ASTM D6923-23

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: D6923 − 23
Standard Test Method for
Evaluation of Engine Oils in a High Speed, Single-Cylinder
Diesel Engine—Caterpillar 1R Test Procedure
This standard is issued under the fixed designation D6923; 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 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 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 the TMC. 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.
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* oil consumption. It is performed in a laboratory using a
standardized high-speed, single-cylinder diesel engine.
1.1 This test method covers stressing an engine oil under
modern high-speed diesel operating conditions and measures 1.2 The values stated in SI units are to be regarded as
the oil’s deposit control, lubrication ability, and resistance to standard. No other units of measurement are included in this
standard.
1.2.1 Exceptions—Where there is no direct SI equivalent
This test method is under the jurisdiction of ASTM Committee D02 on
such as screw threads, national pipe threads/diameters, and
Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of
Subcommittee D02.B0 on Automotive Lubricants.
tubing size, or where a sole source supplier is specified.
Current edition approved July 1, 2023. Published July 2023. Originally approved
1.3 This standard does not purport to address all of the
in 2003. Last previous edition approved in 2018 as D6923 – 18. DOI: 10.1520/
D6923-23. safety concerns, if any, associated with its use. It is the
Until the next revision of this test method, the ASTM Test Monitoring Center
(TMC) will update changes in the test method by means of information letters.
Information letters may be obtained from the ASTM Test Monitoring Center, 203
Armstrong Drive, Freeport, PA 16229. Attention: Director. This edition incorporates Available from Caterpillar Inc., Engine System Technology Development, P.O.
revisions in all information Letters through No. 23-1. Box 610, Mossville, IL 61552-0610.
*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
D6923 − 23
responsibility of the user of this standard to establish appro-
Oil Consumption 12.4.2
Report 13
priate safety, health, and environmental practices and deter-
Forms and Data Dictionary 13.1
mine the applicability of regulatory limitations prior to use.
Test Validity 13.2
Being an engine test method, this test method does have Report Specifics 13.3
Precision and Bias 14
definite hazards that require safe practices (see Appendix X2
Precision 14.1
on Safety).
Bias 14.2
Keywords 9.11.1
1.4 The following is the Table of Contents:
Annexes
Engine and Parts Warranty Annex A1
Scope 1
Referenced Documents 2 Instrument Locations, Measurements and Calculations Annex A2
Cooling System Arrangement Annex A3
Terminology 3
Summary of Test Method 4 Intake Air Mass Flow Sensor Installation Annex A4
Fuel System Design and Required Components Annex A5
Significance and Use 5
Apparatus and Installation 6 Oil System Annex A6
Additional Report Forms Annex A7
Intake Air System 6.2.1
Exhaust System 6.2.2 Engine Assembly and Inspection Information Annex A8
Flushing Instructions and Apparatus Annex A9
Fuel System 6.2.3
Warm-up, Cool-down and Testing Conditions Annex A10
Oil Consumption System 6.2.4
Engine Oil System 6.2.5 Piston and Liner Rating Modifications Annex A11
Return Goods Authorization Claim Form Annex A12
Engine Coolant System 6.2.6
Engine Instrumentation 6.2.7 Appendixes
Various Examples of Supplemental Information for Appendix X1
Reagents and Materials 7
Oil Samples 8 Reference Purposes
Safety Appendix X2
Preparation of Apparatus 9
General Engine Assembly Practices 9.1
1.5 This international standard was developed in accor-
Complete Engine Inspection 9.2
dance with internationally recognized principles on standard-
Copper Component 9.3
Engine Lubricant System Flush 9.4
ization established in the Decision on Principles for the
Engine Piston Cooling Jet 9.5
Development of International Standards, Guides and Recom-
Engine Measurements and Inspections 9.6
mendations issued by the World Trade Organization Technical
Cylinder Head 9.7
Valve Guide Bushings 9.8
Barriers to Trade (TBT) Committee.
