ASTM D7549-09

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information
Designation: D7549 − 09
StandardTest Method for
Evaluation of Heavy-Duty Engine Oils under High Output
Conditions—Caterpillar C13 Test Procedure
This standard is issued under the fixed designation D7549; 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.
INTRODUCTION
Any properly equipped laboratory, without outside assistance, can use the test procedure described
in this test method. The ASTM Test Monitoring Center (TMC) provides calibration and an
assessment of the test results obtained on those oils by the laboratory. By this means the laboratory
will know whether its use of the test method gives results statistically similar to those obtained by
other laboratories. Furthermore, various agencies require that a laboratory utilizes the TMC services
in seeking qualification of oils against specifications. For example, the U.S. Army has such a
requirement in some of its engine oil specifications.Accordingly, this test method is written for those
laboratories that use the TMC services. Laboratories that choose not to use these services should
ignore those portions of the test method that refer to theTMC. Information letters issued periodically
by the TMC may modify this test method. In addition the TMC may issue supplementary memoranda
related to the test method.
1. Scope bility of regulatory limitations prior to use. See Annex A1 for
general safety precautions.
1.1 The test method covers a heavy-duty engine test proce-
dure under high output conditions to evaluate engine oil
2. Referenced Documents
performance with regard to piston deposit formation, piston
2.1 ASTM Standards:
ring sticking and oil consumption control in a combustion
D86 Test Method for Distillation of Petroleum Products at
environmentdesignedtominimizeexhaustemissions.Thistest
Atmospheric Pressure
method is commonly referred to as the Caterpillar C13
D93 Test Methods for Flash Point by Pensky-Martens
Heavy-Duty Engine Oil Test.
Closed Cup Tester
1.2 The values stated in SI units are to be regarded as
D97 Test Method for Pour Point of Petroleum Products
standard. No other units of measurement are included in this
D130 Test Method for Corrosiveness to Copper from Petro-
standard.
leum Products by Copper Strip Test
1.2.1 Exceptions—Where there are no SI equivalent such as
D235 Specification for Mineral Spirits (Petroleum Spirits)
screw threads, National Pipe Treads (NPT), and tubing sizes.
(Hydrocarbon Dry Cleaning Solvent)
1.3 This standard does not purport to address all of the
D445 Test Method for Kinematic Viscosity of Transparent
safety concerns, if any, associated with its use. It is the
and Opaque Liquids (and Calculation of Dynamic Viscos-
responsibility of the user of this standard to establish appro-
ity)
priate safety and health practices and determine the applica-
D482 Test Method for Ash from Petroleum Products
D524 Test Method for Ramsbottom Carbon Residue of
Petroleum Products
This test method is under the jurisdiction of ASTM Committee D02 on D613 Test Method for Cetane Number of Diesel Fuel Oil
Petroleum Products and Lubricants and is the direct responsibility of Subcommittee
D664 Test Method for Acid Number of Petroleum Products
D02.B0 on Automotive Lubricants.
by Potentiometric Titration
Current edition approved June 1, 2009. Published August 2009. DOI: 10.1520/
D975 Specification for Diesel Fuel Oils
D7549-09.
TheASTM Test Monitoring Center will update changes in this test method by
means of Information Letters. Information Letters may be obtained by from the
ASTM Test Monitoring Center, 6555 Penn Avenue, Pittsburgh, PA 15206-4489, For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Attention: Administrator. contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Caterpillar Inc., Engine System Technology Development, PO Box 610, Standards volume information, refer to the standard’s Document Summary page on
Mossville, IL 61552-0610. the ASTM website.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D7549 − 09
D976 Test Method for Calculated Cetane Index of Distillate 3.1.1.1 Discussion—This is a coded reference oil that is
Fuels submitted by a source independent of the test facility. D4175
D1319 Test Method for Hydrocarbon Types in Liquid Petro-
3.1.2 blowby, n—in internal combustion engines, the com-
leum Products by Fluorescent Indicator Adsorption
bustion products and unburned air-and-fuel mixture that enter
D2274 Test Method for Oxidation Stability of Distillate Fuel
the crankcase. D4175
Oil (Accelerated Method)
3.1.3 calibrate, v—todeterminetheindicationoroutputofa
D2622 Test Method for Sulfur in Petroleum Products by
measuring device with respect to that of a standard. D4175
Wavelength Dispersive X-ray Fluorescence Spectrometry
3.1.4 heavy duty, adj—in internal combustion engine
D2709 Test Method for Water and Sediment in Middle
operation, characterized by average speeds, power output, and
Distillate Fuels by Centrifuge
internal temperatures that are close to the potential maximums.
D3524 Test Method for Diesel Fuel Diluent in Used Diesel
D4175
Engine Oils by Gas Chromatography
D4052 Test Method for Density, Relative Density, and API
3.1.5 heavy-duty engine, n—in internal combustion engine
Gravity of Liquids by Digital Density Meter
types, one that is designed to allow operation continuous at or
D4175 Terminology Relating to Petroleum, Petroleum
close to its peak output.
