Designation: D6681 − 10a

Standard Test Method for

Evaluation of Engine Oils in a High Speed, Single-Cylinder
Diesel Engine—Caterpillar 1P Test Procedure1
This standard is issued under the fixed designation D6681; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.

INTRODUCTION

Any properly equipped laboratory without outside assistance can use the test method described in
this standard. However, the ASTM Test Monitoring Center (TMC)2 provides calibration oils and an
assessment of the test results obtained on those oils by the laboratory. By this means the laboratory
will know whether their use of the test method gives results statistically similar to those obtained by
other laboratories. Furthermore, various agencies require that a laboratory utilize the TMC services in
seeking qualification of oils against specifications. For example, the U.S. Army has such a requirement
in some of its engine oil specifications. Accordingly, this test method is written for those laboratories
that use the TMC services. Laboratories that choose not to use these services should ignore those
portions of the test method that refer to the TMC. Information Letters issued periodically by the TMC
may modify this method.3 In addition, the TMC may issue supplementary memoranda related to the
test method.

1. Scope 1.3 This standard does not purport to address all of the
1.1 This test method covers and is required to evaluate the safety concerns, if any, associated with its use. It is the
performance of engine oils intended to satisfy certain American responsibility of the user of this standard to establish appro-
Petroleum Institute (API) C service categories (included in priate safety and health practices and determine the applica-
Specification D4485). It is performed in a laboratory using a bility of regulatory limitations prior to use. Being an engine
standardized high-speed, single-cylinder diesel engine.4 Piston test method, this standard does have definite hazards that
and ring groove deposit-forming tendency and oil consumption require safe practices (see Appendix X2 on Safety).
is measured. The piston, the rings, and the liner are also 1.4 The following is the Table of Contents:
examined for distress and the rings for mobility. Section
Scope 1
1.2 The values stated in SI units are to be regarded as Referenced Documents 2
standard. No other units of measurement are included in this Terminology 3
Summary of Test Method 4
standard. Significance and Use 5
1.2.1 Exceptions—Where there is no direct SI equivalent Apparatus and Installation 6
such as screw threads, National Pipe Threads/diameters, tubing Intake Air System 6.2.1
Exhaust System 6.2.2
size, or where there is a sole source supply equipment Fuel System 6.2.3
specification. Oil Consumption System 6.2.4
Engine Oil System 6.2.5
Oil Heating System [Link]
Oil Sample Valve [Link]
1
This test method is under the jurisdiction of ASTM Committee D02 on Engine Coolant System 6.2.6
Petroleum Products and Lubricants and is the direct responsibility of Subcommittee Engine Instrumentation 6.2.7
D02.B0.02 on Heavy Duty Engine Oils. Reagents and Materials 7
Current edition approved Oct. 1, 2010. Published November 2010. Originally Oil Samples 8
approved in 2001. Last previous edition approved in 2010 as D6681–10. DOI: Preparation of Apparatus 9
10.1520/D6681-10A. General Engine Assembly Practices 9.1
2 Complete Engine Inspection 9.2
ASTM Test Monitoring Center (TMC), 6555 Penn Ave., Pittsburgh, PA
15206–4489. Copper Components 9.3
3
This edition incorporates revisions contained in all information letters through Engine Lubricant System Flush 9.4
10-1. Users of this test method shall contact the ASTM Test Monitoring Center to Engine Piston Cooling Jets 9.5
obtain the most recent information letters. Engine Measurements and Inspections 9.6
4
Available from Caterpillar Inc., Engine System Technology Development, P.O. Cylinder Head 9.7
Box 610, Mossville, IL 61552-0610. Valve Guide Bushings 9.8

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States

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 D6681 − 10a

Section 2. Referenced Documents

Fuel Injector 9.9
Piston and Rings 9.10 2.1 ASTM Standards:5
Cylinder Liner 9.11 D86 Test Method for Distillation of Petroleum Products at
Compression Ratio 9.12
Engine Timing 9.13 Atmospheric Pressure
Engine Coolant System Cleaning Procedure 9.14 D93 Test Methods for Flash Point by Pensky-Martens
Calibration and Standardization 10 Closed Cup Tester
Test Cell Instrumentation 10.1
Instrumentation Standards 10.2 D97 Test Method for Pour Point of Petroleum Products
Coolant Flow 10.3 D130 Test Method for Corrosiveness to Copper from Petro-
Re-calibration Requirements 10.4
Fuel Injectors 10.5
leum Products by Copper Strip Test
Air Flow 10.6 D235 Specification for Mineral Spirits (Petroleum Spirits)
Intake Air Barrel 10.7 (Hydrocarbon Dry Cleaning Solvent)
Fuel Filter 10.8
Oil Scale Flow Rates 10.9
D445 Test Method for Kinematic Viscosity of Transparent
Calibration of Test Stands 10.10 and Opaque Liquids (and Calculation of Dynamic Viscos-
Extending Test Stand Calibration Period 10.11 ity)
Test Run Numbering 10.13
Humidity Calibration Requirements 10.14 D482 Test Method for Ash from Petroleum Products
Calibration of Piston Deposit Raters 10.15 D524 Test Method for Ramsbottom Carbon Residue of
Procedure 11 Petroleum Products
Engine Break-in Procedure 11.1
Cool-down Procedure 11.2 D613 Test Method for Cetane Number of Diesel Fuel Oil
Warm-up Procedure 11.3 D664 Test Method for Acid Number of Petroleum Products
Shutdowns and Lost Time 11.4
Periodic Measurements 11.5
by Potentiometric Titration
Engine Control Systems 11.6 D1319 Test Method for Hydrocarbon Types in Liquid Petro-
Engine Coolant 11.6.1 leum Products by Fluorescent Indicator Adsorption
Engine Fuel System 11.6.2
Engine Oil Temperature 11.6.3
D2274 Test Method for Oxidation Stability of Distillate Fuel
Exhaust Pressure 11.6.4 Oil (Accelerated Method)
Intake Air 11.6.5 D2425 Test Method for Hydrocarbon Types in Middle Dis-
Post-Test Procedures 11.7
Piston Ring Side Clearances 11.7.1
tillates by Mass Spectrometry
Piston Ratings 11.7.2 D2500 Test Method for Cloud Point of Petroleum Products
Referee Ratings 11.7.3 D2622 Test Method for Sulfur in Petroleum Products by
Ring End Gap Increase 11.7.4
Cylinder Liner Wear 11.7.5 Wavelength Dispersive X-ray Fluorescence Spectrometry
Cylinder Liner Bore Polish 11.7.6 D2709 Test Method for Water and Sediment in Middle
Photographs 11.7.7 Distillate Fuels by Centrifuge
Calculation and Interpretation of Results 12
Test Validity 12.1 D3227 Test Method for (Thiol Mercaptan) Sulfur in Gaso-
Calculations 12.2 line, Kerosine, Aviation Turbine, and Distillate Fuels
Quality Index 12.2.1 (Potentiometric Method)
Oil Consumption 12.2.2
Report 13 D3524 Test Method for Diesel Fuel Diluent in Used Diesel
Forms and Data Dictionary 13.1 Engine Oils by Gas Chromatography
Test Validity 13.2
Report Specifics 13.3
D4175 Terminology Relating to Petroleum, Petroleum Prod-
Precision and Bias 14 ucts, and Lubricants
Precision 14.1 D4052 Test Method for Density, Relative Density, and API
Bias 14.1.4
Keywords 15
Gravity of Liquids by Digital Density Meter
Annexes D4485 Specification for Performance of Active API Service
Engine and Parts Warranty Annex A1 Category Engine Oils
Instrument Locations, Measurements, and Calculations Annex A2
Cooling System Arrangement Annex A3
D4739 Test Method for Base Number Determination by
Intake Air Mass Flow Sensor Installation Annex A4 Potentiometric Hydrochloric Acid Titration
Fuel System Design and Required Components Annex A5 D5185 Test Method for Determination of Additive Elements,
Oil System Annex A6
Exhaust and Intake Barrel Piping Annex A7 Wear Metals, and Contaminants in Used Lubricating Oils
Humidity Probe Installation (Location) Annex A8 and Determination of Selected Elements in Base Oils by
Return Goods Authorization (Claim Form) Annex A9 Inductively Coupled Plasma Atomic Emission Spectrom-
Engine Assembly Information Annex A10
Flushing Instructions and Apparatus Annex A11 etry (ICP-AES)
Warm-up, Cool-down and Testing Conditions Annex A12
Piston and Liner Rating Modifications Annex A13
Additional Report Forms Annex A14
Test Report Forms Annex A15 5
For referenced ASTM standards, visit the ASTM website, [Link], or
Appendixes contact ASTM Customer Service at service@[Link]. For Annual Book of ASTM
Various Examples for Reference Purposes Appendix X1 Standards volume information, refer to the standard’s Document Summary page on
Safety Appendix X2 the ASTM website.

Copyright by ASTM Int'l (all rights reserved); 2

 D6681 − 10a
D5862 Test Method for Evaluation of Engine Oils in Two- [Link] Discussion—These oils are mainly submitted for
Stroke Cycle Turbo-Supercharged 6V92TA Diesel Engine testing as candidates to satisfy a specified performance; hence
(Withdrawn 2009)6 the designation of the term.
D6202 Test Method for Automotive Engine Oils on the Fuel 3.1.8 debris, n—in internal combustion engines, solid con-
Economy of Passenger Cars and Light-Duty Trucks in the taminant materials unintentionally introduced into the engine
Sequence VIA Spark Ignition Engine (Withdrawn 2009)6 or resulting from wear. D5862
D6593 Test Method for Evaluation of Automotive Engine
Oils for Inhibition of Deposit Formation in a Spark- 3.1.9 dispersant, n—in engine oil, an additive that reduces
Ignition Internal Combustion Engine Fueled with Gaso- deposits on oil-wetted engine surfaces primarily through sus-
line and Operated Under Low-Temperature, Light-Duty pension of particles. D4175
Conditions 3.1.10 engine oil, n—a liquid that reduces friction or wear,
D7422 Test Method for Evaluation of Diesel Engine Oils in or both, between the moving parts within an engine; removes
T-12 Exhaust Gas Recirculation Diesel Engine heat, particularly from the underside of pistons; and serves as
E29 Practice for Using Significant Digits in Test Data to a combustion gas sealant for the piston rings. D5862
Determine Conformance with Specifications [Link] Discussion—It may contain additives to enhance
G40 Terminology Relating to Wear and Erosion certain properties. Inhibition of engine rusting, deposit forma-
2.2 SAE Standard: tion, valve train wear, oil oxidation and, foaming are examples.
SAE J183 Engine Oil Performance and Engine Service 3.1.11 heavy-duty, adj— in internal combustion engine
Classification7 operation, characterized by average speeds, power output, and
2.3 API Standard: internal temperatures that are generally close to the potential
API 1509 Engine Service Classification and Guide to Crank- maximums. D4485
case Oil Selection8
3.1.12 lubricant, n—any material interposed between two
3. Terminology surfaces that reduces the friction or wear, or both, between
them. D5862
3.1 Definitions:
3.1.1 additive, n—a material added to another, usually in a 3.1.13 lubricating oil, n—a liquid lubricant, usually com-
small amount, to impart or enhance desirable properties or to prising several ingredients, including a major portion of base
suppress undesirable properties. D4175 oil and minor portions of various additives. D41752
3.1.2 automotive, adj—descriptive of equipment associated 3.1.14 oxidation, n—of engine oil, the reaction of the oil
with self-propelled machinery, usually vehicles driven by with an electron acceptor, generally oxygen, that can produce
internal combustion engines. D4485 deleterious acidic or resinous materials often manifested as
sludge formation, varnish formation, viscosity increase, or
3.1.3 blind reference oil, n—a reference oil, the identity of
corrosion, or a combination thereof. D4175
which is unknown by the test facility. D4175
[Link] Discussion—This is a coded reference oil which is 3.1.15 non-reference oil, n—any oil other than a reference
submitted by a source independent from the test facility. oil; such as a research formulation, commercial oil, or candi-
date oil. D4175
3.1.4 blowby, n—in internal combustion engines, that por-
tion of the the combustion products and unburned air/fuel 3.1.16 purchaser, n—of an ASTM test, person or organiza-
mixture that leaks past piston rings into the engine crankcase tion that pays for the conduct of an ASTM test method on a
during operation. D4175 specified product. D6202
3.1.5 calibrate, v—to determine the indication or output of a 3.1.17 reference oil, n—an oil of known performance char-
device (e.g., thermometer, manometer, engine) with respect to acteristics, used as a basis for comparison.
that of a standard. [Link] Discussion—Reference oils are used to calibrate
3.1.6 calibrated test stand, n—a test stand on which the testing facilities, to compare the performance of other oils, or
testing of reference material(s), conducted as specified in the to evaluate other material (such as seals) that interact with oils.
standard, provided acceptable test results. Sub. B Glossary2 D4175
[Link] Discussion—In several automotive lubricant stan- 3.1.18 scoring, n—in tribology, a severe form of wear
dard test methods, the ASTM Test Monitoring Center provides characterized by the formation of extensive grooves and
testing guidance and determines acceptability. scratches in the direction of sliding. G40
3.1.7 candidate oil, n—an oil which is intended to have the 3.1.19 scuffıng, n—in lubrication, damage caused by instan-
performance characteristics necessary to satisfy a specification taneous localized welding between surfaces in relative motion
and is to be tested against that specification. D4175 which does not result in immobilization of the parts. D6593
3.1.20 sponsor, n—of an ASTM test method, an organization
6
The last approved version of this historical standard is referenced on that is responsible for ensuring supply of the apparatus used in
[Link]. the test procedure portion of the test method. D4175
7
Available from the Society of Automotive Engineers Inc., 400 Commonwealth
[Link] Discussion—In some instances, such as a test
Drive, Warrendale, PA 15096.
8
Available from the American Petroleum Institute, 1220 L Street NW, Washing- method for chemical analysis, an ASTM working group can be
ton DC, 20005. the sponsor of the test method. In other instances, a company