Fuel Injector 9.9
Piston and Rings 9.10
2. Referenced Documents
Cylinder Liner 9.11
Compression Ratio 9.12
2.1 ASTM Standards:
Engine Timing 9.13
D86 Test Method for Distillation of Petroleum Products and
Engine Coolant System Cleaning Procedure 9.14
Calibration and Standardization 10
Liquid Fuels at Atmospheric Pressure
Test Cell Instrumentation 10.1
D93 Test Methods for Flash Point by Pensky-Martens
Instrumentation Standards 10.2
Coolant Flow 10.3 Closed Cup Tester
Fuel Injectors 10.4
D97 Test Method for Pour Point of Petroleum Products
Air Flow 10.5
D130 Test Method for Corrosiveness to Copper from Petro-
Intake Air Barrel 10.6
Fuel Filter 10.7 leum Products by Copper Strip Test
Oil Scale Flow Rates 10.8
D235 Specification for Mineral Spirits (Petroleum Spirits)
Test Stand Calibration 10.9
(Hydrocarbon Dry Cleaning Solvent)
Re-calibration Requirements 10.9.1
Extending Test Stand Calibration Period 10.9.2 D445 Test Method for Kinematic Viscosity of Transparent
Test Run Numbering 10.10
and Opaque Liquids (and Calculation of Dynamic Viscos-
Humidity Calibration Requirements 10.11
ity)
Calibration of Piston Deposit Raters 10.12
Procedure 11 D524 Test Method for Ramsbottom Carbon Residue of
Engine Break-in Procedure 11.1
Petroleum Products
Cool-down Procedure 11.2
D613 Test Method for Cetane Number of Diesel Fuel Oil
Warm-up Procedure 11.3
Shutdowns and Lost Time 11.4 D664 Test Method for Acid Number of Petroleum Products
Periodic Measurements 11.5
by Potentiometric Titration
Engine Control Systems 11.6
D976 Test Method for Calculated Cetane Index of Distillate
Engine Coolant 11.6.1
Engine Fuel System 11.6.2
Fuels
Engine Oil Temperature 11.6.3
D1298 Test Method for Density, Relative Density, or API
Exhaust Pressure 11.6.4
Gravity of Crude Petroleum and Liquid Petroleum Prod-
Intake Air 11.6.5
Post-Test Procedures 11.7
ucts by Hydrometer Method
Piston Ring Side Clearances 11.7.1
D1319 Test Method for Hydrocarbon Types in Liquid Petro-
Piston Ratings 11.7.2
leum Products by Fluorescent Indicator Adsorption
Ring Gap End Increase 11.7.3
Cylinder Liner Wear 11.7.4
Cylinder Liner Bore Polish 11.7.5
Photographs 11.7.6
Calculation and Interpretation of Results 12
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Test Validity 12.1
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Calculations 12.4
Standards volume information, refer to the standard’s Document Summary page on
Quality Index 12.4.1
the ASTM website.
D6923 − 23
D2500 Test Method for Cloud Point of Petroleum Products 2.2 Other ASTM Document:
and Liquid Fuels ASTM Deposit Rating Manual 20 (formerly CRC Manual
20)
D2622 Test Method for Sulfur in Petroleum Products by
2.3 SAE Standard:
Wavelength Dispersive X-ray Fluorescence Spectrometry
SAE J183 Engine Oil Performance and Engine Service
D2709 Test Method for Water and Sediment in Middle
Classification
Distillate Fuels by Centrifuge
2.4 API Standard:
D3338 Test Method for Estimation of Net Heat of Combus-
API 1509 Engine Service Classification and Guide to Crank-
tion of Aviation Fuels
case Oil Selection
D3524 Test Method for Diesel Fuel Diluent in Used Diesel
Engine Oils by Gas Chromatography
3. Terminology
D4052 Test Method for Density, Relative Density, and API
3.1 Definitions:
Gravity of Liquids by Digital Density Meter
3.1.1 additive, n—a material added to another, usually in
D4175 Terminology Relating to Petroleum Products, Liquid
small amounts, to impart or enhance desirable properties or to
Fuels, and Lubricants
suppress undesirable properties. D4175
D4485 Specification for Performance of Active API Service
3.1.2 automotive, adj—descriptive of equipment associated
Category Engine Oils
with self-propelled machinery, usually vehicles driven by
D4739 Test Method for Base Number Determination by
internal combustion engines. D4485
Potentiometric Hydrochloric Acid Titration
D4863 Test Method for Determination of Lubricity of Two- 3.1.3 blind reference oil, n—a reference oil, the identity of
Stroke-Cycle Gasoline Engine Lubricants (Withdrawn which is unknown by the test facility.
3.1.3.1 Discussion—This is a coded reference oil, which is
2022)
submitted by a source independent from the test facility. D5844
D5185 Test Method for Multielement Determination of
Used and Unused Lubricating Oils and Base Oils by
3.1.4 blowby, n—in internal combustion engines, the com-
Inductively Coupled Plasma Atomic Emission Spectrom-
bustion products and unburned air-and-fuel mixture that enter
etry (ICP-AES)
the crankcase. D5302
D5302 Test Method for Evaluation of Automotive Engine
3.1.5 calibrate, v—to determine the indication or output of a
Oils for Inhibition of Deposit Formation and Wear in a
measuring device with respect to that of a standard. E344
Spark-Ignition Internal Combustion Engine Fueled with
3.1.6 calibrated test stand, n—a test stand on which the
Gasoline and Operated Under Low-Temperature, Light-
testing of reference material(s), conducted as specified in the
Duty Conditions (Withdrawn 2003)
standard, provided acceptable test results.
