ASTM D6681-23

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: D6681 − 23
Standard Test Method for
Evaluation of Engine Oils in a High Speed, Single-Cylinder
Diesel Engine—Caterpillar 1P Test Procedure
This standard is issued under the fixed designation D6681; 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 method described in
this standard. However, 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 method. In addition, the TMC may issue supplementary memoranda related to the
test method.
1. Scope* 1.3 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
1.1 This test method covers and is required to evaluate the
responsibility of the user of this standard to establish appro-
performance of engine oils intended to satisfy certain American
priate safety, health, and environmental practices and deter-
Petroleum Institute (API) C service categories (included in
mine the applicability of regulatory limitations prior to use.
Specification D4485). It is performed in a laboratory using a
4 Being an engine test method, this standard does have definite
standardized high-speed, single-cylinder diesel engine. Piston
hazards that require safe practices (see Appendix X2 on
and ring groove deposit-forming tendency and oil consumption
Safety).
is measured. The piston, the rings, and the liner are also
1.4 The following is the Table of Contents:
examined for distress and the rings for mobility.
Section
1.2 The values stated in SI units are to be regarded as
Scope 1
standard. No other units of measurement are included in this Referenced Documents 2
Terminology 3
standard.
Summary of Test Method 4
1.2.1 Exceptions—Where there is no direct SI equivalent
Significance and Use 5
such as screw threads, National Pipe Threads/diameters, tubing Apparatus and Installation 6
Intake Air System 6.2.1
size, or where there is a sole source supply equipment
Exhaust System 6.2.2
specification.
Fuel System 6.2.3
Oil Consumption System 6.2.4
Engine Oil System 6.2.5
This test method is under the jurisdiction of ASTM Committee D02 on
Oil Heating System 6.2.5.1
Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of
Oil Sample Valve 6.2.5.2
Subcommittee D02.B0.02 on Heavy Duty Engine Oils.
Engine Coolant System 6.2.6
Current edition approved July 1, 2023. Published July 2023. Originally approved
Engine Instrumentation 6.2.7
in 2001. Last previous edition approved in 2017 as D6681 – 17. DOI: 10.1520/
Reagents and Materials 7
D6681-23. Oil Samples 8
ASTM Test Monitoring Center (TMC), 203 Armstrong Drive, Freeport, PA Preparation of Apparatus 9
General Engine Assembly Practices 9.1
16229.
Complete Engine Inspection 9.2
This edition incorporates revisions contained in all information letters through
Copper Components 9.3
23-1. Users of this test method shall contact the ASTM Test Monitoring Center to
Engine Lubricant System Flush 9.4
obtain the most recent information letters.
Engine Piston Cooling Jets 9.5
Available from Caterpillar Inc., Engine System Technology Development, P.O.
Engine Measurements and Inspections 9.6
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
D6681 − 23
1.5 This international standard was developed in accor-
Section
Cylinder Head 9.7
dance with internationally recognized principles on standard-
Valve Guide Bushings 9.8
ization established in the Decision on Principles for the
Fuel Injector 9.9
Development of International Standards, Guides and Recom-
Piston and Rings 9.10
Cylinder Liner 9.11
mendations issued by the World Trade Organization Technical
Compression Ratio 9.12
Barriers to Trade (TBT) Committee.
Engine Timing 9.13
Engine Coolant System Cleaning Procedure 9.14
Calibration and Standardization 10
2. Referenced Documents
Test Cell Instrumentation 10.1
2.1 ASTM Standards:
Instrumentation Standards 10.2
Coolant Flow 10.3
D86 Test Method for Distillation of Petroleum Products and
Re-calibration Requirements 10.4
Liquid Fuels at Atmospheric Pressure
Fuel Injectors 10.5
D93 Test Methods for Flash Point by Pensky-Martens
Air Flow 10.6
Intake Air Barrel 10.7
Closed Cup Tester
Fuel Filter 10.8
D97 Test Method for Pour Point of Petroleum Products
Oil Scale Flow Rates 10.9
D130 Test Method for Corrosiveness to Copper from Petro-
Calibration of Test Stands 10.10
Extending Test Stand Calibration Period 10.11
leum Products by Copper Strip Test
Test Run Numbering 10.13
D235 Specification for Mineral Spirits (Petroleum Spirits)
Humidity Calibration Requirements 10.14
(Hydrocarbon Dry Cleaning Solvent)
Calibration of Piston Deposit Raters 10.15
Procedure 11
D445 Test Method for Kinematic Viscosity of Transparent
Engine Break-in Procedure 11.1
and Opaque Liquids (and Calculation of Dynamic Viscos-
Cool-down Procedure 11.2
Warm-up Procedure 11.3 ity)
Shutdowns and Lost Time 11.4
D482 Test Method for Ash from Petroleum Products
Periodic Measurements 11.5
D524 Test Method for Ramsbottom Carbon Residue of
Engine Control Systems 11.6
Petroleum Products
Engine Coolant 11.6.1
Engine Fuel System 11.6.2
D613 Test Method for Cetane Number of Diesel Fuel Oil
Engine Oil Temperature 11.6.3
D664 Test Method for Acid Number of Petroleum Products
