ASTM D6618-23

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: D6618 − 23
Standard Test Method for
Evaluation of Engine Oils in Diesel Four-Stroke Cycle
Supercharged 1M-PC Single Cylinder Oil Test Engine
This standard is issued under the fixed designation D6618; 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
This test method can be used by any properly equipped laboratory, without outside assistance.
However, the ASTM Test Monitoring Center (TMC) provides reference oils and an assessment of the
test results obtained on those oils by the laboratory. By this means, the laboratory will know whether
their use of the test method gives results statistically similar to those obtained by other laboratories.
Furthermore, various agencies require that a laboratory utilize the TMC services in seeking
qualification of oils against specifications. For example, the U.S. Army imposes such a requirement,
in connection with several Army engine lubricating oil specifications.
Accordingly, this test method is written for use by laboratories that utilize the TMC services.
Laboratories that choose not to use those services may simply ignore those portions of the test method
that refer to the TMC.
This test method may be modified by means of Information Letters issued by the TMC. In addition,
the TMC may issue supplementary memoranda related to the test method.
1. Scope* 1.2.1 Exception—The values in parentheses are provided for
information only.
1.1 This test method covers a four-stroke cycle diesel
engine test procedure for evaluating engine oils for certain
1.3 This standard does not purport to address all of the
high-temperature performance characteristics, particularly ring
safety concerns, if any, associated with its use. It is the
sticking, ring and cylinder wear, and accumulation of piston
responsibility of the user of this standard to establish appro-
deposits. Such oils include both single viscosity SAE grade and
priate safety, health, and environmental practices and deter-
multiviscosity SAE grade oils used in diesel engines. It is
mine the applicability of regulatory limitations prior to use.
commonly known as the 1M-PC test (PC for Pre-Chamber) and
1.4 This test method is arranged as follows:
is used in several API oil categories, notably the CF and CF-2
TABLE OF CONTENTS
and the military category described in MIL-PRF-2104 (see
Scope 1
Note 1). Reference Documents 2
Terminology 3
NOTE 1—Companion test methods used to evaluate other engine oil Summary of Test Method 4
performance characteristics for API oil categories CF and CF-2 are Significance and Use 5
Apparatus 6
discussed in SAE J304. The companion tests used by the military can be
Test Engine 6.1
found in MIL-PRF-2104.
Engine Accessories 6.2 – 6.14
1.2 The values stated in SI units are to be regarded as
Engine Oil System 6.15
Cooling System 6.16
standard.
Fuel System 6.17
Intake Air System 6.18
Exhaust System 6.19
This test method is under the jurisdiction of ASTM Committee D02 on
Blowby Meter 6.20
Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of
Thermocouples 6.21
Subcommittee D02.B0.02 on Heavy Duty Engine Oils. The test engine sequences
Parts 6.22
were originally developed in 1956 by ASTM Committee D02. Subsequently, the Instrumentation 6.23
procedures were published in an ASTM Special Technical Publication. Crankcase Paint 6.24
Reagents and Materials 7
Current edition approved July 1, 2023. Published July 2023. Originally approved
Fuel 7.1
in 2000. Last previous edition approved in 2016 as D6618 – 16. DOI: 10.1520/
Test Oil 7.2
D6618-23.
Engine Coolant 7.3
ASTM Test Monitoring Center, 203 Armstrong Drive Freeport, PA 16229. The
Cleaning Materials 7.4
TMC issues Information Letters that supplement this test method. This edition
Safety 8
incorporates revisions contained in all information letters through No. 23–1.
*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
D6618 − 23
2. Referenced Documents
Preparation of Apparatus 9
Supplementary Service Information 9.1
2.1 ASTM Standards:
General Engine Inspection 9.2
Intake Air System 9.3 D86 Test Method for Distillation of Petroleum Products and
Cooling System 9.4
Liquid Fuels at Atmospheric Pressure
Engine Cooling System Cleaning 9.5
D93 Test Methods for Flash Point by Pensky-Martens
Instrumentation Calibration Requirements 9.6
Engine Crankcase Cleaning 9.7
Closed Cup Tester
Additional Oil Filter 9.8
D97 Test Method for Pour Point of Petroleum Products
Flushing Procedure Components 9.9
D130 Test Method for Corrosiveness to Copper from Petro-
Flushing Procedures 9.10
Piston Cleaning Preparation 9.11 leum Products by Copper Strip Test
Cylinder Head 9.12
D235 Specification for Mineral Spirits (Petroleum Spirits)
Fuel Nozzle 9.13
(Hydrocarbon Dry Cleaning Solvent)
Measurement 9.14
Procedure 10
D445 Test Method for Kinematic Viscosity of Transparent
Engine Break-in 10.1
and Opaque Liquids (and Calculation of Dynamic Viscos-
Pre-Test Preparations 10.2
ity)
Warm-up Procedure 10.3
Operating Conditions 10.4
D482 Test Method for Ash from Petroleum Products
Periodic Measurements 10.5
D524 Test Method for Ramsbottom Carbon Residue of
Engine Oil Level 10.6
Petroleum Products
Oil Addition Procedure 10.7
Cool-Down Procedure 10.8
D613 Test Method for Cetane Number of Diesel Fuel Oil
Shutdowns 10.9
D664 Test Method for Acid Number of Petroleum Products
Fuel System 10.10
by Potentiometric Titration
Brake Specific Oil Consumption (BSOC) Calculation 10.11
Inspection 11
D1319 Test Method for Hydrocarbon Types in Liquid Petro-
Preparation 11.1
leum Products by Fluorescent Indicator Adsorption
Inspection 11.2
D1796 Test Method for Water and Sediment in Fuel Oils by
