ASTM D5967 Test Method for Evaluation of Diesel Engine Oils in T-8 Diesel Engine
10. Procedure
10.1 Pretest Procedure:
10.1.1 Initial Oil Fill for Flush - The initial oil fill is 45.4 L (48 qt) of test oil: 26.5 L (28 qt) for the pan, 3.8 L (4 qt) for the filters, 1.9 L (2 qt) for the engine oil cooler, and 13.2 L (14 qt) for the auxiliary oil reservoir and lines. Add the first 3.8 L (4 qt) of fresh test oil to the oil filters (1.9 L (2 qt) per filter), then turn on the auxiliary oil pumps and add an additional 41.6 L (44 qt) of test oil to the engine. This oil can be added directly through the engine oil fill tube.
10.1.2 Pretest Oil Flush and Break-In:
10.1.2.1 Start the engine, as described in 11.2. For a new or rebuilt engine, run the break-in sequence described in Table 2. For non-reference oil tests only a pretest oil flush procedure is required. A post test flush should be done prior to a pretest, as described in 11.13.1 and 11.13.2.
10.1.2.2 Shutdown the engine (as shown in 11.3) and drain the test oil from the oil pan, external oil reservoir, and change the oil filters.
10.1.2.3 Install new oil filters and add 3.8 L (4 qt) of fresh test oil to the filters (1.9 L (2 qt) per filter). Start the auxiliary oil pumps and add an additional 41.6 L (44 qt) of new oil to the engine. This oil can be added directly through the engine oil fill tube.
10.2 Engine Start-Up - Each time the engine is started, work up to 20 to 30 % of full load at 1000 to 1400 r/min and hold until the oil sump temperature reaches approximately 66 to 77°C (150 to 170°F). This takes about 10 min for a cold engine; then go to test conditions. Start-ups are not included as test time. Test time starts as soon as the engine returns to the test cycle. The start date and time of a test, is defined as when the test reaches test conditions (after a flush).
NOTE 5 - Caution: The engine should be cranked prior to start-up to fill the engine oil passages. This practice will enhance engine durability significantly.
10.3 Engine Shutdown - The engine may be shut down for periods of time. Before each shutdown, operate the engine at 1000 to 1400 r/min no-load for 10 min, then close the fuel rack. The shutdown operation does not count as test time. Record the length and reason of each shutdown on Form 6, Fig. A1.7, Annex A1.
10.4 Test Cycle - The test cycle includes a pretest oil flush at the conditions shown in Table 2. For new and rebuilt engines, a break-in procedure is also required. Conduct the test at 1800 r/min full-load conditions as described in Table 3. Reference oil test length is 300 h. Non-reference oil test length is 250 h.
10.4.1 At EOT (end of test), the average results for all controlled operational parameters shall be within the stated specifications for the test to be declared operationally valid. For calibration tests, investigate any uncontrolled operational parameters outside the stated specifications jointly by the laboratory and the TMC. Base a validity judgment on the joint agreement between the laboratory and the TMC.
10.5 Oil Addition/Drain - Establish the full mark as the oil weight in the first 1-h period of the test. At the end of every 25-h period, perform a forced drain that equates to an oil consumption of 0.243 g/kW h (0.0004 lb/bhp h). If a sample is required, follow the guidelines set forth in 10.6. If a sample is not required, then drain a sufficient amount of oil to obtain an oil weight that is 1.59 kg (3.5 lb) below the full mark. Then add 1.59 kg (3.5 lb) of new oil to the engine. After a shutdown, use the drain level of the previous period to determine the forced drain quantity.
10.6 Oil Samples:
10.6.1 For reference oil tests, take oil samples of 118 mL (4 oz) at 25-h intervals. For nonreference oil tests, the 25-h, 75-h, and 125-h samples are optional. Obtain oil samples through a drain petcock located in the oil rig return line (oil pan to return pump) (see Fig. A2.8, Annex A2).
