ASTM D7484-23a

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: D7484 − 23a
Standard Test Method for
Evaluation of Automotive Engine Oils for Valve-Train Wear
Performance in Cummins ISB Medium-Duty Diesel Engine
This standard is issued under the fixed designation D7484; 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 procedure described in
this test method. 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 these 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 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 these 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 method.
ASTM International policy is to encourage the development of test procedures based on generic
equipment. It is recognized that there are occasions where critical/sole-source equipment has been
approved by the technical committee (surveillance panel/task force) and is required by the test
procedure. The technical committee that oversees the test procedure is encouraged to clearly identify
if the part is considered critical in the test procedure. If a part is deemed to be critical, ASTM
encourages alternative suppliers to be given the opportunity for consideration of supplying the critical
part/component providing they meet the approval process set forth by the technical committee.
An alternative supplier can start the process by initiating contact with the technical committee
(current chairs shown on ASTM TMC website). The supplier should advise on the details of the part
that is intended to be supplied. The technical committee will review the request and determine
feasibility of an alternative supplier for the requested replacement critical part. In the event that a
replacement critical part has been identified and proven equivalent the sole-source supplier footnote
shall be removed from the test procedure.
1. Scope* engine equipped with exhaust gas recirculation and is used to
evaluate oil performance with regard to valve-train wear.
1.1 This test method, commonly referred to as the Cummins
ISB Test, covers the utilization of a modern, 5.9 L, diesel 1.2 The values stated in SI units are to be regarded as
standard. No other units of measurement are included in this
standard.
This test method is under the jurisdiction of ASTM Committee D02 on
1.2.1 Exceptions—SI units are provided for all parameters
Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of
except where there is no direct equivalent such as the units for
Subcommittee D02.B0 on Automotive Lubricants.
Current edition approved Nov. 1, 2023. Published November 2023. Originally
screw threads, National Pipe Threads/diameters, tubing size, or
approved in 2008. Last previous edition approved in 2023 as D7484 – 23. DOI:
where there is a sole source of supply equipment specification.
10.1520/D7484-23A.
1.2.2 See also A7.1 for clarification; it does not supersede
Until the next revision of this test method, the ASTM Test Monitoring Center
will update changes in the test method by means of information letters. Information 1.2 and 1.2.1.
letters may be obtained from the ASTM Test Monitoring Center, 203 Armstrong
1.3 This standard does not purport to address all of the
Drive, Freeport, PA 16229. Attention Administrator. This edition incorporates
safety concerns, if any, associated with its use. It is the
revisions in all information letters through No. 23-1. www.astmtmc.org.
*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
D7484 − 23a
responsibility of the user of this standard to establish appro- D1319 Test Method for Hydrocarbon Types in Liquid Petro-
priate safety, health, and environmental practices and deter- leum Products by Fluorescent Indicator Adsorption
mine the applicability of regulatory limitations prior to use. D2274 Test Method for Oxidation Stability of Distillate Fuel
See Annex A1 for general safety precautions. Oil (Accelerated Method)
1.4 Table of Contents: D2500 Test Method for Cloud Point of Petroleum Products
and Liquid Fuels
Section
Scope 1
D2622 Test Method for Sulfur in Petroleum Products by
Referenced Documents 2
Wavelength Dispersive X-ray Fluorescence Spectrometry
Terminology 3
D2709 Test Method for Water and Sediment in Middle
Summary of Test Method 4
Significance and Use 5
Distillate Fuels by Centrifuge
Apparatus 6
D3338 Test Method for Estimation of Net Heat of Combus-
Engine Fluids and Cleaning Solvents 7
tion of Aviation Fuels
Preparation of Apparatus 8
Engine/Stand Calibration and Non-Reference 9
D4052 Test Method for Density, Relative Density, and API
Oil Tests
Gravity of Liquids by Digital Density Meter
Test Procedure 10
D4175 Terminology Relating to Petroleum Products, Liquid
Calculations, Ratings, and Test Validity 11
Report 12
Fuels, and Lubricants
Precision and Bias 13
D4294 Test Method for Sulfur in Petroleum and Petroleum
Annexes
Products by Energy Dispersive X-ray Fluorescence Spec-
Safety Precautions Annex A1
Intake Air Aftercooler Annex A2
trometry
The Cummins ISB Engine Build Parts Kit Annex A3
D4739 Test Method for Base Number Determination by
Sensor Locations and Special Hardware Annex A4
Potentiometric Hydrochloric Acid Titration
External Oil System Annex A5
Cummins Service Publications Annex A6
D5185 Test Method for Multielement Determination of
Specified Units and Formats Annex A7
Used and Unused Lubricating Oils and Base Oils by
Oil Analyses Annex A8
Inductively Coupled Plasma Atomic Emission Spectrom-
Alternate Fuel Approval Process Annex A9
etry (ICP-AES)
1.5 This international standard was developed in accor-
D5186 Test Method for Determination of the Aromatic
dance with internationally recognized principles on standard-
Content and Polynuclear Aromatic Content of Diesel
ization established in the Decision on Principles for the
Fuels By Supercritical Fluid Chromatography
Development of International Standards, Guides and Recom-
D5453 Test Method for Determination of Total Sulfur in
mendations issued by the World Trade Organization Technical
Light Hydrocarbons, Spark Ignition Engine Fuel, Diesel
Barriers to Trade (TBT) Committee.