Exhaust Pressure 11.6.4
Intake Air 11.6.5 by Potentiometric Titration
Post-Test Procedures 11.7
D1319 Test Method for Hydrocarbon Types in Liquid Petro-
Piston Ring Side Clearances 11.7.1
leum Products by Fluorescent Indicator Adsorption
Piston Ratings 11.7.2
Referee Ratings 11.7.3 D2274 Test Method for Oxidation Stability of Distillate Fuel
Ring End Gap Increase 11.7.4
Oil (Accelerated Method)
Cylinder Liner Wear 11.7.5
D2425 Test Method for Hydrocarbon Types in Middle Dis-
Cylinder Liner Bore Polish 11.7.6
Photographs 11.7.7
tillates by Mass Spectrometry
Calculation and Interpretation of Results 12
D2500 Test Method for Cloud Point of Petroleum Products
Test Validity 12.1
and Liquid Fuels
Calculations 12.2
Quality Index 12.2.1 D2622 Test Method for Sulfur in Petroleum Products by
Oil Consumption 12.2.2
Wavelength Dispersive X-ray Fluorescence Spectrometry
Report 13
D2709 Test Method for Water and Sediment in Middle
Forms and Data Dictionary 13.1
Test Validity 13.2 Distillate Fuels by Centrifuge
Report Specifics 13.3
D3227 Test Method for (Thiol Mercaptan) Sulfur in
Precision and Bias 14
Gasoline, Kerosine, Aviation Turbine, and Distillate Fuels
Precision 14.1
Bias 14.1.4
(Potentiometric Method)
Keywords 15
D3524 Test Method for Diesel Fuel Diluent in Used Diesel
Annexes
Engine Oils by Gas Chromatography
Engine and Parts Warranty Annex A1
Instrument Locations, Measurements, and Calculations Annex A2
D4175 Terminology Relating to Petroleum Products, Liquid
Cooling System Arrangement Annex A3
Fuels, and Lubricants
Intake Air Mass Flow Sensor Installation Annex A4
D4052 Test Method for Density, Relative Density, and API
Fuel System Design and Required Components Annex A5
Oil System Annex A6
Gravity of Liquids by Digital Density Meter
Exhaust and Intake Barrel Piping Annex A7
D4485 Specification for Performance of Active API Service
Humidity Probe Installation (Location) Annex A8
Category Engine Oils
Return Goods Authorization (Claim Form) Annex A9
Engine Assembly Information Annex A10
D4739 Test Method for Base Number Determination by
Flushing Instructions and Apparatus Annex A11
Potentiometric Hydrochloric Acid Titration
Warm-up, Cool-down and Testing Conditions Annex A12
Piston and Liner Rating Modifications Annex A13
Additional Report Forms Annex A14
Test Report Forms Annex A15
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Appendixes
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Various Examples for Reference Purposes Appendix X1
Standards volume information, refer to the standard’s Document Summary page on
Safety Appendix X2
the ASTM website.
D6681 − 23
D5185 Test Method for Multielement Determination of 3.1.6 calibrated test stand, n—a test stand on which the
Used and Unused Lubricating Oils and Base Oils by testing of reference material(s), conducted as specified in the
Inductively Coupled Plasma Atomic Emission Spectrom- standard, provided acceptable test results. Sub. B Glossary
etry (ICP-AES) 3.1.6.1 Discussion—In several automotive lubricant stan-
D5862 Test Method for Evaluation of Engine Oils in Two- dard test methods, the ASTM Test Monitoring Center provides
Stroke Cycle Turbo-Supercharged 6V92TA Diesel Engine testing guidance and determines acceptability.
(Withdrawn 2009)
3.1.7 candidate oil, n—an oil which is intended to have the
D6202 Test Method for Automotive Engine Oils on the Fuel
performance characteristics necessary to satisfy a specification
Economy of Passenger Cars and Light-Duty Trucks in the
and is to be tested against that specification. D4175
Sequence VIA Spark Ignition Engine (Withdrawn 2009)
3.1.7.1 Discussion—These oils are mainly submitted for
D6593 Test Method for Evaluation of Automotive Engine
testing as candidates to satisfy a specified performance; hence
Oils for Inhibition of Deposit Formation in a Spark-
the designation of the term.
Ignition Internal Combustion Engine Fueled with Gaso-
3.1.8 debris, n—in internal combustion engines, solid con-
line and Operated Under Low-Temperature, Light-Duty
taminant materials unintentionally introduced into the engine
Conditions
or resulting from wear. D5862
D7422 Test Method for Evaluation of Diesel Engine Oils in
3.1.9 dispersant, n—in engine oil, an additive that reduces
T-12 Exhaust Gas Recirculation Diesel Engine
deposits on oil-wetted engine surfaces primarily through sus-
E29 Practice for Using Significant Digits in Test Data to
pension of particles. D4175
Determine Conformance with Specifications
G40 Terminology Relating to Wear and Erosion 3.1.10 engine oil, n—a liquid that reduces friction or wear,
or both, between the moving parts within an engine; removes
2.2 SAE Standard:
heat, particularly from the underside of pistons; and serves as
SAE J183 Engine Oil Performance and Engine Service
a combustion gas sealant for the piston rings. D5862
Classification
3.1.10.1 Discussion—It may contain additives to enhance
2.3 API Standard:
certain properties. Inhibition of engine rusting, deposit
API 1509 Engine Service Classification and Guide to Crank-
formation, valve train wear, oil oxidation and, foaming are
case Oil Selection
examples.