D5844 Test Method for Evaluation of Automotive Engine
3.1.6.1 Discussion—In several automotive lubricant stan-
Oils for Inhibition of Rusting (Sequence IID) (Withdrawn 2
dard test methods, the TMC provides testing guidance and
2003)
determines acceptability. D6681
D5862 Test Method for Evaluation of Engine Oils in Two-
3.1.7 candidate oil, n—an oil which is intended to have the
Stroke Cycle Turbo-Supercharged 6V92TA Diesel Engine
performance characteristics necessary to satisfy a specification
(Withdrawn 2009)
and is to be tested against that specification. D5844
D5966 Test Method for Evaluation of Engine Oils for Roller
3.1.8 debris, n—in internal combustion engines, solid con-
Follower Wear in Light-Duty Diesel Engine
taminant materials unintentionally introduced into the engine
D5967 Test Method for Evaluation of Diesel Engine Oils in
or resulting from wear. D5862
T-8 Diesel Engine
3.1.9 dispersant, n—in engine oil, an additive that reduces
D6202 Test Method for Automotive Engine Oils on the Fuel
deposits on oil-wetted surfaces primarily through suspension of
Economy of Passenger Cars and Light-Duty Trucks in the
particles. D4175
Sequence VIA Spark Ignition Engine (Withdrawn 2009)
D6594 Test Method for Evaluation of Corrosiveness of
3.1.10 engine oil, n—a liquid that reduces friction or wear,
Diesel Engine Oil at 135 °C or both, between the moving parts within an engine; removes
D6681 Test Method for Evaluation of Engine Oils in a High heat, particularly from the underside of pistons; and serves as
a combustion gas sealant for the piston rings.
Speed, Single-Cylinder Diesel Engine—Caterpillar 1P
Test Procedure 3.1.10.1 Discussion—It may contain additives to enhance
certain properties. Inhibition of engine rusting, deposit
E29 Practice for Using Significant Digits in Test Data to
formation, valve train wear, oil oxidation and foaming are
Determine Conformance with Specifications
examples. D5862
E344 Terminology Relating to Thermometry and Hydrom-
etry
G40 Terminology Relating to Wear and Erosion 6
For Stock #TMCMNL20, visit the ASTM website, www.astm.org, or contact
ASTM International Customer Service at service@astm.org.
Available from Society of Automotive Engineers (SAE), 400 Commonwealth
Dr., Warrendale, PA 15096-0001.
5 8
The last approved version of this historical standard is referenced on Available from The American Petroleum Institute (API), 1220 L. St., NW,
www.astm.org. Washington, DC 20005.
D6923 − 23
3.1.11 heavy-duty, adj—in internal combustion engine 4. Summary of Test Method
operation, characterized by average speeds, power output and
4.1 Prior to each test, the power section of the engine is
internal temperatures that are close to the potential maximums.
disassembled, solvent-cleaned, measured, and rebuilt in strict
D4485
accordance with the specifications. A new piston, ring
3.1.12 lubricant, n—any material interposed between two assembly, and cylinder liner are measured and installed for
surfaces that reduces the friction or wear, or both, between
each test. The engine crankcase is solvent-cleaned, and worn or
them. D5862 defective parts are replaced. The test stand is equipped with
feedback control systems for fuel rate, engine speed, and other
3.1.13 lubricating oil, n—a liquid lubricant, usually com-
engine operating conditions. Provide a suitable system for
prising several ingredients, including a major portion of base
filtering, compressing, humidifying, and heating the inlet air
oil and minor portions of various additives. D5966
along with a system for controlling the engine exhaust pres-
3.1.14 non-reference oil, n—any oil other than a reference
sure. Test operation involves the control of the single-cylinder
oil; such as a research formulation, commercial oil or candidate
diesel test engine, using the test oil as a lubricant, at a specified
oil. D5844
speed and fuel rate input, for a total of 504 h. A defined
3.1.15 oxidation, n—of engine oil, the reaction of the oil
break-in precedes each test. A prescribed warm-up is used
with an electron acceptor, generally oxygen, that can produce
when restarting the engine. At the end of the test, the piston
deleterious acidic or resinous materials often manifested as
deposits are rated; the piston, rings and liners are inspected,
sludge formation, varnish formation, viscosity increase, or
measured, and photographed; oil consumption is calculated,
corrosion, or combination thereof. D6681
and the oil is analyzed to determine the test results. Critical
engine operating conditions are statistically analyzed to deter-
3.1.16 purchaser, n—of an ASTM test, person or organiza-
mine if the test was precisely operated. Test acceptability
tion that pays for the conduct of an ASTM test method on a
parameters, for each calibration test, are also statistically
specified product. D6202
analyzed to determine if the engine/test stand produce the
3.1.17 reference oil, n—an oil of known performance
specified results.
characteristics, used as a basis for comparison.
3.1.17.1 Discussion—Reference oils are used to calibrate
5. Significance and Use
testing facilities, to compare the performance of other oils, or
5.1 This is an accelerated engine oil test, performed in a
to evaluate other material (such as seals) that interact with oils.
standardized, calibrated, stationary single-cylinder diesel en-
D5844
gine that gives a measure of (1) piston and ring groove deposit
3.1.18 scoring, n—in tribology, a severe form of wear
forming tendency, (2) piston, ring, and liner scuffing and (3) oil
characterized by the formation of extensive grooves and
consumption. The test is used in the establishment of diesel
scratches in the direction of sliding. G40
engine oil specification requirements as cited in Specification
D4485 for appropriate API Performance Category C oils (API
3.1.19 scuff, scuffıng, n—in lubrication, damage caused by
1509). The test method can also be used in diesel engine oil
instantaneous localized welding between surfaces in relative
development.
motion that does not result in immobilization of the parts.