Rater Training 11.3
Referee Ratings 11.4
the Centrifuge Method (Laboratory Procedure)
Calibration of Test Method 12
D2422 Classification of Industrial Fluid Lubricants by Vis-
Requirements 12.1
cosity System
Reference Oils 12.2
Test Numbering 12.3
D2425 Test Method for Hydrocarbon Types in Middle Dis-
Definition of a Test 12.4
tillates by Mass Spectrometry
New Laboratories and New Test Stands 12.5
D2500 Test Method for Cloud Point of Petroleum Products
Frequency of Calibration Tests 12.6
Specified Test Parameters 12.10
and Liquid Fuels
Acceptance of Calibration Tests 12.11
D2622 Test Method for Sulfur in Petroleum Products by
Failing Reference Oil Calibration Tests 12.12
Wavelength Dispersive X-ray Fluorescence Spectrometry
Non-Standard Tests 12.13
Severity Adjustments and Control Charting 12.14
D4052 Test Method for Density, Relative Density, and API
Test Reporting 12.15
Gravity of Liquids by Digital Density Meter
Reporting Reference Results 12.16
D4175 Terminology Relating to Petroleum Products, Liquid
Analysis of Reference Oils 12.17
Precision and Bias 13
Fuels, and Lubricants
Precision 13.1
D4294 Test Method for Sulfur in Petroleum and Petroleum
Bias 13.2
Keywords 14 Products by Energy Dispersive X-ray Fluorescence Spec-
trometry
ANNEXES
D4485 Specification for Performance of Active API Service
Category Engine Oils
Figures and Schematics Annex A1
Report Forms Annex A2
D4863 Test Method for Determination of Lubricity of Two-
Test Fuel Information Annex A3
Stroke-Cycle Gasoline Engine Lubricants (Withdrawn
APPENDIXES 2022)
D5302 Test Method for Evaluation of Automotive Engine
Humidity Correction Factors Appendix X1
Oils for Inhibition of Deposit Formation and Wear in a
Report Form Examples Appendix X2
1M-PC Multiple Testing Appendix X3 Spark-Ignition Internal Combustion Engine Fueled with
1.5 This international standard was developed in accor-
dance with internationally recognized principles on standard-
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
ization established in the Decision on Principles for the contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
Development of International Standards, Guides and Recom-
the ASTM website.
mendations issued by the World Trade Organization Technical 4
The last approved version of this historical standard is referenced on
Barriers to Trade (TBT) Committee. www.astm.org.
D6618 − 23
Gasoline and Operated Under Low-Temperature, Light- 3.1.7.1 Discussion—Reference oils are used to calibrate
Duty Conditions (Withdrawn 2003) testing facilities, to compare the performance of other oils, or
D5844 Test Method for Evaluation of Automotive Engine to evaluate other materials (such as seals) that interact with
Oils for Inhibition of Rusting (Sequence IID) (Withdrawn oils.
2003)
3.1.8 scuff, scuffıng, n—in lubrication, damage caused by
D5862 Test Method for Evaluation of Engine Oils in Two-
instantaneous localized welding between surfaces in relative
Stroke Cycle Turbo-Supercharged 6V92TA Diesel Engine
motion which does not result in immobilization of the parts.
(Withdrawn 2009)
D4863
D6202 Test Method for Automotive Engine Oils on the Fuel
3.1.9 wear, n—the loss of material from, or relocation of
Economy of Passenger Cars and Light-Duty Trucks in the
material on, a surface. D5302
Sequence VIA Spark Ignition Engine (Withdrawn 2009)
3.1.9.1 Discussion—Wear generally occurs between two
2.2 SAE Standard:
surfaces moving relative to each other and is the result of
SAE J304 Engine Oil Tests
mechanical or chemical action or by a combination of me-
chanical and chemical actions.
2.3 Military Standard:
MIL-PRF-2104 Lubricating Oil, Internal Combustion
3.2 Definitions of Terms Specific to This Standard:
Engine, Combat/Tactical Service
3.2.1 calibration test, n—an engine test conducted on a
2.4 Other ASTM Document:
reference oil under carefully prescribed conditions whose
ASTM Deposit Rating Manual 20 (formerly CRC Manual result is used to determine the suitability of the engine
20)
stand/laboratory to conduct such tests on non-reference oils.
3.2.1.1 Discussion—In this test method, it can also refer to
3. Terminology
tests conducted on parts to ensure their suitability for use in
reference or non-reference tests.
3.1 Definitions:
3.1.1 calibrate, v—to determine the indication or output of a 3.2.2 test, n—any test time accumulated in accordance with
this test method.
measuring device with respect to that of a standard. D4175
3.1.2 candidate oil, n—an oil that is intended to have the
4. Summary of Test Method
performance characteristics necessary to satisfy a specification
4.1 Prior to each test run, the power section of the engine
and is tested against that specification. D5844
(excluding piston assembly) is completely disassembled,
3.1.3 clogging, n—the restriction of a flow path due to the
solvent-cleaned, measured, and rebuilt in strict accordance
accumulation of material along the flow path boundaries.
with furnished specifications. A new piston, piston ring
D5844
assembly, and cylinder liner are installed each test. The engine
3.1.4 engine oil, n—a liquid that reduces friction or wear, or
crankcase is solvent-cleaned, and worn or defective parts are
both, between the moving parts within an engine; removes
replaced. The test stand is equipped with appropriate accesso-
heat, particularly from the underside of pistons; and serves as
ries for controlling speed, fuel rate, and various engine
a combustion gas sealant for the piston rings. D5862
operating conditions. A suitable system for supercharging the
3.1.4.1 Discussion—It may contain additives to enhance
engine with humidified and heated air shall also be provided.