2.4 Other ASTM Document:
3.1.11 heavy-duty, adj—in internal combustion engine
ASTM Deposit Rating Manual 20 (formerly CRC Manual
operation, characterized by average speeds, power output, and
20)
internal temperatures that are generally close to the potential
3. Terminology maximums. D4485
3.1.12 lubricant, n—any material interposed between two
3.1 Definitions:
surfaces that reduces the friction or wear, or both, between
3.1.1 additive, n—a material added to another, usually in a
them. D5862
small amount, to impart or enhance desirable properties or to
suppress undesirable properties. D4175
3.1.13 lubricating oil, n—a liquid lubricant, usually com-
prising several ingredients, including a major portion of base
3.1.2 automotive, adj—descriptive of equipment associated
oil and minor portions of various additives. D4175
with self-propelled machinery, usually vehicles driven by
internal combustion engines. D4485
3.1.14 oxidation, n—of engine oil, the reaction of the oil
with an electron acceptor, generally oxygen, that can produce
3.1.3 blind reference oil, n—a reference oil, the identity of
deleterious acidic or resinous materials often manifested as
which is unknown by the test facility. D4175
sludge formation, varnish formation, viscosity increase, or
3.1.3.1 Discussion—This is a coded reference oil which is
corrosion, or a combination thereof. D4175
submitted by a source independent from the test facility.
3.1.15 non-reference oil, n—any oil other than a reference
3.1.4 blowby, n—in internal combustion engines, that por-
oil; such as a research formulation, commercial oil, or candi-
tion of the the combustion products and unburned air/fuel
date oil. D4175
mixture that leaks past piston rings into the engine crankcase
during operation. D4175
3.1.16 purchaser, n—of an ASTM test, person or organiza-
tion that pays for the conduct of an ASTM test method on a
3.1.5 calibrate, v—to determine the indication or output of a
specified product. D6202
device (e.g., thermometer, manometer, engine) with respect to
that of a standard. 3.1.17 reference oil, n—an oil of known performance
characteristics, used as a basis for comparison.
3.1.17.1 Discussion—Reference oils are used to calibrate
The last approved version of this historical standard is referenced on
testing facilities, to compare the performance of other oils, or
www.astm.org.
7 to evaluate other material (such as seals) that interact with oils.
Available from SAE International (SAE), 400 Commonwealth Dr., Warrendale,
D4175
PA 15096, http://www.sae.org.
Available from American Petroleum Institute (API), 1220 L. St., NW,
3.1.18 scoring, n—in tribology, a severe form of wear
Washington, DC 20005-4070, http://www.api.org.
characterized by the formation of extensive grooves and
For Stock #TMCMNL20, visit the ASTM website, www.astm.org, or contact
ASTM International Customer Service at service@astm.org. scratches in the direction of sliding. G40
D6681 − 23
3.1.19 scuffıng, n—in lubrication, damage caused by instan- 6. Apparatus and Installation
taneous localized welding between surfaces in relative motion
6.1 The test engine is an electronically controlled, direct
which does not result in immobilization of the parts. D6593
injection, in-head camshaft, single-cylinder diesel engine with
3.1.20 sponsor, n—of an ASTM test method, an organization
a four-valve arrangement. The engine has a 137.2 mm bore and
that is responsible for ensuring supply of the apparatus used in
a 165.1 mm stroke resulting in a displacement of 2.4 L.
the test procedure portion of the test method. D4175
6.1.1 The electronic control module (ECM) defines the
3.1.20.1 Discussion—In some instances, such as a test
desired engine fuel timing, monitors and limits maximum
method for chemical analysis, an ASTM working group can be
engine speed, maximum engine power, minimum oil pressure,
the sponsor of the test method. In other instances, a company
and, optionally, maximum engine crankcase pressure. The
with a self-interest may or may not be the developer of the test
ECM also controls the fuel injection duration that defines the
procedure used within the method, but is the sponsor of the test
engine fuel rate based on set conditions from the test cell
method.
feedback control systems. The oil pressure is also set by the
ECM with signals to the 1Y3867 engine air pressure controller
3.1.21 used oil, n—any oil that has been in a piece of
(Mamac) to modulate the facility air supply to the 1Y3898
equipment (for example, an engine, gearbox, transformer, or
Johnson Controls relief valve.
turbine), whether operated or not. D4175
6.1.2 The 1Y3700 engine arrangement also consists of inlet
3.1.22 varnish, n—in internal combustion engines, a hard,
air piping and hoses from the cylinder head to the air barrel and
dry, generally lustrous deposit that can be removed by solvents
exhaust piping and bellows from the cylinder head to the
but not by wiping with a cloth. D4175
exhaust barrel that are specifically designed for oil testing. See
3.1.23 wear, n—the loss of material from a surface, gener-
the Caterpillar Service Manual.
