ASTM D8047 Standard Test Method for Evaluation of Engine Oil Aeration Resistance in a Caterpillar C13 Direct-Injected Turbocharged Automotive Diesel Engine
8. Preparation of Apparatus
8.1 Cleaning ofParts During Rebuild:
8.1.1 General - Preparation of test engine components specific to the Caterpillar C13 engine rebuild are indicated in this section. Use the Caterpillar Service Manual Form SEN R 9700 for the preparation of other components (except for the piston second ring - see 8.2.7.1). Take precautions to prevent rusting of iron components. Use of an engine-parts washer followed by a solvent wash is permitted.

8.1.2 Engine Block - Disassemble the engine, including removal of the crankshaft, camshaft, piston-cooling tubes, oil pump, and oil-gallery plugs. Thoroughly clean the surfaces and oil passages (galleries). Use a nylon brush to clean the oil passages. Removal of camshaft bearings is optional.

8.1.3 Cylinder Head, Intake System, and Duct - Disassemble and clean these components during engine rebuild. Scrub with a nylon brush and solvent. Use of an engine-parts washer followed by a solvent wash is permitted.

8.1.4 Rocker Cover and Oil Pan - Clean the rocker cover and oil pan. Use a nylon brush, as necessary, to remove deposits.

8.1.5 External Oil Mass System - Flush the internal surfaces of the oil lines and the external reservoir with solvent. Repeat until the solvent drains cleanly. Flush the solvent through the oil pumps until the solvent drains cleanly, then air dry.

8.1.6 High-Pressure Turbocharger - Carefully remove the turbine housing from the turbocharger and clean the wastegate valve with solvent and a soft-wire brush.

8.1.7 Cam-Follower Assembly - Take the cam-follower assembly apart and inspect the bushings and pins. Replace the parts as necessary.

8.2 Engine Assembly:
8.2.1 General:
8.2.1.1 Perform an engine assembly at the laboratory's discretion. Instances when an engine rebuild should be considered include not meeting operational conditions, or when reference limits cannot be met.

8.2.1.2 Except as noted in this section, use the procedures described in the Caterpillar Service Manual Form SEN R 9700. Assemble the engine with the components shown in the Engine Build Parts List (Annex A3).

8.2.2 Parts Reuse and Replacement - Reuse engine components, except as noted in 8.2.7, provided they meet production tolerances as described in the Caterpillar Service Manual.

8.2.3 Build-up Oils - For the head, main caps, and rod bolts, use CAT DEO-ULS engine oil as the build-up oil. If test oil is used, the engine build is valid only for the respective test oil.

8.2.4 Coolant Thermostat - Lock the engine-coolant thermostat open.

8.2.5 Fuel Injectors - Use P/N 239-4908 fuel injectors. If fuel injectors are reused, exercise caution to avoid mechanical damage to or contamination of the nozzles. Dedicate the injectors to a particular cylinder. Install the injectors according to the method described in Caterpillar Service Manual Form SENR9700. Use Mobil EF-411 engine oil as the build-up oil for the injector o-rings.

8.2.6 Piston-Cooling Tubes - Aim the piston-cooling tubes at the underside of the pistons according to the specifications on the TMC website. Contact the TMC for details.

8.2.7 New Parts:
8.2.7.1 General - The following new parts are included in the Engine Build Parts List. They are not reusable. Clean the parts prior to use. A full rebuild parts list is available from the TMC. For piston second rings, follow the D7549 Piston Second Ring Pre-Test Cleaning Procedure, available from the TMC. During a test, a replacement of any of the new parts listed below will invalidate the test:

8.2.7.2 List of(Non-Reusable) New Parts:
(1) Pistons
(2) Piston rings (top, second, and oil)
(3) Cylinder liners
(4) Valves (intake, exhaust)
(5) Valve guides
(6) Valve seats
(7) Connecting-rod bearings, main bearings, and thrust plate
(8) Turbochargers
(9) Oil pump
(10) Oil-pressure regulator springs located inside of the oil-filter block

8.3 Operational Measurements:
8.3.1 Specified Units and Formats - See Annex A8.
8.3.1.1 Measurement of Fuel-Consumption Rate - Calibrate the system for measuring the fuel-consumption rate before each sequence of reference-oil tests and within six months after completion of the last successful calibration test. Compensate volumetric systems for temperature, and calibrate them against a standard mass-flow device. The flowmeter on the test stand shall agree within 0.2 % of the calibration standard, that standard itself being calibrated against a national standard.

8.3.1.2 Calibration of Temperature-Measurement System - Calibrate the temperature-measurement systems before each reference-oil test sequence and within six months after completion of the last successful calibration test. Each temperature-measurement system shall agree within +/- 0.5 °C of the laboratory calibration standard, that standard itself being calibrated against a national standard.

8.3.1.3 Calibration of Pressure-Measurement System - Calibrate the pressure-measurement systems before each reference-oil test sequence and within six months after completion of the last successful calibration test. Confirm the calibration standard against a national standard.

8.3.1.4 Calibration ofFDM:
(1) Calibrate the Micro Motion FDM at least once a year. Emerson's Flow Calibration and Service Centers have been found satisfactory for this purpose.
(2) For all reference- and non-reference-oil tests to be considered valid, the FDM shall have a current calibration.
(3) Calibrate the FDM if there are concerns with the accuracy of the density or flow measurements.
(4) A procedure for checking the accuracy of the FDM-determined densities is described in 10.4.

8.3.2 Locations for Temperature-Measurement Sensors:
8.3.2.1 General - The measurement equipment is not specified. Install the sensors such that the tip is located midstream of the flow unless otherwise indicated. The accuracy and measurement of the temperature-measurement sensors and the complete measurement system shall follow the guidelines in ASTM Research Report RR:D02-1218.

