ASTM D5967 Test Method for Evaluation of Diesel Engine Oils in T-8 Diesel Engine
8. Preparation of Apparatus at Rebuild
8.1 Cleaning of Parts:
8.1.1 Engine Block - Thoroughly spray the engine with aliphatic naphtha to remove any oil remaining from the previous test and air-dry.

8.1.2 Rocker Covers and Oil Pan - Remove all sludge, varnish, and oil deposits. Rinse with aliphatic naphtha and air-dry.

8.1.3 Auxiliary Oil System - Flush all oil lines, galleries, and external oil reservoirs, first with a suitable solvent, such as aliphatic naphtha, to remove any previous test oil and then air-dry.

8.1.4 Oil Cooler and Oil Filter - If heavy deposits are present or suspected, flush the oil cooler and filter lines first with a suitable solvent, such as aliphatic naphtha, to remove any previous test oil and then air-dry.

8.1.5 Cylinder Head - Clean the cylinder heads using a wire brush to remove deposits and rinse with aliphatic naphtha to remove any sludge and oil, and then air-dry.

8.2 Valves, Seats, Guides, and Springs - Visually inspect valves, seats, and springs for defects and replace, if defective.
8.2.1 Replace and ream guides to 0.9525 +/- 0.0013 cm (0.3750 +/- 0.0005 in.).

8.3 Cylinder Liner, Piston, and Piston Ring Assembly:
8.3.1 Cylinder Liner Fitting - To ensure proper heat transfer, fit cylinder liners to the block in accordance with the procedure outlined in the Mack Service Manual (see Annex A5).

8.3.2 Piston and Rings - Cylinder liners, pistons, and rings are provided as a set and should be used as a set. Examine piston rings for any handling damage. Measure piston ring end gaps for conformance with Mack specifications and record.

8.4 Injectors and Injection Pump:
8.4.1 Injectors - Servicing of injectors is recommended every 1000 h. Resetting of injector opening pressure is allowed if pressure is below specification.

8.4.2 Injection Pump - The removal of the injection pump is not recommended unless a problem is noted during a test. Removing the injection pump invalidates the test stand calibration. Replacing injection pumps at each calibration is recommended. Only new injection pumps, which have never been serviced or rebuilt, are permitted. High pressure flow calibration equipment, such as a Bacharach No. 72-7010 standard injector tester, is available from Mack approved dealers. Kent-Moore tool numbers J29539 top dead center indicator and J37077 position sensor are recommended for setting the injection timing.

8.5 Assembly Instructions:
8.5.1 General - The test parts specified for this test method are intended to be used without material or dimensional modification. Exceptions, for example, a temporary parts supply problem, shall be approved by the Test Monitoring Center (TMC), and noted in the test report. All replacement test engine parts shall be genuine Mack Truck Inc. parts. Assemble all parts as illustrated in the Mack Service Manual (see A5.2) except where otherwise noted. Target all dimensions for the means of the specifications. Use the buildup oil (Annex A5) for lubricating parts during assembly.
8.5.1.1 Thermostat - Block the thermostat wide open using an all thread rod.

8.5.1.2 Rod Bearings - Check the condition of the connecting rod bearings. Replacement of the connecting rod bearings is at the laboratory's discretion.

8.5.1.3 Main Bearings - Check the condition of the main bearings. Replacement of the main bearings is at the laboratory's discretion.

8.5.1.4 Piston Undercrown Cooling Nozzles - Take particular care in assembling the piston undercrown cooling nozzles to ensure proper piston cooling (as outlined in the Mack Service Manual).

NOTE 2 - Proper oil pressure is also important to ensure sufficient oil volume for proper cooling.