ally occurring between two surfaces in relative motion, and
6.2 Equip the engine test stand with the following accesso-
resulting from mechanical or chemical action or a combination
ries or equipment:
of both. D7422
6.2.1 Intake Air System—The intake air system components
from the cylinder head to the air barrel are a part of the basic
4. Summary of Test Method
1Y3700 engine arrangement. These components consisting of
4.1 Prior to each test, the power section of the engine is
an adapter, elbow, hose, clamps, and flanged tube can be found
disassembled, solvent-cleaned, measured, and rebuilt in strict
in the 1Y3700 Parts Book.
accordance with the specifications. A new piston, ring
6.2.1.1 Purchase the 1Y3978 intake air barrel (which is
assembly, and cylinder liner are measured and installed for
almost identical to the exhaust barrel except for the top cover)
each test. The engine crankcase is solvent-cleaned and worn or
that has been specifically designed from one of the three
10,11
defective parts are replaced. The test stand is equipped with
approved manufacturers. Install the intake air barrel at the
feedback control systems for fuel rate, engine speed, and other
location shown in Annex A7. Do not add insulation to the
engine operating conditions. A suitable system for filtering,
barrel.
compressing, humidifying, and heating the inlet air is required
6.2.1.2 Paint the inside of the intake air piping with Cater-
12,11
along with a system for controlling the engine exhaust pres-
pillar yellow primer or red Glyptal prior to installation.
sure. Test operations involve the control of the single-cylinder
6.2.1.3 Install the air heater elements in the intake air barrel
diesel test engine for a total of 360 h at specified speeds and
as specified in Annex A7 (even if they will not be supplied with
13,11
fuel rate input using the test oil as a lubricant. A defined
electricity).
break-in precedes each test and is also used when restarting an
6.2.1.4 Use an air filter capable of filtering particles 10 μ (or
engine. At the end of the test, the piston deposits are rated, the
smaller).
piston, rings and liners are photographed, inspected and
6.2.1.5 Use a Sierra Model 780 airflow meter with Feature
measured, oil consumption is calculated and the oil is analyzed
1 = F6, Feature 2 = CG and calibration temperature = 60 °C to
14,11
to determine the test results. Critical engine conditions are
measure intake airflow for each calibration test. Annex A4
statistically analyzed to determine if the test was precisely
operated. Test acceptability parameters for each calibration test
are also statistically analyzed to determine if the engine/test
The sole sources of supply of the intake air barrel known to the committee at
stand produce the specified results.
this time are Cimino Machinery Corp., 5958 South Central Ave., Chicago, IL 60638;
Gaspar Inc., 4106 Mahoning Rd. N.E., Canton, OH 44705; and M.L. Wyrick
Welding, 2301 Zanderson Highway 16 N, Jourdanton, TX 78026.
5. Significance and Use
If you are aware of alternative suppliers, please provide this information to
5.1 This is an accelerated engine oil test, performed in a
ASTM International Headquarters. Your comments will receive careful consider-
ation at a meeting of the responsible technical committee , which you may attend.
standardized, calibrated, stationary single-cylinder diesel en-
gine that gives a measure of (1) piston and ring groove deposit
The sole source of supply of the crankcase paint primer known to the
forming tendency, (2) piston, ring and liner scuffing and (3) oil
committee at this time is BASF Coating and Colorant Div., P.O. Box 1297,
consumption. The test is used in the establishment of diesel
Morganton, NC 28655. (Primer No.A123590 and BASF Part No.U27YD005,
Yellow CAT Primer Part No.IE2083A.)
engine oil specification requirements as cited in Specification
The sole source of supply of the air heater elements known to the committee
D4485 for appropriate API Performance Category C oils (API
at this time is Watlow Air Heaters, Chicago, IL 708-490-3900.
1509). The test method can also be used in diesel engine oil
The sole source of supply of the airflow meter known to the committee at this
development. time is Sierra Instruments, Inc., 5 Harris Ct., Monterey, CA 93940.
D6681 − 23
shows the piping requirements for the installation of the Sierra facility air pressure of 280 kPa to levels that vary between
Model 780 airflow meter. 0 kPa to 140 kPa and directs it to the normally closed Johnson
6.2.1.6 Measure the inlet air temperature at the location Controls relief valve. Because the engine oil pressure sensor
shown in Annex A2. Measure the inlet air pressure at the air calibration might vary from the cell data acquisition transducer,
barrel as shown in Annex A7. The location of the 1Y3977 vary the oil pressure adjust signal to the ECM to maintain the
humidity probe is shown in Annex A8. The sample line might oil pressure at the test specifications. See the Electronic
require insulation to prevent dropping below dew point tem- Installation and Operation manual for additional information.
perature and shall not be hygroscopic. Drain taps may be The ECM maintains the oil pressure regardless of engine
installed at the low points of the combustion air system. speed. Measure the oil temperatures at locations shown in
6.2.1.7 Use feedback-equipped controls to maintain filtered, Annex A2.
compressed, and humidified inlet air at the conditions specified 6.2.5.1 Oil Heating System—Use an external oil heating
in Annex A12. system provided by the test facility to maintain the engine oil
6.2.2 Exhaust System—The exhaust system components manifold temperature specified in Annex A12. An example
from the cylinder head to the exhaust barrel are part of the system is shown in Appendix X1. A special 1Y3908 oil cooler
basic 1Y3700 engine arrangement. These components consist- bonnet has been designed to allow separate fluids to the engine
ing of an adapter, elbow, bellows, flange, and clamps can be coolant tower arrangement (see Fig. A6.9). Plug the 1Y3660
found in the 1Y3700 Parts Book. oil cooler adapter and 1Y3908 heat exchanger bonnet as shown
17,11
6.2.2.1 Purchase the 1Y3976 exhaust barrel (which is al- in Annex A6. Use Paratherm NF for the heating fluid. The
most identical to the intake barrel except for the top cover) that temperature of the Paratherm NF is measured by the thermo-
has been specifically designed from one of the three approved couple shown in Annex A2.