Engine Fuel, and Engine Oil by Ultraviolet Fluorescence
D5967 Test Method for Evaluation of Diesel Engine Oils in
2. Referenced Documents
3 T-8 Diesel Engine
2.1 ASTM Standards:
D6078 Test Method for Evaluating Lubricity of Diesel Fuels
D86 Test Method for Distillation of Petroleum Products and
by the Scuffing Load Ball-on-Cylinder Lubricity Evalua-
Liquid Fuels at Atmospheric Pressure
tor (SLBOCLE) (Withdrawn 2021)
D93 Test Methods for Flash Point by Pensky-Martens
D6838 Test Method for Cummins M11 High Soot Test
Closed Cup Tester
(Withdrawn 2019)
D97 Test Method for Pour Point of Petroleum Products
D6975 Test Method for Cummins M11 EGR Test (With-
D130 Test Method for Corrosiveness to Copper from Petro-
drawn 2019)
leum Products by Copper Strip Test
E29 Practice for Using Significant Digits in Test Data to
D235 Specification for Mineral Spirits (Petroleum Spirits)
Determine Conformance with Specifications
(Hydrocarbon Dry Cleaning Solvent)
E178 Practice for Dealing With Outlying Observations
D445 Test Method for Kinematic Viscosity of Transparent
and Opaque Liquids (and Calculation of Dynamic Viscos-
3. Terminology
ity)
3.1 Definitions:
D482 Test Method for Ash from Petroleum Products
D524 Test Method for Ramsbottom Carbon Residue of 3.1.1 blind reference oil, n—a reference oil, the identity of
which is unknown by the test facility.
Petroleum Products
D613 Test Method for Cetane Number of Diesel Fuel Oil 3.1.1.1 Discussion—This is a coded reference oil that is
submitted by a source independent from the test facility. D4175
D664 Test Method for Acid Number of Petroleum Products
by Potentiometric Titration
3.1.2 blowby, n—in internal combustion engines, that por-
D976 Test Method for Calculated Cetane Index of Distillate
tion of the combustion products and unburned air/fuel mixture
Fuels
that leaks past piston rings into the engine crankcase during
operation.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
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 The last approved version of this historical standard is referenced on
the ASTM website. www.astm.org.
D7484 − 23a
3.1.3 calibrate, v—to determine the indication or output of a mode of relatively low-speed and high-power output, with the
device (for example, thermometer, manometer, engine) with potential to cause hesitation.
respect to that of a standard.
3.2.2 ramp, v—to change an engine condition at a pre-
scribed rate when changing from one set of operating condi-
3.1.4 candidate oil, n—an oil that is intended to have the
tions to another set of operating conditions.
performance characteristics necessary to satisfy a specification
3.2.2.1 Discussion—When ramping the engine speed down
and is to be tested against that specification. D4175
to a condition such that the engine lugs, the speed is forced
3.1.5 crosshead, n—an overhead component, located be-
down by increasing the torque in a such a way that the speed
tween the rocker arm and each intake-valve and exhaust-valve
comes to idle before zero torque condition is reached.
pair, that transfers rocker arm travel to the opening and closing
3.2.3 tappet, n—in internal combustion engines, a valve-
of each valve pair.
train component, located between the camshaft and push rod,
3.1.5.1 Discussion—Each cylinder has two crossheads, one
that transfers cam lobe travel to the rocker arm, opening and
for each pair of intake valves and exhaust valves. D6838
closing a pair of intake or exhaust valves.
3.1.6 exhaust gas recirculation (EGR), n—a method by
which a portion of engine’s exhaust is returned to its combus-
4. Summary of Test Method
tion chambers via its inlet system. D6975
4.1 This test method uses a Cummins ISB diesel engine
3.1.7 heavy-duty, adj—in internal combustion engine
with 5.9 L displacement, equipped with exhaust gas recircula-
operation, characterized by average speeds, power output and
tion and featuring an EPA 2004 emissions configuration. Test
internal temperatures that are close to the potential maximums.
operation includes a 17 min warm-up, an 80 h break-in, and a
D4175
350 h test cycle comprising stages A and B. During stage A the
engine is operated with retarded, fuel-injection timing to
3.1.8 non-reference oil, n—any oil other than a reference oil,
generate excess soot; during stage B the engine is operated at
such as a research formulation, commercial oil or candidate oil.
cyclic conditions to induce valve-train wear.
D4175
4.2 Prior to each test, the engine is cleaned and assembled
3.1.9 non-standard test, n—a test that is not conducted in
with new, valve-train components. All aspects of the assembly
conformance with the requirements in the standard test
are specified.
method; such as running in an uncalibrated test stand or using
different test equipment, applying different equipment assem-
4.3 A forced oil drain, an oil sampling, and an oil addition
bly procedures, or using modified operating conditions. D4175
are performed at the end of each 25 h period for the first 100 h
of the test. Thereafter, oil samples are taken every 50 h. Oil
3.1.10 overhead, n—in internal combustion engines, the
additions are not made during the last 250 h of the test cycle.
components of the valve-train located in or above the cylinder
head. D6838
4.4 The test stand is equipped with the appropriate instru-
mentation to control engine speed, fuel flow and other operat-
3.1.11 reference oil, n—an oil of known performance
ing parameters.
characteristics, used as a basis for comparison.