8.5.2 New Parts - Install the following new parts for each rebuild (see Table A5.1, Annex A5 for part numbers):
8.5.2.1 Cylinder liners,

8.5.2.2 Pistons,

8.5.2.3 Piston rings,

8.5.2.4 Overhaul gasket set,

8.5.2.5 Oil filters (also after each test),

8.5.2.6 Engine coolant conditioner (also every test),

8.5.2.7 Primary fuel filter (also every test),

8.5.2.8 Secondary fuel filter (also every test),

8.5.2.9 Valve guides, and

8.5.2.10 Valve stem seals.

8.6 Measurements:
8.6.1 Calibrations - Calibrate thermocouples, pressure gages, speed, and fuel flow measuring equipment prior to each reference test or at any time readout data indicates a need. Conduct calibrations with at least two points that bracket the normal operating range. Make these calibrations part of the laboratory record. During calibration, connect leads, hoses, and read-out systems in the normally used manner and calibrate with necessary standards. Immerse thermocouples in calibration baths. Calibrate standards with instruments traceable to the National Institute of Standards and Technology on a yearly basis.

8.6.2 Temperatures:
8.6.2.1 General - Measure temperatures with thermocouples and conventional readout equipment or equivalent. For 0 to 150°C (0 to 300°F) range, calibrate temperature measuring systems to +/-0.5°C (+/-1°F) at 100 +/- 1°C (210 +/- 2°F) and to +/- 0.5°C (+/-1°F) at 0 +/- 1°C (32 +/- 2°F). Insert all thermocouples so that the tips are located midstream of the flow unless otherwise indicated.

8.6.2.2 Ambient Air - Locate thermocouple in a convenient, well-ventilated position between 2 and 3 m (approximately 6 and 10 ft) from the engine and hot accessories.

8.6.2.3 Coolant - Locate thermocouple in water manifold prior to thermostat housing. Locate in center of water stream (refer to Fig. A2.5, Annex A2).

8.6.2.4 Oil - Locate thermocouple on the right side of the engine on the top of the accessory drive as shown on Fig. A2.5, Annex A2.

8.6.2.5 Intake Air - Locate sensors for dry bulb temperature measurement and humidity in center of air stream at the turbocharger inlet as shown in Fig. A2.3, Annex A2. It is not necessary to control intake air humidity, but measurements are recommended.

8.6.2.6 Fuel In - Locate thermocouple in center of fuel line between secondary filter and injection pump, as shown in Fig. A2.4, Annex A2.

8.6.2.7 Pre-Turbine Temperatures - Locate one thermocouple in each side of exhaust manifold tee section (see Fig. A2.3, Annex A2). The exhaust manifold (pre-turbine) thermocouples and pressure taps are located on the same tee.

8.6.2.8 Exhaust (Tailpipe) Temperature - Locate thermocouple in exhaust pipe downstream of turbine according to Fig. A2.7, Annex A2.

8.6.2.9 Intake Manifold - Locate thermocouple at tapped fitting on intake air manifold, as shown in Fig. A2.6, Annex A2.

8.6.2.10 Additional - Monitor any additional temperatures the test lab regards as helpful in providing a consistent test procedure.

8.6.3 Pressures:
8.6.3.1 Before Filter Oil Pressure - Locate pickup at tapped hole on oil cooler fitting (see Fig. A2.2, Annex A2).

8.6.3.2 After Filter/Main Gallery Oil Pressure - Locate pickup at tapped hole on top of oil filter pad above centrifugal oil filter (see Fig. A2.2, Annex A2).

NOTE 3 - The E7 engine has only one oil gallery, which serves as both a main gallery and a piston cooling gallery.

8.6.3.3 Pre-Turbine Exhaust Pressure - Locate pickup in each side of exhaust manifold tee section (same tap as pre-turbine pressure), Fig. A2.3, Annex A2.

8.6.3.4 Intake Air Boost - Take measurement at tapped fitting provided on intake manifold, as illustrated in Fig. A2.6, Annex A2.

8.6.3.5 Intake Air Total Pressure - Measure with a Keil Probe13 (p/n No. KDF-8-W recommended) located at the turbo inlet (see Fig. A2.3, Annex A2).