manufacturers. Install the exhaust barrel at the location shown 6.2.5.2 Oil Sample Valve—Refer to Annex A2 for the
in Annex A7. Do not add insulation to the barrel. installation location and component makeup of the oil sample
6.2.2.2 Install a restriction valve downstream from the valve. Use of alternate equivalent components for the sample
exhaust barrel. The distance between the valve and barrel is not valve is permitted.
specified. The location of the exhaust thermocouple is shown 6.2.6 Engine Coolant System—The coolant system sche-
in Annex A2. Measure the exhaust pressure at the exhaust matic is shown in Annex A3. Control the coolant temperature
barrel shown in Annex A7. out of the engine using a cell facility feedback system. Use a
6.2.2.3 Use feedback-equipped controls to maintain the 1Y3898 Johnson Controls valve or equivalent fail-open valve
exhaust gases at the pressure specified in Annex A12. to regulate the coolant temperature out of the engine as shown
6.2.3 Fuel System—The fuel system schematic is shown in by the schematic in Annex A3. If the 1Y3898 Johnson valve is
Annex A5. Desired fuel injection timing is controlled by the used, supply facility air pressure at 280 kPa to the controller
engine computer at 13° BTC. Measure the fuel rate using micro that regulates air pressure to the valve at 0 kPa to 140 kPa.
motion device with a maximum range of 90 kg/h scaled to the Install a feedback-equipped control system to pneumatically
15,11
1P operation range specified in Annex A12. Use the day adjust the valve. Remove the 1Y3832 hose originally supplied
tank specified in Annex A5. Measure fuel temperature at the with the engine and install a sight glass using the components
fuel filter base as shown in Annex A2 and control it using the shown in Annex A3.
cell facility feedback system. Use the required fuel heat 6.2.7 Engine Instrumentation—Use feedback-equipped sys-
exchanger(s) and arrange them as specified in Annex A5. Use tems to control the engine operating temperatures, pressures,
the Fisher regulator specified in Annex A5. and flow rates. Measure the engine operating conditions at the
6.2.4 Oil Consumption System—Use an oil scale system to locations shown in Annex A2. For temperature measurements,
accurately measure oil consumption (see Fig. A6.2 and Fig. use thermocouples 1Y468 (intake air), 1Y467 (engine exhaust)
A6.3). The oil scale system shall have a resolution as listed in and 1Y466 (fluids-water, oil, and fuel) or equivalent thermo-
Annex A2. Use flexible hoses similar to Aeroquip flexible hose, couples as specified in Annex A2. Instrument measurement and
FC352-08, to-and-from the oil scale reservoir to eliminate reporting resolutions are shown in Annex A2.
16,11
measurement errors. Use No.5 TFE-fluorocarbon, steel- 6.2.8 A dynamometer with feedback control to maintain
braided hoses to and from the oil scale pumps. The hose length engine torque and speed. Use a starting system capable of at
to-and-from the oil scale cart shall not exceed 2.7 m. Use the least breakaway torque of 136 N·m and sustained torque of
special oil pan adapter described in Fig. A6.4. 102 N·m at 200 r ⁄min.
6.2.5 Engine Oil System—A schematic of the oil system is 6.2.9 Compressed air at 35 kPa to the top of the coolant
shown in Fig. A6.1. Measure oil pressure at the engine oil tower as specified in Annex A3 to ensure water does not boil
manifold (see Annex A2). An engine oil pressure sensor out of the antifreeze mixture and result in less heat rejection
transmits a signal to the ECM that maintains oil pressure at from the engine.
415 kPa. The ECM transmits a signal to an engine-mounted 6.2.10 Measure engine blowby downstream of the engine
Mamac air pressure controller. The Mamac modulates the breather housing by measuring the delta pressure across an
orifice or an equivalent device.
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.
16 17
The sole source of supply of the flexible hose known to the committee at this The sole source of supply of the fluid known to the committee at this time is
time is Aeroquip Industrial Div, 1225 W. Main Street, Van Wert, OH 45891. Paratherm NF Oil, Conshohocken, PA 19428.
D6681 − 23
6.2.11 The crankcase pressure is above atmospheric pres- 7.11 Reference Oil, as supplied by the TMC for calibration
sure with this engine arrangement. Measure it at the location of the test stand.
shown in Annex A2.
