ASTM D6923 Standard Test Method for Evaluation of Engine Oils in a High Speed, Single-Cylinder Diesel Engine - Caterpillar 1R Test Procedure
6. Apparatus and Installation
6.1 The test engine is an electronically controlled, direct injection, in-head camshaft, and single-cylinder diesel engine with a four-valve arrangement. The engine has a 137.2 mm bore and a 165.1 mm stroke resulting in a displacement of 2.4 L.
6.1.1 The Electronic Control Module (ECM) defines the desired engine fuel timing, monitors and limits maximum engine speed, maximum engine power, minimum oil pressure, and, optionally, maximum engine crankcase pressure. The ECM also controls the fuel injection duration that defines the engine fuel rate based on set conditions from the test cell feedback control systems. The oil pressure is also set by the ECM with signals to the 1Y3867 Engine Air Pressure Controller (Mamac) to modulate the facility air supply to the 1Y3898 Johnson Controls Relief Valve.

6.1.2 The 1Y3700 engine arrangement also consists of inlet air piping and hoses from the cylinder head to the air barrel and exhaust piping and bellows from the cylinder head to the exhaust barrel that are specifically designed for oil testing.

6.2 Equip the engine test stand with the following accessories or equipment:
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 1Y3700 engine arrangement. These components consisting of an adapter, elbow, hose, clamps, and flanged tube can be found in the 1Y3700 Parts Book.
6.2.1.1 Purchase the 1Y3978 intake air barrel (which is almost identical to the exhaust barrel except for the top cover) from one of the three approved manufacturers. Install the intake air barrel at the location shown in Annex A2. Do not add insulation to the barrel.

6.2.1.2 Paint the inside of the intake air piping with Caterpillar yellow primer or red Glyptal prior to installation.

6.2.1.3 Install the air heater elements in the intake air barrel as specified in AnnexA2 (even ifthey will not be supplied with electricity).

6.2.1.4 Use an air filter capable of 10 µm (or smaller) filtration.

6.2.1.5 Use a Sierra Model 780 airflow meter with Feature 1 = F6, Feature 2 = CG and calibrated at the following conditions to measure intake airflow for each calibration test:
Temperature = 60 °C
Humidity = 17.8 g/kg
Pressure = 292 kPa (abs)
Approximate flow range = 425 kg/h

Annex A4 shows the piping requirements for the installation of the Sierra Model 780 airflow meter. For tests not using the airflow meter, maintain instrumentation configuration using a spool piece of equivalent dimensions.

6.2.1.6 Measure the inlet air temperature at the location shown in Annex A2. Measure the inlet air pressure at the air barrel as shown in Annex A2. The location of the 1Y3977 Humidity Probe is shown in Annex A4. The sample line may require insulation to prevent dropping below dew point temperature and shall not be hygroscopic. Drain taps may be installed at the low points of the combustion air system.

6.2.1.7 Use feedback-equipped controls to maintain filtered, compressed, and humidified inlet air at the conditions specified in Annex A10.

6.2.2 Exhaust System - The exhaust system components from the cylinder head to the exhaust barrel are part of the basic 1Y3700 engine arrangement. These components consisting of an adapter, elbow, bellows, flange, and clamps can be found in the 1Y3700 Parts Book.
6.2.2.1 Purchase the 1Y3976 exhaust barrel (which is almost identical to the intake barrel except for the top cover) from one of the three approved manufacturers. Install the exhaust barrel at the location shown in Annex A2. Do not add insulation to the barrel. Any of the approved suppliers can modify the exhaust barrel in order to meet appropriate ASME pressure vessel codes that accommodate the high temperature and pressure conditions of this 1R test method. Drawings of the permitted modifications are located with Gaspar, Inc.

6.2.2.2 Install a restriction valve downstream from the exhaust barrel. The distance between the valve and barrel is not specified. The location of the exhaust thermocouple is shown in Annex A2. Measure the exhaust pressure at the exhaust barrel shown in Annex A2.

6.2.2.3 Use feedback-equipped controls to maintain the exhaust gases at the pressure specified in Annex A10.

6.2.3 Fuel System - The fuel system schematic is shown in Annex A5. The ECM controls fuel injection timing at 6° BTC. Measure the fuel rate using a Micro Motion device scaled to the 1R operation range specified in Annex A10. Use the day tank specified in Annex A5. Measure fuel temperature at the fuel filter base as shown in Annex A2 and control it using the cell facility feedback system. Use the required fuel heat exchanger(s) and arrange them as specified in Annex A5. Use the Fisher regulator specified in Annex A5.