Copyright by ASTM Int'l (all rights reserved); 3

 D6681 − 10a
with a self-interest may or may not be the developer of the test and, optionally, maximum engine crankcase pressure. The
procedure used within the method, but is the sponsor of the test ECM also controls the fuel injection duration that defines the
method. engine fuel rate based on set conditions from the test cell
3.1.21 used oil, n—any oil that has been in a piece of feedback control systems. The oil pressure is also set by the
equipment (for example, an engine, gearbox, transformer, or ECM with signals to the 1Y3867 engine air pressure controller
turbine), whether operated or not. D4175 (Mamac) to modulate the facility air supply to the 1Y3898
Johnson Controls relief valve.
3.1.22 varnish, n—in internal combustion engines, a hard,
6.1.2 The 1Y3700 engine arrangement also consists of inlet
dry, generally lustrous deposit that can be removed by solvents
air piping and hoses from the cylinder head to the air barrel and
but not by wiping with a cloth. D4175
exhaust piping and bellows from the cylinder head to the
3.1.23 wear, n—the loss of material from a surface, gener- exhaust barrel that are specifically designed for oil testing. See
ally occurring between two surfaces in relative motion, and the Caterpillar Service Manual.4
resulting from mechanical or chemical action or a combination
6.2 Equip the engine test stand with the following accesso-
of both. D7422
ries or equipment:
6.2.1 Intake Air System—The intake air system components
4. Summary of Test Method
from the cylinder head to the air barrel are a part of the basic
4.1 Prior to each test, the power section of the engine is 1Y3700 engine arrangement. These components consisting of
disassembled, solvent-cleaned, measured, and rebuilt in strict an adapter, elbow, hose, clamps, and flanged tube can be found
accordance with the specifications. A new piston, ring assem- in the 1Y3700 Parts Book.4
bly, and cylinder liner are measured and installed for each test. [Link] The 1Y3978 intake air barrel (which is almost
The engine crankcase is solvent-cleaned and worn or defective identical to the exhaust barrel except for the top cover) has
parts are replaced. The test stand is equipped with feedback been specifically designed and shall be purchased from one of
control systems for fuel rate, engine speed, and other engine the three approved manufacturers.9,10 Install the intake air
operating conditions. A suitable system for filtering, compress- barrel at the location shown in Annex A7. Do not add
ing, humidifying, and heating the inlet air shall be provided insulation to the barrel.
along with a system for controlling the engine exhaust pres- [Link] Paint the inside of the intake air piping with Cater-
sure. Test operations involve the control of the single-cylinder pillar yellow primer or red Glyptal prior to installation.10,11
diesel test engine for a total of 360 h at specified speeds and [Link] Install the air heater elements in the intake air barrel
fuel rate input using the test oil as a lubricant. A defined as specified in Annex A7 (even if they will not be supplied with
break-in precedes each test and is also used when restarting an electricity).10,12
engine. At the end of the test, the piston deposits are rated, the [Link] Use an air filter capable of filtering particles 10 µ (or
piston, rings and liners are photographed, inspected and smaller).
measured, oil consumption is calculated and the oil is analyzed [Link] Use a Sierra Model 780 airflow meter with Feature
to determine the test results. Critical engine conditions are 1 = F6, Feature 2 = CG and calibration temperature = 60 °C to
statistically analyzed to determine if the test was precisely measure intake airflow for each calibration test.10,13Annex A4
operated. Test acceptability parameters for each calibration test shows the piping requirements for the installation of the Sierra
are also statistically analyzed to determine if the engine/test Model 780 airflow meter.
stand produce the specified results. [Link] Measure the inlet air temperature at the location
shown in Annex A2. Measure the inlet air pressure at the air
5. Significance and Use barrel as shown in Annex A7. The location of the 1Y3977
5.1 This is an accelerated engine oil test, performed in a humidity probe is shown in Annex A8. The sample line may
standardized, calibrated, stationary single-cylinder diesel en- require insulation to prevent dropping below dew point tem-
gine that gives a measure of (1) piston and ring groove deposit perature and shall not be hygroscopic. Drain taps may be
forming tendency, (2) piston, ring and liner scuffing and (3) oil installed at the low points of the combustion air system.
consumption. The test is used in the establishment of diesel
engine oil specification requirements as cited in Specification 9
The sole sources of supply of the intake air barrel known to the committee at
D4485 for appropriate API Performance Category C oils (API this time are Cimino Machinery Corp., 5958 South Central Ave., Chicago, IL 60638;
1509). The test method can also be used in diesel engine oil Gaspar Inc., 4106 Mahoning Rd. N.E., Canton, OH 44705; and M.L. Wyrick
development. Welding, 2301 Zanderson Highway 16 N, Jourdanton, TX 78026.
10
If you are aware of alternative suppliers, please provide this information to
ASTM International Headquarters. Your comments will receive careful consider-
6. Apparatus and Installation ation at a meeting of the responsible technical committee 1, which you may attend.
6.1 The test engine is an electronically controlled, direct 11
The sole source of supply of the crankcase paint primer known to the
injection, in-head camshaft, single-cylinder diesel engine with committee at this time is BASF Coating and Colorant Div., P.O. Box 1297,
a four-valve arrangement. The engine has a 137.2 mm bore and Morganton, NC 28655. (Primer No.A123590 and BASF Part No.U27YD005,
a 165.1 mm stroke resulting in a displacement of 2.4 L. Yellow CAT Primer Part No.IE2083A.)
12
The sole source of supply of the air heater elements known to the committee
6.1.1 The electronic control module (ECM) defines the
at this time is Watlow Air Heaters, Chicago, IL 708-490-3900.
desired engine fuel timing, monitors and limits maximum 13
The sole source of supply of the airflow meter known to the committee at this
engine speed, maximum engine power, minimum oil pressure, time is Sierra Instruments, Inc., 5 Harris Ct., Monterey, CA 93940.

Copyright by ASTM Int'l (all rights reserved); 4

 D6681 − 10a
[Link] Use feedback-equipped controls to maintain filtered, vary the oil pressure adjust signal to the ECM to maintain the
compressed, and humidified inlet air at the conditions specified oil pressure at the test specifications. See the Electronic
in Annex A12. Installation and Operation manual for additional information.
6.2.2 Exhaust System—The exhaust system components The ECM maintains the oil pressure regardless of engine
from the cylinder head to the exhaust barrel are part of the speed. Measure the oil temperatures at locations shown in
basic 1Y3700 engine arrangement. These components consist- Annex A2.
ing of an adapter, elbow, bellows, flange, and clamps can be [Link] Oil Heating System—Use an external oil heating
found in the 1Y3700 Parts Book. system provided by the test facility to maintain the engine oil
[Link] The 1Y3976 exhaust barrel (which is almost identi- manifold temperature specified in Annex A12. An example
cal to the intake barrel except for the top cover) has been system is shown in Appendix X1. A special 1Y3908 oil cooler
specifically designed and shall be purchased from one of the bonnet has been designed to allow separate fluids to the engine
three approved manufacturers. Install the exhaust barrel at the coolant tower arrangement (see Fig. A6.9). Plug the 1Y3660
location shown in Annex A7. Do not add insulation to the oil cooler adapter and 1Y3908 heat exchanger bonnet as shown
barrel. in Annex A6. Use Paratherm NF for the heating fluid.10,16 The
[Link] Install a restriction valve downstream from the temperature of the Paratherm NF is measured by the thermo-
exhaust barrel. The distance between the valve and barrel is not couple shown in Annex A2.
specified. The location of the exhaust thermocouple is shown [Link] Oil Sample Valve—Refer to Annex A2 for the
in Annex A2. Measure the exhaust pressure at the exhaust installation location and component makeup of the oil sample
barrel shown in Annex A7. valve. Use of alternate equivalent components for the sample
[Link] Use feedback-equipped controls to maintain the valve is permitted.
exhaust gases at the pressure specified in Annex A12. 6.2.6 Engine Coolant System—The coolant system sche-
6.2.3 Fuel System—The fuel system schematic is shown in matic is shown in Annex A3. Control the coolant temperature
Annex A5. Desired fuel injection timing is controlled by the out of the engine using a cell facility feedback system. Use a
engine computer at 13° BTC. Measure the fuel rate using micro 1Y3898 Johnson Controls valve or equivalent fail-open valve
motion device with a maximum range of 90 kg/h scaled to the to regulate the coolant temperature out of the engine as shown
1P operation range specified in Annex A12.10,14 Use the day by the schematic in Annex A3. If the 1Y3898 Johnson valve is
tank specified in Annex A5. Measure fuel temperature at the used, supply facility air pressure at 280 kPa to the controller
fuel filter base as shown in Annex A2 and control it using the that regulates air pressure to the valve at (0 to 140) kPa. Install
cell facility feedback system. Use the required fuel heat a feedback-equipped control system to pneumatically adjust
exchanger(s) and arrange them as specified in Annex A5. Use the valve. Remove the 1Y3832 hose originally supplied with
the Fisher regulator specified in Annex A5. the engine and install a sight glass using the components shown
6.2.4 Oil Consumption System—Use an oil scale system to in Annex A3.
accurately measure oil consumption (see Fig. A6.2 and Fig. 6.2.7 Engine Instrumentation—Use feedback-equipped sys-
A6.3). The oil scale system shall have a resolution as listed in tems to control the engine operating temperatures, pressures,
Annex A2. Use flexible hoses similar to Aeroquip flexible hose, and flow rates. Measure the engine operating conditions at the
FC352-08, to-and-from the oil scale reservoir to eliminate locations shown in Annex A2. For temperature measurements,
measurement errors.10 ,15 Use No.5 TFE-fluorocarbon, steel- use thermocouples 1Y468 (intake air), 1Y467 (engine exhaust)
braided hoses to and from the oil scale pumps. The hose length and 1Y466 (fluids-water, oil, and fuel) or equivalent thermo-
to-and-from the oil scale cart shall not exceed 2.7 m. Use the couples as specified in Annex A2. Instrument measurement and
special oil pan adapter described in Fig. A6.4. The flow rates reporting resolutions are shown in Annex A2.
for the oil being pumped from the oil pan to the oil scale shall 6.2.8 A dynamometer with feedback control to maintain
be (23.6 to 24.9) kg/h, and (16.3 to 17.7) kg/h for the oil being engine load and speed. Use a starting system capable of at least
pumped from the oil scale to the oil pan. See Annex A6 for the breakaway torque of 136 N·m and sustained torque of 102 N·m
procedure to verify these flow rates. at 200 r/min.
6.2.5 Engine Oil System—A schematic of the oil system is
6.2.9 Compressed air at 35 kPa to the top of the coolant
shown in Fig. A6.1. Measure oil pressure at the engine oil
tower as specified in Annex A3 to ensure water does not boil
manifold (see Annex A2). An engine oil pressure sensor
out of the antifreeze mixture and result in less heat rejection
transmits a signal to the ECM that maintains oil pressure at
from the engine.
415 kPa. The ECM transmits a signal to an engine-mounted
Mamac air pressure controller. The Mamac modulates the 6.2.10 Measure engine blowby down stream of the engine
facility air pressure of 280 kPa to levels that vary between (0 breather housing by measuring the delta pressure across an
to 140) kPa and directs it to the normally closed Johnson orifice or an equivalent device.
Controls relief valve. Because the engine oil pressure sensor 6.2.11 The crankcase pressure is above atmospheric pres-
calibration may vary from the cell data acquisition transducer, sure with this engine arrangement. Measure it at the location
shown in Annex A2.
14
The sole source of supply of the apparatus known to the committee at this time
is Micro Motion, Inc. 7070 Winchester Circle, Boulder, CO 80301.
15 16
The sole source of supply of the flexible hose known to the committee at this The sole source of supply of the fluid known to the committee at this time is
time is Aeroquip Industrial Div, 1225 W. Main Street, Van Wert, OH 45891. Paratherm NF Oil, Conshohocken, PA 19428.