7.12 REO 217, as supplied by the CRC and used when any
6.3 Obtain information concerning the test engine, engine copper components are changed.
electronics system, new engine parts, replacement parts, and
7.13 Sodium Bisulfate (NaHSO ), commercial grade.
permissible substitution or replacement parts from Caterpillar,
7.14 Solvent—Use only mineral spirits meeting the require-
Inc.
ments of Specification D235, Type II, Class C for Aromatic
6.4 Engine and parts warranty information can be found in
Content (0 % to 2 %) by vol, Flash Point (61 °C, min) and
Annex A1. Use the form listed in Annex A9 for returning
Color (not darker than + 25 on Saybolt Scale or 25 on Pt-Co
defective parts.
Scale). (Warning—Combustible. Health hazard.) Obtain a
Certificate of Analysis for each batch of solvent from the
7. Reagents and Materials
supplier.
7.1 Purity of Reagents—Reagent grade chemicals shall be
7.15 Fuel—Obtain the required test fuel from Chevron
used in all tests. Unless otherwise indicated, it is intended that
21,11
Phillips as PC-9-HS Reference Diesel Fuel (see Annex
all reagents conform to the specifications of the Committee on
A14).
Analytical Reagents of the American Chemical Society where
7.16 Test Oil—The total amount of oil needed for each
such specifications are available. Other grades may be used,
lubricant test is approximately 42 L.
provided it is first ascertained that the reagent is of sufficiently
high purity to permit its use without lessening the accuracy of
7.17 Trisodium Phosphate (Na PO ), commercial grade.
3 4
the determination.
22,11
7.18 5.4000 in. Ring Bore Standard Class Z Master.
7.2 Diesel Piston Rating Booth, as described by ASTM
Deposit Rating Manual 20.
8. Oil Samples
7.3 Diesel Piston Rating Lamp, as described by ASTM
8.1 Take purge samples of 250 mL at 48 h, 72 h, 120 h,
Deposit Rating Manual 20
144 h, 168 h, 192 h, 216 h, 264 h, 312 h, and 336 h. Following
19,11
removal of each purge sample, remove a 30 mL sample, then
7.4 Dispersant Engine Cleaner.
add 317 g 6 10 g of new oil. It is not necessary to perform
7.5 Engine Coolant—Use a 50/50 mixture of mineral-free
analysis on these samples of 30 mL. Use the purge sample to
water and Caterpillar brand coolant (P/N 8C684 for 3.8 L or
return to the full mark.
8C3686 for 208 L drum) for engine coolant. Mineral-free water
8.1.1 Take purge samples of 250 mL at 0 h (new) and 24 h,
is defined as water having a mineral content no higher than
96 h, 240 h, 288 h, and 360 h. Following removal of each
34.2 mg/kg total dissolved solids. The coolant mixture may be
purge sample, remove a 90 mL sample and add 370 g 6 10 g
reused for up to 1600 h. Keep the mixture at a 50:50 ratio as
of new oil.
determined by using either Caterpillar testers 5P3514 or
8.1.2 Analyze all 90 mL samples for viscosity by Test
5PO957 or an equivalent tester. Keep the coolant mixture
Method D445 at 100 °C and 40 °C, TBN by Test Method
contamination free. Total solids shall remain below
D4739, TAN by Test Method D664, and the wear metals Al, Cr,
5000 mg ⁄kg. Keep the additive level correct using Caterpillar
Cu, Fe, Pb, Si by Test Method D5185. Analyze the samples for
test kit P/N 8T5296.
fuel dilution taken at 24 h, 240 h, and 360 h by Test Method
7.6 Lead Shot, commercial grade, approximately 5 mm in
D3524. See Fig. A6.7 and Fig. A6.8 for two graphical
diameter. examples and a sample worksheet.
7.7 Light Grease.
9. Preparation of Apparatus
7.8 Mobil EF-411, available from ExxonMobil for engine
9.1 General Engine Assembly Practices—As a part of good
20,11
assembly and calibration of the oil scale pump flow rates.
laboratory practice, inspect all components and assemblies that
7.9 Paratherm NF, as supplied by Paratherm and used as the
are exposed when the engine is disassembled and record the
17,11
fluid to heat the engine oil.
information for future reference. Inspect valve train
components, bearings, journals, housings, seals and gaskets,
7.10 Pentane (Solvent), purity > 99 %, high-performance,
and so forth and replace as needed. Assemble the engine with
liquid chromatography grade.
components and bolt torques as specified in the 1Y3700 engine
Service Manual (see Annex A10 for a partial list). It is the
ACS Reagent Chemicals, Specifications and Procedures for Reagents and
intent of this procedure for all engine assemblies and adjust-
Standard-Grade Reference Materials, American Chemical Society, Washington,
ments to be targeted to the mean of the specified values. Clean
DC. For suggestions on the testing of reagents not listed by the American Chemical
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. The sole source for 1P fuel known to the committee at this time is Chevron
The sole source of supply of the engine cleaner known to the committee at this Phillips Chemical Co., Chevron Tower, 1301 McKinney Street, Houston, TX
time is The Lubrizol Corp., 29400 Lakeland Blvd., Cleveland, OH 44092 77010-3030.
20 22
The sole source of supply of the oil known to the committee at this time is The sole source of supply of the apparatus known to the committee at this time
Mobil EF-411, from Golden West Oil Co., 3010 Aniol St., San Antonio, TX 78219. is Morse-Hemco, 457 Douglas Ave., Holland, MI 49423.