10.6.2 If oil consumption is less than or equal to 1.02 kg (36 oz by weight) during a 25-h period, withdraw a 473-mL (16-oz) purge, then withdraw a 118-mL (4-oz) sample; then drain enough oil to complete the 1.59 kg (3.5 lb) forced drain (include weight of 473-mL purge in 1.59-kg drain).
10.6.3 If the oil consumption is greater than 1.02 kg (36 oz), withdraw a 473-mL (16-oz) purge and then a 118-mL (4-oz) sample. Then return the purge oil to the external oil reservoir. Then drain an amount of oil equal to the difference of the oil consumption of that period from 1.59 kg (3.5 lb). Then follow with the forced oil addition of 1.59 kg (3.5 lb) of new oil.
10.7 Oil Consumption Calculations:
10.7.1 Record the oil weight hourly and compute the oil consumption from these readings.
10.7.2 Calculate the average oil consumption for the test as the average of the 25-h periods from 26 h to end of test. Do not use the first 25-h period to calculate oil consumption since this is a period of stabilization of the oil scale system. Do not include oil drains and samples as oil consumption.
10.7.3 Use the following formula to calculate the oil consumption for a 25-h period:
Oil Consumption (g/kW - h) = (FW - Wn)/(P x 25)
where:
FW = full weight, g,
Wn = oil scale weight at n test hours before additions, samples, or drains, g, and
P = brake power output of the engine, kW.
The reported oil consumption is the average of the 25-h period oil consumption calculations.
10.7.4 The full weight may need to be re-established, depending on the rate of oil consumption of the engine for the 25-h period. If the oil consumption is greater than 0.225 g/kW-h, recalculate the full weight by subtracting the weight of the oil sample and adding the weight of the oil addition (1.59 kg) to the previous 25-h period's weight.
10.8 Fuel Samples - Take fuel samples prior to the start of test (two 0.95-L [1 qt] samples) and at EOT (two 0.95-L [1 qt] samples).
10.9 Periodic Measurements - Make measurements at the end of each test hour or more frequently, if desired, on the parameters listed in 10.9.1 and record on Form 2, Fig. A1.3, Annex A1. Record data before adjustments are made to control parameters to achieve operation at specification mean. Each measurement is to be an hourly snapshot. The TMC encourages automatic data acquisition and permits multiple measurements to be made within an hour. Characterize the procedure used to calculate the hourly average on Fig. A1.8, Annex A1.
10.9.1 Parameters:
10.9.1.1 Speed, r/min,
10.9.1.2 Torque, N•m (lbf•ft),
10.9.1.3 Oil temperature, °C (°F),
10.9.1.4 Water-out temperature, °C (°F),
10.9.1.5 Water-in temperature, °C (°F),
10.9.1.6 Intake air temperature, °C (°F),
10.9.1.7 Intake manifold temperature, °C (°F),
10.9.1.8 Intake air boost, kPa (in. Hg),
10.9.1.9 Fuel flow, s/kg or kg/h (s/lb or lb/h),
10.9.1.10 Fuel inlet temperature, °C (°F),
10.9.1.11 Tailpipe exhaust back pressure, kPa (in. H 2O),
10.9.1.12 Before filter oil pressure, kPa (psi),
10.9.1.13 Main gallery oil pressure, kPa (psi),
10.9.1.14 Crankcase pressure, kPa (in. H2O),
10.9.1.15 Pre-turbine exhaust temperature, front manifold,°C (°F),
10.9.1.16 Pre-turbine exhaust temperature, rear manifold,°C (°F),
10.9.1.17 Inlet restriction, kPa (in. H2O),
10.9.1.18 Tailpipe exhaust temperature, °C (°F),
10.9.1.19 Crankcase blowby, L/min (ft3/min) (see 10.9),
10.9.1.20 Pre-turbine exhaust pressure, front manifold, kPa (in. Hg),
10.9.1.21 Pre-turbine exhaust pressure, rear manifold, kPa (in. Hg), and
10.9.1.22 Inlet air humidity, g/kg (grains/lb).
10.10 Blowby - Record the total crankcase blowby at a minimum of 8-h intervals. Disconnect crankcase aspirating equipment during blowby measurements. Take care to prevent oil traps from occurring in the blowby line at any time during operation.