Copyright by ASTM Int'l (all rights reserved); 5

 D6681 − 10a
6.3 Obtain information concerning the test engine, engine 7.12 REO 217, as supplied by the CRC and used when any
electronics system, new engine parts, replacement parts, and copper components are changed.
permissible substitution or replacement parts from Caterpillar, 7.13 Sodium Bisulfate (NaHSO4), commercial grade.
Inc.
7.14 Solvent—Use only mineral spirits meeting the require-
6.4 Engine and parts warranty information can be found in ments of Specification D235, Type II, Class C for Aromatic
Annex A1. Use the form listed in Annex A9 for returning Content (0 to 2 vol %), Flash Point (61 °C, min) and Color (not
defective parts. darker than + 25 on Saybolt Scale or 25 on Pt-Co Scale).
7. Reagents and Materials (Warning—Combustible. Health hazard.) Obtain a Certificate
of Analysis for each batch of solvent from the supplier.
7.1 Purity of Reagents—Reagent grade chemicals shall be
used in all tests. Unless otherwise indicated, it is intended that 7.15 Fuel—Obtain the required test fuel from Chevron
all reagents conform to the specifications of the Committee on Phillips10,21 as PC-9 0.04 % low sulfur research diesel fuel (see
Analytical Reagents of the American Chemical Society where Annex A14).
such specifications are available.17 Other grades may be used, 7.16 Test Oil—The total amount of oil needed for each
provided it is first ascertained that the reagent is of sufficiently lubricant test is approximately 42 L.
high purity to permit its use without lessening the accuracy of 7.17 Trisodium Phosphate (Na3PO4), commercial grade.
the determination.
7.18 5.4000 in. Ring Bore Standard Class Z Master.10,22
7.2 Diesel Piston Rating Booth, as described by CRC
Manual 20.18 8. Oil Samples
7.3 Diesel Piston Rating Lamp, as described by CRC 8.1 Take a purge sample of 250 mL at (48, 72, 120, 144,
Manual 20.18 168, 192, 216, 264, 312 and 336) h. Following removal of each
7.4 Dispersant Engine Cleaner.10,19 purge sample, remove a sample of 30 mL, then add (317 6
10) g of new oil. It is not necessary to perform analysis on
7.5 Engine Coolant—Use a 50/50 mixture of mineral-free these samples of 30 mL. Use the purge sample to return to the
water and Caterpillar brand coolant (P/N 8C684 for 3.8 L or full mark.
8C3686 for 208 L drum) for engine coolant. Mineral-free water 8.1.1 Take a purge sample of 250 mL at (0 (new), 24, 96,
is defined as water having a mineral content no higher than 240, 288 and 360) h. Following removal of each purge sample,
34.2 mg/kg total dissolved solids. The coolant mixture may be remove a sample of 90 mL and add (370 6 10) g of new oil.
reused for up to 1600 h. Keep the mixture at a 50:50 ratio as 8.1.2 Analyze all samples of 90 mL for viscosity by Test
determined by using either Caterpillar testers 5P3514 or Method D445 at (100 and 40) °C, TBN by Test Method D4739,
5PO957 or an equivalent tester. Keep the coolant mixture TAN by Test Method D664, and the wear metals Al, Cr, Cu, Fe,
contamination free. Total solids shall remain below 5000 Pb, Si by Test Method D5185. Analyze the samples for fuel
mg/kg. Keep the additive level correct using Caterpillar test kit dilution taken at (24, 240, and 360) h by Test Method D3524.
P/N 8T5296. See Fig. A6.7 and Fig. A6.8 for two graphical examples and a
7.6 Lead Shot, commercial grade, approximately 5 mm in sample worksheet.
diameter.
9. Preparation of Apparatus
7.7 Light Grease.
9.1 General Engine Assembly Practices—As a part of good
7.8 Mobil EF-411, available from ExxonMobil for engine laboratory practice, inspect all components and assemblies that
assembly and calibration of the oil scale pump flow rates.10,20 are exposed when the engine is disassembled and record the
7.9 Paratherm NF, as supplied by Paratherm and used as the information for future reference. Inspect valve train compo-
fluid to heat the engine oil.10,16 nents, bearings, journals, housings, seals and gaskets, and so
7.10 Pentane (Solvent), purity > 99 %, high-performance, forth and replace as needed. Assemble the engine with com-
liquid chromatography grade. ponents and bolt torques as specified in the 1Y3700 engine
Service Manual (see Annex A10 for a partial list). It is the
7.11 Reference Oil, as supplied by the TMC for calibration intent of this procedure for all engine assemblies and adjust-
of the test stand. ments to be targeted to the mean of the specified values. Clean
and lubricate the components in keeping with good assembly
17
Reagent Chemicals, American Chemical Society Specifications, American practices. Keep airborne dirt and debris to a minimum in the
Chemical Society, Washington, DC. For Suggestions on the testing of reagents not assembly area. Maintain standard engine assembly techniques
listed by the American Chemical Society, see Annual Standards for Laboratory
Chemicals, BDH Ltd., Poole, Dorset, U.K., and the United States Pharmacopeia
and practices (such as staggering piston ring gap positions, and
and National Formulary, U.S. Pharmacopeial Convention, Inc. (USPC), Rockville, so forth).
MD.
18
Available from the Coordinating Research Council Inc., 3650 Mansell Road
21
Suite 140, Atlanta, GA 30022-8246. The sole source for 1P fuel known to the committee at this time is Chevron
19
The sole source of supply of the engine cleaner known to the committee at this Phillips Chemical Co., Chevron Tower, 1301 McKinney Street, Houston, TX
time is The Lubrizol Corp., 29400 Lakeland Blvd., Cleveland, OH 44092 77010-3030.
20 22
The sole source of supply of the oil known to the committee at this time is The sole source of supply of the apparatus known to the committee at this time
Mobil EF-411, from Golden West Oil Co., 3010 Aniol St., San Antonio, TX 78219. is Morse-Hemco, 457 Douglas Ave., Holland, MI 49423.

Copyright by ASTM Int'l (all rights reserved); 6

 D6681 − 10a
9.2 Complete Engine Inspection—Perform a complete en- 9.8 Valve Guide Bushings—Clean the valve guide bushings
gine inspection at intervals of 13 000 h. Ensure that wearing with a solvent and bristle brush prior to assembly. Lubricate the
surfaces such as main bearings and journals, rod bearings and bushings and valve stems with Mobil EF-411 prior to assem-
journals, camshaft bearings, valve train components, fuel bly. See the 1Y3700 Service Manual for guide reusability
system components, and so forth all are within manufacturer’s specifications. Install new valve guide seals for each test.
specifications. Refer to the 1Y3700 Service Manual for disas- 9.9 Fuel Injector—Remove the fuel injector from the cyl-
sembly, assembly, inspections, and specifications. Paint crank- inder head before reconditioning commences. Refer to the
cases as necessary with either Caterpillar yellow primer or red 1Y3700 Service Manual for removal and assembly. Return
Glyptal.10,11 defective fuel injectors to Caterpillar for warranty and failure-
9.3 Copper Components—Anytime a copper part is re- mode testing using the form listed in Annex A9.
placed, run an engine test using REO 217 until two consecutive 9.10 Piston and Rings—Use a new piston (1Y3400 iron
periods of 12 h show a stable copper level. To eliminate the crown, 1Y3659 aluminum skirt) and new rings (1Y3802,
need to perform this pacification process when replacing the 1Y3803, 1Y3804) for each test.
engine oil cooler, use of a nickel-plated oil cooler is permitted. 9.10.1 Clean all three rings with pentane and a lint-free
9.4 Engine Lubricant System Flush—Flush the engine of 100% cotton towel.
used oil before every test. Annex A11 shows the engine flush 9.10.2 Measure the ring side clearances and ring end gaps
procedure and apparatus. A flushing instruction sheet shown in for all three rings (see Fig. A10.2 and Table A10.1). Keystone
Annex A11 gives the step-by-step process required for flush- ring side clearance measurements require the ring to be
ing. The 1Y3700 engine arrangement includes five flushing confined in a dedicated slotted liner (see Appendix X1) or a
nozzles in the crankcase and front cover (see Annex A11). ring gage10,14 137.16 mm in diameter. Measure the side
These nozzles are piped in parallel with the 1Y3935 filter clearances using four feeler gages of equal width and thickness
flushing adapter (or equivalent) from a laboratory provided of 0.01 mm at intervals of 90° around the piston. Measure the
manifold that pressurizes fluids supplied by a flush cart (see rectangular ring side clearance this way as well. Measure the
Appendix X1). Seal the gear train housing during flush with a minimum side clearance as specified in CRC Manual 20.
1Y3917 round plug with a 117-8801 o-ring as shown in Annex 9.10.3 Record the measurements for these parts before and
A11. Seal the crankcase using a 1Y3979 block flush cover with after each test. Compare the measurements before the test and
an internal bleed passage for the cam oil supply. Bolt a 1Y3980 after the test to determine the amount of wear.
plastic jet aiming fixture to the flush cover that is also used for 9.10.4 Assemble the piston with the part number toward the
flushing (see Annex A11). If the test oil is not available at camshaft.
engine assembly, Mobil EF411 oil may be substituted.
9.11 Cylinder Liner—Use a new 1Y3805 or 1Y3997 cylin-
9.5 Engine Piston Cooling Jets—The piston cooling jets are der liner for each test.
flow-checked at the supplier and serialized to ensure proper 9.11.1 After removing the protective oil/grease with mineral
performance, but the rod clearances are minimal which may spirits (see 7.14), clean the liner bore with a hot tap water and
result in jet movement during assembly. Verify proper jet flow heavy-duty clothes washing detergent solution, then rinse with
positioning using EF-411 before each test with the 1Y3980 hot tap water.
plastic jet aiming fixture and oil pressure to the manifold of 415 9.11.2 Measure and record the liner surface finish. The
kPa. Record the cooling jet serial number. surface finish specification shown in Fig. A10.3 does not apply
9.6 Engine Measurements and Inspections—Measure and to the 1Y3997 cylinder liner.
inspect the engine components prior to each test (see Table 9.11.3 Oil the liner bore with only Mobil EF-411. Assemble
A10.2 for partial specification list). Refer to the 1Y3700 the cylinder liner, block and head with the torque specification
Service Manual for information concerning component reus- shown in the 1Y3700 Service Manual or Fig. A10.1.
ability and assembly not found in this procedure. The part 9.11.4 Measure the liner with a dial bore gage to ensure that
numbers of components that need replacing are found in the the out-of-round and taper conditions are within specified
1Y3700 Parts Manual. Record the crankshaft angles at the tolerances measured at seven intervals as shown in Fig. A10.3.
specified maximum injector lift, exhaust, and intake maximum Measure the cylinder liner projection using the modified
lift before each test using the reference listed in Fig. A10.7. indicator shown in Fig. A10.4.
Record component part numbers and serial numbers and other 9.11.5 Torque the cylinder liner support ring using the
required measurements as shown in the test report. Inspect and procedure shown in Fig. A10.5.
reuse the rocker arm roller followers and camshaft lobe 9.12 Compression Ratio—Before starting each test, measure
surfaces based on Caterpillar Service Publication SEBF8256.4 the piston-to-head clearance to ensure the proper compression
9.7 Cylinder Head—A reconditioned head is required for ratio is used. Determine this dimension by using lead balls,
each test. Measurements after reconditioning shall be within each with a diameter of approximately 3.5 mm. Locate four
specifications as shown in the 1Y3700 Service Manual. Do not lead balls on the top of the piston at 90° intervals on the major
swap the cylinder head/jug assembly from test stand-to-test and minor piston diameters. Hold them in place with light
stand. Use the head/jug assembly used to calibrate the stand for grease. With the piston near the top of the stroke, install the
all non-reference oil testing in that stand. Fig. A10.1 shows the head and block assembly and torque to specifications. Turn the
cylinder head nut torque sequence. engine over top center by hand to compress the lead balls then

Copyright by ASTM Int'l (all rights reserved); 7

 D6681 − 10a
remove the head and block assembly and measure the thickness venturi to L/min: 3.0 in. H2O = 24.3 L/min, 7.1 in. H2O = 37.8
of the lead balls to obtain the average piston-to-head clearance. L/min and 28 in. H2O = 75.7 L/min or use Eq 1 where DP is
The piston-to-head clearance specification is 1.62 mm 6 measured in in. H2O.
0.07 mm. Use multiple 1Y3817 block gaskets to adjust the
L/min 5 =DP 14.44 2 0.69 (1)
clearance. If the piston-to-head measurement exceeds the
tolerance specification, check the crankshaft main and rod 10.4 Re-calibration Requirements—Re-calibration due to
journals, connecting rod and main bearings, and piston pin and parts replacement is not required unless the engine crankcase
rod bushing for excessive wear. The specified compression or crankshaft, or both, require replacing or regrinding, or the
ratio for the 1Y3700 engine is 16.2 to 1. crankshaft is removed for any other purpose besides bearing
replacement, or the head/jug suffer a failure for any reason
9.13 Engine Timing—The engine ECM sets desired fuel
during the calibration period.
injection timing to 13° BTC. Record this timing using the
engine technician service tool. Mechanically time the actual 10.5 Fuel Injectors—The fuel injectors are calibrated during
engine components as shown in Annex A10. Install the the manufacturing process. These fuel injectors can not be
electronic sensors as shown in the Electronic Installation and re-calibrated in the usual manner and require special test
Operation manual. Both the mechanical and electrical systems equipment to ensure proper flow, timing response, and spray
shall be correctly assembled to produce the desired fuel timing. patterns. Therefore, replace the fuel injector at the start of
every calibration test (unless that test is the second of two
9.14 Engine Coolant System Cleaning Procedure—Clean required tests for a new stand or is a rerun of a previous
the coolant system when visual inspections show the presence calibration attempt). If the fuel injector is replaced on a
of any oil, grease, mineral deposits, or rust following the calibrated stand, re-calibration is not required.
procedure listed in Annex A3.
10.6 Air Flow—Install the Sierra Model 780 airflow meter
9.15 After the engine components have been prepared and to measure intake airflow. This meter should be calibrated
assembled, perform the following: yearly at a temperature of 60 °C. Measure the intake airflow
9.15.1 Fill the crankcase with (5800 6 50) g of test oil. during the break-in of every calibration test. Record the last
9.15.2 Install a new 1R0713 oil filter. value recorded during step five of the break-in as shown in
9.15.3 Fill the coolant system with coolant specified in Annex A12.
Section 7. 10.7 Intake Air Barrel—Prior to each stand calibration test,
9.15.4 Ensure the facility coolant to the engine heat ex- inspect the intake air barrel for rust or debris. This may be done
changer is operational. through either of the pipe flanges using a borescope or some
9.15.5 Pressurize the fuel system to remove air, then return other optical means.
the system to a non-pressurized state before starting engine.
10.8 Fuel Filter—Change the fuel filter before every cali-
9.15.6 Ensure all other systems and facilities are operational bration test.
before starting the engine break-in.
10.9 Oil Scale Flow Rates—Verify the oil scale flow rates
10. Calibration and Standardization before the start of every calibration test using the procedure
listed in Annex A6.
10.1 Test Cell Instrumentation—Calibrate all facility read-
10.10 Calibration of Test Stands—Use a blind calibration oil
out instrumentation used for the test immediately prior to
from the TMC to calibrate the engine stand. A stand calibration
subsequent stand calibration. Instrumentation calibration prior
test is required every nine months. The calibration period
to subsequent stand calibration tests (that is, those that follow
begins on the start date of the acceptable calibration test. A test
a failed or invalid first attempt) are at the discretion of the test
stand is considered calibrated when the test results are within
laboratory. Refer to Annex A2 for calibration tolerances and
the acceptability limits as published by TMC and the test is
allowable system time constants.
operationally valid. The TMC may request stand checks on
10.2 Instrumentation Standards—Calibrate all temperature, calibration tests that fail to meet acceptability limits. If the
pressure, flow, and speed measurement standards on a yearly calibration test is operationally valid, send the piston to another
basis. The calibration of all standards shall be traceable to a calibrated laboratory for a referee rating. In order for the test to
national bureau of standards. Maintain all calibration records be considered valid, report the test data to the TMC within
for a minimum of two years. seven days of end-of-test (EOT). The TMC will issue to the
10.3 Coolant Flow—Calibrate the coolant flow rate as testing laboratory a control chart analysis for each calibration
follows: (1) calibrate the differential pressure transducer as test (see Fig. A14.2). The test stand is not considered calibrated
outlined in 10.1 and 10.2 and, (2) replace the Barco venturi if the calibration test was invalid or uninterpretable. Start any
every two years.10,23 Use the following relationships as con- non-reference test prior to the expiration of the calibration
version factors from the differential pressure across the Barco period.
10.11 Guidelines for Adjustments to Calibration Periods—
Reference oil test frequency may be adjusted for the following
23
The sole source of supply of the apparatus known to the committee at this time
reasons:
is Hyspan Precision Products, Inc., 1685 Brandywine Avenue, Chula Vista, CA 10.11.1 Procedural Deviations—On occasions when a labo-
91911. ratory becomes aware of a significant deviation from the test