D6681 − 23
and lubricate the components in keeping with good assembly specifications as shown in the 1Y3700 Service Manual. Do not
practices. Keep airborne dirt and debris to a minimum in the swap the cylinder head/jug assembly from test stand-to-test
assembly area. Maintain standard engine assembly techniques stand. Use the head/jug assembly used to calibrate the stand for
and practices (such as staggering piston ring gap positions, and all non-reference oil testing in that stand. Fig. A10.1 shows the
so forth). cylinder head nut torque sequence.
9.2 Complete Engine Inspection—Perform a complete en-
9.8 Valve Guide Bushings—Clean the valve guide bushings
gine inspection at intervals of 13 000 h. Ensure that wearing with a solvent and bristle brush prior to assembly. Lubricate the
surfaces such as main bearings and journals, rod bearings and
bushings and valve stems with Mobil EF-411 prior to assem-
journals, camshaft bearings, valve train components, fuel bly. See the 1Y3700 Service Manual for guide reusability
system components, and so forth all are within manufacturer’s
specifications. Install new valve guide seals for each test.
specifications. Refer to the 1Y3700 Service Manual for
9.9 Fuel Injector—Remove the fuel injector from the cyl-
disassembly, assembly, inspections, and specifications. Paint
inder head before reconditioning commences. Refer to the
crankcases as necessary with either Caterpillar yellow primer
1Y3700 Service Manual for removal and assembly. Return
12,11
or red Glyptal.
defective fuel injectors to Caterpillar for warranty and failure-
9.3 Copper Components—Anytime a copper part is
mode testing using the form listed in Annex A9.
replaced, run an engine test using REO 217 until two consecu-
9.10 Piston and Rings—Use a new piston (1Y3400 iron
tive periods of 12 h show a stable copper level. To eliminate the
crown, 1Y3659 aluminum skirt) and new rings (1Y3802,
need to perform this pacification process when replacing the
1Y3803, 1Y3804) for each test.
engine oil cooler, use of a nickel-plated oil cooler is permitted.
9.10.1 Clean all three rings with pentane and a lint-free
9.4 Engine Lubricant System Flush—Flush the engine of
100 % cotton towel.
used oil before every test. Annex A11 shows the engine flush
9.10.2 Measure the ring side clearances and ring end gaps
procedure and apparatus. A flushing instruction sheet shown in
for all three rings (see Fig. A10.2 and Table A10.1). Keystone
Annex A11 gives the step-by-step process required for flush-
ring side clearance measurements require the ring to be
ing. The 1Y3700 engine arrangement includes five flushing
confined in a dedicated slotted liner (see Appendix X1) or a
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nozzles in the crankcase and front cover (see Annex A11).
ring gage 137.16 mm in diameter. Measure the side
These nozzles are piped in parallel with the 1Y3935 filter
clearances using four feeler gages of equal width and thickness
flushing adapter (or equivalent) from a laboratory-provided
of 0.01 mm at intervals of 90° around the piston. Measure the
manifold that pressurizes fluids supplied by a flush cart (see
rectangular ring side clearance this way as well. Measure the
Appendix X1). Seal the gear train housing during flush with a
minimum side clearance as specified in ASTM Deposit Rating
1Y3917 round plug with a 117-8801 o-ring as shown in Annex
Manual 20.
A11. Seal the crankcase using a 1Y3979 block flush cover with
9.10.3 Record the measurements for these parts before and
an internal bleed passage for the cam oil supply. Bolt a 1Y3980
after each test. Compare the measurements before the test and
plastic jet aiming fixture to the flush cover that is also used for
after the test to determine the amount of wear.
flushing (see Annex A11). If the test oil is not available at
9.10.4 Assemble the piston with the part number toward the
engine assembly, Mobil EF411 oil may be substituted.
camshaft.
9.5 Engine Piston Cooling Jets—The piston cooling jets are
9.11 Cylinder Liner—Use a new 1Y3805 or 1Y3997 cylin-
flow-checked at the supplier and serialized to ensure proper
der liner for each test.
performance, but the minimal rod clearances might result in jet
9.11.1 After removing the protective oil/grease with mineral
movement during assembly. Verify proper jet flow positioning
spirits (see 7.14), clean the liner bore with a hot tap water and
using EF-411 before each test with the 1Y3980 plastic jet
heavy-duty clothes washing detergent solution, then rinse with
aiming fixture and oil pressure to the manifold of 415 kPa.
hot tap water.
Record the cooling jet serial number.
9.11.2 Measure and record the liner surface finish. The
surface finish specification shown in Fig. A10.3 does not apply
9.6 Engine Measurements and Inspections—Measure and
to the 1Y3997 cylinder liner.
inspect the engine components prior to each test (see Table
9.11.3 Oil the liner bore with only Mobil EF-411. Assemble
A10.2 for partial specification list). Refer to the 1Y3700
Service Manual for information concerning component reus- the cylinder liner, block and head with the torque specification
shown in the 1Y3700 Service Manual or Fig. A10.1.
ability and assembly not found in this procedure. The part
numbers of components that need replacing are found in the 9.11.4 Measure the liner with a dial bore gage to ensure that
the out-of-round and taper conditions are within specified
1Y3700 Parts Manual. Record the crankshaft angles at the
specified maximum injector lift, exhaust, and intake maximum tolerances measured at seven intervals as shown in Fig. A10.3.