Products, and Lubricants
3.1.5.1 Discussion—This type of engine is typically in-
D4294 Test Method for Sulfur in Petroleum and Petroleum
stalled in large trucks and buses as well as farm, industrial, and
Products by Energy Dispersive X-ray Fluorescence Spec-
construction equipment. D4175
trometry
3.1.6 non-reference oil, n—anyoilotherthanareferenceoil,
D4739 Test Method for Base Number Determination by
such as a research formulation, commercial oil, or candidate
Potentiometric Hydrochloric Acid Titration
oil. D4175
D5185 TestMethodforDeterminationofAdditiveElements,
3.1.7 non-standard test, n—a test that is not conducted in
Wear Metals, and Contaminants in Used Lubricating Oils
conformance with the requirements in the standard test
and Determination of Selected Elements in Base Oils by
method, such running on an uncalibrated test stand, using
Inductively Coupled Plasma Atomic Emission Spectrom-
different test equipment, applying different equipment assem-
etry (ICP-AES)
bly procedures, or using modified operating conditions. D4175
D5186 Test Method for Determination of the Aromatic
Content and Polynuclear Aromatic Content of Diesel 3.1.8 reference oil, n—an oil of known performance
characteristics, used as a basis for comparison.
Fuels and Aviation Turbine Fuels By Supercritical Fluid
Chromatography 3.1.8.1 Discussion—Reference oils are used to calibrate
testing facilities, to compare the performance of other oils, or
D5453 Test Method for Determination of Total Sulfur in
Light Hydrocarbons, Spark Ignition Engine Fuel, Diesel to evaluate other materials (such as seals) that interact with
oils. D4175
Engine Fuel, and Engine Oil by Ultraviolet Fluorescence
D5967 Test Method for Evaluation of Diesel Engine Oils in
3.1.9 test oil, n—any oil subjected to evaluation in an
T-8 Diesel Engine
established procedure.
D6078 Test Method for Evaluating Lubricity of Diesel Fuels
3.1.9.1 Discussion—– It can be any oil selected by the
by the Scuffing Load Ball-on-Cylinder Lubricity Evalua-
laboratory conducting the test. It could be an experimental
tor (SLBOCLE)
product or a commercially available oil. Often, it is an oil that
D6681 Test Method for Evaluation of Engine Oils in a High
is a candidate for approval against engine oil specifications
Speed, Single-Cylinder Diesel Engine—Caterpillar 1P
(such as manufacturers’ or military specifications, and so
Test Procedure
forth). D4175
D6987/D6987M Test Method for Evaluation of Diesel En-
3.1.10 wear, n—the loss of material from a surface, gener-
gine Oils in T-10 Exhaust Gas Recirculation Diesel
ally occurring between two surfaces in relative motion, and
Engine
resulting from mechanical or chemical action or a combination
E29 Practice for Using Significant Digits in Test Data to
of both.
Determine Conformance with Specifications
3.2 Definitions of Terms Specific to This Standard:
E178 Practice for Dealing With Outlying Observations
5 3.2.1 overhead, n—in internal combustion engines, the
2.2 Coordinating Research Council (CRC):
components of the valve train located in or above the cylinder
CRC Manual No. 20
head.
3.2.2 tote, n—a container, smaller in capacity than a gallon.
3. Terminology
3.2.3 valve train, n—in internal combustion engines, the
3.1 Definitions:
series of components, such as valves, crossheads, rocker arms,
3.1.1 blind reference oil, n—a reference oil, the identity of
push rods and camshaft that open and close the intake and
which is unknown by the test facility.
exhaust valves.
3.3 Abbreviations and Acronyms:
3.3.1 ACERT—Advanced Combustion Emission Reduction
Available fromASTM Test Monitoring Center, 6555 PennAvenue, Pittsburgh,
PA 15206-4489, Attention: Administrator. Technology
D7549 − 09
3.3.2 ATGC—average top groove carbon of oil consumption under heavy-duty operating conditions
selected to accelerate deposit formation in a turbocharged,
3.3.3 ATGCO—average top groove carbon offset
intercooled four-stroke-cycle diesel engine equipped with a
3.3.4 CARB—California Air Resources Board
combustionsystemthatminimizesfederallycontrolledexhaust
3.3.5 CAT—acronym for Caterpillar
gas emissions.
3.3.6 CRC—Coordinating Research Council
5.2 The results from this test method may be compared
3.3.7 DACA—Data Acquisition and Control Automation against specification requirements to ascertain acceptance.
3.3.8 ECM—engine control module
5.3 The design of the test engine used in this test method is
representative of many, but not all, diesel engines. This factor,
3.3.9 EOT—end of test
along with the accelerated operating conditions, needs to be
3.3.10 HC—heavy carbon
considered when comparing test results against specification
3.3.11 IMP—intake manifold pressure
requirements.
3.3.12 LC—light carbon
6. Apparatus
3.3.13 LTMS—Lubricant Test Monitoring System
6.1 Test Engine Configuration:
3.3.14 MC—medium carbon
6.1.1 Test Engine—The test engine is a production 2004
3.3.15 NPT—National Pipe Thread
Caterpillar 320 kW C13 engine, designed for heavy duty
3.3.16 OC—oil consumption
on-highway truck use. It is an electronically controlled,
3.3.17 P/N—part number
turbocharged, after-cooled, direct injected, six cylinder diesel
engine with an in-block camshaft and a four-valve per cylinder
3.3.18 QI—quality index
arrangement.The engine uses Caterpillar’sACERTtechnology
3.3.19 RPTGC—reference relative top groove carbon pro-
featuring multiple injections per cycle and inlet valve actuation
file
control. It features a 2004 US EPA emissions configuration
3.3.20 SDTGCO—standard deviation top groove carbon
with electronic control of fuel metering, fuel injection timing
outlier
and inlet valve actuation timing. Critical parts that can affect
3.3.21 TGC—top groove carbon piston deposit formation are specified for oil test engine use.
See Annex A3 for source of the test engine and critical and
3.3.22 ULSD—ultra low sulfur diesel
non-critical parts.