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 D6681 − 10a
method, such as might arise during an in-house review or a sequencing for each calibration test until the calibration has
TMC inspection, the laboratory and the TMC shall agree on an been accepted. Increment the run number for any test start.
appropriate course of action to remedy the deviation. This 10.14 Humidity Calibration Requirements—The accuracy
action may include the shortening of existing reference oil of the laboratory’s primary humidity measurement system shall
calibration periods. be within 6 0.6 g of the humidity measuring chilled mirror
10.11.2 Parts and Fuel Shortages—Under special circum- dew point hygrometer. Calibrate the primary laboratory humid-
stances, such as industry-wide parts or fuel shortages, the ity measurement system during the first 24 h of each calibration
surveillance panel may direct the TMC to extend the time test at each stand using a chilled mirror dew point hygrometer
intervals between reference oil tests. These extensions shall not with an accuracy of at least 6 0.55 °C at a dew point of 24 °C.
exceed one regular calibration period. The calibration consists of a series of paired comparison
10.11.3 Reference Oil Test Data Flow—To ensure continu- measurements between the primary system and the chilled
ous severity and precision monitoring, calibration tests are mirror dew point hygrometer. The comparison period lasts
conducted periodically throughout the year. There may be from 20 min to 2 h with measurements taken at 1 min to 6 min
occasions when laboratories conduct a large portion of calibra- intervals, for a total of 20 paired measurements. The measure-
tion tests in a short period of time. This could result in an ment interval should be appropriate for the time constant of the
unacceptably large time frame when very few calibration tests humidity measuring instruments. Ensure that the flow rate is
are conducted. The TMC can shorten or extend calibration within the equipment manufacturer’s specification. Take all
periods as needed to provide a consistent flow of reference oil measurements made with the dew point hygrometer at atmo-
test data. Adjustments to calibration periods are made such that spheric pressure and correct them to standard pressure condi-
laboratories incur no net loss (or gain) in calibration status. tions (101.12 kPa). Compute the difference between each pair
10.11.4 Special Use of the Reference Oil Calibration of measurements and calculate the mean and standard devia-
System—The surveillance panel has the option to use the tion of the differences. The absolute value of the mean
reference oil system to evaluate changes that have potential difference shall not exceed 0.6 g and the standard deviation
impact on test severity and precision. This option is only taken shall be less than or equal to 0.3 g. The primary humidity
when a program of donated tests is not feasible. The surveil- measurement system is deemed calibrated only if both of these
lance panel and the TMC shall develop a detailed plan for the requirements are met. If either of these requirements is not met,
test program. This plan requires all reference oil tests in the investigate the cause, make repairs, and recalibrate. Maintain
program to be completed as close to the same time as possible, the calibration data for a minimum of two years.
so that no laboratory/stand calibration is left in an excessively
long pending status. In order to maintain the integrity of the 10.15 Calibration of Piston Deposit Raters—The piston
reference oil monitoring system, each reference oil test is deposit raters shall be trained by the CRC Rating Task Force
conducted so as to be interpretable for stand calibration. To and maintain rating expertise by attending the rating seminars.
facilitate the required test scheduling, the surveillance panel Each calendar year, each facility shall send at least one Heavy
may direct the TMC to lengthen and shorten reference oil Duty Diesel Piston Rater to either the Task Force meeting held
calibration periods within laboratories such that the laborato- every Spring or the expanded Heavy Duty Piston Rating
ries incur no net loss (or gain) in calibration status. Workshop held every Fall. Each rater shall rate a minimum of
six diesel pistons. If this schedule is not suitable to a particular
10.12 Donated Reference Oil Test Programs—The Surveil- rater or test laboratory, then make alternative arrangements as
lance Panel is charged with maintaining effective reference oil soon as possible to have the rater calibrated.
test severity and precision monitoring. During times of new
parts introductions, new or re-blended reference oil additions, 11. Procedure
and procedural revisions, it may be necessary to evaluate the 11.1 Engine Break-in Procedure—Open any drain taps at
possible effects on severity and precision levels. The surveil- the low points of the combustion air system (if they are
lance panel may choose to conduct a program of donated installed) during the start of the break-in and warm-ups, and
reference oil tests in those laboratories participating in the following any shutdowns.
monitoring system, in order to quantify the effect of a particu- 11.1.1 The engine break-in and operational conditions are
lar change on severity and precision. Typically, the surveillance specified in Annex A12. The total break-in time is 85 min.
panel requests its panel members to volunteer enough reference During the break-in, fix all leaks and make adjustments to
oil test results to create a robust data set. Broad laboratory ensure proper engine operation. Record the ECM personality
participation is needed to provide a representative sampling of module part number and release date.
the industry. To ensure the quality of the data obtained, donated 11.1.2 After the break-in period and while the engine is hot,
tests are conducted on calibrated test stands. The surveillance drain the oil from the crankcase, oil cooler, engine oil filter, and
panel shall arrange an appropriate number of donated tests and weigh scale for 30 min. Then weigh (5800 6 50) g of new test
ensure completion of the test program in a timely manner. oil into the engine.
10.13 Test Run Numbering—Number each test to identify 11.1.3 Start the engine, warm it up, and operate it for 360 h
the test stand number and the test run number. Number all runs at the test conditions specified in step five of Annex A12 with
sequentially. Append repeat calibration runs with a letter that is no oil changes.
also sequential (that is, number the first rerun of test 45 as 46A, 11.1.4 Turn on the oil scale pumps once the engine has
the second as 47B, and so forth). Maintain the letter suffix reached the beginning of Step 5 of the warm-up sequence.

Copyright by ASTM Int'l (all rights reserved); 9

 D6681 − 10a
Record the oil weight in the oil scale as the full mark at the end 11.6.4 Exhaust Pressure—Set the pressure as specified in
of the fourth test hour. Throughout the test, record the oil scale Annex A12 using a facility feedback-controlled restrictor
reading at least once every 6 min. valve.
11.1.5 Count test time from the moment the warm-up time 11.6.5 Intake Air—Filter, compress, and humidify the inlet
is completed. The oil sample frequency is described in Section air to the conditions specified in Annex A12. Heat (or cool, if
8. necessary) the inlet air to the conditions in Annex A12.
11.1.6 Do not remove the cylinder head, piston, or power 11.7 Post-Test Procedures—Remove the piston and ring
assembly from the engine during a test. assembly from the engine. Mark the location of the ring gaps
11.1.7 Reinitialize engine timing calibration after the cam on top of the piston.
shaft/gear or cylinder head has been removed. See the elec-
11.7.1 Piston Ring Side Clearances—Measure the piston
tronic installation and operation manual. Complete this during
ring side clearances prior to removal of the rings to determine
the first step of the break-in.
the level of deposit formation (see Annex A10). Align ring
11.2 Cool-down Procedure—Except for emergency (uncon- gaps to the EOT ring gap marks on the top of the piston. Do not
trolled) stops, shut the engine down by operating it at condi- force the feeler gages between the ring and groove to disturb or
tions shown in Steps 4, 3, 2, and then 1 in Annex A12. remove the deposits.
11.3 Warm-up Procedure—Use the same procedure used for 11.7.2 Piston Ratings—Immerse the piston assembly in
engine break-in to warm-up the engine for all subsequent starts mineral spirits (see 7.14) and air-dry it prior to any rating.
throughout the test. [Link] Process and measure the piston deposits according
to the Modified CRC Diesel Piston Rating Method described in
11.4 Shutdowns and Lost Time—Record the test hours, date,
CRC Manual No. 20 modified by the directions listed in Annex
and length of off-test conditions for all occurrences. Record
A13. Rate only two levels of carbon (heavy and light) on the
when the engine has early inspections or early test termination
second groove and all lands, and only one level of carbon
with the reasons for the occurrences. If the cool down
(light) for the under-crown and cooling groove. Use a com-
procedure is not used, identify the shutdown as an Emergency
bined varnish rating method for the third groove, third land,
Shutdown. A maximum allowed time of off-test conditions is
fourth land, under-crown, and cooling groove (see Annex
125 h. If the engine shuts down, immediately stop the oil scale
A13). An example rating worksheet is shown in Appendix X1.
pumps. In the event of an emergency shutdown, leave the
[Link] Another heavy-duty engine deposit rater shall
engine shut down for 2 h (or more) to allow complete engine
verify all piston deposit ratings done by the testing laboratory.
cool down before restarting. In order to limit foreign matter
In special cases where another rater is not available, the rating
entering the combustion chamber and to protect piston depos-
may be verified by other qualified laboratory personnel. Record
its, rotate the engine to top dead center of the compression
the initials of both the rater and the verifying rater.
stroke during downtime.
11.7.3 Referee Ratings—The referee laboratory rates the
11.5 Periodic Measurements—Record all engine conditions entire piston. Wrap all pistons to be referee-rated in paper with
listed in Step 5 of Annex A12 as a snapshot at least once every CRC desiccant chips. Then place them in plastic and seal
6 min. Record humidity readings using the laboratory’s pri- before shipping to the referee laboratory. Report referee ratings
mary humidity measurement system. Correct the recorded to the TMC within ten days of EOT for calibration tests.
humidity values to standard pressure conditions of 101.12 kPa. Referee-rate piston deposits for all non-reference tests re-
Record the fuel position as indicated by the electronic techni- viewed by Caterpillar.
cian at test hours 24, 240, and 360. 11.7.4 Ring End Gap Increase—Remove all carbon from the
11.6 Engine Control Systems: rings. If scraping of the rings is necessary, use only a wooden
11.6.1 Engine Coolant—Pressurize the coolant system to instrument or equivalent. Measure and record the ring end
(35.0 6 7) kPa as shown in Annex A3 to ensure the water does gaps.
not boil out of the antifreeze. Manually adjust the coolant flow 11.7.5 Cylinder Liner Wear—Use a surface profile measure-
rate by turning the valve on top of the coolant tower to ment to determine the liner wear step in both transverse and
maintain the conditions specified in Annex A12. longitudinal directions relative to the crankshaft. Remove
11.6.2 Engine Fuel System—Control the fuel rate by modi- deposits on the liner above the piston ring travel. Take
fying the fuel limit adjusting the ECM using a facility transverse and longitudinal measurements at the wear step
controller that compares the actual fuel rate to the specified fuel location approximately 13 mm from the top of the liner at four
rate listed in Annex A12. See the Electronic Installation and locations. Record the measurements as the liner wear step.
Operation manual for more details. Manually adjust the Fisher 11.7.6 Cylinder Liner Bore Polish—Section the cylinder
regulator to control fuel pressure. Maintain the fuel pressure liner through the front and rear axis and measure the cylinder
and temperature as specified in Annex A12. liner to determine the amount of bore polishing. Use the liner
11.6.3 Engine Oil Temperature—Maintain the oil manifold rating method listed in Annex A13.
temperature to test specifications as shown in Annex A12. The 11.7.7 Photographs—Photograph the piston and rings
temperature of the Paratherm NF shall not exceed 165 °C at showing the thrust, anti-thrust, front, rear, and undercrown
any time during break-in, warm-up, or testing. Shut off the positions (see Appendix X1). Place the rings on top of the
external oil heater (but not its circulating pump) the moment piston to show ring gaps (thrust view) and 180° from gaps
the engine goes to cool-down. (anti-thrust view). Show the piston from the crown down to at