D4863
6. Apparatus and Installation
3.1.20 sponsor, n—of an ASTM test method, an organization
6.1 The test engine is an electronically controlled, direct
that is responsible for ensuring supply of the apparatus used in
injection, in-head camshaft, and single-cylinder diesel engine
the test procedure portion of the test method.
with a four-valve arrangement. The engine has a 137.2 mm
3.1.20.1 Discussion—In some instances, such as a test
bore and a 165.1 mm stroke resulting in a displacement of
method for chemical analysis, an ASTM working group can be
2.4 L.
the sponsor of the test method. In other instances, a company
6.1.1 The Electronic Control Module (ECM) defines the
with a self-interest may or may not be the developer of the test
desired engine fuel timing, monitors and limits maximum
procedure used within the test method, but is the sponsor of the
engine speed, maximum engine power, minimum oil pressure,
test method. D6594
and, optionally, maximum engine crankcase pressure. The
3.1.21 used oil, n—any oil that has been in a piece of
ECM also controls the fuel injection duration that defines the
equipment (for example, an engine, gearbox, transformer, or
engine fuel rate based on set conditions from the test cell
turbine), whether operated or not. D4175
feedback control systems. The oil pressure is also set by the
3.1.22 varnish, n—in internal combustion engines, a hard, ECM with signals to the 1Y3867 Engine Air Pressure Control-
dry, generally lustrous deposit that can be removed by solvents ler (Mamac) to modulate the facility air supply to the 1Y3898
but not by wiping with a cloth. D5302 Johnson Controls Relief Valve.
6.1.2 The 1Y3700 engine arrangement also consists of inlet
3.1.23 wear, n—the loss of material from, or relocation of
air piping and hoses from the cylinder head to the air barrel and
material on, a surface.
exhaust piping and bellows from the cylinder head to the
3.1.23.1 Discussion—Wear generally occurs between two
exhaust barrel that are specifically designed for oil testing.
surfaces moving relative to each other, and it is the result of
mechanical or chemical action or by a combination of me- 6.2 Equip the engine test stand with the following accesso-
chanical and chemical actions. D5302 ries or equipment:
D6923 − 23
6.2.1 Intake Air System—The intake air system components from one of the three approved manufacturers. Install the
from the cylinder head to the air barrel are a part of the basic exhaust barrel at the location shown in Annex A2. Do not add
1Y3700 engine arrangement. These components consisting of insulation to the barrel. Any of the approved suppliers can
an adapter, elbow, hose, clamps, and flanged tube can be found modify the exhaust barrel in order to meet appropriate ASME
in the 1Y3700 Parts Book. pressure vessel codes that accommodate the high temperature
6.2.1.1 Purchase the 1Y3978 intake air barrel (which is and pressure conditions of this 1R test method. Drawings of the
almost identical to the exhaust barrel except for the top cover) permitted modifications are located with Gaspar, Inc.
from one of the three approved manufacturers. Install the 6.2.2.2 Install a restriction valve downstream from the
intake air barrel at the location shown in Annex A2. Do not add exhaust barrel. The distance between the valve and barrel is not
insulation to the barrel. specified. The location of the exhaust thermocouple is shown
6.2.1.2 Paint the inside of the intake air piping with Cater- in Annex A2. Measure the exhaust pressure at the exhaust
pillar yellow primer or red Glyptal prior to installation. barrel shown in Annex A2.
6.2.1.3 Install the air heater elements in the intake air barrel 6.2.2.3 Use feedback-equipped controls to maintain the
as specified in Annex A2 (even if they will not be supplied with exhaust gases at the pressure specified in Annex A10.
11,12
electricity). 6.2.3 Fuel System—The fuel system schematic is shown in
6.2.1.4 Use an air filter capable of 10 μm (or smaller) Annex A5. The ECM controls fuel injection timing at 6° BTC.
filtration. Measure the fuel rate using a Micro Motion device scaled to
14,12
6.2.1.5 Use a Sierra Model 780 airflow meter with Feature the 1R operation range specified in Annex A10. Use the
1 = F6, Feature 2 = CG and calibrated at the following day tank specified in Annex A5. Measure fuel temperature at
conditions to measure intake airflow for each calibration the fuel filter base as shown in Annex A2 and control it using
13,12
test: the cell facility feedback system. Use the required fuel heat
exchanger(s) and arrange them as specified in Annex A5. Use
Temperature = 60 °C
Humidity = 17.8 g/kg
the Fisher regulator specified in Annex A5.
Pressure = 292 kPa (abs)
6.2.4 Oil Consumption System—Use an oil scale system to
Approximate flow range = 425 kg/h
accurately measure oil consumption (see Annex A6). The oil
Annex A4 shows the piping requirements for the installation
scale system shall have a resolution as listed in Annex A2. Use
of the Sierra Model 780 airflow meter. For tests not using the
flexible hoses similar to Aeroquip flexible hose, FC352-08,
airflow meter, maintain instrumentation configuration using a
to-and-from the oil scale reservoir to eliminate measurement
spool piece of equivalent dimensions.