6.2.4 Oil Consumption System - Use an oil scale system to accurately measure oil consumption (see Annex A6). The oil scale system shall have a resolution as listed in Annex A2. Use flexible hoses similar to Aeroquip flexible hose, FC352-08, to-and-from the oil scale reservoir to eliminate measurement errors. Use No.5 TFE-fluorocarbon, steel-braided hoses to and from the oil scale pumps. The hose length to-and-from the oil scale cart shall not exceed 2700 mm. Use the special oil pan adapter described in Annex A6. The flow rates for the oil consumption oil scale pumps shall be (23.6 to 24.9) kg/h for the oil being pumped from the oil pan to the oil scale, and (16.3 to 17.7) kg ⁄h for the oil being pumped from the oil scale to the oil pan. See Annex A6 for the procedure to verify these flow rates.

6.2.5 Engine Oil System - A schematic of the oil system is shown in Annex A6. Measure oil pressure at the engine oil manifold (see Annex A2). An engine oil pressure sensor transmits a signal to the ECM that maintains oil pressure at 415 kPa. The ECM transmits a signal to an engine-mounted Mamac air pressure controller. The Mamac modulates the facility air pressure of 280 kPa to levels that vary between (0 to 140) kPa and directs it to the normally closed Johnson 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 oil pressure at the test specifications. See the Electronic Installation and Operation manual for additional information. The ECM maintains the oil pressure regardless of engine speed. Measure the oil temperatures at locations shown in Annex A2. Install 1Y4021 gaskets on each side of the 1Y3661 oil pump bypass lock nut to prevent oil aeration (see Annex A6). When a new pump is installed, begin adjustment of the pressure relief plug with 43.7 mm of thread exposed as shown in Annex A6. Optional oil pressure sensor lines may be installed at the oil filter block as shown in Fig.A2.6 for measuring the differential pressure across the oil filter.
6.2.5.1 Oil Heating System - Use an external oil heating system provided by the test facility to maintain the engine oil manifold temperature specified in Annex A10. An example system is shown in Appendix X1. A special 1Y3908 oil cooler bonnet has been designed to allow separate fluids to the engine coolant tower (see Annex A6). Plug the 1Y3660 oil cooler adapter and 1Y3908 heat exchanger bonnet as shown in Annex A6. Use Paratherm NF for the heating fluid. The temperature of the Paratherm NF is measured by the thermocouple shown in Annex A2. An additional heat exchanger may be installed to provide cooling capability, ifnecessary, to maintain test conditions.

6.2.5.2 Oil Sample Valve - Refer to Annex A2 for the installation location and component makeup of the oil sample valve. Use of alternate equivalent components for the sample valve is permitted.

6.2.6 Engine Coolant System - The coolant system schematic is shown in Annex A3. Pressurize the coolant tower with compressed air as specified in Annex A3 to ensure water does not boil out of the antifreeze mixture. Control the coolant temperature out of the engine using a cell facility feedback system. Use a 1Y3898 Johnson Controls valve or equivalent fail-open valve to regulate the coolant temperature out of the engine as shown by the schematic in Annex A3. If the 1Y3898 Johnson valve is used, supply facility air pressure at 280 kPa to the controller that regulates air pressure to the valve at (0 to 140) kPa. Install a feedback-equipped control system to pneumatically adjust the valve. Remove the 1Y3832 hose originally supplied with the engine and install a sight glass using the components shown in Annex A3. Use Caterpillar part no.9X2378 replacement bulk hose for coolant hoses in the Caterpillar 1Y3700 engine.

6.2.7 Engine Instrumentation - Use feedback-equipped systems to control the engine operating temperatures, pressures, and flow rates. Measure the engine operating conditions at the locations shown in Annex A2. For temperature measurements, use thermocouples 1Y468 (intake air), 1Y467 (engine exhaust) and 1Y466 (fluids-water, oil and fuel) or equivalent thermocouples as specified in Annex A2. Install thermocouples with the tips at midstream. The thermocouple insertion depths listed in Annex A2 are approximate depending on the mountings or fittings used. Instrument measurement and reporting resolutions are shown in Annex A2.