4. Summary of Test Method
6.1.2 Oil Heat Exchanger and Oil Heat System—Replace
thestandardCaterpillaroilheatexchangercorewithastainless
4.1 This test method uses a Caterpillar production C13
steal core, Caterpillar P/N 1Y-4026. Additionally install a
diesel engine (see Annex A3 for ordering information and list
remotely mounted heat exchanger. Control the oil temperature
of engine build parts). Test operation includes a 60-min engine
with a dedicated cooling loop and control system which is
warm-up and break-in, followed by a 4-h cool down and valve
separate from the engine coolant (see AnnexA12). Ensure that
lash adjustment.After the valve lash adjustment and any other
the oil cooler bypass valve is blocked closed.
needed adjustments, a 500-h test is begun. The engine is
6.1.3 Oil Pan Modification—Modifytheoilpanasshownin
operated under steady-state, rated-power conditions known to
A4.1.
generate excessive piston deposits or oil consumption or both
6.1.4 Engine Control Module (ECM)—TheECMdefinesthe
in field service. Report the total engine oil consumption as the
desiredenginefueltimingandquantity.Italsolimitsmaximum
sum of the measured volumes in 50-h increments.
engine speed and power. Caterpillar electronic governors are
4.2 Equiptheteststandwiththeappropriateinstrumentation
designed to maintain a speed indicated by the throttle position
to control engine speed, fuel flow, and other operating param-
signal. Speed variation drives fuel demand (rack). Rack and
eters.
engine speed are input to the injection duration and timing
4.3 Determine the engine oil performance by assessing maps to determine duration and timing commands for the fuel
piston deposits and ring sticking, and oil consumption.
injectors. Obtain special oil test engine control software
4.3.1 Prior to each test, clean and assemble the engine with (module P/N 250-6675-03) for correct maps. Contact the
new cylinder liners, pistons, piston rings, bearings and certain
Caterpillar oil test representative through TMC for installation
valve train components. All aspects of the assembly are of this software. Use the Caterpillar engine technician (ET)
specified.After the test, dismantle the engine and examine and
service software package, version 2004B or later, to monitor
rate the parts. engine parameters, flash software, and to change power and
4.3.2 Asample of engine oil is removed and an oil addition
injectortrimvalues.Usethefulldealerversionpurchasedfrom
is made at the end of each 50-h period. The volume of the oil a Caterpillar dealer with a yearly subscription.
addition is the sum of the volume of sample plus the volume of
6.1.5 Crankshaft Position Sensor—Sense the crankshaft
oil consumed by the engine. position using a primary sensor at the crankshaft gear and as
secondary sensor at the camshaft gear. The secondary sensor
5. Significance and Use
5.1 This test method assesses the performance of an engine
oil with respect to control of piston deposits and maintenance Trademark of Caterpillar Inc., 100 North East Adams St., Peoria, IL 61629.
D7549 − 09
TABLE 1 Maximum Allowable System Time Responses
provides position information during cranking and in the event
of a primary sensor position failure. Calibrate the engine Measurement Time Response
control software before starting the timed test operation. Speed 2.0 s
Temperature 3.0 s
6.1.6 Air Compressor—Do not use the engine-mounted air
Pressure 3.0 s
compressor for this test method. Remove the air compressor Flow 45.0 s
andinstallablock-offplatekitinitsplace(P/N227-2574cover
group and P/N 223-3873, plug group) (Fig. A4.5 or equiva-
lent). thesystembyregulatingairpressureatthetopoftheexpansion
tank. Ensure the system has a sight glass to detect air
6.1.6.1 Modify the turbocharger waste-gate for manual
entrapment.
control by replacing the supplied pressure control with a
6.2.6.1 System volume is not specified. Avoid a very large
manual linkage. See Figs. A4.21-A4.23.
volume as it may increase the time required for the engine
6.2 Test Stand Configuration:
coolant to reach operating temperatures.
6.2.1 Engine Mounting—Install the engine so that it is
6.2.7 Pressurized Oil Fill System—The oil fill system is not
upright and the crankshaft is horizontal. specified. A typical system includes an electric pump, a 50 L
reservoir, and a transfer hose. Fig.A4.24 shows the location of
6.2.1.1 Configure the engine mounting hardware to mini-
the pressurized oil fill system.
mize block distortion when the engine is fastened to the
6.2.8 External Oil System—Configure the oil system ac-
mounts. Excessive block distortion may influence test results.
cording to Fig. A5.1. The capacity of the oil reservoir is
6.2.2 Intake Air System—With the exception of the air filter
10–13 L. Ensure that the oil return is drawn from the bottom of
and intake air tube, the intake air system is not specified. See
the oil reservoir Fig. A4.9. Use Viking Pump Model No.
Fig. X1.1 of a typical configuration. Use a suitable air filter.
SG053514. Locate the external oil pumps at an elevation that
Install the intake air tube (Fig. A4.6) at the intake of the
isbelowthepumpsupplyfittingontheoilpan.Thenominaloil
turbochargercompressor.Theintakeairtubeisaminimum305
pump motor speed is 1725 rpm. Figs. A4.1-A4.4 show the
mm of straight, nominal 102 mm diameter tubing. The system
pump supply and return port locations.
configuration upstream of the air tube is not specified.