15,12
errors. Use No. 5 TFE-fluorocarbon, steel-braided hoses to
6.2.1.6 Measure the inlet air temperature at the location
and from the oil scale pumps. The hose length to-and-from the
shown in Annex A2. Measure the inlet air pressure at the air
oil scale cart shall not exceed 2700 mm. Use the special oil pan
barrel as shown in Annex A2. The location of the 1Y3977
adapter described in Annex A6. The flow rates for the oil
Humidity Probe is shown in Annex A4. The sample line may
consumption oil scale pumps shall be (23.6 to 24.9) kg/h for
require insulation to prevent dropping below dew point tem-
the oil being pumped from the oil pan to the oil scale, and (16.3
perature and shall not be hygroscopic. Drain taps may be
to 17.7) kg ⁄h for the oil being pumped from the oil scale to the
installed at the low points of the combustion air system.
oil pan. See Annex A6 for the procedure to verify these flow
6.2.1.7 Use feedback-equipped controls to maintain filtered,
rates.
compressed, and humidified inlet air at the conditions specified
6.2.5 Engine Oil System—A schematic of the oil system is
in Annex A10.
shown in Annex A6. Measure oil pressure at the engine oil
6.2.2 Exhaust System—The exhaust system components
manifold (see Annex A2). An engine oil pressure sensor
from the cylinder head to the exhaust barrel are part of the
transmits a signal to the ECM that maintains oil pressure at
basic 1Y3700 engine arrangement. These components consist-
415 kPa. The ECM transmits a signal to an engine-mounted
ing of an adapter, elbow, bellows, flange, and clamps can be
Mamac air pressure controller. The Mamac modulates the
found in the 1Y3700 Parts Book.
facility air pressure of 280 kPa to levels that vary between (0
6.2.2.1 Purchase the 1Y3976 exhaust barrel (which is al-
to 140) kPa and directs it to the normally closed Johnson
most identical to the intake barrel except for the top cover)
Controls relief valve. Because the engine oil pressure sensor
calibration may vary from the cell data acquisition transducer,
vary the oil pressure adjust signal to the ECM to maintain the
Cimino Machinery Corp., 5958 South Central Ave, Chicago, IL 60638. Gaspar
oil pressure at the test specifications. See the Electronic
Inc., 4106 Mahoning Rd. N.E., Canton, OH 44705. M.L. Wyrick Welding, 2301
Installation and Operation manual for additional information.
Zanderson Highway 16 N, Jourdanton, TX 78026.
Crankcase Paint Primer: BASF Coating and Colorant Div., P.O. Box 1297, The ECM maintains the oil pressure regardless of engine
Morganton, NC 28655. Primer #A123590 & BASF Part #U27YD005. Yellow CAT
speed. Measure the oil temperatures at locations shown in
Primer Part #IE2083A.
Annex A2. Install 1Y4021 gaskets on each side of the 1Y3661
The sole source of supply of the apparatus known to the committee at this time
oil pump bypass lock nut to prevent oil aeration (see Annex
is Watlow Air Heaters, Chicago, IL.
If you are aware of alternative suppliers, please provide this information to
ASTM International Headquarters. Your comments will receive careful consider-
1 14
ation at a meeting of the responsible technical committee, which you may attend. The sole source of supply of the apparatus known to the committee at this time
is Micro Motion, Inc. 7070 Winchester Circle, Boulder, CO 80301.
13 15
The sole source of supply of the apparatus known to the committee at this time The sole source of supply of the apparatus known to the committee at this time
is Sierra Instruments, Inc., 5 Harris Court, Monterey, CA 93940. is Aeroquip Industrial Div, 1225 W. Main Street, Van Wert, OH 45891.
D6923 − 23
A6). When a new pump is installed, begin adjustment of the 6.2.10 Crankcase Pressure—Measure crankcase pressure at
pressure relief plug with 43.7 mm of thread exposed as shown the location shown in Annex A2.
in Annex A6. Optional oil pressure sensor lines may be
NOTE 1—The crankcase pressure is above atmospheric pressure with
installed at the oil filter block as shown in Fig. A2.6 for
this engine.
measuring the differential pressure across the oil filter.
6.3 Obtain information concerning the test engine, engine
6.2.5.1 Oil Heating System—Use an external oil heating
electronics system, new engine parts, replacement parts and
system provided by the test facility to maintain the engine oil
permissible substitution or replacement parts from Caterpillar,
manifold temperature specified in Annex A10. An example
Inc.
system is shown in Appendix X1. A special 1Y3908 oil cooler
6.4 Engine and parts warranty information can be found in
bonnet has been designed to allow separate fluids to the engine
Annex A1. Use the form listed in Annex A12 for returning
coolant tower (see Annex A6). Plug the 1Y3660 oil cooler
defective parts.
adapter and 1Y3908 heat exchanger bonnet as shown in Annex
16,12
A6. Use Paratherm NF for the heating fluid. The tempera-
7. Reagents and Materials
ture of the Paratherm NF is measured by the thermocouple
shown in Annex A2. An additional heat exchanger may be
7.1 Purity of Reagents—Use reagent grade chemicals in all
installed to provide cooling capability, if necessary, to maintain
tests. Unless otherwise indicated, it is intended that all reagents
test conditions.
conform to the specifications of the Committee on Analytical
6.2.5.2 Oil Sample Valve—Refer to Annex A2 for the
Reagents of the American Chemical Society where such
installation location and component makeup of the oil sample
specifications are available. Other grades may be used,
valve. Use of alternative equivalent components for the sample
provided it is first ascertained that the reagent is of sufficiently
valve is permitted.