3.1.11.1 Discussion—Reference oils are used to calibrate
4.5 Oil performance is determined by assessing crosshead
testing facilities, to compare the performance of other oils, or
wear, tappet weight loss and camshaft wear.
to evaluate other materials (such as seals) that interact with
oils. D4175 5. Significance and Use
5.1 This test method was developed to assess the perfor-
3.1.12 sludge, n—in internal combustion engines, a deposit,
principally composed of insoluble resins and oxidation prod- mance of a heavy-duty engine oil in controlling engine wear
under operating conditions selected to accelerate soot produc-
ucts from fuel combustion and the lubricant, that does not drain
from engine parts but can be removed by wiping with a cloth. tion and valve-train wear in a turbocharged and aftercooled
four-cycle diesel engine with sliding tappet followers equipped
D4175
with exhaust gas recirculation hardware.
3.1.13 test oil, n—any oil subjected to evaluation in an
5.2 The design of the engine used in this test method is
established procedure. D4175
representative of many, but not all, modern diesel engines. This
3.1.14 valve-train, n—in internal combustion engines, the
factor, along with the accelerated operating conditions, shall be
series of components such as valves, crossheads, rocker arms,
considered when extrapolating test results.
push rods and camshaft, that open and close the intake and
exhaust valves. D6838
6. Apparatus
3.1.15 wear, n—the loss of material from a surface, gener-
6.1 Test-Engine Configuration:
ally occurring between two surfaces in relative motion, and
6.1.1 Test Engine—The Cummins ISB is an in-line, six-
resulting from mechanical or chemical action or a combination
cylinder, diesel engine with a displacement of 5.9 L. It is
of both. D4175
turbocharged, aftercooled, and has an overhead valve configu-
3.2 Definitions of Terms Specific to This Standard:
ration. It features a 2004 emissions configuration with elec-
3.2.1 lug, v—in internal combustion engine operation, to tronic control of fuel metering and common rail fuel injection.
run the engine in a condition characterized by a combined Obtain the test engine and the engine build parts kit from the
D7484 − 23a
5,6
Central Parts Distributor (CPD). The components of the 6.2.2 Intake Air System—the configuration is shown in Fig.
5,11
engine build parts kit are shown in Table A3.1. A4.6. Use a cobra elbow (part number 3037625). Connect
6.1.2 Remote Oil Heat Exchanger and Bypass Plate— to the cobra elbow using straight, 100 mm diameter tubing with
Remove the stock oil heat exchanger from the engine and a minimum length of 300 mm. Use an air filter typical of those
5,6
replace with a bypass plate (part number ISB-OCBP) shown used in diesel engine testing applications. Install the intake air
in Fig. A4.1. Attach a remote bypass (part number 149-0118- tube (Fig. A4.6) at the intake of the turbocharger compressor.
6,7
00) to the filter head, as shown in Fig. A4.2. The bypass Construct the system to minimize airflow restriction. Install
allows control of the oil temperature by directing the oil to flow methods for controlling the intake air temperature and pres-
through a 76 mm × 102 mm dual-pass, remote oil heat ex- sure.
6,8
changer (part number SN16-003-014-004) as shown in Fig.
NOTE 1—Difficulty in achieving or maintaining intake manifold pres-
A4.3. The oil lines to and from the remote oil heat exchanger
sure or intake manifold temperature, or both, could be indicative of
and filter head shall not be greater than 1000 mm long and shall
insufficient or excessive restriction.
be 19.3 mm nominal outer diameter tubing (Aeroquip “-12” or
6.2.3 Aftercooler—Use a Modine aftercooler for aftercool-
equivalent).
ing. Instructions for obtaining the correct aftercooler are listed
6.1.3 Oil Pan Modification—Modify the oil pan as shown in
in A2.1. An installation photograph is shown in Fig. A4.10.
Fig. A4.4.
6.2.4 Exhaust System—Install a long-radius, 90°-elbow, ex-
6.1.4 Engine Control Module (ECM)—Obtain the ECM
haust tube (see Fig. A4.11) at the discharge flange of the
5,6
from the CPD. Information about the ECM is given in a
turbocharger housing, followed by a sufficient length of
10, 11
Cummins publication. Use the latest Cummins engineer-
straight tubing to allow the temperature and pressure sensors to
ing tools to retard injection timing in order to increase soot
be located 152 mm downstream of the elbow weld seam. Use
generation and overhead wear. Verify that the 2004 EPA
good engineering practice in establishing the total length and
calibration is used. Some engine protection protocols have
diameter of the tube downstream of the sensors. Install a
been disabled to ensure that the test is run according to the
method of controlling exhaust back pressure.
procedure. Obtain prior authorization and instructions from
6.2.5 Exhaust Gas Recirculation System—The components
Cummins Inc. on how to disable the engine protection
for the exhaust gas recirculation system are installed by the
protocols and the use of Cummins engineering tools. 5,11
manufacturer. Replacement parts are available.