8.6.3.6 Exhaust Back Pressure - Locate pickup in exhaust pipe after turbocharger in center of exhaust stream. Measure exhaust back pressure in a straight section of pipe, 30.5 to 40.6 cm (12 to 16 in.) downstream of the turbo with a 1/16 NPT tread pressure tap hole, as shown in Fig. A2.3, Annex A2.

8.6.3.7 Crankcase Pressure - Locate pickup at dipstick tube fitting or other suitable opening direct to the crankcase.

8.6.3.8 Barometric Pressure - Locate barometer approximately 1.2 m (4 ft) above ground level in convenient location in the lab.

8.6.4 Engine Blowby - Connect the metering instrument to the blowby line coming from the valve cover crossover tube (P/N 191GC418A).

8.6.5 Fuel Consumption Measurements - Place the measuring equipment in the fuel line before the primary fuel filter. Install the primary fuel filter before the fuel transfer pump and install the secondary filter before the injection pump. Accurate fuel consumption measurements require proper accounting of return fuel.

NOTE 4 - Caution: Fuel return lines should never be plugged.

8.6.6 Humidity - Place the measurement equipment between the inlet air filter and compressor in such a manner so as not to affect temperature and pressure measurements. Measure humidity at 8-h intervals and report on Form 2, Fig. A1.3, Annex A1.

9. Laboratory and Engine Test Stand Calibration/Non-Reference Requirements
9.1 Calibration Frequency:
9.1.1 To maintain test consistency and severity levels, engine test stand calibration is required at regular intervals. The frequency of calibration is dependent on the laboratories' previous calibration experience or at the discretion of the TMC.

9.1.2 Engine test stand calibration is required when the injection pump is removed from the engine, cylinder heads are replaced, or when pistons, rings, and liner are changed. Cylinder heads can be rebuilt without re-calibrating. If a piston, piston rings, or cylinder liner are changed, then re-calibration is necessary.

9.2 Calibration Reference Oils:
9.2.1 The reference oils used to calibrate test stands have been formulated or selected to represent specific chemical types or performance levels, or both. They can be obtained from the TMC. The TMC will assign reference oils for calibration tests. These oils are supplied under code numbers (blind reference oils).

9.2.2 Reference Oils Analysis - Reference oils are not to be submitted to either physical or chemical analysis, for identification purposes. Identifying the oils by analysis could undermine the confidentiality required to operate an effective blind reference oil system. Therefore, reference oils are supplied with the explicit understanding that they will not be subjected to analysis other than those specified within this procedure unless specifically authorized by the TMC. In such cases in which analysis is authorized, written confirmation of the circumstances involved, the data obtained, and the name of the person authorizing the analysis shall be supplied to the TMC.

9.3 Test Numbering - Number each test to identify the test stand number, the test stand run number, engine serial number, and engine block hours at the start of the test. The sequential stand run number remains unchanged for reruns of aborted, invalid, or unacceptable calibration tests. However, the sequential stand run number shall be followed by the letter A for the first rerun, B for the second, and so forth. For calibration tests, engine block hours are the test hours since last engine rebuild. For non-reference tests, engine block hours are the test hours accumulated since last reference. For example, 58-12A-2H0380-500 defines a test on stand 58 and stand run 12 as a calibration test that was run twice on engine 2H0380 (serial number), which has run 500 h since the last engine rebuild.

9.4 New Laboratories and New Test Stands:
9.4.1 A new stand is defined as an engine, dynamometer/cell and support hardware that has never been previously calibrated under this test procedure. On both new and existing stands the test engine is part of the stand calibration. A new engine in a existing test stand only requires one successful calibration test.