6.2.8.1 Oil Sample Valve Location—Locate the oil sample
NOTE 1—Difficulty in achieving or maintaining intake manifold pres- valve on the return line from the external oil system to the
sure or intake manifold temperature, or both, may be indicative of
engine, and as close as possible to the return pump see Fig.
insufficient or excessive restriction.
A4.9 and Fig. A5.1.
6.2.8.2 Unacceptable Oil System Materials—Do not use
6.2.3 Charge Air Cooler—In addition to the Caterpillar
brassorcopperfittingsbecausetheycanadverselyinfluenceoil
supplied charge air cooler which is engine mounted, use
wear metal analyses in the external oil system.
another cooler to simulate the air-to-air charge air cooler used
6.2.9 Crankcase Aspiration—Vent the blowby gas at the
in most field applications. A Modine (P/N 1A012865) cooler
blowby filter housing located at the left front side of the
has been found suitable for this use. See A2.1 for instructions
cylinder head cover (Fig. A4.10). Use crankcase breather P/N
on obtaining this cooler.Alternatively, other charge air coolers
9Y-4357. Use breather spacer P/N 221-3934 or equivalent
may be used with the following limitations: (1) the cooler shall
20-mm thick plate with a fully open center. Use a P/N 9Y-1758
provide sufficient cooling capacity to control inlet manifold
gasket on each side of the spacer.
temperatures in the range specified elsewhere in this test
6.2.10 Blowby Rate—See the general configuration of this
method; (2) the boost air pressure drop across the cooler not
system in Fig. A4.10. The minimum internal volume of the
exceed 15 kPa; and (3) the cooler is equipped with a drain
blowby canister is 26.5 L. The inside diameter of the pipe
system to remove condensate continuously from the boost air
connecting the breather outlet to the blowby canister 32 mm.
cooler outlet side. Remove the coolant diverter valve dia-
Incline the pipe downward to the canister.The hose connecting
phragm for the Caterpillar supplied charge air cooler.
the blowby canister to the flow rate measuring device is not
6.2.4 Exhaust System—Install the exhaust tube, see Fig.
specified but shall match closely to the inlet of the device. The
A4.7, at the discharge flange of the turbocharger turbine
flow rate measurement device is not specified. The J-TEC
housing. The piping downstream of the exhaust tube is
Associates, Inc. Model No. YF563C does give satisfactory
required,butnotspecified.Provideamethodtocontrolexhaust
results under the conditions specified in this test method.
pressure.
6.3 System Time Responses—The maximum allowable sys-
6.2.5 Fuel System—The fuel supply and filtration system is
tem time responses are shown in Table 1. Determine system
not specified. See Fig. X1.2 for a typical configuration.
time responses in accordance with the Data Acquisition and
Determine the fuel consumption rate by measuring the rate of
Control Automation II (DACA II) Task Force Report.
fresh fuel flowing into the day tank. Provide a method to
control fuel temperature. Return the excess fuel from the
engine into the day tank. 7
The sole source of supply of the apparatus known to the committee at this time
is J-TEC Associates, Inc., 5005 Blairs Forest Lane NE, Suite L, Cedar Rapids, IA
6.2.6 Coolant System—The system configuration is not
52402, www.j-tecassociates.com. If you are aware of alternative suppliers, please
specified. See Fig. X1.3 showing a typical configuration
provide this information toASTM International Headquarters. Your comments will
consisting of a non-ferrous core heat exchanger, a reservoir
receive careful consideration at a meeting of the responsible technical committee,
(expansion tank) and a temperature control valve. Pressurize which you may attend.
D7549 − 09
A
TABLE 2 Cat ELC Coolant Concentrate and
8.1.2 Engine Block—Disassemble the engine, including re-
Premix 50/50 Options
moval of the crankshaft, camshaft, piston cooling tubes, oil
B
Tote,
Container Size 3.8 L 19 L 208 L
pump, and oil gallery plugs.Thoroughly clean the surfaces and
275 g
oil passages (galleries). Use a nylon brush to clean the oil
Concentrate P/N 119-5150 . 136-3707 .
Premixed 50/50 P/N 101-2844 129-2151 101-2845 222-1534
passages. Removal of camshaft bearings is optional.
A
Trademark of Caterpillar Inc., 100 North East Adams St., Peoria, IL 61629. 8.1.3 Cylinder Head, Intake System and Duct—Disassemble
B
A small container.
and clean these components before each test. Scrub with a
nylon brush and solvent. Use of an engine parts washer
followed by a solvent wash is permitted.
6.4 Oil Sample Containers—Preferably use high-density
8.1.4 Rocker Cover and Oil Pan—Clean the Rocker Cover
polyethylene containers for oil samples. (Warning—Avoid
and Oil Pan. Use a nylon brush, as necessary, to remove
using glass containers which may break and cause injury or
deposits.
exposure to hazardous materials.)
8.1.5 External Oil System—Flush the internal surfaces of
the oil lines and the external reservoir with solvent. Repeat
7. Engine Liquids and Cleaning Solvent
until the solvent drains cleanly. Flush the solvent through the
7.1 Test Oil—Approximately 150 L of test oil is required to
oil pumps until the solvent drains cleanly, then air dry.
complete the test.
8.1.6 High Pressure Turbocharger—Carefully remove the
turbinehousingfromtheturbochargerandcleanthewaste-gate
7.2 Test Fuel—Approximately 45 000 L of Chevron Philips
valve with solvent and a soft wire brush.