8.3.2.2 Coolant-Out Temperature - Install the sensor in the fitting on the thermostat housing (Fig. A5.13).

8.3.2.3 Coolant-In Temperature - Install the sensor on the right side of the coolant-pump intake housing at the 1 in. NPT port (Fig. A5.14).

8.3.2.4 Fuel-In Temperature - Install the sensor in the fuel-pump inlet fitting (Fig. A5.16).

8.3.2.5 Oil-Gallery Temperature - Install a 1/8 in. thermocouple at the sensor at the 3/8 in. NPT female boss on the right-rear of the engine (Fig. A5.15) extending from the cross fitting described in A7.2.1 to the center of the oil gallery flow.

8.3.2.6 Intake-Air Temperature - Install the sensor in the inlet air tube 127 mm upstream of the compressor connection (Fig. A5.7).

8.3.2.7 Intake-Manifold Temperature - Install the sensor at the 1/8 in. NPT female boss on the outside radius of the inlet-manifold elbow (Fig. A5.17).

8.3.2.8 Exhaust Temperature - Install the sensor in the exhaust tube (Fig. A5.8).

8.3.2.9 Aeration-System-Enclosure Temperature - Insert the sensor 75 mm directly above the vertical centerline of the Micro Motion FDM and extending into the enclosure to the vertical plane of the FDM face.

8.3.2.10 Oil-Sump Temperature - Insert a thermocouple to a depth of 50 mm into the drain-plug port on the right-front pan pictured in Fig. A5.5.

8.3.2.11 Additional Temperatures - It is permissible to measure any additional temperatures that may be useful for test operation or engine diagnostics.

NOTE 4 - Additional exhaust-sensor locations, at the exhaust ports and pre-turbine (front and rear), are recommended. The detection of changes in exhaust temperatures is an important diagnostic feature.

8.3.3 Locations for Pressure-Measurement Sensors:
8.3.3.1 General - The measurement equipment is not specified. Follow the guidelines in ASTM Research Report RR:D02-1218 for the accuracy and resolution of the pressure-measurement sensors and the complete measurement system. If the laboratory has problems with condensation forming in the pressure lines, install a condensation trap at the lowest elevation of the tubing between the pressure-measurement location and the final pressure sensor for crankcase pressure, intake-air pressure, and exhaust pressure. Route the tubing to avoid intermediate loops or low spots before and after the condensation trap.

8.3.3.2 Oil-Gallery Pressure - Measure the pressure from the upper vertical port of the 3/8 in. 4-way cross fitting on the right rear of the engine (Fig. A5.15).

8.3.3.3 Oil-Filter-Inlet Pressure - Measure the pressure at the plug located on the inlet side of the oil filter assembly (Fig. A5.9).

8.3.3.4 Inlet-Manifold Pressure - Measure the pressure at the 1/4 in. NPT port on the outside radius of the inlet-manifold elbow (Fig. A5.17).

8.3.3.5 Crankcase Pressure - Measure the pressure by installing a bulkhead fitting in the top of the valve cover. (Fig. A5.12).

8.3.3.6 Intake-Air Pressure - Measure the pressure at a wall tap on the intake-air tube 153 mm upstream of the compressor connection (Fig. A5.7).

8.3.3.7 Exhaust Pressure - Measure the pressure on the exhaust tube (Fig. A5.8).

8.3.3.8 Fuel Pressure - Measure the pressure at the fuel-filter head (Fig. A5.25).

8.3.3.9 Coolant Pressure - Measure the pressure on top of the expansion tank (Fig. X1.3).

8.3.3.10 Intercooler Delta Pressure - Measure the pressure drop across the intercooler. Measure the intercooler inlet pressure at the elbow outlet of the CAT charge air cooler (Fig. A5.19). Use the intake-manifold pressure (8.3.3.4) as the intercooler outlet pressure. The intercooler delta pressure is the difference between the intercooler outlet pressure and the intercooler inlet pressure.

8.3.3.11 Additional Pressures - It is permissible to measure any additional pressures that may be useful for test operation or engine diagnostics.

NOTE 5 - See Figs. A5.19 and A5.20 for additional instrument placement information.

8.3.4 Locations for Flow-Rate Measurement:
8.3.4.1 General - The equipment for fuel-rate measurements is not specified. Follow the guidelines in ASTM Research Report RR:D02-1218 13 for the accuracy and resolution of the flow-rate-measurement system.

8.3.4.2 Blowby - Measure the blowby flow rate using a JTEC model VF563A or VF563B. See 6.3.11 for blowby measurement system configuration.

8.3.4.3 Fuel Flow - Determine the fuel consumption rate by measuring the fuel flowing to the day tank (Fig. X1.2).

8.3.5 Controller Outputs and Indications of Malfunction in the Aeration-Measurement System - Record the controller output as % for the sample pressure control regulator. If this value is above 50 % for 15W-40 or lower viscosity oils (that is, for oils with kinematic viscosity at 100 °C less than 12.5 mm2/s) the test is invalid. Oils of higher viscosity need a statement of validity in the comments section of the report if the controller output exceeds 50 %.

8.3.6 Quantities for Aerated-Oil Samples - Measure temperature, pressure, flow rate, and density using the aeration system shown in Annex A7.
8.3.6.1 Record the oil sample temperature as the average of the inlet- and outlet-thermocouple temperatures of the FDM. (This temperature is a theoretical temperature at the midpoint of the FDM.)

8.3.6.2 Record the oil sample pressure as the average of the inlet- and outlet-pressure transducers of the FDM. (This pressure is a theoretical pressure at the midpoint of the FDM.)