ASTM D6894 Standard Test Method for Evaluation of Aeration Resistance of Engine Oils in Direct-Injected Turbocharged Automotive Diesel Engine
6. Apparatus
6.1 Test Engine - The test engine is an International 1994, 7.3L, direct-injection, turbocharged, V-8, diesel engine, rated at 160 kW at 3000 r/min. The engine model number is A215. The engine arrangement is shown in Figs. A1.2 and A1.3 and the lubrication system in Fig.A1.4. This engine is equipped with the HEUI fuel system (see 5.1 and Fig.A1.1). Details of the engine are documented in the International T 444E Diesel Engine Service Manual for Truck Application Form EGES-121 dated April 2002. The engine serial number carries the designation 7.4JU2UXXXXXX. The test engine is installed in a fully instrumented test cell.
6.1.1 Engine Modification - Install a 1/4 in. male national pipe thread (NPT) stainless steel hex nipple in the threaded outlet on the right (passenger) side of the engine's high-pressure oil reservoir. Install a 1/4 in. female NPT inlet and outlet, stainless steel, ball-valve onto the hex nipple with the flow arrow facing away from the reservoir. Install a 1/4 in. male NPT to male No.4 SAE (JIC) 37° flare stainless steel adapter fitting in the downstream side of the ball valve. Make up a polytetrafluoroethylene (PTFE)-lined, stainless steel braid, No.4 hose, with female swivel No.4 SAE (JIC) 37° female flare fittings on each end. The overall line length should be approximately 115 cm. Modify a male No.4 SAE(JIC) 37° flare to 1/4 in. fractional tube female compression adapter fitting so that there is a 0.394 mm orifice through the fitting. Insert a 37.5 cm long, 1/4 in. thin-wall, steel, fractional tube (this is to be the sample wand) into the female compression adapter and tighten. For safety, install an insulating handle around the steel tube to avoid being burned while holding the wand.
6.2 Power Absorption - Install a 186 kW eddy-current absorption dynamometer in the test cell.
6.3 Aeration - The HEUI system takes oil from the main gallery and pressurizes it in a plunger pump up to 20.7 MPa (3000 psi). The arrangement is shown in Fig.A1.1. The pressurized oil operates unit injectors that increase the fuel pressure up to 145 MPa (21000 psi) with the help of intensifiers (see Fig.A1.5). The electronic controls permit varied injection timing and duration to provide optimum fuel economy and emissions. As shown in Table 1, this operation can circulate all the lubricating oil in the sump in approximately 8 s. For oils with unsatisfactory aeration resistance, this very short residence time is insufficient to allow aeration in the oil to dissipate. As a consequence, aerated oil is circulated to the injector intensifiers, adversely affecting the injection timing characteristics and engine operation.
6.4 Instrumentation - The engine and dynamometer shall be instrumented to measure the following parameters:
Engine speed, r/min
Torque, N·m
Power, kW
Fuel flow rate, kg/h
Coolant temperature, in and out, °C
Oil gallery temperature, °C
Intake air temperature, °C
Fuel temperature, °C
Intake manifold temperature after turbocharger, °C
Ambient temperature, °C
Oil gallery pressure, kPa
Intake manifold pressure, kPa
Exhaust pressure, after turbocharger, at left and right manifolds, kPa
Crankcase pressure, kPa
Intake air pressure after filter, kPa
Tailpipe pressure, kPa
6.5 Miscellaneous:
6.5.1 Nine 100 mL graduated glass cylinders.
6.5.2 A weighed, glass sample bottle, of suitable capacity to hold 120 mL, with inert, lined lids.
6.5.3 A weighed oil-drain container, of suitable capacity, for collecting hot purged oil; a 20 L bucket is convenient.
7. Reagents and Materials
7.1 Engine Oil - Use only engine oils of performance category API CI-4, CH-4, and CG-4 or their equivalent performance replacements when running the engine for passivating sealants (see 8.3.3), breaking-in and other routine operations.
7.2 Reference Oils - The TMC uses reference oils (TMC 1004 and TMC 1005) to establish test precision. Calibration tests using these two reference oils are required after 30 operationally valid non-reference oil test runs or one year, whichever is sooner. As new data are generated at the laboratories running this test, the TMC will update the test precision accordingly.
7.3 Test Fuel - Use low-sulfur reference diesel fuel (LSRD-4) containing 0.03 weight % to 0.05 weight % sulfur for this test. All fuel shall meet the fuel specifications shown in Table 2. Include in the final report the fuel analysis for the last batch of fuel used for the test. The fuel supplier provides the analysis. If more than one batch is used, note this in the comments section with the appropriate percentages of run time.
7.4 Engine Coolant - The engine coolant shall be 50/50 percent (by volume) commercially additized ethylene glycol coolant/water. To protect the cylinder walls from external cavitation, add commercially available supplementary coolant additives (SCAs), initially and after every 200 h of engine operation, at the SCA manufacturer's recommended treat rate. Water shall be deionized, demineralized, or distilled.
7.5 Cleaning Materials:
7.5.1 Solvent - Use aliphatic naphtha (Stoddard) hydrocarbon solvent. (Warning - Flammable. Eye irritant. Wear goggles or face shield (as for gasoline).)
7.5.2 Engine Cooling System Cleanser - Use the following:
7.5.2.1 Oxalic Acid Dihydrate Technical Grade. (Warning - Toxic Substance. Avoid contact with eyes, skin, and clothing.)
7.5.2.2 Petro Dispersant 425 surfactant (the sodium salt of alkylatid naphthalene).
NOTE 2 - These chemicals can be purchased as a premixed pack.