PC-10 ultra low sulfur diesel fuel is required to complete the
8.1.7 Cam Follower Assembly—Take the cam follower as-
test. Fuel property tolerances are shown in Annex A6.
sembly apart and inspect the bushings and pins. Replace the
7.3 Engine Coolant—Prepare the engine coolant by mixing
parts as necessary.
50 % volume of mineral-free water with 50 % volume of
Caterpillar brand coolant concentrate (As an option, pre-mixed 8.2 Engine Assembly:
8.2.1 General—Except as noted in this section, use the
coolant is available and may be used directly).
7.3.1 Table 2 shows Caterpillar part numbers for several procedures described in the Caterpillar Service Manual Form
SEN R 9700 (Annex A7). Assemble the engine with the
sized containers of concentrate or premixed coolant.
7.3.2 The mineral-free water shall have a mineral content components shown in the Engine Build Parts List (AnnexA3).
8.2.2 Parts Reuse and Replacement—Reuse engine
not exceeding 34.4 mg/kg of total dissolved solids.
7.3.3 Thecoolantmixturemaybeusedfor6teststartsorup components, except as noted in 8.2.7, and provided that they
meet production tolerances as described in the Caterpillar
to 3400 h. The mixture shall remain at a 50/50 ratio during the
course of the test. Verify by using either Caterpillar testers Service Manual.
8.2.3 Build-up Oils—For the head, main caps, and rod bolts,
5P3514 or 5P0957 or an equivalent tester. Keep the coolant
mixture free from contamination. use Exxon Mobil 600N engine oil as the build-up oil. For the
rest of the engine build, use Mobil EF-411 engine oil or test
7.3.4 Keep the total solids below 5000 mg/kg.
oil to lubricate the parts. If test oil is used, the engine build is
7.3.5 Maintain a correct additive level. Verify by checking
valid only for the respective test oil.
the coolant using Caterpillar test kit P/N 8T5296.
8.2.4 Coolant Thermostat—Lock the engine coolant ther-
7.4 Cleaning Solvent—Use a solvent that meets ASTM
mostat open.
D235, Type II, Class C requirements for aromatic content
8.2.5 Fuel Injectors—Use P/N 239-4908 fuel injectors. If
(0-2 %vol),flashpoint(61°C,min),color(notdarkerthat+25
fuel injectors are reused, exercise caution to avoid mechanical
Saybolt or 25 Pt-Co). Obtain a certificate of analysis for each
damage to or contamination of the nozzles. Dedicate the
batch of solvent from the supplier. (Warning—Combustible.
injectors to a particular cylinder. Install the injectors according
Health Hazard. Use adequate safety precautions.)
to the method described in Caterpillar Service Manual Form
SENR9700 (Annex A7). Use Mobil EF-411 engine oil as the
8. Preparation of Apparatus
build-up oil for the injector o-rings.
8.1 Cleaning of Parts:
8.2.6 Piston Cooling Tubes—Target the piston cooling
8.1.1 General—Preparation of test engine components spe-
tubes. Contact TMC for directions.
cific to the Caterpillar C13 test are indicated in this section.
8.2.7 New Parts—The following new parts are included in
UsetheCaterpillarServiceManualFormSENR9700 (Annex
the Engine Build Parts List. They are not reusable, except as
A7) for the preparation of other components. Take precautions
noted in 10.3.3. Clean the parts prior to use. During a test, a
to protect rusting of iron components. Use of an engine parts
replacementofanyofthenewpartslistedbelowwillinvalidate
washer followed by a solvent wash is permitted.
the test.
8.2.7.1 Pistons.
The sole source of supply of the apparatus known to the committee at this time
is Chevron Phillips Chemical Company LP, 10001 Six Pines Drive, Suite 4036B,
TheWoodlands,TX 77387-4910, www.cpchem.com. If you are aware of alternative Thesolesourceofsupplyoftheapparatusknowntothecommitteeatthistime
suppliers, please provide this information to ASTM International Headquarters. is ExxonMobil Corporation, 3225 Gallows Road, Fairfax, VA 22037, www.exxon-
Your comments will receive careful consideration at a meeting of the responsible mobil.com.Ifyouareawareofalternativesuppliers,pleaseprovidethisinformation
technical committee, which you may attend. to ASTM International Headquarters. Your comments will receive careful consid-
9 1
Available from a Caterpillar parts distributor. eration at a meeting of the responsible technical committee, which you may attend.
D7549 − 09
8.2.7.2 Piston rings (top, second and oil). 8.3.3.8 Exhaust Temperature—Install the sensor in the ex-
8.2.7.3 Cylinder liners. haust tube (Fig. A4.7).
8.2.7.4 Valves (intake, exhaust). 8.3.3.9 Additional Temperatures—It is permissible to mea-
8.2.7.5 Valve guides. sure any additional temperatures that may be useful for test
8.2.7.6 Valve seats. operation or engine diagnostics.
8.2.7.7 Connecting rod bearings, main bearings and thrust
NOTE 2—Additional exhaust sensor locations, at the exhaust ports and
plate.
pre-turbine (front and rear), are recommended. The detection of changes
in exhaust temperatures is an important diagnostic feature.