certain properties. Inhibition of engine rusting, deposit
4.2 Test operation involves the control of the supercharged,
formation, valve train wear, oil oxidation, and foaming are
single-cylinder diesel test engine for a total of 120 h at a fixed
examples.
speed and fuel rate, using the test oil as a lubricant. A 1 h
3.1.5 non-reference oil, n—any oil other than a reference
engine break-in precedes each test. At the conclusion of the
oil: such as a research formulation, commercial oil, or candi-
test, the piston, rings, and cylinder liner are examined. Note the
date oil. D5844
degree of cylinder liner and piston ring wear, the amount and
3.1.6 purchaser, n—of an ASTM test, a person or organiza- nature of piston deposits present, and whether any rings are
tion that pays for the conduct of an ASTM test method on a stuck.
specified product. D6202
5. Significance and Use
3.1.6.1 Discussion—The preferred term is purchaser. Dep-
recated terms that have been used are client, requester, 5.1 The test method is designed to relate to high-speed,
sponsor, and customer.
supercharged diesel engine operation and, in particular, to the
deposit control characteristics and antiwear properties of diesel
3.1.7 reference oil, n—an oil of known performance
crankcase lubricating oils.
characteristics, used as a basis for comparison D5844
5.2 The test method is useful for the evaluation of diesel
engine oil quality and crankcase oil specification acceptance.
This test method, along with others, defines the minimum
Available from SAE International (SAE), 400 Commonwealth Dr., Warrendale,
PA 15096, http://www.sae.org.
performance level of the API categories CF and CF-2 (detailed
Available from Standardization Documents Order Desk, Building 4, Section D,
information about passing limits for these categories is in-
700 Robbins Avenue, Philadelphia, PA 19111-5904, Attn: NPODS.
cluded in Specification D4485). It is also used in MIL-PRF-
For Stock #TMCMNL20, visit the ASTM website, www.astm.org, or contact
ASTM International Customer Service at service@astm.org. 2104.
D6618 − 23
5.3 The results are significant only when all details of the 6.11.1.4 Only piston cooling jets that have been flow-
procedure are followed. The basic engine used in this test checked by the specified industry standard are approved for
method has a precombustion chamber (as compared to direct use. See footnote 11 for supplier. Fig. A1.2 shows the sug-
injection) and is most useful in predicting performance of gested modification of the 1Y8199 oil pan and necessary
engines similarly equipped. This factor should be considered hardware for the cooling nozzle pressure pickup. All test
when extrapolating test results. It has been found useful in engines with serial numbers greater than 2511252 will be
predicting results with high sulfur fuels (that is, greater than provided with the pressure pickup modification.
0.5 % by mass) and with certain preemission controlled en- 6.11.2 Piston Cooling Jet Supplier—To improve precision,
gines. It has also been found useful when correlated with
Perkin Elmer Automotive Research and Southwest Research
deposit control in two-stroke cycle diesel engines. Institute (SWRI) have agreed to provide flow-checked 1M-PC
P-tubes to the industry. Perkin Elmer Automotive Research
6. Apparatus will flow and serialize the units and determine if they are
within specification and will maintain records, while SWRI
6.1 Test Engine—A single-cylinder Caterpillar diesel oil test
will coordinate the redistribution. Send P-tubes to be inspected
engine having a 2.2 L (134.1 in. ) displacement is required.
to Perkin Elmer Automotive Research.
Bore and stroke are 13.0 cm (5.125 in.) and 16.5 cm (6.5 in.)
6.11.2.1 The P-tubes will be flowed, using EF-411 oil at
respectively. The engine arrangement is shown in Fig. A1.1.
37.8 °C 6 0.6 °C (100 °F 6 1 °F) and 165.5 kPa 6 0.5 kPa
The supply of test engines and parts is discussed in 6.22. The
(24 psi 6 0.5 psi) as measured at the location shown in Fig.
engine is equipped with the accessories or equipment listed in
A1.2. The acceptable flow range is 1.89 L ⁄min to 2.27 L ⁄min
6.2 through 6.24.
(0.50 gal ⁄min to 0.60 gal ⁄min).
6.2 Air Pressure—Use a supercharging blower or other
6.11.2.2 To maintain impartiality in selecting P-tubes, only
device arranged to control air pressure.
acceptable assemblies will be forwarded to SWRI as unmarked
6.3 Air Intake System—Use the 1Y38 surge chamber and the
units. These units will be randomly selected for redistribution.
air heater mechanism (see Annex A1) or its equivalent.
In cases in which the only units available are from a single
order, only those units will be returned. Assemblies that fall
6.4 Humidity—Use a system to control humidity to the
outside of the specifications will not be returned. Instead,
specified test conditions.
Perkin Elmer Automotive Research will generate a nonconfor-
6.5 Cooling System—Use a closed, pressurized, circulating
mance report with an additional copy to be sent to the
cooling system having an engine-driven centrifugal water
laboratory that supplied the P-tube. The failed units will be
pump.
returned to Caterpillar for credit. Perkin Elmer Automotive
6.6 Speed/Load Controls—Use a dynamometer or suitable
Research will indicate on the nonconformance report that the
loading device to control engine speed and measure load.
appropriate credit be issued to the originating laboratory.
Additional piston cooling assemblies will need to be supplied
6.7 Starting—Use a suitable starting arrangement capable of
by the requesting laboratory and submitted to Perkin Elmer
420 N·m (310 lbf·ft) breakaway and 373 N·m (275 lbf·ft) sus-
Automotive Research.
tained torque at approximately 200 r ⁄min.