6.1.5 Air Compressor—The engine-mounted air compressor
6.2.6 Fuel Supply—The laboratory fuel supply and filtration
is not used for this test method. Remove the air compressor and
systems are not specified. Determine the fuel-consumption rate
cover the opening by a plate (part number 3954567).
by measuring the rate of fuel flowing into the day tank. Install
6.1.6 Engine Inlet Air Heater—Remove the internal heating
a method of controlling the fuel temperature. Ensure the
elements from the housing of the engine inlet air heater.
fuel-inlet restriction and return restrictions adhere to the
Remove the lower, factory-installed, electrical terminal. Drill 11,14
requirements specified in the Cummins Service Manual.
and tap this hole ( ⁄8 in. NPT) for the inlet manifold pressure
6.2.7 Coolant System—The coolant system configuration is
fitting.
not specified. A typical configuration consists of a non-ferrous-
6.2 Test-Stand Configuration: core heat exchanger, a reservoir (expansion tank), and a
6.2.1 Engine Mounting—Install the engine so that it is temperature-control valve. Pressurize the system by regulating
upright and the crankshaft is horizontal, with minimal block air pressure at the top of the expansion tank. Install a sight
distortion. Due to the cyclic nature of the test, a driveline glass to detect air entrapment.
coupling damper is required.
NOTE 2—Caution: Although the system volume is not specified, an
excessively large volume can increase the time required for the engine
fluid temperatures to attain specification. A system volume that has been
found satisfactory is 35 L or less (including engine).
This CPD is the sole source of supply of the test engine, engine build parts kit
and the ECM known to the committee at this time is Test Engineering, Inc., 12718
6.2.7.1 Block the engine thermostat wide open.
Cimarron Path, Suite 102, San Antonio, TX 78249-3423, www.tei-net.com.
6 6.2.8 Pressurized Oil-Fill System—The oil-fill system is not
If you are aware of alternative suppliers, please provide this information to
ASTM. Your comments will receive careful consideration at a meeting of the specified. A typical configuration includes an electric pump, a
responsible technical committee, which you may attend.
20 L reservoir and transfer hose.
The sole source of supply of this bypass known to the committee at this time
6.2.9 External Oil System—Configure the external oil sys-
is W. G. Sourcing, Inc., 2650 Pleasantdale Road #10, Atlanta, GA 30340.
tem according to Fig. A5.1, using an external reservoir with a
www.wgsourcing.net.
The sole source of supply of the remote oil heat exchanger known to the
volume between 4 L and 8 L. Use Viking Pump (model number
committee at this time is Kinetic Engineering Corporation, 2055 Silber Road, Suite
SG041825) for the external pumps with a nominal pump-
101, Houston, TX 77055. www.kineticengineerinq.com.
motor speed of 1140 r ⁄min. A three-way valve system is
Aeroquip lines are available at a local hose distributors.
e
Troubleshooting and Repair Manual ISB, ISB , QSB 4.5, QSB 5.9, QSB 6.7, permissible and allows the reservoir to be emptied back into
ISC, QSC 8.3, ISL and QSL 9 Engines, CM 850 Electronic Control System Engines,
Bulletin Number 4021416.
11 14 e
Available from local Cummins parts distributors. Troubleshooting and Repair Manual for ISB and ISB (Common Rail Fuel
Cummins Inc., 1900 McKinley Avenue, Columbus, IN 47201. System) Series Engines, Bulletin Number 4021271, June 30, 2004, published by
The sole source of supply of the apparatus known to the committee at this time Cummins Inc.
is Vulkan Driveline Coupling (Part Number VKL3415, available from American The sole source of supply of the apparatus known to the committee at this time
Vulkan USA, 2525 Dundee Road, Winter Haven, FL 33484. www.vulkanusa.com. is Viking Pump, Inc., (unit of IDEX Corporation), 406 State St., P.O. Box 8, Cedar
Falls, IA 50613-0008. www.vikingpumps.com.
D7484 − 23a
TABLE 1 Maximum Allowable System Time Responses
7.4 Solvents and Cleaners Required—(Warning—Use ad-
Measurement Type Time Response, s equate safety precautions with all solvents and cleaners.)
Speed 2.0 7.4.1 Solvent—Use mineral spirits meeting Specification
Torque 2.0
D235, Type II, Class C requirements for aromatic content (0 %
Temperature 3.0
to 2 % vol), flash point (61 °C), and color (not darker than +25
Pressure 3.0
Flow 45.0 on Saybolt Scale or 25 on Pt-Co Scale). Obtain a Certificate of
Analysis for each batch of solvent from the supplier.
(Warning—Combustible. Health hazard.)
7.4.2 Pentane—Used for rinsing and cleaning components
before measurement. (Warning—Flammable. Health hazard.)
the oil pan at the start of Stage B. The location of the three-way
7.4.3 Degreasing Solvent—EnSolv, a proprietary n-propyl
valve is not specified (location shown in Fig. A5.1 is for
bromide based solvent used for cleaning the tappets.
example only).
