arise during an inhouse review or a
represents the test stand number, Y represents the engine serial TMC inspection, the laboratory and theTMC shall agree on an
number, and Z represents the stand run number. For example, appropriate course of action to remedy the deviation. This
test number 27-4B4607-2 indicates stand number 27, engine action may include the shortening of existing reference oil
serialnumber4B4607,andstandrunnumber2.Increment Zby calibration periods.
D7468 − 22
TABLE 3 Warm-up Conditions
9.10.2 Parts and Fuel Shortages—Under special
circumstances, such as industry-wide parts or fuel shortages, Stage
Parameter Unit
the surveillance panel may direct the TMC to extend the time AB C D E
intervalsbetweenreferenceoiltests.Theseextensionsshallnot Stage Length min 5 5 5 5 5
Speed r/min 700 1200 1600 1600 1600
exceed one regular calibration period.
Torque N·m 135 270 540 1085 1470
9.10.3 Reference Oil Test Data Flow—To ensure continuous
Coolant Out °C 75 max 75 max 75 max 75 max 75 max
Temperature
severity and precision monitoring, calibration tests are con-
Oil Gallery °C 125 125 125 125 125
ducted periodically throughout the year. There may be occa-
Temperature max max max max max
sions when laboratories conduct a large portion of calibration
Intake Manifold °C 70 max 70 max 70 max 70 max 70 max
Temperature
tests in a short period of time. This could result in an
unacceptably large time frame when very few calibration tests
are conducted. The TMC can shorten or extend calibration
periods as needed to provide a consistent flow of reference oil
10.4 Fuel Samples—Take a 120 mL fuel sample at the start
test data.Adjustments to calibration periods are made such that
of the test and at EOT.
laboratorieswillincurnonetloss(orgain)incalibrationstatus.
9.10.4 Special Use of the Reference Oil Calibration
10.5 Engine Warm-up—The engine warm-up conditions are
System—The surveillance panel has the option to use the
shown in Table 3.
reference oil system to evaluate changes that have potential
10.5.1 Shutdown During Warm-up—If a shutdown occurs
impact on test severity and precision. This option is only taken
during the warm-up, rerun the entire warm-up.
when a program of donated tests is not feasible. The sur
...