6.11.2.3 Perkin Elmer Automotive Research will enclose a
6.8 Exhaust System—Use an exhaust system using piping
statement with each unit inspected, disclaiming any liability for
and an exhaust barrel as specified in Annex A1. A restriction
subsequent performance of the part. No attempt will be made
valve down stream of the barrel maintains the exhaust gases at
to ensure that the tubing is properly configured or that any
a given back pressure as specified in the test conditions.
other physical property makes it suitable for use. Units
6.9 Data Acquisition—Configure all stands to acquire data
damaged during shipment will not be tested, unless specifically
automatically for speed, fuel flow, intake air pressure, intake
requested. Include a packing list and separate purchase orders
air temperature, coolant temperature, oil-to-bearing
to Perkin Elmer Automotive Research and SWRI with each
temperature, and oil-to-jet pressure (as a minimum) with
shipment. Please specify a name and address where the parts
closed loop control on speed, intake air temperature, coolant
are to be returned.
temperature, and oil-to-bearing temperature (as a minimum).
6.12 Engine Oil Level Gauge—Lower the bayonet gauge
6.10 Cylinder Head and Cylinder Assemblies—Only cylin-
housing 5 cm (2.0 in.) to provide for more accurate oil level
der head and cylinder assemblies that have previously passed a
readings. Parts required for this modification are shown in Fig.
calibration test are acceptable for non-reference testing.
A1.3.
6.11 Piston Cooling Nozzle:
6.13 Crankcase Pressure Control Valve—Install a pressure
6.11.1 Oil Jet Pressure Measurement—The following is
control valve (1Y479) at the crankcase breather outlet to
required to allow for measurement of the piston cooling nozzle
stabilize crankcase pressure. Installation is shown in Fig. A1.4.
pressure:
6.11.1.1 Replace the 3B9407 fitting with a ⁄4 in. tee fitting,
and reconnect the 1Y6 oil line.
Send P-tubes to be inspected to Perkin Elmer Automotive Research, 5404
6.11.1.2 Modify the 1Y8199 oil pan to provide access for
Bandera Road, San Antonio, TX 78238.
the pressure pickup.
Southwest Research Institute, 6220 Culebra Road, P.O. Drawer 28510, San
6.11.1.3 Use oil pressure gauge 8M2743, or equivalent. Antonio, TX 78228-0510.
D6618 − 23
6.14 Oil Cooler Inlet Temperature—Record the temperature 1 cm (42.25 in. 6 0.5 in.). Also, an external fuel pump may be
of the oil cooler inlet by installing a thermocouple in the used in place of the engine-mounted fuel pump. Control the
pipe-tapped hole provided on the rear side of the oil-cooler
fuel rate with either manual or automated fuel rack manipula-
cover adjacent to the oil inlet port. Care should be taken to
tion.
provide sufficient thermocouple insertion depth to provide a
6.18 Intake Air System—Install a dry element oil and
mid-stream oil temperature.
particle filter between the air supply source and each engine to
6.15 Engine Oil System—Use the last chance screen
be run. Use an air filter capable of 10 μm (or smaller) filtration.
1Y3549. Modify the oil pump as shown in Fig. A1.10. Add the
(Oil bath filters are not acceptable in this location.) Make air
external oil pump bypass line for safety and convenience
filter replacements as required to minimize pressure losses and
factors to adjust oil pressure on engine break-in and warm-up.
with sufficient frequency to maintain the air heater barrel as
6.16 Cooling System—Replace the 7.6 cm (3 in.) standard
free as possible form oil and dust particles. The 1Y38 surge
cooling tower with the 12.7 cm (5 in.) pressurized cooling
chamber and air heater assembly required is shown in Annex
tower as shown in Fig. A1.6. Modify the cooling system to
A1.
accommodate the pressurized cooling tower, bypass flow
6.18.1 Suitable equipment is required to maintain the speci-
control and flow meter as shown in Fig. A1.7 and Fig. A1.8.
fied moisture content, temperature, and pressure of the inlet air
10,11
Use a Barco Venturi Meter #BR 12705-16-31. Use brass or
to the cylinder head. The accuracy of the humidification system
stainless steel pipe that has chamfered ends (45°) into and out
is to be within 60.648 g (610 grains) of the humidity-
of the venturi meter [15.2 cm (6 in.) minimum into and 5.1 cm
measuring, chilled-mirror dew point hydrometer (see 9.6.2).
(2 in.) minimum out]. Orient the high pressure tap (the first
seen by the flow) horizontally.
6.19 Exhaust System—Uniformity in exhaust system pres-
sure patterns within a laboratory and from laboratory-to-
6.17 Fuel System—Use a standardized engine fuel system to
laboratory is required to minimize a major test variable. The
ensure that fuel-line pressure transients are held to acceptable
dimensions and distance of the exhaust piping from the exhaust
values and to minimize cranking times. Use a Micro Motion
12,11
elbow to the barrel, as well as the volume of the exhaust barrel,
flow meter having a range no greater than 0 kg ⁄h to
are specified in Figs. A1.30-A1.34. Note the exhaust barrel
90.7 kg ⁄h (0 lb ⁄h to 200 lb ⁄h) to measure fuel flow rate.
may be insulated or water cooled. The downstream distance of
6.17.1 The line lengths, line sizes, and fuel system compo-
the restriction valve from the exhaust barrel is not specified.
nents are shown in Fig. A1.5. Use this system without
modification, with the possible exception that the fuel shut-off
6.19.1 Set the exhaust pressure at specified conditions as
13,11
solenoid is eliminated if the line length from the engine-
given in Table 1 by varying the restriction valve. Measure the
mounted filter to the injector pump is standardized at 107 cm 6
pressure in the exhaust barrel as shown in Fig. A1.31. The
location of the 1Y467 or equivalent exhaust thermocouple is
shown in Fig. A1.30.