9.4.2 A new test stand shall have two acceptable calibration tests to be considered calibrated.

9.4.3 A laboratory not running a test for 12 months from the start of the last test is considered a new laboratory. Under special circumstances (that is, extended downtime due to industry-wide parts shortage or fuel outages) the TMC may extend the lapsed time requirement. Non-reference tests conducted during an extended time allowance shall be annotated on Form 6, Fig. A1.7, Annex A1, Downtime and Comments Summary.

9.4.4 The TMC may schedule more frequent reference oil tests at their discretion.

9.5 Calibrated Laboratories and Test Stands:
9.5.1 A calibration test on a reference oil assigned by the TMC is required after 3000 h of non-reference test time, ten operationally valid non-reference oil tests, or nine months, whichever comes first, have elapsed since the starting date of the last calibration test. A non-reference test may be started in a test stand provided at least 1 h remains in its calibration period.

9.6 Calibration Test Acceptance:
9.6.1 Use the TMC's Lubricant Test Monitoring System (LTMS) for calibration test targets and acceptance criteria.

9.6.2 The specified test parameter for determination of test acceptance is Viscosity Increase in cSt, at 100°C and 3.8 % Thermal Gravimetric Analysis (TGA) soot, as shown in Annexes A3 and A4.
9.6.2.1 Calculate Viscosity Increase at 3.8 % TGA, using linear interpolation from the minimum viscosity that occurs during the test. Do not use the 25-h, 75-h, and 125-h oil sample results to calculate Viscosity Increase at 3.8 % TGA soot.

9.6.3 Soot Requirements - All operationally valid calibration tests on TMC oil 1004-1 shall produce a TGA soot level between 4.0 to 4.6 % at 250 h. All operationally valid calibration tests on TMC oil 1004-2 shall produce a TGA soot level between 4.0 to 4.8 % at 250 h. A laboratory may terminate a calibration test that is projected to miss the 250 h test soot window. Calibration tests with soot levels outside the 250 h soot window are considered operationally invalid.

9.7 Failing Calibration Tests:
9.7.1 Failure of a reference oil test to meet test acceptance bands can be indicative of a false alarm, testing stand, testing laboratory, or industry-related problem. When this occurs, the laboratory, in conjunction with the TMC, shall attempt to determine the problem source.

9.7.2 The TMC will decide, with input as needed from industry expertise (testing laboratories, test developer, ASTM Technical Guidance Committee, Surveillance Panel, and so forth), if the reason for any unacceptable blind reference oil test is isolated to one particular stand or related to other stands. If it is decided that the problem is isolated to an individual stand, calibrated testing on other stands can continue throughout the laboratory. Alternatively, if it is decided that more than one stand may be involved, the involved stands will not be considered calibrated until the problem is identified, corrected, and an acceptable reference oil test completed in one of the involved stands.

9.7.3 If nonstandard tests are conducted on the referenced test stand, the stand may be required to be recalibrated prior to running standard tests at the discretion of the TMC.

9.8 Non-Reference Oil Test Requirements - Non-reference oil tests shall produce a minimum 3.8 % TGA soot level at 250 h. Tests shall run to 250 h regardless of meeting the 3.8 % soot level prior to 250 h. Tests that do not reach 3.8 % soot at 250 h are deemed not interpretable. Fixed non-reference oil pass criteria are published in Specification D4485.
9.8.1 Non-Reference Oil Test Result Severity Adjustments - This test method incorporates the use of a severity adjustment (SA) for non-reference oil test results. A control chart technique, described in the LTMS, has been selected for the purpose of identifying when a bias becomes significant for viscosity increase at 3.8 % TGA soot. When calibration test results identify a significant bias, a SA value is determined in accordance with the LTMS. Report the SA value on Form 1, Fig. A1.2, Annex A1, Test Result Summary, under the non-reference oil test block in the space for SA. Add this SA value to non-reference oil test results, and enter the adjusted viscosity increase at 3.8 % TGA soot value in the appropriate space. The SA remains in effect until a new SA is determined from subsequent calibration tests, or the test results indicate the bias is no longer significant.