6.2.8 Use a dynamometer with feedback control to maintain engine torque and speed. Use a starting system capable of at 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 engine breather housing by measuring the delta pressure across an orifice or an equivalent device.

6.2.10 Crankcase Pressure - Measure crankcase pressure at the location shown in Annex A2.

NOTE 1 - The crankcase pressure is above atmospheric pressure with this engine.

6.3 Obtain information concerning the test engine, engine electronics system, new engine parts, replacement parts and permissible substitution or replacement parts from Caterpillar,Inc.

6.4 Engine and parts warranty information can be found in Annex A1. Use the form listed in Annex A12 for returning defective parts.

7. Reagents and Materials
7.1 Purity of Reagents - Use reagent grade chemicals in all tests. Unless otherwise indicated, it is intended that all reagents conform to the specifications of the Committee on Analytical Reagents of the American Chemical Society where such specifications are available. Other grades may be used, provided it is first ascertained that the reagent is of sufficiently high purity to permit its use without lessening the accuracy of the determination.

7.2 Diesel Piston Rating Booth, as described by ASTM Deposit Rating Manual 20.

7.3 Diesel Piston Rating Lamp, as described by ASTM Deposit Rating Manual 20.

7.4 Engine Coolant - Use a mixture of 50 % mineral-free water and 50 % Caterpillar brand coolant (P/N 8C684 for 3.8 L concentrated or P/N 101-2845 for 208 L drum already premixed) for engine coolant. Mineral-free water is defined as water having a mineral content no higher than 34.2 mg/kg total dissolved solids. The coolant mixture may be reused for 3 test starts or up to 1600 h. Keep the mixture at a 50-50 ratio as determined by using either Caterpillar testers 5P3514 or 5PO957 or an equivalent tester. Keep the coolant mixture contamination free. Total solids shall remain below 5000 mg/kg. Keep the additive level correct using Caterpillar test kit P/N 8T5296.

7.5 Lead Shot, commercial grade, approximately 5 mm in diameter.

7.6 Light Grease.

7.7 Mobil EF-411, to be obtained for engine assembly and calibration of the oil scale pump flow rates.

7.8 Paratherm NF, to be obtained from Paratherm and used as the fluid to heat the engine oil.

7.9 Pentane (Solvent), Purity >99 %, high-performance liquid chromatography grade.

7.10 Reference Oil, to be obtained from the TMC for calibration of the test stand.

7.11 Sodium Bisulfate (NaHSO4), commercial grade.

7.12 Solvent - Use only mineral spirits meeting the requirements of Specification D235, Type II, Class C for Aromatic Content ((0 to 2) vol %), Flash Point (61 °C, min) and Color (not darker than +25 on Saybolt Scale or 25 on Pt-Co Scale). (Warning - Combustible. Health hazard.) Obtain a Certificate of Analysis for each batch of solvent from the supplier.

7.13 Test Fuel - The specified test fuel is Chevron Phillips PC-9-HS Reference Diesel Fuel. The specification requirements are shown in Annex A7.

7.14 Test Oil - The total amount of oil needed for each test is approximately 42 L.

7.15 Trisodium Phosphate (Na3PO4), commercial grade.

7.16 5.4000 in. Ring Bore Standard Class Z Master.

8. Oil Samples and Additions
8.1 Take a 60 mL purge sample and a 120 mL sample at (36, 144, 252, 360, 432, 504) h. Take a 60 mL purge sample and a 30 mL sample at (72, 108, 180, 216, 288, 324, 396, 468) h. Analyze the (36, 144, 252, 360, 432, 504) h samples for (100 and 40) °C viscosity by Test Method D445, BN by Test Method D4739, AN by Test Method D664, wear metals Al, Cr, Cu, Fe, Pb, Si by Test Method D5185, and differential 1R O2 using the peak-area method 5. Analyze the (36, 360, 504) h samples for fuel dilution by Test Method D3524. Analyze the (360, 432, 504) h samples for TGA soot by Annex A4 of Test Method D5967. The (72, 108, 180, 216, 288, 324, 396, 468) h samples are for optional analysis such as wear metals for mechanical problems.

8.2 Add new oil as computed in the worksheet shown in Annex A6.