high purity to permit its use without lessening the accuracy of
6.2.6 Engine Coolant System—The coolant system sche-
the determination.
matic is shown in Annex A3. Pressurize the coolant tower with
7.2 Diesel Piston Rating Booth, as described by ASTM
compressed air as specified in Annex A3 to ensure water does
Deposit Rating Manual 20.
not boil out of the antifreeze mixture. Control the coolant
7.3 Diesel Piston Rating Lamp, as described by ASTM
temperature out of the engine using a cell facility feedback
Deposit Rating Manual 20.
system. Use a 1Y3898 Johnson Controls valve or equivalent
fail-open valve to regulate the coolant temperature out of the
7.4 Engine Coolant—Use a mixture of 50 % mineral-free
engine as shown by the schematic in Annex A3. If the 1Y3898
water and 50 % Caterpillar brand coolant (P/N 8C684 for 3.8 L
Johnson valve is used, supply facility air pressure at 280 kPa to
concentrated or P/N 101-2845 for 208 L drum already pre-
the controller that regulates air pressure to the valve at (0 to
mixed) for engine coolant. Mineral-free water is defined as
140) kPa. Install a feedback-equipped control system to pneu-
water having a mineral content no higher than 34.2 mg/kg total
matically adjust the valve. Remove the 1Y3832 hose originally
dissolved solids. The coolant mixture may be reused for 3 test
supplied with the engine and install a sight glass using the
starts or up to 1600 h. Keep the mixture at a 50-50 ratio as
components shown in Annex A3. Use Caterpillar part no.
determined by using either Caterpillar testers 5P3514 or
9X2378 replacement bulk hose for coolant hoses in the
5PO957 or an equivalent tester. Keep the coolant mixture
Caterpillar 1Y3700 engine.
contamination free. Total solids shall remain below
6.2.7 Engine Instrumentation—Use feedback-equipped sys-
5000 mg ⁄kg. Keep the additive level correct using Caterpillar
tems to control the engine operating temperatures, pressures,
test kit P/N 8T5296.
and flow rates. Measure the engine operating conditions at the
7.5 Lead Shot, commercial grade, approximately 5 mm in
locations shown in Annex A2. For temperature measurements,
diameter.
use thermocouples 1Y468 (intake air), 1Y467 (engine exhaust)
and 1Y466 (fluids-water, oil and fuel) or equivalent thermo- 7.6 Light Grease.
couples as specified in Annex A2. Install thermocouples with
7.7 Mobil EF-411, to be obtained for engine assembly and
the tips at midstream. The thermocouple insertion depths listed 18,12
calibration of the oil scale pump flow rates.
in Annex A2 are approximate depending on the mountings or
7.8 Paratherm NF, to be obtained from Paratherm and used
fittings used. Instrument measurement and reporting resolu-
as the fluid to heat the engine oil.
tions are shown in Annex A2.
6.2.8 Use a dynamometer with feedback control to maintain 7.9 Pentane (Solvent), Purity >99 %, high-performance liq-
engine torque and speed. Use a starting system capable of at uid chromatography grade.
least 136 N·m breakaway torque and 102 N·m sustained torque
at 200 r/min.
6.2.9 Blowby—Measure engine blowby down stream of the
ACS Reagent Chemicals, Specifications and Procedures for Reagents and
engine breather housing by measuring the delta pressure across
Standard-Grade Reference Materials, American Chemical Society, Washington,
DC. For suggestions on the testing of reagents not listed by the American Chemical
an orifice or an equivalent device.
Society, see Analar Standards for Laboratory Chemicals, BDH Ltd., Poole, Dorset,
U.K., and the United States Pharmacopeia and National Formulary, U.S. Pharma-
copeial Convention, Inc. (USPC), Rockville, MD.
16 18
The sole source of supply of the apparatus known to the committee at this time The sole source of supply of Mobil EF-411 known to the committee at this
is Paratherm NF Oil, Conshohocken, PA 19428. time is Golden West Oil Co., 3010 Aniol St, San Antonio, TX 78219.
D6923 − 23
7.10 Reference Oil, to be obtained from the TMC for 9.2 Complete Engine Inspection—Perform a complete en-
calibration of the test stand. gine inspection prior to the first calibration test scheduled after
15 000 h of test time. Ensure that wearing surfaces such as
7.11 Sodium Bisulfate (NaHSO ), commercial grade.
main bearings and journals, rod bearings and journals, cam-
7.12 Solvent—Use only mineral spirits meeting the require-
shaft bearings, valve train components, fuel system
ments of Specification D235, Type II, Class C for Aromatic
components, and so forth all are within manufacturer’s speci-
Content ((0 to 2) vol %), Flash Point (61 °C, min) and Color
fications. Refer to the 1Y3700 Service Manual for disassembly,
(not darker than +25 on Saybolt Scale or 25 on Pt-Co Scale).
assembly, inspections, and specifications. Paint crankcases, as
(Warning—Combustible. Health hazard.) Obtain a Certificate
necessary, with either Caterpillar yellow primer or red Glyp-
of Analysis for each batch of solvent from the supplier.
tal.