Copyright by ASTM Int'l (all rights reserved); 10

 D6681 − 10a
least the bottom of the pin bore. Photograph the piston crown ~ 910.7 g/h !~ 8 h ! 1 ~ 2.1 g/h !~ 8 h !
weighted average 5 (4)
and skirt as one assembly. Photograph the bore ID of the 8 h18 h
sectioned liner (see Appendix X1).
13. Report
12. Calculation or Interpretation of Results
13.1 Forms and Data Dictionary—For reference oil tests,
12.1 Test Validity Descriptions—If a test was run for 360 h the standardized report forms and data dictionary for reporting
according to this test method, declare the test valid. test results and for summarizing the operational data are
12.1.1 If a test was not run as specified by this test method, required. All report forms making up the 1P final report are
the test is operationally invalid. Some examples of an invalid available at the TMC website ([Link]
test are: use of non-specified hardware, non-specified assembly Report values for all the field names listed in the report forms.
methods, a test run whose downtime is greater than 125 h, a Some fields may be blank for short-term tests. Report all
test that has a Quality Index value for a controlled parameter deposits, wear, and engine operational data as shown in the test
below the threshold of zero (see DACA II Report),2 and so report. The data dictionary defines the field lengths, decimal
forth. If a test without data acquisition on any controlled size, data type, units and format for the field names listed in the
parameter has a gap greater than 4 h, the test is operationally test report forms.
invalid.
12.1.2 If a test completes 360 h and the piston, rings, or liner 13.2 Test Validity Reporting—Mark whether the test is
exhibit distress, consider the test non-interpretable. Likewise, Valid, Invalid, or Non-interpretable where indicated in the test
if the test is terminated prior to completing 360 h for reasons report. For a valid stand calibration run, report the test data to
including purchaser request, excessive oil consumption, or TMC who will include the test data in the operationally valid
piston, ring, or liner distress, then consider the test non- database and determine statistical validity using the LTMS
interpretable. method. The LTMS method tracks the severity and precision of
stand and laboratory test results. For a complete definition,
12.2 Calculations—Use the same set of data for all calcu- refer to the LTMS manual, which is available from ASTM Test
lations and graphs in the test report. Monitoring Center.2 For an invalid or non-interpretable stand
12.2.1 Quality Index—Calculate and plot the Quality Index calibration run, report the test data to TMC with comments
according to the instructions in Annex A2. describing why the test is considered invalid or non-
12.2.2 Oil Consumption—Calculate oil consumption in interpretable. TMC will not include the test data in the
grams per hour over intervals of 24 h. Delete the first 4 h of operationally valid database. All operationally invalid and
readings after an oil add from the linear regression. The linear non-interpretable calibration tests are reported by the TMC to
regression technique is shown in Fig. A6.5 and Fig. A6.6. the ASTM Single Cylinder Diesel Surveillance Panel in
Calculate the overall average oil consumption, the initial periodic testing summaries.
average oil consumption, and end-of-test (EOT) average oil NOTE 1—For a valid ACC Registered Oil Test, report the data to the
consumption. The initial average is the average of the data registration organization.24 For an invalid or non-interpretable ACC
points taken at the 24th hour and 48th hour from the oil Registered Oil Test, report the test data to the registration organization
consumption graph. The EOT average is the average of the data with supporting comments describing why the test is considered invalid or
non-interpretable. When tests are presented to Caterpillar for review,
points taken at the 336th hour and 360th hour for a full length include the data from all tests that were registered with the registration
test, or for a short-term test it is the average of the last two data organization as part of the program.
points from the oil consumption graph. Calculate the natural
logarithmic transformation of the average and EOT oil con- 13.3 Report Specifics:
sumption values using the following equations: 13.3.1 If more than one fuel batch is used, report the fuel
batch analysis that is most representative of the fuel in the tank.
transformed average oil consumption 5 ln~ average oil consumption!
13.3.2 Report any causes for any missing or bad test data in
(2) the comment section of the Downtime Summary form. If any
transformed EOT oil consumption 5 ln~ EOT oil consumption! (3) alternative data acquisition method is used, document it as
12.2.3 For a period of 24 h including a shutdown, calculate well.
the oil consumption as follows: 13.3.3 If a calibration period is extended beyond the normal
[Link] Do not include the first oil mass amounts removed nine-month period, make a note in the comment section of the
at 4 h after a shutdown in the linear regression. Downtime Summary form and attach a written confirmation
[Link] Calculate the linear regression for the period before from the TMC to the test report. List the outcomes of previous
the shutdown. calibration runs in the comment section of the Downtime
[Link] Calculate the linear regression for the period after Summary form.
the shutdown. 13.3.4 Attach to the test report the fuel analysis provided by
[Link] Calculate a time-weighted average from both re- the fuel supplier. For calibration tests, attach a copy of the
gressions to obtain the oil consumption for that 24 h period. TMC control chart analysis.
For example, a test experiences a 7 h shutdown at test hour 12.
The slope for the first period of 8 h (hour 4 to 12) is 10.7 g/h,
and the slope for the second period of 8 h (hour 16 to 24) is 2.1 24
Registration Systems, Inc., ACC Monitoring Agency, 4139 Gardendale, Suite
g/h. The weighted average is calculated as follows: 205, San Antonio, TX 78229.

Copyright by ASTM Int'l (all rights reserved); 11

 D6681 − 10a
NOTE 2—It is recommended that test purchasers include the form result is available, the Intermediate Precision Limit can be used
shown in Fig. X1.8 when presenting the test results against specification to calculate a range (test result 6 Intermediate Precision Limit)
limits, such as those in Specification D4485 or military specifications.
outside of which a second test result would be expected to fall
14. Precision and Bias about one time in twenty.
14.1.3 Reproducibility Conditions—Conditions where test
14.1 Test precision is established on the basis of reference
results are obtained with the same test method using the same
oil test results (for operationally valid tests) monitored by the
test oil in different laboratories with different operators using
ASTM Test Monitoring Center. The data are reviewed semi-
different equipment.
annually by the Single-Cylinder Diesel Surveillance Panel.
[Link] Reproducibility Limit—(R)The difference between
Contact the ASTM TMC for current industry data.
two results obtained under reproducibility conditions that
14.1.1 Table 1 summarizes reference oil intermediate preci-

TABLE 1 Reference Oil Test Precision

NOTE 1—These statistics are based on results obtained on Test Monitoring Center reference oils between Feb. 19, 1997 and Dec. 6, 2004.
Test Parameter Sip i.p. SR R
TGC—top groove carbon, demerits 7.90 22.12 7.99 22.37
WD—weighted piston deposits, demerits 44.9 125.7 46.5 130.2
TLC—top land carbon, demerits 10.08 28.22 10.13 28.36
OC—oil consumption, ln(OC)A 0.2660 0.7448 0.2772 0.7762
ETOC—end of test oil consumptions, ln(ETOC)B 0.4467 1.2508 0.4490 1.2572
Legend:
Si.p. = standard deviation for intermediate precision.
i.p. = intermediate precision.
SR = standard deviation for reproducibility.
R = reproducibility.
A
This parameter is transformed using ln(OC). When comparing two test results on this parameter, first apply this transformation to each test result. Compare the absolute
difference between the transformed results with the appropriate (intermediate precision, or reproducibility) precision limit.
B
This parameter is transformed using ln(ETOC). When comparing two test results on this parameter, first apply this transformation to each test result. Compare the
absolute difference between the transformed results with the appropriate (intermediate precision, or reproducibility) precision limit.

sion and reproducibility of the test. The tabulated values are would, in the long run, in the normal and correct conduct of the
current as of Feb. 1, 2005. The Surveillance Panel updates test method, exceed the values shown in Table 1 in only one
these values as necessary. case in twenty. When only a single test result is available, the
14.1.2 Intermediate Precision Conditions—Conditions Reproducibility Limit can be used to calculate a range (test
where test results are obtained with the same test method using result 6 Reproducibility Limit) outside of which a second test
the same test oil, with changing conditions such as operators, result would be expected to fall about one time in twenty.
measuring equipment, test stands, test engines, and time. 14.1.4 Bias—Bias is determined by applying an acceptable
NOTE 3—Intermediate precision is the appropriate term for this test statistical technique to reference oil test results and when a
method rather than repeatability which defines more rigorous within- significant bias is determined, a severity adjustment is permit-
laboratory conditions. ted for non-reference oil test results (see TMC Memo 94-200,
[Link] Intermediate Precision Limit—(i.p.)The difference Lubricant Test Monitoring System document for details2).
between two results obtained under intermediate precision
conditions that would, in the long run, in the normal and 15. Keywords
correct conduct of the test method, exceed the values shown in 15.1 caterpillar 1P test procedure; oil consumption; piston
Table 1 in only one case in twenty. When only a single test deposits; single cylinder oil test

Copyright by ASTM Int'l (all rights reserved); 12

 D6681 − 10a
ANNEXES

(Mandatory Information)

A1. ENGINE AND PARTS WARRANTY

A1.1 Engine Warranty—Caterpillar Inc. warrants single A1.2.2 ESTD will determine if they want the part returned,
cylinder test engines sold by it to be free from defects in or provide warranty without viewing the part.
material and workmanship for a period of 12 months starting
A1.2.3 If ESTD determines that the part is nonconforming
from the date of delivery to the first user. If a defect in material
or workmanship is found during the warranty period, Caterpil- without viewing the part, the test laboratories will be asked to
lar will provide the replacement parts to be installed by the return the part to their Caterpillar dealer. ESTD will contact the
user. There will be no charge to the user for parts furnished by Dealer and let them know the part is coming and to provide
Caterpillar. User at its own expense, shall return all defective warranty for it.
parts to Caterpillar at Caterpillar’s request. User will be A1.2.4 If ESTD wants to view the part, they will issue a
responsible for giving Caterpillar timely notice of a warranty Return Goods Authorization No. (RGA) to the test laboratory.
failure. User will also be responsible for labor costs and any The laboratory will fill out the form shown in Annex A9 and
applicable local taxes. Caterpillar is not responsible for failures send the part and the form to Caterpillar Inc., Tech Center
resulting from abuse, neglect, and/or improper repair. THIS TC-L, Wing 4 - Rm 406, 14009 Old Galena Rd., Mossville, IL
WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER 61552, Att: A.C. Hahn.
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
ANY WARRANTY OF MERCHANTABILITY OR FITNESS A1.2.5 The test laboratories should fax a copy of the RGA
FOR PARTICULAR PURPOSE. REMEDIES UNDER THIS claim form to Caterpillar Inc., Tech Services Div., Tech Center
WARRANTY ARE LIMITED TO THE PROVISION OF Bldg L, Fax: 309-578-4232, Att: A.C. Hahn.
PARTS AS SPECIFIED HEREIN. CATERPILLAR IS NOT A1.2.6 If ESTD determines that the part is nonconforming,
RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL they will contact the dealer for the test laboratory and have the
DAMAGES. dealer provide warranty.
A1.2 Engine Parts Warranty—All parts for the 1Y3700 A1.2.7 A sample of the RGA claim form is shown in Annex
engine which are nonconforming by reason of faulty manufac- A9 and should include: return goods authorization no., part
ture should be discussed with Engine System Technology name, hours on the part, part no., quantity, engine serial no.,
Development (ESTD). date purchased, test laboratory that purchased the part and
A1.2.1 The test laboratories should contact ESTD (R.A. contact person’s name, phone, fax, and address, dealer’s name
Riviere, Telephone: 309-636-5247, Fax: 309-675-1598) when that sold the part, measurements or photographs, or both, to
they believe a part is nonconforming: document the nonconformance.

A2. INSTRUMENT LOCATIONS, MEASUREMENTS, AND CALCULATIONS

A2.1 Tables A2.1-A2.6 and Figs. A2.1-A2.5 provide de- A2.2.6 Round the Quality Index values to the nearest 0.001.
tailed information. A2.2.7 Report Quality Index values on Form 2 of the test
A2.2 Requirements for the Quality Index Calculation: report.
A2.2.1 Round the recorded values in accordance with the NOTE A2.1—Refer to the DACA II Final Report for calculating the
specifications listed in Table A2.5. Quality Index involving the loss of test data or bad quality test data.

A2.2.2 Use the values listed in Table A2.6 for all calcula- A2.3 Formula to calculate the Quality Index:
tions.
(S D 2
1 U1L 2 2X i
A2.2.3 Use data taken at 6 min to calculate the Quality QI 5 1 2 (A2.1)
n U2L
Index.
where:
A2.2.4 Reset data that is greater than the high values listed
Xi = recorded test measurement parameter,
in Table A2.6 from the Over and Under Range Values column
U = upper specification for that parameter,
to the high value for that particular parameter. L = lower specification for that parameter, and
A2.2.5 Reset data that is less than the low values listed in n = total number of data points taken as determined from
Table A2.6 from the Over and Under Range Values column to test length and procedural specified sampling rate.
the low value for that particular parameter.

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TABLE A2.1 Instrument Locations

Parameter Data Acquisition Engine Computer Facility Feedback Control
and Control Sensors (if separate sensor is required)
Cam speed and timing sensor A
Crankshaft speed and timing sensor B (at dyno)
Coolant pressure to jug 1
Coolant temperature to jug 2
Oil temperature to cooler 3
Atmospheric pressure C
Crankcase pressure 4 D
Facility air pressure to cooling tower 5
Oil manifold temperature 6 E 6 or W
Oil sampling valve 7
Oil manifold pressure 8 F
Coolant temperature from engine 9 H 9 or X
Coolant pressure from engine G
Coolant flow barco delta pressure 10
Air inlet manifold pressure (at barrel) I (at barrel)
Air inlet manifold temperature 11 11 or Y
Fuel temperature from filter Z 12
Fuel pressure from head 13
Fuel flow rate (at micro motion) (at micro motion)
Exhaust manifold temperature 14 J
Exhaust manifold pressure (at barrel) (at barrel)
Humidity (at barrel) (at barrel)
Air flow rate (at meter)
Blowby flow rate (at meter)

TABLE A2.2 Thermocouple Diameters, Lengths and Immersion

Depths
Location Diameter, Length, mm, Depth, mm ±3
mm max mm
Oil to manifold not 152 22
applicable
Oil to cooler not 152 27
applicable
External heating oil not 152 27
applicable
Coolant in not 152 40
applicable
Coolant out not 152 26
applicable
Inlet air not 152 57
applicable
Exhaust not 152 67
applicable
Fuel not 152 34
applicable

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TABLE A2.3 Calibration Tolerances
Parameters Tolerance
Torque not applicable due to
differences within the
industry;
TMC will verify each
laboratory it visits
Fuel flow rate 0.4 g/min
Air flow rate ± 2 % of reading from 10-
100 % of calibrated range;
± 0.5 % of FS below 10 %
of calibrated range
Humidity listed in this test method
Temperatures °C
Fuel at filter 0.5
Coolant to jug 0.25
Coolant from engine 0.25
Oil to cooler 0.5
Oil manifold 0.5
External heating oil 0.5
Air inlet manifold 0.5
Exhaust manifold 1.0
Pressures kPa
Fuel from head 0.7
Oil manifold 0.7
Air inlet 0.3
Exhaust 0.3
Crankcase 0.02

TABLE A2.4 Maximum Allowable System Time Constants

Measurements Time, s
Speed 3.0
Fuel flow rate 20.0
Air flow rate 3.0
Oil weight TBD
Temperatures
Fuel at filter 3.0
Coolant to jug 3.0
Coolant from engine 3.0
Oil to cooler 3.0
Oil manifold 3.0
External heating oil 3.0
Air inlet manifold 3.0
Exhaust manifold 3.0
Pressures
Fuel from head 3.0
Oil manifold 3.0
Air inlet 3.0
Exhaust 3.0
Crankcase 3.0