(Warning—Health hazard.)
6.2.9.1 Oil-Sample Valve Location—Locate the oil-sample
valve on the return line from the remote oil heat exchanger
8. Preparation of Apparatus
system to the engine. It is recommended that the valve be
located as shown in Fig. A4.9. 8.1 Cleaning of Parts:
6.2.9.2 Do not use brass or copper fittings in the external oil 8.1.1 General—This section describes the preparation of
system because such metals can influence wear-metals analy- test engine components specific to the Cummins ISB test. Use
ses of the used oil. the Cummins service publications listed in Annex A6 for the
6.2.10 Crankcase Aspiration—Vent the blowby gas at the preparation of other engine components. Take precautions to
port located at the left rear of the flywheel housing, as shown prevent rusting of iron components. Additionally, perform any
in Fig. A4.5. Ensure the vent line proceeds in a downward engraving of test parts for identification purposes on non-
direction into the collection bucket and that the collection contact surfaces and follow by the pre-test cleaning as specified
bucket has a minimum volume of 19 L. in the following sections.
6.2.11 Blowby Rate—The flow-rate device and system con- 8.1.2 Engine Block—The engine block is a parent bore type.
figuration are not specified. Install the system according to This test does not require a complete teardown. Do not clean
good engineering practice and operate the flow-rate device the internal surfaces and passages of the engine block with
according to the manufacturer’s guidelines. solvent.
8.1.3 Rocker Cover and Oil Pan—Clean the rocker cover
6.3 System Time Responses—Table 1 shows the maximum
and oil pan with solvent (see Warning in 7.4.1). Use a brush as
allowable system time responses. Determine system time
necessary to remove deposits.
responses in accordance with the Data Acquisition and Control
16 8.1.4 External Oil System—Flush the internal surfaces of
Automation II (DACA II) Task Force Report.
the oil lines and the external reservoir with solvent. Repeat
6.4 Oil-Sample Containers—High-density polyethylene
until the solvent drains clean. Flush solvent through the oil
containers are recommended for oil samples. (Warning—
pumps until the solvent drains clean.
Glass containers may break and may cause injury or exposure
8.1.5 Crosshead Cleaning and Measurement—Do not
to hazardous materials, or both.)
handle the crossheads with bare hands; use gloves or plastic-
6.5 Mass Balance—Use a balance (electronic or mechani- covered tongs.
8.1.5.1 Clean the crossheads with solvent. Use a non-
cal) to measure the mass of the crossheads and tappets with a
minimum indication resolution of 0.1 mg. metallic, soft-bristle brush if necessary.
8.1.5.2 Allow the crossheads to air dry (do not use com-
7. Engine Fluids and Cleaning Solvents
pressed air).
8.1.5.3 Rinse the crossheads in pentane (see Warning in
7.1 Test Oil—Approximately 80 L of test oil are required to
7.4.2) and allow to air dry (do not use compressed air).
complete the test.
8.1.5.4 Measure each crosshead mass to a tenth of a
7.2 Test Fuel—Approximately 8000 L of PC-10, ultra-low-
milligram (xxx.x mg).
sulfur, diesel fuel from an approved supplier are required to
8.1.5.5 If an electronic scale is used for mass measurement,
complete the test. The TMC maintains a list of approved fuel
use the following procedure:
suppliers. The fuel shall have the properties and tolerances
(1) Demagnetize (degauss) each crosshead prior to mea-
shown in the “PC-10 Fuel Specification” section of the
surement.
“TMC-Monitored Test Fuel Specifications” document main-
(2) Measure each crosshead mass twice, using two orien-
tained by the TMC.
tations 90° apart. If the difference between the two mass
7.3 Engine Coolant—Use 50:50 pre-mixed Fleetguard measurements is greater than 0.2 mg, demagnetize the cross-
Compleat PG. head again and repeat the measurement process.
16 18
Available from the TMC website: www.astmtmc.org. Ensolv is a registered trademark of, and is available from, Enviro Tech
Available from the TMC website at http://www.astmtmc.org/ftp/docs/fuel/tmc- International, Inc., 2525 West LeMoyne Ave., Melrose Park, IL 60160. www.en-
monitored%20test%20fuel%20specifications.pdf. solv.com.
D7484 − 23a
8.1.5.6 For laboratories using the TMC services, report the the serviceability requirements, particularly blowby and cam
crosshead measurements on the form included in the TMC bore, defined in the Cummins Service Manual.
report package (see 12.1). 8.2.3 Build-Up Oil—Use the Cummins-branded oil meeting
8.1.6 Tappet Cleaning and Measurement—Do not handle Cummins Engineering Standard 20078.
the tappets with bare hands; use Ensolv-compatible gloves or 8.2.4 Coolant Thermostat—Lock the engine coolant ther-
plastic covered tongs. mostat open to close off the bypass passage in the engine block.
8.1.6.1 Inspect the tappets for damage and clean with 8.2.5 New Parts—The parts listed below are contained in
solvent. Use a non-metallic, soft-bristle brush if necessary. the ISB Engine Build Parts Kit and are not reusable. Prior to
8.1.6.2 Allow the tappets to air dry (do not use compressed use, clean the valve-train parts with solvent. With the exception
air). of the fuel filter, replacement of any part listed below during a
8.1.6.3 Rinse the tappets with pentane and allow to air dry test invalidates the test.
(do not use compressed air). 8.2.5.1 Rocker Lever Shafts.