7.13 Test Fuel—The specified test fuel is Chevron Phillips
9.3 Copper Components—It is recommended that anytime a
19,12
PC-9-HS Reference Diesel Fuel. The specification require-
copper part is replaced, run an engine test until two consecutive
ments are shown in Annex A7.
12 h periods show a stable copper level in the used oil. Do not
7.14 Test Oil—The total amount of oil needed for each test use rocker arms with a package date earlier than January 2000.
is approximately 42 L.
9.4 Engine Lubricant System Flush—Flush the engine of
7.15 Trisodium Phosphate (Na PO ), commercial grade. used oil before every test. Annex A9 shows the Engine Flush
3 4
20,12 Procedure and Apparatus. A flushing instruction sheet shown in
7.16 5.4000 in. Ring Bore Standard Class Z Master.
Table A9.1 gives the step-by-step process required for flushing.
The 1Y3700 engine includes five flushing nozzles in the
8. Oil Samples and Additions
crankcase and front cover (see Annex A9). These nozzles are
8.1 Take a 60 mL purge sample and a 120 mL sample at (36,
piped in parallel with the 1Y3935 filter flushing adapter (or
144, 252, 360, 432, 504) h. Take a 60 mL purge sample and a
equivalent) from a laboratory–provided manifold that pressur-
30 mL sample at (72, 108, 180, 216, 288, 324, 396, 468) h.
izes fluids supplied by a flush cart (see Appendix X1). To
Analyze the (36, 144, 252, 360, 432, 504) h samples for (100
increase flushing pressure, the oil pan may be plumbed as
and 40) °C viscosity by Test Method D445, BN by Test Method
shown in Appendix X1. Seal the gear train housing during
D4739, AN by Test Method D664, wear metals Al, Cr, Cu, Fe,
flush with a 1Y3917 round plug with a 117-8801 O-ring as
Pb, Si by Test Method D5185, and differential 1R O2 using the
shown in Annex A9. Seal the crankcase using a 1Y3979 block
peak-area method 5. Analyze the (36, 360, 504) h samples for
flush cover with an internal bleed passage for the cam oil
fuel dilution by Test Method D3524. Analyze the (360, 432,
supply. Bolt a 1Y3980 plastic jet aiming fixture to the flush
504) h samples for TGA soot by Annex A4 of Test Method
cover that is also used for flushing (see Annex A9). Modify the
D5967. The (72, 108, 180, 216, 288, 324, 396, 468) h samples
crankcase side covers as shown in Annex A9 to accommodate
are for optional analysis such as wear metals for mechanical
the flushing wand for a thorough flushing of the crankcase. If
problems.
the test oil is not available at engine assembly, Mobil EF411 oil
8.2 Add new oil as computed in the worksheet shown in
may be substituted.
Annex A6.
9.5 Engine Piston Cooling Jet—Use cooling jet part no.
1Y4011 and bolt 1Y4010. The piston cooling jets are flow-
9. Preparation of Apparatus
checked at the supplier and serialized to ensure proper
9.1 General Engine Assembly Practices—As a part of good
performance, but the rod clearances are minimal, which may
laboratory practice, inspect all components and assemblies that
result in jet movement during assembly. Verify proper jet flow
are exposed when the engine is disassembled and record the
positioning using test oil or EF-411 before each test with the
information for future reference. Inspect valve train
1Y3980 plastic jet aiming fixture and 415 kPa oil pressure to
components, bearings, journals, housings, seals and gaskets,
the manifold. Record the cooling jet serial number.
and so forth and replace as needed. Assemble the engine with
9.6 Engine Measurements and Inspections—Measure and
components and bolt torques as specified in the 1Y3700 engine
inspect the engine components prior to each test. Refer to the
Service Manual (see Annex A8 for a partial list). It is the intent
1Y3700 Service Manual for information concerning compo-
of this procedure for all engine assemblies and adjustments to
nent reusability and assembly not found in this procedure. The
be targeted to the mean of the specified values. Clean and
part numbers of components that need replacing are found in
lubricate the components in keeping with good assembly
the 1Y3700 Parts Manual. Record the crankshaft angles at the
practices. Keep airborne dirt and debris to a minimum in the
specified maximum injector lift, exhaust, and intake maximum
assembly area. Maintain standard engine assembly techniques
lift before each test using the reference listed in Annex A8.
and practices (such as staggering piston ring gap positions, and
Record component part numbers and serial numbers and other
so forth).
required measurements as shown in the test report. Inspect and
reuse the rocker arm roller followers and camshaft lobe
19 surfaces based on Caterpillar Service Publication SEBF8256.