8.3 Operational Measurements:
8.3.1 Units and Formats—See Annex A8. 8.3.4 Pressure Measurement Locations:
8.3.2 Instrumentation Calibration:
8.3.4.1 General—The measurement equipment is not speci-
8.3.2.1 Fuel Consumption Rate Measurement—Calibrate fied. Follow the guidelines in ASTM Research Report
the fuel consumption rate measurement system before each
RR:D02-1218 for the accuracy and resolution of the pressure
referenceoiltestsequenceandwithinsixmonthsaftercomple- measurementsensorsandthecompletemeasurementsystem.If
tion of the last successful calibration test. Temperature-
the laboratory has problems with condensation forming in the
compensate volumetric systems, and calibrate them against a pressure lines, install a condensation trap at the lowest eleva-
standard mass flow device. The flowmeter on the test stand
tion of the tubing between the pressure measurement location
shall agree within 0.2 % of the calibration standard, that and the final pressure sensor for crankcase pressure, intake air
standard itself being calibrated against a national standard.
pressure, and exhaust pressure. Route the tubing to avoid
8.3.2.2 Temperature Measurement Calibration—Calibrate intermediate loops or low spots before and after the conden-
thetemperaturemeasurementsystemsbeforeeachreferenceoil
sation trap.
testsequenceandwithinsixmonthsaftercompletionofthelast
8.3.4.2 Oil Gallery Pressure—Measure the pressure at the
successful calibration test. Each temperature measurement
⁄4 in. NPT fitting on the right rear of the engine (Fig. A4.14).
systemshallagreewithin 60.5°Cofthelaboratorycalibration
8.3.4.3 Oil Filter Inlet Pressure—Measure the pressure at
standard, that standard itself being calibrated against a national
the plug located on the inlet side of the oil filter assembly (Fig.
standard.
A4.8).
8.3.2.3 Pressure Measurement Calibration—Calibrate the
8.3.4.4 Inlet Manifold Pressure—Measure the pressure at
pressure measurement systems before each reference oil test
the ⁄4 in. NPT port on the outside radius of the inlet manifold
sequence and within six months after completion of the last
elbow (Fig. A4.16).
successful calibration test. Confirm the calibration standard
8.3.4.5 Crankcase Pressure—Measure the pressure by in-
against a national standard.
stalling a bulkhead fitting in the valve cover, top-front (Fig.
8.3.3 Temperature Measurement Locations:
A4.11).
8.3.3.1 General—See Table A14.1. The measurement
8.3.4.6 Intake Air Pressure—Measure the pressure at a wall
equipment is not specified. Install the sensors such that the tip
tap on the intake air tube 153 mm upstream of the compressor
is located midstream of the flow unless otherwise indicated.
connection (Fig. A4.6).
The accuracy and measurement of the temperature measure-
8.3.4.7 Exhaust Pressure—Measure the pressure on the
ment sensors and the complete measurement system shall
exhaust tube (Fig. A4.7).
follow the guidelines in ASTM Research Report RR:D02-
8.3.4.8 Fuel Pressure—Measure the pressure at the fuel
1218.
filter head (Fig. A4.25).
8.3.3.2 Coolant Out Temperature—Install the sensor in the
8.3.4.9 Coolant Pressure—Measure the pressure on top of
fitting on the thermostat housing (Fig. A4.12).
the expansion tank (Fig. X1.3).
8.3.3.3 Coolant In Temperature—Install the sensor on the
8.3.4.10 Intercooler Delta Pressure—Measure the pressure
right side of the coolant pump intake housing at the 1-in. NPT
drop across the intercooler. Measure the intercooler inlet
port (Fig. A4.13).
pressure at the elbow outlet of the CAT charge air cooler (Fig.
8.3.3.4 Fuel In Temperature—Install the sensor in the fuel
A4.19). Use the intake manifold pressure (8.3.4.4)asthe
pump inlet fitting (Fig. A4.15).
intercooler outlet pressure.The intercooler delta pressure is the
8.3.3.5 Oil Gallery Temperature—Installthesensoratthe ⁄4
difference between the intercooler outlet pressure and the
in. NPT female boss on the right rear of the engine (Fig.
intercooler inlet pressure.
A4.14).
8.3.4.11 Additional Pressures—It is permissible to measure
8.3.3.6 Intake Air Temperature—Install the sensor in the
anyadditionalpressuresthatmaybeusefulfortestoperationor
inlet air tube 127 mm upstream of the compressor connection
engine diagnostics.
(Fig. A4.6).
8.3.3.7 Intake Manifold Temperature—Install the sensor at NOTE 3—See Fig. A4.19 and Fig. A4.20 for additional instrument
1 placement information.
the ⁄8 in. NPT female boss on the outside radius of the inlet
manifold elbow (Fig. A4.16).
8.3.5 Flow Rate Measurement Locations:
8.3.5.1 General—The equipment for the blowby rate and
fuel rate measurements is not specified. Follow the guidelines
in ASTM Research Report RR:D02-1218 for the accuracy
Supporting data have been filed atASTM International Headquarters and may
be obtained by requesting Research Report RR:D02-1218. and resolution of the flow rate measurement system.
D7549 − 09
8.3.5.2 Blowby—The device used to measure the blowby 9.6 Reference Oil Test Acceptance—Determine reference oil
flow rate is not specified. See 6.2.10 for blowby measurement test acceptance in accordance with the LTMS.
system configuration details.