Available from J. P. Bushnell, 3436 Lindell Blvd., St. Louis, MO.
11 6.20 Blowby Meter, a displacement type gas meter or
The sole source of supply of the apparatus known to the committee at this time
equivalent fitted with an oil separator and surge chamber. A
is noted in the adjoining footnote. If you are aware of alternative suppliers, please
provide this information to ASTM Headquarters. Your comments will receive
fitting on the crankcase breather (see Fig. A1.4) permits
careful consideration at a meeting of the responsible technical committee, which
attachment of the meter to the engine by using appropriate
you may attend.
lengths of hose or pipe, or both, suitable to the laboratory’s
Available from Micro Motion, Inc., 7070 Winchester Circle, Boulder, CO
80301.
needs.
Available from Asco, Florham Park, New Jersey 07932.
A,B
TABLE 1 1M-PC Operating Conditions
Speed, r/min 1800 ± 10
Fuel flow, kg/h (lb/h) 8.13 ± 0.07 (17.92 ± 0.15)
Temperature, water from cylinder head,° C (°F) 87.8 ± 2.8 (190 ± 5)
Flow rate, engine coolant, L/min (gal/min) 57.9 ± 3.8 (15.3 ± 1.0)
Temperature, oil to bearings, °C (°F) 96.1 ± 2.8 (205± 5)
Temperature, inlet air to engine, °C (°F) 123.9 ± 2.8 (255± 5)
Temperature, exhaust, °C (°F) 573 ± 28 (1063 ± 50)
Pressure, fuel to injection pump, kPa (psi) 137.9 ± 13.8 (20 ± 2)
Pressure, exhaust, kPa (in. Hg Abs.) 106.7 ± 1.7 (31.5 ± 0.05)
C
Pressure, oil at jet cooling nozzle, kPa (psi) 165.5 ± 13.8 (24± 2)
C
Pressure, oil to bearings maximum, kPa (psi) 220.6 (32)
Pressure, air to engine, kPa (in. Hg Abs.) 179.0 ± 1.0 (53 ± 0.3)
Vacuum, crankcase, kPa (in. H O) 0.25 ± 0.12 (1.0± 0.5)
Humidity, air to engine, g/kg of dry air (grains/lb) 17.8 ± 1.7 (125 ± 12)
3 3
Flow rate, engine air, approximate m /min (ft /min) at 15.6 °C (60 °F), 0.2 (94)
101.3 kPa Abs. (14.7 psi Abs.)
A
Count test time from the moment the conditions in this table are obtained (30 min maximum are allowed for stabilization).
B
Only speed and fuel flow are controlled. Load is used as a verification of engine build and operation.
C
Oil pressure operating specifications apply only to 15W-40 oils. Attempt to maintain these limits for all oils. When oils other than 15W-40 oils fall outside these limits,
explain these deviations from the limits in the comments section of the test report.
D6618 − 23
6.21 Thermocouples—Specified thermocouples (or equiva- 6.24 Crankcase Paint—Inspect crankcases regularly to en-
lents) are required for obtaining temperatures at the following sure proper paint coating. Coat crankcases as necessary, using
16,11
locations: air-to-engine (1Y468), exhaust temperature either of two approved coatings.
(1Y467), and water inlet, water outlet, oil-to-bearings (1Y466).
7. Reagents and Materials
6.21.1 Install thermocouples 1Y468, 1Y467, and 1Y466
only at the temperature-sensing locations provided with the
7.1 Fuel—The specified test fuel is Haltermann Products
17,11
1Y73 engine arrangement. Locate the immersion depth for
0.4 % Sulfur Diesel Test Fuel. All fuel shall meet the fuel
water inlet, water outlet, and oil-to-bearing temperature sensors
specifications as shown in Annex A3 and shall be referenced
so that the tip of the sensor is midstream of the fluid measured.
through the ASTM TMC. Approximately 1137 L (300 gal) are
Immersion depth for the air and exhaust temperature sensors
required for each test. Include the fuel analysis for the last
are measured as follows (variation from these dimensions is
batch used for the test in the final report. The fuel supplier
not permitted):
provides the analysis. If more than one batch is used, note this
6.21.1.1 Air temperature sensor depth: 27 mm 6 2 mm
is in the comments section of the Unscheduled Downtime &
1 1
(1 ⁄16 in. 6 ⁄16 in.)
Maintenance Summary form of the test report with the appro-
6.21.1.2 Exhaust temperature sensor depth: 65 mm 6 2 mm
priate percentages of run time.
9 1
(2 ⁄16 in. 6 ⁄16 in.)
7.2 Test Oil—Approximately 30 L to 34 L (8 gal to 9 gal) of
6.22 Parts:
test oil are required for each test.
6.22.1 Procurement of Parts—Information concerning pro-
7.3 Engine Coolant, a mixture of 118 mL (4 fluid oz) Part
curement of Caterpillar test engines and replacement parts and
18,11
Number 3P2044 coolant additive (Pencool 2000 ) per 4 L
approval of equivalent parts substitutions allowed in this test
(1 gal) of mineral-free water. Mineral-free water is defined as
14,11
method is obtained by contacting Caterpillar Inc. Other
having a mineral content no higher than 34.2 ppm (2 grains/
parts and their sources referred to throughout the procedure are
gal) total dissolved solids. A fresh coolant mixture is used for
found in the footnotes. Use all Caterpillar parts on a first-in-
each new test.
first-out basis.