8.1.6.4 Soak the tappets in Ensolv (see Warning in 7.4.3) for 8.2.5.2 Rocker Lever Assemblies, Complete with Sockets.
30 min, ensuring that each tappet is completely immersed in 8.2.5.3 Tappets.
the solvent. 8.2.5.4 Rocker Lever Sockets.
8.1.6.5 Allow the tappets to air dry (do not use compressed 8.2.5.5 Push Rods.
air). 8.2.5.6 Valve Crossheads.
8.1.6.6 Measure the mass of each tappet, orienting the large, 8.2.5.7 Camshaft.
circular, flat surface in an upwards position, to a tenth of a 8.2.5.8 Test Oil Filter.
milligram (xxx.x mg). 8.2.5.9 Fuel Filter—Replacement during a test does not
8.1.6.7 If an electronic scale is used for mass measurement, invalidate the test.
use the following procedure: 8.2.6 The entire engine may be replaced during a reference
(1) Demagnetize (degauss) each tappet prior to measure- period provided the engine completes the 80 h, new-engine,
ment. break-in cycle specified in 10.1.
(2) Measure the tappet twice, using two orientations, both 8.2.7 Do not replace the cylinder head and power cylinder
with the flat face upwards, 90° apart. If the difference between components during the life of the engine.
the two mass measurements is greater than 0.2 mg, demagne-
8.3 Operational Measurements:
tize the tappet again and repeat the measurement process.
8.3.1 Units and Formats—See Annex A7. Record opera-
8.1.6.8 For laboratories using the TMC services, report the
tional parameters in accordance with the minimum resolutions
tappet measurements on the forms included in the TMC report
given in Table A7.1.
package (see 12.1).
8.3.2 Instrumentation Calibration:
8.1.7 Camshaft Cleaning and Measurement—Clean the
8.3.2.1 Calibration of the Fuel Consumption Rate Measure-
camshaft with solvent. Because contamination can adversely
ment System—Calibrate the fuel consumption rate measure-
affect the wear results, use gloves, not bare hands, to handle the
ment system before every reference oil test sequence and
camshaft.
within nine months after the completion of the last successful
8.1.7.1 Measure the cam lobe heights (heel-to-toe) using a
calibration test. Volumetric systems shall be temperature-
Mitutoyo Snap Gauge (model 201-152), and a Mitutoyo
compensated and calibrated against a mass flow device. The
Digital Indicator (model 543-252B).
flow meter located on the test stand shall indicate within 0.2 %
8.1.7.2 Measure three locations on each lobe: the front edge,
of the calibration standard. The calibration standard shall be
the center, and the rear edge. Report the lobe measurement as
traceable to the National Institute for Standards and Technol-
the average of the three values. 20
ogy (NIST).
8.1.7.3 For laboratories using the TMC services, report the
8.3.2.2 Calibration of the Temperature Measurement
lobe measurements on the forms included in the TMC report
Systems—Calibrate the temperature measurement systems be-
package (see 12.1).
fore every reference oil test sequence. Each temperature
8.2 Engine Assembly: measurement system shall indicate within 60.5 °C of the
8.2.1 General—Except as noted in this section, use the laboratory calibration standard. The calibration standard shall
procedures indicated in the Cummins service publications (see be traceable to NIST.
Annex A6). Assemble the engine with the components from the 8.3.2.3 Calibration of the Pressure Measurement Systems—
ISB Engine Build Parts Kit in numerical order, from front to Calibrate the pressure measurement systems before every
rear (see Annex A3 for details of the kit). reference oil test sequence. The calibration standard shall be
8.2.2 Parts Reuse and Replacement—Except as directed in traceable to NIST.
8.2.5, engine components may be reused or replaced at the 8.3.3 Temperature Measurements:
discretion of the laboratory (Cummins Critical Parts List, CPL 8.3.3.1 Measurement Location—This section specifies the
#8123). The engine block may be reused provided that it meets temperature measurement locations. The measurement equip-
ment is not specified. Install the sensors such that the tip is
located midstream of the flow unless otherwise indicated.
The sole source of supply of the apparatus known to the committee at this time
is Mitutoyo America Corporation, 965 Corporate Blvd., Aurora, IL 60502. www.mi-
tutoyo.com. National Institute for Standards and Technology, www.nist.gov.
D7484 − 23a
Follow the guidelines detailed in the DACA II Task Force 8.3.4.4 Oil Filter Outlet Pressure—Measure the pressure at
Report for the accuracy and resolution of the temperature the ⁄8 in. NPT port located on the remote oil filter assembly, as
measurement sensors and the complete measurement system. shown in Fig. A4.9.
8.3.3.2 Coolant-Out Temperature—Install the sensor as 8.3.4.5 Intake Manifold Pressure—Measure the pressure at
the ⁄4 in. NPT port located in the air heater block at the
shown in Fig. A4.15(a).
top-front of the intake manifold, as shown in Fig. A4.8.