The sole source of supply of the apparatus known to the committee at this time
is Chevron Phillips Chemical Company LP, 10001 Six Pines Dr., Suite 4036B, The
9.7 Cylinder Head—A reconditioned head is required for
Woodlands, TX 77387–4910, www.cpchem.com.
each test. Measurements after reconditioning shall be within
The sole source of supply of the apparatus known to the committee at this time
is Morse-Hemco, 457 Douglas Ave., Holland, MI 49423. specifications as shown in the 1Y3700 Service Manual. Do not
D6923 − 23
swap the cylinder head/jug assembly from test stand-to-test piston diameters. Hold them in place with light grease. With
stand. Use the head/jug assembly used to calibrate the stand for the piston near the top of the stroke, install the head and block
all non-reference oil testing in that stand. In the event of a
assembly and torque to specifications. Turn the engine over top
cylinder head/jug failure during the calibration period, a center by hand to compress the lead balls then remove the head
cylinder head/jug used on a successful 1R calibration attempt
and block assembly and measure the thickness of the lead balls
within the past two years may be used without re-calibration.
to obtain the average piston-to-head clearance. The piston-to-
Annex A8 shows the cylinder head nut torque sequence. Use
head clearance specification is (1.62 6 0.07) mm. Use multiple
Caterpillar part no. 175-7523-J for the inner spring, 175-7526-J
1Y3817 block gaskets to adjust the clearance. If the piston-to-
for the outer spring and 186-2001 for the rotocoil.
head measurement exceeds the tolerance specification, check
the crankshaft main and rod journals, connecting rod and main
9.8 Valve Guide Bushings—Clean the valve guide bushings
bearings, and piston pin and rod bushing for excessive wear.
with a solvent and bristle brush prior to assembly. Lubricate the
The specified compression ratio for the 1Y3700 engine is
bushings and valve stems with Mobil EF-411 prior to assem-
16.2:1.
bly. See the 1Y3700 Service Manual for guide reusability
specifications. Install new valve guide seals for each test.
9.13 Engine Timing—Use ECM EPROM part no. 169-5028
9.9 Fuel Injector—Remove the fuel injector from the cyl-
with a date code of 10/98. The engine ECM sets desired fuel
inder head before reconditioning commences. Refer to the injection timing to 6° (BTC). Record this timing using the
1Y3700 Service Manual for removal and assembly. Return
Engine Technician Service Tool. Mechanically time the actual
defective fuel injectors to Caterpillar for warranty and failure-
engine components as shown in Annex A8. Install the elec-
mode testing using the form listed in Annex A12.
tronic sensors as shown in the Electronic Installation and
Operation manual. Correctly assemble both the mechanical and
9.10 Piston and Rings—Use a new piston (1Y4016 iron
electrical systems to produce the desired fuel timing.
crown, 1Y4015 aluminum skirt) and new rings (1Y4014,
1Y4013, 1Y4012) for each test. Clean all three rings with
9.14 Engine Coolant System Cleaning Procedure—Clean
pentane and a lint-free cotton towel. Measure the ring side
the coolant system when visual inspections show the presence
clearances and ring end gaps for all three rings (see Annex A8).
of any oil, grease, mineral deposits, or rust following the
Keystone ring side clearance measurements require the ring to
procedure listed in Annex A3.
be confined in a dedicated slotted liner (see Appendix X1) or
20,12
9.15 After the engine components have been prepared and
a 137.16 mm ring gauge. Measure the side clearances
assembled, perform the following:
using four feeler gauges of equal width and 0.01 mm gradua-
tions at 90° intervals around the piston. Measure the rectangu-
9.15.1 Fill the crankcase with (5800 6 50) g of test oil.
lar ring side clearance this way as well. Measure the minimum
9.15.2 Install a new 1R0713 oil filter.
side clearance as specified in ASTM Deposit Rating Manual
9.15.3 Fill the coolant system with coolant specified in
20. Record the measurements for these parts before and after
Section 7.
each test. Compare the measurements before the test and after
9.15.4 Ensure the facility coolant to the engine heat ex-
the test to determine the amount of wear. Assemble the piston
changer is operational.
with the part number toward the camshaft.
9.15.5 Pressurize the fuel system to remove air, then return
9.11 Cylinder Liner—Use a new 1Y3805 or 1Y3997 cylin-
the system to a non-pressurized state before starting engine.
der liner for each test. After removing the protective oil/grease
9.15.6 Ensure all other systems and facilities are operational
with solvent, clean the liner bore with a hot tap water and soap
before starting the engine break-in.
solution, then rinse with hot tap water.
9.11.1 Measure and record the liner surface finish. The
10. Calibration and Standardization
surface finish specification shown in Fig. A8.3 does not apply
to the 1Y3997 liner.
10.1 Test Cell Instrumentation—Calibrate all facility read-
9.11.2 Oil the liner bore with only Mobil EF-411. Assemble
out instrumentation used for the test immediately prior to stand
the cylinder liner, block and head with the torque specification
calibration. Instrumentation calibration following a failed or
shown in the 1Y3700 Service Manual or Annex A8.
invalid test is at the discretion of the test laboratory, or as
9.11.3 Measure the liner with a dial bore gauge to ensure
directed by the TMC. Refer to Annex A2 for calibration
that the out-of-round and taper conditions are within specified
tolerances and allowable system time constants.
tolerances measured at seven intervals as shown in Annex A8.
10.2 Instrumentation Standards—Calibrate all temperature,
9.11.4 Measure the cylinder liner projection using the modi-
pressure, flow and speed measurement standards on a yearly
fied indicator shown in Annex A8.
basis. The calibration of all standards shall be traceable to a
9.11.5
...