ASTM D7156 Standard Test Method for Evaluation of Diesel Engine Oils in the T-11 Exhaust Gas Recirculation Diesel Engine
8. Preparation of Apparatus at Rebuild
8.1 Cleaning of Parts:
8.1.1 Engine Block - Thoroughly spray the engine with solvent to remove any oil remaining from the previous test and air-dry, see 7.4. Additionally, wash with solvent after the use of an engine parts washer.
8.1.2 Rocker Covers and Oil Pan - Remove all sludge, varnish, and oil deposits. Rinse with solvent and air-dry. Additionally, wash with solvent after the use of an engine parts washer.
8.1.3 Auxiliary Oil System - Flush all oil lines, galleries and external oil reservoirs first with solvent to remove any previous test oil and then air-dry.
8.1.4 Oil Cooler and Oil Filter - Flush the oil cooler and filter lines first with solvent to remove any previous test oil and then air-dry. Additionally, wash with solvent after the use of an engine parts washer.
8.1.5 Cylinder Head - Clean the cylinder heads using a wire brush to remove deposits and rinse with solvent to remove any sludge and oil and then air-dry. Additionally, wash with solvent after the use of an engine parts washer.
8.1.6 Intake Manifold - At a minimum, clean the intake manifold at rebuild. Frequency of cleaning between rebuilds is at the laboratory's discretion. Scrub the manifold using a nylon brush and solvent, and then wash the manifold using an engine parts washer.
8.1.7 EGR Coolers - Clean by flushing with solvent and then air-drying, see 7.4. At a minimum, clean at rebuild. Frequency of cleaning between rebuilds is at the laboratory's discretion.
8.1.8 EGR Venturi Unit - Spray with solvent and scrub with a nylon brush. At a minimum, clean at rebuild. Frequency of cleaning between rebuilds is at the laboratory's discretion.
8.2 Valves, Seats, Guides, and Springs:
8.2.1 Replace valves, valve guides, seat inserts, valve stem keys and valve stem seals at rebuild.
8.2.2 Use oil when reaming guides. Hone finish, if desired. Valve stem-to-guide clearance shall be (0.038 to 0.089) mm for intake and (0.064 to 0.114) mm for exhaust.
8.3 Cylinder Liner, Piston, and Piston Ring Assembly:
8.3.1 Cylinder Liner Fitting - For proper heat transfer, fit cylinder liners to the block in accordance with the procedure outlined in the Mack Service Manual.
8.3.2 Piston and Rings - Cylinder liners, pistons, and rings are provided as a set and used as a set. Examine piston rings for any handling damage.
8.4 Injectors and Injection Pumps:
8.4.1 Injectors - Injector nozzles are available from the supplier shown in A2.2, Annex A2. Check the injector opening pressure at rebuild. Reset the injector opening pressure if it is outside the specification of (24000 + 2000) kPa. If operating parameters indicate deterioration of injectors, they may be checked and reset, if necessary.
8.4.2 Injection Pumps - The electronic unit pumps (EUP) may be changed at any time using the procedure specified in the Mack Service Manual. Be sure to enter the EUP's four-digit calibration code into the Engine Control Unit (ECU). The calibration code can be found on the EUP label.
8.5 Assembly Instructions:
8.5.1 General - Use only specified test parts for this test without material or dimensional modification. Obtain approval from the Test Monitoring Center (TMC) for exceptions such as a temporary parts supply problem and then note the exception in the test report. Use only genuine Mack Truck Inc. parts as replacement test engine parts. Assemble all parts as illustrated in the Mack Service Manual except where otherwise noted. Target all dimensions for the means of the specifications. Use Bulldog Premium EO-N Premium Plus Oil for lubricating parts during assembly (or later); see A2.11, Annex A2.
8.5.1.1 Thermostat - Block the thermostat wide open.
8.5.1.2 Rod Bearings - Install new rod bearings at rebuild.
8.5.1.3 Main Bearings - Install new main bearings at rebuild.
8.5.1.4 Piston Under-crown Cooling Nozzles - Take particular care in assembling the piston under-crown cooling nozzles to ensure proper piston cooling, see the Mack Service Manual.
NOTE 1 - Proper oil pressure is also important to ensure sufficient oil volume for proper cooling.
8.5.2 New Parts - Use test parts on a first-in/first-out basis. Install the following new parts for each rebuild, see Table A2.1, Annex A2 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.
8.5.2.6 Engine coolant conditioner.
8.5.2.7 Primary fuel filter.
8.5.2.8 Secondary fuel filter.
8.5.2.9 Valve stem seals and keys.
8.5.2.10 Valve guides and inserts.
8.5.2.11 Valves.
8.5.2.12 Connecting rod bearings.
8.5.2.13 Main bearings.
8.5.2.14 Thrust washers.
8.6 Measurements:
8.6.1 Calibrations - Calibrate thermocouples, pressure gages, speed, and fuel flow measuring equipment prior to each reference oil 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. For controlled temperatures, immerse thermocouples in calibration baths. Calibrate standards with instruments traceable to the National Institute of Standards and Technology (NIST) on a yearly basis.
8.6.2 Temperatures:
8.6.2.1 General - Measure temperatures with thermocouples and conventional readout equipment or equivalent. For temperatures in the (0 to 150) °C range, calibrate temperature measuring systems to +/- 0.5 °C for at least two temperatures that bracket the normal operating range. 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 from the engine and hot accessories.