9.7 Reference Oil Accountability:
8.3.5.3 Fuel Flow—Determine the fuel consumption rate by
9.7.1 Keep full accounts of the identification and quantities
measuring the fuel flowing to the day tank (Fig. X1.2).
ofallreferenceoilsused.Withtheexceptionoftheoilanalyses
8.3.5.4 Coolant Flow—Coolant flow rate measurement is
required in 11.3, perform no chemical or physical analyses on
not a test requirement, but may be useful for diagnostic
reference oils without written permission from the TMC. In
purposes. The design and use of a coolant flow measuring
such an event, include the written confirmation and the
system is optional.
analytical results generated in the reference oil test report.
8.3.6 Humidity Measurement—Measure intake air humidity
9.7.2 Retainusedreferenceoilsamplesfor90daysfromthe
anywhereintheairintakesystembetweenairconditioningand
EOT date.
the turbo inlet.
9.8 Non-Reference Oil Tests: Last Start Date—When run-
9. Engine/Stand Calibration and Non-Reference Oil Tests
ning a non-reference oil test during the calibration period;
9.1 General—Calibrate the test stand by conducting a test cranktheenginepriortotheexpirationofthecalibrationperiod
with a blind reference oil. Submit the results to the TMC for
(9.3).
determination of acceptance according to the Lubricant Test
9.9 Donated Reference Oil Test Programs—The surveil-
Monitoring System (LTMS).
lance panel is charged with maintaining effective reference oil
9.2 New Test Stand—A new test stand is one that has never
test severity and precision monitoring. During times of new
been calibrated or has not completed an acceptable reference
parts introductions, new or re-blended reference oil additions,
oil test within 24 months of the end of test (EOT) date of the
and procedural revisions, it may be necessary to evaluate the
last acceptable reference oil test. Perform a calibration (9.2.1)
possible effects on severity and precision levels. The surveil-
to introduce a new test stand.
lance panel may choose to conduct a program of donated
9.2.1 New Test Stand Calibration—Calibrate the new test
reference oil tests in those laboratories participating in the
stand in accordance with the LTMS.
monitoring system to quantify the effect of a particular change
on severity and precision. Typically the surveillance panel
9.3 Stand Calibration Period—The calibration period is 12
operationally valid (Annex A11) non-reference oil tests or 12 requests its panel members to volunteer enough reference oil
test results to create a robust data set. Broad laboratory
months, whichever comes first, from the EOT date of the last
acceptable reference oil test. participation is needed to provide a representative sampling of
theindustry.Toensurethequalityofthedataobtained,donated
9.4 Stand Modification and Calibration Status—Stand cali-
tests are conducted on calibrated test stands. The surveillance
bration status will be invalidated by conducting any non-
panel shall arrange an appropriate number of donated tests and
standard test or modification of the test and control systems, or
ensure completion of the test program in a timely manner.
both. A non-standard test is any test conducted under a
modified procedure, non-procedural hardware, controller set- 9.10 Adjustment to Reference Oil Calibration Periods:
point modifications, or any combination thereof. If changes are
9.10.1 Procedural Deviations—On occasions when a labo-
contemplated, contact the TMC beforehand to ascertain the
ratory becomes aware of a significant deviation from the test
effect on the calibration status.
method, such as might arise during an in-house review or a
TMC inspection, the laboratory and theTMC shall agree on an
9.5 Test Numbering System:
appropriate course of action to remedy the deviation. This
9.5.1 General—The test number has two parts, X and Y. X
action may include the shortening of existing reference oil
represents the test stand number and Y represents the sequen-
calibration periods.
tial test stand run number. For example 27-15 indicates test
9.10.2 Parts and Fuel Shortages—Under special
stand number 27 and test stand run number 15. The test stand
circumstances, such as industry-wide parts or fuel shortages,
run number, Y will increase sequentially by one for each test
the surveillance panel may direct the TMC to extend the time
start (reference oil or non-reference oil). A letter suffix may
intervalsbetweenreferenceoiltests.Theseextensionsshallnot
also be necessary (see 9.5.2).
exceed one regular calibration period.
9.5.2 Reference Oil Tests—A reference oil test conducted
9.10.3 Reference Oil Test Data Flow—To ensure continuous
subsequent to an unacceptable reference oil test shall include a
letter suffix after Y. The letter suffix shall begin with A and severity and precision monitoring, calibration tests are con-
ducted periodically throughout the year. There may be occa-
incremented alphabetically until acceptable reference oil test is
completed. For example, if two consecutive unacceptable sions when laboratories conduct a large portion of calibration
tests in a short period of time. This could result in an
reference oil tests were conducted and the first number was
27-15, the second test number would be 27-16A. A third unacceptably large time frame when very few calibration tests
are conducted. The TMC can shorten or extend calibration
calibration attempt would have the test number 27-17B. If the
third test were acceptable, then 27-17B would identify the periods as needed to provide a consistent flow of reference oil
test data.Adjustments to calibration periods are made such that
reference oil test in the test report.