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TABLE A2.5 Measurement and Reporting Resolutions
Parameter Units Tol Specification Minimum Measurement Round Values to the
Resolution Nearest Whole Number
Speed r/min ±3 1800 1 whole number
Power kW approximately 55 0.1 tenth
Torque N·m approximately 285 0.1 tenth
Fuel rate g/min ±1 185 0.1 tenth
Fuel timing BTC 13
Humidity g/kg ±1.7 17.8 0.1 tenth
Oil mass g 2 whole number
Temperatures °C
Fuel into head ±3 42 0.1 tenth
Coolant into jug approximately 86 0.1 tenth
Coolant from head ±3 90 0.1 tenth
Oil to cooler approximately 128 0.1 tenth
Oil manifold ±3 130 0.1 tenth
External heating oil 165 max 0.1 tenth
Inlet air manifold ±3 60 0.1 tenth
Exhaust manifold approximately 480 1 whole number
Pressures kPa
Fuel from head ±20 275 1 whole number
Coolant into jug approximately 81 1 whole number
Oil manifold ±20 415 1 whole number
Inlet air barrel (abs) ±1 272 0.1 tenth
Exhaust barrel (abs) ±1 265 0.1 tenth
Crankcase approximately 0.10 0.01 hundredth
Flows
Coolant L/min ±2 75 0.1 tenth
Blowby L/min approximately 35 1 whole number
Air kg/h approximately 315 0.1 tenth

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TABLE A2.6 Quality Index Calculation Values and Plotting Axis Scale Definitions
Quality Index U and L ValuesA Over and Under Range ValuesB Plot Axes RangesC
Controlled units L U low high min max increment
Parameters
Speed r/min 1798.530 1801.470 1710 1890 1770 1830 10
Fuel flow g/min 183.970 186.030 125 245 175 200 5
Humidity g/kg 16.780 18.820 5 21 5 40 5
Coolant flow L/min 73.060 76.940 0 82 60 90 5
Coolant out °C 89.379 90.622 55 125 70 110 5
temperature
Oil to Manifold °C 128.798 131.202 60 200 120 150 5
Temperature
Inlet air °C 59.360 60.640 20 100 50 70 5
temperature
Fuel into head °C 40.885 43.116 0 75 30 60 5
temperature
Oil to manifold kPa 404.384 425.616 0 690 380 450 10
pressureD
Inlet air pressure kPa 271.449 272.551 242 302 265 280 5
Exhaust pressure kPa 264.150 265.850 215 315 250 280 5
Fuel pressure kPa 271.471 278.529 125 425 230 300 10
Uncontrolled Parameters
Power kW 50 60 1
Torque N·m 230 310 10
Blowby L/min 5 65 5
Coolant in °C 75 100 5
temperature
Coolant delta °C 0 10 1
Oil cooler in °C 120 140 5
temperature
Heating oil °C 120 165 5
temperature
Exhaust °C 450 500 10
temperature
Crankcase kPa 0.0 1.5 0.1
pressure
Coolant pressure kPa 60 95 5
A
The threshold for operational validity is 0.00.
B
Only to be used in the calculation of Quality Index and Average and does not affect how process is graphed.
C
Quality Index Scales are to range from -0.3 to 1.0 with increments of 0.1. The axis for test time is 0 to 360 h in increments of 30 h. X-axis length should be at least 203
mm; Y-axis length should be at least 140 mm.
D
Oil pressure operating specifications apply only to 15W-40 oils. Attempt to maintain these limits for all oils. When oils other than 15W-40 oils fall outside these limits,
explain these deviations from the limits in the comments section of the test report.

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FIG. A2.1 Instrument Locations—Engine Front View

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FIG. A2.2 Instrument Locations—Top and Left Engine Views

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FIG. A2.3 Instrument Locations—Right Engine View

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FIG. A2.4 Instrument Locations—Top Engine View

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NOTE 1—Turn oil filter block drain valve 180° so that it is facing out and easier to use.

FIG. A2.5 Engine Heating Oil Thermocouple Location

A3. COOLING SYSTEM ARRANGEMENT

A3.1 Install a sight glass as shown using the following A3.2 Cleaning Procedure for the Engine Coolant
components listed in Table A3.1. System——Clean the coolant system when visual inspections
A3.1.1 Reuse one of the straight 37° flare swivel hose show the presence of any oil, grease, mineral deposits, or rust.
fittings on the existing hose for the tower side of assembly. The The engine cooling system arrangement is shown in Fig. A3.1.
90° fitting in the cylinder head is also still used. Installation A3.2.1 To remove oil and grease from the cooling system:
angle will be slightly different.

TABLE A3.1 Coolant Sight Glass Components

Item Quantity Part No. Source Description Location
1 1 2061-20-20S Aeroquip 45° SAE O-ring port inlet to top of coolant tower
to 37° flare
2 1 190265-20S Aeroquip 45° Elbow – SAE O-ring head outlet
to 37° flore swivel
3 2 412-16-20S Aeroquip Male pipe re-usable fitting inlet and outlet of sight glass
4 1 4288 1 in. NPT Female GitsA style OL flow gage (sight glass) locate in middle of hose assembly
5 1 FC350-20 Aeroquip hose ~ 140 mm head side of assembly
6 1 FC350-20 Aeroquip hose ~ 165 mm tower side of assembly
A
Gits Manufacturing Co.

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 D6681 − 10a

FIG. A3.1 Engine Cooling System Arrangement

A3.2.1.1 Operate the engine until oil and water operating A3.2.2.3 Shutdown the engine, drain and flush the engine
temperatures are attained; shutdown the engine and drain the with fresh water and drain the water from the system.
cooling system. A3.2.2.4 Fill the cooling system with a solution of 454 g of
A3.2.1.2 Fill the cooling system with a solution of 454 g of trisodium phosphate (Na3PO4) to 38 L of water; operate the
trisodium phosphate (Na3PO4) to 38 L of water; operate the engine for 5 min to ensure complete mixing of the solution
engine for 5 min to ensure complete mixing of the solution with any material remaining from the previous flush.
with any material remaining from the previous fill. A3.2.2.5 Shutdown the engine and drain the engine, flush
A3.2.1.3 Shutdown the engine and drain and flush the with clear water and drain after flushing.
engine with fresh water and drain the water from the system. A3.2.2.6 Disassemble the engine and prepare for the next
A3.2.2 To remove mineral deposits from the cooling sys- test.
tem:
A3.2.3 If the cooling system is contaminated by oil and
A3.2.2.1 Operate the engine until oil and water operating
mineral deposits, remove the oil from the system, then remove
temperatures are attained; shutdown the engine and drain the
the mineral deposits. Alternatively, the cylinder head coolant
cooling system.
passages may be cleaned after the head is removed.
A3.2.2.2 Fill the cooling system with a solution of 454 g of
commercial sodium bisulfate (NaHSO4) to 19 L of water; then A3.2.4 The coolant pressurization system is shown in Fig.
run the engine at operating temperatures for 30 min. A3.2 and the cooling tower water circuit is shown in Fig. A3.3.

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NOTE 1—Legend:
1. 1⁄4 in. NPT-to-No.4AN (male connector)
2. No. 4 hose
3. Pressure gage (0 to 103) kPa
4. Pressure regulator (self bleeding)
5. Radiator cap (105 to 110) kPa
6. Radiator filler neck
7. Overflow tube (optional)
8. Overflow tank (optional)
FIG. A3.2 Coolant Pressurization System

FIG. A3.3 Cooling Tower Water Circuit

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 D6681 − 10a

A4. INTAKE AIR MASS FLOW SENSOR INSTALLATION

A4.1 The intake air sensor installation is shown in Fig. A4.1

NOTE 1—Meter: Model 780 in-line mass flow meter by Sierra Instruments;
Accuracy: 62 %;
Part No.: 780–F6–CG–(other options).
FIG. A4.1 Intake Air Sensor Installation

A5. FUEL SYSTEM DESIGN AND REQUIRED COMPONENTS

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 D6681 − 10a
TABLE A5.1 Fisher Regulator Information
NOTE 1—Information as it appears on regulator tag.
Type Pressure Inlet, Spring Trim Allowable Inlet
98 Units max Range Material Pressure, max
H-17 PSIG 75 22-75 SST 250

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 D6681 − 10a

FIG. A5.1 Fuel System Design and Required Components

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FIG. A5.2 Fuel Heat Exchanger Plumbing Connections

A6. OIL SYSTEM

A6.1 Verification of Oil Scale Pump Flows——Verify the A6.2.8 Weigh the oil in the discharge pan, subtracting the
oil scale pump flow rates with EF-411 at (26.5 6 5.5) °C as the empty weight.
test fluid using the following procedure. The following equip- A6.2.9 Determine the flow rate.
ment is needed.
A6.3 Procedure for Flow from the Oil Scale to the Oil Pan:
A6.1.1 One stopwatch.
A6.3.1 Repeat the above procedure by disconnecting the
A6.1.2 EF411 oil, (3.8 to 7.6) L at (26.5 6 5.5) °C. line from the oil scale and placing it in the temporary reservoir
A6.1.3 One temporary reservoir pan. pan and disconnecting the line at the oil pan and placing it in
the temporary discharge pan.
A6.1.4 One temporary discharge pan.
A6.3.2 The following materials are needed.
A6.2 Procedure for Flow from Oil Pan to Oil Scale: A6.3.2.1 Steel Tubing, 6.4 mm OD, 4.8 mm ID, approxi-
mately 25 mm in length.
A6.2.1 Disconnect the line from the oil pan and place in
temporary reservoir pan. A6.3.2.2 Adapter Fitting, 1⁄4 in. NPT to desired connection
type (Fig. A6.4 shows an Aeroquip No. 2000-4-4B for a #4,
A6.2.2 Disconnect the line from the oil scale and place in 45° flare).
the temporary discharge pan. A6.3.2.3 Silver Solder.
A6.2.3 The height of the pump relative to the reservoir and A6.3.3 Procedure:
discharge pans shall be within 914 mm to reduce any head A6.3.3.1 Drill adapter fitting on pipe thread end to a
pressure differences, which may affect the flow rates. nominal diameter of 6.4 mm, and a minimum depth of 9.5 mm.
A6.3.3.2 Insert tube into fitting until bottomed out in the 1⁄4
A6.2.4 Prime the system (both hoses and pump), then
in. hole.
shutdown.
A6.3.3.3 Silver solder the tube-to-fitting joint.
A6.2.5 Empty the discharge pan and record the weight of it. A6.3.3.4 Remove oil pan from engine and install the fitting
in location specified.
A6.2.6 Turn the system on and start the stop watch at the
A6.3.3.5 Mark the tube location to achieve (5 6 1) mm
same time.
protrusion into the oil pan.
A6.2.7 Let the system run for 4 min and then stop it. A6.3.3.6 Remove the fitting and cut to length.

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FIG. A6.1 Oil System

A6.3.3.7 Re-install fitting in pan, check protrusion, and yi = oil mass removed at time x,
re-install oil pan on engine. xi = times at which oil mass observations x are made,
m = slope of best-fit line = oil consumption,
A6.4 Oil Consumption Linear Regression Method—If there b = y intercept, and
is good reason to assume that a variable Y is dependent upon r2 = goodness of fit (1 if perfect, 0 if not fit at all).
another variable X and that the relationship is linear, the best-fit
line describing this relationship can be plotted using the A6.5 Oil Sampling Procedure:
following equations. Also see Figs. A6.5 and A6.6. A6.5.1 Record oil scale reading at test hour four _____ g.
This is the Full Mark.
(x i yi 2 ( (xi yi
n A6.5.2 Record the oil mass from the 24th hourly reading
m5 (A6.1)
~ ( x i! 2 _____ g.
(x 2 n 2
i
A6.5.3 Remove purge sample of 250 mL from sample valve
b5 F ( y 2 m(x
n
i
n
i
G (A6.2)
on the oil manifold.
g
2 5

2
r 5
F( x iy i 2 ( (xi
n
yi
G 2

(A6.3)
purge1container container purge
A6.5.4 For test hours 24, 96, 240, 288 and 360, remove a
F( ~ !xi 2
2
~ ( x i!
n
2

G F( ~ ! yi 2
2
~ ( y i! 2
n
G sample of 90 mL from the sample valve on the oil manifold.
g
2 5
where: sample1container container sample

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FIG. A6.2 Oil Scale Measurement System

A6.5.4.1 Add (370 6 10 g) of NEW test oil to the oil weigh purged to be returned 5 FM 2 A (A6.4)
tank.
where:
g
2 5
new oil1container container new oil A5 2
#2; 24th Hourly Reading; ~ Scale Mass! #3; Purge Mass
A6.5.5 For test hours 48, 72, 120, 144, 168, 192, 216, 264,
312 and 336, remove a sample of 30 mL from the sample valve 2
#4; Sample Mass; ~ if taken!
1
#5; New Oil Mass
on the oil manifold.
g
A6.5.7 Record the mass of unused purge sample by using
sample1container
2
container
5
sample scale.
g
A6.5.5.1 Add (317 6 10) g of NEW test oil to the oil weigh 2 5
unused purge1container container unused purge left over
tank.
NOTE A6.1—If you are short in returning to the full mark, use fresh oil
g to make up the difference.
2 5
new oil1container container new oil
A6.5.6 Add back enough purge sample to return the oil
weigh tank to its Full Mark using the following formula:

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NOTE 1—(1) Suction Pump and Hose (or equivalent)

Type: Viking C-90 Pump
Flow: (6 6 1.5) g/h
Speed: 285 r/min
Hose: TFE-fluorocarbon steel braided, ID 6.4 mm, maximum length, 2.74 m
Pulley: OD 126 mm
(2) Return Pump and Hose (or equivalent)
Type: Viking C-92 Pump
Flow Differential: (3 6 1) g/h
Speed: 163 r/min
Hose: TFE-fluorocarbon steel braided, ID 6.4 mm, maximum length 2.74 m
Pulley: OD 200 mm
(3) Pump Motor (both pumps) (or equivalent)
Type: 56 Nema Grainger 6K949
Speed: 1140 r/min
Power: 0.56 kW
Pulley: OD 38 mm
(4) Vent Line: hose ID 6.35 mm
(5) Oil in Reservoir: 1000 g (approximately)
(6) Scale Precision: See Procedure
(7) Flexible Hose: (to and from fixed external sump support) (or equivalent): Aeroquip FC352-08
FIG. A6.3 Low Flow Oil Scale System

FIG. A6.4 Oil Pan Suction Fitting to Oil Scale

FIG. A6.5 Equation of a Straight Line

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FIG. A6.6 Examples of the Goodness of Fit

NOTE 1—Taken at 48, 72, 120, 144, 168, 192, 216, 264, 312, 336 h.
FIG. A6.7 Example of Oil Addition Procedure with 30 mL Sample

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NOTE 1—Taken at NEW, 24, 96, 240, 288, 360 h.

