ASTM D7156 Standard Test Method for Evaluation of Diesel Engine Oils in the T-11 Exhaust Gas Recirculation Diesel Engine
6. Apparatus
6.1 General Description:
6.1.1 The test engine is a Mack E-TECH V-MAC III, electronically controlled fuel injection with six electronic unit pumps, using 2002 cylinder heads (Annex A2). It is an open-chamber, in-line, six-cylinder, four-stroke, turbocharged, charge air-cooled, and compression ignition engine. The bore and stroke are (124 by 165) mm, and the displacement is 12 L.

6.1.2 The ambient laboratory atmosphere shall be relatively free of dirt and other contaminants as required by good laboratory standards. Filtering air, controlling temperature, and controlling humidity in the engine buildup area helps prevent accumulation of dirt and other contaminants on engine parts and aids in measuring and selecting parts for assembly.

6.2 The Test Engine:
6.2.1 Mack T-11 Test Engine - The engine and cylinder heads are available from Mack Trucks, Inc. A complete parts list is shown in Table A2.1, Annex A2. Use test parts on a first-in/first-out basis.

6.2.2 Engine Cooling System:
6.2.2.1 Use a new Mack coolant conditioner shown in Table A2.1, Annex A2, every test, to limit scaling in the cooling system. At the expansion tank, pressurize the system to 103 kPa. Use the coolant shown in 7.3.

6.2.2.2 Use a closed-loop, pressurized external engine cooling system composed of a nonferrous core heat exchanger, reservoir, and water-out temperature control valve. The system shall prevent air entrainment and control jacket temperatures within the specified limit. Install a sight glass between the engine and the cooling tower to check for air entrainment and uniform flow in an effort to prevent localized boiling. Block the thermostat wide open.

6.2.2.3 Flow the coolant from the engine block fitting to the EGR coolers, see Fig.A1.3, Annex A1. Return the EGR coolant flow to the engine coolant-in line, near the coolant pump inlet, see Fig.A1.7, Annex A1.

6.2.3 Auxiliary Oil System:
6.2.3.1 To maintain a constant oil level in the pan, provide an additional minimum volume sump of 11.4 L by using a separate closed tank connected to the engine sump. Circulate oil through the system with an auxiliary pump. The system schematic is shown in Fig.A1.1, Annex A1. The inside diameters of the No. 6 and No. 8 lines are 10 mm and 13 mm, respectively. Use a minimum No. 8 size vent line. Equivalent lines may be substituted forAeroquip lines provided they have the proper inside diameters.

6.2.3.2 Locate the auxiliary oil system suction line on the exhaust side of the oil pan, so that the inside bottom of the auxiliary oil system suction fitting is down from the oil pan rail by 152 mm, and back from the front of the pan by 178 mm. Refer to Fig.A1.4, Annex A1. Connect the auxiliary oil system return line to the power steering pump cover on the front timing gear cover. Refer to Fig.A1.5, Annex A1. Connect the auxiliary oil scale vent line to the top of the auxiliary oil sump bucket and the dipstick tube opening.

6.2.3.3 Use Viking Pump Model SG053514 as the auxiliary oil pumps (see A2.10). Nominal pump speed is 1725 r/min. Shut off the auxiliary oil pumps if the auxiliary oil system goes dry.

6.2.3.4 Use a sight glass to aid in determining the oil level should the auxiliary oil system run dry. An example of a sight glass setup is shown in Fig.A1.18, Annex A1.

6.2.4 Oil Cooling System:
6.2.4.1 Use the oil cooler adapter blocks to mount the oil cooler to the engine. The adapter blocks are available from the supplier list in A2.7, Annex A2.

6.2.4.2 Use the oil filter housing (part number 27GB525M) shown in Fig.A1.8, Annex A1.

6.2.5 Blowby Meter - Use a meter capable of providing data at a minimum frequency of 6 min. To prevent blowby condensate from draining back into the engine, ensure the blowby line has a downward slope to a collection bucket. Ensure the collection bucket has a minimum volume of 18.9 L. Locate the blowby meter downstream of the collection bucket. The slope of the blowby line downstream of the collection bucket is unspecified.

6.2.6 Air Supply and Filtration - Use the Mack air filter element and the Mack filter housing shown in A2.3, Annex A2. Replace the filter cartridge when a ΔP of 2.5 kPa is reached. Install an adjustable valve (flapper) in the inlet air system at least two pipe diameters before any temperature, pressure, and humidity measurement devices. Use the valve to maintain inlet air restriction within required specifications.

6.2.7 Fuel Supply - Heating, cooling, or both of the fuel supply may be required. See Fig.A1.2, Annex A1, for a recommended system.

6.2.8 Intake Manifold and Temperature Control - Use stainless steel intake manifolds (P/N M10105GCX4332RSS for front manifold, M10105GCX5212RSS for rear manifold) available from the supplier listed in A2.2, Annex A2. Use a Modine intercooler to control intake manifold temperature, A2.4, Annex A2.

6.2.9 Injection Timing Control - Remove the engine intake manifold temperature sensor. Use the intake manifold temperature to control injection timing in accordance with the Temperature to Injection Timing Correlation shown in Annex A4.

6.2.10 Oil Pump - Use a Mack P/B 315GC465BM oil pump. The oil pump is available from the supplier listed in A2.2, Annex A2.

6.2.11 EGR Venturi Unit - Use a stainless steel EGR venturi unit, P/N 762GBX433SS, available from the supplier listed in A2.2, Annex A2.

6.2.12 Fuel Pressure Regulator - Use a P/N 691GC227M2 fuel pressure regulator.

7. Engine Fluids
7.1 Test Oil - Use approximately 98 L of test oil for the test.

7.2 Test Fuel - Obtain test fuel from the supplier shown in A2.6, Annex A2. The required fuel properties and tolerances are shown in Annex A7.

7.3 Engine Coolant - Use demineralized water with less than 0.03 g/L of salts or distilled water (do not use antifreeze solutions). Use Pencool 3000 coolant additive at the manufacturer's recommended rate. Pencool 3000 may be obtained from the supplier shown in A2.8, Annex A2.

7.4 Cleaning Materials - Use a solvent meeting Specification D235, Type II, Class C for cleaning parts. (Warning - Use adequate safety precautions with all solvents and cleaners.) Other materials such as diesel fuel may be required by some labs in order to ensure parts cleanliness.)