7.4 Cleaning Materials:
6.22.2 All parts for the 1Y73 engine and the 1Y73 Conver-
7.4.1 Solvent—Use only mineral spirits meeting the require-
sion Kit that are nonconforming by reason of faulty manufac-
ments of Specification D235, Type II, Class C for Aromatic
ture should be discussed with the Engine System Technology
14,11
Content (0 % to 2 %) by vol, Flash Point (142 °F ⁄61 °C, min)
Department (ESTD) at Caterpillar Inc.
and Color (not darker than +25 on Saybolt Scale or 25 on Pt-Co
6.22.2.1 The test labs should contact ESTD when they
Scale). (Warning—Combustible. Health hazard.) Obtain a
believe a part is nonconforming:
Certificate of Analysis for each batch of solvent from the
6.22.2.2 ESTD will determine if they want the part returned,
supplier.
or provide warranty without viewing the part.
7.4.2 Dispersant Engine Cleaner—Use Dispersant Engine
6.22.2.3 If ESTD determines that the part is nonconforming
19,11
Cleaner (order by this name) in solution with mineral
without viewing the part, the test labs will be asked to return
spirits where called for in the engine flush procedure.
the part to their Caterpillar dealer. ESTD will contact the dealer
7.4.3 General Cleaning Agents—Use sodium bi-sulfate
with the information that the part is being returned and provide
(Na SO ) and tri-sodium phosphate (Na PO ) in solution with
warranty for it.
2 4 3 4
water in the cooling system flush procedure. (Warning—Eye
6.22.2.4 If ESTD wants to view the part, they will issue a
and throat irritants; repeated exposure can cause dermatitis.
Return Goods Authorization Number (RGA) to the test lab and
15,11
Wear protective gloves, face mask, or chemical type goggles.)
send the part and the form to Caterpillar Inc.
6.22.2.5 If ESTD determines that the part is nonconforming,
8. Safety
they will contact the dealer for the test lab and have the dealer
provide warranty. 8.1 The operating of engine tests can expose personnel and
6.22.2.6 A sample of the RGA Claim Form is shown in Fig. facilities to a number of safety hazards. It is recommended that
1. It should include return goods authorization number, part only personnel who are thoroughly trained and experienced in
name, hours on the part, part number, quantity, purchase order engine testing should undertake the design, installation and
number, date purchased, test lab that purchased the part, operation of engine test stands. Each laboratory conducting
contact person’s name, phone, fax, and address, dealer’s name engine tests should have its test installation inspected and
that sold the part, and measurements or photographs, or both,
to document the nonconformance.
Crankcase paint in one gallon cans as Yellow Primer Paint Cat Part #IE2083A,
6.23 Instrumentation, capable of meeting (or exceeding) the
Primer #A123590, Serial #BIM0115877, B.A.S.F. Part #U27TD005 is available
from B.A.S.F. Coating and Cocorant Division, P.O. Box 1297, Morganton, NC
calibration tolerances, measuring resolutions, and maximum
28655; and as Glyptal 1201 Red Enamel, Brownell Outlet, 84 Executive Avenue,
system time constants shown in Tables 2-4.
Edison, NJ 08817.
Available from Howell Hydrocarbons and Chemicals, Inc., 1201 South
Sheldon Road, P.O. Box 429, Channel View, TX 77530.
14 18
Caterpillar Inc., Engine System Technology Department, P.O. Box 610, Available directly from Nalco, 4639 Corona Drive, Suite 61, Corpus Christi,
Mossville, IL 61552. TX 78441.
15 19
Caterpillar Inc., Tech Center TC-L, Wing 4, Room 405, 14009 Old Galena Rd., Available from The Lubrizol Corporation, 29400 Lakeland Blvd., Cleveland,
Mossville, IL 61552. OH 44092.
D6618 − 23
FIG. 1 Return Goods Authorization Claim Form
approved by its safety department. Provide personnel working duty guards are required and personnel should be cautioned
on the engines with the proper tools, be alert to common sense against working alongside the engine and coupling shaft.
safety practices, and avoid contact with moving or hot engine Provide barrier protection for personnel. All fuel, oil lines, and
parts. Guards should be installed around all external moving or electrical wiring should be properly routed, guarded, and kept
hot parts. When engines are operating at high speeds, heavy in good order. Scraped knuckles, minor burns, and cuts are
D6618 − 23
TABLE 2 Calibration Tolerances
9.1.2 Pretest Maintenance Check List and Continuing En-
Parameter Tolerance gine Inspection—A recommended list of items that are checked
Speed, r/min 2 or replaced at the intervals specified is shown in Table 5.
Load NA due to differences within industry. TMC to
9.2 General Engine Inspection:
verify each lab during visits.
Fuel flow Absolute error # 0.125 %
9.2.1 Perform a complete engine inspection every 10 000
Humidity NA. Already specified. Checked during
test hours. This inspection is done to ensure that wearing
running conditions as outlined in the test
procedure (see form attached) surfaces, such as main bearings and journals, rod bearings and
Temperatures °C °F
journals, camshaft bearings, and so forth, are within manufac-
Coolant out 0.25 0.5
turer’s specifications. This inspection will terminate the current
Coolant in 0.25 0.5
Oil to bearing 0.5 1.0 test stand calibration (if any). Recalibration is required any
Intake air 0.5 1.0
time the crank is removed for any purpose other than bearing
Exhaust 1.0 2.0
replacement.
Pressures
Oil to bearing, psig 0.7 kPa 0.1
9.2.2 Maintain a complete record of all engine maintenance
Oil to jet, psig 0.7 kPa 0.1
and measurements. Retain a description of inspection methods
Inlet air, in Hg 0.3 kPa 0.1
along with the maintenance records for review when requested.