FIG. A6.8 Example of Oil Addition Procedure with 90mL Sample

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FIG. A6.9 Engine Oil Heating Hardware

A7. EXHAUST AND INTAKE BARREL PIPING

A7.1 The exhaust and intake barrel piping are illustrated in

Figs. A7.1 and A7.2.

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FIG. A7.1 1Y3978 Exhaust Barrel and Piping

NOTE 1—Dummy heater elements may be substituted for the FIREROD cartridge heaters, as long as they are the same dimension of 533 mm by a
diameter of 15.9 mm. The 533 mm is from end-to-end. Length tolerance is 76 mm and the diameter tolerance is 0.40 mm.
NOTE 2—FIREROD cartridge heaters may be purchased from Southwest Heater and Controls, 12052 Forestgate Dr., Dallas, TX 75243.
FIG. A7.2 1Y3976 Intake Air Barrel and Piping

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A8. HUMIDITY PROBE INSTALLATION

A8.1 Figs. A8.1 and A8.2 illustrate the humidity probe

installation locations.

FIG. A8.1 Humidity Probe Installation Location

FIG. A8.2 Humidity Probe Installation Location—Barrel Bottom

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A9. RETURN GOODS AUTHORIZATION

A9.1 Fig. A9.1 is a sample return goods authorization claim

form.

FIG. A9.1 Sample Return Goods Authorization Claim Form

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A10. ENGINE ASSEMBLY INFORMATION

A10.1 1Y3700 Engine Mechanical Timing—Remove the A10.2.1 This procedure is to be followed only on new
camshaft gear to replace cylinder head components after test engine assembly or in the event that a new timing disk, or
and re-time as follows (see Fig. A10.6): crankshaft, or flywheel, or front housing is assembled on an old
A10.1.1 Rotate the engine to position the piston at TDC. engine.
NOTE A10.1—The TDC mark on the flywheel will align with the timing A10.2.2 With the crankshaft connecting rod journal at top
pointer. The 1Y3919 timing pin has a diameter of 6.28 mm and will insert dead center (TDC), the tooth valley V mark on the crankshaft
in the crank gear key-way slot through the timing hole in the front housing gear is 35.38° clockwise from the vertical and the key-way is
near the oil pump flange.
68.48° clockwise from vertical. With the crankshaft gear fixed,
A10.1.2 Pin the camshaft with a second 1Y3919 timing pin assembly of the cluster idler gear on its stub-shaft causes the
with a diameter of 6.28 mm. cluster idler gear to rotate 2.87° clockwise, so that its dash
A10.1.3 Mesh the camshaft gear with the adjustable idler marked tooth is 145.73° counterclockwise from vertical. The V
gear and with the UP mark on the front face of the camshaft and dash marks line up valley-to-tooth.
gear in the 12:00 o’clock position. Assemble the camshaft gear
A10.2.3 Assembly of the adjustable idler gear with its UP
to the camshaft.
mark at the top orients the three kidney-shaped openings in the
A10.1.4 Set lash between the adjustable idler gear and the gear web to allow access to the socket head bolts that attach the
camshaft gear and torque the six socket head bolts at the adjustable idler gear stub-shaft to the front housing plate.
stub-shaft flange.
A10.2.4 Assembly of the camshaft gear with its V mark and
A10.1.5 Remove both timing pins with diameters of
UP mark at the top and with the camshaft pinned to the
6.28 mm.
cylinder head, by design, results with the 12.7 mm bolts
A10.2 1Y3700 Engine Mechanical Timing—General Infor- on-center of the clearance holes in the camshaft gear, each
mation: having a diameter of 17 mm. Additive tolerances for all the
NOTE A10.2—This is not part of the normal engine timing procedure. involved parts can cause the bolts to be off-center in either

NOTE 1—(1) Lubricate stud threads and both washer faces with Mobil EF411 engine oil.
(2) Tighten cylinder head nuts with hand torque wrench:
(a) Tighten nuts 1 through 6 in numerical sequence to 100 6 15 N·m.
(b) Tighten nuts 1 through 6 in numerical sequence to 200 6 15 N·m.
(c) Tighten nuts 1 through 6 in numerical sequence to 400 6 15 N·m.
NOTE 2—Coat valve stems with Mobil EF411 engine oil immediately prior to installation.
FIG. A10.1 Cylinder Head Tightening Procedure

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NOTE 1—Piston part nos: Skirt 1Y3659, Crown 1Y3400;

Rings part nos: Top 1Y3802, Intermediate 1Y3803, Oil 1Y3804.
FIG. A10.2 Piston and Ring Specifications

FIG. A10.3 Cylinder Liner Measurements and Specifications

NOTE 1—Grind the tip to 1.95 6 0.02 mm diameter for 5.0 6 0.5 mm long from spherical end. All dimensions are in mm.
NOTE 2—Indicator measures liner recession from the jug deck surface to the bottom of the liner combustion seal groove. The tip of the 8T0455 indicator
rod requires modifications as indicated.
FIG. A10.4 Cylinder Liner Projection Measurement Indicator Modifications

direction. The purpose of the oversize holes is to ensure that the A10.2.5 With the camshaft and the crankshaft pinned, the
gears will mesh at all off-nominal, but in tolerance dimensions engine is necessarily at top dead center on the firing stroke. The
of the parts. flywheel pointer is at 0° (TDC). The leading edge of a 3°

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NOTE 1—Center the support ring I.D. to the cylinder liner with four feeler gages of equal thickness, hand tighten the stud nuts, but remove feeler gages
before tightening stud nuts.
NOTE 2—Tighten the stud nuts in numerical order as shown with a sequence level of (15, 55, and 105 6 10) N·m.
NOTE 3—The cylinder liner support ring torque sequence may be used after the cylinder head torque sequence as an alternate method if the liner bore
distortion is out of test specifications.
FIG. A10.5 Cylinder Liner Support Ring Tightening Procedure

timing notch on the camshaft gear is on the centerline of the in the front housing shall also slide into a 6° wide notch of the
cam sensor hole in the front housing. The leading edge of a 6° crankshaft timing disk. This verifies that the leading edge of a
notch on the crankshaft timing disk is on the centerline of the notch on the timing disk is on the centerline of the crankshaft
crankshaft sensor hole in the front housing. sensor which sets TDC for the electronic control module
A10.2.6 With the flywheel pointer at 3° after top dead (ECM).
center, a 1Y3918 pin inserted in the crank timing sensor hole

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FIG. A10.6 1Y3700 Engine Timing

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NOTE 1—(a) Timing events in crankshaft degrees (reference only).

(b) As viewed from front.
(c) intake valve clearance set cold at 0.38.
(d) intake valve clearance set cold at 0.76.
(e) 1998 Scote engine.
FIG. A10.7 Timing Events in Crankshaft Degrees (for reference purpose only)

TABLE A10.1 Piston and Ring Specifications

Top Intermediate Oil Control
RingA RingA RingA
Width of groove in piston for piston ring (new) (3.21 ± 0.01) mm
Thickness of piston ring (new) (3.137 ± 0.006) mm
Side clearance between groove and piston ring (new) 0.080 mm, min (0.140 to 0.214) mm (0.057 to 0.089) mm
End gap clearance between end of ring (new)
installed in a gage with a diameter of 137.160 mm (0.585 to 0.737) mm (1.004 to 1.156) mm (0.382 to 0.636) mm
A
This engine uses keystone style piston rings and grooves in the piston. The piston ring lands are also elliptically ground; therefore, measure ring side clearance as follows:
(a) Assemble piston ring on the piston with UP side toward the top of the piston.
(b) Install piston and ring in a ring gage with a diameter of 137.60 mm or modified slotted liner (see Appendix X1).
( c) Push piston and ring until ring to be measured is at the top of the gage. Keep the piston in the center of the gage.
(d) Measure the side clearance with a feeler gage at both major (90° from the centerline of the pin bore) and minor diameters. Each measurement should be within
specification shown.
(e) Install the oil control ring with gap in the spring 180° away from the gap in the ring.

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TABLE A10.2 Engine Assembly Measurements, mm
Items to be checked Specifications Actual
min mean max
Crankshaft end play 0.11 0.34 0.57
Camshaft end play 0.175 0.25 0.325
Main bearing clearance (no.1) (front) 0.089 0.138 0.187
Main bearing clearance (no.2) 0.089 0.138 0.187
Main bearing clearance (no.3) 0.089 0.138 0.187
Main bearing clearance (no.4) 0.089 0.138 0.187
Nozzle tip projection 1 1.3 1.6
Cam gear backlash 0.102 0.216 0.33
Piston to head clearance 1.55 1.62 1.69
Intake valve (1) Recess (closest to manifold) 2.2 2.5 2.8
Intake valve (2) Recess 2.2 2.5 2.8
Exhaust valve (1) Recess (closest to manifold) 1.2 1.5 1.8
Exhaust valve (2) Recess 1.2 1.5 1.8
Initial intake valve lash (cold) 0.38
Initial exhaust valve lash (cold) 0.76
Initial injector setting 78A A

After test intake valve lash (cold) 0.3 0.38 0.46

After test exhaust valve lash (cold) 0.68 0.76 0.84
After test injector setting 77.8A 78A 78.2A A

Flywheel adapter runout (bore TIR) 0.15

Flywheel adapter runout (face TIR)(at R95) 0.15
Timing sensor location in front housing 2° ATDC 3° ATDC 4° ATDC
Liner negative projection 1.12 1.17 1.22
Liner ID taper 0.051
Liner ID out of roundness 0.038
Liner ID smallest anywhere 137.154
Align pointer with TDC mark on flywheel.
Verify top of liner is below jug surface.
Flow cooling jet to verify aim.
Injector and valve max lifts
Injector plunger lift at 72° crank 17.3 18.0 mm 18.7
Exhaust valve lift at 247° crank 13.0 13.7 mm 14.4
Intake valve lift at 456° crank 15.3 16.0 mm 16.7
A
Go/No-Go gage

A11. FLUSHING INSTRUCTIONS AND APPARATUS

A11.1 Table A11.1 is the flushing instruction sheet and Figs.

A11.1-A11.3 illustrate the flushing apparatus.

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TABLE A11.1 Flushing Instruction Sheet
Step Procedure Flushing Fluid Relief ValveA
1 Drain used oil from sump, cooler, oil scale and remove oil filter
Install 1Y3916 plug in front plate (in place of fuel cam/cylinder head)
Install 1Y3979 cover on top of block
Install 1Y3980 piston jet aim fixture on top of 1Y3979 cover
Connect flush cart outlet to filter flush adapter 1Y3935 and 5 spray nozzles open
2 Connect flush cart pump inlet to solvent tank
Install new oil filter on the oil flush cart 7.6 L Stoddard solvent
Open engine sump drain. Then pump solvent into engine to flush used oil no recirculation closed
3 Cleaning mixture of
Connect flush cart pump inlet to engine oil sump 1.9 L Dispersant Engine
Close engine sump drain Cleaner closed 5 min.
Circulate fluid with flush cart and oil scale pumps turned on 5.7 L Stoddard Solvent open 5 min.
4 Drain mixture from sump, cooler, oil scale, flush cart and filters open
5 open 5 min.
Circulate fluid with flush cart and oil scale pumps turned on 7.6 L Stoddard Solvent closed 5 min.
6 Drain fluid from sump, cooler, oil scale, flush cart and filters open
7 Repeat steps 5 and 6 two times or as needed until solvent remains clean
8 open 5 min.
Circulate EF-411 to flush Stoddard solvent 5.6 L EF-411 closed 5 min.
9 Drain oil from sump, cooler, oil scale, flush cart and filters open
10 Circulate EF-411 at 415 kPa manifold pressure and align piston jets 5.6 L EF-411 open 5 min.
11 Drain oil from sump, cooler and oil scale. Rebuild engine for test open
12 After engine is rebuilt, motor engine at a minimum of 200 r/min 5.6 L EF-411 Reconnect for normal operation
13 Drain oil from sump, cooler and oil scale open
A
Supply 50 kPa air pressure to open the Johnson Controls oil relief valve.

FIG. A11.1 Flushing Nozzle Locations

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FIG. A11.2 Flushing Plug

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FIG. A11.3 Flushing Fixture

A12. WARM-UP, COOL-DOWN, AND TESTING CONDITIONS

A12.1 See Table A12.1.