10.11 Centrifugal Oil Filter Mass Gain - Prior to the start of test, determine the mass of the centrifugal oil filter canister. At EOT, remove the centrifugal oil filter canister from the engine and drain upside down for 30 min. After draining, determine the mass of the canister and record on Fig. A1.5, Annex A1. Centrifugal oil filter mass gain determination is required for calibration tests and optional for non-reference oil tests.
10.12 Oil Filter DP Calculation:
10.12.1 The reported oil filter ΔP is the maximum oil filter ΔP that occurs from 0 to 250 h. Calculate the oil filter ΔP as follows:
ΔP = ΔPmax - ΔPinitial
where:
ΔPmax = the maximum ΔP across the oil filter, and
ΔPinitial = the DP across the oil filter at the start of test conditions.
10.12.2 If an oil filter change is made, add the oil filter ΔP value obtained after the filter change to the oil filter ΔP obtained prior to the filter change. If a shutdown occurs, add the oil filter ΔP value obtained after the shutdown to the oil filter ΔP obtained prior to the shutdown.
10.13 Post Test:
10.13.1 Post Test Flush - As soon as possible after the EOT, perform a post test flush. Drain all oil from the oil pan, external oil reservoir, and filters. Perform an initial fill in accordance with 10.1, and use Bulldog Premium Oil as the flush oil. Start the engine as described in 10.2 and run the pretest flush conditions as described in Table 2. Shutdown the engine (see 10.3) and drain the post test flush oil from the oil pan, external oil reservoir, and remove filters.
10.13.2 Post Test Solvent Wash - After the post test flush is performed, wash the top of the cylinder heads (rocker area), rocker arms, and rocker covers with aliphatic naphtha until clean. The oil drain plug should be open for this procedure. Remove the oil pan and wash with aliphatic naphtha until clean. Also wash the external oil rig system and the external oil lines with aliphatic naphtha until clean.
11. Inspection of Fuel and Oil During Test
11.1 Oil Inspection:
11.1.1 Analyze oil samples for viscosity at 100°C (212°F) in accordance with Annex A3; poor test precision can result if the modified test method (see Annex A3) is not followed exactly. To maintain test accuracy and precision, conduct all viscosity and soot measurements at a TMC-calibrated laboratory. Take two samples at 250 h and analyze for viscosity and soot. On Fig. A1.2, Annex A1, the viscosity reported at 250 h is the average of the two samples. Base viscosity increase on the minimum viscosity as reported on Fig. A1.2, Annex A1. In addition to the viscosity measurements, conduct soot analysis in accordance with Annex A4. Determine wear metals content (Fe, Pb, Cu, Cr, Al); additive metals content, silicon, and sodium levels in accordance with Test Method D5185 from new, 150 h, 250 h, and 300 h (if applicable) oil samples. Conduct oil analysis as soon as possible after sampling.
11.2 Fuel Inspections - Use fuel purchase inspections to complete Fig. A1.6, Annex A1, for the last batch of fuel used during the test. If more than one batch is used for a test, list each fuel batch in the fuel batch identifier block on Fig. A1.6, Annex A1. List the fuel batches in chronological order (initial to final batch). In addition, perform the following inspections on NEW and EOT fuel samples:
API Gravity at 15.6°C (60°F), Test Method D287
Total Sulfur, % wt., Test Method D129
Use one 0.95 - L(1 - qt) sample for inspections
11.3 Oil Consumption:
11.3.1 Compute total oil consumption for the test and report in kilograms per kilowatt-hour for each test. A value of 0.182 g/kW-h (0.0003 lb/bhp h) or lower is desirable. For calibration tests, if oil consumption exceeds 0.304 g/kW h (0.0005 lb/bhp-h), the test is considered operationally invalid. Oil consumption greater than 0.304 g/kW-h (0.0005 lb/bhp-h) requires further investigation of the test oil or the engine, or both, to determine the cause.
11.3.2 The recommended oil consumption rig plumbing is shown in Fig. A2.8, Annex A2.