Exhaust, in Hg 0.3 kPa 0.1
Fuel at filter housing., psig 0.7 kPa 0.1
9.3 Intake Air System—Prior to each stand calibration test,
Crankcase vacuum, in H O 0.02 kPa 0.1
inspect the intake air barrel for rust and debris. This may be
done through either of the pipe flanges, using a borescope or
some other optical means. Remove any foreign material.
9.4 Cooling System:
common if proper safety precautions are not taken. Safety
9.4.1 Whenever visual inspection indicates the need, re-
masks or glasses should always be worn by personnel working
move all mineral deposits and oil from the cooling system.
on the engines, and no loose or flowing clothing should be
Make the initial coolant charge at the start of the test with
worn near running engines.
distilled or de-ionized water and a rust inhibitor (Penncol 2000)
8.2 Keep the external parts on the engine and the floor area
(see 7.3). The cooling system shall remain full during all
around the engines clean and free of oil and fuel spills. In
shutdowns that do not require the cooling system to be drained.
addition, keep working areas free of all tripping hazards. In
9.4.2 Make any make-up coolant additions throughout the
case of injury, no matter how slight, first aid attention should be
test with the same treated water solution. Monitor the cooling
applied at once and the incident reported. Personnel should be
system visually at the glass or plastic tube in the 1Y504 water
alert for leaking fuel or exhaust gas. Leaking fuel represents a
outlet line assembly. At any indication of vapor formation, the
fire hazard, and exhaust gas fumes are noxious. Containers of
coolant will have a clouded appearance. Should this occur
oil or fuel cannot be permitted to accumulate in the testing
during a test, shutdown the engine and check for air leakage on
area.
the suction side of the water pump or combustion gas leakage
in the cylinder head. No air is permitted in the system.
8.3 Equip the test installation with a fuel shut-off valve
designed to automatically cut off the fuel supply to the engine
9.5 Engine Cooling System Cleaning—Clean the cooling
when the engine is not running. A remote station for cutting off
system when visual inspection shows the presence of oil or
fuel from the test stand is recommended. Provide suitable
grease, mineral deposits, or rust. Heads may be cleaned when
interlocks so that engine is automatically shut down when any
either on or off the engine. Use the following procedure:
of the following events occur: engine or dynamometer loses
9.5.1 Operate the engine long enough to reach oil and water
field current, engine overspeeds, exhaust system fails, room
operating temperatures; drain the cooling system.
ventilation fails, or the fire protection system is activated.
9.5.2 Fill the cooling system with a solution of 450 g (1 lb)
Consider an excessive vibration pickup interlock if equipment
commercial sodium bisulfate (Na SO ) to 19 L (5 gal) of
2 4
is operated unattended. Provide fixed fire protection
water; then run the engine at operating temperature for ⁄2 h.
equipment, and make dry chemical fire extinguishers available
9.5.3 Drain and flush the engine with fresh water, and drain
at the test stands. (Warning—Many ASTM tests use chemicals
the water from the system.
to flush engines between tests. Some of these chemicals require
9.5.4 Fill the cooling system with a solution of 450 g (1 lb)
that personnel wear face masks, dust breathers, and gloves
of tri-sodium phosphate (Na PO ) to 38 L (10 gal) of water;
3 4
because exothermic reactions are possible. Provide emergency
operate the engine for 5 min to ensure complete mixing of the
showers and face rinse facilities when handling materials.)
Na PO solution with any material left from the previous flush.
3 4
9.5.5 Drain the engine, flush with clear water, and drain
9. Preparation of Apparatus
after flushing.
9.1 Supplementary Service Information:
9.5.6 Disassemble the engine, and prepare for the next test.
9.1.1 Caterpillar Service Manual—Engine service informa-
NOTE 2—If the purpose of the system cleaning is to descale only, 9.5.4
tion not found in this test method may be obtained by referring
and 9.5.5 can be omitted.
to the Caterpillar Single Cylinder Oil Test Engine Service
9.6 Instrumentation Calibration Requirements:
Manual (Form No. SENR2074) and parts manual
14,11
SEBP1299. 9.6.1 General Requirements:
D6618 − 23
TABLE 3 Operational Specifications, Measurement Resolution, and Reporting Resolution
SI Specification US Customary System (USCS) Specification
Parameter Units Spec Minimum Round Values Units Spec Minimum Round Values
Measurement to the Nearest Measurement to the Nearest
Regulation Resolution
Speed r/min 1800 ± 10 1 Whole number r/min 1800 ± 10 1 Whole number
Power kW 31.3 bhp 42
BMEP kPa 951 psig 138
Fuel rate kJ/min 6172 ± 53 Btu/min 5850 ± 50
A
Fuel flow kg/h 8.13 ± 0.07 0.01 Hundredth lb/h 17.92 ± 0.15 0.01 Hundredth
BSFC kg/kWh 0.260 lb/bhp.h 0.427
Humidity g/kg 17.8 ± 1.7 0.1 Tenth grains/lb 125 ± 12 1 Whole number
Oil weight g N/A 1 Whole number lb N/A 0.01 Hundredth
Temperatures
Coolant out °C 87.8 ± 2.8 0.1 Tenth °F 190 ± 5 0.1 Tenth
Coolant in °C 82.8 0.1 Tenth °F 181 0.1 Tenth
Coolant Δ °C 5 ± 1.0 0.1 Tenth °F 9 ± 2 0.1 Tenth
Oil to bearing °C 96.1 ± 2.8 0.1 Tenth °F 205 ± 5 0.1 Tenth
Inlet air °C 123.9 ± 2.8 0.1 Tenth °F 255 ± 5 0.1 Tenth
Exhaust °C 573 ± 28 1 Whole number °F 1063 ± 50 1 Whole number
Pressures
B
Oil to bearing kPa 220.6 Max psig 32 max
B
Oil to jet kPa 165.5 ± 13.8 0.1 Tenth psig 24 ± 2 0.1 Tenth
Inlet air (ABS) kPa 179 ± 1 0.1 Tenth in. Hg 53.0 ± 0.3 0.1 Tenth
Exhaust (ABS) kPa 106.7 ± 1.7 0.1 Tenth in. Hg 31.5 ± 0.5 0.1 Tenth
Fuel at filter kPa 137.9 ± 13.8 0.1 Tenth psig 20 ± 2 0.1 Tenth
housing.