9.5.3 Non-Reference Oil Tests—No letter suffix shall be laboratories incur no net loss (or gain) in calibration status.
added to Y for aborted or operationally invalid non-reference 9.10.4 Special Use of the Reference Oil Calibration
oil tests. System—The surveillance panel has the option to use the
D7549 − 09
TABLE 3 Break-in Conditions
Stage
Parameter Unit
Stage Length min 5 5 10 20 20
Speed rpm 1100 1200 1600 1800 1800 ± 5
Fuel Flow g/min Record Record Record Record 1200 ± 6
Torque N·m 0 480 1000 1160 Record
A
Coolant Out Temperature °C 88 88 88 88 88 ± 2
A
Oil Gallery Temperature °C Record Record Record Record 98 ± 2
A
Intake Manifold Temperature °C 40 40 40 40 40 ± 2
A
This is the control set-point. It can require up to 30 min of operation to achieve.
reference oil system to evaluate changes that have potential sensor components as specified in Caterpillar Service Manual
impact on test severity and precision. This option is only taken Form SEN R 9700 (Annex A7). If the coolant temperature is
when a program of donated tests is not feasible. The surveil- less than 18 °C, the engine will operate under cold mode
lance panel and the TMC shall develop a detailed plan for the therebypreventingthetimingcalibrationprocedurefrombeing
test program. This plan requires all reference oil tests in the performed. When this happens, start the engine and allow it to
program to be completed as close to the same time as possible, idle until the speed drops from 1000 rpm to 600 rpm, signaling
so that no laboratory or stand calibration is left in an exces- that the coolant temperature has exceeded 18 °C. After the
sively long pending status. In order to obtain the integrity of timing calibration is completed, continue break-in conditions
the reference oil monitoring system each reference oil test is as shown in Table 3. Turn on the external oil weigh system
conducted so as to be interpretable for stand calibration. To pumps at the beginning of stage 2.
facilitate the required test scheduling, the surveillance panel
10.5.1 Shutdown During Break-in—If a shutdown occurs
may direct the TMC to lengthen and shorten reference oil
during the break-in, resume the break-in from the point at
calibration periods within laboratories such that the laborato-
which the shutdown occurred. Such an occurrence is described
ries incur no net loss (or gain) in calibration status.
in Other Comments on the appropriate form.
NOTE 4—Use the break-in as an opportunity to confirm engine
10. Procedure
performance and to make repairs prior to the start of the 500-h test
10.1 Engine Installation and Stand Connections—Installthe procedure.
test engine on the stand and connect the engine to the stand
10.5.2 Valve Lash Adjustment—At the completion of the
support equipment.
60-min break-in, shut the engine down, using the normal
10.2 Coolant System Fill—Fill the cooling system with shutdown procedure as shown in 10.7.1. Allow the engine to
pre-diluted Caterpillar Extended Life Coolant (see 7.3 for part cool for a minimum of 4 h and then perform the valve lash
numbers and available container sizes). The coolant for non- adjustment as described in Caterpillar Service Manual Form
reference oil tests may be reused provided the level of SEN R 9700 (Annex A7) At the same time, do the inlet valve
inhibitors is within specification requirements. Use new cool- actuator valve adjustment.
ant for each reference oil test. Pressurize the cooling system as
10.6 Warm-up—Start the engine, perform the warm-up
required by the specification and check for leaks prior to
(Table 4), and proceed directly to the test conditions (Table 5).
adding the test oil.
At the engine start, the oil gallery temperature shall be at least
10.3 Oil Fill for Break-in and Test:
15 °C. The start-up oil gallery pressure shall be at least 350
10.3.1 Install a new Caterpillar 1R-0716 oil filter.
kPa.
10.3.2 Use the pressurized oil fill system (6.2.7) to charge
10.7 Shutdown and Maintenance—The test may be shut
the engine with 32.8 6 0.2 kg of test oil at the location shown
down at the discretion of the laboratory to perform repairs.
in Fig. A4.8.
However, the intent of this test method is to conduct the 500-h
10.3.3 Engine Build Committed—After the test oil has been
test procedure without shutdowns.
introduced into the engine, the engine build and test number
10.7.1 Normal Shutdown—A normal shutdown is accom-
arevalidonlyfortherespectivetest.However,iftheenginehas
plishedbyrampingin30sfromtestconditionstostage2ofthe
not been cranked (whereby the test parts have not been
warm-up conditions (Table 4), running for 5 min at stage 2,
subjected to wear or injected fuel, or both), then the new parts
ramping in 30 s to stage 1, running for 5 min at stage 1, and
may be used again. Disassemble and clean the engine accord-
then stopping the engine.
ing to 8.1.
10.7.2 Emergency Shutdown—An emergency shutdown oc-
10.4 Fuel Samples—Take a minimum 60 mL fuel sample at
curs when the normal shutdown cannot be performed, such as
the start of the test and at EOT.
under an alarm condition. Such an occurrence is described in
Other Comments of the appropriate form.
10.5 Engine Warm-up and Break-in—Prior to firing the
engine, ensure that the oil temperature is at least 15 °C.The oil 10.7.3 Maintenance—Engine components or stand support
gallery startup pressure shall be at least 350 kPa. Perform a equipment, or both may be repaired or replaced at the discre-
timing calibration for the engine control software and timing tion of the laboratory, and in accordance with this test method.
D7549 − 09
TABLE 4 Warm-up Conditions
Stage
Parameter Unit
Stage Length min 2.5 2.5 5 10 10
Speed rpm 1100 1200 1600 1800 1800
Fuel Flow g/min Record Record Record Record 1200
Torque N·m 0 480 1000 1160 Record
A
Coolant Out Temperature °C 88 88 88 88 88
A
Oil Gallery Temperature °C Record Record Record Record 98 ± 2
A
Intake Manifold Temperature °C 40 40 40 40 40
A
This is the control set-point. It can require up to 30 min of operation to achieve.
TABLE 5 500-h Test, Schedule of Conditions
shall resume when the test has been returned to the test
Parameter Unit Requirement operation schedule and all controlled parameters are within
Test Length
...