Measure the cylinder liner projection using the modified
lift before each test using the reference listed in Fig. A10.7.
Record component part numbers and serial numbers and other indicator shown in Fig. A10.4.
9.11.5 Torque the cylinder liner support ring using the
required measurements as shown in the test report. Inspect and
reuse the rocker arm roller followers and camshaft lobe procedure shown in Fig. A10.5.
surfaces based on Caterpillar Service Publication SEBF8256.
9.12 Compression Ratio—Before starting each test, measure
9.7 Cylinder Head—A reconditioned head is required for the piston-to-head clearance to ensure the proper compression
each test. Measurements after reconditioning shall be within ratio is used. Determine this dimension by using lead balls,
D6681 − 23
23,11
each with a diameter of approximately 3.5 mm. Locate four every two years. Use the following relationships as con-
lead balls on the top of the piston at 90° intervals on the major version factors from the differential pressure across the Barco
and minor piston diameters. Hold them in place with light venturi to liters per minute: 3.0 in. H O = 24.3 L/min, 7.1 in.
grease. With the piston near the top of the stroke, install the H O = 37.8 L/min and 28 in. H O = 75.7 L/min or use Eq 1
2 2
head and block assembly and torque to specifications. Turn the where ΔP is measured in in. H O.
engine over top center by hand to compress the lead balls then
L/min 5 =ΔP 14.44 2 0.69 (1)
remove the head and block assembly and measure the thickness
10.4 Re-calibration Requirements—Re-calibration due to
of the lead balls to obtain the average piston-to-head clearance.
parts replacement is not required unless the engine crankcase
The piston-to-head clearance specification is 1.62 mm 6
or crankshaft, or both, require replacing or regrinding, or the
0.07 mm. Use multiple 1Y3817 block gaskets to adjust the
crankshaft is removed for any other purpose besides bearing
clearance. If the piston-to-head measurement exceeds the
replacement, or the head/jug suffer a failure for any reason
tolerance specification, check the crankshaft main and rod
during the calibration period.
journals, connecting rod and main bearings, and piston pin and
rod bushing for excessive wear. The specified compression
10.5 Fuel Injectors—The fuel injectors are calibrated during
ratio for the 1Y3700 engine is 16.2 to 1.
the manufacturing process. These fuel injectors can not be
re-calibrated in the usual manner and require special test
9.13 Engine Timing—The engine ECM sets desired fuel
equipment to ensure proper flow, timing response, and spray
injection timing to 13° BTC. Record this timing using the
patterns. Therefore, replace the fuel injector at the start of
engine technician service tool. Mechanically time the actual
every calibration test (unless that test is the second of two
engine components as shown in Annex A10. Install the
required tests for a new stand or is a rerun of a previous
electronic sensors as shown in the Electronic Installation and
calibration attempt). If the fuel injector is replaced on a
Operation manual. Correctly assemble both the mechanical and
calibrated stand, re-calibration is not required.
electrical systems to produce the desired fuel timing.
10.6 Air Flow—Install the Sierra Model 780 airflow meter
9.14 Engine Coolant System Cleaning Procedure—Clean
to measure intake airflow. This meter should be calibrated
the coolant system when visual inspections show the presence
yearly at a temperature of 60 °C. Measure the intake airflow
of any oil, grease, mineral deposits, or rust following the
during the break-in of every calibration test. Record the last
procedure listed in Annex A3.
value recorded during step five of the break-in as shown in
9.15 After the engine components have been prepared and
Annex A12.
assembled, perform the following:
10.7 Intake Air Barrel—Prior to each stand calibration test,
9.15.1 Fill the crankcase with 5800 g 6 50 g of test oil.
inspect the intake air barrel for rust or debris. This may be done
9.15.2 Install a new 1R0713 oil filter.
through either of the pipe flanges using a borescope or some
9.15.3 Fill the coolant system with coolant specified in
other optical means.
Section 7.
10.8 Fuel Filter—Change the fuel filter before every cali-
9.15.4 Ensure the facility coolant to the engine heat ex-
bration test.
changer is operational.
10.9 Oil Scale Flow Rates—Verify the oil scale flow rates
9.15.5 Pressurize the fuel system to remove air, then return
before the start of every calibration test using the procedure
the system to a non-pressurized state before starting engine.
listed in Annex A6.
9.15.6 Ensure all other systems and facilities are operational
10.10 Calibration of Test Stands—Use a blind calibration oil
before starting the engine break-in.
from the TMC to calibrate the engine stand. A stand calibration
test is required every nine months. The calibration period
10. Calibration and Standardization
begins on the start date of the acceptable calibration test. A test
10.1 Test Cell Instrumentation—Calibrate all facility read-
stand is considered calibrated when the test results are within
out instrumentation used for the test immediately prior to
the acceptability limits as published by TMC and the test is
subsequent stand calibration. Instrumentation calibration prior
operationally valid. The TMC may request stand checks on
to subsequent stand calibration tests (that is, those that follow
calibration tests that fail to meet acceptability limits. If the
a failed or invalid first attempt) are at the discretion of the test
calibration test is operationally valid, send the
...