8.6.2.3 Coolant - Locate the coolant-out thermocouple in the water manifold prior to the thermostat housing. Locate in center of water stream. Refer to Fig.A1.6, Annex A1. Locate the coolant-in thermocouple anywhere between the heat exchanger and the coolant pump inlet (upstream of the junction with the EGR coolant return). Refer to Fig.A1.7, Annex A1.
8.6.2.4 Oil Gallery - Locate thermocouple at the center port on the filter housing. Insertion depth is 98 mm. Refer to Fig.A1.8, Annex A1.
8.6.2.5 Oil Sump Temperature - Using a front sump oil pan configuration, locate the thermocouple on the exhaust side of the oil pan, from the front by 127 mm and from the top by 178 mm. The thermocouple length is 102 mm. Refer to Fig.A1.4, Annex A1.
8.6.2.6 Intake Air Temperature - Locate the intake air thermocouple in the center of the air stream at the turbocharger inlet as shown in Fig.A1.9, Annex A1. Locate the temperature thermocouple upstream of the compressor inlet connection approximately 102 mm. It is not necessary to control intake air humidity, but measurements are required.
8.6.2.7 Fuel In - Locate a thermocouple at the fitting on the outlet side of the fuel transfer pump as shown in Fig.A1.10, Annex A1.
8.6.2.8 Pre-Turbine Exhaust - Locate one thermocouple in each side of the exhaust manifold section see Fig.A1.11, Annex A1. Locate the thermocouple downstream of the preturbine exhaust pressure sensor.
8.6.2.9 Exhaust Tailpipe - Locate a thermocouple in the exhaust pipe downstream of the turbine in accordance with Fig.A1.12, Annex A1.
8.6.2.10 Intake Manifold - Locate a thermocouple at the tapped fitting on the intake air manifold as shown in Fig.A1.13, Annex A1.
8.6.2.11 EGR Cooler Inlet - Distinct EGR cooler inlet temperature measurements are not necessary. Use the pre-turbine exhaust temperatures instead see 8.6.2.8.
8.6.2.12 EGR Cooler Outlet - Locate a thermocouple as shown in Fig.A1.14, Annex A1.
8.6.2.13 EGR Pre-Venturi - Locate a thermocouple as shown in Fig.A1.15, Annex A1. Locate the EGR pre-venturi thermocouple downstream of the EGR pre-venturi pressure sensor pickup.
8.6.2.14 Additional - Monitor any additional temperatures that the test laboratory regards as helpful in providing a consistent test procedure.
8.6.3 Pressures - Pressure measurements, sensors, and sensor calibrations shall conform to the research report.
8.6.3.1 Before Oil Filter - Locate pickup at tapped hole on oil cooler fitting. See Fig.A1.16, Annex A1.
8.6.3.2 After Oil Filter (Main Oil Gallery) - Locate pickup at the left port of the filter-housing. See Fig.A1.8, Annex A1.
NOTE 2 - The E7 engine has only one oil gallery, which serves as both a main gallery and piston-cooling gallery.
8.6.3.3 Pre-Turbine Exhaust - Locate pickup in each side of exhaust manifold section (tap is upstream of the pre-turbine temperature thermocouple), see Fig.A1.11, Annex A1. This measurement is not mandatory, but it is recommended for diagnostic and safety purposes.
8.6.3.4 Intake Manifold (Air Boost) - Take measurement at tapped fitting provided on the intake manifold as shown in Fig.A1.17, Annex A1.
8.6.3.5 Intake Air Pressure (Intake Air Restriction) - Measure with a Keil Probe (p/n KDF-8-W required) located upstream of the compressor inlet (see Fig.A1.9, Annex A1) approximately 203 mm. The probes may be obtained from the supplier shown in A2.11.
8.6.3.6 Exhaust Back - Locate pickup in exhaust pipe after turbocharger in center of exhaust stream. Measure exhaust backpressure in a straight section of pipe, downstream of the turbo by (305 to 406) mm, with a pressure tap hole as shown in Fig.A1.12, Annex A1.
8.6.3.7 Crankcase Pressure - Locate pickup at any location in the auxiliary oil system vent line, such as between the dipstick tube fitting and the top of the auxiliary oil sump bucket.
8.6.3.8 Compressor Discharge - Locate pickup within 152 mm of the second compressor.
8.6.3.9 Coolant System - Locate pickup at the top of the coolant system expansion tank.
8.6.3.10 Barometric Pressure - Locate barometer in a convenient location in the lab, above ground level approximately 1.2 m.
8.6.3.11 EGR Pre-Venturi Pressure - Locate pickup as shown in Fig.A1.15, Annex A1. Locate the EGR pre-venturi pressure pickup upstream of the EGR pre-venturi temperature thermocouple.
8.6.3.12 Fuel Pressure - Locate pickup at the end of the fuel rail as shown in Fig.A1.19, Annex A1.
8.6.4 Carbon Dioxide Sensors - Locate the intake probe as shown in Fig.A1.8, Annex A1. Locate the exhaust probe as shown in Fig.A1.12, Annex A1.
8.6.5 Engine Blowby - Connect the metering instrument to the filter element canister on the engine front cover.
8.6.6 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 unit injection pumps. Do not allow the fuel return lines to become plugged. Accurate fuel consumption measurements require proper accounting of return fuel.
8.6.7 Humidity - Place the measurement equipment between the inlet air filter and compressor in such a manner as not to affect temperature and pressure measurements. Do not condition the intake air downstream of the humidity sensor. Report humidity on the appropriate form.
8.7 System Time Responses - The maximum allowable system time responses are shown in Table 1. Determine system time responses in accordance with the Data Acquisition and Control Automation II (DACA II) Task Force Report.