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TABLE A12.1 Warm-up, Cool-down, and Testing Conditions
NOTE 1—(a) Engine controlled to torque specification for Steps 2, 3, 4 and 5 min of Step 5.
(b) Engine controlled to fuel rate specification for last 55 min of Step 5.
(c) Air pressure at coolant tower controlled to 35 kPa.
(d) Oil pressure operating specifications apply only to 15W-40 oils. Attempt to maintain these limits for all oils. When oils other than 15W-40 oils fall
outside these limits, explain these deviations from the limits in the comments section of the test report.
NOTE 2—Ramp Up Conditions Between Warm-up Steps:
(a) Torque (N·m/min); at 5 min (beginning at Step 2)— 20 N·m/min.
(b) Speed (r/min); at 10 min (beginning at Step 3)— 100 r/min/min.
(c) Inlet air pressure (kPa); at 10 min (beginning at Step 3)— 12 kPa/min.
(d) Exhaust air pressure (kPa); at 10 min (beginning at Step 3)— 12 kPa/min.
(e) Inlet air temperature (°C); at 10 min (at start of test)— 5 °C/min.
Parameter Units Tol Test Specifications
Step 1 Step 2 Step 3 Step 4 Step 5
5 min 5 min 5 min 10 min 60 min
Speed r/min ±3 1000 1000 1400 1800 1800
Power kW idle 10 26 41 ;55
Torque N·m (a) ±5 100 176 219 ;285
Fuel rate g/min (b) ±1 48 95 148 185
Fuel timing BTC 13 13 13 13 13
Humidity g/kg ±1.7 17.8
Temperatures °C
Fuel into head ±3 ;31 ;32 ;33 ;36 42
Coolant into jug ;41 ;51 ;82 ;86 86
Coolant from head ±3 42 52 83 90 90
Oil to cooler ;128
Oil manifold (d) ±3 130
External heating oil 165 max 165 max 165 max 165 max 165 max
Intake air manifold ±3 60 60 60
Exhaust manifold ;120 ;275 ;340 ;370 ;480
Pressures kPa
Fuel from head ±20 275 275 275 275 275
Coolant into jug (c) ;44 ;44 ;70 ;81 ;81
Oil manifold ±20 415 415 415 415 415
Intake air barrel ±1 120 120 157 225 272
(abs)
Exhaust barrel ±1 104 146 217 265
(abs)
Crankcase ;.05 ;.10
Flows
Coolant L/min ±2 ;34 ;34 ;55 75 75
Blowby L/min ;35 ;35
Air kg/h ;315

A13. PISTON AND LINER RATING MODIFICATIONS

A13.1 The 1P piston deposits are accessed using the Modi- Demerit Varnish Zonal Rating 5 Area % 3 ~ 10 2 Merit Rating!
fied CRC Diesel Piston Rating Method described in CRC (A13.1)
Manual No. 18. Three levels of carbon (heavy, medium, and
A13.1.1 Example—15 % × (10.0 – 8.5) = 0.15 × 1.5 = 0.22
light) are rated for grooves one and three. Only two levels of
demerits using rounding guidelines presented in Practice E29.
carbon (heavy and light) are rated for the second groove and all
lands, and only one level of carbon (light) is rated for the A13.1.2 Fig. A13.1 shows the deposit rating areas for the
cooling gallery and under-crown. The carbon deposit factors under-crown and cooling gallery of the piston crown.
are 1.00 for heavy, 0.5 for medium, and 0.25 for light carbon.
A13.2 The rating location factors were chosen to yield
The varnish merit values range from 1.0 to 10 using the CRC separation between low and high calibration oils. All required
Rust/Varnish Rating Scale where 10 is clean and 1.0 is rating equipment, such as the rating booth and particular lamp
maximum intensity. The merit varnish values are converted to used, are described in CRC Manual No. 18.
demerit values resulting in deposit factors that range from 0 for
clean to 9.0 for maximum intensity. The merit varnish values A13.3 Use the following procedure for calculating this test
are converted to demerit values using Eq A13.1: method’s piston deposit ratings:

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NOTE 1—Area 1—Under-crown: All surfaces of the under-crown including transition radius, but not the vertical sides of the pin bore struts.
Area 2—Cooling gallery: Only the upper radius area.
FIG. A13.1 Under-crown and Cooling Gallery Rating Areas

A13.3.1 Rate the piston as is normally done according to the

Modified CRC Diesel Piston Rating Method described in CRC
Manual No. 18.
A13.3.2 For groove three, land three, land four, the cooling
gallery and under-crown, replace the rater-assigned varnish
merit values with the restricted factors listed in Table A13.1.
A13.3.3 Calculate a demerit value for each area.
A13.3.4 Round each demerit to the nearest 0.01 demerits
according to Practice E29. FIG. A13.2 Liner Thrust and Anti-Thrust Locations

A13.3.5 Add the demerits to get the individual unweighted

demerit value for each piston location. A13.4.1.3 Surface Preparation—Caution should be ob-
served in the handling of the liners due to the sharpness of the
A13.3.6 Multiply the unweighted demerit value by its cut edges. Wipe both halves of the liner using Stoddard solvent
location factor to get the individual weighted demerit rating for on a dampened soft rag followed by a clean soft dry rag.
each piston location.
A13.4.2 Definition of Terms—A clear plastic segmented
A13.3.7 Round each individual weighted demerit rating to overlay (see Fig. X1.6) is recommended as a useful rating aid
the nearest 0.01 demerits. in estimating the percentage of the area covered.
A13.3.8 Add all individual weighted demerit ratings to get A13.4.2.1 Bore Polishing—Those areas of surface which
WDP. are instantly recognizable as mirror finish regardless of random
A13.3.9 Round WDP to the nearest 0.1 demerits. crosshatch honing marks.
A13.4.2.2 Scuffıng—Localized adhesive wear distinguished
A13.3.10 Top groove carbon (TGC) equals the total carbon by concentrated marks in the direction of motion, observed as
demerits for groove one. a matte finish which is caused by a momentary welding and
A13.3.11 Top land carbon (TLC) equals the total carbon tearing of metal.
demerits for land one.
NOTE A13.1—Bore polishing and scuffing should be differentiated
between and reported separately.
A13.4 Liner Rating Procedure—Liner rating should follow
the sequence outlined herein. If deposits above ring travel are A13.4.2.3 Scratching—Random singular lines in the direc-
to be evaluated this should be done immediately upon comple- tion of motion generally a result of debris or installation of
tion of the test or disassembly. components. These need not be quantified, but should be noted
in the appropriate remarks section.
A13.4.1 Liner Preparation:
A13.4.1.1 Marking—Thrust and anti-thrust sides are A13.4.3 Liner Rating:
marked T & AT along with appropriate test identification (run A13.4.3.1 Rating Environment—Rate liners in the CRC
number, and so forth). See Fig. A13.2. rating booth with the same light as specified to rate pistons or
A13.4.1.2 Cutting—Liners are cut along the front and rear, a two-bulb fluorescent desk lamp.
leaving the thrust and anti-thrust halves. A13.4.3.2 Bore Polishing—The overlay is inserted in the
liner half and the (10 to 15) % segments with 1 % indicators
used as a guide in estimating the amount of polishing. Record
the percent polish for each segment and then summarize those
TABLE A13.1 Grouped Varnish Rating Factors
ten areas for each half. Tracing paper or equivalent may be
Rater-Assigned Varnish Merit Value Restricted Factor used for a permanent record of the liner polishing.
1.0–4.0 7.5 A13.4.3.3 Area Rated—The area to be rated is generally
4.1–7.0 4.5
7.1–9.9 1.5 defined as the area swept by the rings which is the distance
from the top of the first ring at TDC to the bottom of the ring

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 D6681 − 10a
at BDC. On many occasions, it is required that the area above 20-segmented template. Carbon deposits can be rated in two
top ring travel be rated. levels. Other conditions such as polishing, scratching/scuffing
A13.4.3.4 Liner Scuffıng Rating—Liner scuffing can be can be reported in area covered, if required.
rated in a similar manner as bore polishing.
A13.4.3.5 Above Top Ring Travel Conditions—Area per-
centages may be determined in the liner by use of the

A14. ADDITIONAL REPORT FORMS

A14.1 Figs. A14.1 and A14.2 are sample report forms.

LSRD 4
Product: _________________ Batch No.: _____________
Product No.: ______________ TMC No.: _____________
TMO No.: _____________
Tank No.: ______________
Analysis Date: ____________
Shipment Date: ____________
SPECIFICATIONS
TEST METHOD UNITS RESULTS, °C
MIN TARGET MAX
Distillation — IBF D86 °C 177
10 % °C 210
50 % °C 249
90 % °C 299
Distillation — EP °C 327
Recovery vol % REPORT
Residue vol % REPORT
Loss vol % REPORT
Gravity D4052 °API 32.0 36.0
Pour Point D97 °C -17
Cloud Point D2500 °C -12
Flash Point D93 °C 54
Viscosity @ 40 °C D445 mm2/s 2 3.2
Mercaptan Sulfur D3227 mass % REPORT
Sulfur D2622 mass % 0.030 0.050
Composition, Aromat- D1319 vol % 28.0
ics
Composition, Olefins D1319 vol % REPORT
Composition, Satu- D1319 vol % REPORT
rates
Basic sediment & wa- D2709 vol %
ter
Ramsbottom Carbon, D524 mass %
10% residue
Ash content D482 mass %
Total Acid Number D664 mg KOH/s REPORT
Strong Acid Number D664 mg KOH/s REPORT
Accelerated Stability D2274 mg/100 mL REPORT
Copper Corrosion D130
Cetane Number D613
Aliphatic paraffins D2425 mass % REPORT
Monocycloparaffins D2425 mass % REPORT
Dicycloparaffins D2425 mass % REPORT
Tricycloparaffins D2425 mass % REPORT
Alkylbenzenes D2425 mass % REPORT
Indanes/Tetralins D2425 mass % REPORT
Indenes D2425 mass % REPORT
Napthalene D2425 mass % REPORT
Napthalenes D2425 mass % REPORT
Acenaphthenes D2425 mass % REPORT
Acenaphthylenes D2425 mass % REPORT
Tricylic aromatices D2425 mass % REPORT
Approved by: ______________ Analyst: __________________

NOTE 1—Include a copy of Suppliers Fuel Sheet in the Test Report.

FIG. A14.1 Fuel Batch Analysis Example

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FIG. A14.2 Example of Fax Copy of TMC Control Chart Analysis for Calibration Tests

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A15. REPORT FORMS

A15.1 Download report forms and data dictionary from the Report Form Table of Contents
ASTM Test Monitoring Center (TMC) Web Page at: http:// 10. Downtime Summary Form 7
11. Ring Measurements Form 8
[Link]/. TMC can also provide hardcopies on 12. Liner Measurements Form 9
request. 13. Characteristics of the Data Acquisition Form 10
System
Report Form Table of Contents
14. Engine Operational Data Plots Form 11
1. Final Report Cover Sheet Cover
15. Torque and Exhaust Temperature History Form 12
2. Test Report Summary Form 1
16. Oil Consumption Plot Form 13
3. Operational Summary Form 2
17. Piston, Ring, and Liner Photographs Form 14
4. Assembly Measurement and Parts Record Form 3
18. Severity Adjustment History Form 15
5. Piston Rating Summary Form 4
19. Fuel Batch Analysis Form 16
6. Piston Rating Worksheet Form 4a
20. TMC Control Chart Analysis Form 17
7. Supplemental Piston Deposits (Groove Sides Form 5
and Rings) NOTE A15.1—If the test will be submitted to the registration organiza-
8. Referee Rating Form 5a tion as a candidate oil, then use the same forms used for reporting
9. Oil Analysis Form 6 reference test results and add the ACC Conformance Statement, Form 18.

APPENDIXES

(Nonmandatory Information)

X1. VARIOUS EXAMPLES FOR REFERENCE PURPOSES

X1.1 See Figs. X1.1-X1.8.

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FIG. X1.1 Rating Worksheet Example

FIG. X1.2 Engine Oil Heating System

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NOTE 1—Use a 1Y3555 liner from the 1K/1N test. The liner shall be free of I.D. distortion or surface distress.
FIG. X1.3 Ring Side Clearance Measurement Fixture

FIG. X1.4 Flushing Cart Flow Schematic

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FIG. X1.5 Oil Filter Flushing Adapter Example

NOTE 1—Material is clear plastic; dimensions are in mm.

FIG. X1.6 Bore Polish Grid

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FIG. X1.7 Example of Piston, Rings and Liner Photograph Layout

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NOTE 1—If testing candidate lubricants in accordance with Specification D4485, the results of multiple testing should be reported on this form.
FIG. X1.8 Example of Multiple Test Summary Sheet

X2. SAFETY

X2.1 The operating of engine tests can expose personnel around the engines should be kept clean and free of oil and fuel
and facilities to a number of safety hazards. It is recommended spills. In addition, working areas should be free of all tripping
that only personnel who are thoroughly trained and experi- hazards. In case of injury, no matter how slight, first aid
enced in engine testing should undertake the design, installa- attention should be applied at once and the incident reported.
tion, and operation of engine test stands. Each laboratory Leaking fuel represents a fire hazard and exhaust gas fumes are
conducting engine tests should have their test installation noxious. Do not allow containers of oil or fuel to accumulate in
inspected and approved by their Safety Department. Personnel the testing area. The test installation should be equipped with
working on the engines should be provided with the proper a fuel shut-off valve which is designed to automatically cut off
tools, be alert to common sense safety practices and avoid the fuel supply to the engine when the engine is not running. A
contact with external moving or hot parts. When engines are remote station for cutting off fuel from the test stand is
operating at high speeds, heavy duty guards are required and recommended. Suitable interlocks should be provided so that
personnel should be cautioned against working alongside the the engine is automatically shut down when any of the
engine and coupling shaft. Barrier protection should be pro- following events occur: the engine dynamometer loses field
vided for personnel. All fuel, oil lines, and electrical wiring current, engine over-speeds, low oil pressure, high water
should be properly routed, guarded, and kept in good order. temperature, exhaust system fails, room ventilation fails, or the
Scraped knuckles, minor burns, and cuts are common if proper fire protection system is activated. Consider an excessive
safety precautions are not taken. Safety masks or glasses vibration pickup interlock if equipment operates unattended.
should always be worn by personnel working on the engines Fixed fire protection equipment should be provided and dry
and no loose or flowing clothing should be worn near running chemical fire extinguishers should be available at the test
engines. The external parts of the engine and the floor area stands.

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ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentioned
in this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the risk
of infringement of such rights, are entirely their own responsibility.

This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years and
if not revised, either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standards
and should be addressed to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of the
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