8.3.3.3 Coolant-In Temperature—Install the sensor on the
8.3.4.6 Crankcase Pressure—Measure the pressure at the
right side of the engine on the inlet pipe to the coolant pump
dipstick port located on the left side of the test engine, as
intake housing, as shown in Fig. A4.15(b).
shown in Fig. A4.12.
8.3.3.4 Fuel-In Temperature—Install the sensor in the fuel
8.3.4.7 Intake Air Pressure—Measure the pressure on the
pump inlet fitting, as shown in Fig. A4.13. The maximum
intake air tube, as shown in Fig. A4.6. Locate the pressure tap
allowable sensor size is 4.8 mm diameter. Install the sensor to
upstream of the cobra elbow 150 mm to 200 mm; ensure that
the center of the banjo fitting.
there is straight tubing upstream of the sensor of at least
8.3.3.5 Oil Gallery Temperature—Install the sensor at the
150 mm in length.
metric, straight-thread hole on the left front of the engine, near
8.3.4.8 Exhaust Back Pressure—Measure the static pressure
the ECM, as shown in Fig. A4.12.
through a hole in the exhaust tube, as shown in Fig. A4.11.
8.3.3.6 Intake Air Temperature—Install the sensor as shown
8.3.4.9 Fuel Pressure—Measure the pressure on the engine-
on Fig. A4.6. Locate the sensor upstream of the cobra elbow
mounted outlet of the fuel filter, as shown in Fig. A4.14.
150 mm to 200 mm; ensure that there is straight tubing
8.3.4.10 Coolant Pressure—Measure the pressure on top of
upstream of the sensor of at least 150 mm in length. Do not
the expansion tank.
install the sensor upstream of the intake air pressure tap.
8.3.4.11 Additional Pressure Measurements—Monitor any
8.3.3.7 Intake Manifold Temperature—Install the sensor at
additional pressures considered to be beneficial.
the top of the aluminum snorkel on the air inlet tube, as shown
8.3.5 Flow Rate:
in Fig. A4.7. The insertion depth from the outside surface of the
8.3.5.1 Flow-Rate Location and Measurement Equipment—
aluminum snorkel shall be 114 mm.
The flow-rate measurement locations are specified in this
8.3.3.8 Exhaust Temperature—Install the sensor as shown in
section. The equipment or type of system for the blowby and
Fig. A4.11.
fuel flow rates is not specified. Follow the guidelines detailed
8.3.3.9 Oil Sump Temperature—Install the sensor from the
in the DACA II Task Force Report for the accuracy and
outside pan boss, identified as the Factory/OEM metric-
resolution of the flow-rate measurement system.
threaded hole, as shown in Fig. A4.4(a), at an insertion depth
8.3.5.2 Blowby Flow Rate—Use engineering judgment and
of 60 mm.
the manufacturer’s guidelines concerning the installation and
8.3.3.10 Additional Temperature Measurements—Monitor
use of the blowby flow-rate measurement device.
any additional temperatures that the laboratory considers
8.3.5.3 Fuel Flow Rate—Determine the fuel consumption
beneficial.
rate by measuring the fuel flowing to the day tank.
NOTE 3—Measurement of the EGR cooler gas inlet and outlet, and
coolant inlet and outlet temperatures is recommended. Additional exhaust
9. Engine/Stand Calibration and Non-Reference Oil Tests
temperature sensor locations, such as the exhaust ports and pre-turbine
NOTE 5—This section is addressed to those laboratories that choose to
(front and rear), are also recommended. The detection of changes in
utilize the services of the TMC in maintaining calibration of the test
exhaust temperature(s) is an important diagnostic in terms of satisfactory
stand.
engine operation.
9.1 General—Calibrate the test engine and the test stand by
8.3.4 Pressure Measurements:
conducting a test with a blind reference oil. Submit the results
8.3.4.1 Measurement Location and Equipment—This sec- 2
to the TMC for determination of acceptance according to the
tion specifies the pressure measurement locations. The mea-
Lubricant Test Monitoring System (LTMS).
surement equipment is not specified. Follow the guidelines
9.1.1 Because the Cummins ISB common rail engine is a
detailed in the DACA II Task Force Report for the accuracy
parent bore block and is not completely rebuilt before each test,
and resolution of the pressure measurement sensors and the
an engine is not referenced to a stand. The stand is calibrated
complete measurement system.
for use with different ISB common rail engines as supplied
from the CPD.
NOTE 4—It is beneficial to install a condensation trap at the lowest
elevation of the tubing between the pressure measurement location and the
9.2 New Test Stand—A new test stand is defined as a stand
final pressure sensor for crankcase pressure, intake air pressure, and
that has never been successfully calibrated before. Perform a
exhaust pressure. Route the tubing to avoid intermediate loops or low
spots before and after the condensation trap. calibration as described in 9.1 to introduce a new test stand into
the system.
8.3.4.2 Oil Gallery Pressure—Measure the pressure at the
metric, straight-thread fitting on the left front of the engine, 9.3 Stand Calibration Period:
located near the ECM, as shown in Fig. A4.12.