Crankcase vac kPa 0.25 ± 0.12 0.01 Hundredth in. H O 1 ± 0.5 0.1 Tenth
Flows
Coolant flow L/min 57.9 ± 3.8 0.1 Tenth gal/min 15.3 ± 1.0 0.1 Tenth
A
Fuel flow spec is based on the high heating value of 19.590 Btu ⁄lb at an A.P.I. gravity of 35. Fuel spec is 33 to 35 A.P.I. gravity.
B
Oil pressure operating specifications apply only to 15W-40 oils. Attempt to maintain these limits for all oils. When oils other than 15W-40 oils fall outside these limits,
explain these deviations from the limits in the comments section of the test report.
TABLE 4 Maximum Allowable System Time Constants
9.6.2.1 Calibrate the primary laboratory humidity measure-
Measurements ment system during the first 24 h of each individual stand
Speed 3.0 s calibration test using a chilled-mirror dew point hygrometer
Fuel Flow 73.0 s
with an accuracy of at least 60.55 °C at 24 °C (61 °F at 75 °F)
Temperatures
dew point. The calibration consists of a series of paired
Coolant Out 3.0 s
Coolant In 3.0 s
comparison measurements between the primary system and the
Oil to Bearings 3.0 s
chilled-mirror dew point hygrometer. The comparison period
Intake air 3.0 s
lasts from 20 min to 2 h with measurements taken at 1 min to
Exhaust 3.0 s
Pressures 6 min intervals, for a total of 20 paired measurements. The
Oil to Bearings 3.0 s
measurement interval should be appropriate for the time
Oil to Jet 3.0 s
constant of the humidity measuring instruments.
Intake Air 3.0 s
Exhaust 3.0 s
9.6.2.2 The location of the hygrometer tap is shown in Fig.
Fuel at Filter 3.0 s
A1.28. The sample line may require insulation to prevent
Crankcase Vac. 3.0 s
dropping below dew point temperature and shall not be
hygroscopic. The flow rate shall be verified to be within the
equipment manufacturer’s specification.
9.6.1.1 Calibrate all facility read-out instrumentation used
for the test immediately prior to commencing a test stand 9.6.2.3 All measurements taken with the dew point hygrom-
calibration. Instrumentation calibrations prior to subsequent eter are at atmospheric pressure and corrected to standard
stand calibration tests (that is, those that follow a failed or conditions (101.12 kPa [29.92 in. Hg]) using the perfect gas
invalid first attempt) are at the discretion of the test laboratory. law or Table X1.1 to Table X1.9 in Appendix X1. Compute the
Make these calibrations part of the laboratory record (refer to difference between each pair of measurements and use to form
Tables 2-4 for specifications). a mean and standard deviation. The absolute value of the mean
9.6.1.2 Calibrate on a yearly basis all temperature, pressure, difference shall not exceed 0.648 g (10 grains), and the
flow, and speed measurement standards with instruments standard deviation shall be less than or equal to 0.324 g
traceable to a national bureau of standards (for example, the (5 grains). Both of these requirements shall be met for the
National Bureau of Standards and Technology or its successor primary humidity measurement system to be considered cali-
agency for labs operating in the United States). Maintain brated. If either of these requirements cannot be met, the
records of all calibrations for a minimum of two years. laboratory should investigate the cause, make repairs, and
9.6.2 Specific Humidity Requirements: recalibrate. Maintain the calibration data for two years.
D6618 − 23
A B
TABLE 5 Pretest Maintenance Check List and Continuing Engine Inspection
Item to be checked Remarks
Fuel injection pump adjusting screw (2F8337) Inspect before each test. Replace as necessary.
Fuel injection pump Check pump plunger sector gear for tooth wear—general condition of pump (visual); replace pump
as necessary.
Fuel injection valve Install new before each test. Inspect fuel injection line orifice (both ends) for correct diameter,
1.57 mm (0.062 in.) minimum.
Fuel injection timing 3.81 mm ± 0.127 mm (0.150 in. ± 0.005 in.) lift, BPC at 8° BTC.
Injection pump inlet seal (2M4453) Install new before each test.
Filter-fuel system Install when fuel pressure cannot be held within test limits.
Cylinder head New (calibration test only) or reconditioned head for each test. Measure and record valve head and
stem projection. Measure prechamber orifice diameter (7.59 mm to 7.64 mm [0.299 in. to 0.301 in.]).
Cylinder head gasket (1Y7960) Install new before each test.
Piston cooling jet Inspect for plugging and proper positioning before each test; use aiming guide. Verify piston-to-
cooling jet clearance.
Water pump and fuel transfer pump belts Inspect and adjust as necessary. (Measure deflection at point midway between pulleys - water and
fuel.)
Belt deflection Force
19.05 mm 111 N
(0.75 in.) (25 lb)
Fuel pressure 138 kPa (20 psi)
Water flow 58.
...