9.3.1 A test stand calibration test is carried out 12 months or
8.3.4.3 Oil Filter Inlet Pressure—Measure the pressure at 12 operationally valid non-reference oil tests, whichever comes
the ⁄8 in. NPT port located on the remote oil filter assembly, as first, following the completion of the last successful calibration
shown in Fig. A4.9. test.
D7484 − 23a
9.3.2 Last Start Date—A non-reference oil test can be members to volunteer enough reference oil test results to create
completed provided the warm-up is started prior to the expi- a robust data set. Broad laboratory participation is needed to
ration of the calibration period. provide a representative sampling of the industry. To ensure the
quality of the data obtained, donated tests are conducted on
9.4 Stand Modification and Calibration Status—
calibrated test stands. The Surveillance Panel shall arrange an
Modification of the test stand control systems or the conducting
appropriate number of donated tests and ensure completion of
of any non-standard test, or both, can invalidate the calibration
the test program in a timely manner.
status. A non-standard test includes any test conducted under a
modified procedure, non-procedural hardware, controller set-
9.9 Adjustments to Reference Oil Calibration Periods:
point modifications, or a combination thereof. Contact the
9.9.1 Procedural Deviations—On occasions when a labora-
TMC to determine if any such proposed modifications will
tory becomes aware of a significant deviation from the test
affect the calibration status.
method, such as might arise during an in-house review or a
9.5 Test Numbering System:
TMC inspection, the laboratory and the TMC shall agree on an
9.5.1 General—The test number has four parts, W-X-Y-Z:
appropriate course of action to remedy the deviation. This
W represents the test stand number, X represents the run
action may include the shortening of existing reference oil
number for that stand (and has a XXX format), Y represents the
calibration periods.
eight-digit serial number for that engine, and Z represents the
9.9.2 Parts and Fuel Shortages—Under special
number of test hours completed by that engine block prior to
circumstances, such as industrywide parts or fuel shortages, the
starting the test and has a format XXXX. The value for the
Surveillance Panel may direct the TMC to extend the time
number of test hours on the engine, Z, does NOT include the
intervals between reference oil tests. These extensions shall not
80 h break-in time (see 10.1) nor does it include time for
exceed one regular calibration period.
warm-up and cool-down run times. As an example, test number
9.9.3 Reference Oil Test Data Flow—To ensure continuous
64-002-57216596-0350 indicates stand number 64, test num-
severity and precision monitoring, calibration tests are con-
ber 002 for that stand, engine serial number 57216596, and the
ducted periodically throughout the year. There may be occa-
engine has 0350 test hours prior to starting this test on engine
sions when laboratories conduct a large portion of calibration
block 57216596. Every test start (reference oil and non-
tests in a short period of time. This could result in an
reference oil) increments X by one.
unacceptably large time frame when very few calibration tests
9.5.2 Reference Oil Tests—The sequential stand run number
are conducted. The TMC can shorten or extend calibration
remains unchanged for reruns of aborted, invalid, or unaccept-
periods as needed to provide a consistent flow of reference oil
able calibration tests. However, follow the sequential stand run
test data. Adjustments to calibration periods are made such that
number by a letter suffix (A for the first rerun, B for the second,
laboratories incur no net loss (or gain) in calibration status.
and so forth).
9.9.4 Special Use of the Reference Oil Calibration System—
9.5.3 Non-Reference Oil Tests—Do not add a letter suffix to
The Surveillance Panel has the option to use the reference oil
X for aborted or operationally invalid, non-reference oil tests.
system to evaluate changes that have potential impact on test
9.6 Reference Oil Test Acceptance:
severity and precision. This option is only taken when a
9.6.1 Reference oil test acceptance is determined in accor-
program of donated tests is not feasible. The Surveillance
dance with the LTMS.
Panel and the TMC shall develop a detailed plan for the test
9.7 Reference Oil Accountability:
program. This plan requires all reference oil tests in the
9.7.1 Laboratories shall provide a full accounting of the program to be completed as close to the same time as possible,
identification and quantities of all reference oils used. With the
so that no laboratory/stand calibration is left in an excessively
exception of the oil analyses required in 11.4, perform no
long pending status. In order to maintain the integrity of the
physical or chemical analyses of reference oils without written
reference oil monitoring system, each reference oil test is
permission from the TMC. In such an event, include the written
conducted so as to be interpretable for stand calibration. To
confirmation and the data generated in the reference oil test
facilitate the required test scheduling, the Surveillance Panel
report.
may direct the TMC to lengthen and shorten reference oil
9.7.2 Retain used reference oil samples for 90 days from the
calibration periods within laboratories such that the laborato-
End of Test (EOT) date.
ries incur no net loss (or gain) in calibration status.
9.8 Donated Reference Oil Test Programs—The ASTM 9.9.5 Non-Reference Oil Test Result Severity Adjustments—
This test method incorporates the use of a Severity Adjustment
D02.B0.02 Cummins Surveillance Panel is charged with main-
taining effective reference oil test severity and precision (SA) for non-reference oil test results. A control chart
technique, described in the LTMS, has been selected for
monitoring. During times of new parts introductions, new or
re-blended reference oil additions, and procedural revisions, it identi
...